INtro EV-RSR
The electrical
Porsche 964 RSR
Welcome to the revitalized journey of a classic – Project 964 RSR-e Tribute.
When innovation meets history, we get a symphony of modernity wrapped in the essence of a classic. This project embodies the crossroads of passion, technology, and sustainability. We're not merely resurrecting a 30-year-old legend; we're infusing it with a modern heartbeat. Our mission? To retain the soul, feel, look, and driving experience of the iconic Porsche 964 RSR, while crafting it with a tapestry of Carbon fiber and a medley of meticulously 3D printed Onyx components.
Why take on such a monumental task? Because we believe in challenging the boundaries. We're not only making a statement about the prowess of modern engineering; we're showcasing that technology can harmoniously coexist with sustainability. This electrified tribute will retain its legendary performance, reimagined with a conscientious approach to the environment. Every charge, every drive, will draw purely from the benevolent energy of the sun, thanks to our dedicated solar panels.
The pandemic may have introduced hurdles, but it's only bolstered our determination. With Brink Motorsport as our esteemed collaborator, we are fast-tracking towards our vision. Stay tuned, as we accelerate towards our completion goal in early 2024. Dive into this electric odyssey with us, and witness the fusion of past, present, and future.
2023-09-12Sculpting lightness
2023-08-22 Center console
2023-08-04 Acoustics draft concept
2023-07-01 final battery installation
2021-08-31 3D printed ONYX mould for Autoclave prepreg
2021-06-20 3D printing the engine prototype
2021-06-04 The Tower of Power battery placement
2021-05-13 Doors out and 3D scanned, into Fusion 360
2021-04-30 3D printing the batteries as prototypes
2020-11-10 Carbon Skinning
2020-10-18 Holder of the Hood
2020-09-20 Dollies in Onyx
2020-05-01 A short summer as RSR Tribute petrol car
2020-02-25 The paint job
2020-02-10 The color of Steve McQueen
2019-12-01 The search for RSR rims
2019-08-01 The body make over
2019-05-01 The donor car
Hunting kilograms
Sculpting Lightness
Our Porsche 964 RSR EV Weighs In
CAD and 3D printed prototype
Center console
The Electrified Porsche 964 RSR: Crafting the Perfect Center Console
When restoring and electrifying a vintage beauty like the Porsche 964 RSR, every detail counts. As we pave our way through this journey, our current challenge revolves around integrating the AEM module and the Alpine media system.The confines of the classic dashboard are indeed limited, presenting a challenge that can only be met with innovation. Our solution? Designing a bespoke center console tailored to the Porsche. Situated right ahead of the handbrake, this console will feature buttons dedicated to 'Drive', 'Neutral', 'Park', and other essential controls.
The centerpiece of this console is a meticulously angled section, 3D printed in the environmentally-conscious Addnite Black Velvet. This filament, made from 100% recycled material, brings together recycled EPDM and tire rubber, offering durability and a touch of sustainability. The setup ensures easy access to both dashboards, optimizing driver convenience.
For the purists among our readers, it's worth noting that in this initial rendition, we're sidelining the original instruments. However, rest assured, reincorporating them is on our agenda for future iterations.One of the unsung heroes in this design process is the cable management. Cables will be discreetly channeled within the hollow sections of the 3D printed console, ensuring a clean look without any compromise on functionality.Leveraging a scanned model of the interior has been invaluable. As a designer, this approach provides a more immediate and precise perspective, significantly streamlining the modeling process in Fusion 360.
Stay tuned as we continue to breathe new electric life into this iconic Porsche 964 RSR!
Design concept draft
Acoustic concept
On winding roads, with the engine purring silently, what we need are some rock 'n roll anthems to complement the ride!
