In a time when most manufacturing plants utilize hundreds of state-of-the-art robots to assemble vehicles, a unique plant in Detroit is producing hand-built performance vehicles.

At the Conner Avenue Assembly Plant, workers hand-build the new Dodge Viper SRT10 and all-new 600-horsepower 8.4-liter SRT V-10 engine. Utilizing 26 work stations on a 705-foot-long assembly line, 48 hand-picked UAW workers assemble each vehicle. Each vehicle remains stationary for up to 49 minutes per work area as the craft people make any necessary adjustments. This process eliminates traditional repair stations with all procedures verified by team members.

Each Dodge Viper is primarily made of seven component modules (instrument panel, fuel tank, suspension corner modules, wheels and tires, cooling module, lift gate assembly and full dressed engine). With the exception of the engine, all modules are shipped to the Conner facility from other locations. Stamping, casting and welding all take place off-site with body panels arriving already painted.

In a process normally performed only on race cars, an alignment machine sets caster and camber at normal ride height, at jounce and at rebound (upward and downward travel of suspension). Typical factory alignments set caster and camber in the normal ride height position only. The 2008 Dodge Viper SRT10 is the only U.S. production vehicle set up for such alignment at the factory.

“Our assembly process is just as exceptional as the car,” said Melissa Holobach, Plant Manager – Conner Avenue Assembly Plant, Sterling Heights Vehicle Test Center (SHVTC) and Pilot Operations. “The process of building these vehicles by hand has allowed us the freedom to produce race-inspired performance without the constraints of mass production,” Holobach said. “Our workforce is committed to producing the best vehicles possible and it shows in their commitment to detail.”

The all-new 600-horsepower 8.4-liter SRT V-10 engine is built next to the vehicle on a 24-station circular line by nine Craftspersons. These nine workers assemble and certify each engine before they are installed in the chassis.

Each Dodge Viper is tested in place on the assembly line utilizing special rollers. At this stage the vehicle is a rolling chassis without its body panels. During this “roll test” it is driven through all six speeds of the transmission, up to 90 mph to verify vehicle function.

Since its introduction as a concept car at the 1989 North American International Auto Show in Detroit, the Dodge Viper has captured the hearts and imagination of enthusiasts around the world. The 2008 Dodge Viper SRT10 is offered in both Roadster and Coupe versions. With its dramatic styling and 600 horsepower, the 2008 Dodge Viper SRT10 is the ultimate American sports car.

With 600 horsepower – 90 more than before, and 0-to-60 performance in less than four seconds, the 2008 Dodge Viper SRT10 sets a new benchmark for the ultimate American sports car.

The new 2008 Dodge Viper SRT10 will arrive in Dodge showrooms in North America this fall with a new level of customization options, including five new exterior colors, four new interior color combinations and a new wheel design.

Old material from 2003

In 2003, a plant worker told us that Viper staffing has been reduced, and there has been sizable turnover in the upper reaches of plant management. More troubling are changes in plant management and what appears to be condescending treatment of the skilled craftsmen who build Vipers (and who used to build Prowlers).

A factory worker sent us copies of several plant announcements which fundamentally change the way Vipers have been built since their introduction over ten years ago. Originally, they were made by craftsmen who controlled the line, which did not move until each person had done their job. This ranged between an hour at most, 37 minutes at present - the shortest time so far. Now, the line moves automatically, unless a stop button is pressed - and people have been advised not to press the button. This might sound reasonable, but the Viper is not a full production car; the parts are at a prototype level of fit, with holes sometimes containing flash, brackets sometimes not bent correctly, and formed parts sometimes needing to be tweaked.

Management has benchmarked the Corvette and other vehicles and is trying to build a car with prototype level parts but production-car times; despite the fact that the Corvette is built as a production car, with much higher volumes. With the Viper no longer being emphasized as an image builder (perhaps because it hasn't any Mercedes parts), workers seem to believe that, if the Viper does not earn a substantial profit, it will be pulled.

The memos are interesting at least as much for their tone as for their content. Note that in the 9/16 memo, the new manager - who didn't officially start until 9/18 - complains about employees eating, sleeping, etc. during work hours. An employee called this "ridiculous and insulting." The Viper plant has only about one hundred people - once considered the best Chrysler craftpeople. This behavior would be hard to get away with, and unlikely to begin with. Ms Williams came from Toyota, which is normally seen as having more respect forits workers.

Operations have reportedly shut down due to lack of parts on many occasions, though breakeven is at 12 cars per day and average is about 11 per day. Management's stated goal is to produce 13 per day.

oh20 reported that the 2008 Viper Coupe and Convertible both averaged over 200 mph around the Transportation Research Center’s 7.5 mile oval test track in Ohio. The convertible even averaged 197 mph with the top down. Both have similar drag (aerodynamic) numbers, according to representatives of the SRT team.

