Step 1: Inspection
The first stage in our process consists of a comprehensive 200 point inspection process. We inspect all aspects of the vehicle to determine which direction to take. In some cases the donor car may not meet our quality control standards and a substitute will be located.
Step 2: Dismantling
The second step in our process is completely dismantling the car to determine which components can be used or must be replaced. Once the car is completely dismantled every aspect of the vehicle is meticulously inspected for signs of damage and rust. We replace panels that show signs of rust or imperfections. Most body panels are still manufactured and can be obtained easily but some elements are not and must be repaired. In many cases the rust can be topical such as the engine bay and foot wells due to brake fluid which erodes paint. Once we are happy with the body and fitment of doors, bonnet and boot lid we move to the next stage.
Step 3: Ordering
After assessing what is required to complete the build we begin by ordering drivetrain components as they have the longest lead time. Next we begin placing orders for all necessary elements from windows to brake pads. We don’t begin the build until all critical components have been ordered. We have a large stock of standard components which keeps our build times shorter. Some builds can be delayed when out of stock or custom order items are requested.
Step 4: Fabrication
Depending on the model selected our fabrication process may differ but all builds require a significant amount of metal panel removal and replacement. Additionally we introduce strengthening components by welding in order to increase torsional rigidity. When upgrading performance to the degree we do it is imperative that the strength of the body is improved to meet our requirements. At this point we also create all necessary brackets and custom components such as intakes, exhaust systems, etc.
Step 5: Test Fit
At this point we install the subframes and test fit each of the drivetrain elements. It is important to test clearance and make sure all body parts are aligned properly prior to paint. Once test fit is done we dismantle the car and prepare it for paint. At this stage we also bench test the engine, electronic, and hydraulic components to ensure smooth operation prior to instal.
Step 6: Paint & Body
At this stage we deliver a completely bare shell with doors, bonnet, arches, seam seals, boot lid, and other painted components to our painters. This is a critical stage that is often rushed by builders, we require this to be done in all Super Cooper builds. A ground up restoration like this takes time but the result is incredible. This stage takes several weeks to complete depending on the condition of the body.
Step 7: Install
Once we have test fitted the freshly painted shell and are happy with the door gaps and fitment we begin installing brake and fuel lines, electrical wiring, subframes, suspension, Drivetrain, and more.
Step 8: Interior
At this stage the car is operational and is ready for upholstery. Depending on the level of interior complexity we begin with the headliner and work down. The car is delivered to ur upholsterers for premium level interiors. Basic interiors are completed in house and recovering is outsourced. The stereo system, A/C, and electronic components are installed in conjunction with the interior. Once complete the car will be ready for road testing.
Step 9: Test & Tune
We perform an extensive test and tune prior to delivery. Each Super Cooper must complete a 150mi brake in, and pass our five point on road test, which consists of handling, ride quality, acceleration, braking, and long distance driving. Suspension, braking and alignment adjustments are addressed in this stage.