By SEMA News Editors

 

SEMA Garage and BigRep America today announced a new partnership that will give SEMA members throughout North America access to their newly offered large-format 3D printing services. Through this collaboration, the SEMA Garage facility in Diamond Bar, California, will serve as the hub for these services, enabling members to produce parts ranging from early-stage prototypes to functional components using BigRep's catalog of validated 3D-printing filaments.

SEMA Garage is the product development and technology resource center of SEMA, serving member companies in the automotive specialty equipment industry. It has consistently positioned itself at the forefront of emerging manufacturing and product development technologies, offering advanced vehicle testing, 3D scanning, OEM data and manufacturing services to support members' product development, research and compliance needs. The addition of large-format additive manufacturing represents the next chapter in that commitment.

"We couldn't be more excited about this partnership with SEMA Garage. It's a meaningful step forward in how we bring large-format additive manufacturing to the automotive industry in North America," said Jeff Olson, president, BigRep America. "The automotive sector has always been at the heart of what we do, and by working directly with SEMA Garage, we're making it easier than ever for their members to tap into that technology for real large-scale applications."

"SEMA Garage is thrilled to partner with BigRep to bring large-format rapid prototyping into our Product Development service lineup," said Jim Moore, vice president, OEM and product development, SEMA. "This cutting-edge capability gives our members the tools to stretch the limits of innovation and improve the speed and efficiency of their development process."

The Diamond Bar facility will be home to the BigRep STUDIO, a large-format 3D printer with a well-established track record in the automotive industry. The STUDIO is purpose-built for professional environments, capable of printing parts at full-scale using a broad range of materials--from standard prototyping filaments to engineering-grade thermoplastics suited for demanding functional applications.

BigRep brings deep roots in the automotive sector to this partnership. The company has worked with major automotive OEMs, including Ford, and has supported aftermarket shops nationwide in producing custom parts, interior components, and fabrication tooling. BigRep technology has also made its way into motorsports through a collaboration with LEGACY MOTOR CLUB of the NASCAR Cup Series, where large-format printing has been used to develop large-scale tooling, aerodynamic components and race-ready parts.

For more information, contact productdevelopment@sema.org.

By SEMA News Editors

 

Registration is now open for the SEMA Show Exhibitor Summit, which returns to Las Vegas in June, at the Las Vegas Convention Center South Hall Skybridge. View the agenda and register at semashow.com/exhibitor-summit.

The Exhibitor Summit--which takes place Wednesday, June 10 and Thursday, June 11, with hotel check-out Friday, June 12--is an exhibitor's strategic head start. Whether a company is a first-timer or a seasoned exhibitor, this event is where exhibitors can refine their plan, cut unnecessary costs and unlock true SEMA Show success. The program will cover how to:

• Boost ROI: Work directly with experts to plan, budget and optimize SEMA Show investments.
• Drive Traffic: Learn proven strategies to attract buyers and generate leads.
• Save Money: Learn insider strategies to cut costs on drayage, electrical and rigging.
• Perfect Your Launch: Get a step-by-step roadmap for product launches and media engagement.
• Promote Your Brand: Explore sponsorship and marketing opportunities to increase brand visibility.
• Network: Build direct relationships with the SEMA team and fellow industry leaders.

Preview The New LVCC

In addition, this year's Summit delivers an all-access preview of the newly remodeled Las Vegas Convention Center, now featuring a modernized campus designed to elevate the exhibitor and attendee experience with:

• A reimagined Central Hall Grand Lobby that features a striking glass curtain wall and abundant natural light.
• New digital signage creating high-visibility branding opportunities in the Grand Lobby.
• A climate-controlled concourse that connects the North and South Halls.
• A new East entrance, state-of-the-art boardroom and modern administrative offices redefine the South Hall.
• The extended West Hall ribbon roof brings bold cohesion across the campus.

Register to join this event in Las Vegas this June, and the SEMA team will have the rest covered. Exhibitors enjoy complimentary event registration, a two-night hotel stay (for up to two representatives from each exhibiting company) and select meals--all courtesy of SEMA.

View the agenda and register at semashow.com/exhibitor-summit.

