...

Participating SASFT Member Companies

Steel Companies
North America
Fuel System Manufacturers
Europe
STEEL FUEL TANK SYSTEM PROVIDERS . . .
AK Steel Corporation Inergy Automotive Systems
Dofasco Inc. Unipart Eberspacher
Mittal Steel USA
North American Stainless Fuel System Manufacturers
Nucor Corporation Asia
Severstal North America Inc. Dong Hee Industrial Co. Ltd.
Stelco Inc. Horie Metal Co., Ltd.
United States Steel Corporation Unipres Corporation

Steel Companies Material/Equipment Suppliers

Europe North America
Corus Comau-Pico
ThyssenKrupp Stahl Harley Davidson Engineering
Arcelor ITT Industries
Magni Group, Inc.
Steel Companies
Asia Material/Equipment Suppliers
JFE Steel Europe
Nippon Steel Corporation Soudronic Automotive NAFTA
Nisshin Steel
Sumitomo Metal Industries, Ltd. Associate Members
Tata Steel (Auto Manufacturers)
DaimlerChrysler Corporation
Fuel System Manufacturers Ford Motor Company
Americas General Motors Corporation
Aethra Componentes Automotivos Ltda Nissan Motor Co., Ltd.
Fuel Systems LLC
Martinrea International
Metalsa
Spectra Premium Industries

...The Link to a Global Network of Steel Fuel Tank Manufacturers

Strategic Alliance for Steel Fuel Tanks

2000 Town Center, Suite 320
Southfield, Michigan 48075
tel: 810.225.8250
fax: 810.220.3065

www.sasft.org www.sasft.org
Introductory Message 3

Benefits of Using Steel Fuel Tanks 4

Proven Corrosion Resistance 6

Steel Fuel Tank Manufacturers 10

Strategic Partners 20

-1-

The Strategic Alliance for Steel Fuel Tanks (SASFT) is an international alliance of
companies specializing in the various areas of fuel tank production and possessing a
common interest in the development, optimization and application of steel fuel tanks for
automobiles.
SASFT was organized by the American Iron and Steel Institute (AISI) in 2000 to bring
together the diverse business disciplines involved in designing, manufacturing and
supplying steel fuel tanks in the automotive market.
SASFT’s global reach recognizes that different business and technological issues impact the
types of fuel tanks produced in different regions of the world. By understanding these issues,
rational, optimized approaches can be fully deployed for steel fuel tanks.
-2-
Introductory Message
For over a century, North American steel producers have left their day-to-day rivalries behind to work as partners
and members of the American Iron and Steel Institute (AISI) in furthering its mission to promote steel as the
material of choice and to enhance the competitiveness of the North American steel industry and its member
companies. AISI's overall mission centers around common goals and a clear vision for the future:
- To provide high-quality, value-added products to a wide array of customers;
- To lead the world in innovation and technology in the production of steel;
- To produce steel in a safe and environmentally responsible manner; and
- To increase the market for North American steel in both traditional and innovative applications.
AISI is comprised of producer member companies, including integrated, electric furnace, and reconstituted mills;
associate member companies, which are suppliers to, or customers of, the industry; and affiliate member organiza-
tions, which are downstream steel producers of products such as cold rolled strip, pipe and tube, and coated sheet.
Traditionally, AISI members have addressed steel production and marketing issues through committee activities.
Additionally, especially for market applications, AISI has coordinated broader participation of its steel industry
members together with other companies having common interest in the development of specific markets. The
combined resources of diverse participating companies have led to great accomplishments and exciting new product
applications.
One such AISI-organized group, the Strategic Alliance for Steel Fuel Tanks (SASFT) has been highly successful in
steel fuel tank technical developments, market research, and establishing a global network for steel fuel tank
manufacturing. The need to create such an alliance became critical as the market for steel fuel tanks was impacted
by the growth of plastic fuel tanks.
Today, the same environmental issues that are driving automakers to increase fuel efficiency, reduce emissions
(exhaust and evaporative), and optimize end-of-life recycling are also affecting the competition between plastic fuel
tanks and steel fuel tanks. The impermeable nature of steel facilitates compliance to demanding evaporative
emission standards. In fact, all of the gasoline-powered vehicles certified to meet the California Air Resources Board
(CARB) Partial Zero Emission Vehicle (PZEV) standards in 2005 have steel fuel tanks. In addition, steel tanks are
fully recycled, at no cost to the automaker or consumer, using an existing infrastructure. When the environmental
benefits of steel fuel tanks are combined with steel's improvements in design flexibility, manufacturability, durability,
cost competitiveness, and support services, today's steel tanks truly offer "performance with environmental
responsibility.”
We invite you to learn more about how steel fuel tanks can benefit your team by contacting AISI, SASFT or any of
the member companies profiled in this brochure.
Sincerely,
Andrew G. Sharkey, III Dr. Peter Mould
President and CEO Program Manager
American Iron and Steel Institute Strategic Alliance for Steel Fuel Tanks
-3-
Benefits of Steel Fuel Tanks

Steel fuel tanks have been widely used since the early days of the automobile's develop-
ment. Thus, a strong history of performance, safety, low cost, and recyclability of steel
fuel tanks has been established. Despite the growth of plastic fuel tanks in recent years,
steel tanks are better suited to today's demanding environmental and engineering
performance requirements.
Attractive Cost
As the environmental restrictions on evaporative emissions increase, the manufacturing costs for producing ultra-
low evaporative emission plastic tanks are increasing. In contrast, steel fuel tanks continue to be an attractive means
of achieving emission targets at affordable cost. The worldwide steel industry has developed a variety of steel
systems to meet the specific approaches favored by automakers (e.g., pre-painted, post-painted and bare steels).
These advanced systems are durable and have improved formability and weldability.
Technical Assistance and Support to Automakers
The global steel tank manufacturers have the ability to assist automakers in tank design, meeting specific perfor-
mance needs and in assurance testing. Furthermore, the SASFT network of steel fuel tank manufacturers,
equipment suppliers and steel companies can be utilized to facilitate development and application of new technolo-
gies.
...The weight of steel fuel tanks can be competitive with plastic using
today's new lightweight and highly formable sheet steels...
Optimizing Fuel Tank Capacity by Efficient Use of Engineering Space
The engineering space that accommodates a fuel tank is becoming increasingly
restricted and complex. Steel has the advantage of utilizing this space more
efficiently compared with plastic tanks, where allowances must be made for
thermal expansion and warpage. Additionally, the variable wall thickness of
plastic tanks (ranging from 2 to 15 mm) restricts the fuel volume compared with a
constant thickness (typically <1 mm) steel shell. New joining techniques are emerging allowing a reduced flange,
enabling the steel shell to be expanded further. It is estimated that fuel capacity increases up to 10% or more can be
realized by reducing or eliminating the weld flange.
Safety
Vehicles equipped with steel tanks have demonstrated the ability to meet all current and future government
regulations and requirements for fuel system integrity after front, rear and side impacts.

