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Costs and build reality
£6.3m to £12.1m to set up and £55k to £77k to build each car, which puts a realistic price at £96k to £143k against a £58k target.
The card
parts 07 of 07Costs and build reality
The notes
renderedAll figures are my own rough estimates for planning, not quotes. They assume about 500 cars over the first five years.
one-off setup and development
| Item | Cost |
|---|---|
| Engine development, prototypes, dyno and calibration | £1.5m to £3.0m |
| Chassis and vehicle engineering, 4 to 6 prototype cars | £2.0m to £4.0m |
| Body design, patterns and moulds | £0.6m to £1.2m |
| LED blade lighting development and approval | £0.3m to £0.6m |
| Approval and testing | £0.4m to £0.8m |
| Facility fit-out, jigs, oven, dyno cell, paint booth | £1.5m to £2.5m |
| Total | £6.3m to £12.1m |
| Per car over 500 cars | £12,600 to £24,200 |
build cost per car
| Item | Cost |
|---|---|
| Engine, including supercharger | £12k to £16k |
| Sequential transaxle and paddle shift | £10k to £15k |
| Chassis and carbon body | £7k to £10k |
| Suspension, brakes, wheels, tyres | £5k to £7k |
| Interior, soft top and trim | £4k to £6k |
| Electrics, ECU, LED lights | £3k to £5k |
| Labour, around 350 to 450 hours | £14k to £18k |
| Total | £55k to £77k |
what this means for the price
£58k including VAT is about £48k to the maker, which is below the estimated build cost before any development is paid back. Adding development recovery and an 18% margin, the price lands at roughly £96k to £143k including VAT.
Ways to close the gap: a cheaper gearbox, a naturally aspirated entry model without the supercharger, fewer carbon panels, higher volume, or outsourcing the engine build to an established specialist.
build reality
- Engine joining is the big job. Two bike engines cannot simply be bolted together. Builders such as Hartley have done this before, with Hayabusa heads on a custom billet crankcase, which is the model here. Budget for real development time.
- Price pressure. The cost estimates above put a realistic price well above the £58k target. The headline price needs a decision before the business case goes further.
- UK road approval. A small maker would go through Individual Vehicle Approval. Drive-by noise limits are the main risk for a high-revving engine, so the exhaust needs valves for a quiet mode.
- Supply. Donor parts depend on one manufacturer's engine continuing in production.
All performance figures are design targets or estimates, not tested numbers.