Race

Performance, Race

BBi R&D: 3D Scanning and Reverse Engineering with Creaform and 3D INFOTECH

Garbage in, garbage out as they say. Reverse engineering is part of every day development at BBi Autosport when creating new performance upgrades or bespoke components. Speed, accuracy and simplicity is key when it comes to gathering data as this helps shorten the development cycle and increase quality. We seek to have OEM like fit and finish with best possible performance possible within every part. For a lot of our development we are using laser scanners to collect data - which allow us to create 3D snapshots of cars and components. This way we do not need to keep referencing the vehicle.

Chris from 3D INFOTECH brought over the latest offering from Creaform - the HandySCAN Black. This is a simple hand-held scanner featuring blue laser technology which performs great on dark and reflective surfaces. The way these scanners collect data is by shining laser beam flashes onto surfaces and using special cameras to capture how the lasers bounce back. Small reflective dots allow the scanner software to create a coordinate system and align all the snapshots together - creating a larger 3D picture. The speed of capture, accuracy has been greatly improved with the HandySCAN Black as it was very impressive how fast it soaked up all the details. What is also very useful is that the objects that are being scanned do not need to be stationary. The 991.2 Carrera T exhaust that we were scanning could be picked up, rotated and moved (as long as the dots are still on) which allowed for much easier and quicker capture.

How that data is handled is just as important as the scanner hardware. Creaform has a great software package that reviews all scanned points, consolidates and optimizes the points and forms a clean, easy to manage file to be used in parametric modelling software.

These scanners allow us to reduce R&D time and reduce dependency on having the vehicle physically in-house for the duration of the development. The 3D snapshots of the parts and car allow us to work within a 3D environment, creating components that would perfectly mesh with the factory parts as needed.

We will update more as we keep developing the Porsche Carrera exhaust system, how we use the data and how our concepts come to life.

 

Performance, Race

Porsche Motorsport 991.1 GT3 Cup Body Conversion Now Available

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How do you make your roadgoing Porsche 991.1 GT3 stand out from the rest? You can transform it to look like a factory GT3 Cup race car with genuine Porsche Motorsport parts! This exclusive front and rear end conversion package comes complete with Front Bumper, Fenders, Flares, Tow Hook, Wing, Uprights, Decklid, and Supporting Hardware (not shown). All components in this package are unpainted. Professional installation is required and available at our facility. Additional components including the hood and rear bumper are all available separately for a complete motorsport look.

 

Performance, Race

Postdating the 964 and 993 : BBi Billet Uprights

Porsche 964 and 993 platforms are still considered quite sophisticated for their time. But time is unforgiving when it comes to technology advances, materials and design. Time simply leaves everything in its dust.

The market has improved support for these cars with hardware, accessories and electronics, but no one thoroughly addressed the outdated suspension geometry. In 2017 we took on bringing the 964/993 platforms up to date using the latest tools and manufacturing processes. Porsche left a lot on the plate in the 90s and we picked up where they left off. To help with this effort we once again partnered with Scarbo Performance who have years of experience developing complex suspension systems and creating incredible parts.

6 Months of Development | 200+ hours of engineering | 4 iterations

We started off with 3D Laser scanning the front suspension of the 964 and 993 platforms, modelling all the components to create a virtual setup of each car in CAD. Furthermore, we scanned the standard OE uprights as well as the EVO variants to evaluate what were were working with.

With the factory configurations set in CAD we started to work on our design targeting what needed to be updated based on how we needed to set the cars. After a complete kinematics study we needed to eliminate bump steer, address the ackerman angle and add adjustability. Most of the cars we work with are also lowered which cut into shock travel. We found that the Evo uprights were well designed, but still left room for improvement.

After 6 months of development, with over 200 hours of engineering and after 4 design iterations we locked the design. The end result is a geometry, strength and weight optimized part. It is machined form 6061 billet aluminum on 5-axis CNC machines and hard coat anodized in black.

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The roll center has been corrected and bump steer has been virtually eliminated. The shock mount was also lowered by 50mm, accommodating lowered vehicles and gaining back shock travel. We have retained full compatibility with OE heat shielding, sensors and bearings. The caliper mounts are designed for the OEM Porsche 993 Brembo units.

The whole upright is not just optimized for suspension geometry but for strength and weight. To ensure best performance on track, the part was subject to extensive FEA testing to be 2x stronger than the OE part. We’ve added structural ribbing to increase rigidity. It has also been optimized for weight. Each upright is just 5.56lbs despite the added strength and denser material.

Bump Steer Curves

The goal is to have no change in steering angle, as the wheels travels up and down (a flat line). The Evo uprights are a significant improvement over OE, but we found further improvement there with the BBi units.
  • Developed for lower ride height: 50mm lower than OEM, non RS

  • Adjusted Strut mount location for full shock travel

  • Corrected Roll Center

  • Virtually eliminated Bump Steer

  • Perfect Ackerman

  • Retains OE Shield Mounting

  • Reinforced Tie Rod and Control Arm mounting

  • FEA Tested for strength vs. weight optimization (2x Stronger, 5.56lbs/pc)

  • 6061-T6 Aluminum with Steel Tapered Inserts

  • 5-Axis CNC Machined

We are very satisfied with the part and the impact it has on these older platforms. Combined with our spherical control arm joints, inner and outer tie rods and a solid coil over setup - it really transforms the car as a whole. We have sold over 50 sets now since the product launched. Francis was one of our first customers with the setup. He tracks and daily drives his car.

