David Finest Sports Cars
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DAVID ATELIER
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PORSCHE 964 RESTORATION: BODY, CHASSIS, AND RS BRAKES

DAVID ATELIER
PORSCHE 964 RESTORATION · PART 2 OF 6

PORSCHE 964 RESTORATION: BODY, SUSPENSION, AND RS BRAKES

The second phase of the project takes the Porsche 964 significantly further, both technically and visually: The body is professionally prepared, the KW V3 HLS is adjusted, the axles are overhauled, and the brake system is converted to Porsche 964 RS specifications.

THE PROJECT IS TAKING SHAPE

Following the assessment and disassembly described in Part 1, the Porsche 964 is now moving into the next phase.

The body has been completely stripped of paint, revealing dents, previous repairs, and minor irregularities. At the same time, the new KW V3 with HLS is being installed for the first time so that the lines, pump, and mounting points can be precisely adjusted before painting.

At the same time, additional components are already being prepared for the later assembly: The axles are being overhauled, the new BBS wheels are ready to go, the brake system is being converted to Porsche 964 RS specifications, and the new Recaro Pole Position seats with Pepita upholstery have also arrived.

PORSCHE 964 RESTORATION: WHAT HAPPENS IN PART 2?

BODYWORK

After the paint is removed, minor dents, old repair spots, and unevenness become visible. Instead of simply filling these areas with body filler, the affected areas are professionally reshaped and, in some cases, tin-plated.

KW V3 HLS

The new suspension is installed on a trial basis before painting. This allows the hydraulic lines, pump, and cable routing to be optimally adjusted without having to make unnecessary modifications to the freshly painted body later on.

RS BRAKE SYSTEM

Since the engine will eventually have significantly more power, the braking system will also be modified. A larger system based on the Porsche 964 RS braking system will be used.

INTERIOR & WHEELS

The new BBS wheels are already ready to go. The Recaro Pole Position seats with black Pepita upholstery have also arrived, offering a first glimpse of the future interior design.

THE BODY IS COMPLETELY UNPAINTED

In this phase of the project, the Porsche 964 is being restored without any paint.

There’s a clear reason for this: Dents, bumps, and previous repairs can only be reliably identified once the body is completely stripped.

In several places, it is evident that the vehicle has already sustained minor damage over the course of its life. Among other things, there are areas that were previously filled with body filler.

For the current restoration, a different approach is being taken.

The panels are being restored to their original shape as much as possible. This ensures that the subsequent paint job can be applied to a significantly cleaner body surface.

LESS FILLER, MORE PRECISE BODYWORK

The front cover serves as an example.

An existing dent has already been pulled out, but it still needs further work and tinning. This will significantly reduce the amount of body filler needed later on.

Older damage is also visible on the side panels. A dented wheel well, which had previously been repaired with body filler, is now being professionally pulled out again.

The focus here is not on the quickest repair, but on restoring the body as cleanly and durably as possible.

KW V3 HLS: SUSPENSION WITH LIFT FUNCTION

The new KW V3 with HLS has already been installed in the vehicle on a trial basis.

The HLS uses hydraulic cylinders and allows the vehicle to be raised or lowered at the push of a button. The system is designed for both the front and rear axles.

The owner plans to drive the Porsche in Tyrol at a later date, among other places. Steep driveways, narrow ramps, bumps, and mountain passes are part of everyday life there.

The HLS therefore enables two things at once:

a sporty, low ride height
better everyday practicality when encountering obstacles

WHY THE CHASSIS IS ADJUSTED BEFORE PAINTING

The assembly is deliberately carried out now, before the body is painted.

For the hydraulic system, the pump, lines, and cable routes must be precisely positioned. In the trunk, a temporary mounting position for the pump is first determined.

For the steel-braided hose, for example, an existing, unused cable passage is used. This minimizes the need for additional modifications to the body.

As few modifications as possible, as many as necessary.

CUSTOM-MADE HLS HOSES

The system’s wiring is also customized for each vehicle.

A longer steel-braided hose is delivered, which is measured precisely on site and cut to the required length.

Since the HLS is being built as a custom configuration for this vehicle, the cable routing and positioning must be determined on a case-by-case basis.

Only when everything fits properly will the system be dismantled again, and the body can be sent to the paint shop.

CLUBSPORT DUST SHIELDS FOR MORE ADJUSTMENT OPTIONS

In addition, KW V3 Clubsport strut bearings are used.

They allow for more precise suspension tuning and help tailor the vehicle’s handling more specifically to the vehicle itself and its intended use.

The goal remains the same as in Part 1:

A classic Porsche 964 that handles like a sports car but is still practical for everyday use.

AXLES AND BEARINGS ARE BEING OVERHAULED

While the body is at the paint shop, work continues on refurbishing the axles.

Wheel bearings and other suspension components are inspected and replaced as needed. A few defective bearings had already become visible after the ice blasting.

This does not mean that components that look clean are automatically in like-new technical condition.

This, in particular, shows once again why it is important to thoroughly disassemble the vehicle.

BBS WHEELS: THE FIRST TEST FIT

The new set of wheels has also arrived in the meantime.

The BBS wheels are initially mounted on a trial basis to assess the vehicle’s height and proportions. A final adjustment is not yet possible at this stage, as the vehicle is largely empty and therefore does not yet have its final weight.

The final height and axle geometry are therefore adjusted only after the vehicle has been fully assembled and painted.

