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Out of the box

We take a peek inside Ford's factory outfit

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The public entrance to the FPR Race Centre in Victoria takes the form of a team merchandise outlet and stylish café that has been fitted with windows that offer close-up views of the FPR crew working on the team’s BA Falcon V8 Supercars for drivers Jason Bright and Greg Ritter.

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The main workshop area consists of three purpose-built car bays complete with hoists and work benches. These have been centrally located in the building, enabling all of the sub-assembly components to be manufactured and supplied from either side with all components coming together in the centre of the facility for the build or maintenance of each car.

The cars can then be easily loaded into the team transporter, one of two brand-new B-Double trailers and their prime movers, which also have permanent parking and loading positions within the race centre building.

On the same level as the race workshop floor is an office area which houses the FPR race engineers, operations manager and factory manager. Adjacent to this office area is a room for the repair of carbon fibre components. This composites repair facility will be continually developed as the year progresses and space has been allocated for future expansion of the team’s composites production capability.

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(1) Public entrance
(2) Merchandise retail outlet
(3) Coffee shop and public viewing platform (open Monday-Saturday)
(4) Showroom & car display area
(5) Racecar assembly area
(6) Factory, team manager and race engineering office
(7) Pit crew gymnasium above fabrication area
(8) Machine shop
(9) R&D and electronic engineering
(10) Goods receiving and parts storeroom
(11) Differential, transmission and engine assembly

A newly equipped fabrication workshop is located to the left side of the workshop floor, featuring new tooling, including a power bender, power folder, manual equipment and modern jigging equipment. This well-appointed fabrication area enables the team to build BA Falcon bodyshells and rollcages for the first time.

The biggest step forward in the new FPR Race Centre can be found in the team’s state-of-the-art machine shop. The team has installed two Mori Seiki CNC machines, one featuring a four-axis turning centre and the other equipped with a three-axis milling machine. Joining this leading-edge CAD/CAM equipment are three high-quality manual machines including a surface grinder, mill and lathe.

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Fabrication area (below gymnasium)
(A) Carbon composites manufacturing
(B) Autoclave (carbon fibre oven)
(C) Fabrication - Chassis and vehicle
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(1) Mori Seiki CNC machine
(2) Mori Seiki CNC machine
(3) Mill & Lathe (hand operated)
(4) Machining office
(5) Damper engineering
(6) Research & Development
(7) Electronics engineering

Adjacent to the machine shop is a separate area devoted purely to team research and development. This part of the race centre includes precision equipment that allows the team to test the torsion levels of their BA Falcon V8 Supercar chassis through physical tests and modelling. A separate enclosed working area within the R & D room enables FPR to build, test and develop shock absorbers (dampers).

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(A)Sub-assembly
(B)Parts cleaning area
(C)Engine assembly
(D)Dyno control room
(E)Dynamometer cell #1
(F)Dynamometer cell #2
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The right side of the workshop floor finds a well-equipped store facility, designed to handle large V8 Supercar components such as body parts along with the smaller fastening and quarantined components that are destined for engine and transmission sub-assemblies.

Adjacent to the stores facility are three pristinely clean build rooms for the team’s differential housings, transmissions and engine sub-assemblies. At the rear of these rooms is a "dirty" area for the detailed cleaning of these components prior to re-assembly.

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A view into the racecar assembly area.
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Far left: The top floor houses FPR's CAD systems and engineers. The rest is dedicated office area for Ford Performance Racing and Ford Performance Vehicles. The floor also features large conference rooms for corporate and team sponsor functions plus full catering facilities.

The sub-assembly area features a new crack-testing machine that allows the team to electronically analyse all driveline and engine components. The engine build shop next door contains three build stations, each equipped with its own computer to accurately log mileage and engine component life. The completed engines are then taken through to the adjacent 1200 horsepower dynamometer cell.

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Visitors will see this from the public viewing area.

This high-capacity dynamometer actually exceeds the power requirements for V8 Supercar engines, being deliberately commissioned to ensure the highest performance results resolution within the power ranges required.

The dyno room is equipped with a high level of sensitive technical equipment and has also been designed to accommodate a second dyno cell in the future. The entire area is climate controlled, both within the dyno cells and for the engine air-inlet feeds.

At the outside of the FPR Race Centre is an undercover cleaning area for chassis components and the team transporters, which can also be used as an undercover loading area for the team’s B-Double transporters if required, with ample turning space incorporated into the site design. The delivery bay to the FPR Race Centre stores facility is also completely undercover.

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Inside the 'Top Secret' engine assembly area. Each engine work station is fitted with its own computer for monitoring life cycles of components used.
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Sub-assembly area where the drive train components are built and maintained. Both areas are permanently maintained to cleanroom standards.
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