
Starting in first gear
Good morning.
The biggest check written in the car business last week was not for a battery plant or a software company. It was for a paint shop. Ford is putting $1 billion into the building where it paints Super Dutys, Expeditions, and Navigators, and if that sounds like a lot of money for a room that sprays cars, you have never been inside one. The paint shop is the most expensive, most regulated, and least flexible thing in an assembly plant. Put money there and you have told everyone what the plant will build for the next fifteen years.
Also this morning: a BMW that stickered at $167,000 three years ago closes on Cars & Bids this afternoon, with bidding at less than a third of that, Porsche has turned the GT3 into a race car by taking things out of it rather than putting things in, and we do the arithmetic on what the "entry-level" race car actually costs once you start racing it.
In today's newsletter, we'll get into:
Auction Desk: A 2023 BMW XM, 644 hp of plug-in hybrid V8, closing this afternoon on Cars & Bids
One Big Story: Ford is spending $1 billion to paint trucks, and why that tells you more than any press release
Engineer's Corner: The Porsche 911 Challenge and the engineering of a near-production race car
Garage Economics: The $275,000 race car is the cheap part
Let’s roll.
THE AUCTION DESK
2023 BMW XM, Cars & Bids, closes this afternoon
When BMW M launched the XM for 2023, the pitch was that it was only the second car developed entirely by M, after the M1, and that its hybrid system shared technology with the M Hybrid V8 that races at Daytona and Le Mans. The reality was a 6,000-pound plug-in hybrid SUV with a face people argued about and a positioning problem: the customer who wanted M's engineering wanted it in something lighter, and the customer who wanted a big luxury SUV had cheaper BMWs to buy.
This one is Black Sapphire Metallic under matte paint protection film, over a Sakhir Orange interior, which is the only combination that makes the XM look like it was designed on purpose. One Florida owner since March 2023, 47,900 miles, clean title, $167,395 on the window sticker. The equipment list is most of the order form: M Driver's Package, 22-inch 922M wheels, Adaptive M Suspension Pro, M Sport differential, massaging front seats, Bowers & Wilkins. Under the hood, the S68 twin-turbo hybrid V8 we covered Friday, 644 hp and 590 lb-ft through an eight-speed automatic. Flaws are chips in the film, curb rash on the front wheels, and one Carfax line worth a closer look: minor front damage in September 2023, at about 10,000 miles. The service history is dense, eight oil changes in under 48,000 miles, which is the kind of thing a first owner does while the car is still their favorite.
As of Sunday the high bid is $51,000, and a Sunday bid on a Monday auction is a placeholder, not a price. Cars & Bids auctions are decided in the last hour, when the bidders who have been watching all week finally show up. The current number is the floor of serious interest.
My call: the top bid lands between $55,000 and $60,000, and the reserve sits somewhere around $58,000 to $60,000. Take $57,500 as the middle of the range and the math is $109,900 gone in three and a half years, two-thirds of the sticker, or about $2.29 for every mile the first owner drove. Very few cars at this price point have lost more, faster, and the ones that have are usually badged Maserati. The buyer this afternoon is not paying for the badge. They are paying for a 644-hp, fully loaded SUV at the price of a well-optioned X3.
📈 Market signal: The cheapest 2023 XMs on Autotrader this weekend, four dealer cars with 40,000 to 54,000 miles, are asking $65,000 to $68,500 with fees included. That is a tight band for cars with the same miles as this one, and it puts the dealer floor about $15,000 above the current bid. Take out dealer margin and reconditioning and the private-sale equivalent is somewhere in the high $50,000s to low $60,000s.
ONE BIG STORY
Ford is spending $1 billion to paint trucks

Source: Ford Motor Company
On Thursday, Ford confirmed a $1 billion investment in Kentucky Truck Plant in Louisville, nearly all of it for a new paint shop. Kentucky Truck builds the Super Duty, the Expedition, and the Lincoln Navigator, employs about 11,500 people, and is Ford's highest-revenue plant in the country. The F-150 sells more units; these three carry the fattest margins, and they all come out of one building.
If you have never been inside an assembly plant, a paint shop is a sealed building inside the building, with its own air handling, ovens, and robots, where every body goes through a chemical bath, primer, color, and clear coat with a bake between each. It is usually the single most expensive system in the plant. It is the most regulated, because solvent emissions are what the state permits. And it is the least flexible: a body shop can be retooled for a new model in months, but a paint shop is sized for a certain body and volume and stays that way for decades.
So this is less about paint than about commitment. Nobody builds a $1 billion paint shop for a plant they intend to wind down. Ford has just told Louisville it will build big body-on-frame trucks and SUVs there, at volume, for the life of the shop.
The context makes it a pattern. Ford has already put about $2 billion into the Louisville Assembly Plant across town for the Fathom electric pickup, and another $2 billion into the former battery joint-venture plant in Glendale for grid storage under the Ford Energy name. That is $5 billion in one state on three different bets: gas trucks, an electric truck, and batteries that never go in a car. The announcement also landed two days after Ford's reply to the Transportation Secretary's letter about its China ties, which is the kind of timing that does not happen by accident.
The takeaway: A paint shop is the least flexible thing Ford could have spent $1 billion on, which is why it is the clearest signal of what Kentucky Truck will build for the next couple decades. Watch-number: 11,500, the Kentucky Truck headcount, and whether Ford ever says what the new shop does to it.
ENGINEER’S CORNER
How Porsche turned a road car into a race car
Porsche's new 911 Challenge is the bottom rung of a customer racing ladder that now runs GT3 R, Cup, GT4 R, Challenge, all on the 911 platform. The Cayman is gone from customer racing. What is interesting about the Challenge is not what Porsche added. It is how little they changed, and where.
Start with the engine. The 4.0-liter flat-six is the road-going GT3 unit, same 9,000-rpm redline, but it makes 508 hp at 8,500 rpm instead of 502. Porsche says the engine is largely derived from the production GT3 and that the racing muffler keeps a catalytic converter but does not need a particulate filter. A GPF is a ceramic honeycomb that traps soot, and it costs back-pressure, which costs power at the top of the rev range where a GT3 lives. Deleting it is the most likely source of the extra six horsepower, and it is legal because a race car does not need to meet road emissions. Everything else in the engine is production. That is the whole philosophy of the car in one part.
The gearbox is the seven-speed PDK from the road car, paddles and automatic mode included. The Cup car uses a sequential racing gearbox; this does not. PDK is heavier and slower to shift than a proper dog-box, but it is also a known quantity for anyone who has tracked their GT3, and it does not need a rebuild every few thousand kilometers.
The chassis is where the racing parts show up: dampers with a motorsport-specific curve, an anti-roll bar adjustable to three positions, 380 mm steel brake discs front and rear (the same hardware as the Cup and GT4 R), and 18-inch wheels on the standard five-bolt hub rather than center-lock. That last one is a cost decision dressed as a technical one. Center-lock hubs are faster at a pit stop and lighter, but they need a torque procedure, special sockets, and expensive wheels. Five-bolt means the hubs are stock, the wheels are cheap, and a tire change in a club paddock is a tire change.
Then the safety equipment: a welded-in roll cage, which also stiffens the shell more than any bolt-in cage can; a 110-liter FIA FT3 fuel cell; a fire suppression system; a single racing seat with a six-point harness; a three-jack air system; a four-position mechanically adjustable rear wing. All the sound deadening, carpet, trim, and passenger seat are gone. Air conditioning stays, because Porsche has watched enough amateurs lose concentration in a hot car.
I spent part of my career on a customer race car program, and the question owners ask before they ask about lap time is what a front bumper costs and how long it takes to get one. A car built from production parts answers that question with a parts catalog that already exists. That is not a compromise. For a customer racer, it is the engineering.
The takeaway: The 911 Challenge is a production GT3 with the emissions hardware removed and the safety hardware welded in. Porsche kept the road-car parts wherever it could because familiar parts are cheaper to run, and that is the product.
GARAGE ECONOMICS
The $275,000 race car is the cheap part
Porsche is offering the 911 Challenge to 2027 one-make entrants at $275,000, delivered to the US. That number gets the headlines. It is also, by a comfortable margin, the smallest number in a racing budget.
Here is how a season in a one-make series breaks down, in rough terms, because nobody publishes exact figures and every team's invoice is different. The car is a capital cost: you buy it once and, if you do not crash it, you sell it later for a meaningful fraction of what you paid. Everything below is an operating cost, and it recurs.
Tires are the first line. A set of racing slicks for a car in this class runs somewhere in the low-to-mid four figures, and a race weekend with practice, qualifying, and two sprint races can consume two to four sets depending on the series rules. Multiply by a season of six to eight rounds and tires alone can approach the price of a new Cayman.
Entry fees, fuel, and consumables (pads, rotors, fluids) add a five-figure line. Then there is the part the brochure never mentions: the team. Transport, a crew of two to four, a data engineer, a spot on a transporter, hotels, and pre-season testing are what turn a $275,000 purchase into an annual budget. Commonly quoted figures for a full season in the North American Sprint Challenge land in the low-to-mid six figures; the Carrera Cup, one step up, is frequently quoted at double that.
This is the economic logic behind the production-parts decision in Engineer's Corner. Porsche says outright that the car was designed to minimize operating and spare-parts costs. A five-bolt wheel, a stock PDK, a steel brake disc, a body panel that is the same as the road car: each of those trims the line that recurs, not the line that is paid once. If the goal is to get a new customer through their first season without a repair bill ending it, the parts that matter are the ones that get replaced after a crash.
The resale question follows: this year's Challenge car is next year's club racer, and the buyer pool for a used race car with an existing parts catalog is far larger than for one with a bespoke gearbox.
The takeaway: The $275,000 is the smallest number in the budget. A season of tires, consumables, and crew costs as much again or more, and Porsche built the car around keeping that second number down.
🏁 THE COOL-DOWN LAP
The 2015 M5 Competition Package from Friday sold at $29,500. My read was low-to-mid $30s, and I wrote that under $30,000 would be a soft Friday rather than a soft car. Congrats to the new custodian that scored himself a rocketship for less than a new Honda Accord.
Tesla began rolling out FSD v14.3.9 over the weekend with Automatic Collision Evasion, limited to paying HW4 customers. It steers and brakes around an imminent collision without driver input. The open question is who owns the outcome when it does something the driver did not ask for.
Goodwood Revival runs this Friday through Sunday in West Sussex, with Bonhams' single combined sale on Saturday the 19th. Results next Monday.
Brampton watch-number: Stellantis' deadline at Brampton Assembly is this Sunday, September 20. It has not moved.
Wednesday: hydrogen at Le Mans. The ACO and FIA agreed in June to let hydrogen-powered Hypercars race at the top level under the 2030 rules, and Toyota ran a liquid-hydrogen prototype on the circuit before this year's race. Fuel cell or hydrogen combustion, 700-bar tanks or cryogenic liquid, and how you refuel either one in a pit lane at 3 a.m. That is Wednesday's Engineer's Corner.
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