Factory Tour Thread

Ok people. I may be in London in a couple of weeks (traveling from Us). I wan to try and schedule a tour. How do I get to Hethel from London? How much walking and how much standing is involved? I'm nursing a knee injury so want to plan ahead.

I flew into Luton and rented a car. 2 hour drive. #forthedrivers, right?
 
Here’s a brief write up from my factory visit on 3rd May.

Our guide Nick was excellent, showing us numerous parts of the process in great detail. We saw cars and panels in all FE colours, plus vivid red and white. Much has been said on the paint colours and complexity. My take away was that the overall finish is very good and of a high quality, but not some amazing new layered effect. Most of the benefit is the ability to remove the errors of hand paining with the very latest automated spray nozzle in only a few steps. Attracting the paint to an electrically charged primer is key to this process. Clever stuff for composite panels. Panels are all painted away from the car on a wire jig and added once the tub has the bulkheads and roof glued on, before being placed on the automated trolley.

Front and rear assemblies are built separately, with hvac etc up front and engine/brakes/discs etc. on rear. Boxes of brake components from J.Juan piled up.. Subframe is already bespoke, with tour or sports and labeled with the finished colour. Certainly no room for a front storage space. Note: Once the bonnet is added, it’s bolted down, but still hinged along the front edge. Engines from Toyota get a load of parts removed, including the flywheel. The starter has to be relocated, so again plenty of work to fit into the steel subframe (aluminium on i4). Gearbox comes from a diesel avensis, I believe, due to being stronger to cope with the 400+ torque. I think they also change gears 2,3,4,5 to better match the V6 delivery. A fairly large hole is drilled into the gearbox housing to allow for oil cooling (again not standard).

Aluminium tubs come from another Lotus Norwich factory (Lotus Structures?) and they then add mounts, wiring, tank, cooling pipes etc. This is the only time tubs are worked on on their side. They then move to a robot section to apply glue for firewall bulkheads, roof rails and roof. Makes me think how easy it would be to alter the design of a solid roof to a removable panel etc. The current tubs were being put through as MT stage (machine tooling verification).

@freefall_junkie already mentioned the impressive in-house seat assembly process onto the Ferrari Lear frame with leather coming from The Bridge of Wier factory. Certainly very bespoke to Lotus and great looking. Red is very bright red (not rich), tan is toffee, ice looked light white grey through the car window. Finish is matt not gloss.

Each of the 40+ stations has 17 minutes to complete their task and scattered between them are at least 3 quality stations. Something Lotus hasn’t had before. At the end of the line the cars are setup for geometry then rolling road tested to 60mph. Outside is a brand new rattle test track, which every car gets taken around. Possibly 4 rows of 20m long.

Bonus elements included; Meeting Mark, another forum member! The sun was out and shinning on Magma, Seneca and White models. Seeing the white GT4 car being thrashed around the track, sitting in and revving a PP Seneca V6, a pair of racing Esprits in reception, hearing about the EV program especially the Hetel built Evija 😍
 
Here’s a brief write up from my factory visit on 3rd May.

Our guide Nick was excellent, showing us numerous parts of the process in great detail. We saw cars and panels in all FE colours, plus vivid red and white. Much has been said on the paint colours and complexity. My take away was that the overall finish is very good and of a high quality, but not some amazing new layered effect. Most of the benefit is the ability to remove the errors of hand paining with the very latest automated spray nozzle in only a few steps. Attracting the paint to an electrically charged primer is key to this process. Clever stuff for composite panels. Panels are all painted away from the car on a wire jig and added once the tub has the bulkheads and roof glued on, before being placed on the automated trolley.

Front and rear assemblies are built separately, with hvac etc up front and engine/brakes/discs etc. on rear. Boxes of brake components from J.Juan piled up.. Subframe is already bespoke, with tour or sports and labeled with the finished colour. Certainly no room for a front storage space. Note: Once the bonnet is added, it’s bolted down, but still hinged along the front edge. Engines from Toyota get a load of parts removed, including the flywheel. The starter has to be relocated, so again plenty of work to fit into the steel subframe (aluminium on i4). Gearbox comes from a diesel avensis, I believe, due to being stronger to cope with the 400+ torque. I think they also change gears 2,3,4,5 to better match the V6 delivery. A fairly large hole is drilled into the gearbox housing to allow for oil cooling (again not standard).

