Ep 5. Morgan 3-Wheeler

In this episode of How It's Made: Dream Cars, we get an inside look into how the iconic Morgan 3-Wheeler is made. The Morgan Motor Company, based in England, has been producing these unique three-wheeled vehicles since the early 1900s. The 3-Wheeler is a timeless classic, still produced today with its vintage-inspired look, bare aluminum body, and exposed engine.

The episode begins by showcasing the Morgan factory floor, where we meet some of the skilled workers who handcraft the 3-Wheeler from start to finish. The Morgan factory is a traditional workshop that blends modern technology with time-honored techniques. We see one worker hand-beating the aluminum panels of a 3-Wheeler body with a traditional hammer and dolly. Another worker operates a modern computer-controlled laser cutter that makes precise cuts and holes in the aluminum.

The Morgan 3-Wheeler starts as a bare aluminum chassis, which is hand-built on a jig to ensure accuracy. The chassis is engineered to be both strong and lightweight, made from a combination of steel and aluminum. The engine, a 2.0-liter V-twin, is produced by S&S, an American motorcycle engine manufacturer. The engine produces around 80 horsepower and is mated to a five-speed manual transmission.

We see the engine being installed into the 3-Wheeler chassis, and the drivetrain being fitted. The front suspension is a unique system, with coil-over shocks and a single-sided front fork. The wheels are a combination of wire-spoked rims and hand-fitted tires. The rear of the vehicle features a polished stainless-steel exhaust pipe and a single tail light that is housed in a metal housing.

The body of the Morgan 3-Wheeler takes shape in several stages. First, aluminum panels are hand-beaten and shaped over a wooden form to create the main body shell. This process is done entirely by hand, with workers using traditional hammers and dollies to shape the metal. Once the panels are shaped, they are joined together with rivets to create the final body shell. The body shell is then hand-finished, with workers using sandpaper and buffing wheels to create a smooth, polished surface.

Next, we see the interior of the 3-Wheeler being fitted. The car features a single bucket seat, upholstered in high-quality leather. The dashboard is a striking piece of full-metal, featuring a large speedometer and tachometer, an array of toggle switches, and a retro-styled ignition key. The steering wheel is a classic design, with polished aluminum and a wooden rim.

We then see the 3-Wheeler being painted. The Morgan 3-Wheeler is a custom order vehicle, and buyers can choose from a range of colors, including classic British Racing Green and an array of metallic finishes. The paintwork is done by hand, by a team of experienced painters who use a combination of airbrushing and traditional methods to achieve a flawless finish.

Finally, we see the Morgan 3-Wheeler being assembled, with all the components coming together to create the final product. We see the wheels being fitted, the lights wired up, and the final testing being done. Every Morgan 3-Wheeler is a unique creation, made to order and tailored to the exact specifications of the buyer. The episode finishes with a montage of the completed 3-Wheelers, cruising along winding country lanes and turning heads wherever they go.

In conclusion, this episode of How It's Made: Dream Cars provides a fascinating look into the traditional techniques and modern technology used to create the iconic Morgan 3-Wheeler. From the hand-beaten aluminum body to the bespoke paint finishes, every aspect of the 3-Wheeler is carefully crafted by skilled workers. For car enthusiasts and lovers of traditional craftsmanship, this episode is a must-watch.