3D printed Prototypes and batteries
final Battery installation
Redefining the Classic Porsche Experience with Modern Engineering
When you think of a classic Porsche 964, it’s not just about the sleek design or the brand's prestige, but also about the unique driving experience it offers. For enthusiasts, it's the weight distribution, the balance, and the roar of the engine – elements that conjure up a nostalgia that's deeply rooted in automotive history.
However, blending modern technology with this classic beauty, while retaining its original charm, is a meticulous balancing act. At the heart of our endeavor with the Porsche EV-RSR project was a singular vision: to fuse the Porsche's classic experience with the advantages of an electric powertrain, without compromising on its legendary weight distribution.
After rigorous simulations and design iterations, the decision to place all the battery packs inside the Brink Motorsport-developed crash box was born out of necessity and innovation. And while this decision transformed the 964 from a 2+2 to a dedicated two-seater, we believe that the enhancements in performance, safety, and driving experience will be the payoff that true Porsche aficionados will appreciate. Especially when considering the limitations of the original rear seats.
Using our 3D printed prototypes, we’ve laid out the foundation for the final engine, gearbox, and battery placements. This process allowed us to visualize, iterate, and perfect the setup before investing in the actual components – a testament to the merging of classic craftsmanship with modern technology.
As we near the finish line, we've sourced the final pieces of this electrified puzzle: the Engine, VCU, charging units, and more. In our upcoming updates, slated for November 2023, we'll provide a detailed insight into weight metrics, distribution, and the intricate engine bay montage.
For now, we leave you with a sneak peek of our reimagined classic: A Porsche 964, breathing new life, yet preserving its iconic heartbeat.
Stay tuned!
Reimagining Automotive Manufacturing:
The Era of 3D Printed Moulds
One of the primary challenges in the world of automotive engineering has always been creating robust, durable, and adaptable components that can endure the rigorous demands of the road. But as technology propels us into a new era, we're pioneering innovative approaches that marry tradition with state-of-the-art methodologies. Enter our 3D print farm, equipped with over 20 Markforged Onyx 3D printers, our latest weapons in the war against conventionality.
ONYX, a robust fusion of Nylon and Carbon fiber, has proven to be a game-changer for automotive applications. Its resilience to extreme conditions, be it temperature, pressure, or chemicals, makes it a prime contender in the world of mould-making.
Our experiments with this material have been nothing short of enlightening. Through rigorous tests in autoclave environments, subjecting our moulds to intense heat and pressure, we discerned the optimal infill for our projects. The honeycomb structure, although a classic choice, didn't quite cut it for us. But the triangular infill, at a range of 37-55%, emerged as the champion, perfectly withstanding the demanding conditions.
However, size limitations of the printer bed posed a unique challenge. But we weren't about to be deterred by such a trivial hurdle. The design we've conceptualized for the Porsche's door in Fusion 360 is no small feat. But with innovation and resourcefulness, we've pieced together an impressive mould from eight different parts, each printed simultaneously on different Markforged machines. The end result? A magnificent mould stretching an impressive 1100 mm x 500 mm, primed and ready for its first encounter with prepreg Carbon fiber and later, Bcomp prepreg.
It's awe-inspiring to see the old-world craft of carbon fiber work blend seamlessly with the cutting-edge technology of 3D printing. As we forge ahead, these moulds stand as a testament to the future of automotive manufacturing, promising efficiency, precision, and innovation. So, stay tuned. We're just revving up!
The Dawn of the Electrical Era:
Out with the Old, In with the New
Last night marked a significant milestone in our journey. With skilled hands and precision, we bid farewell to the vintage combustion engine and gearbox, extracting it from its home of decades. As it was hoisted and removed, a striking comparison emerged. Standing next to its streamlined, sleek electric successor, the combustion engine looked like a relic from another age.
The intricacies, complexities, and sheer bulk of the combustion mechanism starkly contrasted with the clean, minimalist design of the electric motor. It’s astonishing to realize that for over a century, we've relied on such a convoluted system. One can't help but wonder: Were we ensnared in a web of familiar comfort, blind to the untapped potential of simpler, more efficient technologies?
