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Performance Specialist
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193 Posts
Discussion Starter #1
We’ve been wanting to start an ongoing thread of all things Fabspeed: who we are, what we do, and what we build.



Fabspeed Motorsport is a precision machine shop, tuner, and manufacturer of performance products for exotic cars, located in a 26,000 square foot facility in Fort Washington, PA.



We are a team of passionate of over fifty automotive enthusiasts and craftsmen constantly working towards excellence. We proudly offer a wider selection of performance products for exotic cars than any other competitor in the industry with over a thousand different products and configurations.





Our knowledge depth, experience, and passion allows us to custom-tailor personalized performance solutions that perfectly complement the lifestyle and goals of every exotic car enthusiast. Sound, look, and service the way you want it. Our team of performance specialists are standing by to help you discover, understand, and exceed your automotive goals.



We look forward to updating this thread with interesting content on a regular basis. Posts will range from notable projects that come through the shop, to extracurricular activities like racing, technology, and much more. Subscribe and stay tuned!



Thread Directory:
Fabspeed History (Soon)
Shop Cars (Soon)
About Us (Soon)
Heavy Machinery (Soon)
 

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Performance Specialist
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193 Posts
Discussion Starter #2
FABSPEED MOTORSPORT | Shop Tour

SHOP TOUR

If you’re local to the Philadelphia area or traveling through, we encourage you to stop by and check out our shop. For our friends in other areas, we hope you’ll join us on this brief virtual tour of the Fabspeed Motorsport facility!



Welcome to our 26,000sqft headquarters and manufacturing facility located just outside of Philadelphia, PA!





The cars in the showroom are always cycling, but you can count on there always being some very impressive machinery on-hand.



Make yourself at home as we work on your vehicle. Relax, handle business, or chat with our tuner before grabbing lunch with your dedicated Performance Specialist.



This where the wrenches turn and the magic happens. At any given time we have a wide variety of different vehicles in for research and development as well as in-house installations and upgrades. We can install, develop, and build components for any exotic or high-end sports car, from McLaren’s to BMW’s.




We have a separate office in the shop which is home to our R&D team and recently expanded customer service department.



Our Unison all-electric CNC Mandrel Tube Bender, Haas CNC Machining Centers, Bystronic Press Brake, and Flow Waterjet are at the heart of our product manufacturing capabilities. We’ll post more information about our precision manufacturing division in our next post to showcase all the tools and equipment that we work with.





The Fabspeed Dynojet: fresh tunes served daily.



In our next post, we’ll dive into some of our R&D and fabrication processes in greater detail.



Keep an eye out for our annual Open-House events where we bring together the local exotics community for a full day of shop tours, dyno demos, and exotic cars glistening in the sun!



Metal, machinery, and sparks coming soon. Stay tuned!
 

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Performance Specialist
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193 Posts
Discussion Starter #5

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Performance Specialist
Joined
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193 Posts
Discussion Starter #7
FABSPEED MOTORSPORT | Heavy Machinery

At the very core of Fabspeed’s business is our development and manufacturing division. Thankfully, our team is comprised of some of the best minds in the business with access to cutting-edge technology and machinery.

A perfect example of that technology is our 7-axis Romer CMM Digitizing Arm. This highly precise 3D scanning tool allows us to map out the exhaust tunnel and tubing bends of each new product that we develop, along with various mounting points, brackets, and more.



3D-digitizing and CAD designing components assists us both during and after the initial development period. We’re often asked to make special alterations for customers with aftermarket body kits, track-oriented race setups, and other conditions which warrant unique and additional engineering changes. This data is also invaluable when it comes time to utilize our CAD-driven CNC equipment for the production of precision components.



Our Dimension Elite Additive Manufacturing Center (3D printer) has outstanding resolution and makes quick work of many of our prototypes. A prime example is our cast x-pipe which we incorporate into many of our products. This component began life as a digital concept, and went through many different 3D-printed variations before we found the optimal configuration for maximum flow performance. We also 3D-printed quality control gauges and jigs to ensure proper gap fit of our McLaren Supersport X-Pipe Exhaust System with both factory catalytic converters and our HJS-equipped Sport Cats.

The beating heart of our manufacturing facility is our Unison Breeze all-electric CNC mandrel tube bender It is capable of bending tubes up to 76mm (3”) in diameter as tight as a 1D radius, and pumps them out quickly and efficiently.



The Bystronic Xpert 150-ton press brake is a top-of-the-line sheet bender and looks the part. It’s one of the only press brakes available that doesn’t produce angle errors and is known for having the highest repetition accuracy on the market. This baby makes quick work of our brackets, heat shields, mounting tabs, and more.



No, it's not a hot tub. That’s our Flow Mach 4 XD-Series dynamic waterjet cutting station, which uses an 80,000psi stream of water and garnet to carve through metal like butter. A 6’ x 12’ cutting table allows for a wealth of production options. This bad boy can achieve tolerances as tight as ±0.002” and has the capability to cut through up to 6” of solid steel. We use it to cut out everything from flange blanks to our carbon fiber marque wall art signs.



We utilize two HAAS CNC machines: a VF-2 vertical CNC mill and an ST-20 CNC Turning Center. These sister systems create our custom flanges; countersinking, drilling, and milling within 10/1000ths tolerance for a leak free seal. It may be more cost effective to purchase pre-made flanges, but we prefer to maintain full control over the components we produce with the ability to make alterations at a moment’s notice.



Our VF-2 vertical CNC mill boasts a 30" x 16" x 20" (762 x 406 x 508 mm) capacity, 40-degree taper, a 30hp (22.4 kW) vector drive which spins up to 8100 rpm, 20-station tool changer carousel, and a 55-gallon coolant circulation system.



