Computer-aided design (CAD) systems weren’t around when I began in the industry, and although most, if not all, of my colleagues have long since converted, I’ve stuck with my drawing board. Call me a dinosaur, but I think of it as my first language; for me it represents a state of continuity and I like continuity; it’s something I strive for. If I were to convert to CAD I’d have to learn something new, and not only is there a time penalty to doing that, but there’s the question of whether I’d be as fluent in my new language as I was in my old.
Besides, what I value about the drawing board is that you can have everything at scale in front of you, whereas on a CAD system you’re limited by the size of the monitor. I also like the fact that I can sketch freeform and change it quickly. It’s an illustration of how fast I can work that when I’m flat-out I keep at least two people occupied taking my paper drawings and turning them into CAD drawings. And these are just the ones I think are worth transcribing. It’s usually taken several iterations to get to that point; my consumption of erasers is only just behind my consumption of pencil lead.
I’m happiest when working on a big regulation change. Drawing the RB7, the 2011 car, was just such a time: an overhaul that included the incorporation of the KERS system (it stands for ‘kinetic energy recovery system’), which stores energy in a battery under braking and then releases it during acceleration.
Other designers were saying that the best place to put the battery was under the fuel tank: it’s nice and central, it’s in a relatively cool location and it’s easy to connect from a wiring point of view. But aerodynamically, I wanted to get the engine as far forward in the chassis as possible so as to allow a very tight rear end to the bodywork, and the best way to achieve that was to take the heavy KERS battery and put it near the back of the car, which in turn would allow the engine to be moved forward to keep the weight distribution balanced. My suggestion was that we put the battery behind the engine, in front of the gearbox.
Figure 1: Placement of the KERS system in the RB7.
Initially I proposed this to Rob Marshall, our chief designer. His reaction was a deep breath. You want to take the batteries, which we know are a difficult thing to manage, very sensitive to vibration, prone to shorting out, sensitive to temperature – you want to take these and put them between the engine and the gearbox, one of the most hostile environments on the car? Really?
I was insistent. I said, ‘Look, Rob, I’m sorry, and I know it’s difficult, but not only does putting them in this location give us a good advantage, but it’s an advantage we’ll have locked in, because it’ll be impossible for a team to copy that within a season, it’s such a fundamental part of the architecture of the car.’
So Rob went away and started talking to his engineers in the design office, and came back and said, ‘No, everybody agrees, it’s just not possible, we can’t do it.’
My feeling was that it ought to be possible, so I drew some layouts that split the battery into four units, two mounted inside the gearbox case just in front of the clutch and two mounted alongside but on the outside of the gearbox case. I drew some ducting to put the batteries into their own little compartments with cold air blowing over them in addition to the water-cooling they have anyway.
Fortunately Rob is not only a very creative designer but also a designer who understands that if there is an overall performance benefit to be had, and if it looks viable, you’ve got to give it a go. It was a brave, I guess you could argue an irresponsible decision, in that if we hadn’t got it to work it would have compromised our season.
It took longer than I hoped. During the early part of the season, the KERS system was in the habit of packing up and was constantly in danger of catching fire. But once we made it reliable, we had this underlying baked-in package advantage that we were able to carry for the balance of that season and the next two, a key part of the 2011, 2012 and 2013 championship-winning cars. Which, as you can imagine, appealed to my inner love of continuity.
If the fact that I still use a drawing board and pencil sounds old-fashioned, that’s nothing compared to my start in education. At four I was sent to the local convent school where I was told that being left-handed was a sign of the devil. The nuns made me sit on the offending hand, as though I could drive out the demon using the power of my godly bum.
It didn’t work. I’m still left-handed. What’s more, when I went from that school to Emscote Lawn prep school in Warwick, I still couldn’t write. As a result I was placed in the lower set. And what do kids in the lower set do? They mess around.
My earliest experiments in aerodynamics came during a craze for making darts out of felt-tip pens and launching them at the blackboard. We’d have competitions, and I was getting pretty good until one particular French lesson, when for reasons best known to my 12-year-old self I launched my dart straight up into a polystyrene ceiling tile. The teacher turned from the blackboard, alerted by suppressed laughter that fluttered across the room, and what he saw was a classroom full of boys with their hands clamped over their mouths and one, me, sitting bolt upright with an expression like butter wouldn’t melt.
Sure enough, he made his way through the desks to mine, about to demand what was going on, when the dart above our heads chose that moment to come unstuck from the ceiling, stall, turn sideways and bank straight into the side of his neck. Statistically, it was a one in a thousand chance. It was poetry.
That wasn’t my only caning. The other one was for rigging up a peashooter from a Bunsen burner tube and accidentally tagging a science teacher instead of the mate I was aiming at.
Speech days were especially boring. On one particular occasion, me and my friend James had been playing in the woods, found some aerosol cans and lobbed them on the school incinerator. Expecting them to blow up straightaway, we took cover behind some trees, only to be frustrated by a distinct lack of pyrotechnics. Eventually we got tired of waiting and wandered off.
Shortly after that, speech day commenced, parents assembled and we took our seats, ready to be bored rigid, when suddenly from the woods came a series of booms and the stage was showered in ash. James and I looked at each other gleefully, but we counted ourselves lucky not to be caught and punished for it.
When it came to the challenge of making a hot-air balloon, I was able to put to good use my interest in building things. By this time I was beginning to understand the concept that if you want something to go up, you need to make it big in order to achieve a good volume-to-surface-area ratio, so I made a large balloon out of tissue and bent coat-hangers, complete with solid-fuel pellets for heat. Unfortunately the pellets didn’t generate enough oomph to get the balloon airborne, so I carted my dad’s propane burner into school and used that instead. The headmaster came out to see what was going on, leant on the burner and burnt his hand, which cemented his dislike of me.
At home I continued messing about with motor cars. In 1968 Dad bought a red Lotus Elan in kit form (other families had large saloons, we had sporty two-seaters), which according to Lotus you could build yourself – ‘in a weekend’, although even Dad could never manage that – and save on car purchase tax. Manna from heaven for an obsessive tinkerer like my dad, and I was his willing helper, happy to put up with his occasional, volcanic loss of temper in order to watch a car being built from a kit.
Meanwhile, I’d started building model kits. Most of my friends were making Messerschmitts and Spitfires but naturally I preferred cars, and my favourite was a one-twelfth-scale Tamiya model of a Lotus 49, as driven by Jim Clark and Graham Hill.
This was the first year that Lotus and their founder Colin Chapman had introduced corporate sponsorship, so the model was liveried in red, white and gold and had all the right details, moving suspension, the works. It was a great model by any standard, but what was especially noteworthy from my point of view was that the parts were individually labelled. Suddenly I was able to put a name to all the bits and pieces I’d see on the floor of the garage. ‘Ah, that’s a lower wishbone. That’s a rear upright.’ This, to me, was better than French lessons.