Back in the day. Faster turbo swapped srt4’s had this problem. A big ass turbo, even with a downpipe with no cat, would blow the welds on a 3” aftermarket exhaust. They’d just start cracking if the turbo was big enough
the solution was either going 4” after the downpipe or going with a custom 2.5” or 3” side exit exhaust
but we aren’t talking about mopar stage 3 srt4’s. These were fully built running low 9’s
stock exhaust with aftermarket downpipe on a GTI will be fine beyond 400whp. This combination would more than likely be right at the limit on a maxed out vortex xl. Any bigger than a vortex xl I’d would be wise to increase diameter after the downpipe
good exhaust welds don’t just pop or crack from back pressure. But sometimes that back pressure, if it’s strong enough to almost cause restrictions at each bend, can crack welds. This phenomenon won’t happen immediately. Just little by little. Till you can actually hear the exhaust leaks. Especially pre muffler
the only one amongst us that’s more qualified to speak on this particular subject is probably gonna be
@GTI Jake since he seems to be the only one making cat back exhausts for the masses. Hopefully he can chime in
jakes cat backs are of high quality. And in pics his welds look really well considered, neat and professional. But even his cat back isn’t invincible
the awe and borla and a few others are three inches till the axle back. Then it shrinks to like 2 inches. I can imagine that shrink spot where it goes from 3” to 2” cracking some if the vehicle has a maxed out vortex xl. Where as jakes version stays true 3” front to back, thusly being able to take more abuse vs an awe or borla