FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
A few months ago, I decided to take my next step towards Boxster bliss. My focus was exhaust, more specifically headers and cats. Many of my friends have said, “the car sounds great, just leave it alone.” But, as many of you can relate to, I am on a mission to make my boxster sound and perform exactly how I think it should have left the factory. Many forum members are aware of the vast amount of exhaust offerings for our cars. In fact making a decision can be a little overwhelming. This post is intended to help those who already have or are considering an FVD / M&M exhaust, headers and cats.
I own a 2006 987.1 Boxster S (3.2L, 6 speed) and have the added the following modifications in the order that they are listed:
1. FVD Software & BMC Sport filter
2. FVD Sound Version Sport Muffler
3. H&R Lowering Springs
4. OZ Ultraleggera HLT 19” Wheels with 7mm FVD spacers (front) & 18 mm FVD spacers (rear).
5. 75mm throttle body with 75 mm IPD Plenum
As many of you know, the vast majority of FVD exhaust systems (about 85% of our entire Porsche line up) are made by M&M exhaust, GmBH in germany. M&M actually stands for Motorsport and Marine by the way, they also make racing exhausts for boats!
Here is a little more background on M&M.
FVD sound version muffler background:
In order for me to expand on the headers and cats, a little background is necessary on our sport mufflers. I purchased the FVD Sound Version muffler. I have had it for nearly a year now and couldn’t be happier with its performance and sound. When driven softly and it is extremely docile, and parallels the stock sound and interior noise level, drone is non-existant. With a slight increase of rpm’s this system teases you with what is to come. You find yourself trying to sneak out of the neighborhood on an early morning a little quicker, dying hit wide open throttle. When you open it above 2,800 – 3,000 rpms the sound is absolute bliss. To me the Boxster’s and Caymans have much more of a mechanical sound than a 911 and the sound version muffler highlights this extremely well. It adds a lower, deeper horizontally opposed flat six tone at lower rpms and then changes pitch at higher tones like a GT3 Cup Car. M&M is spot on with this muffler and I am extremely finicky about a Porsche sounding like a Porsche. It must be the years of following ALMS and the Grand-Am series.
Logical Progression, FVD /M&M sport muffler to complete system:
Up to this point, M&M was only making a complete system with headers, cats, muffler and tips OR a sport muffler option that I mentioned above. They didn’t have a modular system. Most of us want to start with the M&M muffler and eventually acquire the headers and cats, depending on how mod crazy we are of course
. So about 4 months ago I asked M&M to put modular headers and cats into action to cater to those who want to take their cars to the extreme on the tracks or on the streets.
M&M Headers:
Once I received my headers and cat’s I knew that M&M had delivered on all the points we had discussed.
When I inspected the headers I noticed how beautifully manufactured they were. M&M builds these systems by hand and they are magnificent. Let me start with the flanges that meet the engine block. Most aftermarket flanges for the boxster and caymans are a thick single plates. M&M uses a double flange, which is welded together to dissipate thermal stress.
http://multimedia.fvd-web.com/********/987/headerx.jpg
Thick single plates tend to warp over time which will eventually lead to exhaust leaks. M&M cannot take this risk as the vast majority of their systems are used on racetracks all over the world. The double flange is more time consuming to make but it M&M does not sacrifice when it comes to their systems.
From the flange the primary tubing widens then smoothly narrows back down. Interestingly enough M&M does not mandrel bend the primary tubing. Contrary to what many of us think about mandrel bending being a superior way to get around a corner. M&M’s stance is that mandrel bent headers have been proven to crack under the severe stresses found on the race track. The mandrel bending process actually stresses and thins the material, which leads to cracking. M&M segment the primarys and actually welds them together by filling the sections with forming gas. Forming gas actually pressurizes the area being welded to create a smooth inner surface. Once this is completed then they pass a tool inside the header, which will actually grind away any left over slag. This process produces extremely durable headers with a superior straight through design that ensures higher gas velocity and less exhaust gas restriction.
