bjowett
Supporting Vendor
DTT, always good reads with your projects...
The factory 200 muffler does have an internal flap, other than exhaust routing it seems to be the only difference between the 200 and Tundra. If I recall correctly, the 200 has 3 - 5 more hp than the Tundra, and it would be probable that the muffler is the cause.
While building my exhaust last spring, I took measurements of the stock Tundra system and made some speculations... from a post on Tundra Soloutions...
Since there are lots of great exhaust threads from bolt ons to nice fab work, I thought I would share a simple Borla exhaust project that I'm building for my Tundra and hypothesize/speculate about the stock system a bit. I bought a bunch of Borla exhausts and parts to sell on ebay a few years back, and there are a couple systems still unsold. One looks like it may be a nice fit for the Tundra. Originally a $600+ system for an 01 Dodge V10, it is a single system w/ large 20" muffler and 3" OD tubing.
The stock system is well designed for what it is. Toyota took care to slowly step down the tube size throughout the system to help keep the velocity up and probably reduce noise some. It runs tight off the header, maybe 2.12"? Then jumps to 2.50" to the first converter, then drops to 2.40" out of there, keeps that diameter though the second converter all the way to flanges where the rear exhaust bolts on (just aft the transfer case). The exhaust then drops to 2.12 into the muffler, then 2.75 out to the tailpipe. A better example may be tube ID area in sq in.
3.14" x 2 = 6.28"
4.45" x 2 = 8.9"
4.08" x 2 = 8.16"
3.14" x 2 = 6.28"
muffler ???
tailpipe = 5.43"
That squeeze at the back of the header/top of downpipe is either a big bottle kneck or some type merge collector (can that exist on the tri Y stocker?). The 2.5" downpipe is a nice size, the 2.40" pipe are decent. Then the big drop back to the 2.12" pipes, through the muffler, and out the single 2.75" tail pipe. Since Toyota took the time to produce the system like this, it seems prudent that maybe in order allow nice gains all the way through the power band and not just a big peak number, that running 2.25" duals all the way back might not be the best option...? Instead of dropping to 6.28" pipes, adding 2.25" pipes would give about 7.06", then either a single 3" OD pipe @ 6.42" or dual 2.12" that would give 6.28... Thoughts? other than I am over thinking this...
On to my project, I'm going to try 2.25" back to the muufler, merge collector em', run through the 3" muffler and out the 3" tailpipe. Here's the Borla system I'll be basing it on, not bad for $150.
The factory 200 muffler does have an internal flap, other than exhaust routing it seems to be the only difference between the 200 and Tundra. If I recall correctly, the 200 has 3 - 5 more hp than the Tundra, and it would be probable that the muffler is the cause.
While building my exhaust last spring, I took measurements of the stock Tundra system and made some speculations... from a post on Tundra Soloutions...
Since there are lots of great exhaust threads from bolt ons to nice fab work, I thought I would share a simple Borla exhaust project that I'm building for my Tundra and hypothesize/speculate about the stock system a bit. I bought a bunch of Borla exhausts and parts to sell on ebay a few years back, and there are a couple systems still unsold. One looks like it may be a nice fit for the Tundra. Originally a $600+ system for an 01 Dodge V10, it is a single system w/ large 20" muffler and 3" OD tubing.
The stock system is well designed for what it is. Toyota took care to slowly step down the tube size throughout the system to help keep the velocity up and probably reduce noise some. It runs tight off the header, maybe 2.12"? Then jumps to 2.50" to the first converter, then drops to 2.40" out of there, keeps that diameter though the second converter all the way to flanges where the rear exhaust bolts on (just aft the transfer case). The exhaust then drops to 2.12 into the muffler, then 2.75 out to the tailpipe. A better example may be tube ID area in sq in.
3.14" x 2 = 6.28"
4.45" x 2 = 8.9"
4.08" x 2 = 8.16"
3.14" x 2 = 6.28"
muffler ???
tailpipe = 5.43"
That squeeze at the back of the header/top of downpipe is either a big bottle kneck or some type merge collector (can that exist on the tri Y stocker?). The 2.5" downpipe is a nice size, the 2.40" pipe are decent. Then the big drop back to the 2.12" pipes, through the muffler, and out the single 2.75" tail pipe. Since Toyota took the time to produce the system like this, it seems prudent that maybe in order allow nice gains all the way through the power band and not just a big peak number, that running 2.25" duals all the way back might not be the best option...? Instead of dropping to 6.28" pipes, adding 2.25" pipes would give about 7.06", then either a single 3" OD pipe @ 6.42" or dual 2.12" that would give 6.28... Thoughts? other than I am over thinking this...
On to my project, I'm going to try 2.25" back to the muufler, merge collector em', run through the 3" muffler and out the 3" tailpipe. Here's the Borla system I'll be basing it on, not bad for $150.
I am going to have him put in a suspension lift,ARB bull bar w/9,500lb winch,lockers,sliders,on board air compressor,dual battery,roof mounted front and rear lights by piaa and a ARB roof rack. That should just about do it. Did I leave anything out. This will be my dedicated off road, camping, fishing, mall truck. 
The wife says "your max is $15k and I don't want to hear the truck needs anything else". Hey, got to keep the wife happy. 
Wow, there is no way I would cut the front bumper myself and be able to put in the bull bar and not to mention the lift. Good for you and I am sure you saved a bunch of cash. But, I like keeping others employed by letting them do all the work while I enjoy watching. 
It's too easy to take shortcuts that could cause problems later down the road (i.e. moving the drain plug on the winch).
