Jipopotamo

Ok guys, so exhaust is something I am still fairly new with and need some seasoned opinions on. Once again, three of us are headed out in December towards South America via the 87 4Runner 5spd 22re.

Took it for inspection yesterday and they got me on the exhaust system. I live in Austin, TX which is pretty stringent with emissions testing. In short, my muffler is clogged and I do not have a legal exiting tailpipe that extends all the way to the rear of the vehicle.

So I need to redo the exhaust system. Main questions:
Stock pipe is 1.875" and I can benefit from going to either 2" or 2.25"?
If the muffler is clogged is the cat also probably due for replacement?
Is this something I need a shop to do or can you get everything you need for a DIY setup? I am up for anything, just need to know it's practical.
Local highly reputable shop quoted me $400 for new everything from the cat to the tip, with labor. Would I be able to cut costs by doing this myself or would it be more trouble than it's worth?

I like the idea of self bending, I've done it before. I just don't know what grade of pipe or where to get it from. Also something I have been toying with is the weld vs. bolt on debate. What if you did a bolt on clamp system but at all the clamp joints you used a sealing coat of all those "exhaust sealer putty/wrap/stuff" at the clamping joints, thus creating a type of gasket and a cold weld seal. Whatcha think guys?

Lumpy

You should be able to get a aftermarket CAT for about $60.00 and a muffler for $40.00 depending on how quite you like it. When I redid mine I went from the collector back with schedule 40 2.25" and she sounds nice. I used a cheap-o muffler from ebay (which later I found out that I could have purchased from Advanced Auto for the same price - shipping). I had the pipe given to me all I had to get were some elbows since I do not have access to a bender. I had less than $100.00 all said and done.

pruney81

find a good shop that bends all their own pipe and buy a cat and a muffler and have them weld it all together, should be alot cheaper than the $400 you got quoted