DDK - Die Deutschen Klassiker

On the Spain tour it meant it was easy to find James if for example we ended up within a 10 mile radius of him

Ha ha, not noisy at all then!

There could be differences between our cars James. Mine has what I think is a sport cat which looks like this;



The problem is that these can be full bypass, or 100 / 200 cell versions, which I suspect will have considerable sound deadening qualities. They all look the same from the outside, so the only way I will be able to tell is to remove and look down it.

Of course my rear silencer under the bumper might be knackered too - it visibly looks fine but who knows?!


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A usb borescope via the lambda sensor boss would reveal the inside?

That’s a great idea - have one of those too. Thanks


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rhd racer wrote: ↑Tue Jul 22, 2025 11:54 am Ha ha, not noisy at all then!

There could be differences between our cars James. Mine has what I think is a sport cat which looks like this;



The problem is that these can be full bypass, or 100 / 200 cell versions, which I suspect will have considerable sound deadening qualities. They all look the same from the outside, so the only way I will be able to tell is to remove and look down it.

Of course my rear silencer under the bumper might be knackered too - it visibly looks fine but who knows?!


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well turns out on my car, with the cat bypass fitted, it wont pass the MOT emissions ! . I'm now going to fit a 100 cell cat .

Let me know how you get on James - haven’t popped a camera in mine yet, been doing house stuff for a bit now the racing has finished.

I also had a flat battery on the 964 the other day so trying to revive the battery on the conditioner / rejuv cycle whilst the weather is still good


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Current plan is to refit the original cat ( quickly repaired by my mate ) for the mot and then try and find a cost effective 200 cell

I have been driving the 964 at any opportunity recently and decided that I need to give it some love and do both a few jobs that need doing, and start getting it ready to paint, in a rolling kind of way.

Naturally, I have gone for an entirely cosmetic job first! I really like the short number plate on the car - I don’t know why, it just draws the eye in a nice way and is entirely road legal spacing wise. So I have had an idea festering forever to deal with the spacing issue this creates, which frankly looks a bit cumbersome




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We were away last week but this week I have been heroically DIY ing so thought I would give the bumper a go. A managed to find a damaged repairable one at Prestige Breakers in Leeds ( super helpful, ask for Neil) and collected it yesterday after doing so odd jobs for my mother in law in Sheffield. Turns out they have loads of 964 parts having bought a load of gear from Singer. For only £80 I got what I needed to do this the easy way.

Prior plates riveted to repair - no good bumpers died in this operation




After calculating the standard 1/2” spacing plus my plate, I marked out the donor

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The plan was to make a shortened section, plastic weld it, then graft it in



And that’s pretty much how it played out. I mounted the two pieces onto a small block off wood to keep them stable whilst joining, and then ground off the paint where I would plastic weld, and bevelled the main edges for the filler rod





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I them grafted the two pieces together - I found using fine wire mesh and a gas soldering iron was strongest, effectively it heats the gauze and the plastic beneath and you push the gauze into the molten pool. If you work one spot at a time like doing a seam weld by a series of net spots in the pool of molten metal, it worked well but took ages



I was amazed at how strong this was before even using the filler rod on the front edge. I chose to do this last as the panel would need a very subtle curve to set into the new panel

Using a hole saw I made a blank for the tow eye cover which would be in the wrong place, and then just worked everything from the back to make it strong







Now for the donor bumper I bought a few years ago with the front wings and rear quarters I will eventually fit


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I removed the lower grill from the bumper (amazing how much strength this adds to the structure) so I could cut the recess. Then a simple mark up and jig saw cut. I didnt do the top edge until I could let the bottom of the new panel in properly so as to not over or under do it



Once cut I effectively did a few ‘spot welds’ to hold the panel in place so I could flip it over and work in the mesh




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A very slow process, but it is in, dead square and strong. I made my own fill rods with the offcuts so as to use exactly the same formulation of plastic

A quick flapper disc on the rough edges and it is ready for filler




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Nice work! One of those subtle ‘if you know you know’ mods

Cheers Mark

Exactly that - the 964 choices are back dating or wide body / RSR style pretty much apart from the obvious RS thing which I have already done externally. That leaves subtle things - I actually fancy de-guttering from a looks perspective but not sure I am onboard with the wet carpets / wind noise / process of achieving!


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