The 3" exhaust was totally worth it. Definitely more power and the sound is just awesome. I towed my 80 series about 1100 miles a couple weeks ago and could definitely notice a gain in power, even at part throttle. Made it much easier to go up hills and mountain passes. I usually tow at 70 MPH and an ecoboost 3.5L F-150 blew past me on a flat section but I caught up to him and passed him at the next mountain pass and I never saw him again. He was towing a small travel trailer that was probably about the same as my load if not lighter.
This past weekend I drove out to Lincoln, NE and back with no trailer, just wife and dogs. Truck performed awesome as usual. I can now say with confidence that E85 is completely worth it. I really notice almost no difference in MPG with E85 vs. 91 octane. MPG pretty much only depends on the speed I drive and whether it's flat or hilly. Was getting 13 MPG at 75 MPH with E85 and 13.7 MPG at 75 MPH with 91 octane.
I was again blown away by the speed of my truck down at only 1000 ft elevation in Lincoln. I was ripping around big time

It's downright fast. I decided to order a smaller pulley for the blower.
Lastly, I noticed that after 8 hours on the road the truck was getting lethargic and at partial load would sometimes run lean, fuel pressure was weak, and it would hesitate from a stop if I stomped on it. I think it just comes down to the 2-speed fuel pump setup on the VVTI 100s. It runs the fuel pump at a lower voltage at low speeds and idle and then increases the voltage at high RPM. Doesn't make much sense to me but I'm sure there's a reason Toyota did it.
I decided to ditch this 2-speed system by removing the fuel pump relay so the pump gets constant voltage all the time. I followed
@white_lx s ideas in a previous thread here:
Engine shutting off during long trips. - https://forum.ih8mud.com/threads/engine-shutting-off-during-long-trips.739113/page-14#post-13265637
Basically I just made a jumper and put it in the relay's normally-on positions so it will never divert power through the fuel pump resistor. Resistors increase resistance with heat so driving long distances on a hot day could reduce the voltage to the fuel pump even more. When the truck is cold it runs fine then as it heats up it causes problems. The fuel pump should also run cooler at a higher voltage (counter-intuitive but true).
I immediately noticed my fuel pressure bumped up about 5 psi at idle. Will report back if there are any issues.
Jumper:
In place of relay:
Exhaust got a nice golden hue to it after some driving. Looks sweet!