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As far as the engine goes, it would fit the same as a 1965 273. So you want to buy headers to fit the 65 Barracuda V8. The engine year is irrelevant.

My local shop just built a 2.25" dual pipe on my 67 fastback. It is a little ugly with butt welds, but it comes out right at the valance. I also have the 68 valance with dual rectangular cutouts, and 68 tips. They didn't do anything to the tank or the hanger, except slip a short piece of hose...

67 is a weird animal; actually different from 68-up if you want it to fit right due to the different fuel tank hanger arrangement. Don't know how a 64 compares to that. I suspect your best bet would be to go to your local exhaust guy (not Midas — the hole in the wall place the local motorheads...

I had my muffler guy do exactly what you suggested — just cut off and weld shut at the Y and run a second pipe straight back. This was on a 273 4bbl so the pipe was good sized to start with. Used 1968 340 OEM replacement mufflers. Not too noisy, just right. Any kind of crossover is significant...

Oh, when I converted my 67 FB, I just had the local exhaust shop fab up a new right side pipe and a new left side head pipe. No big deal, and it didn't cost an arm and a leg. I used 68 340 spec OEM mufflers.

It's not as tight on a 69 as it is on a 67. The 67 has the fuel tank hanger in the way on the passenger side. The 69 has dual straps running fore and aft so that's not a problem. 2.5 should fit easy.

Well, you might as well go 2" from the muffler back. It wouldn't help going 2-1/4 after the muffler. You would still see a benefit compared to the 1-3/4 end-to-end system.

I am thinking that in 68 it was 1-3/4. But I don't have a reference to confirm that.

Yeah, I don't see why it couldn't be a service part. In fact, it must have been, as it was obviously not installed on a car from the factory. Probably was the last batch of that part, though.

For there to be a carbon residue, it seems like you are running too rich, or the choke is staying on too long. Or maybe you just drive short distances at low speeds. But that's what I would look into.

One the other side... My muffler guy recommended against any kind of crossover. My car of course is a completely different ticket than a big block with headers -- 273 4bbl with manifolds and 2.5" back to dual Super Turbos. I don't think HP/torque was even considered -- he thought it would kill...

The factory setup on the 1967 Barracuda 273 Commando was a single 2.5 pipe to a big low-restriction muffler and a resonator. It was considered to sound pretty good. You probably have room to run 3" all the way on an A-body.

You can run 2.25" tailpipes out the back, no problem. Just carefully route it around the fuel tank strap J-bolt on the right side. I slipped a piece of rubber hose over the bolt so it doesn't rattle. I am using a pair of Walker Super Turbo mufflers sized for a 1968 Barracuda 340. I'm guessing...