John Tupper talks with enthusiast and YouTuber Cormac Boylan about his background in media and radio, and how he entered the Rolls-Royce and Bentley world. You may know him from his popular Youtube channel and his input and articles in many well known newspapers and magazines.
John takes him on a tour around IntroCar HQ showing him the backdrop for the research and development of new products and how it's all laid out in the Wimbledon premises.
For a summary of the content of the Video Tour... read on!
Introducing Cormac
Cormac was 14 when he joined the BBC’s Young Reporter scheme. After work experience with both 'What Car?' and 'Autocar' magazines he did his first voluntary job on local radio station '103 The Eye' from 2017-2020. He then moved to Nottingham radio as presenter where he remains today.
He bought his first Rolls-Royce at 20, a 1989 Silver Spirit in Lagoon Blue, followed shortly after by a Bentley Arnage, and his latest acquisition is a project Rolls-Royce Silver Shadow. He has written car reviews on his vehicles for some of the major newspapers such as the Sun and the Express as well as many other locals.
He has created his own popular YouTube channel : Cormac on Cars - https://www.youtube.com/@cormaconcars4224
How did Cormac get into the Rolls-Royce & Bentley industry?
Academically Cormac struggled in school, but started with the BBC at the age of 14 on the BBC School of News Report and from there progressed to 'What Car?' magazine, which is a major National car magazine based in Twickenham. From there he got his first job on community radio volunteering and remained there for three years. Cormac then progressed to other radio stations and at the age of 20 bought his first Rolls Royce motorcar. After acquiring the Rolls-Royce, Cormac got the opportunity to write about it in an article in 'Spirit and Speed' magazine. At the time he was at Nottingham radio, concurrently studying Media (camera work, filming, writing, scripts etc), and he then progressed to buying his first Bentley and second Rolls-Royce. Cormac is currently still with Nottingham Radio as Radio Presenter.
The articles went on to be published into popular mainstream newspapers and then all around the world... which inspired Cormac with the YouTube channel 'Cormac on Cars' where enthusiasts and private individuals share their cars with him to review.
Cormac represents a younger generation looking at some of these old Rolls-Royce & Bentleys now and understanding just what it's like to own one: whether it's possible and what you have to do to maintain them. It's breaking the mold a little on the stereotypical Rolls-Royce or Bentley owner.
A Tour Around IntroCar HQ
A lot of what we do at IntroCar is to buy in volume which gives us the chance to keep prices down. It also enables other manufacturers to get more heft on the marketplace. This does mean however, a LOT of stock!
Starting with a Mk VI and R-Type Quarter Light Seal (Right Hand RB2562 and Left Hand RB2563) shown here.
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Everything is barcoded and moved around on handheld terminals through the warehouse so that we know exactly where everything is. There may be multiple different locations for stock. For example there may be ten downstairs next to the pick area and then an overflow bin upstairs. For overflow there is also another warehouse in IntroCar's Surrey location.
Meeting Mo Rahnama (Director of Quality)
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Director of Quality at IntroCar, previously from Brompton Bikes, and before that Lotus and McLaren. Mo has brought a whole other side to our business and helps with design and testing for example, these V8 head gaskets. Cormac mentioned this on a previous video about head gaskets blowing on the Bentley Arnage. Cormac has a 4.4 Twin Turbo, which is a Green Label. He had been recommended the Green Label due to issues with the head gasket on the Red Label model.
IntroCar spent 3 and a half years designing this Rolls-Royce & Bentley V8 Cylinder Head Gasket (07V103147) shown. It's designed to get rid of some of the problems that came with the known head gasket failures. So that's an upgrade, fits the Bentley Red Label models and the one shown is a sample inspection sample. There were 25 of those reports on the first batch. The late Arnage R and T had an MLS (Metal Laminate Sheet) gasket. This is a composite. This V8 Cylinder Head Gasket fits all Rolls-Royce and Bentley vehicles manufactured from 1959 to 2002 - the V8 engines.
Shown here is a product a customer sent us and said "can you make that?" and here is the finished product - a Fan Outlet to Intake Duct Gaitor (UD5166GTR) for Rolls-Royce Silver Cloud II & Silver Cloud III models and Bentley S2 & S3.
