At that price point, it would seem a mount with principals similar to a RSS semi solid motor mount would be an improvement.
Did this Boxster have solid motor mounts?
It doesn't make sense, if engine is allowed to move and the exhaust is rigid
just my $.02

 

^ Bingo.

Using flex hinges/sections in a Boxster/Cayman exhaust system design would help immensely re. vibration, movement, and thermal expansion. Otherwise the weakest link is going to eventually fail.... and some of those welds look laughable.

We have had even extremely well made (i.e. appropriate welding) systems eventually fail on Cayman race cars.

 

Single side weld because the can thickness compared to the bracket thickness is thin and double sided wheel would put too much heat into the can and cause cracking. A better solution is to stitch a plate to the can and then weld the bracket to the plate. Gives a strong system less prone to cracking

 

Hi PL Newman and our other Porsche Rennlist friends and followers.

I’m very sorry to hear that you have had a problem with our 986 Spec Boxster race exhaust system. At Fabspeed Motorsport USA, we take pride in both our design and in our quality control and when we hear about a customer who is disappointed, we will do whatever we can to change to make it right.

Performance parts such as our Spec Boxster Race Exhaust System are subjected to varying degrees of stress and severe operating environments; generally we have been pleased with the system’s performance and durability in most competition situations.

Racers know that suspension modifications required to be make a car competitive on the track stiffen everything by eliminating all rubber components in the engine and suspension. This allows for significant handling improvements, but induces resonance based vibrations that can be unique to each car. At Fabspeed, we understand this theory and we engineer to it, but sometimes the real world gets in our way. We always look at occasional failures as an opportunity to improve and this is one of those cases.

Here’s what we’ve done:

We have made revisions to our welding process in certain high load bearing areas, added gussets to provide extra material and strength, and updated our final quality control inspection to verify the new procedure. We are confident that our changes have made the product more durable in those critical high stress, all out competition racing conditions.

Here’s what we want to do:

We need to restore your confidence in us, so please contact me direct at 215-646-4945 (888-646-4945) and I will do whatever is necessary to make this right for you.

For other Porsche gung-ho racers who may have this Fabspeed system, operating under race conditions, we are happy and motivated to update their systems to our current design specifications. We will be as proactive as possible and try to reach out to current system users, but also don’t hesitate to call or message us directly.

Thanks
The Fabspeed Team

 

If a plate was stitched welded to the exhaust component where the bracket welds fail, then the bracket can be welded on both sides. The plate for stitch welding should be 2x the width of the bracket.