How the 2020 Lincoln Continental Coach Door Edition Is Built
The first thing to know about the Lincoln Continental Coach Door Edition and how it is made is that the process has virtually nothing to do with stretching a Lincoln MKT for bachelorette parties. This factory section was completely designed and manufactured in-house at Lincoln with input and collaboration from Cabot Coach Builders, a company certified by Lincoln as a Qualified Vehicle Modifier over 30 years ago. And most of the parts used in its construction are produced by Lincoln and shipped to Haverhill, Massachusetts, where Cabot does “the job.”
Make the cut
Fully assembled Continental Black Label cars are shipped to Cabot, where cutting and slicing is done. The roof is cut about 5 inches to the back of where the B-pillar structure meets the roof rails, roughly where you see the 6-inch wide glass panel that extends the panoramic sunroof. The roof stretches and the rocker panel and floor tray extension are roughly below this point. This approach means very little metallic finishing and painting is required.
Lincoln worked with the supplier of its panoramic sunroof to lengthen the rails, brackets and sunroof shade by 6 inches and add an additional fixed glass panel behind the motorhome to compensate for the stretch in the wheelbase. It is designed, tested and assembled to the same specifications as the standard roof.
Swap hinges and latches
Obviously, the B-pillar is an essential part of the Continental’s side impact protection, so replacing it to convert the rear door hinge pillar to a rear door latch bracket was out of the question. Instead, Lincoln designed a panel that mounts over the existing pillar and provides front and rear latch brackets. Production of this and others that convert the rear locking point to a hinge stud, not to mention the doors themselves, are contracted by one of Ford’s local prototyping shops on metal dies. tender at low volume “kirksite”.
Doors and floors
Doors and windows are produced by Lincoln and sent to Cabot. Ditto for the ground stamping inserts and the extended drive shaft. Lincoln also sends stainless steel tailpipe extensions and additional protective material under the floor to store them under existing trims. Instead of extending the exhaust heat shield, a white heat-reflecting paint covers the extended area of the floor hump.
Door handles and fittings
Replicating the Coach Door concept custom door handles that mirror and meet at the door intersection would have been costly to produce and introduced many opportunities for quality and reliability issues. Lincoln’s much safer solution was to work with its door handle and trim suppliers to simply swap the left and right rear door handle and trim pieces, bringing the handles to the front of the rear doors. They had to modify the trim and end caps a bit, but this way the hardware, electrical switches, and gaskets are all mass production parts. Two pieces of daylight opening trim (DLO) are cut and spliced with a small piece of trim hiding the joint where they meet at the B-pillar.
This is where Cabot really gets his share of this transaction, so to speak. He sews and applies the padding of the interior side trim panels behind the rear doors, matching the color and materials of the Lincoln Black Label door trim. It also produces the circulating rear console which connects the original front console, above the original rear bench seat and meets the rear passage, which for 2020 becomes a lockable storage bin. This unit also incorporates most of what came fitted into the stock Continental folding armrest. The wood trim of this console and the champagne holder cover are designed to match the veneers adorning the dashboard and door panels.