gallery -
1995 ‘Rearsby Newspaper’ as an alternative to a brochure. Proposed new Design & Development Centre (building designed in-house and construction project managed in-house. Completed in 1995); test and development rigs; prototype workshop and an intriguing glimpse of a ‘First’ - namely a world-leading next-generation plastic pedal box.
Pedal box and gearshift production cells including robots in the team; manual gearshift developed a in-house venture for Honda Civic; Zani high-speed press with moving bed quick tool change; progression tooling presswork and Orii Robots Komatsu press line.
Engel injection moulding machines for the production of plastic pedal box and pedals; plastic gas pedal and bearings; the next world-leading plastic pedal box due to enter production for Rover; Jaguar hollow pedals demonstrating 2 for 1 weight saving; new/latest re-investment in the latest CAD 5 system, compatible with our customer systems; stress analysis of pedals; drive-by-wire accelerator systems; the latest “open box” Rearsby handbrake lever design innovation - for ease of assembly, incorporating plastic catch-rod and 'jig-saw' racket teeth handbrake for Nissan
ABB Asea robots offering pedal box to spot-welders.
Coil stock to finished pressing per press stroke, in Zani high-speed press
Fanuc CNC Wire-eroder in toolroom producing a blanking die.
Aerial Shot taken by Ivor Vaughan. North site/No.5/General Office to the left of Gaddesby Lane. No.6, No.4 to the right of Gaddesby Lane with the old canteen (was the Leicestershire Flying club house) and what was to become the Development workshops at the bottom of the photoraph. The Design House was constructed this side of Development in 1995.
Front page of the first Rearsby Automotive sales brochure, following the MBO in 1982. A Jungheinrich Cloos robot welding a prototype Jaquar hollow pedal is shown within the new RAL logo.
Rearsby heritage products and and automotive customer models with Rearsby parts; a Delorean pedal box assembly and a photo of the General Office.
Valeo sprung-cente clutch plate; Rearsby-designed solid centre after-market plate, Maestro/Montego handbrake incorporating the ‘jigsaw’ ratchet teeth; Delorean pedal box; Leyland and Ford D Series truck gearshifts, Mini auto gearshift; Sherpa steering columns and Ford Transit gear lever.
Double-headed Friction welder on Metro steering column production; Cyanide heat-treatment; Powder-coat paint plant; Fine-Blanking of Vauxhall J & K car handbrake quadrants; Cell incorporating Mori-Seiki CNC machining centre with indexing table; Double-headed CO2 welding suspension links; Zinc plating plant and Cloos robot fusion welder
Cloos robot (our first robot welder); Charmile Die-sinker & Fanuc Wire eroder in the Toolroom; Mori-Seike Fanuc controller; Quality, Jig and Tool Design and development/test dept.
The wide range of Rearsby output. Land Rover 88” side-member; Chrysler axle tubes; Austin Metro and Sherpa steering columns, Ford D Series gearshift; Range Rover pedal box; Mini, Land Rover and Maestro door, hood and truck lid hinges; Ford Transit and Sherpa gear levers; Valeo and Min clutch plates; handbrake levers for Austin-Rover, Ford, Vauxhall, Chrysler, Land Rover, Range Rover and Sherpa handbrake levers; suspension links/arms for Austin Rover and various chassis sub-assemblies.
Aerial shot and location of Rearsby with respect to its major customer pant locations. Maestro ‘jig-saw’ quadrant.
Gearshift assembly cell.
Test and Development workshop 1990s. Gearshift and handbrakes are under test. The white Dennison tensile/compression load test machine was purchased from Triumph Motorcycles, Meriden following its closure.
Engel injection moulding machines purchased for pedal box and pedal production. One of the first off tooling Rover 75 pedal boxes being examined.
Double-headed Thompson friction welder on Austin-Rover Metro steering column production
Spectacular shot (but not a good weld resulting!!) of robots in a pedal box cell.
New “Vehicle set” cell under development for Nissan production.
Mori-Seike Vertical Machining centre Fanuc Control panel.
Test/development workshop in the 1980s.
Flip-side of the Quality card handed to all employees as part of their quality training.
Rearsby Quality Policy stated on a "Credit card”.
Zani 400 tonne high speed progression press. Moving bolsters facilitated quick tool change. It was capable of 120strokes/min!!
Computervision Cadds 5X. Full 3D with Surfacing including Finite Element Analysis. Compatible with all all our customer CAD systems.The Rearsby designed 'open box’ handbrake lever design is shown.
Fine Blanking of GM “J" and “K" car handbrake quadrants.
Powder coat paint plant circa 1997.
Cyanide Heat treatment from the 1970s.
Jig and Tool design 1970s, early 80s, before CAD.
Komatsu pressline, linked and loaded by Orii press robot’s - ”Poetry in motion”. The line was equipped with quick-change die change facilties.
Zani control panel. The handsome setter-operator of this press was former member of the pop band “Love Affair” who had a No.1 chart hit in 1968, “Everlasting Love".
Progression presswork stages for the main gearshift bracket - part of a manual gearshift mechanism.
1990s Brochure showing 3D CAD image of a pedal box design, 300 tonne blanking press, Komatsu robot welding Nissan Primera rear suspension links and Pedal box assembly cell.
1990s Brochure. Nissan and Rover handbrake levers, Rover front suspension arm, Nissan rear suspension links, Jaguar pedal box, Leyland-DAF truck gear lever CNC machining, 100 tonne press and final assembly cells.
1990s Brochure. Engineering plastic accelerator pedal developed by Rearsby for the Ford Fiesta, Rover automatic gearshift mechanism, Nissan manual gearshift, presswork blanking, robot-loaded CNC lathe, Komatsu welding robot, Toolroom Fanuc CNC wire-eroder and production cell.
1990s Brochure. Mini steering column, Nissan Micra suspension links, Rover and Honda pedal box, cell based Statistical Process Control, test/development rigs, CAD system, and accelerated environment salt-spray chamber.
