INtro EV-RSR

The electrical

Porsche 964 RSR

Welcome to project EV-RSR

Our mission with this project is to use all our know-how in 3D design, 3D fabrication, automotive and motorsport knowledge to turn a 30 year old car into a modern electrically powered vehicle with the soul, feel, look and driving experience still in it, but updated in Carbon fiber and hundreds of 3D printed Onyx parts.
We are doing this to make a statement. We are doing this because it is crazy, but we have to show that it can be done and in a sustainable way with the environment in mind. We still will use our design and engineering skills to make it safe, fast, fun, but it will be a protector of mother Earth, only using sunburned energy from solar panels to power it's electrical engine.
3D printed mould

huge 3D printed mould for carbon fibre door panels

Our 3D print farm has more than 20 Markforged Onyx 3D printers. They print in ONYX which is a hybrid Nylon/Carbon fiber filament that is very well suited for tough applications involving high temperatures, pressure and chemicals. It is the perfect choice for automotive applications as well as creating moulds for various repetetive products that requires a mould of some sort. We made a lot of tests in autoclave environment with up to 125 degress and 6 bar pressure. The cubes on the photos was the reference with various infills to figure out what was standing off the heat. Actually they all worked well. Less well was the honeycomb infill so that will not be used, insted we go for 37-55% triangular infill that turned out to work perfectly. A 3D printer has a limited print bed that limits how big parts you can print in one go. That doesnt stop us from building full size moulds for Carbon fiber prepreg. The door design in Fusion 360 is now moving into final stage with the printing of the complete finished ONYX mould, that is visible below. The 3D printed mould is made up from 8 parts all printed on different Markforged 3D printers simultaneously. The final form is around 1100 mm x 500 mm. Next step will be to prepare the mould for the autoclave and its first meeting with prepreg Carbon fiber and later Bcomp prep preg. More to come....


saving humanity?

Electrical vs CoMBUSTION engine

Thanks to our great mechanics, last night the old combustion engine and gearbox was removed from the car. The lift worked fine and we managed to remove the old antique piece of engineering that in contrast to the electrical counterpart seems like super old tech. When you see the difference in scale, simplicity and minimalism you get stunned how we can have used these combustion engines for so long. Honestly a small degree of "they cheated us for these years" sneak up on you... Thank you Elon Musk for starting a new era in automotive and transportation, thanks to you and Tesla we now can progress as human species and focus on a more environmental friendly alternative to fossil fuel driven engines. Just by the difference in size, you can imagine how much more energy is consumed in the process of making an engine and gearbox like that, suddenly it just felt like a thing in the past. Welcome electrical future, lets hurry up so we can save mankind... (the planet will always survive)
3D printing

Electrical engine 3D printed

To enable us to build brackets and test the whole drive chain we 3D print prototypes of the engine and gearbox. Everything needs a physical stand-in. The engine from Cascadia is printed in more than 30 parts, the gearbox from BorgWarner in 3 parts. Most parts are printed in recycled PLA and some in ONYX on our Markforged machines.  As we now move into the phase of the build where the RSR host car is emptied from all ancient combustion engine parts, electronics, gear box, drive chain etc we can already with our prototype start the assembly process and manufacture end use parts for the arrival of the real engine around December 2021. This will make us sure of the placement and how gearbox, drive shafts and all mounting brackets should be made. We can deliver a engine and gearbox prototype of this magnitude in less than a week using our paralell process with more than 100 printers in the 3D farm...
Battery fitting

the tower of power

Its time to start look at how to place the 21 battery cells into the car. It will be quite challenging as you can imagine from the 3D renderings. The weight of the 21 cells are 210 Kilograms so it means it is crucial to get a good weight distribution around the car. We would like to keep the 911 feel in the car and get it to a 62% rear to 38% front distribution. We will run 823 Volt system and get a total of 35.7 kW/h. The max theroretical power output will be 525 kW!! The real question we are asking ourselves and what we will work on during the summer is if it makes more sense to lower the Horsepower of the engine to match the original RSR that had 360 Hp. That would mean we could use 14 batteries instead of 21 and shave off 70Kg in battery weight... It might be a better option. 
prototyping