We use our RMI UF-50 laser engraver to mark components with “left” and “right” annotations, and even offer a personalization service to really make our parts your own!




All of the fancy machinery on the planet wouldn’t do us any good without our team of highly-talented machinists and fabricators. Our specialists are trained to manipulate metal with all manner of tools and technology.



Check out some of our team and equipment in action in our How It’s Made video, which shows the various processes involved in manufacturing our world-famous Porsche Turbo Supersport Exhaust Systems!

https://www.youtube.com/watch?v=-t4zn97WFDg

Thank you for taking the time to learn about our manufacturing. Next up we'll dive into the origins of Fabspeed and how we’ve grown over the decades.
 

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Performance Specialist
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193 Posts
Discussion Starter #8 (Edited)
FABSPEED MOTORSPORT | History

1986 - owner & founder, Joe Fabiani, purchased his first Porsche, a 1985 911 Carrera Cabriolet, and got involved with SCCA auto-x racing. This lead him to a few stints at Skip Barber racing school and eventually high performance track driving at Road Atlanta, Watkins Glen, Lime Rock, Summit Point, and many more courses.

His first dedicated track car, a 993 Carrera, went under the knife for a full RSR Clubsport conversion in 1994. When it came time to choose an exhaust, he was unsatisfied with the selection and quality of the aftermarket exhaust systems available at the time, so he set out to build one for himself.

1998 - Joe leading the pack at Sebring


Word quickly spread and his results at the track spoke for themselves. Other Porsche enthusiasts wanted a piece of the action, and so Joe took the plunge and decided to give up his brokerage desk for his own machine shop. Fabspeed was born.

2000 - Fabspeed goes digital; the first Fabspeed.com site launches



Fabspeed’s first dedicated shop in Ambler, PA began refining the sound and performance of Porsche exhaust systems - notably the 993 Turbo and 930 Turbo - but why stop there? A complete exhaust package was developed for the Ferrari 360, the Lamborghini Gallardo, and soon more supercars filled the shop.

Seeing red at the Fabspeed Ambler facility in 2010


Within a few years, business was booming. Joe had expanded the Fabspeed product line to include hundreds of different performance products for almost every model of Porsche. Within a few short years, that list would also include applications for Ferrari, Lamborghini, Maserati, Bentley, McLaren, Aston Martin, and more.

2012 - Fabspeed moves into its new 26,000sqft manufacturing facility and showroom in Fort Washington, PA



Today, with the help of state-of-the-art CNC manufacturing that you saw in our previous post, and a team of passionate craftsmen, Fabspeed proudly offers more performance products for exotic cars than any other competitor in the industry. This depth, experience, and passion allows Fabspeed to custom-tailor personalized performance solutions that perfectly complement the lifestyle and goals of every exotic car enthusiast.

 

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Performance Specialist
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193 Posts
Discussion Starter #9
FABSPEED MOTORSPORT | BMW March ///Madness

For decades, Fabspeed has led the industry with our performance products for Porsche, Ferrari, Lamborghini, McLaren, and other high end marques.

Now that our team includes several BMW owners, BMW club-racers, and former BMW employees, we are excited to be taking what we’ve learned over the last 20+ years and applying that experience and technology towards designing and fabricating performance exhaust products for the Ultimate Driving Machines.


Our product development inspiration comes from many different sources. For some projects, our marketing and R&D teams take the reigns. In other cases, we rely on our customers to tell us what they want, and we set out to fulfill those requests. Such was the case when a local Bimmerpost forum member stopped by with a request: spice up the exhaust note of his 2015 M3 which was already equipped with an M-Performance rear muffler. We worked with Matt to bring this product to life for the community. Our design includes dual x-pipe sections for optimal flow blending (also utilized on our full M3 & M4 Valvetronic Exhaust System) and a unique flex bellow which allows for straightforward installation.


If you aren’t familiar with the pinnacle of our BMW lineup, it’s high time you get acquainted.

Meet the Fabspeed F8x M3/M4 Valvetronic Exhaust System...



When the BMW community came to us looking for additional tip options, we tasked our fabrication shop with producing a sleek, track oriented variant that we would make right here in-house. We crafted the Single Wall Brushed Quad Tips to complement the more aggressive carbon fiber aftermarket diffusers while offering adjustment that allows the tips to be set at a desired depth within the bumper. Producing these in-house allows us to make them at a custom length to match any setup.


We’ve taken on a new Performance Specialist, Bobby, who hails from a BMW background and has an M235i and 335i with which we developed a new system for.

Our Muffler Bypass Exhaust isn’t winning any awards for Most Complicated Design, but it’s leading the pack in contention for Most Grin-Inducing Sound. This is our easily reversible, weight reducing, sound enhancing, cost effective exhaust solution for the F3x 335 & 435 models.


The addition of a performance downpipe encourages a symphony of crackles and burbles on command.


Fabspeed is the largest distributor of HJS catalysts in the US, and second largest in the world! Our experience with pairing the correct cell count, duration, and diameter with specific vehicle applications has paid off. After much R&D, we are one of - if not the only - company providing a 200-cell high flow catalyst-equipped performance downpipe for N55 engine cars that does not trigger a check engine light. We also offer HJS’s own 300-cell Euro 6 compliant downpipe in addition to our Catbypass Downpipe to cover anyone's needs.


Our enthusiasm and passion to drive new innovation doesn’t stop at BMW. We apply these same processes to all of the makes and models that we work with. Thank you for reading about our BMW development, subscribe for future features on more marques!

 
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