In Formula 1, where drivers push speeds beyond 200 mph, collisions with barriers are an unfortunate reality. What stands out is the remarkable speed with which teams restore wrecked cars to racing condition.
“There’s always a sense of controlled urgency, depending on the severity of the crash,” explained Ollie Middleton, the lead mechanic for Carlos Sainz at Williams.
While a crash during a race often means a driver cannot finish, incidents in practice or qualifying prompt teams to undertake rapid repairs. The restoration process begins immediately after impact, even before the car reaches the garage.
A recent example occurred at the Japanese Grand Prix in Suzuka, when Alpine’s Jack Doohan crashed just minutes into the second practice session.
“The TV footage clearly showed the extent of the damage at Suzuka,” said Rob Cherry, Alpine’s race team manager. “Along with the visual, we rely heavily on telemetry data from sensors that monitor suspension loads and chassis g-forces to assess the damage quickly.”
Teams arrive at each Grand Prix with a stock of spare parts ready for such scenarios. Once the damaged car is back in the garage, mechanics perform a thorough visual inspection to complement the data analysis.
“Data tells us if any components have exceeded their strain limits,” Middleton noted. “But seeing the damage firsthand, like crushed radiators, shifts the approach to a detailed, step-by-step repair plan.”
For Doohan’s crash, Alpine transported a spare chassis from their freight container to the pit garage. With approval from the sport’s governing body, the FIA, the team proceeded to swap the chassis and begin repairs.
The A525 car received a new front and rear wing, floor, bodywork, gearbox, suspension parts, and exhaust system. Fortunately, the power unit remained undamaged and reusable. The entire reconstruction took approximately eight hours, allowing the car to rejoin the final practice session the next day.
Cherry described the teamwork as seamless. “Everyone knows their role and limits, but they chip in wherever needed—from clearing debris to fitting parts—without confusion or wasted effort.”
Once the major structural components are replaced, the team methodically reassembles the car with precision.
“When structural damage occurs, it becomes a complex, tightly coordinated task,” Middleton said. “You might be working inches away from colleagues, simultaneously installing suspension parts and repairing body panels. It’s intense, but everyone is focused and silent, fully aware of each step.”
Mechanics categorize parts into those that are beyond repair and those that might be reusable after further inspection.
“We separate scrap from parts that appear intact but require detailed checks,” Cherry explained. “These components return to the factory for rigorous evaluation and sign-off by engineering leads before being cleared for track use. In the current cost cap era, teams are more careful about discarding parts due to their value.”
The location and timing of a crash also affect the difficulty of repairs. Street circuits, with limited access, present logistical challenges in swiftly recovering damaged cars.
“Tracks like Jeddah are unforgiving; even minor contact with walls can cause major damage,” Middleton said. “Towards the season’s end, especially during triple-header weekends, the strain on spares grows, making repairs even more demanding.”
Crashes close to qualifying sessions add extra pressure to the repair crews.
“The tight window between final practice and qualifying is the most stressful,” Cherry said. “A driver like Vitaly Petrov, who had a knack for crashing during this period, forced the team to rebuild extensively in just a couple of hours.”
Despite these challenges, teams consistently manage to prepare the cars in time, showcasing the camaraderie and expertise of the mechanics.
“No one welcomes accidents, but there’s a quiet satisfaction in overcoming the challenge,” Cherry added. “Given manuals and documentation, anyone could rebuild an F1 car eventually. The real skill lies in doing it accurately and rapidly under pressure.”
Williams faced a daunting situation during last year’s São Paulo Grand Prix qualifying, when two major crashes occurred just hours before the race.
“It’s every team’s nightmare, knowing the odds are against you,” Middleton said. “We managed to get one car on track despite limited spares. The emotional rollercoaster—from despair to the thrill of seeing the car race reliably—is immense.”