Elon Musk and Tesla have undeniably paved the way, igniting a revolution that challenges the automotive status quo. Their daring vision has emboldened enthusiasts and engineers worldwide, including us, to reconsider the norm and explore cleaner, more sustainable alternatives.
The sheer difference in footprint between the two engines is a testament to more than just technological evolution. It's a poignant reminder of the excesses of the past, urging us to tread more mindfully as we race into the future. Yes, the planet might outlive us, but we owe it to future generations to leave a legacy that’s both innovative and conscious.
Welcome to the electrical era — it's time to charge ahead.
From Pixels to Reality
Prototyping the Electrical Powerhouse
In our quest to bring the Porsche 911 EV-RSR vision to life, transitioning from the digital realm to tangible prototypes remains an essential step. For us, everything requires a tangible counterpart during this transformative phase.
Enter our meticulously 3D printed Cascadia engine, a true marvel of modern engineering, rendered in over 30 distinct parts. Complementing this is the BorgWarner gearbox, split into three detailed components. While most elements have been materialized using recycled PLA, certain crucial components benefit from the robust ONYX material printed on our advanced Markforged machines.
As the RSR donor car is gradually relieved of its classic combustion remnants – from its vintage powertrain to the time-tested gears and electronics – our 3D printed proxies are proving invaluable. These stand-ins pave the way for the actual assembly, guiding our design and implementation decisions.
With the impending arrival of the genuine engine by December 2021, these prototypes enable us to forecast, plan, and start crafting the integral components that will form the heart of our electric beast. Our unparalleled printing capacity, boasting a fleet of over 100 printers, ensures we can bring these ambitious prototypes to reality in under a week.
In the seamless blend of old and new, we're crafting a future where the roar of the engine is replaced by the silent hum of progress.
Balancing Power and Precision:
The Battery Challenge
As we embark on the electrifying journey of embedding the 21 battery cells into our beloved Porsche 911 EV-RSR, we're faced with a complex puzzle - a dance between power and weight distribution, as vividly showcased in our 3D visualizations.
Tipping the scales at 210 kilograms for the entirety of the cells, the overarching aim is to strike that perfect balance, retaining the distinct 911 sensation with an ideal weight spread of 62% at the rear and 38% upfront. As we gear up to harness the might of an 823 Volt system, we're looking at a whopping total of 35.7 kW/h. The sheer power at our fingertips? An exhilarating 525 kW!
But, amidst this electrified enthusiasm, emerges a fundamental question, one that will shape our endeavors throughout the summer: Is raw power truly the endgame? By dialing down the horsepower to align with the original RSR's 360 Hp, we could potentially trim our battery count down to 14, shedding 70Kg off our total weight. Is the pursuit of authentic homage perhaps a more worthy aspiration than sheer force?
Our journey is as much about honoring legacy as it is about innovation. Stay tuned as we navigate this intriguing crossroads.
Breathing Life into Legacy
Door Design Evolution
Having captured every contour of the door's internal anatomy through our precise 3D scanning process, the thrilling phase of design and prototyping beckons. These scans, now seamlessly integrated into our Fusion 360 model, serve as the foundational canvas upon which we reimagine the doors of our Porsche 911 EV-RSR.
Function meets finesse as we carefully plot the incorporation of modern elements like speakers, a revamped handle, and an elegant strap, all while ensuring harmony with the car's innate structure. Our debut concept reflects a juxtaposition of past and present – a minimalist Carbon fiber inner design, luminous and streamlined, that pays homage to the classic by reincorporating certain iconic design fragments.
The goal? A door that encapsulates the essence of the original yet is unequivocally futuristic in its appeal.
