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Wont 1 1/2 on a 2.7 motor choke it down too much?
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No, it's better to be a tad small than big, as w/ brakes smaller is advantageous, the smallest diameter pipe that will pass the gas at peak rpm and load is what is wanted, there is more to it than that but that is a good starting point, other things like primary length, transitions, collector design and size all enter into the equation. Most of us need to buy off the shelf anyway.
When you start getting into race 3.2s 1 5/8 OD is starting to get useful.