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Did my first Track day last weekend and discovered at the end of the day that the Catback has failed in a big way.
The welds on the small connecting pipe that runs from the mufflers cans left to right has completely snaped!
The whole assembly is so rigid that no wonder it failed due to vibration. Also there is no stress relief in this system.
The noise with that hole was terrible, the CS sounded like a farty 4 cylinder rice burner.
I'll post some more info about this and the fix soon.
See the gaping hole below!
Please let me know what happens with this. The sponsorship of a former Milltek reseller - Stratmosphere - ran out in February and they chose not to renew their sponsorship. I reached out to Phil Millington of Milltek asking him directly if Milltek wanted to become a sponsor or if they had another reseller who they would recommend. I also asked about my failed headers and to date I have not received a response and had sort of given up on them. So I am keenly interested in whether or not you get a response and what the resolution is. To be fair, I must say that I have not seen any other catback systems fail in this fashion.
After a week of sending emails to Milltek Ive had no reply. Not happy.
Took the car to a professional custom exhaust shop to have the system fixed. They repaired the welds on the cross connect pipe and inserted a flexi joint and a flange with bolts for disconnecting. The result is great and vibration from one side is now isolated from the other.
One interesting thing is that the inherently small but noticeable resonance before is now even better/lower than before. Bonus!
I post some pics of the mods soon.
Good to hear you were able to get it fixed but I'm not pleased to hear that Milltek just isn't responding these days, I wonder if some of our UK friends could pay them a visit in person?
Good to hear you were able to get it fixed but I'm not pleased to hear that Milltek just isn't responding these days, I wonder if some of our UK friends could pay them a visit in person?
Allan Whittaker (Tess Tickle), of Motordrive knows Phil Millington of Milltek so he is the best person to ask........
I know Allan is testing - long term, an original Milltek 100 Cell Full System with regular monitoring of Cat Performance so that failure modes can be assessed. I have the first 100 cell system sold and 5,000 miles on, no problems.
Allan drives his Cayman very hard, both as a daily driver and on the track. He is again out on the track today, and is probably going to clock up around 250 miles at Bedford Autodrome, a 4.2 mile long track with a 1 KM straight where we get up to 150 mph and also technical twisty bits........ ( I don't know how that stacks up compared with your US Driving Experiences, AutoCross, TrackDays etc - but I regularly exceed 200 miles on every track outing.........)
I'll point him to this thread...............
Motordrive
Motordrive
Moslo Mill
Ebury Street
Radcliffe
Manchester
M26 4BL
UK
Oddly enough my first set of cats (100cel) which I sold with my first system have never failed. My second set from Milltek which were 200cel were the ones that failed. Hopefully Tess can go over and have a strong talk with Phil.
This situation with Milltek could not have come at a better time.
I've refused to take delivery of my Milltek catback exhaust system.
I've requested from Milltek/Distributor an assurance, in writing, before taking delivery of the catback. This assurance is also connected to my intended purchase of the new Milltek header. There are also other conditions attached to the purchase delivery.
From the time this situation with Milltek was reported, I have not received any positive response from Milltek. I've informed the Distributor/Milltek that they have until April 11 to come up with an assurance that's acceptable to me.
Milltek must realize that these days, information is just a "google search" away. We may lose (the cost of) a catback or header, but Milltek has a lot more too lose. People are watching.
Milltek Catback Failure
Wifey traded her Boxster for a 2008 RS60 Spyder. 