Aluminium tubs come from another Lotus Norwich factory (Lotus Structures?) and they then add mounts, wiring, tank, cooling pipes etc. This is the only time tubs are worked on on their side. They then move to a robot section to apply glue for firewall bulkheads, roof rails and roof. Makes me think how easy it would be to alter the design of a solid roof to a removable panel etc. The current tubs were being put through as MT stage (machine tooling verification).

@freefall_junkie already mentioned the impressive in-house seat assembly process onto the Ferrari Lear frame with leather coming from The Bridge of Wier factory. Certainly very bespoke to Lotus and great looking. Red is very bright red (not rich), tan is toffee, ice looked light white grey through the car window. Finish is matt not gloss.

Each of the 40+ stations has 17 minutes to complete their task and scattered between them are at least 3 quality stations. Something Lotus hasn’t had before. At the end of the line the cars are setup for geometry then rolling road tested to 60mph. Outside is a brand new rattle test track, which every car gets taken around. Possibly 4 rows of 20m long.

Bonus elements included; Meeting Mark, another forum member! The sun was out and shinning on Magma, Seneca and White models. Seeing the white GT4 car being thrashed around the track, sitting in and revving a PP Seneca V6, a pair of racing Esprits in reception, hearing about the EV program especially the Hetel built Evija 😍
Thank you. Really appreciate you sharing your experience with us. Any comments on how Magma and Seneca looked under the sun?
 
Here’s a brief write up from my factory visit on 3rd May.

...Much has been said on the paint colours and complexity. My take away was that the overall finish is very good and of a high quality, but not some amazing new layered effect. ...
Since I believe I was the only one saying anything about paint complexity, obviously it was important to you to say that. Feel better now?

There is a base/primer layer, a color layer that may include the metallics, but usually it's separate, then a metallic with tint layer is more typical, then clear on top of that. That's a minimum of 3, and probably 4 layers. That's called multi-layer. They're doing this all in a single pass, correct? That's the benefit of their new system, to be able to achieve a high-quality multi-layer paint job in one pass. That speeds up moving panels through the painting process, and from the looks of it, appears to give a premium look and finish which I personally think is amazing for a fairly rapid one-pass process.

Have you ever had a car custom painted? I have, and it is NOT a quick one-pass process. For their new paint system to be able to do that in one-pass, with a variable nozzle spray pattern on the fly for paint efficiency... that's impressive. At least I think so. That's new for Lotus, and I for one think it's amazing. If you don't feel that way about it, that's up to you.

It's going to be interesting to see what Lotus is going to charge for these FE colors as options. Acura charged $6,000 for their multi-layer special paint job. Alfa Romeo charged $2,500 for their special tri-color red. Porsche is charging (if I remember right) about $3,700 for their version of Seneca. If Lotus keeps theirs down around $1,200-$1,500 due to the efficiency of their new system, that will be an advantage. Just like the car looks more expensive than it is, the paint job would look more expensive than what others are charging for that quality of a look.
 
Thank you. Really appreciate you sharing your experience with us. Any comments on how Magma and Seneca looked under the sun?
I was lucky enough to see both colours outside and in a parking spot side-by-side indoors. Together they looked amazing. Magma indoors next to Seneca looked like the Forza render - quite a dark red and lots of reflections. Yellow badge contrasts nicely. Outside the Magma was a slight disappointment for me and not popping as much as expected. Gold fleck not enough for me. Seneca, although familiar, looks solid blue from afar but with the sun on edges you can see the paint sparkle. Both are winners but switched from red to blue in my build. I’d love to share some pics, but not allowed…
 
Since I believe I was the only one saying anything about paint complexity, obviously it was important to you to say that. Feel better now?

There is a base/primer layer, a color layer that may include the metallics, but usually it's separate, then a metallic with tint layer is more typical, then clear on top of that. That's a minimum of 3, and probably 4 layers. That's called multi-layer. They're doing this all in a single pass, correct? That's the benefit of their new system, to be able to achieve a high-quality multi-layer paint job in one pass. That speeds up moving panels through the painting process, and from the looks of it, appears to give a premium look and finish which I personally think is amazing for a fairly rapid one-pass process.

