Theon Design is an Oxfordshire-based design and engineering company that takes 964-era Porsche 911s and revives them into better-than-new, tailor-made cars. John Marcar has driven the latest custom-built creation ahead of it’s hand over to the customer.

There's just something about a classic 911

10 years ago, in 2016, I joined a close friend, Tim, on a road trip around Europe. The car we drove on our adventure was a 1976 Porsche 911 SC with fascinating provenance. The 911 SC began its life as a racing car, was later road-registered, and used as a weekend road car in the North of England until around 2015. By the time the 1976 SC was in the hands of Tim and me, it's fair to say, the ex-racer-turned-weekend-toy had earned its stripes (and many a battle scar), yet there we were, about to embark on many thousands of demanding miles.

It was the first time I'd driven a 1970s-era 911 for any great length of time. The road trip totalled around 3500 miles, and it all ended spectacularly, with the engine 'letting go' as we boarded the Ferry from France to the UK. The final day of that particular road trip features the all-too-vivid memory of an event I plan never to repeat... pushing a car through passport control to an audience of very amused fellow motorists and less-than-sympathetic border control officers.

Putting the final days' disaster aside, that road trip sits fondly in my memory as one of the best all-around driving experiences of my life. Thousands of miles of mountain passes, circuit visits, and sporadic catch-up meals with friends dotted in far-flung corners of the continent all made it special, but it was the car, the leggy 1970s 911, that was the real star of the show.

It's a privilege to drive any classic car, but there is something about a 911 that is unrivalled by any of the competition of a similar age, even one that’s lived a hard life on the road and race track. The seating position, visibility, and the utterly immersive sounds and vibrations from an air-cooled 911 bring a whole new dimension to driving and unlock a sense of engagement that no other make or model can replicate.

Theon Design does things differently.

Theon Design operates out of a fairly inconspicuous workshop in Oxfordshire. From the outside of the unit, there aren't many clues to suggest that, behind the roller shutters, is a collection of beautiful Porsche 911s in various stages of a bespoke build. I was greeted by a member of the Theon Design team and welcomed into the space, and it was immediately clear that I was stepping into an above-average workshop building considerably above-average cars.

The classic 911 is possibly the most popular model to receive the custom, revival, or retro-build treatment. I've personally been fortunate enough to visit an array of similar outfits, all of which offer varying levels of reworking, rebuilding, and backdating of 911s; however, at the Theon workshop, things are different.

Waiting for me in the line-up of cars was the stunning green '3.8 Coupe' that I'd been invited to drive, and the company co-founder, Adam Hawley, was there to show me the car and talk me through its many features and details.

Adam comes from a car design background, having previously penned for BMW, Lotus, and JLR. In 2016, Adam decided to captain his own ship and founded Theon with the aim of designing and building the best classic 911 possible.

Ten years on, the company has a catalogue of successful tailor-made builds, all of which are now dotted around the world, being enjoyed by their respective customers. The latest model, the green 3.8 Coupe, is a shining example of what the outfit can achieve within a meticulous 18-month build process.

The Gorgeous Green 3.8 Coupe

The latest build is a 3.8-litre coupe. Its consigner is an appropriately design-focused professional based in Mexico. The first thing that grabbed me about the model was the colour. At the time of consignment, the customer had shared their love for two shades of Porsche Green, 'Nato Olive' and 'Underberg'. The paint on the 3.8 Coupe is a blend of the two shades, and the result is sublime. Theon sensibly outsources paint to a nearby trusted paint shop, and the quality of the work speaks for itself.

The Finer Details

Door shuts, panel gaps, and even rubber trims and window surrounds are all absolutely perfect. Nothing catches your eye beyond being 'just right', and the closer I looked for the finer details and finishing touches, the more I realised just how special these builds are. Whilst cars are being built, panels that will soon be hidden by fuel tanks are painted and polished to the same standard as bonnets and doors. Fire extinguishers mounted out of sight of the driver's seat are wrapped in premium leather matching the interior upholstery, and even the front strut brace, hidden under the bonnet, is wrapped in the same hounds-tooth fabric that lines the centre of the custom-finished Recaro bucket seats.

964 Donor Car

All Theon Design builds start with a donor vehicle, which can be sourced on behalf of the customer or provided on consignment. For the green 3.8 Coupe, the donor was a 964 Carrera 4, which, in the first stages of the build, was stripped back to bare metal ahead of an overhaul of the car's underpinnings. This is the norm for Theon, allowing for a back-to-bare-metal blank canvas, making the donor totally unrecognisable from its original form when completed. Once stripped back to its raw form, the body is closely inspected, any unsightly previous repairs are addressed, and even the chassis is checked and, if necessary, straightened to ensure the best possible starting point ahead of the build process.

Weight Reduction

When consigning a car, customers can choose to have their panels made from either steel (as per the original early 1970s specification) or carbon fibre. The carbon option, as selected on the 3.8 Coupe, contributes towards a significant weight saving of 325kg compared to an original 1960-70s-era model. Additional weight savings come from lighter, more concise wiring looms, which, thanks to new components and hardware, independently save up to 24kg compared to the original looms.

Engine and Performance

Powering the 3.8 Coupe is a tuned and refined 3.8-litre flat-six engine that produces more than adequate 407bhp to the rear wheels. The engine remains naturally aspirated but features newer components, such as an air intake plenum from a 997-era 911 GT3. The polished plenum feeds air to six individual throttle bodies, each contributing to an incredible orchestral soundtrack as the revs climb.

