Porsche 917K #1 1971 Racing Gulf Edition in 1/8 scale MODEL KIT

Every Pocher kit creation is the result of a labour of love. Our expert engineers spend years researching, designing and finalising the details of each kit, so that you get something that is as close to the real thing as possible.

Our Lead Engineer, George, talks to us about the challenges he found in creating the Porsche 917K kit. Get ready to learn a little bit more about the model you love!

Creating the design

If you’ve ever built a Pocher kit, you will understand the complexity that comes in each design. But as tricky as they can be to put together, it is even tougher to create the kit components themselves! “Pocher kits are challenging, they have hundreds of small and intricate parts.

“The model was designed in a somewhat modular fashion, breaking down the complex structure into manageable subassemblies. This allows enthusiasts to tackle smaller, less daunting sections one at a time, but we also tried to have the vehicle come together in a similar way to the way the vehicle was built, which is why the engine is a bit of a squeeze to fit in.”

But the difficulties come even before the design process begins. “Accessing such an iconic and rare car can be quite challenging, as they aren't just sitting in your neighbour’s garage. Sometimes, you'll have to travel hours or fly to another country to get a look at one.

“One particularly difficult aspect was getting access to an engine out of the car, as a lot of detail is hidden behind body panels, frames, and tubes. Capturing the intricate details and precise measurements of the original Porsche 917 requires extensive research and access to original drawings, photographs and expert consultations.

“Other than this, understanding how this particular vehicle looked at this exact race took a lot of research, as not many images were available.”

The importance of accuracy

And of course, Pocher customers demand accuracy and intricate detailing on their premium model kits. That can be extremely difficult on older cars, as George soon discovered.

“Ensuring accuracy is challenging given that these cars are over 50 years old, with each one differing from the next. Over time, they have deviated from their original specifications, changing from day to day and race to race, and often being repaired using parts from other vehicles, resulting in some chassis becoming amalgamations of several others. However, our approach to accuracy involves several key steps, starting with thorough research. Access to vehicle drawings, high-resolution photographs, books and consultations with Porsche experts is essential.

“We used advanced CAD software and LiDAR scanning of several Porsche 917s for precise measurements. We could then create and refine 3D printed prototypes, incorporating feedback from experts.

Porsche couldn’t provide George with any blueprints or designs of the original car, so he had to rely on information from several knowledgeable third-party restoration workshops.

“Alfred Kist from ORCA Restoration in Germany was particularly helpful. His extensive expertise and willingness to share detailed insights were invaluable in ensuring the accuracy and authenticity of the model. Through Alfred and other experts/owners such as Mark Finburgh, I was able to access detailed information and gain a deeper understanding of the intricacies of the Porsche 917, which significantly contributed to the success of the project. Porsche did have the final sign off on the model too.”

Using technology to get the design right

Different technologies really help with ensuring precise measurements and almost exact replica parts. However, as George points out, perfect replica kits are almost impossible to create: “Compromise must be made in terms of detail and decoration as realistically these models are built to a certain budget, otherwise the cost can really spiral out of control. So, we will often get feedback that certain areas are incorrect or don’t fit together as the real vehicle would, and often these are done for practical reasons. “

LiDAR scanning is the first part of the kit-creating process. This technology uses laser light to measure distances and create detailed, three-dimensional maps of an environment. It works by emitting laser pulses and measuring the time it takes for them to bounce back after hitting an object.

By calculating the time delay, LiDAR can determine the exact distance to each point on the object's surface. This process is repeated millions of times per second, allowing the creation of a precise 3D representation of the scanned area. LiDAR is commonly used in lots of different applications, and a similar technology is also now used in autonomous cars.

We then import scan data into our advanced CAD software (we use PTC Creo) for detailed 3D modelling. We also use technologies like 3D printing for initial prototyping and CNC machining for precision parts.

Premium materials for premium models

The primary material for the model is die-cast metal, typically zinc alloy, which is complemented by high-quality plastics, rubber and small amounts of stainless steel for specific components. Moulds for casting metal parts are precisely crafted, while intricate detailing is achieved through techniques like electroplating, painting, and pad printing. The combination of these materials and technologies ensures the final product is a highly accurate and durable replica of the original vehicle

The process for prototyping and testing is comprehensive too. George breaks it down: “It starts with 3D modelling using CAD software. The first prototype is a 3D-printed prototype, which is made to evaluate shape and fit. This is then built, and the prototype is reviewed and refined based on feedback. We will then approve the CAD and sometime later we will receive an engineering prototype which is made of the actual materials.

“The prototype is tested for proper fit and assembly and then moving parts are tested for smooth operation.

“Several rounds of refinement and re-prototyping are done based on testing results, typically involving three to five iterations. And then a refined pre-production prototype is created and reviews for approval. We’ll assess the paint and finish quality and then it’s time for production testing.

“A small batch is produced and inspected for quality and consistency. This meticulous process ensures that the final model is a high-fidelity representation of the original vehicle, both aesthetically and functionally.”

George’s favourite bits of the Porsche 917K model

The Pocher 917K is a fantastic kit, but George has his own favourite features. “It’s only a small thing, but I like that we’ve made the fan spin, the brake callipers and discs are finely detailed, and I like all the detail that we’ve put into the dashboard.”

And he’s always thinking of the end user, ensuring each kit comes with comprehensive, step-by-step assembly instructions with clear diagrams, so even complex steps are easy to follow. This helps builders understand the sequence and orientation of parts.

“We also try to use high-quality, precisely manufactured parts largely in die-cast, which reduces the likelihood of fit issues and makes assembly smoother. Components are engineered to fit together intuitively, minimizing the need for modifications or adjustments.”

And he has a top tip for builders: “The process of building up the engine and gearbox is a lengthy process, and one that you should take care of and certainly don’t rush. However, after this stage is complete, it's satisfying to see what you have built.”

Watch the full interview here: