In order to achieve the typical RS extension to the rear, a standard side section has to be produced as a thin sheet metal part. Specialists position the side section in the tool, mark the interfaces and use a template to draw the outline. A body saw is used to cut away the marked area.
The thin sheet metal part which has been worked on and the fender extension must be positioned accurately in the tool mould and fixed using magnets before joining.
The fixed parts are joined together in a gas tungsten arc welding process (WIG). The welder starts by positioning the joining points at some distance from each other and then gradually brings them closer together until there is only 5-7 millimeters between them. The two parts are then fully welded together. Special tools are used to measure the new side section with millimeter accuracy.
This is where the highly sensitive phase of production starts. Because the thin metal sheeting is very unforgiving of errors, the welded seam must be formed by hand. An intuitive touch is required. The experts start by carefully flattening the interface using special tools and gently going over it with a body plane. Multiple grinding processes follow in increasingly fine gradations in order to produce a surface suitable for painting.
5. Quality Stamp
The manufacturing of a 911 Carrera RS 2.7 thin sheet metal side section is high-quality work which deserves a quality seal. The Porsche trademark is stamped into the frame of the light housing as definite proof: “guaranteed original” and “made in Germany”!