Race cars made in NZ

Craig Greenwood is one of the best examples of someone who turned his passion into a business. He is also one of New Zealand’s most prolific racing car builders. Craig got into motor racing in the early 1990s, progressing from competitive cart racing to Formula Vee (now Formula First). The class is based on a 1200 cc VW motor and uses a collection of stock parts to form a competitive car from the engine, transmission, front suspension, brakes and wheels built into a space frame. The body is fibreglass or carbon fibre. It’s a racing class that allows an enthusiast to build and maintain his own car. Craig bought his first car but soon decided to build his own, working nights and weekends in a cramped single garage with little more than an oxy-acetylene welder, a hacksaw and a hand-held drill. “I wasn’t all that successful at first. Of 18 starts I made, I only finished four,” says Craig. “I realised that just knowing how to weld a chassis wasn’t enough, so I started to read about designing and building race cars.”

From racing to making, Craig Greenwood has met the challenge
By Jude Woodside
Photographs:
Jude Woodside

Craig Greenwood, Formula Challenge designer-builder

Craig Greenwood is one of the best examples of someone who turned his passion into a business. He is also one of New Zealand’s most prolific racing car builders.
Craig got into motor racing in the early 1990s, progressing from competitive kart racing to Formula Vee (now Formula First). The class is based on a 1200 cc VW motor and uses a collection of stock parts to form a competitive car from the engine, transmission, front suspension, brakes and wheels built into a space frame.
The body is fibreglass or carbon fibre. It’s a racing class that allows an enthusiast to build and maintain their own car. Craig bought his first car but soon decided to build his own, working nights and weekends in a cramped single garage with little more than an oxy-acetylene welder, a hacksaw and a hand-held drill.
“I wasn’t all that successful at first. Of 18 starts I made, I only finished four,” says Craig.
“I realised that just knowing how to weld a chassis wasn’t enough, so I started to read about designing and building race cars.”

The cars are driven via chain drive. This is similar to the locked diff common on race cars but allows for a very efficient transfer of power and less weight

Competitive
The cars got better, and he started becoming competitive. He realised it was more productive to build multiple cars and race them as a team. By 1993, with three cars, Greenwood started a scholarship system to find other drivers for his team. He was by now becoming competitive in the class. Before long, he had a team of six and was one of the biggest racing teams in the competition.
Craig went on to win the New Zealand Formula Vee Championship in 1997, and his team won in 1998 and 1999. Craig has built 23 Formula Firsts and developed a reputation for building quick and reliable cars, most of which are still racing.
By 1999, Craig had come up with a new design. Based on the Formula First series and with the knowledge earned from running his own team, he knew the drawbacks in the current design.

The space frame body of a Formula Challenge designed by Greenwood

Motorcycle engine
“I realised I could build a car from a space frame and a motorcycle engine. I wanted to make it simple. The car needed to have easy access to replace or work on the motor, it needed to have easily replaceable parts, and above all, it needed to look and sound like a racing car. So we designed the body to look like a ’99 Ferrari.”
Craig wanted to go beyond simply owning the team, he started a new series—Formula Challenge. With that, he also pioneered the “arrive-and-drive” concept, where drivers could lease cars or simply rent the car for the race. All the cars were set up to be identical; the only variable should be the skill of the driver. This was intended to be a driver’s championship. He also ran a scholarship program to encourage new talent.
By 2002, the series had won recognition on TV with a winter series. The series ran to 2005.
Formula Challenge Racing now concentrates on providing individuals with the thrill of piloting a car that looks, sounds and handles like the real thing. It has a base at Taupo raceway but is also available at Hampton Downs and now at Rua Puna. They run 12 open-wheeler Formula Challenge cars and nine Vs, both Ford and Holden, to cater to all tastes.
The Challenge car has changed little; the power plant is a Suzuki GSXR 1100 cc motorcycle engine. The car sports wings, spoilers and a demountable nose section which has a safety element. In any impact, the nose section helps to absorb damage without distorting the chassis or suspension.
The suspension is hard in typical race-car style, and the steering is positive and responsive. The sequential five-speed gearbox is controlled with two buttons on a demountable steering wheel.
The car generates an impressive 150 brake horsepower with a top speed of 230 km/h. It is capable of 0-100 km/h in 3.8 secs. It can generate a force of nearly 2Gs on corners, and at a maximum of only 40 mm off the ground, the driver has a sense that the speed is electrifying.
Before heading off for a few laps, drivers see a video of a track drive. The cars are linked to a datalogger so the team can analyse each lap with the drivers to highlight good and bad practices to help drivers fine tune their skills.

Formula Challenge garage

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The Shed magazine August/September 2025 issue 122 on sale now

Keep on rolling
Growing up near a railway station sparked Greville Wills’ lifelong love for trains. Throughout his working career, he has experienced a diverse range of jobs. Today, he identifies as an old-school tinkerer, a model engineering enthusiast, and a “Mr. Fix-it.”
Space is definitely at a premium in Greville Wills’ garage workshop. On first look, the visual jumble of tools, projects, ornaments, neons, and former business equipment is confounding. Yet despite the wriggle room between the maze of workstations, there is an underlying order.
Greville is an old-school tinkerer, model engineering enthusiast, and a Mr. Fix-It to his neighbours. He always knew the space here was going to be tight, so before he moved in, he pre-measured and drew a plan for everything from machine placement to car park spaces, factoring in ergonomics and power supply locations to make certain everything would fit and work efficiently.
He is adamant that the layout suits his needs and says, “When I’m making things, everything is here. It is a single person’s workshop, where I can do most things. If assembling or constructing something of size, I just push the cars out to use that space temporarily.”

It’s good to be square

We need a range of squares to use for the many different situations we encounter in the workshop. For instance, we need a square to set up our machines – it is vital that your saw bench cuts square when you want it to. The blade obviously needs to be at right angles to the table and the sliding table or sledge needs to be square. The same for your planer.
The fence should be set square and you should regularly check that it remains square. Imagine the consequences of spending considerable time cutting mortise and tenon joints for fine furniture only to find they fit poorly due to the machined timber not being square. Errors also tend to compound over a project.

Build an Almost Ready to Fly Warhawk

Then there is the relatively new kid on the block: the ARF (Almost Ready to Fly) model.
These come all packaged up in a huge box, beautifully built and packed, with all the hardware. But you do need to assemble them which can take up to a week. It isn’t quite ‘instant plane’ but it does provide some building satisfaction and a sense of achievement, albeit a rather shallow one, a bit like a healthy walk down to the bakery to buy a pie or taking Viagra.
To the supplied kit, you need to add various glues, an engine and electrical components (servos, relays, wires) to operate elevator, rudder, ailerons, throttle, flaps, undercarriage etc. The engine these days could be glow plug, 4-stroke or 2-stroke, electric or petrol.
This part of the hobby is now huge and the range and quality of products is astounding. ARF aircraft kits are readily available from many hobby shops and certainly online from within New Zealand and from lands far away.