Ultra-Low Evaporative Emissions Capability

Evaporation of gasoline from automotive fuel systems is a major contributor toward air pollution and its attendant
health hazards. This has led national and regional government agencies to restrict the amount of automobile
evaporative emissions. Steel's inherent impermeability is ideal for limiting evaporative emissions. In fact, steel is Summary of the Benefits of Steel Fuel Tanks
now the material of choice for meeting the California Air Resources Board's (CARB) Partial Zero Emission Vehicle „ Best material for PZEV applications thanks to inherent impermeability to hydrocarbons.
(PZEV) requirements. In the 2005 model year, 29 PZEV-certified vehicles use steel fuel tanks. In contrast, plastic
fuel tanks are still struggling to demonstrate PZEV capability. „ Cost competitive with current co-extruded blow-molded plastic fuel tanks.

Recyclability „ Corrosion resistant to road environments (15-year life minimum or 150,000 miles).
Steel fuel tanks have been, and continue to be, fully recyclable through an existing infrastructure of dismantling,
shredding and re-melting at steel mills. The steel recycling infrastructure is a profitable industry and, hence, no „ Compatible with all fuels.
end-of-life vehicle costs are incurred by vehicle makers or consumers. In contrast, the absorption of gasoline in the
walls of plastic tanks complicates their end-of-life treatment and no fully developed recycling infrastructure is in „ Good design flexibility (complex shape/saddle tank capability).
place anywhere in the world. Plastic tanks must be either landfilled or incinerated at a significant cost. Landfilling
depletes valuable land resources and together with incineration creates additional environmental concern for toxins „ Readily manufacturable by well-proven, conventional, low cost, widely available processes.
in the soil or air.
„ Over 100 years of proven performance and safety.
Design Flexibility
Newly developed steels and steel systems have improved formability. As a result, complex shaped tanks can be „ 100% recyclable. Nearly 15 millions tons of steel are recycled annually from automobiles.
readily manufactured by conventional stamping processes. Many 'saddle shaped' tanks are routinely produced today
from steel. A recent SASFT design feasibility study showed that a current in-production plastic saddle tank could be
produced from steel with 4% increased fuel capacity and a proportional increase in weight.

Durability
In addition to meeting ultra-low emission standards, CARB stipulates that fuel
systems shall meet a 15-year or 150,000 mile life. SASFT, in an extensive two-
year test program, has demonstrated that 10 steel systems will meet both
external corrosion resistance to road environments and internal
corrosion resistance to aggressive fuels.

-4- -5-
Proven Corrosion Resistance
A two-year corrosion test program sponsored by SASFT, conducted by an independent test laboratory, has
demonstrated that multiple commerically available steel systems will achieve 15-20 year corrosion durability in fuel
tank applications. Ten steel systems throughout the world were tested in the program. The steel systems were
representative of three principal approaches used by automakers for their fuel tanks: pre-painting with minimal
post-painting, post-painting after tank fabrication, and bare steels (such as stainless steels).
Steel systems selected for external and internal (fuel) corrosion testing
Test specimens were specially designed to reflect the unique corrosion conditions of a fuel tank affixed to a vehicle.
The External Corrosion specimens incorporated a scribe line to simulate a scratch exposing the bare steel, a
dome simulating forming strains, a weld flange with a clip to simulate
a crevice corrosion site, and an area exposed to gravel
impact which simulates stone chipping conditions.
To assess the External Corrosion resistance, two
simulative bench-scale procedures were used: the
Neutral Salt Spray test (ASTM B117) with exposures
up to 2000 hours and the Cyclic Corrosion test (SAE
J2334) with exposures up to 120 and 160 cycles. The
latter exposures were selected to simulate road lives
of 15 years and 20 years, respectively. Perforation was
adopted as the criterion for failure. However, the progress of
corrosion was assessed qualitatively by visual observation and
photographs, and quantitatively by measuring pit depths over the
entire specimen, assessing coating integrity by creepback at the
scribe line and determining chip ratings after gravel impact.
To determine the Internal Corrosion resistance, deep drawn cups and
flat lids were assembled to contain an aggressive fuel (CE10A), which
was chosen on the basis of prior experience by automakers and their recommendations to
SASFT. The fuel-cup assembly was sealed by an inert gasket and clamping rings.
-6-
The fuel cup assemblies were held at 45 + 2°C for 39
weeks to simulate a 15-year tank exposure. The fuel
was changed every four weeks to simulate repeated
fuel tank filling and to replenish contaminant ions and
minimize oxygen depletion (per the test fluid specifica-
tions of SAE J1747). The extent of corrosion was
evaluated qualitatively by recording the extent and
location of corrosion and quantitatively by weight changes
and pit depths.
The following key findings were obtained from the two External
Corrosion tests:
- No perforation was observed at any location for any of the steel systems. Corrosion pit depths were
observed at isolated locations for only two steels. In the two samples, the maximum depths of the pits
were 0.2 to 0.4 mm, representing about 20 to 40 percent of the original steel thickness.
- The extent of corrosion (red and white rusting) varied by location on the specimen and from material
to material. In most samples, slight (<15% surface area) or moderate (15-30%) rusting was
observed; pronounced rusting (>30%) occurred only in a few instances. The variations in the
extent of corrosion were not of such significance to rate one steel system as clearly superior to any other.
- The integrity of the paint systems, as indicated by resistance to gravel impact and creepback, varied in
proportion to the thickness of the paint films as follows:
- Those pre-painted systems having thin organic resin films (about 9 thick) and one stainless steel,
having an inorganic paint film (about 17 thick), showed small amounts of paint chip loss after initial
gravel impacts. However, subsequent gravel impacts did not progressively increase the paint chip loss.
- Those post-painted systems having thick coatings (up to 370 ) showed no paint chip loss or
creepback at the scribe line.
The results for the Internal Corrosion (fuel) tests showed:
- Very minor weight losses (<0.13%) for all the specimens after the maximum 39-week
exposure.
- Some variations in the extent of a white residue occurred between the samples. The white residue
occurred primarily at the liquid-vapor interface. However, the quantity of the residue was insufficient
to conduct any post-exposure analysis.
- No perforation occurred and, in fact, no pits deeper than 0.1 mm were observed in any of the cups or
lids.
The results demonstrate that all of the steel systems tested in this bench-scale study resist external and internal
corrosion (in the severe environments that can be experienced by automotive fuel tanks) for up to 20 years. Thus, it
is fully expected that the systems will exceed the 15-year durability requirements of CARB.
As a result of the SASFT corrosion studies, automakers are encouraged to conduct their own tests (including
proving ground tests) to validate on-vehicle corrosion durability. Steel companies can provide additional informa-
tion on the availability, manufacturability and cost of specific systems.
-7-
Global Map of Steel Fuel Tank Manufacturers

