Our second day in Brazil started in carburetor factory Brosol….

Right at the assembly lines! Up to 400 different parts goes into one carburetor!

Quality control does matter for a carburetor production process! Every single carburetor is vacuum AND fluid tested even in different airflow and even in different gears!!

The testing lady works 43 years in this factory!

Busy assembly lines, produce up to 3000 carburetors a month!!

Mandatory picture…

Walter, the man who’s right from me in the picture, is the plant engineer and work 55(!) years for this factory, he’s the walking carburetor encyclopedia!

Next….We visited the push rod tube manufacturer, first we stick a BBT sticker to the owner, Mr Wilson, his Fusca…

The main machine in the production of push rod tubes… every 6 seconds a push rod comes out!

I can operate a machine like that…. LOL!

Final pressing…

….and liquid pressure test of every of our push rods!

This company makes also a lot of pulleys etc… excentre stamp presses enough… oh yes they’re still my favourite machinery!

The original VW blueprint is still the holy bible for the production!

The cut away gives us the right views of the inner structure… what can be improved???

Next we go to a factory specialised in Alu and Zinc Alloy pressure injection… very wide product range… as long as its aluminum or zinc alloy…:)

This is NOT soup! This is liquid aluminum!!

Enough half products and castings to fill an entire warehouse!!

Main reason for this visit was our production of ignition steering locks, for split window bus and for beetle… we getting close! Two more internal parts to develop and we can start assembly process development…

This will be a BBT exclusive product!

Ok lunch!! Let’s get some Brazilian BBQ…. what called Churascaria… ever heard of Picanha? It’s the best beef money can buy!

Up to the next factory… we lined up behind this cool Vw model we don’t have in Europe…

This factory makes our window winder mechanisms… bullet proof and super solid! A couple of euro’s more expensive as the Chinese crap on the market.

We follow these for years and don’t get returns at all! The BBT window regulators do work like they supposed to do… hope You buy them already?

we came here to understand the production process and for sure we’re impressed by the incredible nice organised production process!

They even have their own zinc facilities!

Assembly was well thought out and again very well organised with a very good lay out… Up to 6000(!) window regulators a day, very impressive!

Every window regulator is fully tested on its own!

Last factory make BBT bumper brackets, unfortunately no pictures allowed. sorry…:(

Tomorrow we see more productions, so stay tuned! we’re not home yet!

Where does the big KLM bird fly us this time???

Direction Sao Paolo Brazil, for another factory tour of suppliers, part of our purchase manager overseas (Jerry) training program….

Impressive skyline for sure…:)

oh, Jerry found already what’s important…:)

me too… Brazil is a country for meat lovers, let’s start at lunch…:)

First supplier lunch, hospitality here is second to none!!

and yes… they do have APE here too…:)

Fusca’s everywhere… Fusca is the local Brazilian “nickname” for the beetle… and yes, there’s still plenty on the road here!

ok, let’s get to work here… first factory was a steering box and all steering box components manufacturer… Now TRW is bought by ZF we face difficulties in supply, to have an alternative right in your back pocket is not an extra ordinary luxury thing in this situation…

We start at the casting and raw material warehouse…

To continu in the production… we’re very satisfied what we see! the factory came a LOOOOOONG way since our last visit here in 2009!

Lots of CNC machines to choose from…:)

Motivated people, even here in the packing division!

Lots of special machines… Gonzo, this one You have to know!

And finally the assembly…. a lot of skilled craftsmen that really know what they do… high quality for sure!

Oh and they make steering boxes for the old Brazilian kombi, as far as we know every Kombi imported from Brazil in Europe for sure need one of those!!

And finally these lovely girls will make sure all our paperwork will be going smooth!

Second we visit a factory that make small locks, handles, catches,  receivers etc… small parts and a lot like key barrels etc mainly in zinc alloy… impressive machinery!

and a LOT of tooling!

This is how Zinc Alloy comes out of the form after being injected and cooled down!…

Cleaning of the moulds for the next process!

Very impressive machinery…

Do you recognise this part???

He Mauci, where you think you’re going????

Thanks for bringing us here buddy!

The most enthusiast sales team of them all??

Jerry checking on samples…

Ok day one is over, tomorrow we see more… now first we have to find a hotel! Seems we don’t have a reservation yet!

Today BBT will have no product update because of various reasons…

But….The imens growing quantities of sheetmetal we receive now with our growing sheetmetal line forced us for extra shelves… Danny and Tim from good in dept worked hi and low this week to get a new shelf ready for future deliveries!

We wanted to share some pictures…