PORSCHE 964 RESTORATION: ASSEMBLY BEGINS

ASSEMBLY OF THE PORSCHE 964 BEGINS

Following the paint job and extensive preparation, the restoration of the Porsche 964 begins.

The body is back at DAVID ATELIER and is now being fully restored, step by step. The team is working its way through the vehicle from front to back.

A lot of the work was already prepared while the body was still on the rolling stand. It’s much easier to install wiring—especially in the sill area—when the body is in this condition.

Next come the axles, suspension, wiring, and numerous small components that turn the painted body into a complete vehicle once again.

RETAIN ORIGINAL PARTS INSTEAD OF REPLACING THEM EN MASSE

An important principle of the project is also upheld during assembly: components that are still in good working order are reused whenever possible.

Instead of simply replacing usable original parts, they are cleaned, refurbished, and recoated as needed.

Screws and metal parts, for example, are sent for galvanizing. This restores their high-quality appearance while also providing them with new corrosion protection.

Components are replaced with new ones only if they are severely damaged or corroded.

This ensures that as much of the vehicle’s original structure as possible is preserved.

THE FRONT AXLE IS BEING REBUILT

Numerous components have already been installed on the front axle.

The cross members, side members, and other chassis parts are back in place. Many bolts have been freshly galvanized, while individual fasteners that were excessively worn have been replaced.

The wheel carrier has also been completely refurbished.

The housing has been recoated, a new wheel bearing has been pressed in, and the wheel hub has been freshly galvanized.

Step by step, the individual restored components are being reassembled into a complete front axle.

THE KW V3 HLS FINDS ITS FINAL HOME

The KW V3 with hydraulic HLS—which was already prepared in Part 2—is now finally being integrated into the vehicle.

The pressure lines were cut to the required length and neatly installed.

The HLS system’s high-pressure pump is now located where the spare tire used to be.

From there, the lines run both forward and backward to the individual dampers.

This means that the technical foundation for the hydraulic lift function is now firmly integrated into the vehicle.

THE REAR AXLE WILL ALSO BE OVERHAULED

Work is also progressing on the rear axle.

The axle beams were glass bead blasted, while the sheet metal and bolted joints were recoated or galvanized.

In addition, the swing arm will be fitted with a new main bearing.

The old bearing was clearly worn out and is therefore being replaced with a slightly stiffer version.

This not only restores the vehicle to its original condition, but also specifically enhances its future handling characteristics.

THE PORSCHE IS BACK ON ITS OWN WHEELS

Now that the second side of the car has also been completed, the Porsche can stand on its own wheels again for the first time.

This marks an important milestone.

The completely disassembled and painted body is being transformed back into a drivable vehicle.

However, the actual reassembly is far from complete.

WIRES AND CONNECTIONS ARE RETURNING TO THEIR PROPER PLACES

Numerous systems have now been fully reinstalled under the vehicle.

These include, among other things:

• Fuel Lines
• Brake lines
• Vent lines
• Vent lines
• Oil lines
• HLS Hydraulic lines

All components were cleaned, inspected, and refurbished as needed prior to installation.

As a result, the traces of the complete disassembly gradually disappear.

THE ENGINE COMPARTMENT IS BEING PREPARED FOR THE ENGINE

A lot has already happened under the hood, too.

A new engine insulation mat has been installed, the housing vents and lines are back in place, and the power steering reservoir and a new fuel filter have also been installed.

The wiring was also neatly rerouted.

Cables and wires were cleaned, partially rewrapped, and then reinstalled along their original routes.

This prepares the engine compartment, step by step, for the eventual installation of the fully overhauled engine.

EVEN INVISIBLE PARTS ARE RECONDITIONED

Attention to detail is not limited to components that will remain visible in the finished vehicle.

Even brackets, screws, and small metal parts—which are barely visible after assembly—were cleaned or re-galvanized.

This is precisely where the commitment to a comprehensive restoration is evident.

The vehicle should look high-quality not only in the areas where it is immediately visible, but also in the areas that will remain largely hidden later on.

THE OIL SYSTEM IS BEING COMPLETELY REBUILT

The oil system is also already largely complete.

A new oil filter is combined with the reconditioned oil filter housing. The connections have been re-galvanized, the housing components have been glass-bead blasted, and the oil lines have been replaced.

The system continues on to the newly reconditioned oil tank and the thermostat housing.

Revised connections and new wiring are also being used there.

Finally, the oil flows to the oil cooler assembly in the front of the vehicle, which was also cleaned and refitted with a new oil cooler.

THE AIR CONDITIONING UNIT AND PIPING ARE BACK IN THE VEHICLE

At the same time, the air conditioning system is being rebuilt on the driver’s side.

The air conditioning condenser is already in place, and the corresponding lines have been routed through the side sill.

Other components are also being replaced or prepared.

This means that another important component of the vehicle is now ready for final assembly.

BBS LE MANS AND THE LARGER BRAKE SYSTEM IN THE FIRST TEST

The BBS Le Mans wheels, which are the final choice, are being installed on a trial basis.

In particular, they check whether the wheels are compatible with the larger braking system and whether there is sufficient clearance.

Only when all the components fit together can the final ride height and axle geometry be determined later.

THE TRUNK IS ALMOST FULLY EQUIPPED

Assembly is also nearing completion in the front section.

The wiper linkage, heater housing, and numerous lines are back in their original places.

Various components of the heating system were replaced, including the evaporator and some of the air conditioning lines.

The fuse box has also been reinstalled.

As a result, even the previously completely empty trunk regains its original structural configuration.

THE GAS TANK AND ABS MODULE HAVE BEEN REINSTALLED

The fuel tank has now been securely bolted in place.

The ABS module is back in place as well and has been fitted with a newly powder-coated bracket.

Screws and pipes were refurbished or re-galvanized.

The expansion tank for the brakes and clutch has also been reinstalled.

As a result, more and more technical systems are now fully operational.

THE NEXT BIG STEP: ENGINE, TRANSMISSION, AND INTERIOR

With the axles, chassis, wiring, and key technical systems in place, a large part of the reconstruction is now complete.

The next phase of the project will focus on the bodywork details, the interior trim, and the installation of the engine and transmission.

The so-called “wedding” marks one of the most important moments of the entire restoration process.

After that, the Porsche 964 will finally be nearing completion.

KEY FACTS FROM PART 5

RESTORATION ALSO MEANS REUSE

Part 5 highlights an aspect that is barely visible on a fully restored car body:

how many original parts actually make their way back into the vehicle.

Not every older component needs to be replaced automatically.

If screws, brackets, wiring, or other components are still technically sound, they can be professionally cleaned and refurbished.

This preserves the original substance and conserves resources, while still restoring the vehicle to a very high standard both technically and visually.