This was designed in Computer-aided Design (CAD), then the tool was made from the CAD drawings. That is an Air Intake Vent which has gone from a destroyed version to a brand new product.
Another example here is the Steering Column Seal (UR1255) for Rolls-Royce Silver Cloud I and Bentley S1 also alongside the finished product here!
It’s actually a polyurethane just because the manufacturing technique suits that. That material originally would probably have been natural rubber which does perish. The 3D model is shown on the screen here.
This part - Jacking Point Seal (UB13438) is the seal that fits behind the jacking point flap in the sill on each side of the car. It has been unavailable from the factory for some years for Rolls-Royce Silver Shadow, Silver Shadow II, Silver Wraith II, Corniche, Bentley T1 & T2.
IntroCar is still working on it currently, then will go to the toolmakers. Mo has introduced a level of rigor in the design process which has been transformational. It makes it easier to get products right which is what we really want. Everything shown here in Mo's department is a work in progress. This part for example hasn't been available for maybe 20 years but every car got them and they are in the condition we see here. It's now being manufactured in a Polyurethane which is a more suitable material.
Gas Springs for the Bentley Arnage series are here in production as a work in progress.
In some instance it could be Original Equipment products we need to work from or we could be buying second hand to source a sample. Sometimes we do stuff directly from an engineering drawing. In the example of the Jacking Point Seal, although we were able to get a sample, most of the information actually came from the original engineering drawing that we got from the archives. So from the sample we then took a 2D drawing but you can't do much with that in terms of making a tool, or a product. You turn into 3D and once you have a 3D drawing then you can get into the manufacture.
Most importantly we need to consider firstly the right material and secondly that it's been treated properly. You can't just make someting out of stainless steel for example - it’s got to be the right steel and it’s got to be to the right thickness.
Here is a Water Pump and Pulley (RE2602) for Rolls-Royce and Bentley models from 1945 to 1955 which we make from scratch... and there are many more where that came from!
The IntroCar Warehouse
The first thing we come to here in the warehouse is a core engine that's going to get rebuilt for an SZ car. It's an aluminum block, 6.7L
Bentley Continental GT Brake Discs (3W0615301R) are here - weighing in at 19 kilos each - for first generation Bentley Continental GT (2004-2017), Continental Flying Spur (2005-2013), Flying Spur (2014-2019), & Continental GTC (2007-2018). IntroCar carries a lot of brake discs and rotors. It's such a big, big wheel. The energy going through those, when they brake, is the equivalent of the output of a small power station. That's the amount of heat and energy they have to dissipate and why they are so big!
This is a new project we have just commenced on - the Track Rod Assembly - Right Hand UR27220 and Left Hand UR27221 for the SZ cars (Rolls-Royce and Bentley motorcars manufactured between 1981-1998 & two door models manufactured from 1999-2003) and it is a complete unit. We had to make a thousand of these at a time. This will fit Rolls-Royce & Bentley models up to 1998 so even the latest Brooklands but also early Spirits use these. The actual inspection sheet for these Track Rod Assemblies is about 39 pages long!
Next here is an Front Upper Wishbone Balljoint - PD20799PD for the Rolls-Royce Silver Seraph and Bentley Arnage and every aspect of this part is quality controlled. A full Arnage and Silver Seraph Front Suspension Kit (ARSUSKIT1) is available also! We used traditional engineering drawings for this balljoint because it's a relatively symmetrical part. You've got pressings and the bolt pin itself, which is machined then the housing and then just the rubber gaiter, those are relatively simple processes. The challenge with this Balljoint is mainly managing volumes. You don't get to do this balljoint in 50 or 100 of them at a time. Typically it's a question of 500 at a time at best and that means multi-year stocks. You can't just buy a couple of months stock and then replenish unfortunately in the aftermarket industry.
So we're developing literally thousands and thousands of lines and have been for several years now.