 

Have questions about the Exhibitor Summit? Contact SEMA Show Management at 909-396-0289 or email regmgr@sema.org.

---

In related news, SEMA has launched a new customer management system ahead of this year's SEMA Show, November 3-6, 2026, in Las Vegas. Read more about that here, or visit semashow.com/exhibitor.

To improve how SEMA engages with exhibitors and serves the industry year-round, the association has migrated to a new customer management system powered by Salesforce.

By Ashley Reyes

 

The SEMA Businesswomen's Network (SBN) has named Jennifer Reed, company coordinator at Dee Zee, as the network's newest #SheIsSEMA spotlight member. 

Get to know Reed in her interview with SEMA News below. 

SEMA News: How many years have you been with your current company and what do you enjoy most about working there? 

Jennifer Reed: I started working with Dee Zee in December 2021. What I enjoy most about working here is the opportunity to support both employees and customers by helping resolve any issues they may encounter. I find fulfillment in being a reliable resource for others and contributing to a positive experience for everyone involved. I also enjoy leading events, taking on a variety of tasks and being involved in diverse projects. These experiences keep my role dynamic and engaging, and they allow me to continuously grow while making a meaningful impact.

SN: What is the most challenging part of running your business or job? 

JR: One of the most challenging aspects of my position is ensuring consistent communication and inclusion across all three shifts. It can be difficult to coordinate efforts so that every team member, regardless of their shift, receives the same information and can participate in events and initiatives. However, I see this as an important priority, and I continually look for ways to improve accessibility and engagement for all employees.

SN: How many years have you been in the industry and what was your first industry job? 

JR: This is my first role within this specific industry. However, I'm very familiar with the company and have always appreciated that it is family-owned and values a strong sense of community. While the industry itself is new to me, I bring a solid background in administrative roles, which has allowed me to quickly adapt and contribute effectively. My previous experience has helped me develop strong organizational, communication and problem-solving skills that align well with the needs of this role.

SN: What are three qualities that got you to where you are today? 

JR: Three qualities that have helped me get to where I am today are dependability, attentiveness and a positive attitude. I take pride in being someone others can count on--I rarely, if ever, miss work, and I'm always fully present and engaged in what needs to be done. I'm highly attentive to the needs of both employees and customers, and I approach every task with care and dedication. I also bring positive energy to the workplace, which helps create a supportive and collaborative environment. I've been fortunate to receive recognition from the owner, managers, team leads, employees and customers, and it's incredibly rewarding when people remember you for your hard work and the impact you've made.

SN: What have been your biggest challenges and accomplishments as a woman in the industry? 

JR: As a woman in the industry, one of my biggest challenges has been navigating cultural differences in a diverse workplace. At times, I've encountered situations where individuals from certain cultural backgrounds were initially hesitant to accept guidance or support from a woman. It was frustrating, but I chose to meet those moments with professionalism and persistence. Over time, by consistently showing that I'm knowledgeable, approachable and genuinely here to help, I've earned the respect of many of my colleagues. One of my proudest accomplishments is that I'm now recognized and respected by employees across different teams and backgrounds--and they seek out my input and trust my support.

SN: Who are your role models or mentors in the industry? 

JR: I wouldn't say I have just one specific role model or mentor--instead, I've learned something valuable from nearly everyone I've worked with. I'm the kind of person who listens closely, takes in different perspectives and tries to use that insight to improve how I support others. That said, our steering team and company leaders have been especially impactful. They bring a wealth of experience, and I often draw on their knowledge and examples when facing challenges. Their guidance has helped me approach situations more confidently and has made the work I do run more smoothly.

SN: What is the best career advice you have received? 

JR: The best career advice I've received is that life is too short--and that each of us plays an important role in the world. This advice has really shaped both my personal and professional mindset. I've learned not to stress over every little thing. Instead, I focus on what truly matters, address what needs my attention and let go of the things that aren't worth the energy. This approach has helped me stay grounded, manage stress and be more effective in how I work with others.

SN: Have you always wanted to work in the automotive industry? What keeps you here? 

JR: I didn't originally plan to work in the automotive industry--I actually wanted to become a counselor and help people in that way. But now that I'm here, I've discovered a real passion for it. I've always had a high-energy fascination with the wide variety of transportation and how everything connects. What truly keeps me here, though, is the sense of community. Being part of a family-owned business and receiving respect and support from my colleagues makes me love what I do. It's that environment--and the ability to make a positive impact--that keeps me motivated every day.

SN: Who was the most influential person on your career/goals? 

JR: The most influential people in my career and goals have been my parents. They were both incredibly hard workers and earned a great deal of respect over the years because of their dedication and integrity. Watching them set that example showed me the value of work ethic, perseverance and treating others with respect. That kind of legacy is priceless to me, and it's something I strive to carry forward in my own career.

---

Fill out a #SheIsSEMA spotlight form to submit a self-nomination or nominate a colleague and highlight how you or she is contributing to the specialty-equipment industry. Selected candidates are automatically eligible to be considered for SBN's #SheIsSEMA Woman of the Year award, featured on SBN's social media, SEMA News and recognized on the sema.org/she-is-sema website. 

From the SEMA Washington, D.C., office

 

SEMA and PRI are leading a national effort to protect racetracks from NIMBY-generated nuisance complaints and lawsuits. Here’s the latest: 

Right-to-race legislation in Wisconsin continues to enjoy positive momentum, with the Wisconsin State Assembly recently passing AB 880 with no opposition. 

The bill protects long-standing race tracks from nuisance-based lawsuits brought by nearby property owners who moved into the area after the tracks were already established.  

• The legislation now moves to the Senate, where it must pass the Senate Transportation and Local Government Committee before it reaches the Senate floor. 

In Wisconsin, SEMA and PRI emphasized that many motorsports facilities are small, multi-generational businesses built through decades of hard work, as well as personal and community investment. 

Learn more about the Right to Race campaign here. 

For more information, contact SEMA and PRI Senior Manager for State Government Affairs Tierra Hubbard at tierrah@sema.org. 

Image courtesy of Shutterstock | Aaron of L.A. Photography

From the SEMA Washington, D.C., office

 

SEMA and PRI are leading a national effort to protect racetracks from NIMBY-generated nuisance complaints and lawsuits. Here’s the latest: 

Right-to-race legislation in Wisconsin continues to enjoy positive momentum, with the Wisconsin State Assembly recently passing AB 880 with no opposition. 

The bill protects long-standing race tracks from nuisance-based lawsuits brought by nearby property owners who moved into the area after the tracks were already established.  

• The legislation now moves to the Senate, where it must pass the Senate Transportation and Local Government Committee before it reaches the Senate floor. 

In Wisconsin, SEMA and PRI emphasized that many motorsports facilities are small, multi-generational businesses built through decades of hard work, as well as personal and community investment. 

Learn more about the Right to Race campaign here. 

For more information, contact SEMA and PRI Senior Manager for State Government Affairs Tierra Hubbard at tierrah@sema.org. 

Image courtesy of Shutterstock | Aaron of L.A. Photography

By Jack Haworth

Photography by Kyle Kuhnhausen

 

To make a name for yourself at the annual SEMA Show, you need to think, design and build beyond convention. Surface-level aesthetics may generate casual attention, but true credibility is earned with thoughtful engineering, precise execution and detailed craftsmanship.

Within the aftermarket community, Kyle Kuhnhausen is quickly becoming a household name.

In 2018, he showed up to the SEMA Show with his "InZanity" '72 Datsun 240z build, earning him a Top 4 spot and Top Young Gun Award in the SEMA Battle of the Builders (BOTB). In 2020, his Ballistic Beige '64 Corvette Stingray earned him a BOTB Top 12 spot, as well as the attention of a new client looking to build a nice Pro Touring car, but one that was "kind of the run-of-the-mill thing you'd see at Barrett-Jackson."

Five years and 10,000 hours of work later, that nice Pro Touring car was ready for its big debut -- at the 2025 SEMA Show in Las Vegas.

It was Kuhnhausen's most impressive and ambitious build yet -- "Serious66," a modernized '66 C2 Corvette masterpiece, "conceived to merge American heritage with European refinement."

