정기점검 수리 사례

2026. 8. 31. 작업

난이도 & 준비물

증상

insane build, bravo, looking forward to seeing this at a trackday at some point!

처리 내용

Chapter 3- Part 1 – Polo GT2I was at a crossroads 3 years ago with the car, it needed a fair amount of money investing into it (bespoke suspension components mainly) which I was unconvinced by. Waxing £10k on custom parts which might not work wasn't appealing. The Polo at this stage had a 1.8T 20v fitted in the front, with most of the difficult parts packaged. Suspension niggled me a lot, and it wasn't an area I wanted to compromise on. So, sensible heads prevailed and I decided to copy something that worked.After a huge amount of research, I decided I'd stick the Polo bodyshell onto something which was a proven package out the box, in 2022 I bought a 996 Turbo and found it easy to work on and well packaged as a platform, so started digging around it's stable mates. A pool-side trawl of Facebook Market Place on holiday saw me the proud owner of this Speed Yellow 986 Boxster S shell:With the Boxster shell in the garage, it was time to do some measuring and then a little 3D scanning. The process is fairly time consuming, mainly around creating geometry references (the little reflective dots) or coating existing surfaces in talc/alcohol so the scanner maintains it's origin and doesn't duplicate or ghost the point cloud, which causes multiple issues. Once you've spent many hours scanning, merging scans and let the PC chew through everything (this took about 16 hours to process) I ended up with a virtual Polo:The next step was to remove the rear quarters from the 986 shell, as I knew these wouldn't be required and was more interested in the surfaces beneath, a few spot welds later and it was looking something like this:I then proceeded to write the numbers 1-10 on tape a hundred or so times, and stick them all over the shell. This helps when reviewing the scanned data to quickly check for ghosting (multiple data sets of the same geometry with offsets)Once this was done the 9 scans are assembled and the software does some trick mating... which works most of the time. Turn