The Coolant Pump / Water Pump Housings (UE75554) for the Rolls-Royce Spirit Series shown are bought in bulk and are then are assembled in relatively small volumes
Here is an example of a fully rebuilt engine (Bentley Mk VI Engine - RSRTSX) with all of our own products in it. It’s even got a new Water Pump. So we fully rebuilt the engine - it has had everything done to it including a brand new complete clutch because we do an upgraded Diaphragm Clutch Upgrade Kit (RH7199KT) for the Rolls-Royce Silver Dawn, Silver Wraith, Bentley Mk VI and R-Type.
Anyone want an engine? ;)
The way the warehouse is organized is that where we first started the tour we showed the slow moving parts and as you get closer to the 'goods out' area we are into the fast moving parts. This keeps the pick rate at the maximum efficiency.
"It’s like being a kid in a sweet shop!"
We do things like full Decoke sets... see the full list of Decarbonisation (Decoke) Kits for all Rolls-Royce & Bentley models here and these Gas Struts are for the Bonnet (Hood) and the Uprated Gas Struts for the Trunk / Boot (PR55888PB). IntroCar stocks a huge range of Gas Struts for Rolls-Royce Silver Seraph, Park Ward, Bentley Arnage Green Label, Red Label, Le Mans, R, RL, Birkin,Blue Train, Final Series, & Diamond series models, as well as many others, as they always go on the cars. There is a video here to show the improvement from the original design to the uprated version of these PR55888PB Gas Struts here.
Here are the Trunk / Boot Gas Struts (UB77773) for the Bentley Continental R (00999 Onwards), Continental SC (65000-65104) & Continental T (01500 Onwards).
Shown here is a Door Seal (R4-206) for a Rolls-Royce Silver Shadow 2 door MPW, Corniche, Bentley Corniche and also for some of the Coachbuilt Continental cars - we do a lot of body seal work because rubbers on old cars obviously are often knackered.
You don't get hold of all of this stuff in just a few months. This has been years and years of building the products and pure passion for the brand.
The Prestige Parts brand stands for heritage and for doing things the right way, not cutting corners and it takes a long time to get your money back.
So we wanted to have a brand that was the alternative to the genuine products supporting the brands and supporting the Rolls-Royce and Bentley marque.
Obviously we're developing our own ranges alongside what they offer and hopefully, we'll keep these cars on the road, which is what we want! There are literally hundreds of projects in development. Some of them will take weeks, some of them will take months, some will take years.
But there's always every week something coming off the Research & Development track - so there you go!
Parts which are reviewed in this interview include:
- QuarterLight Seal RB2563 https://www.introcar.com/left-hand-quarterlight-seal-rb2563
- v8 Cylinder Head Gasket 07V103147 https://www.introcar.com/v8-cylinder-head-gasket-07v103147
- Fan Outlet to Intake Duct Gaiter UD5166GTR https://www.introcar.com/gaiter-fan-outlet-to-intake-duct-ud5166gtr
- Steering Column Seal UR1255 https://www.introcar.com/seal-steering-column-ur1255
- Jacking Point Seal UB13438 https://www.introcar.com/seal-ub13438
- Waterpump and Pulley RE2602 https://www.introcar.com/early-waterpump-and-pulley-re2602
- Air Grille RH12590 https://www.introcar.com/air-grille-rhright-hand-drive-rh12590
- Brake Disc 3W0615301R https://www.introcar.com/brake-disc-vented-3w0615301r
- Track Rod Assembly UR27220 https://www.introcar.com/track-rod-assembly-right-hand-ur27220
- Upper Wishbone Balljoint PD20799PD https://www.introcar.com/front-upper-wishbone-ball-joint-pd20799pd
- AGM Battery 0147397 https://www.introcar.com/92ah-agm-battery-0147397
- Coolant Pump UE75554 https://www.introcar.com/housing-impellor-coolant-pump-ue75554
- Road Spring RH13387 https://www.introcar.com/road-spring-front-rh13387
- Bentley Mk VI Engine RSRTSX https://www.introcar.com/engine-only-mkvi-4-5l-rsrtsx
- Rocker Cover Bush EB3998 https://www.introcar.com/bush-rocker-cover-eb3998
- Gas Strut UB77773 https://www.introcar.com/strut-gas-trunk-ub77773
- Door Seal R4-206 https://www.introcar.com/door-seal-10ft-r4-206