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I can tell you that on an EVO you can get a one piece pipe on, but it would be clumsy to handle, and heavy an the *** end so you'd have to support it while torquing to the heads. My Rinehart is 2-pc, the muffler and the 2-1 headers.
Making the collector would be tough depending on the inlet size versus the outlet size. On OCC they once took two smaller pipes and welded them into a larger ellongated or egged-out pipe.
I can recomend Custom Craft in Midland AR. (479-639-2742) for your system. They do great work. They also coat systems. Give them a call. They are great to work with.
Stepped primary pipes as long as you can make them (bring the rear forward around the cone) and end them behind the trans. size would be dictated by the size of the motor, if it's not a stroker with significant head work, I would say 1 3/4" stepped to 1 7/8" X ~18" keep your merge as straight as possible 2 1/4" collector.
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