2 1/2" ory... whats being left on the table?
Your headers have a 2.5" collector?
Whats the merge look like? If it is a crappy merge I would consider changing that before the 2.5" pipes... Of course if your going to do that you may as well consider doing the whole thing...
I'd still consider having the 3" exit pipe cut off the end of the merger and a Burns stainless RD-300-16-304-S welded up to it then run it into a 3.5" muffler. The only reason I don't recommend a 4" merge exit is because the 2.5" pipes then technically become the next possible restriction, so you won't benefit from go up to a 4" over the 3.5" in conjunction with the 2.5" pipes.
Hopefully this make sense.
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and here is the headers. im assuming the collectors are 2.5"