Removal
Revamping with Digital Precision: Doors Decoded
The metamorphosis of our Porsche 911 EV-RSR advances, as we peel back layers to its core. Our first mission? Tackling the doors. But, instead of a mere disassembly, we've chosen a path paved with digital innovation. Prior to removing the door sides, they undergo a thorough 3D scanning process. This not only provides us with a detailed blueprint in Fusion 360 but also ensures our design retains the car's authentic essence.
By overlaying 2D geometries on the scanned meshes and establishing fresh construction planes, we've meticulously documented every inch of the original architecture. Such precision is pivotal in preserving those subtle nuances, curves, and contours intrinsic to the car's three-decade legacy. As we conjure a modern redesign, these scans ensure that the spirit of the original interior, with its intricate details and unique characteristics, is seamlessly interwoven.
Prototyping Batteries with 3D Precision
2021-04-30
Prototyping Batteries with 3D Precision
The journey of our Porsche 911 EV-RSR transformation is advancing, albeit amid the hustle and bustle of bolstering our lab's manufacturing capabilities. A significant stride in our EV odyssey is conceptualizing the heart of the electric beast - the batteries. Instead of diving headfirst into battery acquisition, we've opted for a meticulous approach.
To optimize our space utility and determine the most efficient battery configuration, we're 3D printing battery prototypes. These tangible replicas, crafted on our Prusa 3D printer with the lustrous silver Prusa PLA Filament, will serve as crucial placeholders. They will guide our decisions on placement, orientation, cabling, mounting, and even the intricacies of liquid cooling.
Mapping Out the EV-RSR Blueprint
Once our battery configuration is outlined, our sights are set on digitally mapping the Porsche. By 3D scanning the front, rear, and interiors, we aim to construct a digital twin of the car. This virtual representation will be indispensable as we commence the significant overhaul - stripping away the interiors, engine, gearbox, and tank. Interestingly, these very components we'll be parting with will help fund our green revolution, as we'll sell them to facilitate the EV transformation.
As we inch closer to our dream, expect updates complete with 3D scans and a sneak peek into our rendering processes. The synergy of legacy, innovation, and sustainability continues to unfold.
Carbon skinning
2020-11-10
Breathing Life into the Vintage
Decades of wear and tear can leave their marks on classics, and our 30-year-old Porsche wasn’t exempt from this rule. A distinctive protective plate, nestled to the lower left of the driver's domain, bore the brunt of time's passage. But at lostboyslab, we see potential in every challenge. We meticulously ground down this weary plate, bid farewell to the remnants of old glue and dated insulation, and reimagined it with a pristine layer of Carbon Fiber weave. Through a conventional wet lay process, harnessed in tandem with Epoxy Resin, this transformation was set into motion. Granted, our lack of an oven or vacuum system at the time turned this endeavor into a labor of love. But the result? A revitalized component boasting the distinctive carbon finish, devoid of cracks, odorous insulation, and harmful glues.
Marrying 3D Innovation with Carbon Aesthetics
While 3D printing is our forte, not every component beckons for it. Some simply call for rejuvenation. Yet, our curiosity doesn’t end there. We are intrigued by the marriage of carbon wet lay skinning to a 3D printed core, particularly one featuring a honeycomb design. Imagine the harmonization: internal structures 3D printed from sustainable, recycled materials, all cloaked in a sheen of weaved Carbon. This blend of sustainability and aesthetic elegance is a vision we’re eager to explore. So, stay tuned as we delve deeper into this frontier.
Harnessing 3D Scanning
2020-10-18
Innovating the Design Process
At the core of our operations at lostboyslab, 3D scanning stands as a transformative tool. While traditional engineering methodologies often sidestep this phase, opting instead for a sequence of trial-and-error with multiple prototypes, we’ve elevated our approach. By integrating 3D scanning, we dramatically trim the prototype phase, streamlining our pathway to more efficient and ingenious solutions. With the world transitioning to digital realms, having a virtual context—curated through meticulous scanning and subsequent digital enhancements—offers unparalleled advantages. This "virtual context" is then seamlessly integrated into Fusion 360, facilitating the design process within the confines of the vehicle's digital twin.
