Before you discount the heat shield, check it out one last time! I had checked visually 3 times. The last time I checked when the exhaust was HOT. I threw on my welding gloves and got under there with a screw driver. Sure enough, one of the welds on the crossover pipe looked fine, but when I pried under it with the screw driver it bent right out. I had pried under it cold before and never saw it move.
It's worth a try,because if that's the problem it's an easy fix!
BTW, I thought mine was suddenly getting louder, but I had recently removed the carpet and had the floor pan drain plugs open after washing the heap out. The heat shield is right under your feet!
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Rock Krawler 2.5 Max Travel, + upper control arms:RRD remote reservoir shocks:Teraflex Speed Bumps:Poison Spyder bumpers, fenders, and rockers: Gen Right tire carrier: Rigid duallies, 20 and 50 bars, fogs: Trucklites: Off Road Hero's Top: Genesis Off Road dual battery kit: