By Luke Gilmore
When passion meets innovation, the results are often extraordinary. ISAT intern, Jack Sellers, has been hard at work recreating a vital part for our client’s Porsche 356B Super 90. This part is known as a sunroof handle cup. Vintage Porsches often require parts that are either expensive or unavailable. The sunroof handle cup, which fits snugly between the sunroof’s upholstery and latch mechanism, was one such elusive piece. Starting in June, Jack decided to take on the challenge.
The Process Was Far From Being Straightforward
To recreate this part, Jack had to navigate complex software like Blender and SolidWorks. While the learning curve was steep, Jack embraced the opportunity. “It’s been a challenge, but I’ve appreciated the opportunity to learn the software so I can apply it at future jobs,” he said. The project kicked off with a 3D scan of the original part, done by Andrew Strack, head of the Makerspace at JMU. Using advanced equipment, the scan captured the part in stunning detail, producing a raw file that contained over a million polygons. The challenge was to clean up and downsize the file while maintaining accuracy—a task requiring patience and meticulous attention to detail.
Jack turned to Blender’s smoothing tool, which highlighted areas of unevenness in the model, such as leftover glue from the original part. As you can see in the video, these imperfections were carefully removed, leading to a cleaner, more functional design. The downsized file now boasts just 75,000 polygons. This resource will be shared through the MAAP website in the near future, where Porsche enthusiasts can download the file and print the part themselves.
A Blend of Passion and Innovation Can Overcome Any Challenge
The project is not only a testament to Jack’s dedication but also a showcase of how technology like 3D scanning and modeling can breathe new life into vintage cars. Whether it’s downsizing complex models or navigating intricate software tools, Jack’s work demonstrates that the blend of passion and innovation can overcome any challenge. Stay tuned for the release of this file on the MAAP website!