21st Century Outlaw 997 Project

[Darren C]

When the M1.6mm nuts turned up....well I thought the bolts were hard to pick up

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Anyways I got to do a dry assembly

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The last machining thing to do, was to turn down a step on the outside of the rim so it fit & located into my tailpipe tube.

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With the parts made they needed tidying up.....

[Darren C]

A proportion of the centres needed to be black to add definition & replicate a Fuch.

I decided against paint as the tailpipe would continually go, hot-cold & be subject to gases & acids in the fumes so ended up choosing black nickel plating.
To prepare the parts I put them in a tumbler polisher for a few days (same type as folks polish pebbles in for a hobby) This really cleans the intricate sections up a treat. I final surface hand polish and they were ready to be dropped off at the electroplaters.

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When they come back they're all black, so the next stage was to hand polish through the nickel back down to the stainless steel
Firstly with blocked 1200 grit & Brasso

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And finally with a pair of Vals old pants (no sticky backed plastic) on a block with Brasso, and eh Blue Peter, a mirror finish

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[Darren C]

Repeat 4 times

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Next the rims got a mirror finish polish

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[Darren C]

And finally the last post this evening...the assembly.

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Now I fully appreciate that that two of these as tailpipes may seem a little odd at first, even Marmite to some, but I think its just a case of personal folly & over indulgence on my part with a modicum of why the hell not!
After all, I am trying to break new ground here

[mrk]

Fantastic!

[Tosh]

Uneffinbelievable work

[keith fellowes]

You redefine the word 'patience'
Fantastic

[defianty]

Great, I love me some attention to detail.

[jjeffries]

This project - and your vision/skills - simply blows my mind...I could not have imagined what you have created nor the techniques you're using to put thought into reality. I have to imagine that your are blazing a trail that could well start a trend, and a path being beaten to your door...so many 997's out there, all over the world...and owners who will want to get in on the air-cooled-inspired cool factor with all the usability and availability of the modern Porsche. I perceive that's not necessarily your objective, but at a minimum I bet your ideas will be much emulated. John in CT/USA

[Bruce M]

Was sure the tailpipe ornaments would look naff but you have taken them to jewellery levels so I might have to “eat my hat”

[Darren C]

Just a few sequential posts this evening to update progress over the last couple of weeks.

Been busy with work, other cars & car shows (that time of year ) but have managed to get a little bit done on the 997 Outlaw.

With the 1st rear bumper out of the mold it's had time to cure a little now so I set about cutting all the openings, holes & slots etc using the faint lines in the GRP.

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To stop Gelcoat splinters & chips I used a small 2.5mm drill to stitch drill out, then a range of files & sandpaper etc to finish (all standard stuff )

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[Darren C]

Then repeat the other side

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Then onto the fiddly bit where the 991 air/heat outlet bezel/surround fits along the bottom of the bumper behind the wheel

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And cut out the same way

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[Darren C]

And again repeat

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It's kinda involved as the 991 bezels contain a "U" channel that slips onto the bumper from behind. This means the thickness of the GRP and the external profile of the slots surround have to fit too.

All time consuming stuff.

[Darren C]

Next the tow eye plug.

Retaining a section of old 997 bumper with the eye hole I could transfer that to my bumper. (It was too thin/fragile to cast into the mold, so has to be cut afterwards)

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So with a chain of 2.5mm stitch holes, so not to chip the Gelcoat, I cut it out.

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A few hours later with a swiss file it was good for the plug

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[Darren C]

Plug test fitted

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Time to move on to numberplate lights

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