ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

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 ICON 917RSK -Dave Eaton and John Hartland

Project 917RSK: Summary of Chassis Design and build as of 20th Nov 2013.
1. Chassis design was developed using a combination of the 14.5: 1 scale drawings in the book Porsche
917: Archiv 1968 -1974 Walter Naher, the Gunnar Racing videos of rebuilding 021, and many other
photos collected from various other books and the web.
2. The chassis design and tube diameters reflects the original geometry accurately, with only minor
changes in the lower engine bay area to package the G50 clutch slave and starter motor. And a small
widening of the lower engine bay frame to help package the exhausts.
3. Main chassis (less all brackets and roll bar) is made-up of 206 T45 laser cut tubes. These tubes were
cut direct from the iges files generated from the intersected and trimmed Catia tube models. Welding
has been a combination of TIG and MIG, dependent on joint design an access.
4. The chassis is completely circular tube, as the original was. And not like the replicas produced in
Australia, South Africa, or the US which use a substantial amount of square tube to simply the design.
5. Chassis weight (less brackets and roll bar) is 98Kgs, and final weight is anticipated to be around
115Kg.
6. It has taken approx 2500 CAD hours to design and engineer the jig and chassis. But the design time
has reaped benefits regards chassis build time, as the first chassis has taken approx 200 hours to build.
7. Tecosim have run CAE run to check the torsional rigidity of the chassis, which is approx
28,500Nm/deg. As a comparison the GT40 monocoque is approx 17,000Nm/deg. Low speed 20 &
30mph front impact was assessed, which resulted in a reduction in wall stock of 5 tubes to lower the G-
spike from 70 to 40.

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 ICON 917RSK -Dave Eaton and John Hartland

Project 917RSK: Summary of Chassis Design and build as of 20th Nov 2013-Contd.
8. Next step 1: To manufacture the roll bar, outriggers, screen hoop and roof bows. Then offer-up the
body panels, and finalise the roll bar and screen hoop positions. Screen hoop, roll bar, outriggers
completed mid July. First assembly of the shell took place the following week. Tillett seat ordered July
29th, anticipate 2 weeks for delivery.
9. Next Step 2: The suspension geometry, chassis pick-up points, and brackets are all designed, in CAD.
These will all be laser cut from 3mm T45, and located in the correct position with 4 x corner jigs. Front
suspension jigs and suspension brackets CAD completed Sept 2013, and manufactured Oct 2013. Rear
suspension jigs and suspension brackets CAD completed Dec 2013, and manufactured Jan 2014.
10. Next step 3: All other brackets (pedal box, wipers, rear lamps, slaves, reinforcements etc) will be the
final parts to be assembled.
11. It is anticipated that these next 3 phases to complete this accurate replica chassis will be completed by
end of Jan / Feb 2014.
12. Engine and gearbox are 964 3.6L & 5 speed inverted G50. Exact engine spec is TBC. The engine will
use Jenvey Fuel Injection and Engine Management system so I can run CATS to pass the IVA emission
requirements.
13. And ultimately the car (and project) will be put through the rigorous IVA process, so that it can be
driven with confidence on the road or track. Because I cannot build a 917 without being able to pose on
the public highways!

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 ICON 917RSK -Dave Eaton and John Hartland

Project 917RSK: Summary of Chassis Design and build as of 20th Nov 2013-Contd.
Slides 5 to 8: Show the chassis wireframe, and chassis design prior to intersecting and
trimming the tube joints.
Slides 9 to 11: Show various aspects of the suspension, pedals, and driveline package.
Slide 12: Shows the CAE torsional rigidity study completed on the frame.
Slides 13 to 15: Shows the scanning process, the resulting section file, and positioned scan
section file positioned over the chassis model.
Slides 16 to 18: Shows the surfaced bodyshell developed from the scan section file.
Slides 19 to 24: Shows the 1st, 2nd , & 3rd chassis layer tubes.
Slides 25 to 28: Show the 1st, 2nd, & 3rd chassis layers & assembled to the jig.
Slides 29 to 51: Show the chassis jig and chassis build with detailed photos of the laser cuts
joints, before and after welding.
Slides 52 to 54: Show the completed main tubular chassis (less roll bar, screen hoop, and
brackets). Chassis build accuracy is 5mm in 2310mm.
Slides 55 & 57: Shows the chassis with screen & roof hoop, and removable roll bar.

