Issues with FabSpeed muffler/tips on a 360

Why you may want to reconsider buying FabSpeed products....

About a year ago, I purchased the FabSpeed muffler and tips thru Vivid Racing. Upon opening the box, it appeared to be nicely polished and pretty. I did the install on my 2001 360 coupe along with Agency Power headers (Jet Hot coated) and Kinetix high flow CATS. The headers had their own issue where their fabricator forgot to drill the main port for the SAI. Luckily I caught that before installation. Everything else went in fine and sounds great.

A couple of days ago, I was getting some annoying resonance out the back, especially at 3,300 rpm. I dove in looking at what mile be lose, working too close to something, or what. One of the first things I wanted to do was tighten the bolts that hold the tips to the muffler flange. I can't believe that all of the hardware (bolts, washers, and nuts) are rusted! What appears to be stainless steel pipes, flanges, etc... held together with steel, or cheaply plated steel hardware. Shame!!!

I wiggled, kicked, and poked and I was getting a metallic ring from the right side tip. It seems that the fabricator put a couple of 'small' tack welds where the two tips come close together. Of course the were fractured and would hit together. The left side tips were even closer together and had even small tack welds. That side did not seem to make any noise. Given the level of vibration, heat and harmonics, I am appalled at this low level of quality. Now it appears that I will have to remove the rear bumper 'again' and hope the rusted nuts come off so I can do a better job of welding the tip supports so that they or some other part of the muffler does not crack. There is at least one post where the pipes going into the muffler tore off. If you have the FabSpeed muffler, you may want to have all of the mounting hardware checked for tightness from time to time. Also maybe replace the crappy hardware for something better.

I don't know where they have the design and fabrication done, but there is definite lack there. If this is truly 'Made In The USA', then SHAME ON THE FABRICATOR and the Company sell it!!!!!!!!

I should not have to spend my time fixing what was not a cheap purchase!!!!!

And don't even get me started on all of the Cheap Chinese Crap that a lot of stores sell here :-( Bring jobs and quality back to the USA!!!!!!!!!!!!!

 

Robert,
Thanks for the Holiday Wishes. Hope the same for you.

I will be calling FabSpeed on this issue and will post pix. Today I dug in deeper and found that the muffler shield also cut into and thru the aluminum cover that goes over the engine cover latch (also holds the 'open lid' sensor). With the muffler shield removed, I was still getting a rattle at 3,200 rpm. My temp fix was to (of all things) use a small wad of duct tape jammed in between the muffler tips where the outer most tack weld was. This got rid of the rattle!!!!

I have not looked into what FabSpeed's warranty is, especially after a year from purchase.

Most likely I will just fix it myself. I know what the problem is, I have a nice TIG welder and do it 'right'. Also use quality stainless hardware to replace the rusted crap.

Have a Happy Thanksgiving you all-

 

Alright guys.... here are the pix along with another issue.

First, since the muffler and tips are stainless steel, the hardware should also be stainless so as not to have galvanic corrosion.

Second, the tack welds that are to prevent the tips from banging together should have been much larger/stronger given the harsh environment (heat cycle, vibration, harmonics).

Third, the 'shield' that mounts over the muffler should have a notch at the rear lower edge to give adequate clearance between the engine latch cover and cover bracket. The notch would not be noticed as it would be low.

Fourth, I am debating to make new brackets to replace the left and right uprights (the brackets with '360' cut through them). All of the laser cut corners are sharp. This is exactly the ideal feature to propagate cracks. Also the bent tabs are rather sharp (small bend radii) and no bend reliefs to prevent the start of cracks. There is a F-Chat post that has pix of this very issue!

These are no small isolated issues, but flawed design. The tiny tack welds might be a QC issue, but that is no excuse as there should be two metal straps about .125" thick and 3/8" wide joining the tips instead of tack welds. Cost more, you bet, but they would last as long as the welding is done properly.

I have been designing sheet metal enclosures and structures for Naval surface ships, aircraft and submarines for over thirty-five years. I have seen what it takes to survive shock and vibration where failure is not an option. The exhaust system is a very demanding environment.

Pix... The rust, broken miniscule tack weld and the latch cover cut through by the muffler shield. The pix with the drywall screw is my temp fix to stop the rattle at 3200 rpm. The little nub of weld adjacent to the screw is where I filed the weld down. The vibration is so severe, the tips still managed to hit together. The screw worked as I had a couple of car events where I did not need the rattle.

The thought of sending the muffler and tips back to FabSpeed... No, not an option!!!
I will do the fixes myself because I will get it done right and won't be disappointed. Not happy that I have to pull the muffler again and buy a new latch cover.

Those who have The FabSpeed products, all I can say is 'Good Luck to You'.
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login

 

An quality anti-seze product would take care of that issue!!!

 

Well the muffler 'was' pushed in as far as the joints would allow and there 'was' space between the muffler and the latch cover/and bracket. It seems that the muffler shield came back around too far. However when the shield went on I could not see how close it got because that point is so low.

The person/persons who designed the upright brackets do not understand proper sheet metal fabrication practice.

I stand by all of my opinions on this product.

 

At this point, I will upgrade (fix) what I have for now. I just ordered a new bonnet latch cover (Ricambi $106.42 shipping included) and a piece of sheet 304 SS (Online Metals $$51.16 shipping included). I have a bunch of SS socket head screws, washers, locking nuts.

My design that will not have stress points (sharp corners and lack of bend radii) and will last. Also I will weld in straps to join the tips in two places on each pair.

This 'should' put an end to this mess.

Buyers Beware of crappy products!!!!!!

 

That would be true unless you apply anti-seze compound. That will prevent galling, etc...
Do a Google search, etc, check the manufactures product info...

 

I will post pix as my fixes for this design failure progresses. I will pull the muffler/tips on Monday, part and sheet metal material should be received later in the week.