Originally posted by rbattelle
It makes sense that you'll lose horsepower with a 5 inch exhaust. You no longer have an exhaust flow capacity properly matched to your engine airflow. Your pumping losses associated with the oversized exhaust cause a drop in horsepower (and I'd bet torque too!).
Remember, a certain amount of backpressure is beneficial. I would say that without a bigger turbo, bigger injectors, and a whole lot higher flow rate, anything bigger than 4 inch is going to hurt you. For those who have already invested in 5 inch exhaust, a more restrictive muffler might help. Otherwise you'll have to make up some flow restrictors and insert them in the piping.