Have you ever had a car custom painted? I have, and it is NOT a quick one-pass process. For their new paint system to be able to do that in one-pass, with a variable nozzle spray pattern on the fly for paint efficiency... that's impressive. At least I think so. That's new for Lotus, and I for one think it's amazing. If you don't feel that way about it, that's up to you.

It's going to be interesting to see what Lotus is going to charge for these FE colors as options. Acura charged $6,000 for their multi-layer special paint job. Alfa Romeo charged $2,500 for their special tri-color red. Porsche is charging (if I remember right) about $3,700 for their version of Seneca. If Lotus keeps theirs down around $1,200-$1,500 due to the efficiency of their new system, that will be an advantage. Just like the car looks more expensive than it is, the paint job would look more expensive than what others are charging for that quality of a look.
What did I say to offend? I'm just relaying my findings on the day and opinion. Regarding the single pass, I think Nick said it's multiple steps with some heat baking in between.
 
There is a base/primer layer, a color layer that may include the metallics, but usually it's separate, then a metallic with tint layer is more typical, then clear on top of that. That's a minimum of 3, and probably 4 layers. That's called multi-layer. They're doing this all in a single pass, correct? That's the benefit of their new system, to be able to achieve a high-quality multi-layer paint job in one pass. That speeds up moving panels through the painting process, and from the looks of it, appears to give a premium look and finish which I personally think is amazing for a fairly rapid one-pass process.
Umm, how would you apply three layers of different paints with ‘one pass’? That makes no sense.

Each layer of paint needs to be applied separately through separate nozzles (eg basecoat is usually thicker and needs a larger nozzle with different air pressure), dried in a predefined window of time then onto the next layer - otherwise everything would just bleed together and run.
 
I was lucky enough to see both colours outside and in a parking spot side-by-side indoors. Together they looked amazing. Magma indoors next to Seneca looked like the Forza render - quite a dark red and lots of reflections. Yellow badge contrasts nicely. Outside the Magma was a slight disappointment for me and not popping as much as expected. Gold fleck not enough for me. Seneca, although familiar, looks solid blue from afar but with the sun on edges you can see the paint sparkle. Both are winners but switched from red to blue in my build. I’d love to share some pics, but not allowed…
I'd echo what James says. Magma looks a bit maroon in a low light, but more red in the sun. Very classy with black wheels.

Seneca really, really pops in the sun, and is unusual in that it looks solid until you get up close. It was lighter than I remembered from the roadshow and is certainly a very striking colour. My wife talked me out of Hethel Yellow on the grounds that it is too shouty, but I reckon Seneca is almost as bold.

Honestly I don't think you can go far wrong with any of the FE colours. The car looks stunning in all of them.
 
I would like to know which, if any, of those modifications to the transmission we're done previously on the Evora, or if these are totally new changes?
 
Factory Tour notes 5th May…

Just got home after this morning’s factory tour so thought I’d share my thoughts & observations.

Firstly, a few things that have been noted by others who’ve been on the tour…
  • Nick the tour guide is a superb host
  • You get the feeling that Lotus is a happy & friendly place to work (happy staff=happy cars)
  • Huge focus on quality throughout the build process. Hugely impressive stuff!
Notes on colours…
  • There’s no such thing as a bad/disappointing colour. They all looked great to me & my wife.
  • I got to see magma red, dark verdant, Hethel yellow, Seneca blue outdoors in both full sun & shade.
  • I saw all 6 FE colours indoors under factory lights.
  • Hethel yellow - rich & warm mustard
  • Magma red - deep & opulent cherry
  • Nimbus grey - fluid silvery bronze/beige
  • Shadow grey - dark & sophisticated
  • Seneca blue - lively/electric
  • Dark verdant - simply stunning
Notes on interiors…
  • As noted by others, the quality of finish of all the alcantara & leathers were brilliant. So much better than the show car. You won’t be disappointed.
  • I got to see all interior colour options. Again, like the exterior colour options, they all looked brilliant, particularly the tan leather which really shows off the Kef speakers beautifully.
V6 engine sound…
  • Lovely exotic growl on start up inside the factory
  • I got to hear a few V6 drive by whilst outside. They fill the air with a delightful, visceral rumble.
Now for the best bit…
  • Upon informing Nick (the consummate tour host) that we were still undecided between Magma red, Hethel yellow & dark verdant & needed to finalise our order today, he very kindly got on his phone & called a colleague to ask if he could swing by to give us all a DV drive by outside.
  • We all put the tour on hold & headed outside to see the DV Emira with black forged wheels driving towards us in the bright Norfolk sunshine (yes it does exist!).
  • The shimmer & shine of DV in full sun was breathtaking (cue audible gasps from the tour group).
  • As us Brits say about sunshine, “don’t blink or you’ll miss it” so cue the cloud & shade, which really changed the look of the dark verdant to an equally stunning almost black, almost deep teal finish.
  • My wife said it’s like the Superman of car colours - is it a bird, is it a plane, is it green, is it black, is it teal? Whatever it is, it has bucket loads of enigmatic je ne sais quoi
To conclude…
  • Congrats to Lotus for taking my excitement level to a new level.
  • Congrats to anybody who’s ordered an Emira. I’m convinced it’s going to be worth the wait(weight).
  • Needless to say from my descriptions, I’ve changed the order from Hethel yellow with tan interior (I tried to make it work in my head, but it just didn’t) to DV with tan.
  • Having seen DV inside the factory & outside in both sun & shade, I think the configurator provides a good representation of how the car looks in different light conditions. However, it looks even better in the flesh!
And finally…

