Morgan's sales are booming thanks to American demand for the 3 Wheeler
Malvern's museum follows the early years of founder HFS Morgan in the 1880s to the modern day fuel-cell powered Life Car concept
This display area features four racing cars, including a brace of Aero 8 GT3 racers and the show car that launched the Aero 8
A Morgan 4/4 rolling chassis ready to be fitted with doors and bonnet before heading to the paint shop
Proof that there’s no wood in a Morgan chassis. The two main load-bearing beams of the 4/4 are galvanised steel
The Aero SuperSports coupe frame is known jokingly on the line as the ‘pick-up’, as this picture graphically demonstrates
The Plus 8’s canvas roof is lighter than the hardtop, so needs less supporting understructure
Fitting out a Plus 8. After installing the BMW V8 and gearbox, an assembly worker selects tools as he builds the front wishbone
Plus 8 chassis' awaiting their first running test. Fluids are filled and the car is started for the first time
Because the Supersport's alloy platform and skin panels are engineered to tighter tolerances, the frame is built inside the body
Spotted in the wood shop is a 60-year old body jig, brought out to fashion a coupe body for a '52 Morgan undergoing restoration
Hand-finishing is the unique feature of every Morgan. Here a worker is trimming the alloy bonnet on a Plus 8
The Plus 8’s front valence and wing tops are shaped, joined and shipped in one-piece to Malvern. Don’t ask the replacement cost
Already fitted to the 3 Wheeler's tubular frame are the vee-twin, MX-5 gearbox, prop-shaft and rear diff
Bodies for the 3 Wheeler are so light they can be stacked three-deep at the back of the final assembly area
The 3 Wheeler is the quickest Morgan to build, taking about 40 hours. Plus 8 is 160 hours; a traditional model 49 hours
Between the paint shop and final assembly is the staff canteen. ‘It’s boy’s food,’ jokes one of Morgan’s female staffers
At current production rates 24 cars are leaving Malvern every week. A 4/4 awaits final trimming
Framed by the spare-wheel cutout, a worker delicately manoeuvres a Plus 8 body into position
A detail of the Plus 8’s wishbone front suspension. Visible is the cast upright, hefty vented disc and AP racing caliper
Those black lines on the Plus 8 are the mastic to seal the body to chassis. Line workers refer to it as the damp-proof course
The last stage before shipping is a lengthy PDI where trim and paintwork blemishes are picked out and rectified
Morgan, the longest-surviving British-owned sportscar maker, will set a production record in 2012 with nigh-on 1600 cars assembled at the company’s Malvern works.
Production has been on a climb ever since Morgan went back to its roots last year and launched a modern day 3 Wheeler, powered by a punchy US-built vee-twin.
The 3 Wheeler will make up around half of production in 2012 - its first full-year - largely thanks to buoyant demand in the US.
Seeing workers lovingly assemble cars at Morgan is a thing of beauty. A visit to Morgan’s warren of brick-built assembly buildings at Malvern ought to be on every enthusiast’s wish-list.