(From the Porsche Newsroom) — They are the Turbo 50 Years, the Dakar and the S/T, and they are current limited-edition models of the Porsche 911. These exclusive models of the sports car icon combine outstanding design, special drive and chassis components as well as individual equipment details to create a unique driving experience. Special production processes and steps apply for the production of the limited-edition 911 models at the Zuffenhausen site. The construction of the limited-edition 911 models combines the highest levels of exclusivity and manufacturing precision with the art of personalisation.
In addition to a highly automated body shop and a regular assembly line, Porsche also employs up to three Manufaktur stages: the Exclusive Manufaktur, the Sonderwunsch department and the carbon fibre Manufaktur. Another special feature is the in-house saddlery, where the employees — who are largely self-taught — apply the model-specific leather, Race-Tex and textile covers. Limited-edition models with two-tone paintwork, such as the 911 Dakar, are painted by hand in the Manufaktur tradition. One characteristic of 911 construction in Zuffenhausen is that all variants and derivatives are produced on a single production line — from the Carrera to the limited-edition models and the racing cars for the worldwide Porsche Carrera Cups.
“Exclusive 911 models such as an S/T or Dakar represent the pinnacle of the available variants of our sports car icon. On the one hand, they continue the Manufaktur tradition of historic sports cars such as the 356. On the other, they also symbolise the dreams of our customers, dreams that we fulfil here as Porsche Production,” says Albrecht Reimold, Member of the Executive Board, Production and Logistics at Porsche AG.
“In the production process of the 911 models, the Zuffenhausen plant combines the strengths of automated production with the advantages of an automobile Manufaktur in a unique way,” explains Vice President Plant Zuffenhausen Jens Brücker. “The limited-edition 911 models are a really special opportunity to showcase our automotive craftsmanship. The different Manufaktur stages in the plant mean that we can make the exclusive 911 models truly unique.”
In the case of the limited-edition 911 models, the manual assembly steps in particular make the difference: production in the Exclusive Manufaktur takes us from the application of special leather and fabric covers in the interior to refinement by means of various trims and decorative elements in the exterior, and even individually personalised design elements. In the Sonderwunsch Manufaktur, even the most unusual wishes become reality — right up to the production of one-of-a-kind items.
The refinement of Porsche models in the Exclusive Manufaktur is mainly carried out by applying elaborate craftsmanship. Customers can choose from around 1,000 options. For example, there are decor variants or different packages, such as the Heritage Design Package for the 911 S/T or the Rally Design Package for the 911 Dakar.
With various colour, material and equipment variants for the exterior and interior, there are countless possibilities to refine one’s Porsche. These also include exterior decorative elements for bonnets, doors and side panels or additional leather, Race-Tex and fabric features for the interior — for example, for the centre console or the air conditioning vents.
The employees apply individual details manually, such as the number decals on the doors or various leather trims on the dashboard at the transition to the doors. Conspicuous details such as ground projection spotlights in the doors with labels such as the ‘Icons of Cool’ logo of the Heritage Design Strategy also give the coveted 911 models an even more individual touch. On average, a personalised 911 spends up to six days in the Exclusive Manufaktur.
The paintwork of the 911 Dakar models with Rallye Design package differs from the regular painting process and has a special unique selling point: if future owners of a 911 Dakar choose the Rally Design Package, they will receive the two-tone paintwork in White/Gentian Blue Metallic with decorative stripes in gold/red. After applying the White undercoat, the employees apply the blue contrast paint manually to the car’s body. Manual painting takes approximately seven-and-a-half hours. The undercoat is sanded by hand, masked, then the paint is applied by hand in Gentian Blue Metallic. For this manual painting process, new work processes and areas were established in advance of production, including a so-called multi-line for the manual paint application. Finally, the finishing touches are added in the Exclusive Manufaktur, where the employees apply the decorative films for the characteristic red and gold dividing strips by hand.
