At ECD Auto Design, every stage in the assembly process is instrumental to the customization of each vehicle. The North Line at the ECD Rover Dome is where the SUV’s such as the classic Land Rover Defenders, Range Rovers, and Toyota FJs are built. Once the donor vehicle is torn down and the chassis is galvanized and prepped, it moves into the main shop area onto the North Line. The first assembly bay is where the chassis is built. This critical phase sets the foundation for the entire vehicle, ensuring it meets the high standards of performance and durability expected by ECD’s discerning clientele. We sat down with Marty, who is the skilled technician for the SUV chassis assembly bay to provide an insider’s view and walk us through the process of building a chassis from start to finish.

The Chassis Building Process: A Step-by-Step Guide

The journey of building a chassis at ECD is a carefully orchestrated process, which begins before the frame reaches the bay. Some of the major steps in the process include:

1. Axle Assembly: The process starts with the axles, building them up before the frame comes out of the teardown shop. This involves adding the differential, followed by the calipers and rotors, and finally running the brake lines.
2. Frame Preparation: Once the frame is ready it is brought into the main assembly area and begins its journey to becoming a custom one-of-one vehicle. Before anything is assembled onto it, it must go through a detailed inspection. The technician checks the Raptor lining, ensuring there are no light spots or exposed metal that could result in rust. This is a crucial quality check to confirm that the frame is free of any imperfections, such as bad welds.
3. Bracket Installation: The next step involves setting the brackets for the rear axle. This includes installing the rear shock brackets before the axle can be loaded. Additionally, the front radius bracket needs to be ground to achieve a perfect fit.
4. Axle Mounting: With the brackets in place, the front and rear axles are carefully hung onto the frame.
5. Suspension Setup: Depending on the build, the suspension is installed next. This may include traditional springs or modern airbags, followed by the installation of the shocks.
6. Brake Lines: The next step in the process is to run the brake lines from the rear to the front of the chassis. As with all working pieces, it is vital to integrate the lines seamlessly with the rest of the vehicle.
7. Steering Gearbox and Linkage: The sealed gearbox is installed on the chassis next. This is an important mechanism as it converts the rotation movement from the steering wheel to the side-to-side motion of the wheels.
8. Wheels and Tires: Temporary wheels tires are added to the chassis just to give it the ability to roll through the next assembly bays. Final wheels and tires will be installed at a later step.
9. Final Checks: Before the chassis moves on, the differentials are dropped and filled, and a thorough quality check is performed.
10. Next Bay: Once the work in this bay is completed, the rolling chassis will make its way to the next bay in the process, the Driveline Bay.

Ensuring Quality and Precision

Quality is paramount at ECD, and each technician at each stage of the assembly process is meticulous about meeting the company’s high standards. From ensuring there are no light spots in the Raptor lining to double-checking welds and fitment, nothing is left to chance. The team relies on well-documented procedures to guide them through each step, a system that is invaluable for the process.

Teamwork: The Backbone of Chassis Assembly

Effective communication and teamwork are essential in the Chassis Bay. “Competency and common sense are the most important qualities here,” Marty notes. He recalls a time when a significant challenge arose during production, and how, through collaboration with a fellow team member, they overcame the obstacle. “We communicated openly, worked together to find a solution, and got the job done without compromising quality.”