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Inside McLaren’s Secret Skunkworks

5/21/2013 11:41:44 AM
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Somewhere in Woking there’s a dream factory for McLaren owners; a place where your wildest upgrade fantasies come true. Join us inside…

A rebuild, RE-TRIM AND service for your recently acquired 386kph F1 supercar? Or new comfort orientated suspension and a lightweight exhaust for the Mercedes SLR that’s also in the garage? How about a run of five bespoke high performance 12Cs for you and four friends? Maybe a multi-million pound one off inspired by Audrey Hepburn and aubergines? Perhaps it’s just some contrasting interior stitching when the computer says ‘No’ on McLaren’s car configurator? Whatever it is literally, whatever – you need McLaren Special Operations, a tiny team dedicated to creating specially tailored MP4-12Cs, and maintaining, updating and personalizing the SLR and iconic F1. Join us for a sneaky tour…

Inside McLaren’s secret skunk works

We try not to say no,’ explains McLaren Special Operations boss Paul Mackenzie as we look down on a pristine workshop packed with 12Cs, F1s and SLRs. ‘One of the things we talked about right up front is that we can’t be the style police. We realize every region is different, every culture is different in its tastes, and every customer is different. Is there a limit? We haven’t reached that limit.’

Don’t agree? Doesn’t matter. MSO’s most famous creation is the X-1, a unique 12C-based supercar-cum- sculpture unveiled earlier this year at the Pebble Beach Concours d’ Elegance, and built at great expense – we hear upwards of R30m for a McLaren customer with a 12C, F1 and SLR already in his ample collection. Public approval hasn’t exactly been universal, but whether you, I or the world like it is beside the point. The X-1 was born from a private conversation with McLaren chairman Ron Dennis. The anonymous owner personally briefed design director Frank Stephenson. His preferred designer, McLaren and an external design house all submitted competing proposals; 30% and full size scale models were built before the project was signed off; and throughout he was kept up to date with live styling reviews via the 101-inch plasma screen in his office. Short of starting your own car company, it’s MCLAREN F1 ‘It’s the most customized F1 in the modern day,’ says sales boss Marcus Korbach as immersed as you can get.

some F1 parts are becoming increasingly rare: the magnesium wheels are on long lead times, Michelin has to build special batches of tires, and sourcing the unique windscreen (it uses the same demisting tech as '90s fighter jets) is MSO's latest headache. Original FIA-spec "bag" tank can't handle the ethanol in modern fuel, so a new one has been developed. "It's a very important part of our heritage and we're committed to keeping the car on the road," says Mackenzie

Some F1 parts are becoming increasingly rare: the magnesium wheels are on long lead times, Michelin has to build special batches of tires, and sourcing the unique windscreen (it uses the same demisting tech as '90s fighter jets) is MSO's latest headache. Original FIA-spec "bag" tank can't handle the ethanol in modern fuel, so a new one has been developed. "It's a very important part of our heritage and we're committed to keeping the car on the road," says Mackenzie

Another customer – together with four friends commissioned MSO to build five MP4-12C HS models with revised, higher-down force bodywork (a circa 40% increase) and was intimately involved with the dynamic set-up. ‘If the project is big enough, and it certainly was with HS (and X-1), we allow the customer to really come and be part of the team,’ says Mackenzie. ‘With the HS we invited the client over to Bruntingthorpe [McLaren’s test track] and together with our chief test driver Chris Goodwin, he was part of the final sign-off process.’

Only two exist. Not everyone is quite so lavish, but they’re not paying a pittance to tailor their cars either. ‘The average is around £6000 (approx. R84k),’ reveals McLaren’s head of sales Marcus Korbach. ‘But that’s constantly growing as our options grow.’ At the start of 2012 MSO set an internal target to ‘touch’ 10% of all 12Cs produced; it’s already at 25%, and seeing more and more cars with a spend of 75$k (R700k) or more.

MCLAREN 12C Singapore Edition, unveiled at the 2012 GP

But if 12C customers want customization, the F1 clientele want originality. MSO evolved from McLaren’s Customer Care team, a department set up in the late ’90s to look after F1 road cars as production came to an end. ‘Because communication about MSO has grown, we’re now starting to see F1s that have been lost for a long time,’ explains Korbach. ‘We now know where all 64 are, we have direct contact with 61, and we look after around 50 of them through MSO and our global service centers [there’s one in Germany, one in Japan, and two in the USA]. And when an F1 changes hands, it tends to come back to us, almost like the customer goes through the ordering process again. He specs his F1, and we hand over his brand new car.’

On one hand the F1 is a relatively simple car to work on, the lack of airbags meaning re-trims and rebuilds aren’t a colossal headache. But modern computers won’t communicate with the F1’s two-decade-old electronic system, so senior technician Pani Tsouris digs out one of MSO’s three prized antique laptops. I’m half expecting him to wheel over a whole cupboard full of early Amstrad, but it’s actually no bigger than my MacBook. They picked it up on eBay for $6K (R56k).

Inside McLaren’s secret skunkworks

And because MSO’s 34-strong team isn’t busy enough, it also works on the SLR that McLaren built and co- developed with Mercedes. ‘Throughout production of the SLR we realized there were a few areas we could optimize,’ says Korbach. ‘We felt we could make the SLR more comfortable but not lose any performance so we developed the suspension and handling. And we carried on developing everything else…’

It’s quite a remit and not one that takes place behind the ultra-modern glass walls of the McLaren Technology Centre, but rather behind the bland brick walls of an industrial estate on the other side of Woking. Heavily modified retro VWs and American muscle cars fill the car park, the GT racing department has just moved in next door, and Mackenzie is also in charge of the new F1-succeeding P1 supercar program. The dream factory is open.

Maddest McLaren ever

If there is a limit, surely this is it?

This is the x-1, McLaren Special Operations’ showcase, a three-year project started by an F1 owner and Ron Dennis before the 12C was even on sale. The carbon fiber MonoCell tub is pinched from the 12C but means every panel can be unique, the rear wheels are enclosed, MSO engineered a staggeringly costly set of headlamps and taillights for it, and it’s got full Euro type approval.

McLaren X-1: street legal in Europe

‘We took the car to Spain and did durability testing, rough-roads trials, heat and aerodynamics work, just to make sure it ticked all the boxes,’ says Mackenzie. ‘Then we came back, stripped it down, made sure everything was perfect, and built it back up. We were very conscious we were delivering a McLaren, so it has to deliver on the McLaren brand. We don’t cut corners.’

Can MSO’s cars get any more extreme? ‘You can decide if you want your car to be road legal,’ says Korbach. ‘But if you don’t need road homologation, that opens another whole door of possibilities…’

 
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