The final result, in terms of power-to-weight ratio, matches that of a modern 992.2-era Porsche 911 GT3.

Unexpected touches

Elsewhere in the 3.8 Coupe, small touches enhance the car's daily usability. An air lift system is fitted to the front axle to help with steep bumps and slopes. A Focal sound system is installed in the car, with a discreet Bluetooth unit for high-quality audio streaming from a mobile device. A self-dimming rear-view mirror also helps reduce glare from inevitably higher-following vehicles, along with a high-level 3rd brake light, expertly fitted into an original vent above the rear screen for added safety and visibility. The rear-view mirror is also an optional high-definition colour screen with a live feed from a camera mounted on the rear bumper.

Walking around the car and obsessing over the interior continuously offers visual rewards. Everything I considered a need, requirement, or luxury on the build is already in place and finished to a perfect standard. All that remained to experience was the drive.

The Drive

Turning the key on the 3.8 Coupe rewards the familiar 911 rumble from the air- and oil-cooled engine at the rear. The soundtrack of an air-cooled flat six is beautifully unique, and with the reworked intake and exhaust system, it becomes even silkier and more purposeful. A toggle switch on the dashboard opens a valve in the exhaust backbox, delivering even more atmosphere into and out of the car.

As I prepared to exit the workshop car park and head onto the Oxfordshire roads, I couldn't help but think back to my eventful road trip in the 911 SC 10 years earlier. Whilst the interior environment felt familiar in the loosest sense, what made the tired old SC feel special on my road trip was only amplified by what I was now experiencing in the tight and new Theon Design creation.

Selecting 1st gear and working my way up to 5th rewards a tight, precise gear shift, a far cry from the 1970s-era 911 I'd spent the best part of 2 weeks driving around the continent. The brand-new clutch feels light and intuitive, and the electric-assisted power steering takes the strain out of slow manoeuvres whilst maintaining the direct feel and engagement on faster sections of road.

Road Performance

With a power-to-weight ratio of a modern 911 GT3, the 3.8 Coupe feels utterly unique through the steering wheel and pedals. At the time of specification, the throttle linkage can be specified as fly-by-wire; however, on this particular car, the system is cable-driven, as requested by the customer. The result of the cable is a response from the soul of your foot directly to those six individual throttle bodies. The experience is wholly atmospheric.

Suspension, Chassis and Brakes

The 3.8 Coupe is fitted with a remarkable semi-active suspension system built by TracTive. A small twistable knob to the right of the steering column allows for adjustment to the shock absorbers and offers a stiffer or softer ride on demand. Often, a significant challenge with weight reduction on an already lightweight platform is getting the spring rate right. The ride on the 3.8 Coupe is flawless. Being a consigned-and-sold customer car, I was in no position to push any limits; however, on a couple of undulating roads and faster corners, the quality of the craft is clear. The chassis feels tight, precise and brilliantly rewarding.

Shielded by gorgeous Fuchs alloy wheels are 'RS Specification' Brembo brakes, which offer braking performance more than adequate for the car’s weight.

The Ultimate Head Turner

I'm lucky, I get to drive a lot of very interesting performance cars, but the true gauge on what's deemed special is best judged by the casual observer. Driving the 3.8 Coupe makes you feel like a celebrity by proxy. Almost every passerby, pedestrian, and fellow motorist I passed couldn't help but look, most offering a smile in appreciation.

With Adam Hawley in the passenger seat for the duration of my drive, he asked the inevitable question after hearing of my previous exploits in the 911 SC,

"So, how does it compare to the 911 you road tripped with?" - he asked. My reply;

"Where do you want me to start?"

The reality, of course, is that beyond the overall shape, dimensions and interior layout of the two 911s, the overall contrast is stark. The 1976 911 SC I drove on my 3500-mile road trip was loud, rattly, and raw. Getting in and out of the SC involved navigating old roll cages, ill-fitting bucket seats, and harnesses. Whilst driving, ear defenders were obligatory, and driving days were ended in good spirits, but with true exhaustion.

Theon Design’s 3.8 Coupe, however, would have soaked up every mile of that trip in sublime comfort. The suspension setup and tuned geometry offer the perfect balance of ease and performance. The 3.8 Coupe is usable and forgiving, whilst still encapsulating the raw, direct feel of a 1970s-era 911. As far as I can tell, there is no compromise with the 3.8 Coupe; it simply works. It's a car that could be enjoyed for a spirited Sunday drive or used for a continental adventure with a friend. The most magical part of the build is that no '911-magic' is lost in the re-creation of the model. The 3.8 Coupe still feels, in every way, just as spirited, engaging, and mechanically enthused as an original early-70s-era 911 should, with added comfort, refinement, and stunning detail.

Perfection Reimagined

What Theon Design has created sits far beyond what many would deem as a high-end project or custom build. It's a drivable, usable and crucially enjoyable work of art which takes nothing away from the experience of a classic 911. The fit, finish, sight, smell and sound are all as dare I say it? as close to perfect as I could have hoped for.

Of course, perfection comes at a price, and Theon Design advises that a starting figure of £430,000 should be expected when commissioning a build, with the donor car provided at an additional cost. To some, spending almost half a million on a classic 911 might seem absurd, but for the few that can, and for those who truly 'get it', the price is worth every penny.

words by John Marcar
photography by Theon Design

Theon Design 3.8 Coupe Review - Classic Porsche Perfection