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OK...so when I accelerate from a stop, there's a certain point where something under the car rattles (very loudly actually).
When under the car, I can't seem to find anything loose. I can't get it to rattle when the car isn't actually moving (i.e. revving in the driveway)...so of course this complicates the diagnosis since it only rattles when moving.
It sounds like a piece of loose sheet metal rattling between a loose bolt head and another piece of metal, like a heat shield or skid plate.
Are there any common things I might be missing that are prone to losen up and rattle?
I'll check that...but wouldn't I expect the motor to rock quiet a bit while revving in the driveway as well if this were the case?
But revving in the driveway won't produce the same results because the engine isn't under load. I could be incorrect, but a lot more force will be taxed on the mounts while moving/accelerating. You also mentioned only at certain times you hear the rattle, which could mean a frequency resonance from the mounts or the exhaust.
I would check the mounts, then really shake the exhaust and see if hits anything.
My .02