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Well forget my post #43 about the "rattle" possibly coming from the exhaust "flappers".
I recently zip tied mine open to see how it would sound and the rattle was there in all it's glory on a 32 degree morning.
But another data point. The East Coast has been suffering through a very cold snap for the past week or so. So it's 15 degrees F and I go out for a ride. Absolutely no rattle. It was a short ride to the store. Back in the car that is now only slightly warm and the rattle is back in full.
I've been out now on a few sub 20 degree days and no rattle detected.
So it seems that the rattle only occurs in a rather narrow temperature band. From my experience it seems that the strong rattle will occur only between 25 and 35 degrees on a cold car. And will be a very weak rattle between 35 and 50 degrees.
The mystery continues.
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