We got to see the launch of the GT4 which was drop dead gorgeous
65D8B645-C3E1-46D8-B608-4940FB169910.jpeg
 
Factory Tour notes 5th May…

Just got home after this morning’s factory tour so thought I’d share my thoughts & observations.

Firstly, a few things that have been noted by others who’ve been on the tour…
  • Nick the tour guide is a superb host
  • You get the feeling that Lotus is a happy & friendly place to work (happy staff=happy cars)
  • Huge focus on quality throughout the build process. Hugely impressive stuff!
Notes on colours…
  • There’s no such thing as a bad/disappointing colour. They all looked great to me & my wife.
  • I got to see magma red, dark verdant, Hethel yellow, Seneca blue outdoors in both full sun & shade.
  • I saw all 6 FE colours indoors under factory lights.
  • Hethel yellow - rich & warm mustard
  • Magma red - deep & opulent cherry
  • Nimbus grey - fluid silvery bronze/beige
  • Shadow grey - dark & sophisticated
  • Seneca blue - lively/electric
  • Dark verdant - simply stunning
Notes on interiors…
  • As noted by others, the quality of finish of all the alcantara & leathers were brilliant. So much better than the show car. You won’t be disappointed.
  • I got to see all interior colour options. Again, like the exterior colour options, they all looked brilliant, particularly the tan leather which really shows off the Kef speakers beautifully.
V6 engine sound…
  • Lovely exotic growl on start up inside the factory
  • I got to hear a few V6 drive by whilst outside. They fill the air with a delightful, visceral rumble.
Now for the best bit…
  • Upon informing Nick (the consummate tour host) that we were still undecided between Magma red, Hethel yellow & dark verdant & needed to finalise our order today, he very kindly got on his phone & called a colleague to ask if he could swing by to give us all a DV drive by outside.
  • We all put the tour on hold & headed outside to see the DV Emira with black forged wheels driving towards us in the bright Norfolk sunshine (yes it does exist!).
  • The shimmer & shine of DV in full sun was breathtaking (cue audible gasps from the tour group).
  • As us Brits say about sunshine, “don’t blink or you’ll miss it” so cue the cloud & shade, which really changed the look of the dark verdant to an equally stunning almost black, almost deep teal finish.
  • My wife said it’s like the Superman of car colours - is it a bird, is it a plane, is it green, is it black, is it teal? Whatever it is, it has bucket loads of enigmatic je ne sais quoi
To conclude…
  • Congrats to Lotus for taking my excitement level to a new level.
  • Congrats to anybody who’s ordered an Emira. I’m convinced it’s going to be worth the wait(weight).
  • Needless to say from my descriptions, I’ve changed the order from Hethel yellow with tan interior (I tried to make it work in my head, but it just didn’t) to DV with tan.
  • Having seen DV inside the factory & outside in both sun & shade, I think the configurator provides a good representation of how the car looks in different light conditions. However, it looks even better in the flesh!
And finally…

We got to see the launch of the GT4 which was drop dead gorgeous
View attachment 5211
Did the DV have black pack? Or would it be lost on DV? Even with black wheels?
I'm wondering if when I get my GT spoiler if I'll have to get it painted to match car, or black will be ok😜
 
Factory Tour notes 5th May…

Just got home after this morning’s factory tour so thought I’d share my thoughts & observations.

