Niche appeal: the EV chassis that could save low-volume makers

Even Yates’s decision to make his new car look like an old one – the 1955 Porsche 356A, a favourite since childhood – is highly relevant to the PACES story. The Coupé will undoubtedly win attention, but its familiar shape shouldn’t divert people the way a new design might do, when it’s what’s underneath that really counts. Yates accepts that the EV skateboard idea isn’t new. Automotive giants have been proposing them for decades, technology companies like Lotus and Williams have elaborate skateboard concepts they hope will lure major customers, and there are various iterations already in production. So what makes PACES special?

o what makes PACES special? “We’ve specifically designed it for low-volume manufacture,” explains Yates. “PACES is flexible, scalable, highly adaptable and cost-effective. It’s ideal for small batches. At present, electrification is really, really hard for niche manufacturers. Component supply to meet their needs is in its infancy. Most don’t have the capability or the skill sets. PACES is a sophisticated design that already complies with all relevant standards. It’s a modern, thoroughly engineered, premium product.”

Better still, Yates explains, PACES comes with a ready-made team of component suppliers – one big advantage of Rally Prep’s involvement with other potent small businesses, in grant-funded research projects administered by the Niche Vehicle Network and the Advanced Propulsion Centre. And against all odds for a self-taught automotive engineer, Yates has also found that handling the application forms and interviews needed to raise grant funding, and supplying the complex data required to meet ISO standards, has become part of his skill set.

Largely as a result of this participation in grant-funded projects, Yates and Rally Prep have close relations with companies such as Crewkerne-based Ariel, Potenza Technology (a supplier of new-tech EV control systems in Warwick) and Equipmake (a fast-expanding Norfolk electric motor manufacturer). There are others.

One especially close link is with Stalcom, based at Pershore, whose FlexTech ready-made lightweight extrusions are designed to interlock and bond accurately together – without any need for jigs – to form extremely rigid chassis structures that suit many different applications. There’s little or no need for tooling or post-assembly machining, which is always costly.

These are the keys to low cost, Yates explains; bigger-scale skateboard concepts use bespoke corner castings and extrusions to do what PACES can achieve with flat, laser-cut pieces.

Yet just like the best of them, a rigid PACES chassis can be delivered to within 1mm of variability across the whole structure, from end to end.

Looking back, Yates feels the phases of his varied car-building career have equipped him “pretty well” for the diverse requirements of this project. Born into a car-mad family (he was collected from hospital in his dad’s rally-prepped Cooper S), he stepped away from formal education at A-level stage to do his own thing. Building cars for a hobby turned into a business when he moved to Cornwall as a 25-year-old, and his love for the region – his workshop is down the road from Newquay airport – is now so strong, he swears he’ll never move.

Success at motorsport and demand for his services in the mid-2000s encouraged Yates to design and build a car of his own, the Subaru Impreza-based Murtaya roadster. Customer cars were launched in 2008, but though Yates and his partner sold about 40 units, the project hit the buffers and by 2011 he had “no premises and no car, just a bike for getting around”. Those were tough lessons.

However, out of hardship and necessity, Rally Prep was born. “I went back to doing what I knew I was good at,” says Yates. Despite what seems like a remote location, it has become a highly successful business, carving a reputation for quality work that led to a contract to prepare rapid, works-sanctioned Toyota GT86 rally cars that won a class title in the British Rally Championship in 2016.

But by then Yates and his “super-skilled group” of Rally Prep colleagues were involved in other projects, among them a forerunner of PACES, also a configurable aluminium chassis, which they showed at the Goodwood Festival of Speed (“nobody was interested back then”) plus R&D work for other companies. But Yates’s rising consciousness of how the changing world of propulsion would soon strike Britain’s unique niche vehicle market kept driving him towards his own solution to its problems.

The wider world is only just becoming aware of Yates’s PACES concept, but whispers about it have already elicited expressions of interest – one from a “big name” company whose plan for a factory is already backed by semi-government funding, another for a sub-3.5-tonne front-drive EV van, and a third proposing a big-scale overseas bus project.

The smell of success is not going to Yates’s head, however. “I’ve already experienced the highs and lows of the niche industry,” he says, “so I’m not getting carried away. But this time it does look as if our technology is ready to suit the way the market’s changing. Things might start coming together quite quickly.”

A dream car come true

Neil Yate's love of the seminal 1950s Porsche goes back to childhood; he had one on his bedroom wall and swore one day he’d own a full-sized version. He can’t have imagined, however, that the car’s compact curves would sit above an up-to-the minute aluminium modular chassis of his own design. Or an electric powertrain capable of driving it for 200 miles. Yet both are crucial components in Yates’s 2022 WEV Coupé, a car with that classic Porsche outline, built on a PACES chassis and powered by a rear-mounted electric motor.

It’s a simple car compared with much of the machinery Rally Prep has built, but Yates is still delighted that the first prototype “just worked”. Nine months of trials have already been conducted and they’ve been very promising. The plan is to build, develop and publicise the car through 2021 (despite Covid, Watt EV is only a few weeks behind the lively schedule Yates laid out a year ago) and customer cars should start to flow early next year.

After its latest round of developments, the first prototype weighs just 902kg. Yates expects the production version, with all running gear and a relatively light and simple interior, to weigh less than 1000kg. His simulation tools, which after recent tuning align accurately with the prototype’s real-time performance, predict that a production car with a single 107bhp motor will deliver 0-62mph acceleration in 7.2sec, or 5.3sec with the optional 160bhp unit. The battery is a 39.6kWh unit that uses Nissan Leaf cells. With the lower-powered motor, the indicated WLTP range is 230 miles, or 180-190 miles in the real world.

That’s impressive, and underscores the importance of light weight and good aerodynamics in an EV. Though venerable, the Porsche outline is sleek, the underbody is flat and the frontal area is comparatively small. The WEV Coupé uses the 356’s body dimensions and wheelbase almost exactly, but it has neater lights, finer panel gaps, smoother flanks and wider tracks so its wheels fill the arches better than the originals ever did.