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 ICON 917RSK -Dave Eaton and John Hartland

Project 917: Summary of Chassis Design and build as of 20th Nov 2013-Contd.
Slide 58: Shows the purpose designed rack, and initial assembly to the chassis.
Slides 59 & 61: These show the front and rear suspension jig design and manufacture, and
assembled to the chassis with all the brackets located.
Slides 62 & 63: Show the removable roll bar bracket layout, then fully assembled. Then
bracket assembly to the chassis, and finally assembled to the chassis.
Slide 64: Shows the screen hoop initial assembly and relationship to the body.
Slides 65 to 67: Show the first assembly of the body shell to the chassis.

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ICON 917RSK -Dave Eaton and John Hartland

Shows the wireframe geometry, that supports the chassis

model. This geometry is based on 3D points, and can be
modified by changing the point coordinates. This then updates
the position of all the affected tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Chassis Model with Roll Bar with Suspension Brackets Feb 2014
(Perspective on). Chassis tubes are fully trimmed, and CAD
models used to laser cut 206 tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Chassis Model with Roll Bar with Suspension Brackets Feb 2014
(Perspective on). Chassis tubes are fully trimmed, and CAD
models used to laser cut 206 tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Chassis Model with Roll Bar with Suspension Brackets Jan 2014
(Perspective on). Chassis tubes are fully trimmed, and CAD
models used to laser cut 206 tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Chassis Model with Roll Bar with Suspension Brackets Jan 2014
(Perspective on). Chassis tubes are fully trimmed, and CAD
models used to laser cut 206 tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Chassis Model with Roll Bar with Suspension Brackets
(Perspective on). Chassis tubes are now fully trimmed, and CAD
models used to laser cut 206 tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Frt area of chassis showing suspension mounts, pedal
box & cylinders, pedals, and footrest.

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 ICON 917RSK -Dave Eaton and John Hartland
Frt suspension upper mounting for the roll bar, steering rack, shocker
absorber, and upper wishbone-view from front.

Shock absorber
Roll bar

Upr Wishbone

Steering rack

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ICON 917RSK -Dave Eaton and John Hartland
Frt suspension mounts for lower front wishbone.

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ICON 917RSK -Dave Eaton and John Hartland
Rear of chassis showing suspension radius arm mounts,
and the upper and lower wishbone mounts.

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ICON 917RSK -Dave Eaton and John Hartland

Shows 964 Engine and G50 Box modelled in CAD and packaged ino the
chassis. This allows accurate set-up of the engine & box mounts,
driveshaft angles, exhaust and ancillaries package etc.

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ICON 917RSK -Dave Eaton and John Hartland

PV of 964 Engine Block now modelled: Chassis width increased by

40m at rear to improve ease of engine removal.

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ICON 917RSK -Dave Eaton and John Hartland

Torsional Rigidity. The initial figure of 32500Nm/deg has reduced to approx

28000Nm/deg, due to a reduction in wall stock when changing from metric tube sizes
to imperial to enable use of T45 which is produced using SWG thicknesses.

Max displacement 7.5E-4

Steel : 32,500 Nm/°

(Aluminium : ~11,000 Nm/°

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ICON 917RSK -Dave Eaton and John Hartland

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ICON 917RSK -Dave Eaton and John Hartland

Body shell mounted on wood

support frame.

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ICON 917RSK -Dave Eaton and John Hartland

Body shell mounted on wood support frame, with approx

2000 reflective dots replied ready for scanning.

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ICON 917RSK -Dave Eaton and John Hartland
Body shell scanning. Maximum scanning volume is 1 cubic meter. So
shell was scanned in 8 x 1 cubic meter chunks. And these chunks
were assembled in the post scanning data processing stage.

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ICON 917RSK -Dave Eaton and John Hartland

Body shell scanning. This shows the front wheel arch vents
surface generated into data.

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ICON 917RSK -Dave Eaton and John Hartland

Body shell scan surface file after assembling the 8 separate

scan chunks.

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ICON 917RSK -Dave Eaton and John Hartland
Body shell scan section file. The surface scan file is basic
quality, and no good for cutting GRP lay-up tools.
25mm sections are cut in X, Y, and Z directions. Then class-A
surface has been developed using these sections.

