JLR bids farewell to iconic Defender with replica production line

SOLIHULL-based Land Rover is preparing a fond farewell for its iconic Defender with the opening of an authentic replica of the production line used to manufacture its first 4×4 in 1948.

The ‘Defender Celebration Line’ re-creates in detail how the first Series I Land Rover was built at the Lode Lane plant just after the Second World War.

The new visitor attraction forms part of a new Defender tour and showcases replica models in various stages of production, each one meticulously built using identical parts and in precisely the same way as the original Series I.

The display gives an insight into life on a car production line in the late 1940’s using original tools and a draftsmen’s drawing board where visitors are also asked to wear authentic overalls known as ‘cow gowns.’

The attraction boasts an area dedicated to the story behind the original Series I and features video footage of Land Rover founder Maurice Wilks provided by his family.

The Celebration Line is located in the heart of the Defender production line which is housed inside one of the original production buildings at JLR’s Solihull factory.  The opening of the attraction marks the start of a year of celebration as the Defender enters its final year of production in the UK.

Jaguar Land Rover Heritage Director, John Edwards, said the heritage line would take visitors back to the beginning of the world’s most famous 4×4 manufacturer.
 
“Land Rover has a rich heritage based around the Series I and Defender models, and we wanted to create something extra special that would give visitors and enthusiasts a unique insight into how it all started back in 1948,” he said.

“It has been a huge task to recreate a production line from almost 70 years ago, from sourcing original parts for the Series I models, to authentically re-creating the working environment and uniform of employees who were here. The team involved has been meticulous in their research, planning and creation of what is a fitting tribute to the legendary heritage of Land Rover.”

The company turned to one of the world’s leading Land Rover enthusiasts and restorers and curator of the famous Dunsfold Collection of historic Land Rovers, Phil Bashall, to help create the vehicles for the production line.

Bashall, who built his first Series I Land Rover at the age of 13, said: “It’s been a struggle at times, but a real labour of love to source all of the original parts needed for vehicles that stopped production so many years ago.”

While he had thousands of original parts in store, he still endured a long and painstaking search to find all the brakes, clutches, gaskets and pedals required for the exhibit. He enlisted the help of skilled craftsmen and the Land Rover Series I Club to build a replica chassis for the Series I models, along with some of the aluminium bodywork for the vehicles.

Once he had collected all of the parts over a period of months, it took him and his mechanic five weeks to build the five Series I models.

His guiding light in the challenge and the man who co-ordinated the Celebration Line project is Roger Crathorne.

Crathorne, known simply as ‘Mr Land Rover’, was born in Solihull and joined Land Rover as an apprentice in 1963. He retired last year having completed more than 50 years’ service.

He said: “No other car maker in the world has anything as authentic and with such meticulous attention to detail as our heritage line. It has taken months of searching and dedication to put this project together, but it has been worth it.”

The new Defender factory tour lasts approximately three hours. The tour starts at the beginning of the production process – the body shop. Here bodies are manufactured prior to being shipped to paint. The tour then continues in final assembly where visitors can see the engine and gearbox lowered onto the chassis and watch as the labour intensive process of assembling the painted body panels begins.

The tour is part of the company’s strategy of embracing its heritage; a strategy evident in the recent acquisition of British enthusiast James Hull’s collection of 543 mostly British classic cars and featuring many significant Jaguar models including XK SS, C, D and E-types.  

The driving force behind the strategy is the new Special Vehicle Operations division, which was launched by JLR last year and is headed by John Edwards.

Today, 450 people are employed on the Defender production line, including a family which has seen three generations dedicate themselves to the manufacture of the iconic vehicles.