Almac
Almac is a New Zealand kit-car company known for fibreglass-bodied replicas and original sports-car designs.
Last updated August 31, 2026
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Overview
Almac is a New Zealand specialist vehicle manufacturer and kit-car business based in Upper Hutt. Its roots lie in Almac Reinforced Plastics Ltd, a fibreglass-product company established by Alex McDonald in 1971. McDonald developed an interest in kit cars during a period living in England, where he purchased a Jem Marsh Sirocco, a sports car associated with the founder of the Marcos car company. After moving to New Zealand, he continued exploring the possibilities of low-volume sports-car construction. The company’s automotive work began with McDonald’s own attempt to design a Volkswagen-based sports car. In 1976 he created a vehicle influenced by the shape of the 1974 Lotus Elite. The completed car was sold to Phil Derby, who used it as a track car, but the design was not developed into a production range. McDonald’s friends subsequently encouraged him to concentrate on replica vehicles, as the Volkswagen-based kit-car market was beginning to weaken. Almac’s first commercially significant automobile was a fibreglass-bodied replica of the Shelby Cobra 427. McDonald worked with George Ulyate on scale drawings and contracted KiwiRaceCars.com, then known as Graham Berry Race Cars Limited, to produce the chassis and assemble vehicles around Almac’s bodywork. The first car was displayed at the 1984 National Hot Rod Show, and 17 cars were sold during that year. The vehicles were not badged as Almac products, and some were later mistaken for original Cobras. More than 450 Cobra bodies were ultimately produced using Almac fibreglass components, making the model the company’s most successful and recognizable line. Almac broadened its range in 1986 with the TC, a sports car loosely influenced by the MG TC. Unlike the Cobra, it was not presented as a direct replica. It was designed to use a Triumph Herald chassis, and the company supplied both kits and some turnkey cars. Production ended in 1988 because suitable Triumph Herald chassis became increasingly difficult to source and the donor platform imposed limitations on engine capacity. The TG followed the TC. Development began in 1988, with production kits reaching the market in 1989. The TG used an Almac-designed chassis and Holden Gemini donor components. It achieved lower volumes than the TC, with demand declining after approximately 16 examples. During the 1990s Almac sought to create a more distinctive in-house sports car rather than relying primarily on replicas. Alex McDonald and his son Stuart worked on a modern Cobra interpretation, ultimately redesigning the project around a purpose-built chassis, Ford Cortina components and a Leyland P76 V8. The resulting Sabre was publicized in specialist motoring publications, but production ceased in 2001 after nine cars. A second-generation Sabre project began in 2002 as the kit-car market showed signs of renewed interest. The Sabre Series 2 received a stronger chassis, retained the Cortina windscreen, adopted a Toyota Lexus V8 engine and gained substantially revised bodywork. It was launched at the Hamilton Motor Show in March 2004, where five orders were reported. Almac also developed the Clubsprint, a Lotus Seven-influenced kit using Ford Escort components, and later produced the larger Clubsprint XL to address demand for additional cabin and chassis space. Almac operates in the specialist and enthusiast automotive sector, where customers assemble vehicles using donor-car components or commission completed cars. Its products reflect the economics of low-volume manufacturing: fibreglass construction, adaptable donor platforms and designs aimed at hobbyists, club racers and classic-car enthusiasts. On 31 May 2024, ownership of the company changed when Malcolm Sankey of Matamata Panelworks purchased the business. The available reference material does not establish the company’s production plans, workforce, financial performance or detailed post-acquisition strategy.