...Steel is the material of choice for low evaporative emission (PZEV) vehicles in California - all 29 PZEV-compliant vehicles in 2005 have steel tanks.
Green steel for clean automobiles...
Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

Aethra Componentes Automotivos Ltda. DONGHEE Industrial Co. Ltd.

Aethra Componentes Automotivos Ltda. operates in partnership with practically all Over the last 30 years, DONGHEE Industrial Co. has prioritized customer satisfaction, the growth and develop-
auto companies established in the country, in the development of vehicles for series ment of its partners and affiliates through technology development and quality improvement. DONGHEE is
production. It is the leading Brazilian supplier for its product line, which comprises the distinguished by its services, which range from product development to production technology. Implementation of
following items: welded sets for bodies (complete chassis and floors); medium and large size stampings; shafts and a six sigma campaign has increased innovation and doubled productivity.
crossbeams for suspension; complete systems for fuel tanks; luggage boots; and tools developed for new vehicles.
DONGHEE Industrial Co. is consistently adopting cutting-edge technology and accumulating new production skills.
DONGHEE has become a leading company in the Korean automobile industry and is gaining recognition in the
world market. The Company's promise to its clients is to be a customer-oriented and a value-oriented organization
GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS that provides optimal service in the digital era. DONGHEE constantly strives to nurture a dynamic corporate
HEADQUARTERS
culture. The company also invests in fostering human resources, a key management strategy, and in securing
Facility Type City, State, Facility Size Number of Quality
Aethra Componentes Automotivos Ltda. Province, Country (Sq. Ft) Employees Certification advanced technology to become a global company.
Rua Carolina, 51-Morro do Valente
Betim - MG - Brazil 32686-190 R&D Eng. Div. Contagem/Brazil 800 48 QS-16949, ISO-14000
Phone: +55.31.3597.3020 Prototypes Belo Horizonte/Brazil 10,880 30 QS-16949, ISO-14000
www.aethra.com.br TEC - Tool &
CONTACT Devices Contagem/Brazil 13,272 234 QS-16949, ISO-14000
Marcus Andrade, Sales Director Chassis* Betim/Brazil 211,367 506 QS-16949, ISO-14000
Phone: +55.31.3396.8097
Juiz de Fora** Juiz de Forz/Brazil 1737 06 QS-16949, ISO-14000
GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS
Cell: +55.31.8802.0367
Fax: +55.31.3591.2765 Contagem/Brazil HEADQUARTERS Facility Type City, State, Facility Size Number of Quality
Vehicle Body 148,245 582 QS-16949, ISO-14000 (Sq. Ft) Employees Certification
E-mail: marcus@aethra.com.br DONGHEE Industrial Company, Ltd. Province, Country
or Hammer Contagem II/Brazil 24,610 187 QS-16949, ISO-14000 #218 Hwang-Sung-Dong Nam-Gu
Plant Ulsan, Korea 530,000 601 TS-16949
Marley Lemos, Quality Manager Industrial Center Contagem II/Brazil 15,336 217 QS-16949, ISO-14000 Ulsan Metro-city South Korea 680-160
Phone: +55.31.3597.3019 Phone: (82) 52-259-0733 Plant Busan, Korea 285,000 194 QS-9000
Fax: +55.31.8802.9548 Parana Parana/Brazil 6,313 100 QS-16949, ISO-14000
www.donghee.co.kr
E-mail: marley.lemos@aethra.com.br Trucks Resende/Brazil 14,800 179 QS-16949, ISO-14000 Plant Asan, Korea 500,000 452 QS-9000
*=Fuel Tanks and Rear Axle **=Fuel Tack CONTACT
Plant Zhangjigang, China 250,000 116 --
Dae Sik Kim
CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES Director, R & D Plant Hwasung, Korea 285,000 373 QS-9000
Phone: (82) 31-211-3965
OEM MODEL YEAR - RANGE PRODUCT / SERVICES PLANT Cell: (82) 16-9322-9380 Plant Ulsan, Korea 90,000 332 QS-9000
Fiat Palio Family Palio Family Chassis Division Fax: (82) 31-212-3927
Plant Asan, Korea 355,000 90 --
E-Mail: dskim@donghee.co.kr
Volkswagen Fox Fox Chassis Division
Plant Kwangju, Korea 364,725 95 --
Mercedes-Benz A Class Frontier Chassis Division
Renault-Nissan Frontier A Class Juiz de Fora Division CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES
OEM PROGRAM MODEL YEAR - RANGE PRODUCT / SERVICES PLANT
FULL SERVICE SUPPLIER CAPABILITIES Hyundai Motors All Passenger Vehicles 1996 - Present Ulsan, Asan, Hwasung,
Suspension Assembly - Front Kwangju, China
FUNCTION DESCRIPTION Hyundai Motors All SUV, RV Vehicles 1996 - Present
Product Engineering Ulsan, Asan, Hwasung,
1 Plant
Hyundai Motors All Light Trucks 1996 - Present Suspension Assembly - Rear Kwangju, China, Slovakia
Product Design 2
Kia Motors All Passenger Vehicles 1999 - Present Ulsan, Asan, Hwasung,
Design Software CAD : Fuel Tank Assembly Kwangju, China, Slovakia
• 04 Workstations SGI Octane with Software CATIA V4.2.4
- CATIA • 04 Workstations SGI Octane with Software Pro Engineer WF Kia Motors All SUV, RV Vehicles 1999 - Present
- Ideas • 07 PCs with software AutoCad 2002/Mechanical 6/Inventor Pedal Assembly Busan, Asan, Slovakia
- Unigraphics • 04 IBM Intellistation with CATIA V5 R10 Kia Motors All Light Trucks 1999 - Present
• 01 SUN Workstation ULTRA 60 with C3P IDEAS
- Other • 01 PC with Unigraphics NX Sunroof Assembly Ulsan, Asan, China
Ssangyong Motors SUV 2000 - Present
CAM :
• 04 Workstations Pentium with software CAM CAMPEADOR
• 01 Workstation Pentium with Mastercam
• 01 Workstation Pentium with software CAM WORKNC FULL SERVICE SUPPLIER CAPABILITIES ADDITIONAL INFORMATION
• New products development in CODESIGN: Economical and Technical Viability
Program Management Studies; Product Design Assembly Project; Components Project; Material Project
• Modifications Management
FUNCTION DONGHEE Industrial Co. is the representative company of DONGHEE Group.
• Update of mathematical drawings
• Analysis of technical norms and standards Product Engineering There are eight companies in DONGHEE Group, including:
• Metodologies:
• QFD / DFM / DFA / VE / FMEA / CAD / CAE / CAM Product Designers - DONGHEE Industrial Co. (Ulsan) - DONGHEE Co. (Buscan)
• Computer Static and Dynamic Analysis - DONGHEE ACS Co. (Hwasung) - DONGHEE Webasto (Ulsan)
• Prototypes, Pilot Production and Avant-Series Development: Project of Soft Toolings; Design Software
Construction of Soft Tollings for Draw and Trim; Laser Cutting; Models; Checking Fixtures - DONGHEE Auto Co. (Seosan) - DONGHEE China (Zhangjigang)
• Laboratorial Analyses - CATIA - DONGHEE Slovakia (Slovakia) - DONGHEE Automotive Co.
Product Testing and • Mechanical Tests (vibration, fatigue, pressure, bursting, etc )
• Field Analyses (Kwangiu)
Validation • Product Certification
• Complete Dimensional Control of Vehicle Body Program Management
• Software Comparation Between Model Surface and Components in Real Time
• 5 Axles CNC Machines
• Tridimensional Measurement Product Testing and Validation
• 3 / 5 Axles Laser Cutting Machines (thickness up to 17 mm)
CAE :
CAE • 01 Workstation SGI Octane with Software PATRAN/NASTRAN
• 01 Workstation IBM RS6000 with Software AUTOFORM(stamping simulation) Aethra Headquarters, Contagem, MG, Brazil CAE

