How to Build a Car
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How to Build a Car
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As were Tiga, a Formula Two team out of Caversham near Reading. Theirs was a nice, tidy workshop run by a couple of Aussies, Tim Schenken and Howden Ganley. During my interview with Schenken, Ganley returned from a trip to Reading library laden down with books, apparently hoping to understand how to design and build his own wind tunnel. I admired his can-do spirit, but building a wind tunnel after a visit to Reading library felt somewhat optimistic.
Still, they were a likeable pair, and they too offered me a job subject to sponsorship. Which never arrived, meaning neither did the job.
In desperation I went for an interview at British Leyland, an all-day thing where I joined a bunch of other applicants. The worker in charge of my group told us he’d spent the previous year performing stress-analysis tests on the tailgate of a Morris Ital estate car, and I thought to myself, I don’t think I can do that – spend a whole year performing stress-analysis tests on a tailgate.
We went for lunch and, gazing out of the canteen windows, we could see a car shrouded in what looked like black bin liners doing circuits of a test track. There was great excitement among the other candidates. Could it be …? Was this the exciting new British Leyland car? The Metro. That confirmed my worry: I definitely cannot do this job and remain sane!
Way more encouraging was a job offer from Lotus, except that, typical of my luck at the time, it wasn’t Lotus the racing team but Lotus road cars. And while I had personal history with Lotus road cars, and there was always a chance I might be able to attract attention from the team, their big hit of the time was the Lotus Esprit, which I thought was an ugly, awful thing enjoying unwarranted popularity thanks to its appearance in The Spy Who Loved Me.
Arriving for an interview I was struck by the fact that the factory was an utter pigsty. As well as the Esprit, bits of which I saw were made of thick, poorly contoured fibreglass, they were deep into research and design for the DeLorean, which had all the hallmarks of the design monstrosity it would later prove to be.
Still, it was a job offer, the best I had, and I was about to accept – on the verge of doing so, in fact – when the phone rang.
At the other end was Harvey Postlethwaite, technical director at Fittipaldi Automotive and already on the road to becoming a design legend, with a later stint at Ferrari sealing the deal in that regard.
Harvey liked the project sample I’d sent. Would I come for an interview?
A day or so later I rode into the Fittipaldi HQ at Reading, which turned out to be a small factory unit, a couple of Portacabin offices and a herringbone car park. Sitting in reception, still in my biking leathers, I was greeted by Harvey, hair a mess, big grin on his face.
‘You’re a biker,’ he said, delighted by the sight of my leathers. ‘What have you got?’
‘Ducati 900SS,’ I told him.
‘Fantastic,’ he said, ‘mine’s a Moto Guzzi Le Mans.’
This was a time when one of the hot points of discussion in the bike magazines was about which was the superior Italian bike, Moto Guzzi or Ducati. Harvey was eager for first-hand experience and asked if he could take my Ducati out for a spin.
‘Sure,’ I said, and stood in the car park for what felt like an age as he took my bike for a run God knows where, returning and taking off his helmet to reveal even messier hair and an even bigger grin.
‘Right,’ he said, ‘when can you start?’
As interviews go, it beat sitting in the British Leyland canteen.
Turn One
HOW TO BUILD A MARCH 83G
CHAPTER 8
I began at Fittipaldi with the title of ‘junior aerodynamicist’, but because they didn’t have any other aerodynamicists, I was senior aerodynamicist as well.
It was that sort of place, teeming with early 1980s chaos and run on a diet of cigarettes, coffee and beige polyester. A team of around 35 was split between the factory and Portacabin offices, but although it was a respectable size for the time – a bit smaller than Lotus but not by much – its problem was that there were more chiefs than Indians thanks to the fact that it was comprised of two teams that had merged: the original Fittipaldi Automotive, founded by driver-brothers Wilson and Emerson, and Wolf Racing, whose main driver was Keke Rosberg (father of Nico).
Parachuted into the middle of the post-merger manoeuvring, I managed to steer clear of the various office politics, stepped-on toes and egos that had been bruised by the fusion. Being junior meant I could move easily between the Portacabins in the gravel car park and the factory, where on Fridays, after the traditional lunchtime in the pub, workers sat down to an afternoon of hard-core pornography. I didn’t care. I was just happy to be in Formula One at last.
One day, the atmosphere in the Portacabins was more than usually fevered thanks to the expected arrival of Emerson.
Never being one to idolise drivers, my own fires were under control, but I was intrigued because I hadn’t yet crossed paths with the great man, his visits to base camp being somewhat infrequent.
Then, as now, my office overlooked the car park, and as the morning wore on I noticed that somebody had left a chassis stand in Emerson’s parking space. As I say, he hardly ever came in, so whoever put it there probably thought it was a safe place. Except on this particular occasion it wasn’t, because Emerson came haring into the car park, typical racing driver, going way too fast and coming in blind, sideways into his parking spot in a spray of gravel … slap-bang into the chassis stand.
It would have been a pretty impressive bit of driving if not for the crash at the end of it. The chassis stand went flying through the hedge, having stoved in the front of Emerson’s Rover – one of those awful wedge-shaped Rovers, only now it had steam rising from where the chassis stand had burst the radiator.