"Five years of uncompromising work distilled into a singular vision: the essence of a '66 C2 elevated with modern engineering, bespoke craftsmanship and cohesive design," writes Kuhnhausen on his website. "Every surface, seam and system has been re-imagined from one-off body details and integrated glass, to an LT4/ZF8HP drivetrain and hand-built interior. Serious66 is not just restored, it's comprehensively re-engineered -- a study in restraint, innovation and execution."

Kuhnhausen said he dubbed his project Serious66 to reflect the nature of the build, "serious thought, serious hardware and serious execution." It wasn't the type of build that begs for cheap attention, but one that confidently unveils its brilliance through countless small details that add up to a serious achievement.

"Each decision balanced subtle restraint with bold execution, producing a Corvette that feels both instantly familiar and entirely new," he notes.

 

At first glance, the C2 silhouette does look familiar. But its refined finish disguises an engineering marvel, "one that preserves the midyear silhouette while advancing every other aspect to the highest standards of performance and craftsmanship."

Kuhnhausen's craftsmanship was acknowledged with a 2025 SEMA Best Engineered Vehicle of the Year Award -- a coveted accolade honoring a SEMA Show feature vehicle that demonstrates exceptional engineering throughout the entire vehicle, beyond just physical appearance.

According to Kuhnhausen, the success of Serious66 is best experienced behind the wheel.

"Driving this car is actually the greatest part of the whole experience. It truly drives like a new car with the 8HP transmission and the direct-injected LT4. The gearbox knows exactly what you want to do, the ride is plush but sporty, you can have a conversation in the cabin at freeway speeds. It really all comes together and as close as I've ever felt to driving a 911 GT3 Porsche is in this car."

EUROPEAN INSPIRATION

Kuhnhausen credits his client with shaping several of Serious66's distinctive design features, inspired by a visit to the Guggenheim Museum Bilbao and their exhibit of '60s European cars.

"He was sending me pictures day and night of all these key factors of iconic '60s European cars like the Ferrari 250 GTO, Jaguar E-Type and Mercedes 300SL Gullwing," said Kuhnhausen. "The common theme of those was they all had these smooth rockers, where the rocker seamlessly transitions to the ground and rolls under the car a little bit."

Integrating elements of European refinement into a classic American sports car would be a unique challenge, but Kuhnhausen was up for it.

 

"The guiding philosophy became refinement without erasure, to honor the C2's essence while elevating it with uninterrupted surfaces, integrated engineering, and timeless detail. More than 3,600 hours were dedicated to bodywork alone, with hundreds of one-off, CNC-machined and fabricated parts and vacuum-formed components developed to execute the vision."

Intricate solutions are implemented throughout the car, helping to refine the vehicle's overall aesthetic and performance. For example, even the fuel fill unit has been completely redesigned.

"The fuel fill location is moved to display the central body line uninterrupted," says Kuhnhausen. "It is now packaged in a fully bespoke CNC-machined assembly under the rear emblem."

MILLIMETERS TO SPARE

Serious66 has been upgraded with all cutting-edge modern systems. This includes creature comforts like A/C and stereo and excellent Pro-Touring performance created by a direct injected dry-sump oiled LT4 and ZF8HP-70 eight-speed automatic transmission that seamlessly communicates with the engine ECU via CAN-bus network.

"Function is always the driving factor," says Kuhnhausen. "We don't build anything that isn't made to drive and use as intended. But to do that, you need substantially more hardware than most people put into these things."

The challenge lies with the platform itself; the C2 Corvette offers notoriously little room for even modest modifications.

"I've done a Datsun 240Z, which is a really small car, and I feel like it had a lot more room for stuff than a C2 Corvette," said Kuhnhausen. "C2s are one of the hardest packaging cars ever, when you start interjecting modern tech and you have five different computers. I had to get super creative."

To further intensify the challenge, he needed to fit a very tall driver into this very small car -- 6-ft. 5-in. tall.

 

"The firewall is completely custom and recessed 4 in. in the center for engine clearance and bellhousing access, along with the driver's footwell being protruded into the engine bay up to 6 in. over stock in portions and downwards to more comfortably accommodate the driver with full brake pedal swing."

