Upon obtaining both the GT4 RS and 718 GT4, we initiated the crucial 3D scanning phase. Initially, our focus was on scanning the rear space where the GT4 RS intake resides. This allowed us to define the boundary conditions and mounting points between the original intake and various elements such as side window openings, rollbars, and the engine bay's bodywork. Notably, the original intake ducts are mounted in such a way that it requires a cutout of the stock interior window lining. The rollbar sits quite low above the connecting ducts, so the ducts require a change in geometry to freely pass under. Furthermore, the bottom central component of the intake is securely fastened to the bodywork around the edge of a former heatshield on non RS models.
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As we disassembled the original intake entirely, we uncovered some intriguing engineering aspects. Porsche's engineers had executed their work meticulously. The repositioning of the throttle body atop the engine was justified by the aim of achieving enhanced and more direct airflow from the scoops to the throttle body. The air's path through smartly designed filters, from bottom to top, streamlines its journey to the throttle body—a brilliant solution within a confined space. Surprisingly, the scoops themselves are hollow carbon fiber, affixed to the carbon fiber duct using double-sided tape. Additionally, the connecting duct features a specially designed silicone coupling to cover the interior lining cutout, while its shell comprises carbon fiber, albeit with a plastic insert for interfacing with the central piece. Within this central piece, three main components are evident, all constructed entirely of plastic: the bottom piece serving as a heatshield, the central piece housing the filters, and the upper piece sealing the entire assembly. The upper piece features a carbon fiber exterior for aesthetic purposes. Consequently, the sole disparity between non-Weissach and Weissach models is the absence of external scoops and the carbon fiber skin on the central piece, with all other aspects and materials remaining identical. We posit that this design distinction was primarily driven by financial considerations.
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Moreover, we meticulously 3D scanned each component individually. Our objective was to mirror the external dimensions and design as closely as possible. Disassembling these components was not overly complex but did necessitate a modicum of automotive knowledge and access to appropriate tools. The 3D scanning process for the 718 GT4 was comparatively straightforward, yielding advantageous results. The consistency of rear side window boundaries, bottom mounting points, and the heatshield opening above the engine remained unchanged. Furthermore, we accurately identified the stock Y pipe's position and various boundary surfaces, including those of the stock plenum and rollbar. We also examined the air filter housings, although they would be rendered obsolete once our system was installed.
