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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.

Why won't automakers slap on a turbo badge anymore?

Where have all the turbos gone? Not the actual pieces that go in the engine, mind you, those are everywhere these days as automakers downsize cylinder counts and boost efficiency and CO2 claims. But the turbo badges and fanfare are missing. Back when turbos were something to get excited about there was "turbo-driven," "turbonium," and "The Turbo Zone," among other silly lines. But now that basically every car is getting some sort of boost even on the lowliest trims, automakers are almost sliding in the turbos under the radar. Or if you look at some of the nomenclature, pretending they don't exist at all. The 911 Turbo badge shows where the car goes from being sane to lunatic. It's an important border. The latest automaker to hide that it has boosted the turbo presence is Porsche with the 2017 911 lineup. Even the standard Carrera models now get turbocharged flat-six engines, meaning the 911 Turbo models aren't quite as special as they once were. Porsche is in a sticky situation with this. The 911 Turbo, after all, signifies where the 911 family takes off from being a sports car and becomes the Ferrari fighter. The 911 Turbo badge shows where the car goes from being sane to lunatic. It's an important border, but now Porsche has crossed it and is trying to downplay the fact. There are a lot of exaggerations with displacement badges today, with claims the 2.0-liter turbo four in a Mercedes C Class equates to a naturally aspirated 3.0-liter six to make a C300. Volvo is pretty far up there, too, saying an XC90 T8 means V8 power, even though it's a 2.0-liter turbocharged and supercharged four with electric assist. I don't know why BMW can't just call the car a 330i Turbo, rather than inflating the numbers up to 340i. Saab tried all of this back in the '90s when it decided to turbocharge its entire lineup, from light pressure units all the way up to models actually called "Saab 9-3 HOT" (for high-output turbo). But then the brand deleted any external reference to the turbo under the hood and people wondered why they were buying a $42,000 four-cylinder convertible. And that didn't turn out well. Even though these turbo replacements often make more power than their naturally aspirated predecessors, they're very different engines. People knew something changed when they exchanged their leased 328i with a 3.0-liter six for a 328i with a 2.0-liter turbo four.

The mid-engine Porsche backstory

As an automaker's identity evolves over years, its signature becomes defined by any number of factors - heritage (Mercedes-Benz), image (Lamborghini), or market share (Toyota). In the case of Porsche, it was an engineering quirk that forged the German company's most enduring character trait.
Porsche would not have survived - let alone, thrived - in today's saturated landscape had it not been for the 911, and that slope-tailed sports car wouldn't have sprung to life without its predecessor, the 356. While phenomenal success of those rear-engine icons built the company, forays into the mid-engine configuration have played a significant part in establishing the brand's identity.
The Mid-Engine Prototype Of Ferry Porsche's Dreams