Finally sorted, some of the wadding had started to come out of the stainless box I mentioned, it was like a wizards hat, I just kept pulling and pulling, I don't think there's any acoustic material left in there anymore, oh well, a nice little burble on idle and at lower revs with a little pop on the over run, not noticeably louder at higher rpm and thankfully no droning, sadly no rasp but you can't have everything.
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02 V40 T4 S, "Sargent silver" she's back!
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