Door design and prototyping

With the 3D scan done, we can now design our new parts in the context of the internal body structure of the doors. The scans are added to the same Fusion 360 model and we can design new parts in the assembly, as we take measure and see how we can fit speakers, new handle, strap etc. This shows the first concept of the design in Carbon fiber inside with a light and minimalistic touch and feel, but still re using some design elements and shapes from the original.
Removal

Doors out and 3d scanned

Time has come to remove the old interior, the door sides are removed but before we do it, we 3D scan the inside to have a reference in Fusion 360 for the new design.  We fit 2D geometry to the mesh in sections and create new construction planes to work from. This is the way we document the parts we remove and also allow us to design in the contect of the 30 year old interior, to catch small elements, forms and shapes to be reborn in the new concept.

3D printing prototypes for the batteries

2021-04-30

Physical prototypes of the batteries

We have been so busy with building up a lot of manufacturing solutions in the lab, so it's been a while since we updated the Porsche 911 EV-RSR. The work is now in progress with 3D printing the actual batteries, that is the potential candidate as energy source in the RSR. Before purchasing the real batteries, we are starting to look at space planning, orientation and how to mount them in the front trunk and the rear seat space. This physical simulation will help us make a lot of decisions and give us an opportunity to try out many different options and solutions. The batteries are printed on the Prusa 3D printer with silver Prusa PLA Filament. We will print as many prototypes as we need and build everything around them complete with cabling, montage and liquid cooling. Next step will be to 3D scan the whole front, rear and also interior to have a digital representation of the car, before we start to remove all interior, engine, gearbox, tank etc... These items will be sold to finance the rebuild to electrical. We will soon update with some 3D scans and rendering of the scanning process.

Carbon skinning

2020-11-10

Finishing up some broken parts

Some parts in the 30 year old Porsche is in quite bad shape. This piece of protective plate is situated to lower left of the drivers section in the car. It was in really bad shape, so we grinded it down, removed all old glue and insulation material and gave it a new finish with a one layer of Carbon Fiber weave. We used a traditional wet lay process with Epoxy Resin. At this time we had no oven or vacuum system so it was a quite long and tedious process. The end result was a nice Carbon look with a part that is now strong and without cracks and old smelly insulation and toxic glue. Some products do not make sense to 3D print and is better off just giving it a new strength and a fresh look.

We do find the process of Carbon wet lay skinning very interesting together with a 3D printed internal structure with a honeycomb layout. This could mean we could print the inner parts in recycled materials and then finish it off with an outer surface layer in weaved Carbon. More on this in the future...

holder of the hood

2020-10-18

3D scanning to enable design in context

At the lostboyslab we work intensively with 3D scanning before we adress a problem and then a solution in the CAD software. Many engineers simply neglect this part and focus on old ways of measure and 3D print a number of prototypes before they get it right. By 3D scanning we can have much less prototypes and get to a much smarter solution faster. It is much easier to work in a mechanical 3D CAD software when you have a virtual context, that is what we create by scanning the area first, make some magic to it and then import it into Fusion 360 to enable us to model new parts inside the front bay of the "virtual" car.

Carbon parts designed in 3D

The image above shows the 3D scanned parts of the inside front hood area where we build a very light construction for a hood stick in weaved carbon fiber and four individual parts that makes up the solution to keep the hood open. The Carbon fiber tube is sourced in the UK from easy composite. The click holder, the swing, the end part in the tube and the part for the stick in open hood state is all made in 3D CAD and 3D printed in ONYX on our Markforged 3D printers. We fasten the different components in places where there were already available screws to minimise the work and necessity of drilling in the body work. Now we can put away the baseball bat that served as hood stick for the whole summer :-)

"dollies" in ONYX

2020-09.20

Design and build with 3D printers

Our ambition is to build everything for the car ourselves in the 3D lab, so first thing to build in our 3D CAD software Fusion 360 was parts for the "dollies", so we could have the car "lifted" up at all time and easily push it around with no wheels on... For this we engineered perfectly fit chassi connectors as every Porsche has these, it will help us to fit the chassi and secure it well on the four dollies we built for the car.

