Body Structure

Body Structure

The purpose of redesigning the body structure of the new 911 Carrera/S (997) was to increase torsional and flexural rigidity in comparison with the previous 911 Carrera (996) 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). The designers also managed to enlarge the passenger compartment without changing the exterior dimensions.

These improvements were achieved with four main changes:
- Use of the spot welding/bonding method
- Redesigning of the joint areas (A-pillar, roof frame connection)
- Use of a new bulkhead cross member made of boron steel
- Optimization of the upper load path for transmission of forces in frontal and side impacts

The Porsche body structure is still executed as a light-weight design with high-strength and maximum strength steels. This concept ensures excellent passive safety.







TECHNICAL MANUAL: Refer to the Technical Data when performing repair work in these areas.

The spot welding/bonding method used to join the side sections and the floor assembly has further increased the torsional and flexural rigidity of the body structure (torsional values increased by 8% while flexural rigidity rose by 40%). The redesigned joint areas (A-pillar joins, connection for the roof frame tube) have also contributed to these excellent results.

Spot Weld Bonding







The spot weld bonding material is applied primarily in the areas marked "A".

The bulkhead cross member in the front of the vehicle has been completely re-engineered and is now made of boron steel. This has allowed the cross section to be matched to the package conditions and available footwell space and at the same time the rigidity increased. The increased rigidity of the cross member and the improved anchorage have significantly reduced footwell penetration 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. This provides taller drivers with more legroom and allows them to find an optimum seat position. The seat anchorage has been lowered by 10 mm as part of the redesign of the body. This results in a lower seat position, which lowers the center of gravity of the vehicle and provides more headroom for taller passengers.