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Acura NSX will use Cosworth block, plus other neat tidbits

The blue NSX you see here was built just two weeks ago. Prototype number six, it rolled off Acura's newest assembly line in Ohio and was rushed out to the Monterey peninsula for various car week activities. We had a chance to sit down with several members of the NSX team to discuss the car, the long road from concept to production, and some interesting details. Below are some choice bits from our conversations. Acura is pretty proud of the fact that NSX version 2.0 was designed and is being built in the US. The new assembly line, called the Performance Manufacturing Center, is in Honda's hometown of Marysville, Ohio. While the line is brand new, the building has seen many uses over its lifetime, most recently as a warehouse facility. PMC staff numbers about 100, with 60 technical and 40 non-technical associates. The car uses parts sourced globally, and one of those sources is Cosworth. The engine blocks and heads come from the English firm and get assembled into twin-turbo powerhouses at Honda's nearby Anna, Ohio, engine plant. The Cosworth name is rarely associated with a bad engine, so we were geeked to hear the NSX's 550-plus-horsepower hybrid powertrain has good genes. Acura hasn't decided how many cars will come to the US each year, but supplies will be limited. We're told there is a total figure for global sales – basically anywhere Honda and Acura vehicles are sold – but they're not ready to divulge that number. Dealer allocation is also yet to be sorted out, although we're told that any dealer that has the necessary tools and equipment to service the new NSX will be able to sell them. Acura currently has 272 US dealers. The switch from the transverse engine originally planned to a longitudinal twin-turbo engine threw everyone involved for a loop. The designers had to lengthen their nearly finalized design, and the engineers working on the production process had to revise or redo much of their work. Though we've been waiting a while for the car since the concept first surfaced in 2012, it's pretty amazing to think that the car was engineered one and a half times and a new factory was built in about three years. But yeah, it's delayed, with series production now set to commence in the spring of 2016. One result of the switch to a longitudinal engine is a transmission hump in the cargo area aft of the engine. The hold is still sized to fit a bag of golf clubs, though it will be a tight fit.

Honda's Acura NSX masterstroke: building the factory in Ohio

When Honda announced it was going to build its NSX supercar in Ohio instead of Japan, it caught everybody in the industry by surprise. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Now Honda has a supercar production facility in rural Ohio that would be the envy of any Formula One team. The people at Honda call it the PMC, but its official name is the Performance Manufacturing Center. It's a building that started out as a shipping facility for suppliers, but Honda invested $70 million to transform it into a showcase facility that will build the NSX. Honda benchmarked the assembly operations at Ferrari, Lamborghini, McLaren, and Bentley before work began on its facility. The 200,000 square-foot building will also double as a customer reception center – Honda will open the doors for customers to come see their car being built. It's also going to offer them high-speed test drives at the gigantic Transportation Research Center just down the road. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Inside, the layout is wide open and well lit. There are no stripes or lines on the floor and none of the different departments are walled off. This creates a more welcoming appearance and lets you get a comprehensive view of the entire process at a glance. And with an eye towards future lessons learned, most of the equipment is of a modular design that can be easily reconfigured or moved. The body shop and paint shop are enclosed by glass walls so that anyone can see what's going on inside. And while you'll see some automation here and there, the idea was to achieve a blend between man and machine, not to try and automate everything. This is a low-volume facility with production targeted at only eight to ten cars a day. The plant runs four days a week with one ten-hour shift. Don't expect to see rows of new NSXs parked on any dealer's lot. The car will only be built to order. Honda is obsessed with ensuring the NSX is built to the most exacting quality standards. The plant people pored over the JD Power Appeal study to determine what supercar customers care about the most, then looked at which aspects of that directly tie into manufacturing. They developed their quality control strategy with three goals in mind. First, they wanted to build everything right the first time with no adjustments.

It turns out Takata isn't willing to expand airbag recall nationally after all

There have been "approximately 0.000006 failures per air bag deployment, which is far below the failure rate" of most recalls, Takata claims. Takata has seemingly made an about face following reports that it would expand its regional airbag recall into a nationwide repair effort, issuing a scathing, four-page letter rebutting allegations by the National Highway Traffic Safety Administration and its Office of Defects while simultaneously attacking the government's handling of the situation. The Japanese supplier claims in its letter that the "currently available, reliable information does not support a nationwide determination of a safety defect," arguing that there were "approximately 0.000006 failures per air bag deployment, which is far below the failure rate in the vast majority of the thousands of recalls," The Detroit News reports. Takata then breaks down the two specific incidents mentioned in NHTSA's original recall request letter, a 2005 Honda Accord and 2007 Ford Mustang. Referencing the two crashes, NHTSA Administrator David Friedman said last month "one incident is an anomaly, but two are a trend." The supplier, though, argues the Honda issue is already being covered by that company's soon-to-be-national recall (more on that in a moment). The company then goes on to point out that neither Takata nor NHTSA has been able to analyze the Mustang's airbag inflator, saying that such a lack of examination meant there was "no way to ascertain what actually occurred during the incident, whether any inflator ruptured, and whether any inflator rupture that may have occurred was related to the incidents that led to the current regional campaigns." Takata alleges that NHTSA has disobeyed its own statutes. Takata also took the opportunity to take a few swipes at NHTSA's behavior during the airbag scandal, saying it was "very surprised to receive" a recall request letter because the ODI had yet to even receive the company's responses to a pair of special orders. It also alleged that NHTSA was disobeying its own statute, which says only manufacturers of vehicles and replacement equipment can "decide in good faith whether their products contain a safety related defect," and that the government can only "issue an initial decision that a safety-related defect exists" to those same entities.