I just noticed that I am shooting pretty decent flames out of my exhaust under hard revs.
"Doc, it hurts when I bend my arm like this!"
"Don't bend your arm like that."
Stop romping on it for no reason, and don't let your kids play with your truck.
I just did the bassani catted y-pipe through a 3" Hooker Aero chamber.
Do the Ford catted Y-pipe thru a Ford 2-chamber.
I know this can't be good. Just for some background, I have done TONS of repairs-IAC, TPS, Cap, plugs, wires, harmonic balancer and fuel pump, etc etc etc in the last 2 months. Timing supposedly is fine, but I do have an exhaust leak where the Y meet the stock manifold, thanks to a bad Bassani pipe.
STOP replacing parts; especially if you're gonna replace them with aftermarket crap that neither fits nor works.
Start DIAGNOSING things, and only replace parts that FAIL a published test. Only replace them with parts that PASS the same test. Take as much time as you need to UNDERSTAND each system so you can figure out what's not working right. In this case, you have 2 apparent issues: 1) overfuelling or poor combustion putting too much unburned fuel into the exhaust, and 2) ineffective 2ndry air system not handling the unburned fuel in the exhaust. Start with #1: EXHAUST LEAKS, fuel pressure, FPR leak, combustion chamber deposits, plug color & gap, wire & coil resistance, cap & rotor condition, HEGO contamination... Don't move on until ALL of that is 100% fixed.
These captions explain the NATURE of an exhaust leak, even though they show a different leak location than your main one: