More of the same.

The difference between a race car and a street car are many, but it starts with the chassis.  The Challenge car chassis is made by the same crew and with the same materials as the Mk3 street car chassis, but with more.  More materials, more welding, more strength.  Let’s also take a hard look at how the frames are made and what materials we use. 

Materials:

To make a better frame you need to start with better materials.  We use certified materials.  Plate steel is type A-36.  All round tubing is 1018-1020 DOM (drawn over mandrel).  Front and rear round tubing re-inforces the standard FFR chassis.

Like the roadsters we make, each challenge chassis is made right.  In order to control variability we built complex computer-designed frame jigs for all our chassis kits and sub-assemblies.  The CAD/CAM based jigs are built with laser-cut tooling steel and hold parts to an accuracy of .010”.  What that means to you is that all of your running gear and accessories will bolt right into place like they should. 

In addition to accurate tooling, we have developed in-house manufacturing controls to help maintain quality, reproducibility and reliability.  For example, our welders all use the same MillermaticÔ 250 MIG welding machines. By keeping our equipment and settings standardized we can maintain better weld consistency. 

We perform regular cross-training on manufacturing team members and our crew has established QC procedures to make sure each frame, component or assembly is done right. Before your frame goes to chassis assembly it has already passed three separate Quality Control inspections.

Our welded parts are made in the USA with American labor.  We have made over 6,000 roadster frames and we’ve made each one by hand, one frame at a time.  The end result of all this work is a frame that is made with the materials and accuracy that the design deserves.