Firstly, a few things that have been noted by others who’ve been on the tour…
  • Nick the tour guide is a superb host
  • You get the feeling that Lotus is a happy & friendly place to work (happy staff=happy cars)
  • Huge focus on quality throughout the build process. Hugely impressive stuff!
Notes on colours…
  • There’s no such thing as a bad/disappointing colour. They all looked great to me & my wife.
  • I got to see magma red, dark verdant, Hethel yellow, Seneca blue outdoors in both full sun & shade.
  • I saw all 6 FE colours indoors under factory lights.
  • Hethel yellow - rich & warm mustard
  • Magma red - deep & opulent cherry
  • Nimbus grey - fluid silvery bronze/beige
  • Shadow grey - dark & sophisticated
  • Seneca blue - lively/electric
  • Dark verdant - simply stunning
Notes on interiors…
  • As noted by others, the quality of finish of all the alcantara & leathers were brilliant. So much better than the show car. You won’t be disappointed.
  • I got to see all interior colour options. Again, like the exterior colour options, they all looked brilliant, particularly the tan leather which really shows off the Kef speakers beautifully.
V6 engine sound…
  • Lovely exotic growl on start up inside the factory
  • I got to hear a few V6 drive by whilst outside. They fill the air with a delightful, visceral rumble.
Now for the best bit…
  • Upon informing Nick (the consummate tour host) that we were still undecided between Magma red, Hethel yellow & dark verdant & needed to finalise our order today, he very kindly got on his phone & called a colleague to ask if he could swing by to give us all a DV drive by outside.
  • We all put the tour on hold & headed outside to see the DV Emira with black forged wheels driving towards us in the bright Norfolk sunshine (yes it does exist!).
  • The shimmer & shine of DV in full sun was breathtaking (cue audible gasps from the tour group).
  • As us Brits say about sunshine, “don’t blink or you’ll miss it” so cue the cloud & shade, which really changed the look of the dark verdant to an equally stunning almost black, almost deep teal finish.
  • My wife said it’s like the Superman of car colours - is it a bird, is it a plane, is it green, is it black, is it teal? Whatever it is, it has bucket loads of enigmatic je ne sais quoi
To conclude…
  • Congrats to Lotus for taking my excitement level to a new level.
  • Congrats to anybody who’s ordered an Emira. I’m convinced it’s going to be worth the wait(weight).
  • Needless to say from my descriptions, I’ve changed the order from Hethel yellow with tan interior (I tried to make it work in my head, but it just didn’t) to DV with tan.
  • Having seen DV inside the factory & outside in both sun & shade, I think the configurator provides a good representation of how the car looks in different light conditions. However, it looks even better in the flesh!
And finally…

We got to see the launch of the GT4 which was drop dead gorgeous
View attachment 5211
Nice write up and what a brilliant way to finalise your colour choice. DV with tan is indeed a great combination.

And that yellow GT4, wow! We only saw the white one. Wouldn't you just love it if Lotus did a road legal version to sock it to the Cayman GT4 RS :)
 
Did the DV have black pack? Or would it be lost on DV? Even with black wheels?
I'm wondering if when I get my GT spoiler if I'll have to get it painted to match car, or black will be ok😜
Hi I was there today and took a picture of the DV which I’ve just checked , pretty sure no black pack . It looked so black as it pulled up ! You only then notice it’s very dark green sparkle.
There were quit a few cars that were pre production with things like pre production seats , the lotus badge missing on the bonnet and pre production wheels , such as this DV one. Most of us had orders on the tour . I was the odd one out as I’ve ordered the i4 engine ! Today for me was to help with the colours, however outside was a white Emira which I liked the most , but is not a launch colour. Dam !
 
Did the DV have black pack? Or would it be lost on DV? Even with black wheels?
I'm wondering if when I get my GT spoiler if I'll have to get it painted to match car, or black will be ok😜
I saw several DV cars today. 2 inside without black pack & one outside with black pack. It took me a while to spot the black pack on the car outside so it’s not hugely obvious. IMHO the quality & depth of the metallic DV paint on the roof & wing mirrors is much more special than the black pack finish. Personally, I’d go no black pack with the DV & consider adding it later if preferable.
I’d be v tempted by the GT spoiler at some point. I didn’t think it would add to the overall ‘supercar’ look but it really does.
 
