Operations Crew gets the job done

40,000 sq. ft. optimized for maximum performance

 

It’s hard for us on the inside to really grasp everything that’s happening on a daily basis at Factory Five.  The truth is, most people cannot get their mind around the concept of our production processes (trust us, we’ve baffled business consultants).
 

 

Think about it - four component kit models, three of which are completely distinct in virtually every aspect.  Two of those models have two additional and unique package configurations, each one comprising of thousands of parts.  These parts are attained from vendors all over the world, some components as simple as a plastic hose, others as intricate as the most technologically advanced in automotive systems.  Similarly, the vendors vary from mom-and-pop cottage industry shops to Tier 1 automotive suppliers.

 

Couple all this with in-house manufactured components, as well as packaging and assembly operations and you have a recipe for complexity unmatched by many companies in any industry.
 

The new storage racks take advantage of the building’s
vertical space

 
 
Wile we have stretched the building on Tow Rd to 40,000 sq. ft. we are busting at the seams at the current rate of production.  In order to accommodate the entire inventory (the new complete kit configurations require 3-4 times as much warehousing space as the base kit), we have recently added bulk storage (“Home Depot” style) racks which allow us to utilize the vertical space available in the building.  Ultimately, if you haven’t seen the shop recently, you will be amazed at what it looks like today.
 

Shipping and Receiving Crew – (L to R) Jessie, Eddie and Meredith
Dee ensures that all of the parts get here on time
 


Packaging team of Mike and Charlie are charged with the monumental task of collecting 3000+ parts for each kit


Josh makes sure that each chassis is assembled correctly with 90% of the aluminum prefitted & the body securely bolted onto the frame
 

There are over 200 sq. ft of laser-cut aluminum panels per kit – all of which are professionally bent for you in advance, and most pre-positioned on the chassis too
By keeping the bodies light, and focusing on the toughest tube steel chassis on the planet, we assure a lightweight yet unbelievably safe, strong and rigid car in the end
 
 

A base Roadster kit works out to be 13 boxes, depending upon options and configuration
A complete Roadster kit can be 29 or more boxes
 
 

Within Operations we’ve broken down the processes into Packaging/Assembly (shown here) and Manufacturing.  Since they are two distinct areas, we’ve separated the two.  We’ll walk you through the Manufacturing areas of Welding and Molding next.

 

If you decide to come out to the factory and pick-up your personally, we’ll have a dedicated staff assist in the process.  After all, we’ve probably done 4000 deliveries over the years, so we know what we are doing.
 

We have a custom forklift boom that can guide your chassis kit onto an open car hauler or into an enclosed car trailer or box truck
If you have room for it, we can simply load the pallet of boxes onto your truck bed.  If not, we’ll be happy to assist you in loading the individual boxes
 
 

If you would prefer to have the kit delivered to you (as much as we would like to, we can’t be located near where everyone of our customers), there are two methods to get it.

 

Stewart Transport has filled the void for a reliable delivery method anywhere within the contiguous US, and will drop the chassis and boxes off right in your driveway.  For shipments to any other country, you’ll probably end up having the kit crated and shipped with a commercial carrier (still the best alternative in many cases).