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ICON 917RSK -Dave Eaton and John Hartland

Body shell X-Sections with the chassis model. The chassis

CAD model can then be adjusted, so that it fits correctly to the
sections & associated surfaces developed from the sections.

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ICON 917RSK -Dave Eaton and John Hartland

99cm wide screen positioned in the surfaced shell.

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ICON 917RSK -Dave Eaton and John Hartland

First 1:1 fully surfaced model with cut lines, and oil cooler ducts added.
The surfaces will need further re-work to improve highlights. This can
be done at a later date, prior to cutting gel coat lay-up tools.

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ICON 917RSK -Dave Eaton and John Hartland

First 1:1 fully surfaced model with cut lines, and oil cooler ducts added.
The surfaces will need further re-work to improve highlights. This can
be done at a later date, prior to cutting gel coat lay-up tools.

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ICON 917RSK -Dave Eaton and John Hartland

First 1:1 fully surfaced model with cut lines, and oil cooler ducts added.
The surfaces will need further re-work to improve highlights. This can
be done at a later date, prior to cutting gel coat lay-up tools.

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ICON 917RSK -Dave Eaton and John Hartland

Jig final design with 1st & 2nd chassis

layers assembled-Rotated PV

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ICON 917RSK -Dave Eaton and John Hartland

Jig final design with 1st & 2nd chassis

layers assembled-Rotated front view LHS

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ICON 917RSK -Dave Eaton and John Hartland

Jig final design with 1st & 2nd chassis

layers assembled-Rotated rear view LHS

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ICON 917RSK -Dave Eaton and John Hartland

Jig Rotated Front Section

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ICON 917RSK -Dave Eaton and John Hartland

Jig final design with 1st & 2nd chassis

layers assembled-Rotated rear view LHS

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ICON 917RSK -Dave Eaton and John Hartland

Jig final design with 1st & 2nd chassis

layers assembled-Side view LHS

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ICON 917RSK -Dave Eaton and John Hartland

1st Chassis Layer Tubes.

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ICON 917RSK -Dave Eaton and John Hartland

2nd Chassis Layer Tubes.

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ICON 917RSK -Dave Eaton and John Hartland

3rd Chassis Layer Tubes.

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ICON 917RSK -Dave Eaton and John Hartland

1st, 2nd, and 3rd Chassis Layer Tubes, assembled to 1st & 2nd layer tube
supports. 3rd Layer supports not designed yet.

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ICON 917RSK -Dave Eaton and John Hartland

Lower Base & Upper Jig Fames on 5m x 3m Surface Plate, to

check accuracy (straight and flat), prior to final jig assembly

Checking the jig base

for flat after welding-
approx 2mm over 4m.

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ICON 917RSK -Dave Eaton and John Hartland

Fully assembled Jig with 1st and 2nd chassis layers

tubes and 3 adjustable levelling frames.

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ICON 917RSK -Dave Eaton and John Hartland

Fully assembled Jig with 1st and 2nd chassis layers

tubes and 3 levelling frames.

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ICON 917RSK -Dave Eaton and John Hartland

Fully assembled Jig with 1st and 2nd chassis layers

tubes and 3 levelling frames.

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ICON 917RSK -Dave Eaton and John Hartland
Local view of 1st layer laser cut tube joints assembled
into 5mm support plates.

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ICON 917RSK -Dave Eaton and John Hartland

Rear of chassis with the 1st layer assembled into 5mm support plates.

This is the only area

which has changed
from the original 917
design, to package the
G50 slave and starter.

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ICON 917RSK -Dave Eaton and John Hartland

Rear view 1st & 2nd assembled chassis layer tubes.

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ICON 917RSK -Dave Eaton and John Hartland

Overhead view of 1st & 2nd layer out rigger frames.

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ICON 917RSK -Dave Eaton and John Hartland

Initial assembly of 2nd layer front triangulation joint into support plates.

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ICON 917RSK -Dave Eaton and John Hartland

View of 1st & 2nd chassis layer assembled tubes-RHS front .

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ICON 917RSK -Dave Eaton and John Hartland
Detailed view of rear tank vertical & joints 1st & 2nd chassis
layer tubes-RHS.

