One of the world's more unlikely production cars is the Morgan. Now describing itself as "the oldest independent British car maker," Morgan has achieved European Whole Vehicle Type Approval for its two-seat models. Morgans have retained their classic appearance for decades, and changes to meet the European legislation have not threatened that.  They include a high level brake light;  larger, safer cockpit, and anti-theft immobilizers.

Charles Morgan, Joint Managing Director, said:  "While retaining our traditional coachbuilding skills and hand-built manufacturing processes, we have been able to surpass the latest legislative requirements."
Morgan has also invested to surpass US regulations. US emissions legislation required development of onboard diagnostics, a new wiring harness, and a solid-state digital ignition system.  Driver and passenger airbags are fitted for the US and are optional for Europe. They are of the depowered type designed to operate in conjunction with seat belts for maximum protection.

Morgan has made changes to its manufacturing processes. Every part of the factory's process and layout, from laying down the chassis to hand stitching the trim, has been "refined," according to the company. The time each car is in the production phase has been cut from 40 to a "regular and repeatable" 24 days.  A major pivot of these changes is a reduction in work-in-progress with manufacture now regulated to a constant and controlled workflow. The new layout includes specially dcsigned line-side parts bins and racking systems for quick and easy parts picking. In the body shop, where 72-piece ash frames for all models are assembled before being paneled with aluminum, the new system has speeded parts supply.

 Production of Morgan's long, sweeping front fenders are now formed with aluminum pressings using superplastic forming, with detail finishing by hand. The forming process forces the heated alloy into a tool. As the force used is air pressure, only single-surfacc tools, whose shape matches precisely that of the component, are required. Morgan said that the company's aim is to manufacture,  in limited numbers, a car  that lasts the life of the owner - and to reduce the waiting list for new cars to three years in any of its  export markets.