Thanks for all you help chaps, some very good and useful points in there.
To be honest, I think the exhaust is too loud as is, whether it's breaking any laws or not. The other half doesn't like it and it makes long journeys stressful. So, I'm going to get it looked at on Friday and go from there. I'll definitely get a silenced de-cat pipe regardless and may go for a transverse box, similar to Carl's design but, coming out the original exit, maybe with 2 passes through a silencer. I have a SPL meter at home so, will check the before and after sound levels in the same/similar circumstances for comparison. I'll get the new rear box made to mate up to the existing system so, I can stick the original back box back on, if I'm not happy with the flow of the new big back box, obviously after plod has seen and approved it.
As far as I'm concerned, that will be the best that I can do (I physically couldn't do anymore to quieten it anyway, due to the shape of the floor pan) so, if it goes to court, I'll make sure that all my facts are in the right place as, I know he's wrong !
Anyway, to answer Steve's question, the actual size of character, imports can have on their plates if "the vehicle does not have European Community Whole Type Approval' and 'the vehicle's construction/design cannot accomodate standard size number plates' is:
Height: 64mm
Width: 44mm
Stroke: 10mm
Space between characters: 10mm
These are the same size rulings that apply to motorbikes.
There is no documentation to state what physically size the plate has to be, unlike standard plates where margin size is stated which will give you the physical plate size. So, lawfully, you can have the plate any size you like, as long as the characters are the correct size.
This info can be found in a document titled 'Current Requirements on the Display of Number Plates', on the dvla website.
If you want information on the road traffic act 1988, go to
www.opsi.gov.uk/acts look in the 1988 section and scroll down to the 'Road Traffic Act 1988 C52'.
Hope this helps.