How Morgan Builds a £120k Supersport Out of Wood | Full Factory Tour
From the moment you walk into the factory, history is everywhere. Founded in 1909, Morgan kicked off with lightweight, powerful cyclecars. The old storage “pigeon holes,” original factory floors, and a blend of pre-war and modern machinery form the backdrop to a unique coach-building process. You’ll find everything from wood shaping hand tools to CNC machines, seamlessly mixing tradition with cutting-edge technology.
The journey of a Morgan Supersport starts with its chassis, which these days is a bonded and riveted aluminium structure—not wood, despite what so many people assume. The new CXV chassis is stiffer, lighter, and forms the backbone for everything else. Whether left- or right-hand drive, four- or six-cylinder, each variant gets tailored pre-assembly, right down to suspension preference: you can go with a standard set-up or opt for an adjustable damper package to fine-tune your ride.
Then comes the engine—sourced from BMW. The car is built around a B58 inline-six, tuned for Morgan and paired with a ZF 8-speed auto. 335bhp in a car that weighs about 1,100kg means the performance is as serious as a modern sports car gets, but in true Morgan spirit, there’s more here than just fast numbers.
Morgan’s real secret sauce, though, is the wooden frame. Crafted from ash, chosen for being tough but flexible and stable, it forms the skeleton that the aluminium body panels are hammered and shaped over. There’s no mass production here. Every frame is made and finished by hand, cut from Lincolnshire ash, clamped and formed with tools that have barely changed since the 1950s. Each craftsman “owns” their project from start to finish, meaning every customer can literally connect with the expert who built their frame.
This woodwork is functional and beautiful. It helps shape the car, supports noise and vibration absorption, and is so well seasoned that it’s resistant to movement or warping. For customers who want to show off a bit of that craftsmanship, a slice of exposed ash is left visible in the boot of the Supersport—a tactile reminder that you’re driving something altogether different.
Once the frame is shaped, the real artistry begins. Aluminum panels are rolled, cut, and hammered into perfect alignment over the wood—sometimes using age-old hand tricks, sometimes with the help of modern data-point scanners and jigs. The result: a car that’s featherweight, truly hand-built, and always just slightly unique.
Trimming is the next step. Interiors are finished in top-grade Scottish leather—no shortcuts, no low-quality grades for hidden bits. Everything from the seats to the dashboard can be fully customized, from bold color choices to custom stitching and even logos. There’s a “zero waste” mentality, using natural materials for padding and upholstery wherever possible.
After a final paint finish and fit-out, each Morgan gets tested and fettled to perfection. When ready, it’s a stunning combination of heritage and innovation. The outside is all curves, hand-beaten aluminum, and classic proportions; underneath it’s stiff, refined, and fast.
Driving the Supersport is a blend of the old and the new. You get the soundtrack of a modern straight-six, instant torque, and strong acceleration—the car officially does 0-60mph in about 3.9 seconds, with all the grip and balance you expect in a performance car. Still, there are touches everywhere that remind you this is special: visibility out the big panoramic glass, the tactile feel of the wood, and a ride that feels alive under you, not artificial or insulated.
What you get with a Morgan Supersport isn’t just a car, but a direct link to a living tradition of coachbuilding—a rare story of craftsmanship surviving the global era of mass production. Each car is made, not just built. Every detail, from the ash structure to the final bolt, speaks of skill, pride, and artistry passed through generations. And on the road, whether you’re savoring the engine note or simply running your fingers along the dash, you know you’re experiencing something few manufacturers today can offer: a car with a real soul, handbuilt just for you.