Artistry in Carbon: Digital Design Brought to Life
Visualize, if you will, the intricately 3D-scanned contours of the front hood's interior. Now, picture a feather-light architecture sculpted from woven carbon fiber, effortlessly supporting the hood's expanse. This ensemble, including the sleek hood stick, is the result of our digital-to-real translation. Sourced from easy composite in the UK, the carbon fiber tube elegantly complements the quartet of components: the click holder, the swing, the tube's end, and the stick's anchoring point—all conceived in 3D CAD and actualized using ONYX on our Markforged printers. And here's our nod to seamless integration: these components fit snugly, latching onto pre-existing screws, negating the need to mar the body with additional drillings. Say goodbye to the makeshift baseball bat that previously held court as our summer's hood prop!
Crafting in the Digital Age
2020-09.20
Embracing 3D
Our quest is clear: to craft each component of the car within the walls of our 3D lab. The first task undertaken within the digital workspace of Fusion 360 catered to the creation of "dollies" - essential aids that ensure our car remains elevated, facilitating effortless movement even without its wheels. Our design meticulously accounted for the unique chassis connectors inherent to Porsches, ensuring a seamless integration and stable placement atop the quartet of dollies tailored for our vehicle.
The ONYX Advantage
The Markforged ONYX One machines, at the heart of our lab, were entrusted with this task. Their output? Components crafted from ONYX—a robust composite blending chopped Carbon Fiber and Nylon. This durable material is poised to replace everything from traditional ABS plastics to Aluminum in vehicular components, offering superior strength.
Yet, our commitment doesn't halt at precision; it extends to sustainability. We harbor a deep appreciation for recycled materials, especially PETG, envisioning a future where numerous components are shaped from this eco-friendly alternative. But let's be clear: while sustainability drives us, we won't compromise on safety or functionality. Critical components demanding unmatched strength will be birthed from ONYX—with or without reinforcements. Not only does this align with our eco-vision—being considerably more energy-efficient than traditional CNC-milled aluminum parts—it also offers a cost advantage.
A Brief Dance with Petrol:
2020-05-01
A Tribute Car's Summer Soiree
Thus concluded the maiden year of our car's transformative journey. But this was only the beginning. We're poised to delve deep, scrutinizing every nut, bolt, and wire—refining and redefining in pursuit of perfection. Stay with us, as we chronicle each step of our odyssey to meld vintage allure with a sustainable heart.
The Dawn of Electric Dreams: Ready for Revamp
Confronted with a faltering engine and a leaky gearbox, a traditional restoration would've dictated an extensive overhaul. But at lostboyslab, we aren't about the conventional. Our vision compels us to challenge norms, pushing boundaries both in EV conversion and complete vehicular metamorphosis. Armed with state-of-the-art 3D design tools and a dedicated print farm, we're set to embark on a mission of reimagining, redesigning, and revitalizing.
The Paint job
2020-02-25
Spring's Embrace: The Allure of Slate Grey
The photos we received from our painter spoke a thousand words. Bathed in the lustrous slate grey, our Porsche looked nothing short of breathtaking. The anticipation was palpable; we were itching to feel the Swedish spring breeze rush past as we took our restored beauty for a spin.
Alas, perfection can't be rushed. Although we yearned to unveil our masterpiece to the world, we had to exhibit patience for just a few more months. The wait culminated in a grand reveal at the Porsche 964 tribe gathering in May. Set against the iconic backdrop of the Ljungbyhed racetrack in southern Sweden, it was an experience that echoed the legacy and passion of the Porsche brand.
The color of steve Mcqueen
2020-02-10
A Nod to Cinematic Royalty: The Iconic Slate Grey
In our mission to bring this masterpiece to life, we sought inspiration from a legend. Steve McQueen's final custom-ordered 911 Turbo boasted an enchanting slate grey hue—a color that resonated deeply with us as Californians with an insatiable passion for racing. This wasn't just any shade; it was a statement of style and heritage.
