What are the biggest holes so far?
I started with 1/2"dia holes (one each side) on my 2002 2.7 and liked the extra sound. Eventually I wanted more, but could not find a larger diameter drill bit that was long enough to reach with the fixed exhaust tip. Then one day I ran across a 'stepped' drill bit and a drill bit extension, and slowly worked my way up to a 3/4"dia each side. I think it sounds even better. Definitely not too loud.
What have others tried?
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