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Ever wondered what happens to all the parts from the Subaru Impreza WRC2006 rally cars once they've been used on a rally? Do they get thrown away or used again? Once the cars return from a rally they are stripped down to a bare shell and the build process starts all over again. We caught up with sub-assembly supervisor (and qualified sky diver) Phil Lovell to talk through the process the parts will go through after an event.
Phil, what's your role within the Subaru World Rally Team?
I'm responsible for the day-to-day running of the sub-assembly department and liaising with sub-assembly technicians, engineers and the drawing office. I'm in charge of the overall quality control in the department, to ensure all parts are reconditioned to a high standard. I have nine staff, including two Senior Technicians who support me. We strip, clean and recondition various parts of the rally car, such as the steering rack, uprights, pedal box and handbrake, to name a few.
How long have you been working for the Subaru World Rally Team?
I've been with SWRT for 15 years. I started as a sub-assembly technician, which involved attending rallies as sub-assembly and damper support on the rally cars. I travelled in the job for eight years, then took on the role as sub-assembly supervisor.
What process do the components go through to get reconditioned?
Details of a new component are entered onto a computer system that we refer to as a 'lifecheck'. It logs the life of a part, which car it's been on and how many miles it's covered. The part will then be put on a World Rally Car to compete in an event. The cars will be stripped on their return from a rally and any parts which can be reconditioned and used again will be returned to us. We will strip and clean the part and send it to the inspection department. They will dimensionally check the component to make sure it's not bent or cracked. If it passes all of the tests it will come back to us and will be rebuilt using new nuts and bolts and any other parts it may require.
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What are the advantages of going through this process and not buying new parts each time?
It would be hugely expensive to buy new parts every time when it is not necessary.
How often do you rebuild a part?
It all depends on the part. The pedal box unit, for example, will be rebuilt every third rally and all the components in the pedal box have a certain number of miles they can run before they need to be replaced with new ones. That's why the lifecheck computer system is so important, because we know when a part needs replacing.
What do you most enjoy about your job?
I enjoying taking on enthusiastic technicians who are eager to get into motorsport. The sub-assembly department is a good stepping stone to gain knowledge, skills and experience. The majority of them will eventually move into the rally team, but I also have a few established members of the team who have previously worked a travelling role but now want to specialise in one area. It's a good mix and makes a very strong team.
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2006
2006