History
Almac’s automotive history developed from the fibreglass manufacturing activities of Almac Reinforced Plastics Ltd, founded by Alex McDonald in 1971. McDonald had acquired an interest in kit cars while living in England, including through ownership of a Jem Marsh Sirocco. After relocating to New Zealand, he looked for ways to apply fibreglass production to locally viable sports-car projects. In 1976 McDonald designed a Volkswagen-chassis sports car with styling influenced by the 1974 Lotus Elite. The completed example was sold to Phil Derby for track use, but the design did not proceed into series production. As Volkswagen-based kit cars became less commercially attractive in New Zealand, McDonald’s associates suggested a replica-oriented approach. With George Ulyate, he prepared drawings for a Shelby Cobra 427 interpretation. KiwiRaceCars.com, then operating as Graham Berry Race Cars Limited, supplied the chassis and built the cars around Almac-produced fibreglass bodies. The first Cobra was shown at the 1984 National Hot Rod Show, and 17 cars were sold that year. Although the early examples were not badged as Almac vehicles, the company became an important supplier of Cobra-style fibreglass bodies. More than 450 Cobra bodies were produced, establishing a substantial installed base among New Zealand kit-car builders and owners. Almac attempted to diversify beyond the Cobra in 1986 with the TC, a non-replica design loosely based on the MG TC and intended for Triumph Herald chassis. The company supplied kits and also built turnkey examples. This program ended in 1988 as sound Herald donor chassis became scarce and the platform restricted engine options. The TG, developed from 1988 and sold from 1989, moved to an Almac-designed chassis with Holden Gemini donor components. It reached approximately 16 examples before demand declined. The company then pursued a more original sports-car identity. Alex McDonald and his son Stuart began a modern Cobra-related design, but an early version was abandoned before completion. A redesigned project became the Sabre, using a purpose-built chassis, Ford Cortina components and a Leyland P76 V8. Specialist motoring coverage helped publicize the car, but changing market conditions worked against it. The Mazda MX-5 offered a readily available modern alternative, while legislative changes encouraged imports of inexpensive used Japanese cars. The Sabre’s association with Ford Cortina hardware also limited its appeal, and production ended in 2001 after nine cars. Development of the Sabre Series 2 began in 2002. The new version incorporated a stronger chassis, a retained Cortina windscreen, Toyota Lexus V8 power and substantially revised styling. It was launched at the Hamilton Motor Show in March 2004, with five orders reported. Around the same period, Almac introduced the Clubsprint, a Lotus Seven-influenced kit using Mark I or Mark II Ford Escort components. A larger Clubsprint XL was subsequently developed for customers seeking more room and a larger chassis. The company’s business model has remained focused on specialist, low-volume vehicle production rather than mass-market manufacturing. Its fibreglass bodies, kit packages and occasional turnkey builds are aimed at enthusiasts who value distinctive styling, self-build projects and traditional sports-car layouts. On 31 May 2024, Malcolm Sankey of Matamata Panelworks purchased the company. Publicly available material identifies the ownership change but does not provide enough information to describe later production volumes, staffing, financial results or a new corporate strategy.
- 2024
Ownership changes to Malcolm Sankey
[1]Malcolm Sankey of Matamata Panelworks purchases Almac on 31 May.
- 2004
Sabre Series 2 debuts at Hamilton Motor Show
[1]The updated Sabre is launched in March with revised bodywork, a stronger chassis and Toyota Lexus V8 power.
- 2002
Sabre Series 2 development begins
[1]Almac starts work on a stronger, substantially revised Sabre using updated mechanical components.
- 2002
Clubsprint is launched
[1]Almac introduces the Lotus Seven-influenced Clubsprint kit using Ford Escort donor parts.
- 2001
Original Sabre production ends
[1]Production of the first-generation Sabre ends after nine vehicles.
- 1994
Sabre receives specialist-car coverage
[1]The Sabre is featured in New Zealand Classic Car magazine as Almac develops its more original sports-car design.
- 1989
TG kits go on sale
[1]The TG enters the market with an Almac-designed chassis and Holden Gemini donor components.
- 1988
TC production ends and TG development begins
[1]The TC program ends as suitable Triumph Herald chassis become difficult to find, while development starts on the TG.
