I have a 1994 F150 4x4 with the Inline 6 (300 CID) and a 5 Speed. Last night both my cats overheated (were glowing red) and melted the rest of my exhaust system (galvanization was coming off the clamps!). I'm now looking for full replacement from the stock manifolds back.
1) I know there must be a reason why there's 2 cats on this truck, but do I need to replace both or can I get away with just installing 1 universal or performance cat?
2) Any suggestions one how to convert this to dual exhaust would be appreciated. I'm a full-time student and cannot afford over-the-top Fully Custom exhaust. I have to borrow the money to fix this!

 

Ouch!
Do you know why the catalytic converters overheated? I don't think you want to risk killing new converters.
Why would you convert to dual exhaust? Essentially it means "dual money". That's not the course I would take. In fact I would look into getting a used exhaust system from junk yard.

 

I know the converter and pipe assy for a 4.9 is very expensive.
One thing I have found is an exhaust system from Ford is also expensive and sometimes comes in one piece welded and can be a job to install, however, when compared to any aftermarket replacement pipes there is no comparison because the Ford pipes are heavier and last much, much longer. Only you know how long you expect to keep the vehicle and how much use it will receive. It would be wise to determine the cause for the glowing exhaust before you get involved with the pipes.

 

Well I found the reason for the cats glowing. The distributor was so loose I could turn it approximately 90 degrees! I do believe at least 2 of the cylinders were blowing unburned fuel down the exhaust.
I'm still working out finding the timing on it, now that I have new plugs, wires, dist. cap and rotor. I'm not putting on any exhaust until i fix the It's Not Running Right Now problem. I just bought this truck about 6 days ago "for a steal of a deal" (which now I know why!).

 

If you have the distributor-mounted TFI sensor type of distributor, which proved somewhat of a problem for Ford: The TFI (Thick Film Integrated) sensors often got too hot mounted thusly. Many Ford vehicles came with the TFI mounted on an aluminum heat-sink fastened to the fender apron or firewall.

My own '96 F-150 quit suddenly; the distributor was found to be at fault: the Hall-Effect generator within the distributor has died. These are available and can be replaced and the old distributor body used. Got mine at NAPA. imp