ONYX

We 3D printed these on our Markforged ONYX one machines, the ONYX material is a composite that is a mix of chopped Carbon Fiber and Nylon. Very strong and sturdy material that is well suited for exchanging all parts in a vehicle from ABS plastics to Aluminium. At the lab we just love recycled materials like PETG and we have the intention to build a lot of components in that plastic as it makes sense from a sustainability point of view, however we will not make sacrifices on parts that is critical from safety or functionality, that will be done in ONYX with or without reinforcement as this is still much more cost efficient and less energy consuming than milling aluminium parts with CNC tech.

A short summer for the tribute car as a petrol RSR

2020-05-01

A short summer drive

This ended really the first year of total make over for this car. We will now work with every single part and component of the car, refine and re-define everything. We will update every small step from now on, on our quest in creating the ultimate vintage sports car with a environmental friendly driveline... 

EV conversion and total rebuild interior can start

With a leaking engine and gearbox, the engine would need a full rebuild. As a lostboyslab project we want to challenge everything, it also means we will push the limits of EV conversion as well as rebuilding every part of the car with our 3D design tools and 3D print farm...

The Paint job

2020-02-25

Spring time with slate grey

We got some pictures from the painter and it looked absolutely gorgeous. At this point we really wanted to get the car out in the spring in Sweden for a ride but it took a couple of more months before we could use the car at Porsche 964 tribe hang in May at the race track of Ljungbhyed in south of Sweden...

The color of steve Mcqueen

2020-02-10

A legendary color

The last special order 911 Turbo to Steve McQueen had a very special slate grey color which as we are all Californian and racing maniacs, the color of this car was truly spectacular. It was not easy to find the correct codes from that time but we found out the grey 6604 code was the correct one... It looks great in the Californian sun, but would it look good in the cold and dark North of Europe....?

The RSR original rims

2019-12-01

Searching for originals

Our search for original rims was focused on Germany, as this is the location where probably most of these RSR rims in good shape would be. As Porsche only built 62 RSR cars and most of them for CUP racing, we knew it would be hard. Luckily we found a set original rims in absolute mint condition, 28 years old but as NEW! This was great as we all know how important WHEELS is on any car. In a large scale EV project we know, we wouldn't spend so much on rims, but this is our showcase project and we want the EV-RSR to pop!

The body make over

2019-08-01

The body rebuild

The work could start with rebuilding the car with the super wide RSR carbon boy components. You can see how wide the rear is, that is the original rims on the car, with no spacers, the wide body is really wide...

The work progressed really well but we didn't really see the car for almost 4 months as we were occupied with work in California, but when we saw the first images of the car we were very pleased. The body parts. were fitted almost perfectly and we now had to find original rims for the RSR car as well as decide the color of the RSR tribute..

The donor car

2019-05-01

A donor needed

The donor car, a mystic blue metallic 964 C4 from 1991 was the chosen one for our project. The Porsche 911 (964) is probably the most legendary sports car of all time and among all those 60 years of variation and evolution we wanted to base our project on a car that have great build quality and was iconic as a sports car.

Porsche 964

The car was really in decent condition and actually would have worked nicely as a vintage car with some updates and maintenance to engine and some minor rust here and where. Redoing this project we would probably go for a car in worse condition, but the 964 Porsches are very popular among Porsche purists so most cars are well maintained. We were certain that this car was never in any serious accident as this would make it harder to build a Carbon fiber body on top of the chassi if it were anything than straight....

RSR Tribute

The 964 was built between 1988-1993 (fact check!) but we wanted this car to be very special som we wanted to make it into a 964 RSR Tribute with the wide rear track width and more race like appearance. The 911 Turbo and RSR race car versions were always the school boy dream that was posters on our walls back in the days. In our community with motorsport and racing we have a good relation with a custom car builder outside of Helsingborg in Sweden. They have long experience in building and renovating race cars and building very special cars in Carbon fiber. We assigned them to make the major changes of the cars body as this was not our main interest with the project that lies in rebuilding everything inside with electrical engines, batteries, electrical system and hundreds of 3D printed parts and components in ONYX (Carbon/Nylon composite). So the car was sent to Elite Projects in August 2019 for a total make over...