Navigating through the annals of automotive history to locate the precise color codes was no small task. Yet, determination led us to the elusive grey 6604 code, ensuring authenticity to our tribute. In the golden embrace of the Californian sun, the color radiates a distinctive brilliance. But a question lingered: would this captivating shade hold its allure in the contrasting, often stark, ambience of Northern Europe?
The Quest for Authenticity:
2019-12-01
Rims from the Heartland
The pursuit for those elusive original rims led us straight to Germany. Given the country's storied association with Porsche, it seemed the likeliest place to find RSR rims in pristine condition. But with only 62 RSR cars ever manufactured, predominantly for CUP racing, the task was monumental.
Imagine our elation when we stumbled upon a set of original rims that, despite their 28 years, shone with the splendor of the brand new! In the realm of automobile aesthetics, wheels aren't just functional components; they're the finishing touch that can make or break a vehicle's stance.
While we understand that for a sprawling EV project, such indulgences might seem extravagant, we viewed this venture differently. This was our showpiece, our statement. And we were determined to ensure our EV-RSR didn't just stand out, but stood unparalleled.
RSR Body Transformation
2019-08-01
Embracing the RSR Body Transformation
Diving into the body reconstruction, we embarked on introducing the RSR's signature super-wide Carbon body components. Just a glance at the rear reveals its grandeur – those are the original Carrera 4 rims, mind you, and they’re snugly nested without spacers. Yes, the wide body is that expansive.
Despite our intense commitments in California, which kept us away from our treasured 964 for almost four months, the team tirelessly pushed the rebuild forward. And when we finally glimpsed those initial photographs, our anticipation was met with satisfaction. The precision with which the body parts married the chassis was nearly flawless.
Now, as we stood on the threshold of the next phase, two crucial decisions awaited: zeroing in on the perfect RSR original rims and selecting the hue befitting our RSR tribute.
In Search of the Perfect Donor
2019-05-01
In Search of the Perfect Donor
Our quest led us to a mystic blue metallic 964 C4 from 1991, a machine that beckoned with promise. The Porsche 911 (964) isn't just any sports car; it's arguably the most iconic one ever to grace the roads. Amid six decades of innovation and evolution, our heart was set on this model. It wasn’t just about the build quality; it was about harnessing the soul of a sports car icon..
Diving into the 964's Legacy
Upon acquisition, it was evident that our gem was in commendable condition. With a touch of engine maintenance and some rust treatments, it could have thrived as a classic. In hindsight, a car in a more worn state would have been a practical choice for our venture. Yet, Porsches, especially the 964s, have a devout following. It's rare to find one left unattended; the Porsche purists ensure that. Our inspections reassured us—no traces of serious accidents. An unblemished chassis was crucial, especially since our vision involved draping it with a Carbon fiber body.
A Nod to the RSR Legacy
Yes, the 964 graced the roads between 1988-1993 (fact check, readers!), but our aspirations soared higher. We dreamt of a 964 RSR Tribute – evoking memories of its wide rear track width and its more pronounced racing aura. The 911 Turbo and RSR racers weren’t just cars; they were the dreams of every schoolboy, immortalized in posters that adorned countless walls.
Our deep ties within the motorsport community brought us to a custom car maestro located just outside of Helsingborg, Sweden. With a storied history of crafting and revamping race cars and a mastery over Carbon fiber, we knew our 964 was in the right hands. Our focus remained unwavering: to breathe new life into the car with electric engines, batteries, and a modern electrical system. And not to forget, the hundreds of 3D printed components in ONYX (a robust Carbon/Nylon composite). Entrusting the bodywork transformation to Elite Projects in August 2019, we eagerly awaited the metamorphosis.