Since the truck's exhaust is gone (completely), I'm intending to run a 2.5 inch exhaust. The muffler shop said it would cost minimally or nothing more (about 250 total, including the catalyst) to go from 2 inch to 2.5, so that's what I'm doing, and hoping to get a nice sound from it. I don't want it loud.

I have no means of porting the exhaust manifold, however. If I can some up with something, I'd at least port match the int and exh @ the head.

This is not a "maximum horsepower" build, but rather, one to maximize power between 1500 and 3500, with an emphasis on the lower half of that range.

I don't think you want to match the exhaust. IIRC the floor of it ground out will make it lazy.

I did a build for a friends 81 van. I did the bowls, unshrouded the chambers, opened the intakes 1/8th of an inch bigger than the intake manifold for an anti-reversion effect.

Polished the chambers and took .060 off the bottom. When he ran it through emissions it was very very clean! Non working air pump too!

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'72 Duster 198 stock cam, 3:23's Hookers on jack stands for 8 years in the driveway
'79 Maxivan 360 Offy Qjet Comp RV cam/rusting in the driveway.
93 D350 160HP Cummins Auto Dually Clubcab needs a injector pump
2005 Golden Couch Buick