The long tube design utilizes all of the space that the stock header and cat took up. M&M extended the header out away from the block as far as they could for smoother more laminar flow. They took the path of least resistance and then gradually smoothed it back towards the flange. Look at the pictures below for reference.
http://multimedia.fvd-web.com/********/boxhead/boxhead4.jpg
http://multimedia.fvd-web.com/********/987/installed1.jpg
http://multimedia.fvd-web.com/********/boxhead/boxheadr1.jpg
Note the picture below, the stock headers come off of the block smoothly on 2 banks but note the hard near 45 degree angle of the third? Then note the short 4.5 – 5” (estimate as I did not actually measure) travel until they meet the “collector”. The stock headers and many of our competitors systems suffer from extremely short primary tubing, which robs power. M&M thinks outside of the box, they would rather extend the length of the primaries and moved the cats all the way back towards the muffler.
http://multimedia.fvd-web.com/********/boxhead/boxheadr4.jpg
Stock Porsche headers tend to end with simply cut tubes that merge together. As you can imagine, 3 exhaust paths slammed together so abruptly tend to cause turbulence. Turbulence equates to reduction in velocity and an increase of heat. The M&M set up incorporates a collector that smoothes out exhaust flow, creating more velocity and reducing backpressure. But, this isn’t your ordinary collector, they take it to another level. Many of our competitors use “pyramid style collector” which is manufactured from the center of the merging tubing outward to the flange in a pyramid shape. M&M’s collector gently guides exhaust gases from the walls of the merging piping towards the center creating a “singular” exhaust stream through the center of the flange. See the pictures below of the M&M merge collector, this picture is actually taken of a turbo header as I couldn’t get proper pictures of the boxster collector with the flash.
http://multimedia.fvd-web.com/********/987/collector1.jpg
http://multimedia.fvd-web.com/********/987/collector2.jpg
M&M Cat’s:
M&M’s design sets the cats all the way back to allow for maximum exhaust velocity and the ability to build up good back pressure for low end and mid range torque. These systems can be ordered with HJS “HF” (High Flow) cats or HJS “HD” (High Durability) cats. I chose 200 cell HJS HD cats. They are the latest HJS cats, and are nicknamed “HD” for high durability matrix design catalytic converters. They have a SM-matrix (winding of three flat and corrugated foils) and a special connection to the matrix sheath, which equates to extremely high durability for track and street use. The added benefit is that they DO NOT generate catalytic efficiency codes (CHECK ENGINE LIGHT) that most OEM Porsche programs (EU 5 software) generate. HD cats are perfect for those who are consistently tracking their cars or want to run sport cats without a software program. The cats are secured to the M&M muffler using the sleeves that came with the muffler.
http://multimedia.fvd-web.com/********/boxhead/boxhead5.jpg
http://multimedia.fvd-web.com/********/987/installed5.jpg
The sound:
Obviously the muffler is dictating most of the sound with this set up so the deep, rich flat 6 tonal quality is enhanced. Personally I enjoy louder exhaust systems that enrich the sound that Porsche intended these cars to have. In my opinion many systems on the market are lacking a true Porsche tonal quality. After living with this set up for a few weeks I have decided that it is exactly what I was looking for.
With the HJS “HD” cats the sound has a little more rasp than with the muffler alone particularly when cold. I think that the rasp is due to the sheathing of the cats, which I explained above. I have heard a few of these M&M systems with normal “HF” cats and they don’t exhibit that raspy tonal quality at all. When the system warms up the rasp is noticeable between 3,800 and 4,000 rpms and then goes away as quickly as it comes in. I don’t enjoy raspy systems at all but this set up just hints rasp and settles back in to deep, rich tones. It seems to add another auditory dimension that adds to it’s exotic sound.
While this configuration sounds more aggressive it still lacks that over the top aggressive sound found with many other systems. This is a more refined aggressive if you will, more of an exotic Porsche aggressive. In the lower to mid range rpms this system has the deep, low aggressive tones of a 997 RSR. When you approach the 3,800 – 4,000 rpms you hear shades of a more exotic Ferrari with the additional rasp. The sound then builds to a higher Cup Car pitch and then lessens in volume at the very top end. The sound at the top end is quieter and somewhat similar to what you experience up to 2,800 rpms. The decibels taper off at the top and bottom of the rpm spectrum. You can still modulate this system with the right foot just like you did with the muffler. The fact that you can still make this system sound like a stock system below 2,800 - 3,000 rpms is unbelievable!! I never imagined that would be possible but it’s a fact and it is a testament to just how good this system is.
