Innovative Drivetrain Engineering for Blockbuster Film Production
Client: Major Film Production Company
Project: Modification of Mercedes X-Class Pickups for Advanced Drifting Capabilities
Services Provided: Drivetrain Engineering and Consultancy
Challenge: Enable controlled drifting on permanent 4WD vehicles without built-in rear differential lock
Solution: Customized drivetrain modifications including a remote switchable air locker and a reengineered transfer box
Outcome: Successful adaptation of vehicles for high-performance film stunts
Background
Our client, a renowned film production company, approached us with a unique challenge. They required specialized modifications to Mercedes X-Class Pickups for dynamic drifting scenes in an upcoming blockbuster film. The task was to adapt these inherently 4WD vehicles for controlled, rear-wheel drifting on loose surfaces.
The Challenge
The Mercedes X-Class's permanent 4WD system, lacking a built-in rear differential lock, presented a significant engineering challenge. The system's design, which distributes torque across axles via multiple clutch plates, complicated the task of achieving the desired drifting effect.
Our Approach
Our team embarked on a meticulous process to reengineer the vehicle's drivetrain. We explored several options, including limited slip differentials and permanently locked differentials. However, considering the project's time constraints and the need for versatility in vehicle handling, we opted for a remote switchable air locker. This innovative solution enabled the rear differential to transition from open to fully locked at the push of a button, offering the flexibility required for film shooting.
Simultaneously, we tackled the challenge of the transfer box. Our initial strategy involved a 3D-printed device to replacing the stepper motor to lock the transfer box in high range & at maximum lock whilst disconnecting the front axle, ensuring the vehicle remained rear-wheel drive. However, this approach partially succeeded, as the clutches eventually slipped, attempting to redirect power to the now disconnected front axle.
Collaborative Innovation
In collaboration with the production company, we developed a more robust solution. By laser cutting a custom clutch pack, we achieved a permanent lock, effectively converting the vehicle to rear-wheel drive. This solution, while less reversible, met the project's requirements, considering the vehicles' likely fate in stunt scenes.
Outcome
Our innovative approach and collaborative efforts resulted in the successful modification of the Mercedes X-Class Pickups. The vehicles performed exceptionally in the film's demanding stunt sequences, showcasing our ability to deliver tailored solutions under tight deadlines.
Conclusion
This project exemplifies our expertise in drivetrain engineering and our commitment to providing creative, effective solutions. Our ability to adapt and innovate in challenging scenarios positions us as a leader in the field of automotive engineering consultancy. We look forward to tackling similar challenges and contributing to the success of future projects.