Nice write up and what a brilliant way to finalise your colour choice. DV with tan is indeed a great combination.

And that yellow GT4, wow! We only saw the white one. Wouldn't you just love it if Lotus did a road legal version to sock it to the Cayman GT4 RS :)
Thanks very much. Yeah, the GT4 was really special. I kept glancing back & forth between it & my Cayman 718 that was parked outside. Miles apart in the wow factor department 🤯
 
Factory Tour notes 5th May…

Just got home after this morning’s factory tour so thought I’d share my thoughts & observations.

Firstly, a few things that have been noted by others who’ve been on the tour…
  • Nick the tour guide is a superb host
  • You get the feeling that Lotus is a happy & friendly place to work (happy staff=happy cars)
  • Huge focus on quality throughout the build process. Hugely impressive stuff!
Notes on colours…
  • There’s no such thing as a bad/disappointing colour. They all looked great to me & my wife.
  • I got to see magma red, dark verdant, Hethel yellow, Seneca blue outdoors in both full sun & shade.
  • I saw all 6 FE colours indoors under factory lights.
  • Hethel yellow - rich & warm mustard
  • Magma red - deep & opulent cherry
  • Nimbus grey - fluid silvery bronze/beige
  • Shadow grey - dark & sophisticated
  • Seneca blue - lively/electric
  • Dark verdant - simply stunning
Notes on interiors…
  • As noted by others, the quality of finish of all the alcantara & leathers were brilliant. So much better than the show car. You won’t be disappointed.
  • I got to see all interior colour options. Again, like the exterior colour options, they all looked brilliant, particularly the tan leather which really shows off the Kef speakers beautifully.
V6 engine sound…
  • Lovely exotic growl on start up inside the factory
  • I got to hear a few V6 drive by whilst outside. They fill the air with a delightful, visceral rumble.
Now for the best bit…
  • Upon informing Nick (the consummate tour host) that we were still undecided between Magma red, Hethel yellow & dark verdant & needed to finalise our order today, he very kindly got on his phone & called a colleague to ask if he could swing by to give us all a DV drive by outside.
  • We all put the tour on hold & headed outside to see the DV Emira with black forged wheels driving towards us in the bright Norfolk sunshine (yes it does exist!).
  • The shimmer & shine of DV in full sun was breathtaking (cue audible gasps from the tour group).
  • As us Brits say about sunshine, “don’t blink or you’ll miss it” so cue the cloud & shade, which really changed the look of the dark verdant to an equally stunning almost black, almost deep teal finish.
  • My wife said it’s like the Superman of car colours - is it a bird, is it a plane, is it green, is it black, is it teal? Whatever it is, it has bucket loads of enigmatic je ne sais quoi
To conclude…
  • Congrats to Lotus for taking my excitement level to a new level.
  • Congrats to anybody who’s ordered an Emira. I’m convinced it’s going to be worth the wait(weight).
  • Needless to say from my descriptions, I’ve changed the order from Hethel yellow with tan interior (I tried to make it work in my head, but it just didn’t) to DV with tan.
  • Having seen DV inside the factory & outside in both sun & shade, I think the configurator provides a good representation of how the car looks in different light conditions. However, it looks even better in the flesh!
And finally…

We got to see the launch of the GT4 which was drop dead gorgeous
View attachment 5211
Superb! Thanks for the feedback. Did you happen to take note on the deviated stitching on the dash and other interior bits? Did you notice if it continued through to the manual shift boot and sun visors?
 
Superb! Thanks for the feedback. Did you happen to take note on the deviated stitching on the dash and other interior bits? Did you notice if it continued through to the manual shift boot and sun visors?
Pleasure! I’ve found this forum so helpful since the Emira emerged so it’s nice to give something back.
I’m afraid I’m unable to recall these specific details about the stitching, but I was really impressed with the overall finish.
If I’m honest, I was a bit underwhelmed by the show car’s interior having just stepped out of my 718 on the day, but I had the opposite feeling on my drive home from Hethel today. I’m itching to spend more time inside the Emira after today’s tour.
 

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