- 10 - - 11 -
Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

Elsa LLC... Fuel Systems LLC

ELSA Corporation, an automotive component manufacturer is located in Fuel Systems LLC was acquired in 2001 by TMB Industries. All five manufacturing
Elwood, Indiana. ELSA specializes in fuel tanks, exhaust systems, and structural locations are QS-9000 and ISO-9002 certified. They specialize in vehicular mounted
components for OEM customers. fuel tanks and fuel tank modules for vehicles ranging from heavy-duty, medium-duty
and light-duty trucks to specialty vehicles with applications including military,
construction, off-highway, and emergency usage. Fuel Systems manufacturing and
design functions work hand-in-hand with their customers to ensure that every tank is designed and manufactured to
fit the exact customer specification. The technological capabilities, particularly in the areas of state-of-the-art
testing, metal processing, and robotic welding, ensure the highest possible quality. Combined with a second-to-none
work ethic and unparalleled pride in performance from over 400 employees, these strengths keep customers
satisfied and continually invested. Fuel Systems is a Tier-1 supplier and is the sole source for many of their OEM
customers for their metallic fuel tank needs.

GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS
Facility Type City, State, Facility Size Number of Quality City, State, Facility Size Number of Quality
HEADQUARTERS Province, Country (Sq. Ft) Employees Certification HEADQUARTERS Facility Type Province, Country (Sq. Ft) Employees Certification
Elsa LLC Fuel Systems LLC
Manufacturing Elwood, Indiana 320,000 470 QS-9000 Corporate Office Grand Rapids, Michigan -- 24 QS-9000,
1240 South State Road 1950 Waldorf NW ISO-14001
Elwood, Indiana 40636 Sakamoto Industries Grand Rapids, Michigan 49544
Technical of Ota City, Japan 520,000 810 ISO-9001 QS-9000,
Phone: (765) 557-2000 Phone: (616) 735-3500 Mfg. / Technical Walker, Michigan 45,000 75
www.elsallc.com ISO-14001
www.fuelsystemsllc.com
QS -9000,
CURRENT FUEL SYSTEM BUSINESS Mfg. / Technical Springfield, Ohio 60,000 130
CONTACT CONTACT ISO-14001
Brad Stewart OEM PROGRAM MODEL YEAR - RANGE Steve Witherspoon QS-9000,
Sales Manager Vice President of Sales & Marketing Mfg. / Technical Charlotte, North Carolina 60,000 100 ISO-14001
Subaru 21Z 2004 thru 2008
Phone: (765) 557-2078 Phone: (810) 794-2093
Fax: (765) 557-1547 Mitsubishi PSU, PS41 2003 thru 2007 QS-9000,
Cell: (313) 706-4738 Mfg. / Technical Wytheville, Virginia 45,000 75 ISO-14001
E-Mail: bstewart@elsallc.com Fax: (810) 794-5933
E-Mail:switherspoon@fuelsystemsllc.com QS-9000,
Mfg. / Technical Chicago, Illinois 45,000 40 ISO-14001