As I stood watching Emerson emerge, gesticulating wildly and swearing loudly in Portuguese, and saw everybody run from the offices to witness the commotion, I remember thinking that they were all so human. Even Emerson, this hugely respected driver, was just as fallible as the rest of us.
CHAPTER 9
In 1981, the skirts that Lotus had introduced for their ground-effect car were lifted. New FIA regulations insisted they be at least 6cm off the ground, and could no longer slide up and down, which of course would hugely reduce their effectiveness since they’d no longer be sealed to the track.
In response, teams fitted rubber skirts to the cars, but they didn’t work nearly as well because they flexed in a poorly controlled way and wore out – which is something that rubber does when it slides along the ground.
Those 1981 cars were really 1980 cars with these much less effective skirts. It was my first taste of a major regulation change, and I felt the aero needed to be fundamentally redesigned to re-optimise to this new limitation.
My idea was simple: to raise the underwing and make it longer, so that the leakage under the rubber skirts would be, as a percentage of the overall flow under the car, smaller. It was a sound principle, but to accommodate it meant significantly redesigning the rear suspension.
Straightaway, I was into something I find fascinating: the integration of mechanical and aerodynamic design (something I had tried to bear in mind with my project at Southampton).
We started to develop it through 1981 with the intention of it being the car for 1982. Once a month we’d load a Vauxhall Chevette van with the model and any other tools we needed, and then Pip, our fabricator, and I would drive to the wind tunnel at Imperial College in Kensington.
They were early morning starts, the whole operation conducted in a hurry. On one particularly icy morning I span the Chevette across the slip road onto the M4, clouting the barrier on the outside. Together, we pulled the wheel arch back out to stop it rubbing on the wheel, clambered shivering back inside and kept on going.
Once at the tunnel, we’d do a run on the model, measure how much downforce and drag it produced, and then make alterations to it – for example, by changing the front wing altogether, varying the angle of the existing wing, or doing the same to the sidepods or the diffuser.
Nowadays, there’s almost no adlibbing on the model; everything on it is a pre-manufactured part and test schedules are followed because that’s the best way to be efficient. Back then, though, we’d come armed with all sorts of bits and pieces, with Pip and the model-maker on hand to make alterations, and me recording the results and making calls on what to do next. We had limited resources and there was a lot of improvisation, but if we had an interesting direction we’d make a part on the spot, stick it on and try it.
Our numbers were good, a big improvement on the 1981 car. Bearing in mind we had no idea what other teams were getting from their own cars – you rarely do, of course – we were quietly confident that we had a decent design on our hands. Joining Williams years later, I compared notes with Patrick Head, and based on what he told me about the 1982 Williams car, ours would have been very competitive.
But it’s by no means an easy feat to translate wind tunnel results to the finished article. You need sufficient resources for engineering, detailed design and manufacturing, and in that respect Williams always had a head start. But on paper at least, our Fittipaldi was championship material. We could have been a contender.
The ifs and buts of motor racing. In the event, the rug was pulled …
I’d started at Fittipaldi in August 1980, but by Christmas 1981 it became apparent that there was something rotten in the state of Reading. When I first began, the team was sponsored by Skol beer, and there was, if you will excuse the pun, a fair bit of money swilling about for development and a can-do atmosphere. At the end of that year Skol pulled out, to be replaced by Avis for 1981, meaning much less finance available.
Work continued on the 1982 car. We’d begun designing a rear suspension to complement the aerodynamics – to the point that drawings were ready to go off for manufacturing the components – when suddenly the whole thing was stopped because there was no money left to build the car. We were told we would have to use the 1981 car in 1982.
Staff began leaving. Harvey joined Ferrari. One of the team managers, Peter Warr, left for Lotus and the other, Peter Mackintosh, joined March. That positive, can-do attitude evaporated.
It was with a heavy heart that I found myself looking for something new.
CHAPTER 10
In those days, every motor racing team effectively had three engineering disciplines: the design and aerodynamics offices, and race engineering, though the race engineers would be doubling up with working in the design office during the week.
Since then, the industry has mushroomed, and nobody crosses from one department to another. You’ll have, let’s say, 90 people in aerodynamics, another 70 in the design office, and perhaps 30 in race engineering and simulation, the latter being a relatively new area.
Me, I’m known chiefly as an aerodynamicist, but that’s a product of the fact that aerodynamics is the biggest single performance differentiator. Therefore, I tend to spend most of my time looking at aerodynamics, with the mechanical layout a close second, in order to make sure the two complement one another in a package. In fact, my sole interest lies in improving the ability of the car to score points, and what helps me do that is my experience across the disciplines.
Which brings me back to early 1982, when of the three key areas – aerodynamics, mechanical design and race engineering – I only had experience of the first. With Fittipaldi I had been loosely involved in the design of the rear suspension for the axed 1982 car, but not in the detail. I’d been to the track a grand total of once, and that was for a cold test at Donington where I just stood and watched the car do a few shakedown laps. I’d never even worn a set of headphones.