SRT powertrain engineers had to not only increase performance, but also comply with regulatory requirements such as federal Tier 2, Bin 5 and California’s Low Emissions Vehicle (LEV) 2 mandates. Working with specialists from McLaren Performance Technologies and Ricardo, Inc., SRT engineers began by following the racer’s basic formula for more power: bigger displacement, more efficient breathing and higher engine speed.

The new Dodge Viper SRT10’s deep-skirted V-10 aluminum engine block was bored out 1 mm, raising the displacement to 8.4 liters from 8.3 liters. With strengthened bulkheads and improved water jackets for better cooling, the block includes pressed-in iron cylinder liners and cross-bolted main bearing caps for strength and durability.

Horsepower didn't come only from the engine, the use of a plastic hood allowed engineers to increase the airflow through the hood scoop; openings along each side are not just for show, but to circulate air within the engine compartment, to keep power going with a warm engine. It also lowered weight and helped keep the Viper costs down. Other body panels are also plastic, and carbon fiber is used for some structural parts to keep weight down.

The Viper SRT10’s 8.4-liter engine breathes through new cylinder heads equipped with Computer Numerically Controlled (CNC)-shaped combustion chambers, larger valves and Variable Valve Timing (VVT). VVT electronically adjusts when the exhaust valves are open and closed according to engine speed and load, allowing the engine to “breathe” cleaner and more efficiently.

The 2008 Dodge Viper SRT10 V-10’s two-piece intake manifold combines a cast aluminum lower with smooth runners for better air flow, bolted to a die-cast aluminum upper plenum. A revised air-cleaner box with a low-restriction filter sends air through a dual electronic throttle control into the intake module.

The air-fuel mixture is ignited by platinum-tip spark plugs fired by individual plug coils mounted on the cylinder-head covers. The pistons themselves are equipped with larger-diameter floating pins with bronze bushings for higher loads. Forged powder-metal connecting rods are secured with aircraft-quality fasteners for increased fatigue strength.

Engine lubrication is managed by a larger oil pump and a swinging oil pickup adapted from Viper competition engines, to improve oil pressure in high-rpm and hard-cornering conditions.

Spent gases exit through tubular air-gap headers, which improve exhaust flow and ensure quick catalyst light-off. The headers’ stamped stainless-steel outer shell acts as a thermal heat shield for the individual stainless-steel runners that contribute to better flow separation and exhaust tuning.

The 2008 Dodge Viper SRT10’s V-10 channels its power through a new, smaller-diameter, twin-disc clutch (a change from the larger-diameter, single-disc setup). The new clutch reduces rotating inertia by 18 percent, resulting in reduced clutch-pedal effort and improved engagement feel.

The TR6060 transmission is the latest evolution of the Tremec T56 six-speed manual. It features 10% wider gears for higher torque capacity, and a new synchronizer package. A new shifter system results in reduced shifter travel. There is also now a provision for adding an external transmission cooler.

2008 Viper braking, ride, and handling

14-inch brake rotors are gripped by Brembo 44/40 dual opposing piston calipers in the front and by Brembo 42/38 dual opposing calipers in the rear. Anti-lock braking (ABS) prevents lockup during hard braking. This system results in a benchmark braking performance of 60-to-0 mph in less than 100 feet.

   

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The ride and handling of the 2008 Dodge Viper SRT10 is defined by a race-bred, fully independent, four-wheel suspension featuring lightweight, high-performance aluminum control arms and knuckles, damped by lightweight coil-over shock absorbers. SRT engineers retained the tried-and-true Dana M44-4 rear axle and outfitted it with a new GKN Visco-Lok speed-sensing limited-slip differential for improved traction.

The Dodge Viper SRT10 rides on polished, forged aluminum, 18 x 10-inch front and 19 x 13-inch rear wheels now available in three styles: the five-spoke, the H-spoke and the all-new Razor wheel with five U-shaped spokes. The wheels are clad in Michelin® Pilot® Sport PS2 tires. The four-groove tread-design tires provide maximum grip, reduced road noise and superior handling in both wet and dry conditions.

2008-2010 Dodge Viper styling and bodies

The new 2008 Dodge Viper SRT10 will arrive in North America this summer with four new interior color combinations, and a new wheel design. Buyers can now choose the bezel finishes on the center instrument panel and console.

The 2008 Dodge Viper SRT10 is still available in Roadster and Coupe forms. Both feature a new hood with a larger, more efficient hood scoop for air induction and larger, functional hood louvers to cool the 600-horsepower V-10 engine underneath.

Eight exterior colors will be introduced throughout the model year – five of which are new - including Venom Red, Snakeskin Green, Viper Violet, Viper Orange and Bright Blue. Racing stripes continue to be an option with six dual painted stripe colors available: white, black, silver, graphite, blue and red.

In fact, the only body panels shared by the two Vipers are front fascia and fenders, hood and doors. However, the iconic Viper SRT10 design cues have been maintained, including the crosshair grille, deep-cut side scallops, swept-back fenders, and lowered hood lines.

