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transmission system for the Roadster. The goal had always been to get from zero to 60 mph as quickly as possible in the hopes that the raw speed of the Roadster would attract a lot of attention and make it fun to drive. To do this, Tesla’s engineers had decided on a two-speed transmission, which is the underlying mechanism in the car for transferring power from the motor to the wheels. The first gear would take the car from zero to 60 mph in less than four seconds, and then the second gear would take the car up to 130 mph. Tesla had hired Xtrac, a British company specializing in transmission designs, to build this part and had every reason to believe that this would be one of the smoother bits of the Roadster’s journey. “People had been making transmissions since Robert Fulton built the steam engine,” said Bill Currie,8 a veteran Silicon Valley engineer and employee No. 86 at Tesla. “We thought you would just order one. But the first one we had lasted forty seconds.” The initial transmission could not handle the big jump from the first to the second gear, and the fear was that the second gear would engage at high speed and not be synchronized with the motor properly, which would result in catastrophic damage to the car. Lyons and the other engineers quickly set out to try to fix the issue. They found a couple of other contractors to design replacements and again hoped that these longtime transmission experts would deliver something usable with relative ease. It soon became apparent, however, that the contractors were not always putting their A team to work on this project for a tiny start-up in Silicon Valley and that the new transmissions were no better than the first. During tests, Tesla found that the transmissions would sometimes break after 150 miles and that the mean time between failures was about 2,000 miles. When a team from Detroit ran a root cause analysis of the transmission to find failures, they discovered fourteen separate issues that could cause the system to break. Tesla had wanted to deliver the Roadster in November 2007, but the transmission issues lingered, and by the time January 1, 2008, rolled around, the company had to once again start from scratch, on a third transmission push. Tesla also faced issues abroad. The company had decided to send a team of its youngest, most energetic engineers to Thailand to set up a battery factory. Tesla partnered with an enthusiastic although not totally capable manufacturing partner. The Tesla engineers had been told that they could fly over and manage the construction of a state-of-the-art battery factory. Instead of a factory, they found a concrete slab with posts holding up a roof. The building was about a three-hour drive south from Bangkok, and had been left mostly open like many of the other factories because of the incredible heat. The other manufacturing operations dealt with making stoves, tires, and commodities that could withstand the elements. Tesla had sensitive batteries and electronics, and like parts of the Falcon 1, they’d be chewed up by the salty, humid conditions. Eventually, Tesla’s partner paid about $75,000 to put in drywall, coat the floor, and create storage rooms with temperature controls. Tesla’s engineers ended up working maddening hours trying to train the Thai workers on how to handle the electronics properly. The development of the battery technology, which had once moved along at a rapid pace, slowed to a crawl. The battery factory was one part of a supply chain that stretched across the globe, adding cost and delays to the Roadster production. Body panels for the car were to be made in France, while the motors were to come from Taiwan. Tesla planned on buying battery cells in China and shipping them to Thailand to turn the piece parts into battery packs. The battery packs, which had to be stored for a minimal amount of time to avoid degradation, would then be taken to port and shipped to England, where they needed to clear customs. Tesla then planned for Lotus to build the body of the car, attachPDF Image | SpaceX and the Quest
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