Dan McKenzie, Director, Carbonwurks, with one of the company's development cars, a BMW M4 G82, featuring some of the best carbon fibre products from Carbonwurks and other manufacturers. Picture: Dorset Biz News.
Published: January 20, 2023 | Updated: 21st January 2023
Former racing driver Dan McKenzie has first-hand experience of the astonishing qualities of carbon fibre.
Because it’s literally helped save his life.
The 34-year-old said: “My passion for carbon fibre stems back nearly 20 years having raced in Formula 3, Formula 2, Renault World Series 3.5 and putting my life in the hands of the carbon fibre monocoque that I sat in.
“After being involved in a few pretty hefty shunts at over 150mph, I was amazed at how carbon fibre could take such an impact and leave me able to jump out of the car and carry on with the rest of my day.
“Since my continual involvement in motorsport, and spending so much time around carbon fibre, I have become almost obsessed with the stuff.”
In 2009, the former student at Bournemouth School for Boys was the British Formula 3 national class champion.
Around the same time he started what was to become Carbonwurks.
Dan said: “I was still focusing on motorsport racing but thought I’d like to start a sideline business.
“It began with a laptop and a bit of space in the garage, developing a few carbon fibre parts.
“I had to learn everything.
“Carbon fibre was becoming increasingly popular in road cars but there weren’t many high-quality after-market options.
“You either had to pay the full manufacturer’s price or go for some very cheap and nasty stuff.
“I wanted to create products that were made for the road, however to the highest possible standards.”
Fast forward to 2023 and Carbonwurks, based on the Abbey Business Park at Holton Heath, ships out around 3,000 individual orders a year to every country imaginable.
In total it produces and sells between 5,000 and 6,000 individual parts.
The business, which has a seven-strong team including four full-time employees, also repairs carbon fibre products and offers performance tuning parts, bodyshop facilities, engine remapping, vinyl wrapping as well as garage services.
All of the parts on offer have either been tried or tested on one of Carbonwurks’ development vehicles.
Dan said: “We do all the repair work here as well as bespoke parts and some low run manufacturing parts produced to our design specifications.
“We have lots of competitors but, to the best of our knowledge, there are none that make in-house, repair in-house and can install.
“We do all kinds of weird, wonderful and random stuff including boat and bike panels.”
Previously operating at three separate locations, Carbonwurks moved to its present 2,500 sq ft site last year.
A five-figure sum was spent on refurbishing the building including two custom-built fabrication rooms at the back of the workshop for carbon fibre repair and skinning.
In 2022, the company also received Made in Britain accreditation and took on Tim Borrill as Operations & Marketing Manager.
Other members of the team include Dan’s mum, Steph, who looks after the accounts while dad Iain and brother-in-law Rob McKenzie-Watkins are fellow directors.
Dan said: “From my earliest memories I wanted to do everything as quickly as I could.
“I wanted to go fast whether that was on a bike, skateboard or a race to climb to the top of the tree.
“I was offered a Formula 1 contract but the money barrier [drivers have to find millions of pounds from investors or sponsors] was too high. It still stings a little.
“It’s taken a long time to get to where we are today.
“I am proud of what we’ve achieved but we’ve got a great bunch of staff. They’re all fantastic at what they do.
“Over the next five years we would like to expand on our products and services we currently offer along with both car detailing and PPF (paint protection film).
“Beyond that, we would like to have a dedicated part of the company dealing with high end/supercar servicing along with car restorations.
“This will lead us into our end goal which is to build up our motorsports services and establish a race team in the future.
“Getting back to our roots in the motorsports industry again is my dream.”
But Dan can still indulge his passion for speed.
As a full member of the British Racing Drivers’ Club, which is by invitation only, he has access to Silverstone.
He said: “We’re able to stress test parts on cars at speeds of up to 200 miles per hour.
“It’s a definite perk of the job.”
