The Making Of The Lexus LFA Supercar. An Inside Report In 5 Chapters

One of two circular looms on the planet. 12 layers of seamless carbon fiber are woven into what will be part T3-3RH, part A-pillar, part roof support

This 5 chapter series gives you unprecedented access to the LFA Works in Motomachi. Here, 500 LFA supercars are being handmade by 170 people, and you can watch how they do it.

The baking happens in the autoclave next door. Picture it as a garage-sized pressure cooker. Pieces in the autoclave are covered with foil, then vacuum is applied that presses the layered piece into its mold. Two bars of pressure is applied to the autoclave, and at a constant temperature of 150 C, the parts are cooked to perfection.””

Chapter One: From A Bar To Bar None. How the LFA was born, and why it is made from carbon fiber.

The strongest parts of the LFA are made in a clean room. Our hair is covered. We wear long white coveralls. Booties go over our shoes. Someone vacuums me from top to bottom.””

Chapter Two: In The Clean Room. Where the LFA is made from the strongest and most expensive type of carbon fiber available.

Building the body of one LFA takes four days, we race through it in three hours. On the fourth day, there is what is called a body-in-white in the car making industry. Except that in the case of the LFA, it is a body-in-black. In a shiny, glossy black that we usually associate with carbon fiber.””

Chapter Three: Call Me Names. How the LFA really received its name.

Some likened the sound to “the roar of an angel”, some to “an F1-inspired tune.” Lesser poets could compare it to the sound of a circular saw.””

Chapter Four Balance Of Power. We watch the V10 engine go into the LFA.

What will happen to the LFA Works at the end of the year? Will Tanahashi, now 59, simply go into retirement? Will the 170 associates who make the LFA go back to making Crowns, Corollas and Camrys?

Chapter Five: Exam Week. We examine Chief Engineer Tanahashi about how the LFA influences future cars, and what will come after the LFA.