DDK - Die Deutschen Klassiker

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.

The holes in the pedestals were then countersunk & assembled with M4 bolts.
I also added a couple of drain holes

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

And the final result after many hours on the buffing wheel...
I suppose they'll do for now

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

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

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

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

Smoothing out all bubbles
For an almost invisible result
Then installing Rivetnuts for an OEM style numberplate fixing & next the numberplate lights.

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

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 )

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

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

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

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