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First of all, I have to say DAMN, this place is dead! I'm new here but no one ever seems to help much. It's just a bunch of friggin' questions with no answers! I"ll try to help:
1. Do you need a cat? Well, no, you don't. Do you want to pass smog? Then yes, you need a cat. I don't know much about these pickups because I'm new to the seen, but in the rice world (imports) taking off the cat increases the sound only a little, often deepening it. It relieves lots of backpressure which was good in the import world, and I don't see how it could hurt too much with your application. At lower speeds, maybe you will lose some torque, but you will def. gain high-end horsepower.
2. A header WILL give you some horsepower, but very minimal since you aren't pushing out much horsepower anyway. I wouldn't go spending lots of money on one unless your REALLY want a complete exhaust sytem. You can't really make these trucks fast without some sore of FI or engine swap so I wouldn't bother.
3. I would say 2.5 inch would be plenty if not too much. Don't go over that. Another thing to consider; a complete custom exhaust without a cat, and even with a muffler, would be loud. Stock exhaust and aftermarket ones come with special sections on the piping lined with sound-resonating (like a gun silencer) that makes it quiet.
4. Yes, a big exhuast and header, and no cat, will lose you lots of backpressure but it really frees up the high end. I wouldn't be too worried though because personally I like the way it feels. But don't go spending lots of money.
I don't know... I tried to help so if you have any more questions, shoot. I'm not an expert, just my 2 cents.
-Adam
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