Restoration / Rebuild process

During every step of the restoration process, the project will be under the control of one of our Trustees, Duncan Fox, who is an experienced engineer and owns Group 7 Sportscars Ltd, a company dedicated to restoring McLaren racing cars.

The Trust is able to utilize his skills in conjunction with a set of original McLaren factory drawings to ensure the restoration project is completed to produce a safe and authentic McLaren M8A.  Several engineers and mechanics that worked for McLaren Racing are now resident in New Zealand and have also volunteered their services and knowledge to assist with the rebuilding. 

Restoration Process Steps

• Research – extensive research has taken place over the last eighteen months to evidence the cars history, its pictorial history, procurement of original plans, the availability of components, body moulds and general requirements.
• Dismantling -the restoration has begun with the complete dis-assembly of the car into its component pieces.  This step is necessary in order to check the physical state of each component for compliance with the drawings and photographic historical record.  Each component has then been checked to ascertain its condition and whether it required replacement or refurbishment.  In most instances, damage and corrosion has necessitated total replacement of most components. 
• Monocoque - Aluminum to match the original material has been sourced from the USA, original rivets have been sourced from the UK and new steel bulkheads have been rebuilt.  Cutting, bending and reconstruction of the aluminum panels that form the tub will be the next major process.  Now that the monocoque has been reconstructed, a number of mechanical components require replacement – these include replacement of magnesium suspension uprights, wheel rims, etc.  These require replacement because the magnesium alloy has a finite working life and then becomes prone to stress failure.  Moulds have been reproduced using the original pieces and these components have been manufactured. 
• Rolling chassis – Following the assembly of the suspension uprights and the refurbishment of the springs, dampers and pivot joints, the car will then be mounted on new alloy wheels and tyres and will represent a stage known as a rolling chassis.  At this point the chassis can be pushed along and is starting to represent the look of the finished product. 
• Chassis components/Cockpit – Following the completion of the rolling chassis a number of reconstructed and refurbished components can be added to the vehicle.  The majority of these have needed complete replacement due to age not being the original units.  In order to complete the chassis, magnesium steering components will need to be replaced along with a refurbished steering wheel.  To complete the cockpit a new seat and driving instruments have been fitted and connected to a new electrical wiring harness.  Finally the rubber fuel cells have been replaced due to their deterioration and at this point the chassis is ready to receive the fibreglass body components and the engine and gearbox assembly.