Internally there is a small amount of resonance in the cabin and frankly I expected it. Peoples opinions on resonance and drone differ. To me resonance is when you have a loud exhaust system that penetrates the cabin. Drone is when that resonance becomes uncomfortable. This system has resonance, a small amount but it is there. Remember, I wanted more power and more sound and the drawback was some resonance. This system’s resonance does not escalate to annoying drone by any stretch of the imagination. It is simply just louder in the cabin, which I completely accept. I am sure some can find some drone if you drive at about 45 mph in 6th gear, but how many of us really do that?? :crazy:
My Boxster S Video (I am working on an extended video as well):
Boxster S Video with M&M headers, 200 Cell HD cats and the TUV (quiet) muffler:
The weight savings:
Another benefit of this system is the weight savings. Simply put…
Stock Mufflers ( 18.25 lbs x 2 = 36.5 lbs )
+ Stock Headers ( 8.35 lbs x 2 = 16.7 lbs )
+ Stock Tips ( 8.40 lbs )
= 61.6 lbs.
http://multimedia.fvd-web.com/********/987/muffler.jpg
http://multimedia.fvd-web.com/********/boxhead/boxheadr4.jpg
http://multimedia.fvd-web.com/********/987/tips.jpg
FVD / M&M Muffler with tips ( 25 lbs )
+ FVD / M&M Headers & Cats ( 12.6 x 2 = 25.2 )
= 50.2 lbs.
So the total weight savings is 11.4 lbs.
http://multimedia.fvd-web.com/********/boxhead/boxhead4.jpg
http://multimedia.fvd-web.com/********/boxhead/boxhead8.jpg
The power:
Finally I am at the business end of my findings. Since I have had this car and settled in to it’s power I have always yearned for even more. With this header and cat set up I can officially say that this car has now reached it’s peak. I was impressed by the addition of software, then the sport muffler. When I added the throttle body and the IPD Plenum I thought that I was getting close to reaching this car’s potential. But with the addition of the headers and cats all of my previous upgrades have simultaneously come together to make this little car downright evil. I really didn’t think it was possible for a Boxster S to be scary fast but it is! Ok, ok I know some of you turbo guys are saying scary fast? You don’t know what that is.
To be quite frank I was a little bit worried about losing to much backpressure with this set up. Loose to much backpressure and you loose your low end and mid range torque. To my surprise this set up is not lacking anywhere!! With the stock system I was unimpressed with the flat spot between 4,000 and 5,000 rpms. Those days are simply a memory now. My car pulls hard through every gear. The real power comes in between 3,000 and 6,000 rpms. All that I can say is that the respect that I have for M&M has grown tremendously. They are the business, no questions asked.
In tuning any of the cars that I have owned over the years I have always relied on the seat of your pant’s test and real world take it to the track attitude. Personally I don’t have much faith in dyno tests and most of them around here are run by our competition. So, I would rather share verified Performance Box data with video. I will be doing these tests within the next week or so. I will keep you posted.
Header and Cat Facts from our website:
- + 20 crank hp & + 19 crank torque
- 2" tubing (50 mm) straight through design for max. power
- 200 Cell HJS Tri Metal High Flow Cats (“HF” Cats)**
- Weighs 12.6 lbs. (5.7 Kg)
- 26 lb weight savings over complete OEM exhaust system!!!
- T 316 stainless steel for improved durability over T 304
- Made in Germany by M&M Exhaust GmbH
- Intoxicating Cup Car like growl above 2,800 rpms.
- 8 on a scale of 1-10 in volume (1 being stock) above 2,800 rpms.
- 4 on a scale of 1-10 in volume (1 being stock) below 2,800 rpms
- Additional hardware is not necessary, headers and cats reuse the M&M muffler sleeves.
- No DME programming necessary with HJS HD Cats**
Link to the website for the 200 cell "HF" cat version.
Please Note we also have a new cat bypass version of these headers. I will be posting on that very shortly as well.
Link for the cat bypass.
Pricing:
1. FVD / M&M headers with 200cell "HF" cats: $ 2,995.00
Current retail is $ 3,788.80, that's a savings of $ 793.80!!
2. FVD / M&M headers with Cat Bypass: $ 1,995.00
Current retail is $ 2,768.37, that's a savings of $ 773.37!!
Just so everyone knows the latest "HD" cats will be more expensive but if enough people show interest we will also create special pricing.
Thanks in advance for your time, I really didn't mean to right a book.
Rhonda
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Great post Rhonda.
