The Morgan Motor Company’s workshop is a car factory like no other…
The spa town of Malvern sits in the English Midlands and is an unlikely place for a car factory. Yet it’s been home to Morgan Motor Company for more than 100 years. Founded in 1913, the workshop is a living, breathing piece of history – not just in its foundations, but in the coachbuilding craft that is still practised here. However, as our gallery shows, behind the unashamedly traditional exterior there’s a company that’s also keen to embrace modern production methods and processes…
Working with lightweight aluminium, the craftsmen in the sheet metal shop fuse traditional techniques with modern processes. Surface specialists then undertake a multistage process to further refine the hand-beaten metal panels
Working with lightweight aluminium, the craftsmen in the sheet metal shop fuse traditional techniques with modern processes. Surface specialists then undertake a multistage process to further refine the hand-beaten metal panels
Working with lightweight aluminium, the craftsmen in the sheet metal shop fuse traditional techniques with modern processes. Surface specialists then undertake a multistage process to further refine the hand-beaten metal panels
The lightweight wood frame is the structure from which the body panels and interior leather work is hung. Ash has always been used in Morgan cars – lightweight, durable and incredibly flexible. yielding effective vibration dampening
The body frames are constructed in the wood shop using a series of standardised components – some milled from solid and others laminated from separate strips of ash – that are bonded together on a metal jig
The lightweight wood frame is the structure from which the body panels and interior leather work is hung. Ash has always been used in Morgan cars – lightweight, durable and incredibly flexible. yielding effective vibration dampening
The lightweight wood frame is the structure from which the body panels and interior leather work is hung. Ash has always been used in Morgan cars – lightweight, durable and incredibly flexible. yielding effective vibration dampening
The lightweight wood frame is the structure from which the body panels and interior leather work is hung. Ash has always been used in Morgan cars – lightweight, durable and incredibly flexible. yielding effective vibration dampening
The Plus Six features a bonded and riveted aluminium platform that houses a turbocharged BMW straight six and an eight-speed ZF automatic transmission
Each rolling chassis undergoes a rigorous series of electrical, engine and quality tests before the addition of bodywork
The lightweight wood frame is the structure from which the body panels and interior leather work is hung. Ash has always been used in Morgan cars – lightweight, durable and incredibly flexible. yielding effective vibration dampening
Body panels are shaped by hand on-site, starting with flat, uncut sheets of aluminium. The wings, however, are produced using the Superform process, creating an A-grade surface, ready to paint
Production starts in the chassis shop as each platform is hand-assembled then undergoes a series of electrical, engine and quality tests before the addition of bodywork
The BMW B58 is Morgan’s first turbocharged engine. Engineers had to accommodate additional components on both the intake and exhaust sides
Each car requires at least four hides of leather to trim, a task that takes over 30 hours to complete
Each car requires at least four hides of leather to trim, a task that takes over 30 hours to complete
Pre-delivery inspection examines every panel under natural light evaluation strips
The Pickersleigh Road site from where Morgan cars have been built since 1914, is itself built into the foothills of the Malverns
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