PORSCHE 964 RS BRAKES: MORE BRAKING POWER FOR MORE ENGINE POWER

Since the engine will later be enlarged to 3.8 liters and tuned to produce about 300 PS, the braking performance will also be adjusted.

A larger braking system based on the Porsche 964 RS is used.

While the previous brake disc has a diameter of about 300 millimeters, the RS brake disc is larger, at about 330 millimeters.

The larger diameter provides greater leverage, resulting in:

better braking performance
shorter braking distances
greater thermal reserves
Overall improved braking performance

At the same time, the larger red brake system also looks much better behind the new BBS wheels.

RECARO POLE POSITION WITH PEPITA

The project is also making visible progress on the interior.

The new Recaro Pole Position seats have arrived. The seats are black on the outside, and the center panels feature the classic Pepita upholstery.

As a result, the interior deliberately incorporates classic Porsche design elements while remaining sporty and functional.

Combined with RS carpet and a Momo steering wheel, the result is an interior that will be significantly more minimalist and driver-oriented than the production version.

NEW INSULATION MATERIAL FOR INTERIORS

The interior has since been dismantled even further.

The existing insulation has been removed, while the wiring harness remains in the vehicle for now.

Later, new insulation material will be customized and installed in collaboration with the upholsterer.

This does more than just reduce weight. Noise comfort and interior quality are also deliberately taken into account.

THE NEXT BIG STEP: PAINTING

Once the current modifications are complete, the vehicle will be completely disassembled again.

The suspension and axles will be removed again, and then the body will be placed on a paint rack.

Then the Porsche goes to the paint shop. The video estimates that this step will take about a month.

Only then will the actual rebuild begin.

KEY FACTS FROM PART 2

01
BODYWORK EXPOSED

Old repairs, dents, and imperfections are identified and professionally repaired.

02
KW V3 HLS

The chassis, including the hydraulic lift system, is fully adjusted before painting.

03
PORSCHE 964 RS BRAKES

Larger brake rotors and calipers provide greater braking power to match the increased engine output.

04
: RECARO & BBS

The Recaro Pole Position with Pepita and the new BBS wheels offer the first concrete glimpse of what the car will look like.

RESTORATION WITH AN EYE TOWARD THE VEHICLE AS A WHOLE

Part 2 clearly demonstrates why the order of operations is crucial in a comprehensive restoration.

Before paint is applied to the body, the chassis, hydraulics, lines, and all mounting points must be finalized. At the same time, the axles and brake system are already being tuned to the future engine output.

The body, mechanical systems, chassis, and design are therefore not developed sequentially as separate components.

They are conceived from the very beginning as a single vehicle concept.

PORSCHE 964 RESTORATION—FROM EXISTING PARTS TO A COMPLETE REBUILD BY DAVID ATELIER FINEST SPORTS CARS, Part 3

THE PROJECT CONTINUES

Following bodywork and technical modifications, the Porsche is ready for the next major phase of the project.

Before the rebuild can begin, the vehicle will be fully painted. At the same time, work on the axles and other technical components continues.

NEXT PHASE OF THE PROJECT

PORSCHE 964 RESTORATION · PART 3 OF 6

VIEW THE NEXT PART OF THE PROJECT

THE MOST IMPORTANT QUESTIONS ABOUT PORSCHE 964 RESTORATION

What suspension system does the Porsche 964 have?

A KW V3 with a hydraulic HLS system is installed on both the front and rear axles.

Why is the HLS installed before painting?

The pump, lines, and mounting points must be individually adapted to the body. This work is intentionally performed before painting so that no unnecessary modifications to the finished body are required afterward.

Which brake system is being installed?

The Porsche will be equipped with a larger braking system based on the Porsche 964 RS.

How big are the new brake rotors?

The video describes an increase from about 300 millimeters to about 330 millimeters.

Why does the Porsche need larger brakes?

The engine will later be upgraded to 3.8 liters and approximately 300 PS. The larger braking system is therefore designed to match the increased engine power.

What seats does the Porsche 964 have?

The car is equipped with Recaro Pole Position seats featuring a black exterior and classic Pepita upholstery.

Which wheels will the vehicle get?

The BBS wheels announced in Part 1 will be used.

When is the final vehicle height adjusted?

Only after the vehicle has been fully painted and reassembled. At that point, the weight and axle load will match the vehicle’s final specifications, and the final wheel alignment can be performed.

CONCLUSION: FROM PLANNING TO TECHNOLOGY

While Part 1 focused primarily on the initial assessment and the overall concept, Part 2 begins with the actual technical implementation.

The body is meticulously prepared, old repairs are corrected, and the KW V3 HLS is precisely adjusted to fit the vehicle.

At the same time, the next components take shape: Porsche 964 RS brakes, BBS wheels, and Recaro Pole Position seats with Pepita upholstery.

This marks the first time we see how the planned vehicle is taking shape, step by step, from the disassembled Porsche.

TRANSCRIPT OF THE PROJECT EPISODE

Part 2 of the six-part Porsche 964 restoration series focuses on the preparations prior to painting. The completely stripped body reveals previous damage and repairs, which are now being professionally addressed.

At the same time, the KW V3 suspension with hydraulic HLS is being adjusted, the axles and bearings are being prepared, and plans are underway for the larger Porsche 964 RS brake system. The BBS wheels and Recaro Pole Position seats with Pepita upholstery have also already arrived.