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05 – Espace technique

Innovative body production on the new 911

New composite design for bodywork: Production of the new 911 requires new production technologies, in recognition of which Porsche has established a new 28,000 m² bodywork plant on the factory premises. Details.


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Covering and Installing Your Own 911 RS-Style Door Cards

My 1976 Porsche 912E’s original red door cards have seen better days. At some point in the car’s life the outer window scraper seal had shrunk about an inch, and the plastic vapor barrier was removed entirely. As a result, rain water entered the door’s interior and was wicked out through the door card’s board backing, and additionally found its way into the door pockets. Both the door cards and the door pockets were warped beyond usability, and some of the hardware had started to rust. While investigating solutions for new door cards, I decided to spice up the interior a little, adding a bit more whimsy to the car in the process. What fun are cars if you take them too seriously?

I’d taken the door pockets out a number of months ago, as they were saggy and didn’t hold anything anymore. The speaker grilles had been riveted to the door panel years ago, and even the door handle wasn’t in great shape anymore. Realistically, none of this was salvageable, so I had to wholesale start over. It’s a little simpler than it sounds.

The first step was to order a door panel kit from AppBiz. I bought the later RS America-style DIY kit on eBay for about 350 dollars, and was pleasantly surprised by the quality of the parts provided. You can order a pre-finished kit for just over $600, but they’re only available in black, and I didn’t think that would fit the red interior of my car. The kit includes the door cards themselves, pre-fitted with a soft foam backing, and pre-cut with all of the holes you might need for your application. Also included are the door handles, the pull straps, all of the hardware, and a thick mil vinyl bag.

I ordered the jacquard material from Fabric.com on closeout for $17.55 per yard. I purchased four yards, but one probably would have been enough, and two would have been plenty.

That vinyl bag was important, because it can double as a new door vapor barrier if yours is missing (like mine was). Simply lay the plastic bag out on your new door card and cut it to just slightly smaller than the door card itself.

The first step on the door itself is to install the door pull release strap. This is a pretty simple installation with a nut and a bolt going through the mechanism on the door, as well as both halves of the grommetted strap.

Once cut to the right size, I put it on the door with a few squirts of 3M spray adhesive. The addition of hardware and the door card itself will help keep it pretty water tight. From there, it was just a matter of cutting a hole for the window winder, the door speaker, and the door release pull strap.

Line up the door panel on the door, and mark off the mounting holes for the new RS-style door handle with a sharpie. Drill the holes into the door (make sure your window is up, or your drill bit will shatter the window when it breaks through the back side) just big enough for the collapsing bolt cage to fit into the door.

The kit comes with a special tool to get this job done. It’s pretty simple, but make sure the cage is fully collapsed before you install the door. I had one too loose, and it simply spun inside the door instead of tightening down. I had to start from square one on this step for one door.

Once fully collapsed, this provides a new threaded hole for the door handle to attach to the door. Twice per door, and you’re ready to roll.

The door is ready for a panel, so it’s time to prepare the panel for the door.

Again using the door panel itself as a template, mark out and cut the fabric to just a little larger—perhaps an inch on all sides—than the panel.

More spray adhesive is used to attach the fabric to the door card backing. You can fold the excess fabric over the edges and use the same glue to attach it to the back, or you can use a staple gun as would originally have been used by the factory. In either case, you can cut the folds off of the back of the door card so that there is only one layer of fabric backing. And you’ll want to make sure the screw holes at the very bottom of the door card are clear to the back as well.

Then you can cut holes in the panel for the things your car has. In my case, that would be for the window winder, the door speaker, the two door handle bolt holes, and a thin slit for the door pull.

I again chose to rivet the speaker surround to the door card itself. This required a pair of holes drilled in the door card. I then colored the tops of the rivets with black sharpie to keep them from being visible through the speaker grille. The speakers themselves are bolted directly to the metal of the door, so this only needs to support the grille. I purchased this generic speaker grille set from Amazon at $12 each.

Once the outer speaker grille is installed, you can’t see much beyond the mesh of the grille. It’s a clean and inexpensive option for my application.

With the grilles installed, I put the door panel on the car with the included clips, then bolted on the new handle, reinstalled the window winder, put three screws into the mounting points at the bottom of the door, and re-fitted the padded vinyl door topper.

