Thanks flyinmiata :/
#25
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Ooops. That's what I get for skimming through your post. But it's reassuring that FM added the braces to eliminate future failure in that area (hopefully). Sucks that I have to pay for shipping both ways, but it's better than being SOL.
#28
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It does suck to have to pay shipping (it will only be one way though). I would recommend you give them a deposit ($200 IIRC) and then they advance you a new one. Then you can use the box and packaging to return the old one. I still ended up cutting down their box to save a lot of shipping $$$ because the dimensions are originally above what the post office considers a "very large package"(hey-o!)
#29
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I'm not a welder or a structural engineer, but it seems to me that triangular gussets (well, obviously not triangular on the curved part of the muffler) might have worked better than those strut braces.