PRODUCT AND SERVICES

CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES
PRODUCT / SERVICES PLANT
MODEL PRODUCT / SERVICES PLANT
Elwood, Indiana OEM PROGRAM YEAR - RANGE
Fuel Tanks
Ford Fuel Tanks/Modules Since 1972 Fuel Tanks/Modules Walker, Michigan
Exhaust Systems Elwood, Indiana GM Fuel Tanks/Modules Since 1970
Fuel Tanks/Modules Chicago, Illinois
International
Truck & Engine Fuel Tanks/Modules Since 1962
FULL SERVICE SUPPLIER CAPABILITIES Fuel Tanks/Modules Springfield, Ohio
Volvo Fuel Tanks Since 1977
FUNCTION DESCRIPTION Mack Fuel Tanks Since 1987 Fuel Tanks/Stampings Charlotte, North Carolina
Product Engineer Japan Freightliner Fuel Tanks Since 1990
Fuel Tanks Fuel Tanks/Stampings Wytheville, Virginia
Product Designer Japan Hino Since 2003
Design Software
- CATIA
- Ideas
Japan FULL SERVICE SUPPLIER CAPABILITIES ADDITIONAL INFORMATION
- Unigraphics FUNCTION Fuel System engineers and manufacturing specialists assist their customers at the initial
- Other design stage of the product development cycle. They've seen a lot of fuel tanks over the
Product Engineering years, and have developed a strong sense of what works. By bringing this insight to the
Program Management Yes table before design specifications are finalized, they help to save time and money and
Product Designer address quality issues right from the beginning. When the manufacturing process begins,
Product Testing and Validation Japan
Design Software they handle everything from raw stock to finished product, performing with excellence
CAE Japan on every element of the process, including stamping, bending, forming, piercing,
- CATIA trimming, welding and finishing operations. They are completely configured to handle
- Ideas steel, aluminized steel or aluminum - regardless of the configuration required.
- Unigraphics Fuel Systems offers their customers multiple types of finishes: primer paint, epoxy
ADDITIONAL INFORMATION - Solid Works powder paint, aluminum cleaning and high-lustre polished aluminum. And their tank
modules arrive ready to bolt onto the vehicle - completely equipped with all necessary
Program Management mounting hardware. Fuel Systems is a one-stop source - from design to delivery - for
Sakamoto Industries Co. Ltd. is our parent company top-of-the line fuel tanks, whether an application is for specialty vehicle, or light-duty,
located in Ota City, Japan. Our product development/ Product Testing and Validation
medium-duty or heavy-duty truck.
validation activities are done in Japan while working CAE
with the Japanese OEMs.

- 12 - - 13 -
Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

Horie Metal CO., Ltd. Martinrea International Inc.

Horie Metal was established in 1942 and acquired by Toyota Motor A global leader in the production of quality fluid management systems, metal parts,
Corporation in 1972. In 2001, a total 50 million steel tanks had been assemblies and modules, Martinrea International Inc. is a Tier-1 automotive supplier and
produced since 1961. The company has the largest market share in Japan. supplier to other industrial sectors. Recognized for innovation in engineering solutions and
thought-leadership in technologically-advanced product development and manufacturing,
Fuel system parts are produced using plated low carbon steel, stainless steel, and other metals. Horie Metal CO., Martinrea’s expertise includes: fluid handling; metal forming including hydroforming,
Ltd. has in-house stamping, brazing, welding (spot, seam, projection, plasma arc, MIG, etc.), bending, painting, stampings, welded assemblies and multi-axis laser cutting; prototyping; and tooling.
assembling, leak testing (water sink, helium) processes. Functional areas include fuel systems, structural & occupant safety, engine and transmission components, power
steering and brake components, and HVAC and exhaust components. As of January 2004, the company employed
over 3000 people at 17 divisions in Canada, the United States, Mexico and Europe. Martinrea International Inc. is
a public company with its common shares trading on the Toronto Stock Exchange under the trading symbol
“MRE.”

GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS
Facility Type City, State / Facility Size Number of Quality Facility Type City, State, Facility Size
HEADQUARTERS Province, Country (Sq. Ft) Employees Certification HEADQUARTERS Province, Country (Sq. Ft)
Horie Metal CO., LTD. 30 Aviva Park Drive
Main Plant & Tech Center Konosu-cho,Toyota, 350K (Floor) ISO-/QS -9000,
2-26, Konoshu-Cho Aichi, Japan 650K (Land) 991 Vaughan, Ontario Technical Centers and Laboratories Troy, MI; Dexter, MI; Mississauga, ON;
ISO-14001 75,000+
Toyota, Aichi, Japan 471-8510 Canada L4L 9C7 Lincoln Park, MI; Basildon, UK
Phone: +81-(0)565-29-2211 Hirota Plant Hirota-cho, Toyota, 140K (Floor) 189
Aichi, Japan 300K (Land) Phone: (416) 749-0314
www.asnohorie.co.jp Mississauga, ON (2 locations);
www.martinrea.com Fluid Handling (Fuel, Vapor, Brake Tubing,
Miyoshi-cho, Hoses and Assemblies; Fuel Filler Brampton, ON; St. Mary's, ON;
Miyoshi Plant Nishikamo, Aichi, 40K (Floor) 30
CONTACT Japan 100K (Land) Assemblies; Fuel Tank Assemblies; Dexter, MI; Reed City, MI; Clare, MI;
CONTACT 800,000+
Jun Takeoka Transmission & Engine Oil Cooler Lines North Vernon, IN; Saltillo, Coahuila,
Tahara, Aichi, Japan 45K (Floor) Ray Sheffield and Assemblies; Heater Inlet/Outlet
Assistant Manager Tahara Plant 140K (Land) 110 Mexico; Hermosillo, Sonora, Mexico;
Director, Fuel Tanks Assemblies; Air Conditioning Lines)
Phone: +81-(0)565-29-8941 Born, Netherlands; Essex, UK
A. Plukdaeng, Rayong, 90K (Floor) QS-9000 2319 Bishop Circle East
Cell: +81-(0)90-8158-2292 Asnohorie Thailand (Plant) Thailand 3300K (Land) 328 ISO-9001
ISO-14001 Dexter, Michigan 48130 Metal Forming (Stamping, Hydroforming,
E-Mail: juntakeoka@asnohorie.co.jp Vaughan, ON; Brampton, ON;
Lemanhabang, Bekasi, 60K (Floor) Tel: (734) 426-4376 Frames, Structural/Occupant Safety, 450,000+
Fax: +81-(0)565-29-3371 Asnohorie Indonesia (Plant) 195 Exhaust Components) Markham, ON; Corydon, IN
Indonesia 150K (Land) Email: rsheffield@martinrea.com

CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES CURRENT FUEL SYSTEM BUSINESS FULL SERVICE SUPPLIER CAPABILITIES
PRODUCT / SERVICES PLANT PROGRAM NUMBER OF DESCRIPTION
OEM PROGRAM OEM PROGRAMS
Fuel Tanks Main, Tahara, Hirota, Indonesia, Thailand Product Engineering
Toyota Over 30 Models for Tanks Fuel, Vapor, Brake Line 8
Over 40 Models for Filler Pipes Fuel Filler Pipes Hirota, Tahara, Indonesia, Thailand Assemblies and Bundles Product Design
Ford Fuel Filler Assemblies 8 Design Software - CATIA (v.4 and v.5), I-Deas, Unigraphics
Honda 1 Model for Tanks
Fuel Doors Hirota, Tahara Fuel Tank Assemblies
Dainhatsu 1 Model for Tank (Indonesia) 2 Program Management
2 Models for Filler Pipes Blanking, Slitting Miyoshi Fuel, Vapor, Brake Line
General 17 Project Testing & Validation
Hino 1 Model for Tanks and Filler Pipes Motors Assemblies and Bundles
Tank Straps Main CAE - Nastran (NX v3), LS-Dyna 3D, HyperMesh, LS-POST; Linear, Non-
Suzuki (Indonesia) 1 Model for Tanks and Filler Pipes Fuel Filler Assemblies 1 Linear, Dynamic, Optimization, Crashworthiness, Metal Forming Analysis
Plastic Components Hirota Fuel, Vapor, Brake Line
Auto Alliance Thailand 2 Models for Filler Pipes Daimler- 1 Fuel Filler Assemblies
Pump Units Main Chrysler Assemblies and Bundles
Siam Nissan (Thailand) 2 Models for Filler Pipes Fuel, Vapor, Brake Line Assemblies and Bundles
Fuel Filler Assemblies 8

FULL SERVICE SUPPLIER CAPABILITIES ADDITIONAL INFORMATION

FUNCTION
Martinrea recently established a highly-automated fuel tank assembly facility in Hermosillo, Sonora, Mexico. This facility
Product Engineering features the first Soudronic CONTOUR 2 welding cell in North America, as well as 100% helium leak detection for
Product Design PZEV emissions compliance, enabling Martinrea to produce steel fuel tanks with unmatched flexibility and quality. At full
volume, the plant will produce approximately 400,000 fuel tank assemblies per year, with provisions for expansion as
Design Software
- CATIA
necessary.
- Ideas
Martinrea’s capability to design, develop, test, and manufacture complete near-zero emissions fuel systems is unmatched.
Program Management With in-house design and testing expertise, program management, and manufacturing capabilities for Fuel Fillers, Fuel/
Product Testing and Validation Vapor/Brake Bundles and Fuel Tank Assemblies, Martinrea can deliver complete system solutions from concept to
CAE customer.

- 14 - - 15 -
Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

Metalsa Spectra Premium Industries

Metalsa, Mexico, together with its partner Tower Automotive is a leading global designer and
manufacturer of a broad range of structural components, assemblies and modules, many of
which are critical to the vehicle’s structural integrity. Metalsa and Tower Automotive are the
largest independent, global suppliers of stamped, formed, and welded components and
assemblies. As a worldwide leader with over 12,000 colleagues in more than 15 countries,
Tower Automotive is headquartered in Novi, Michigan with technical centers located in
metropolitan Detroit, Europe and Asia. With these building blocks, Tower Automotive has
created a value-based and safety-focused company uniquely positioned to meet the needs and
challenges of their global automotive customers. From its San Luis Potosi plant, Metalsa provides the US and Mexico
automotive industry with upper body structural stampings and metal fuel systems for passenger cars and light trucks.
This Strategic Business Unit provides customers with specialized attention, point-of-use logistics services, product
design and validation, and prototype fabrication.
Innovative and future-oriented, Spectra Premium Industries, Inc. (SPI), is a leading manufac-
turer of steel fuel tank systems, aluminum radiators and high-pressure die cast mangnesium
alloy parts.
SPI is a Tier-1 full service supplier to the automotive industry for the manufacture of steel fuel
tank systems. They are experienced in the design, engineering, and validation of fuel systems
to meet today's stringent emission standards.
With a low-cost flexible manufacturing system and an integrated tool and die manufacturing facility, SPI offers its
customers superior products and the best possible quality/price ratio.

GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS
City, State / Facility Size Number of Quality Facility Type City, State, Province, Country Facility Size Number of Quality
Facility Type HEADQUARTERS (Sq. Ft) Employees Certification
HEADQUARTERS Province, Country (Sq. Ft) Employees Certification
Metalsa Spectra Premium Industries ISO-9001,
QS-9000, Plant Boucherville, Quebec QS-9000,
Carretera Miguel Aleman Km 16.5 Plant and HQ Apodaca, N.L., Mexico 340,000 2402 1421 Ampere Street Canada 450,000 600
ISO-14001 Boucherville, Quebec ISO-14001
Apodaca, Nuevo Leon
TS -16949 Canada J4V 5Z5 Debert, Nova Scotia 125,000 ISO-9001,
Mexico 66600 Plant San Luis Potosi, SLP Plant Canada 75 ISO-14001
Mexico 170,000 514 ISO-14001 Phone: (450) 641-3090
Phone: +52 (81) 8369-7400 VDA6.1
www.metalsa.com.mx www.spectrapremium.com Plant Laval, Quebec ISO-9001,
Canada 170,000 250 ISO-14001
CONTACT IN USA QS-9000 CONTACT
Plant Roanoke, Virginia 200,000 241 ISO-14000 Mark Church
Abraham Tijerina Plant Boisbriand, Quebec 90,000 70 TS-16949
Innovation and Technology Director Director - Fuel System Programs Canada
Phone: (248) 374-5046 Sales Office Novi, Michigan 45K (Floor) 5 -- Phone: (519) 977-7013
Plant Haley, Ontario 89,000 90 QS-9000
140K (Land) Cell: (514) 918-1366 Canada
Cell: (248) 961-5000
Fax: (248) 374-5049 E-Mail: churchm@spectrapremium.com Windsor, Ontario
Sales Office Cincinnati, Ohio 90K (Floor) 1 -- Fax: (519) 258-9461 Technical Center Canada -- 10 --
E-Mail: abraham.tijerina@metalsa.com.mx 3300K (Land)

CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES
OEM PROGRAM ANNUAL VOLUME PRODUCT / SERVICES PLANT MODEL
OEM PROGRAM YEAR - RANGE PRODUCT / SERVICES PLANT
Nissan HS 99 - 170,000/yr Steel Fuel Tank Modules SLP
Nissan TK 03 - 40,000/yr General Motors Service Parts -- Fuel System Boucherville
Upper Body Structures SLP
Nissan GS 90 - 80,000/yr
Control Arms Apodaca / SLP General Motors GMX281 2004 - 2006
Nissan D21 90 - 40,000/yr Radiators Laval/Stratford
Light Truck Chassis Frames Apodaca
GM S-CAR 95 - 80,000/yr Bombardier Spyder 2007 - 2009
Engine Cradles Apodaca Radiator Components Debert
Ford P96 97 - 15,000/yr
JS AWD 2007 - 2011
Ford P131 97 - 15,000/yr Rear Axles Apodaca DaimlerChrysler JS PZEV 2008 - 2010 Die-Cast Magnesium Haley/Boisbriand
Ford F53 98 - 10,000/yr Heavy Truck Siderails Apodaca / Roanoke JC PZEV 2008 - 2011 Components

FULL SERVICE SUPPLIER CAPABILITIES OTHER DESIGN SOFTWARE FULL SERVICE SUPPLIER CAPABILITIES ADDITIONAL INFORMATION
FUNCTION QUANTITY Pro-Engineer CAE Software: Hypermesh, ANSA, Nastran, FUNCTION SPI has in-house tooling capabilities enabling the rapid
Product Engineering 10 Optistruc, Hyperform, LS-Dyna, ADAMS Product Engineering development of prototype and production parts.
Product Design 25
Product Design
Design Software ADDITIONAL INFORMATION SPI has developed a flexible automated production line
Design Software
- CATIA capable of producing low volume and high volume production
Yes - CATIA
- Ideas Low Carbon Steel (LCS) and High-Strength Steel (HSS) with enhanced permanent controls.
- Unigraphics - Ideas
Stamping; Hydroforming, Roll Forming, Heat Treat- - Unigraphics
ment, Laser Cutting, Sequencing Centers, ELPO, Wax Program Management SPI is a Tier-1 full service supplier and offers complete
Program Management 8
and Water Base Coating. product design, engineering, development and validation
Product Testing and Validation 11 Product Testing and Validation
testing services.
CAE 7 CAE

- 16 - - 17 -
Steel Fuel Tank Manufacturers Steel Fuel Tank Manufacturers

..
Unipart Eberspacher Unipres Corporation
Unipart Eberspächer is a 50/50 joint venture company, founded in 1998, With more than 50 years of involvement with stamping technology, Unipres
between the Unipart Group of Companies (UGC), one of the UK's top 20 Corporation has continued to build upon and refine its technical expertise. In those
private companies and Eberspächer GmbH, the world’s fourth largest few decades, passenger car design, including car body structures and transmissions,
manufacturer of exhaust systems with a global network of manufacturing sites has evolved with remarkable speed. Technologies developed exclusively by Unipres
supporting the automotive industry. have provided the background to the realization of high-quality components capable of
ever better performance. The history of Unipres’ technology is a history of constant exploration on the cutting
Unipart Eberspächer is based in Coventry, UK manufacturing steel fuel tanks, exhaust systems, catalytic
edge of the field, with new challenges being met and mastered. When you discover even a small part of that
converters and fabricated manifolds with a full service supplier capability including design, development testing,
and validation,and program management through to volume production. history, Unipres believes your concepts of press technology will be changed forever.

GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS GENERAL INFORMATION LOCATIONS - TECHNICAL CENTERS AND PLANTS
Facility Type City, State / Number of Quality Facility Type City, State / Facility Size Number of Quality
HEADQUARTERS Province, Country Employees Certification HEADQUARTERS Province, Country (Sq. Ft) Employees Certification
Unipart Eberspacher Exhaust Systems Unipres Corporation Tochigi City,
Design and Development 1-19-20 Shin-Yokohama Plant for Body Parts and ISO-9001
Beresford Avenue 20 TS-16949 Tochigi Pref. 351,300 233
(Fuels) Coventry, UK Kohoku-ward,Yokohama City, Fuel Tank Japan ISO-14001
Coventry, UK CV6 5LZ
Phone: +44 (0) 2476 638663 Kanagawa Prefecture, Japan 222-8581
Fuji City, ISO-9001
Phone: +81-45-470-8250 Engineering Center Shizuoka Pref. Japan 24,600 140
www.uees.co.uk ISO-14001
Manufacturing Coventry, UK 280 TS-16949 www.unipres.co.jp
CONTACT
Geoff Morris - Sales Manager Oyama City, Tochigi ISO-9001
CONTACT Plant for Body Parts 262,300 191
Phone: +44 (0) 2476 835029 Pref. Japan ISO-14001
Design and Development TS-16949 Hirohumi Kondo
E-Mail: geoffmorris@uees.co.uk (Exhausts) UK, Germany, USA 300 Deputy General Manager
ISO-9000 Yamato City, Kanagawa ISO-9001
Phone: +81 545-62-5060 Plant for Body Parts 377,100 587
Pref. Japan ISO-14001
Phil North - Design Engineering Fax: +81 545-62-5125
Phone: +44 (0) 2476 835024 Global 2,000 TS-16949 E-Mail: h-kondoh@gm.unipre.co.jp Yokosuka City, ISO-9001
Manufacturing Plant for Body Parts 90,600 126
E-Mail: philnorth@uees.co.uk ISO-9000 Kanagawa Pref. Japan ISO-14001

CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES CURRENT FUEL SYSTEM BUSINESS PRODUCT AND SERVICES
OEM PROGRAM MODEL YEAR - RANGE PRODUCT / SERVICES PLANT OEM PROGRAM MODEL YEAR - RANGE PRODUCT / SERVICES PLANT
Aston Martin Vanquish 2002 Nissan SKYLINE/Infinity G35 Since 2002
Steel fuel tanks / design, Nissan Maxima Tochigi Plant
Coventry, UK Nissan STAGEA Since 2002
Aston Martin DB9 2004 development & manufacture
Nissan FAIRLADY Z/350Z Since 2002
Aston Martin V8 Vantage 2005 Nissan Infinity FX45 Since 2003 Nissan Sunny Tochigi Plant
Exhaust systems (inc.
Germany, UK and other Nissan FUGA/Infinity M45 Since 2004
Bentley Arnarge 2004 catalysts, manifolds and
DPF’s) design, development global locations Nissan CIMA/Infinity Q45 Since 2001 Nissan Presage Tochigi Plant
Jaguar XK8 2006 and manufacture Nissan SERENA Since 2005

FULL SERVICE SUPPLIER CAPABILITIES ADDITIONAL INFORMATION FULL SERVICE SUPPLIER CAPABILITIES
FUNCTION FUNCTION
Unipart Eberspächer is currently installing a new high
Product Engineering technology steel fuel tank manufacturing cell into its Product Engineering

Product Design Coventry UK factory. This will produce complex saddle- Product Design
shaped stainless steel tanks and include state-of-the-art
Design Software Design Software
- CATIA
welding on a Soudronic CONTOUR 2 seamwelder supported - CATIA
- Ideas by a new helium leak test facility. - Ideas

Program Management Program Management

Product Testing and Validation Product Testing and Validation

CAE CAE

- 18 - - 19 -
 Strategic Partners
Comau Pico is the innovative leader in industrial automation. As a member of the Comau Group
Comau Pico is part of the largest full-service automotive supplier in the world. With over 50
years of experience in automated assembly tooling, Comau Pico offers an unparalleled range of
products and services to the North American market. Using the latest technology Comau Pico
delivers complete turnkey systems that meet and exceed the design and manufacturing needs of
its customers.
Since 1903, Harley-Davidson has produced the most enduring and recognizable
motorcycles in the world. No other motorcycle has the look, the sound and the
feel of their two-wheeled pieces of art. The motorcycle defines Harley-Davidson, but a wide range of other
products and services is available to increase the enjoyment of the experience or give newcomers a taste of our
world.
Harley-Davidson, Inc. employs some 8,000 people worldwide. Corporate headquarters are in Milwaukee,
Wisconsin. The company's domestic production facilities are located in the Milwaukee area, East Troy and
Tomahawk, Wisconsin; York, Pennsylvania and Kansas City, Missouri. Other key business operations are located in
Chicago, Illinois; Franklin, Wisconsin; Talladega, Alabama; Highland Heights, Ohio; Ann Arbor, Michigan; Carson
City, Nevada and Plano, Texas. Harley-Davidson also maintains operations in strategic international markets,
including throughout the continent of Europe, Brazil, and Japan, to support its worldwide dealer and distributor
network.
ITT Industries, Inc. is a global engineering and manufacturing
company with leading positions in the markets it serves, generating
2003 sales of $5.63 billion. ITT Industries is the world's premier
supplier of pumps, systems and services to move, control and treat
water and other fluids. The company is a major supplier of sophisticated military defense systems, and provides
advanced technical and operational services to a broad range of government agencies. ITT Industries also
produces connectors, switches, keypads and cabling used in telecommunications, computing, aerospace and
industrial applications, as well as network services. Further, ITT Industries makes industrial components for a
number of other markets, including transportation, construction and aerospace. Based in White Plains, New
York, ITT Industries employs approximately 39,000 people around the world.
- 20 -
Founded in 1974, The Magni Group has become America's fastest
growing coating company. With customers on five continents, the
company's primary business is extending the customer's product life by eliminating corrosion. In addition to
corrosion control, Magni coatings also provide lubricity and conductivity, which can improve product
performance. Magni develops, manufactures, and applies protective coating systems for a wide variety of metal
products. Magni manufactures both solvent and waterborne liquid coatings used for rust prevention on metal
surfaces. These coatings are sold to a great variety of industrial manufacturers including coil coaters. The
automobile industry is the primary market for Magni Group's products. In addition to selling coatings, the group
also applies the coatings to automobile parts and fasteners.
Soudronic automotive supports the automotive industry's efforts to
produce lighter, safer and better cars. By offering superior welding
solutions for the manufacture of fuel tanks, tailored and tubular blanks,
patchworks and other demanding parts, the company works in close cooperation with many of the world's
leading steel converters and car manufacturers. The vast majority of the 40 million cars produced annually feature
a growing number of tailored blanks. More and more car bodies are built with tailored blanks in combination
with hydroformed steel parts made of tubular blanks. The installed base of their welding systems produce several
million tailored blanks, fuel tanks and tens of thousands of tubular blanks per year. Services offered include:
service and maintenance, prototyping, back-up production, sampling/demonstration, system engineering,
project management, training, and spare parts. The latest activity added to the project family is quality control
systems for laser and arc welding.
Associate Members
- 21 -