Either get the flange machined to an HX40 and use the standard hx40 downpipe or source a 4.2" Marmon clamp and flange the can be welded to your current downpipe. Finding the clamp is the hard part. I just sourced a clamp that is 4.1xxx" for $13 but I will need to make the flange from some sheet steel.
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Very true but pricey. When I measured the exhaust housing the outlet was 3.1" so a 3.5OD exhaust pipe should be just slightly larger. My charger is going on a 6.7 tow vehicle and wont be performance oriented so I am running 3" down to the exhaust brake then picking up the 4" again just prior to entering the DPF. I don't see much of a flow loss running pipe the same size as the exhaust housing opening. Going to header wrap it as well to make sure it all flows well.
It's the same size as a DT466 outlet. You can pick the flange up at any shop that carries class 6-8 truck parts. Donaldson, nelson, and ricker plus many other manufactures can get the parts per application. Hope this helps.