Sometimes worse while driving and at higher revs. Sounds like metal on metal. Any ideas what it is?

I have suspicions on a couple of possibilities but wanted to see what others thought.

http://preview.tinyurl.com/lpen6p8

It may be the DMF or it could be an exhaust heat shield

I've had shield rattles before and it doesn't really sound like that to me. Also DMF possible but it drives smoothly and gear changes and take up is smooth too. I'd it was DMF I would expect it to happen all the time not at higher revs and mainly when changing gear.

It may be the DMF or it could be an exhaust heat shield

+ 1

sounds like it could be heat shields. I would start and check these and exhaust system first.

Have noticed that after I did a forced DPF regneration the noise seems to go and then comes back later usually when the DPF regeneration error code has come back up. Odd I know but there you go.

Update the rattle has steadily got worse in fact it is quite embarrassing now. It seemed to go with regeneration and comes back but now it is much worse. I have checked the oil as I have read of diesel leaking into the sump and the oil is fine. Have checked the turbo impeller too there is slight movement of the shaft up and down but very little so hopefully it is not turbo trouble, can't quite pinpoint where the rattle is coming from though. Hopefully getting it back to the garage I bought it from on Friday to look at it and discuss the DPF issues. Just done a forced regen and it kicked out some good black puffs of smoke although it took 5 attempts to get it to do a static regeneration no idea why it failed each time then worked.

Really beginning to wish I had bought a petrol or a 90bhp version without the DPF.

I had a sound like that. For me it was the heat shield hitting the exhaust. It happen when the heat shield dropped and the exhurst vibrated making a stupid sound.

It isn't that your baffles are shot in the exhaust? Wife's Clio makes a right racket because the baffles are gone in one of the boxes.

Sent from my Gen 1 WAP phone

Well it turns out the bottom pulley was had it and that had also caused the tensioner to rattle. Garage stuck a used tensioner on it for me in the meantime but it still rattled just not as much, so then they chucked a used pulley on it too, both came off a Peugeot 206 that was in the garage, rattle is now gone.