21st Century Outlaw 997 Project

[Darren C]

Next I did some final file/fitting against the Mirror cones

Next the rivets that temporarily held the underside closing plates on, were drilled out & M4 nuts welded on the reverse.

[Darren C]

The holes in the pedestals were then countersunk & assembled with M4 bolts.

I also added a couple of drain holes

[Darren C]

Then came the time consuming filing with ever decreasing range of cut to remove all imperfections & any working marks

Then Block sanding with ever decreasing grit paper

All in preparation for mirror Polishing of the Stainless Steel

[Darren C]

And the final result after many hours on the buffing wheel...

I suppose they'll do for now

[Darren C]

So in the meantime back to the bumper..

For the 991 vents I made stainless mesh inserts starting with the wire frame, that was welded together

Then dressed for an invisible join

[Darren C]

Continually checking fit in the 991 vent rear bumper inserts

Next secured to the double crimp Stainless diamond mesh in a position so that the diamond holes are square & equal (OCD ) ready to weld

Then I made some stainless pins & tabs to secure it

[Darren C]

The pins were filed for a perfect fit to the frames before it was all welded together

Then I carefully cleaned up all the welds before drilling & bolted them into the plastic surrounds

[Darren C]

With my bumper back from the paintshop I set about building it up.

Making stoneguard film templates for the arch edges

Then taping in place & cutting out from the film

Then attaching to the arches

[Darren C]

Smoothing out all bubbles

For an almost invisible result

Then installing Rivetnuts for an OEM style numberplate fixing & next the numberplate lights.

[Darren C]

To harvest the park sensors & wiring loom I then had to remove my existing bumper.

And swap everything over..

Next fit the mesh inserts

But before the bumper could be fitted there was a few more jobs to do

[Darren C]

For my new twin centre exit exhaust pipes I had to cut & modify the existing 997 heat sheild. The edges were then folded over to finish the opening.

There's also 2 x stainless tube braces on a 997 behind the rear wheels that hold the lower bumper edge. With my new bumper being slightly deeper than standard I had to make new longer braces.

And in comparison... (never did like all the bends in the OEM ones )

[Darren C]

Final preps were in the clip in lower valance...

My plan is for twin centre pipes, but until I've finished making them I needed to run with the existing exhaust.

This would look odd if I left out the valance on my new bumper, so having purchased a brand new 991 valance I was in a quandary what to do? In the end I bought a used valance off flea bay so cut it about as a temporary fix to clear the C2 tailpipes.

So on a sunny Sunday I got everything out the garage & ready for final fitting.

last job was to black out the bottom of my heat shield (which are silver) in a position behind the side vents.

While that was drying, all the paint edges on the car I taped up with 3-4 layers of masking tape, as was the edges on the bumper.
With the help of my son the Bumper went on a treat

[Darren C]

The two side braces fitted perfectly...

And I had a new set of size matched (to the new retro opening) numberplates specially made up with a Martini Homage 21st Century Outlaw spin

[Darren C]

So without further ado here's the bumper on the car

[Darren C]

So, mirrors, boot spoiler, Bonnet, front bumper, exhaust & interior yet to do....best I get cracking