21st Century Outlaw 997 Project

[Darren C]

Filed out to suit

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I purchased 2 new fittings from Porsche to use as a guide

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And fitted nicely

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[Darren C]

So finally tonight my next job is getting the 991 rear valance insert to fit. This allows swap out for numerous exhaust tailpipe possibilities, rather than casting my GRP bumper with cut-outs and no flexibility to alter easily.
The original 991 part has 12 x tang/tabs and two concealed screws to attach it to the bumper in a rather complex PU molding.

This was my original nightmare which led to the silicone flex mold route I took. The original 991 mounting for this as I said is very complex (easy to PU inject plastic in a die, but not so easy to split mold at home in GRP)

Here's a close up of how it came out on my bumper, so you can see what a task to get that detail was!

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So the next stage is to cut those 12 slots.....1st one

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Then hopefully with 11 more the lower valance will slot in nicely

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So that's where I'm up to at the moment, 11 more fiddly swiss file slots to go at about 45 mins each

[hot66]

Look good. Can’t wait to see the finished car now.

[911hillclimber]

More hard work and sore fingers.
Would a dremmel ease the pain?

[Darren C]

Dremel bits seem to loose their edge very, very quickly on fibre glass & those little sanding bobbins go "thwap" and shoot off into the unknown far too easily

[sladey]

Nice work Darren - thanks for sharing

[Darren C]

This week during the evenings I've been drill, cutting & filing out the remaining valance slots and dressing other areas of the GRP bumper.

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With all this done I could finally test fit the 991 lower valance

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With all the main bits done I pressed on this week so that by the weekend I'd be in a position to trial fit the bumper to the car

[Darren C]

This morning I carefully removed the standard 997 rear bumper

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But discovered a whole load of sh*te behind it that needed a good clean
Anyways after a few hours it all came up well & I got to fix a few issues with loose heat shields etc

The old & new were placed side by side and measurements taken

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More filing & grinding was required to a few bits, here & there and I was good to go with first trial fit

[Darren C]

So folks, I'm just going to post a few pictures, words not necessary

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[Darren C]

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[KS]

Excellent work!

[Tosh]

This morning I carefully removed the standard 997 rear bumper

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But discovered a whole load of sh*te behind it that needed a good clean

Oh dear, I must have been here too long
I saw that pic and thought "there's no way Darren would put anything over that grime".
And then read the caption

[1968911s]

Will there be a duck tail for that rear lid?

[Darren C]

Thanks for asking....

I've been pro & anti Ducktail over the last 18 months while thinking about what to do with a 997.

Porsche did the "ducktail thing" with the Sports Classic & to be honest I've never been a Ducktail fan of anything other than on the original RS cars and as Porsche have already done that on a 997, I'm trying to do something new.
So after much thought, I plan on retaining the motorised 997 spoiler, but remake it in a retro/backdate Outlaw Grille style. Possibly engineered with a more chunky look than a dainty original grille (to take into account how much the 997 has grown in size over the years).

Since my car is a 3.8 Carrera S, I have already got an original 3.8L grille badge to put on my new chunky grille topped motorised spoiler.

Watch this space as they say, bumpers almost ready for paint & the stainless spun versions of my home made mirrors are now back from the metal spinners. Picture updates to follow

[Darren C]

Just a few posts this evening to bring you up to date on progress.

With the bumper back off the car after trial fitting it was time to sort out the park sensors. The GRP was thicker than the PU so to make sure the sensors sit flush I thinned it down from the rear.

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Until it measured the same as the original PU

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I'd already removed the sensor holders from the used bumper that made up part of the original plug form (Porsche stick these on with double sided tape ) so made sure all 4 fitted ok.

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