- 1986
Almac TC is introduced
[1]The company adds the TC, a sports-car design loosely influenced by the MG TC and intended for Triumph Herald chassis.
- 1984
Almac Cobra 427 project reaches the market
[1]The first Cobra-style car is displayed at the National Hot Rod Show and 17 cars are sold during the year.
Products and positioning
A New Zealand specialist kit-car manufacturer serving automotive enthusiasts with fibreglass-bodied replicas and low-volume sports-car designs that use donor-car or purpose-built chassis.
Cobra-style kit car · 1984
Almac 427
The 427 was Almac’s first commercially important automotive product. Developed with George Ulyate and built around chassis supplied by KiwiRaceCars.com, it used an Almac fibreglass body styled after the Shelby Cobra 427. The earliest cars were not badged as Almac products. The line became the company’s strongest-volume program, with more than 450 Cobra bodies reportedly produced.
Sports-car kit · 1986
Almac TC
The TC was introduced as a design loosely influenced by the MG TC rather than as a direct replica. It was engineered to fit a Triumph Herald chassis, and Almac supplied both kit versions and some turnkey cars. Approximately 25 kits were sold over two years. Production ended when suitable donor chassis became difficult to obtain and the platform limited engine choices.
Sports-car kit · 1989
Almac TG
The TG evolved from the TC but introduced an Almac-designed chassis and Holden Gemini donor components. Its first kits reached customers in 1989. The model did not match the TC’s sales performance, and demand tapered after approximately 16 examples.
Original sports-car kit · 1991
Almac Sabre
The first Sabre represented Almac’s effort to move beyond replica-based products. It used a purpose-built chassis, Ford Cortina components and a Leyland P76 V8 engine. Although the car received coverage in enthusiast publications, market competition from the Mazda MX-5 and imported Japanese cars constrained demand. Production ended in 2001 after nine cars.
Updated sports-car kit · 2004
Almac Sabre Series 2
The Sabre Series 2 was developed from 2002 and launched at the Hamilton Motor Show in March 2004. It received a stronger chassis, substantially revised exterior styling, a retained Ford Cortina windscreen and a Toyota Lexus V8 engine. Five orders were reported at the launch event.
Seven-style kit car · 2002
Almac Clubsprint
The Clubsprint was developed as a relatively affordable lightweight sports-car kit influenced by the Lotus Seven format. The design used Mark I or Mark II Ford Escort parts and was promoted through Classic Car magazine in 2002. A larger Clubsprint XL variant was later created for customers wanting more space and a larger chassis.
Larger Seven-style kit car
Almac Clubsprint XL
The Clubsprint XL expanded the Clubsprint concept with a larger chassis intended to meet demand from customers who wanted more room than the standard lightweight package provided. Detailed production totals and current availability are not established by the available reference material.
Brand decisions
2024
Sale of Almac to Matamata Panelworks owner Malcolm SankeyM&ABackground
After decades under the McDonald-founded business, ownership of Almac changed on 31 May 2024.
Action taken
Malcolm Sankey of Matamata Panelworks purchased the company.
Aftermath
The available source confirms the ownership transfer but does not document the buyer’s subsequent operating strategy or production plans.
2002
Development of the Sabre Series 2Generation changeBackground
The original Sabre had reached only limited production, while Almac continued seeking a stronger and more competitive modern sports-car package.
Action taken
The company designed a new chassis, retained the Cortina windscreen, selected Toyota Lexus V8 power and revised the body styling.
Aftermath
The revised model debuted in 2004 and attracted five reported orders at launch.
1984
Commercial introduction of the Almac 427Product launchBackground
After an earlier Volkswagen-based design failed to develop into a product, McDonald shifted toward a Cobra-style fibreglass body and worked with an external chassis builder.
Action taken
Almac displayed the first car at the National Hot Rod Show and began supplying the 427 body and related kit components.
Aftermath
The 427 became Almac’s largest-volume program, with more than 450 bodies reportedly produced over time.
Sources1 sources
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