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ICON 917RSK -Dave Eaton and John Hartland
Detailed view 3rd chassis layer joints at bulkhead and rear
lower frame joint.

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ICON 917RSK -Dave Eaton and John Hartland
Detailed view of welded joints of 1st chassis layer joint at
bulkhead to floor frame-RH & LHS.

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ICON 917RSK -Dave Eaton and John Hartland
Detailed view of welded joints of 1st chassis layer joint at
bulkhead to floor frame-RH & LHS.

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ICON 917RSK -Dave Eaton and John Hartland
Detailed view of welded joints of 2nd chassis layer joint at
Front Upper Frame-RH & LHS.

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ICON 917RSK -Dave Eaton and John Hartland
Laser cut 5mm supports for tail area pre-assembled on plate, prior
to assembly to jig with tail tubes.

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ICON 917RSK -Dave Eaton and John Hartland
Engine bay, 3rd layer chassis build status as of 11th June 2013. Tubes
assembled in routed jig plates, awaiting final welding.

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ICON 917RSK -Dave Eaton and John Hartland
Fuel tank out riggers, with removal cross-brace, to allow access to
electronics on one side, and stowage on the other side.

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ICON 917RSK -Dave Eaton and John Hartland

Jig with 1st and 2nd chassis layers supports & tubes assembled.

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ICON 917RSK -Dave Eaton and John Hartland

Jig at 90degs, to allow easy welding access to inner areas of the frame.

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ICON 917RSK -Dave Eaton and John Hartland

Jig at 60degs, to allow easy welding access to inner areas of the frame.

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ICON 917RSK -Dave Eaton and John Hartland

Jig with 1st, 2nd, and 3rd chassis layers supports &
tubes assembled.

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ICON 917RSK -Dave Eaton and John Hartland

Jig with 1st, 2nd, and 3rd chassis layers tubes assembled and welded.

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ICON 917RSK -Dave Eaton and John Hartland
Main chassis fully welded(approx 210 laser cut tubes) being
weighed-coming in at 98Kg.

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ICON 917RSK -Dave Eaton and John Hartland

Main chassis fully welded(approx 210 laser cut tubes) being

weighed-coming in at 98Kg.

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ICON 917RSK -Dave Eaton and John Hartland
Local views of the chassis showing the well it reflects the
original 917 chassis design.

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ICON 917RSK -Dave Eaton and John Hartland
Overhead side views of the chassis & jig, with the screen, roof, & body
outriggers assembled. And with the roll bar assembled. Dec 2013.

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ICON 917RSK -Dave Eaton and John Hartland
Central side view of the chassis & jig, with the screen, roof, & body
outriggers assembled. And with the roll bar assembled. Dec 2013.

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ICON 917RSK -Dave Eaton and John Hartland
Front and Rear views of the chassis & jig, with the screen, roof, & body
outriggers assembled. And with the roll bar assembled. Dec 2013.

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ICON 917RSK -Dave Eaton and John Hartland

Steering racks delivered, and initially assembled to the chassis.

Good fit no problems.

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ICON 917RSK -Dave Eaton and John Hartland

Front Suspension Jigs Manufacture from CAD to completion.

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ICON 917RSK -Dave Eaton and John Hartland
Front Suspension Bracket layout. And Jigs assembled to the
chassis with all suspension brackets initially located.

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ICON 917RSK -Dave Eaton and John Hartland

Rear Suspension Jigs Manufacture from CAD to completion.

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ICON 917RSK -Dave Eaton and John Hartland
Final CAD for the removable Roll Bar fully assembled,
and fitted to the chassis mounting brackets.

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ICON 917RSK -Dave Eaton and John Hartland
Removable Roll Bar, components layout and fully welded. And initial
assembly of brackets to the chassis.

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ICON 917RSK -Dave Eaton and John Hartland
Removable Roll Bar fully assembled, and fitted to the
chassis mounting brackets.

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ICON 917RSK -Dave Eaton and John Hartland
Initial assembly of the body shell to the screen support hoop. Further
revisions are being made to .

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ICON 917RSK -Dave Eaton and John Hartland

First fit of bodyshell on chassis.

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ICON 917RSK -Dave Eaton and John Hartland

First fit of bodyshell on chassis.

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ICON 917RSK -Dave Eaton and John Hartland

First fit of bodyshell on chassis.

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