Porsche 911 Carrera 4s 2009 on 2040-cars

Auto blog

2015 Porsche 918 Spyder: Touring the factory

Willy Wonka granted just five lucky Golden Ticket holders access to his incredible chocolate factory, yet we consider ourselves just as fortunate, as Porsche invited us to be among the first of just four American journalists to see behind the closed doors of its 918 Spyder assembly plant in Zuffenhausen, Germany. Of course, there were no Oompa Loompas or flowing chocolate rivers, but the vast white hall tasked with producing only 918 examples of the automaker's limited-production flagship revealed details that make Wonka's Golden Egg sorting room seem rather mundane in comparison. Unlike a traditional automobile manufacturing plant, which often encompass all processes of making a vehicle (e.g., stamping steel panels, welding components and painting), the 918 Spyder is built in an assembly plant. This means that hundreds of already manufactured parts, each crafted by Porsche offsite suppliers, are brought under one roof to be assembled into a perfectly finished product that is much sweeter – and far more expensive – than any candy delicacy. Our tour guide was Michael Drolshagen, Porsche's Director of Production, Logistics and Quality - a walking encyclopedia when it comes to the engineering and assembly of the 918 Spyder. Drolshagen generously offered us unrestricted access to walk among the factory's 110 workers – and a couple-dozen vehicles in process – to photograph everything. This is a story best told with pictures, so we've put together a raft of our best images in a high-resolution gallery and captioned each with a detailed description. If you've still got questions, please voice them in Comments section and we'll do our best to answer.

Porsche finally moving ahead with flat four engine

When Porsche released the first Boxster in 1996 and the first Cayman in 2005, the idea was to create an entry-level model for the German automaker's sports car range. The latest iterations of both closely related models, however, have begun to encroach dangerously on the 911's territory, particularly in their newest GTS specifications. That could be about to change, however, with the introduction of a four-cylinder engine for the compact mid-engined coupe and roadster.
According to Automotive News, Porsche is finally preparing to launch a new boxer four engine in the Boxster and Cayman, following years of speculation. The engine would be based on the same architecture as the company's famous flat six, but with two fewer cylinders to cut weight. Don't expect it to cut much in the way of performance, however: Porsche chief Matthias Muller indicates that the new engine could produce as much as 395 horsepower - significantly more than even the 340hp flat six in the Cayman GTS, suggesting that the engine could even find its way into the 911 as well.
It's no more clear which markets would get the four-cylinder engine, either. But wherever it is offered and in whichever form, it wouldn't be the first time we'd see a Porsche with a four-pot engine. Not by a long shot. Both the classic 912 and 356 were powered by boxer fours, as was the 914 - not to mention the 718 pictured above and the iconic 550 Spyder. The front-engined 924, 944 and 968 packed inline-four engines, but the last of those were discontinued in the 1990s. The prospect of a four-cylinder Boxster/Cayman has been rumored for many years now, most recently joined by the possibility of a four-pot Macan as well.

Porsche busts out new Boxster GTS and Cayman GTS

Baby 911. The poor man's Porsche. That's what they called the Boxster when it debuted some 20 years ago. They said the same of the first Cayman when it arrived a decade later, but they stopped saying it when the latest iterations hit the scene two years ago. That's because Zuffenhausen's entry-level models have long since stepped out of their big brother's shadow and into their own. And that's all the more true of the new Boxster GTS and Cayman GTS.
Based on the Boxster S and Cayman S, the new GTS models benefit from an enhanced 3.4-liter flat six that produces 330 horsepower and 273 pound-feet of torque in the roadster or 340 hp and 280 lb-ft in the coupe - representing an increase of 15 hp and 7 lb-ft in either model. Both also come with the Sport Chrono package as standard, along with adjustable suspension and 20-inch alloys, blacked out to match the dynamic headlight surrounds and other muted trim.
Those disappointed by the unavailability of a manual transmission in the fire-prone 911 GT3 will be pleased to note that a six-speed manual comes standard, but those enamored of letting a pair of clutches shift themselves seamlessly will want to spring for the optional seven-speed DCT. So equipped and with launch control engaged, the Boxster GTS will rocket from a standstill to 62 miles per hour in 4.7 seconds, while the incrementally lighter, more powerful Cayman will hit it in 4.6. Either way you're looking at a third of a second quicker than the Boxster/Cayman S. There's also a 20-millimeter lowered suspension on offer for track-day enthusiasts.