Obviously this can be re-created with any fabric, vinyl, or leather, should you choose. I went with a fun option for the heck of it, and really enjoy the finished product. It’s a simple and easy weekend project. In reality, from start to finish, it took me about five hours to do both doors. It’s a good kit and I highly recommend it.

RS-Style Door Panel Installation Costs

AppBiz RS America Door Panel Kit – $340 (via eBay)

Navajo Southwest Toluca Jacquard Fabric – $17.55 per yard x 4 yards (via Fabric.com)

4.5″ RetroSound speaker grilles – $11.98 each x 2 speaker grilles (via Amazon.com)

Total – $434.16

Door Panel Installation Weight Loss Total – The only real weight lost here was in the door pockets and the chunky rubber door handle. Maybe a couple of pounds.


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Aérodynamisme actif de la Porsche 911 type 992

L’aérodynamisme actif amélioré de la nouvelle Porsche 911 type 992 renforce l’harmonie entre l’efficacité énergétique et la performance. Pour cela, la stratégie de régulation des éléments actifs comme le becquet arrière et les volets d’air de refroidissement a été modifiée en fonction de la vitesse et du programme de conduite. La nouvelle 911 régule désormais …


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Porsche Releases New Updates To The N-Spec Tire Rating System

With every new generation of Porsche, the outer limit of grip are tested with heavier cars, larger contact patches, and way more power than ever before. In order for your new Porsche to continually improve, tire technology has to continue evolving to cope with the demands of the modern and more advanced Porsche. The company has been working directly with its tire suppliers to create the N-spec rating to confirm for Porsche owners that a specific tire has been approved to maximize the performance of their car.

Unlike some sports car companies, which simply pick a tire from a tire manufacturer’s lineup, Porsche works directly with tire manufacturers from the beginning of a new tire’s lifecycle, long before production begins. To be an OE supplier to Porsche, the final product must be jointly developed between tire engineers and Porsche’s vehicle engineers. While dry weather grip is important for your GT to achieve its Nurburgring lap time, there is an equal focus on wet weather performance, as Porsches were built to be driven even in inclement weather.

The first, and perhaps most important metric for a new tire is its speed rating. The tire company will confirm that the new tire is capable of supporting the weight of the Porsche vehicle, the stresses of added downforce, and the incredible energy it takes to reach a Porsche’s top speed. Then the tires are subjected to a barrage of additional tests, confirming the prototype meets Porsche’s standards for road noise, wet weather grip, and dry weather handling. Durability is a top priority for Porsche, especially at speed.

Only once the tire has passed all of these rigorous tests, and the engineering department has signed off, can the tire be branded with an N-spec. New for 2019, N-spec tires will receive a specification based on which Porsche model line it is approved for. As before, the first letter will stay N, simply identifying the tire as N-spec. There will also still be a numeral from 0 to 4 which indicates which revision of the tire it is, with 0 identifying it as the original design and construction. New this year is a second letter wedged in the middle which identifies which vehicle in the Porsche lineup it’s been homologated for. 911 models are NA, Boxster and Cayman models are NB, Cayenne models are NC, Panamera models are ND, and finally Macan models receive an NE specification tire.

Here is the update, as stated by Tire Rack:

A specification ending with the “0” marking is assigned to the first approved version of a tire design. As that design is refined externally or internally, the later significant evolutions will result in new generations of the tire to be branded in succession. For example, the NA0 branding indicates the first version of a Porsche 911 Carrera tire design. Similarly, NC1 is the second version of a Porsche Cayenne tire design. When a completely new tire design is approved, it receives the “N#0” branding, and the succession begins again.

It is also important to know that while Porsche N-specification tires have been fine tuned to meet the specific performance needs of Porsche vehicles, the tire manufacturers may also build other tires featuring the same name, size and speed rating as the N-specification tires for non-Porsche applications. These tires may not be branded with the Porsche N-specification because they do not share the same internal construction and/or tread compound ingredients as the N-specification tires. Using tires that are not N-specific is not recommended and mixing them with other N-specification tires is not permissible.

As before, Porsche recommends replacing tires in axle pairs if they have more than 30% wear, and do not permit for mixed tire types on a single car. If the N-number of your tires has been discontinued, Porsche recommends replacing all four tires to the updated N-spec number revision.


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How the new 911 got its “drive”

The powertrain of the new 911 Carrera is even more efficient and powerful than its predecessor. Read all about how the engineers in Weissach revamped the classic 3-litre six-cylinder boxer engine here.


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