Body Structure
Body Structure
The purpose of redesigning the body structure of the new Boxster/S (987) series was to increase torsional and flexural rigidity in comparison with the previous Boxster/S (986) and also to further improve crash safety in a frontal or offset crash (frontal crash with head-on collision on one side of the vehicle).
Additional objectives were improved body seams and an increase in the space available to the vehicle's occupants, particularly taller persons.
These improvements have been achieved by means of seven main changes:
- Use of the spot welding/bonding method
- Redesigning of the joint areas (A-pillar, sills)
- Use of a new bulkhead cross member made of boron steel
- Repositioning of the pedals towards the front
- Use of "tailored blanks" for the front side members
- Integration of an additional load path at the level of the upper door trims
At the same time, the precision of the production process has been further improved by way of the Porsche fixing concept, whereby special reference points define the relative positioning of the body components with a very high level of precision. The attendant very high process reliability ensures uniform joint lines throughout all areas of the body.
The Porsche body structure is still executed as a light weight design with high strength and ultra high strength steels. This concept ensures very good passive safety. The torsional and flexural rigidity of the body structure has been further increased by using the spot welding/bonding method to join the side sections and the floor assembly. Torsional rigidity has increased by 9 %, flexural rigidity by 14 %. The redesigned joint areas (A-pillar / sills) have also contributed to these excellent results.
The bulkhead cross member in the front of the vehicle has been completely reengineered. It now consists of high strength steel (boron 02) and is produced by a new process. This has allowed the cross section to be matched to the package conditions and optimization of the available footwell space. The strength of the cross member has also been increased. The increased rigidity of the cross member and the improved anchorage have significantly reduced footwell intrusion in the event of a crash. The reduction in the cross section has also allowed the anchorage for the pedals and the pedals themselves to be moved forwards by 10 mm. In order to improve ergonomics, the clutch pedal has been moved forward by 15 mm. This provides taller drivers with more legroom and allows them to find an optimum seat position.
The new seats featuring comprehensive improvements, such as higher headrests, increased shoulder width and markedly improved lateral support also afford tall persons substantial benefits in the interior.
The tailored blanks employed in the rear side members on the previous Boxster/S (986) models are also used in the front side members on the Boxster/S (987). These blanks consist of fine panels made of different types of steel in various thicknesses which are welded together by way of laser technology. This enables the vehicle's weight to be reduced and crash zones to be defined. In conjunction with the front side members, the bulkhead cross member in the upper tier ensures an extremely robust structure.