21st Century Outlaw 997 Project

[911hillclimber]

Whew!
Mammoth work with mammoth results Darren.

Unique and must be very satisfying to see it all finally.

[Bootsy]

Like that

[LMR]

Stunning!!

[Berny]

Lovely finish and so much attention to detail .

[Darren C]

Thanks for the kind comments

So to continue, I started to make up my own rear exhaust section to join onto the Eurocup Full Flow Stainless system installed during engine rebuild. Starting with the link plate made previously & some pipe fittings

Next I got hold of some 108mm diameter stainless pipe to make the tailpipes, cut to length and squared off the ends precariously in the lathe

[Darren C]

Next I marked out the relief so that it could sit flush in the link bracket

Then cut them out

So it all fit snug

[Darren C]

The tip rims were then set up, paying attention to the position of the split rim holes (so the petal centres would be vertical & matching) and marked out for condensate drain semi circular holes. In this way the tips wouldn't collect water on start up.

Repeat for both

Then carefully machine out a relief in the rear of the "rim" to match the 108mm tube

[Darren C]

The rims were the micro tig welded to the tube from the inside. A bit like wallpapering your hall through the letterbox

Then after a polish to remove blueing the centres were fitted using the M1.6mm nuts & bolts. Fiddly a fook, ended up using a sticky caulking to hold the nuts as they're too small to pick up by hand

[Darren C]

Every M1.6 nut & bolt was fitted with locktite & tightened with a homemade spanner.

Then just when my eyes & patience had gone complete, I had the second one to do

[Darren C]

Out with the welder again, set up pipe & fittings, then tack in place.

Once this was tacked up I found that the two rear lower 997 bumper supports fouled the new pipe & wouldn't let it sit far enough to the rear to clear the CATs'
So make two new ones
To be fair the old ones were a bit scabby, so I used some 6mm stainless for the new brackets, shaped concave (as opposed to the original convex, to follow the contour, just behind the bumper for maximum space.

[Darren C]

The big day arrived when it was time to do a dry run on the car, which involved cutting back the Eurocup pipes just before the original 997 tips.
So with brave pills at hand I cut them with an angle grinder, then tube cutter on my new assembly to suit.

Measure 26 times, cut once

The bumper brackets were swapped over, then with the aid of a pair of swaged 90 stainless bends, chocks & lots of measuring, I tacked it in position.

[mycar]

That is a lot of work.

[Darren C]

The whole assembly was then removed for fully welding up.

With its proximity close to the inside of the rear valance & CATs I decided to heat wrap it in these positions after welding.

Being a paranoid engineer, I thought it prudent to make a spring hanger to support the section by the tailpipes. Not that they're heavy, more peace of mind, as there's an additional overhang weight that wasn't there before.

Just by chance the 997 has heat shield threaded fixings dead centre above where I wanted to put the hanger, so these were used in combination with some extra ones.

[Darren C]

All that was left to do was make up a bracket on my exhaust to join with the spring hanger. Using a "spare" link & tubes I'd made if it all went Pete Tong, I took some more measurements.

Then imagineered a bracket in Stainless

And welded it in place

[Darren C]

Finally the assembly was Polished to remove all weld blueing & refitted back on the car with some new pipe clamps, and the spring hanger tension set

The last job was then to swap out the 991 lower valance insert that I'd cut for the original wide spaced 997 tailpipes, with a new one. This is in two parts with a separate insert around the centre tailpipes. I decided in the end to cut about 2" off the bottom to reveal the 21st Century Outlaw script for all to see