In this week’s Case Study, the Nitron Suspension Development Team has been working on a Porsche 911 996 Turbo, upgrading the original dampers to the ultimate suspension setup. This included the following:
- Top spec Nitron elec-TRON R3 coilovers
- The new Nitron Front Axle Lift (FAL) system with remote control
- Nitron elec-TRON Damper Control Unit (DCU)
- A 3D printed OEM replacement of the 996 central compartment tray to perfectly accommodate the DCU control knob
The customer had previously experienced Porsche’s PASM (Porsche Active Suspension Management) system and desired a similar setup for their 996, which was never offered with PASM from the factory. They requested an easily accessible and adjustable solution. Additionally, they wanted the car to be capable of raising above standard ride height to improve everyday usability, making it easier to navigate speed bumps, high curbs, and trailer loading. This feature was particularly important for enhancing access to the vehicle as the customer uses a wheelchair.
What was installed?
Top spec elec-TRON R3 coilovers
The Nitron elec-TRON R3 coilover kit combines the Nitron proportional solenoid valve with independent manual compression control. Designed for enthusiasts or professionals looking to further optimise their vehicle’s suspension performance for more extreme driving conditions and a higher level of performance. Piggyback or remotely mounted reservoirs allow quick and simple independent adjustment of high-speed and low-speed compression damping.
At the heart of the elec-TRON system is Nitron’s proportional solenoid valve, delivering unparalleled precision and control over the damping system. Each shock absorber in the elec-TRON system is equipped with an independent valve, allowing for individual damping control at each wheel. This is essential for optimising handling, stability and ride comfort.
The elec-TRON proportional valve operates within a range of 300-1800mA, providing a broad adjustment capability and a rapid response time of just 6 to 8 milliseconds from full hard to full soft. This system governs both compression and rebound damping. The valve is piston rod-mounted, fine-tuning the bleed characteristics of the shim stack, and is integrated with Nitron’s gas-pressurized mono-tube construction, ensuring maximum performance and reliability.
In the elec-TRON R3 coilover kit, the manual settings establish a baseline for the adjustments made by the main elec-TRON valve. The system can precisely adjust damping force based on a variety of factors such as g-load conditions, vehicle speed, road surface, and driver input. This results in highly accurate and responsive damping, significantly enhancing the overall performance of the vehicle.
The customer was very keen not to drill or modify the bodywork in order to fit the R3’s external canisters. They were therefore attached on the Nitron Bi-Axis Hose and Nitron Dry Brake system, allowing them to be run through original passages in the car. The canisters were then mounted in easy access locations utilising OEM hardpoints so that they could be adjusted by the customer, whilst remaining in his wheelchair.
Nitron Front Axle Lift (FAL) System
The Nitron Front Axle Lift (FAL) system allows the 996’s front axle to rise 25mm (30-35mm at the splitter) at the shock. This is an essential system that was designed to protect the car from damage caused by steep driveways and speed bumps or loading on/off trailers. A remote control to operate the FAL system from outside the vehicle was supplied to the driver to aid with access and a secondary wired button was also installed in the vehicle’s glove box in case they ever forgot the remote.
The system has also been designed with precision and ease in mind, featuring a no-drill installation process. This innovative approach means Nitron can mount the system without making any permanent modifications to the vehicle. No holes, no hassle. It preserves the structural integrity of the vehicle while significantly reducing installation time, making it a smart, clean, and warranty-safe upgrade for any performance enthusiast.
Nitron elec-TRON Damper Control Unit (DCU)
Allowing the driver to transform the shock set up from passive damping to a semi active system. Nitron’s elec-TRON valve is continually adjusting the damping levels every 5 milliseconds, depending on the information it receives from the DCU. It decides what position the valve should be in (and therefore what damping levels are created) by assessing all the data it receives about the car, its attitude and the forces acting on it (braking, cornering and accelerating). The DCU is fitted with a 6 position rotary control switch, allowing the user to access a number of pre-installed damping maps.
To eliminate the need to cut any holes in the original 996 central tray, an OEM fit replacement was 3D modelled using CAD software and printed to perfectly accommodate the DCU rotary control switch as seen in the images below.
