Sound did change a little bit, but only when I really got on it. Others with the TRD box seemed to notice a sound difference with just a a little throttle. I too have asked the question to the forum regarding the big difference between the aftermarket CAI's vs the OEM, but did not get an answer. I seem to remember one post way back which suggested the OEM has some unwanted "baffles" in the tube area, where as the aftermarket units eliminated them, hence better un disturbed air flow. I can't confirm this and hopefully others will chime in with their thoughts.
I too want to open up the exhaust a bit, to better match the KN filter's better air flow. I am also looking at Flowmaster, Model 12586 which is the 22 incher. Most posts that I have read seem to favor this one over the 18 incher. The later being too loud. Before I pull the trigger, would really like to hear a comparison of the 22 inch and 24 inch. (Don't have the model number of the 24 inch right now). I live in a neighbor hood of mostly older retired folk and do not want to make enemies when I leave for golf at 7:00 AM!