Help Planning Exhaust/Turbo/Intercooler Mods - Early 99

[AlaskanEngineer]

Ok folks, I got back from my 7500 miles of driving and decided its time to start thinking of mods for this fall. There are two biggies on my plate right now: exhaust and intercooler/tranny cooler.

Exhaust question:
Looking to lower my egts and improve overall engine breathing without going deaf. I rather like having a moderately quiet truck (considering its a diesel) and really don't want to straight pipe it. Stacks are a definite no. Would like something basically same as stock truck dump location and sound level, but obviously need it larger diameter and better flow. I am a novice on what I will need here, so if some general info plus some specific recommendations could be made I would be much obliged. I believe I need new downpipes to do this right, don't know if that means a larger exhaust wheel for the turbo or not, and a larger diameter exhaust and some sort of muffler. An "exhaust mods for dummies" explanation of this would be VERY welcome!!

I have also heard talk of some flexible up-pipes to eliminate a common boost leak location... this is more on the air/turbo/intercooler end of things and has nothing to do with my exhaust, correct?

While I am messing with the exhaust related topics: I need to keep my exhaust warm up valve because of where I live, no deleting that allowed, fast warm-ups highly desirable. I would like to add an exhaust brake for when I am towing bigger loads, saw Jody's decel tune which uses that valve, but not sure I like the idea... comments or other ideas are welcome. I guess part of what I don't like is the having to use the tuner to do it instead of a lever or some other quick reacting control in the cab.

Next, to help lower my EGT's I was thinking of doing the 6.0 intercooler at same time as the 6.0 tranny cooler. Will they both fit? And is the intercooler worth it considering it won't take higher boost pressures? Keep in mind I have no plans of ever putting big oil or stage 2 injectors on this rig, so not sure I would ever need a larger turbo. If I were to kill this turbo, what would be my best bet for said new turbo (again no plans for oversize injectors) and would the 6.0 intercooler take the pressures?

Thats the end of my performance questions for now... thanks in advance for all the help! You will see another post with electrical questions popping up soon too.

Lastly, do you think it would have been uncalled for to break this post up into 2 or 3 threads? I am trying not to clutter...

[CHUCK]

I'd be more concered with the trans temps, and exhaust. Then take care of the intercooler.
Being different year trucks, and the limited space in the nose of the OBS trucks...A 7.3 intercooler and the 6.0 trans cooler fits in the OBS truck (with a few modifacations) so I'd say yaes to them fitting in SD truck. IIRC, the 6.0 intercooler is pretty much a drop in, in place of the 7.3 intercooler.
As far as exhaust...yea a better flowing system is desired. I'd check with farmboysdiesel, about your concerns on noise level and pricing.