I must agree with your description of the sound that the M&M cat-back exhaust system generates. I've been looking for the longest time trying to find the "right" aftermarket exhaust for my 2006 CS. While I was looking to improve the performance of my car, I also wanted to enhance the sound of the Cayman. Particularly, I wanted to make sure that the sound I end up with sounds like a Porsche. IMO there are a lot of good aftermarket cat-back systems out there for the Cayman, but there are only two that keeps the integrity of the true Porsche sound and they are: the FVD Brombacher and speedART cat-back systems, which coincidentally are both made by M&M.
It's been three weeks since I've had my FVD/M&M cat-back exhaust installed and have been extremely happy with my decision and the positive results:
- Power is more consistent through all the gears = linear?
- Seat of my pants tells me there is more than the advertised 11 hp and torque gain = Car pulls much harder than stock
- NO DRONE!
- And the sound at WOT... Cup Car like sound = Heaven
Your description of the manufacturing process that makes M&M headers stand out from other after market headers is very interesting. I am definitely considering adding the M&M headers to my wish list.
Lastly, I would like to thank you for your utmost professionalism and excellent customer service. I've heard people on this forum say you were great, I agree 110%.
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Golfish,
Thanks for the kind words.
I am absolutely thrilled to hear you are enjoying your exhaust!! Seems you have the same idea as me in regards to the "integrity of the true Porsche sound".
I don't like to comment on anything in reference to speedART but when it is used in conjunction with M&M, I only ask that those who are interested in an M&M product look for the M&M logo on the exhaust itself. Here is an example...
It was nice to go into a little more depth with my car. I can't wait to post the Performance Box results. I just received the Performance Box from Germany so I will have something posted in a few days.
Your very welcome but there is absolutely no need to thank me for the customer service. I am just doing my job.
Thanks again and most importantly keep enjoying that exhaust!!
Rhonda
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
is the exhaust system with the "hd" 200 cats clean enough to pass california emmisions testing? i'm guessing that for you, like most aftermarket companies, CARB certification just isn't worth the drama. but would they at least pass the emissions test?
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Rhonda,
I own a 2006 CS with many boltons as there are around with software etc...
Do you think that running your catless header version with a catless R. Catback will result in too much backpressure loss?
Thanks,
Jose
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Justaddcoffee,
The 200 cell HD cats will certainly pass emissions and we have considered the CARB certification as many states will be adopting this idea in the future. Perhaps we will be addressing this in 2011 but certainly not currently.
Jose,
Are you running a catless M&M style muffler? Sorry, I am not sure what a catless R. set up is. These headers and cats only work with M&M mufflers like the picture below as they use a open sleeved end not the stock style flange.
http://multimedia.fvd-web.com/********/987/installed5.jpg
Regarding the backpressure, the catless headers are designed to work with either the sound version or TUV M&M muffler. You won't loose low end or mid range torque.
Hope this info helps.
Thanks,
Rhonda
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Rhonda,
The catback is a catless Remus and this is where I wanted an opinion since I just bought this catback just a few months ago (with intention to keep) and I am currently using a header (catless also) which I dont feel good about.
Thanks
Jose
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Rhonda,
Are you still with us here?
Jose
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
From Rhonda's description, it sounds like the header only works with M&M exhausts. And looking at the pictures, you'll not be able to connect your Remus race muffler with the M&M headers. I'm not sure you'll be able to tell much real-world difference between a catless header v. race-cat headers. I'm sure some would argue there is a difference... and I don't disagree. But not sure what or how that will translate into real world experience.
For me, I have the Fabspeed headers with 200c/race cats paired with the Remus exhaust and love the setup.
Jose
lithium1330 is right on ! The Fabspeed will not dissapoint you .they will add 15 HP solid to the rear wheels .there are some really nice readings about the Cayman Interseries cars that use the Fabspeed Exhaust and Headers to help thier cars with the HP
Rhondas setup sounds quiter then the Remus and Fabspeed combo
I would add 2 numbers to all of her number ratings
Re: FVD Brombacher – M&M Headers and Cats for all Cayman & Boxster M&M mufflers
Cant wait til Im able to make the move and get these mods!! Sounds great!!
Re: Jose
prodgers,
You cannot compare our headers to the fabspeed in the slightest. The FVD headers are a completely different design.
Also these are built by M&M in Germany who build systems like these...
Which is currently running under the new RSR.
None of our competition can make that same claim.
Re: Jose
Making this a little easier to find for a few customers...Thx, R
Nice!
ive just picked up a set of Catless race headers for my 987.2- plan on running it through stock cat back. Hope it sounds great and performs well!
