How to Win, Porsche Style

Nov 23, 2011
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I lived and worked in Germany for almost 8 years. Often, I would rent a Porsche for a month at times when I had to travel a lot. Believe me, there is nothing like travelling down a German Autobahn at over 300 kph. One day I was going about 150 mph, and a BMW passed me so fast that I got out to see if I had a flat tire.
I had to go to Stuttgart often, and one day met the Porsche VP of QC, and envigled a full day tour of their Engine Assembly line. It takes about 3 hours to assemble an engine from scratch, prior to the final HP test. The engines are on an overhead track, and one single mechanic follows it from station to station. No one else touches the engine, and that mechanic's name (who earns over 100 k in Euro a year, but only after over 15 years of earning his way up the ladder), remains attached to that engine forever.
At the end of the line the engine is tested at 4000, 6000 and 8500 RPM. The engine must be withing 4% of the advertised HP standard. If more or less, the engine is torn down to determine why.
I asked about the ones that were over? They are also never released, but are torn down to determine why, with all the accurate QC parts, that engine exceeded expectations.
I asked how often on over standard engines, do you find out why? Answer: They seldom find out the answer, it's just a fluke that a combination of parts just happen to all click better than expected.
WHAT DOES THIS HAVE TO DO WITH PINEWOOD CARS?
In 3 classes (SS, UNLIM and SR) I attempted to copy the Porsche model.
I built at least 5 identical cars (same body shape and construction, same axles, and same wheels). Each time, one of them always came out on top. However, even after that, I go through a process of trading of wheels and axles, to try to increase the top car's time.
This is a time consuming way to go, not to forget expensive. However, in SS, I leave the best car untouched, keep working on the 2nd best, and give the rest away to my grandchildren or local Cubs in my Church.
HOWEVER, there must be better ways to go. I know DD4H doesn't go through this routine, and I have never been able to beat GoatBoy in unlimited, and I haven't yet beat Kinser in anything.
BUT, I constantly listen to the DD4H DVD, and I attempt to follow it to a T, expecially in wheel and axle prep with all cars, but one car is invariably faster.
GO FIGURE
 
OPA...You gave me the best idea yet for testing process changes when you suggested everyone should build an unlimited car because they are simple and as at turns out, with a bit of work, one can have an unlimited running faster than the record holder in SS easy. I built mine with the same angles for the axles as my SS so I can change the back wheel opposite the DFW out and substitute any test axle and wheel for SS I want to test. Now the speed drops, but it is directly a function of just that slow wheel and axle. One can run many tests very fast and get good data on process changes. You can even test every wheel going on your next car to see if they all match speed. This takes almost all the building variation out of your testing and lets you concentrate on preps as a separate issue.