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FINAL UPDATE: Cut the muffler off and am running open exhaust. It's a tad louder than I like, but still not near as loud as open exhaust was 20 years ago on a truck.
Update: Holley replied with “no question” to my email explaining the issue. The question I had was implied with me explaining the raspy popping , unless that’s fucking normal for these mufflers. Terrible customer service. I am just going to trash the muffler and go with dynomax. I swear on everything holy I’ll never purchase another flowmaster or holley product. Nor will I ever recommend them to anyone else.
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New install, just muffler swap from factory muffler. No exhaust leaks I can locate. Sounds awful. From the cab it sounds the same as stock. Super quiet. Which isn’t exactly what I was wanting. Outside it sounds like raspy popping and barely louder than factory. Contacted Holley, parent company of flowmaster, and they haven’t emailed me back in a week. Not sure if I’ve somehow messed up a simple muffler swap, or if the muffler is defective. Can’t get flowmaster to reply.