The Dodge Viper SRT10 Coupe’s hard top with its “double bubble” styling makes it more torsionally stiff than the Roadster; it has increased downforce and high-speed stability with its sloping roofline and deck-lid spoiler, as well as an additional 6.25 cubic feet of trunk space than the Viper SRT10 Roadster, for a total of 14.65 cubic feet. The roof and headliner structure offer more room to accommodate a safety cage, while maintaining as much headroom as possible.

The 2008 Dodge Viper SRT10 Roadster and Coupe cockpit retains its characteristic red push-button starter and performance-oriented, functional instrument panel with center-mounted tachometer and 220-mph speedometer.

The 2008 Dodge Viper SRT10 will be hand-built at the Conner Avenue Assembly Plant in Detroit.

2008-2010 Dodge Viper SRT10 Safety and Security

The following safety and security technologies are featured on the 2008 Dodge Viper SRT10:

• Adjustable Pedals
• Advanced Multistage Front Air Bags with Occupant Classification System (OCS): Inflates with a force appropriate to the severity of the impact. The OCS measures the conditions for activation or deactivation of the passenger side front air bag based upon the weight of the occupant
• Anti-lock Brake System (ABS)
• BeltAlert: Periodically activates a chime and illuminates an icon in the instrument cluster to remind the driver and front passenger to buckle up if a vehicle is driven without the driver being properly belted
• Center High-mounted Stop Lamp (CHMSL): The shelf-mounted center high mounted stop lamp uses light emitting diodes (LEDs) for longer life Constant Force Retractors (CFR): Distribute force or load exerted on a seat belt, and then gradually release the seat belt webbing in a controlled manner
• Crumple Zones: Designed to compress during an accident to absorb energy, decreasing transfer of that energy to the occupants
• Energy-absorbing Steering Column: The manual-adjust steering column uses two hydroformed coaxial tubes that can move relative to each other to allow the column to move forward for enhanced energy absorption during a crash. The power-adjust steering column employs a calibrated bending element that deforms during column stroke for optimal energy management
• Interior Head-impact Protection: Interior pillars above the beltline and instrument panel – including areas around windshield and rear window headers, roof and side rail structures, and shoulder-belt turning loops – specifically designed to limit head-impact force
• Knee Bolsters: The lower instrument panel and the glove-box door are designed to properly position the occupant, enabling the air bags to work effectively
• Remote Keyless Entry (RKE)
• Tire-pressure Monitoring (TPM): Pressure-sensor modules within the valve stems of all four wheels send continuous radio-frequency signals to a receiver, and the system informs occupants when the pressure is too low

  
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2008-2010 Dodge Viper SRT-10 Performance & Standard Features

2008 Dodge Viper Handling, Ride & Braking Standard Features
- Four-wheel ABS
- Four disc brakes including four ventilated discs
- Immobilizer
- Rear limited slip differential
- Wishbone front and rear suspension independent with stabilizer bar and coil springs

2008 Dodge Viper Exterior & Aerodynamics Standard Features
- Body color front and rear bumpers
- Fixed hoop convertible rollover protection
- Manual softtop convertible roof with glass rear window
- Driver and passenger power body color door mirrors
- External dimensions: overall length (inches): 175.6, overall width (inches): 75.2, overall height (inches): 47.6, wheelbase (inches): 98.8, front track (inches): 61.6, rear track (inches): 60.9 and curb to curb turning circle (feet): 40.5
- Front fog lights
- Projector beam lens Bi-Xenon headlights
- Luxury trim alloy & leather on gear knob
- Black paint
- Fixed rear window with defogger
- Tinted glass on cabin
- Weights: curb weight (lbs) 3,440
- Windshield wipers with variable intermittent wipe

2008 Dodge Viper Interior Standard Features
- 12v power outlet: front and 1
- Air conditioning
- Element antenna
- Peripheral anti-theft protection
- Front ashtray
- RDS audio system with AM/FM, Disc Autochanger and six-disc remote changer
- Cargo capacity: all seats in place (cu ft): 8.4
- Front seats cigar lighter
- Clock
- Full dashboard console, full floor console with covered storage box
- Courtesy lights
- Door ajar warning
- Driver front airbag with multi-stage deployment, passenger front airbag with occupant sensors and multi-stage deployment
- Sports driver and passenger seat
- 3-point reel front seat belts on driver seat and passenger seat with pre-tensioners
- Front seat center armrest
- Two head restraints on front seats
- Headlight control with time delay switch-off
- Height adjustable pedals
- Illuminated entry system
- Internal dimensions: front headroom (inches): 36.5, front leg room (inches): 42.4 and front shoulder room (inches): 54.1
- Low tire pressure indicator
- Remote power locks
- Power steering
- Front power windows with two one-touch
- Front reading lights
- Rear view mirror
- Remote control remote trunk/hatch release
- Suede seat upholstery with additional leather
- Seating: two seats
- Seven speaker(s)
- Leather covered steering wheel with tilt adjustment
- Tachometer
- Ventilation system

    
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2008  Dodge Viper ACR
   

   

2008 VIPER SRT-10
By color scheme:

2009 VIPER SRT-10
Production Break down by color scheme:

Only 500 to be built including

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