"Huge Difference - turn-in is much more immediate, no more on-center wiggle/sloppiness, the weight through the wheel loads up in a nice way now, and that bump steer is no more! The wheel carriers were installed with the tie rods and ball joints from you guys as well. Amazing package!" - Francis

These BBi 964/993 Uprights are available to order as well as the supporting components. We can pre-assemble bearing and help you spec the ideal suspension configuration for your aircooled Porsche.


 

BBi Society, Performance, Race

Season Opener : RaceBBi at Willow Springs 01.27.19

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Towards the end of 2018 BBi partnered with SpeedDistrict and jump started the RaceBBi track days. High performance driving events (HPDE) are meant to provide an outlet for enthusiasts to push the limit of their vehicles on local tracks. We wanted to expand the experience and tailor it to our customers by providing track side support, instruction and hospitality. This enables us to educate our customers on their latest upgrades, build confidence in their vehicles and setups and do so within a safe environment with our technicians and tools on hand.

We started off 2019 with the first RaceBBi track day at Willow Springs Raceway near Rosamond, CA. The main track, Big Willow, is 2.5 miles long with nine turns and significant elevation change. Willow Springs is also the oldest permanent racetrack in the United States, opening in November of 1953. It is now a Historical Point of Interest in California. Fastest time at this track is 1 minute and 6.05 seconds as set by Michael Andretti in a CART Indycar. Please don’t try to beat that… yet.

Some cars were delivered in time for the event. We had just completed another milestone for the BBi 4.0l 997 GT3: full E85 compatibility. That means a new in-tank fuel system update, injectors and flex fuel sensor. The Syvecs ECU handles all the tuning changes with the flex fuel sensor. Our calibrator was collecting data logs as the car ran the sessions. Nothing beats real-world data. This is a real example of how much can be done when we have full control over the engine, being able to adjust the smallest details to enhance performance and drivability.

The 991.2 GT3RS has barely over 100 miles on the clock and was finished for this event as well. BBi StreetCup spring package updates the spring rates and our Corner Balance and Alignment set it up for the track. Wheels were swapped to the Manthey BBS WEC spec Magnesium wheels, wrapped in the new Michelin Pilot Sport Cup 2 R Tires resulting in massive grip and weight loss. BBi 3D printed inconel long tube headers with side muffler deletes uncorked the already impressive engine (and reduced weight) To top it all off we loaded a BBi ECU calibration to take advantage of the flow and get a bit more power out of higher octane fuel. The car is quite impressive out of the box, but there is more to be had and we will keep dialing it in.

The Ultima GTR always turns heads (and ears) and it was back out for some more testing and validation. Its an impressive machine as its built like a race car with a massive engine and now a sequential transmission. MoTeC keeps the powerplant going and the traction control logic works great to keep the car steady. We collected data logs to ensure all is within spec.

Driver instruction is a big part of this experience and understanding of vehicle dynamics. We will walk you through the best line around the track, talk about brake and acceleration zones. We also talk about proper reactions to ensure your safety on the specific track and in regards to other drivers. Thoughout the day our team works with the drivers, getting feedback on the vehicles and feel and recommending shock settings, advising on tire wear and track conditions. Each car is also continuously inspected for debris, damage or other hazards or issues.

Working with our customers and seeing our builds being thrashed around the track is also massively beneficial for us in how we develop product, ECU calibrations and chassis setups. We collect telemetry and logs from the cars after sessions, we gather driver and instructor feedback and complete post track day inspections. The wealth of data and notes gathered helps us review design requirements and adjust products and services as needed.

At the end of the day we get to see our work perform and our customers enjoying their cars. We develop these parts and work with our clients create their bespoke machines for this exact purpose. There are more events in 2019 (Check out the Calendar) and we look forward to working with more of you! The Buttonwillow RaceBBi event (02.08.19) is up and registration is open (Link)

Thank you SpeedDistrict for hosting, Jason of Shift-S3ctor for spearheading this, the instructors for their patience and wisdom and our crew for their relentless support and energy. We also are grateful for our Partners who help us support their products or share their resources to build these machines.

Here are some more photos from this day.

 

Performance, Race

BBi in the SpeedHunters' Crosshairs

The BBi guys were participating in some local track days and Trevor was the photographer on duty. Started to chat cars and the Porsche world seemed to pique his interest. Next time Trevor was in town we got together, talked shop, talked builds and he snapped some photos while at it.

Trevor is one of the regular contributors at SpeedHunters where he applies his eye for a well framed shot along with a bit of geeking out with his background in mechanical engineering. It was an absolute pleasure talking to Trevor and we are honored to have BBi profiled by SpeedHunters. We look forward to having him back for some progress updates on the builds and do some deep dives into whys, hows and whats behind each project.

For the time being - head over to SpeedHunters and check out our shop.

http://www.speedhunters.com/2019/01/hunting-huntington-beach-inside-bbi-autosport/

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