Right Materials, Best Tools, Good People

The same crew that molds, trims and finishes all the FFR roadster parts, also make the Coupe parts.  Since 1994 we’ve built and shipped more than 6,000 body shells, over 25,000 body panels and designed and built over 100 complex molds and tools… so we know a thing or two about composites.

The way we use fiberglass in making replica bodies is completely different than most kit car companies, and not at all like the classic kit car of fiberglass plopped on top of a flat ladder frame.

Manufacturing

From our very first molds in 1995, we have learned a great deal about the tools that molded parts need to be made right.  The quality of the part you get comes down to three simple things… 1) The quality of the raw material (resins/cloth),  2) The quality of the tooling (molds, trimming equipment, etc), and 3) The skill of the people who actually lay-up, cure, and trim the parts. 

To control our quality, we design, build and own all of our own tooling.  We use an Eastman M9000 CNC cloth cutting machine to ensure consistency of all composite fabrics and patterns.  Our 10 man molding department uses only hand-laid processes for every single part, and molded parts are trimmed on our RPT Technologies robotic trimming machine. 

Our molding technologies have grown tremendously over the years.  Today we put as much QC work into our fiberglass parts as we do our steel frames.  You’ll notice that the parts carry control numbers that correspond to the date of manufacture, mold number, and molding department member who made the part.

You can count on us to deliver a part that is engineered to be the correct strength and fits right.  The Coupe body shells are shipped assembled to the frame.  The bulk of the parts are unfinished (taken right out of the mold and require bodywork).  Recently we changed our process from molded edges on panels to a high speed router trimming method.  This eliminated air voids on tight radius areas and enabled us to make the parts match the openings better (the panels are actually made too big, enabling you to make really tight gaps on all hoods, doors and trunks).