Classic car specialists at Dr. Ing. h.c. F. Porsche AG are continually working to update their inventory, which currently consists of around 35,000 classic parts, and they are meeting the high demand for rare original replacement parts with new products. Parts supply assumes a central role at Porsche Classic, since two-thirds of all Porsche cars ever built are still on the world’s streets today. But the manufacture of new parts, in particular, sometimes poses unusual challenges for Classic employees.

First, it is necessary to assess market demand and examine historical archive documents; a check is also made of the availability and condition of original tools. Often, the deciding factors in whether a new original part becomes available are the close relationships that Porsche cultivates with its production suppliers. In the end, a lot of effort is often expended for low part volumes. If a supplier no longer exists today, new supply sources must be found, or it might even be necessary to produce an entirely new tool. Of course, the highest priority is to fulfil the high Porsche requirements for quality and safety, which in turn requires extensive and expensive technical testing. Just as for new vehicles, all safety-relevant parts are subjected to extensive tests at the Porsche development centre in Weissach. New legal requirements must also be considered – such as the prohibition of certain materials.

The inventory of Porsche Classic now includes a whole series of new parts. Some highlights are the 85 litre plastic fuel tank for the 911 of model years 1970 to 1973 and the left front wing with fuel tank fitting for 911 sport cars of model years 1965 to 1973. This new part was especially challenging; since the original wing supplier went bankrupt, a new supplier had to take over its production.

The new supplier, who specialises in sheetmetal forming technology and is an established long-term Porsche partner, will supply the complicated parts in the future. In relocating production of the parts, the quality of the original parts was significantly improved by revising the original tools and optimising the production process. Some key figures illustrate the immense effort involved in reissuing the 99 versions of wings and side panels for the 911 and 964 model series: Individual 911 wing assemblies consist of up to 44 individual parts, 110 tools are needed for their production and eleven fixtures to assemble them. To relocate production to the new production site, no less than 1,400 tonnes of material had to be moved in 80 truck shipments – and the project for relocating production took six months.

Another original part – small and yet very significant – is once again available as well. It is the original Porsche emblem for the bonnet of the early 911 model years 1965 to 1973 with order number 901 at the lower right of the back page.