Electronics were another major problem, but Kuhnhausen managed to solve it with creative solutions. He repurposed the glovebox as an electronics access point, with a custom steel liner to house the fuel pump PWM controller, engine harness fuse panel and diagnostic port, and TurboLamik transmission controller.

Additionally, he utilized one aspect of his client's vision for dual purpose.

"The suitcase was so instrumental in the vibe that the client wanted [it] based off the Mercedes Gullwing, just something really timeless and classy. But then I interjected and found a way to make it a functional piece of the car. So, it has a removable faux floor in a plaid covering, and that's where I hide a lot of the electronics."

Once it was time to put the car on the chassis, the clearances were minimal.

"We're talking millimeter-space constraints once it's all said and done because we didn't pull any punches on the performance aspect," Kuhnhausen explains. "That was very important to me; that we didn't build a show car."

THE GREAT EQUALIZER

Kuhnhausen created hundreds of one-off components to address packaging constraints, improve performance and refine the overall build. While fabrication remains his specialty, CAD programming and 3D printing has elevated the work to another level.

 

"I'm on the computer almost as much as I am behind a welding hood nowadays," says Kuhnhausen. "I'll 3D print the prototype in-house just to make sure the dimensions are right, and then I'll send it to SendCutSend and I'll get a metal part back in a few days. I don't have a million-dollar 12-kW fiber laser, but I get results like that and it doesn't slow up my workflow too much. It's really equalized the industry."

Kuhnhausen is well-skilled in the traditional methods of fabricating by hand. He built a C2 similar to Serious66 in 2019, using minimal CAD programming at the time.

"I've done it by hand, but now that I have all these tools at my disposal, there's no going back," asserts Kuhnhausen. "It just creates such a better product and gives me the ability to build off of the platform I just created. I have all those parts in CAD, so if I want to do another one, I don't have to start from zero."

Kuhnhausen's utilization of CAD and 3D printing began to increase around the time he launched the Serious66 project in 2020. Now he has four 3D printers that are "pretty much going 24 hours a day," building tools to sell online and prototyping his latest ideas.

"It just gets crazier every year. Now we can do 3D printing in metal and in engineering-grade materials. You can build anything you want to build and do it on a fairly reasonable budget. A 3D scanner is under $5,000 and you can get a good 3D printer for a $1,000. It's really scaled down to something that's utilizable."

As shops continue to expand their use of this technology, Kuhnhausen is seeing an explosion of creativity unleashed across the industry.

"Every big hot-rod shop now is building incredibly badass stuff that wasn't even something you could think about 10 years ago. Most shops now have a staff engineer versus fabricators. The precision has just gone through the roof, and the technology has followed to where we're building darn near aerospace-grade hot rods. It's just wild."

 

While a hot-rod space race may initially sound like a disadvantage for the small shops, that hasn't proven to be the case. Online fabrication services like SendCutSend have also helped even the playing field.

"SendCutSend just got into CNC five-axis milling. You can have a one-off part CNC five-axis milled and have it at your doorstep in under a week versus what used to be probably 10 times the cost and five times the lead time. It was basically priced out of being an option, whereas now it's the standard."

LIKE FATHER, LIKE SON

This new standard is unleashing the potential of talented builders like Kyle Kuhnhausen.

While his cars consistently attract attention at the SEMA Show, they are built alongside his father in a modest 1,200-sq.-ft. shop in rural Oregon. No large staff or million-dollar machines, just a father and son working together to produce some of the most innovative builds in the industry.

"My dad owned a mechanics and bodyshop, and he did a lot of drag racing on the weekends," said Kuhnhausen. "There are pictures of me at six months old sitting on the air cleaner of his drag car. I just recreated that with my daughter on top of the motor of Serious66, so it came full circle. It's just in my blood; I grew up fully immersed in it my whole life."

Kyle is only 34 years old, but the two have been working together for more than 20 years. He got his first job at his dad's shop when he was 12, the same age he learned to MIG weld. Today those roles are reversed. Kyle owns the shop -- Kuhnhausen Metal Concepts -- and his "semi-retired" dad is his only employee.

"My dad is my best friend and my mentor. Even back when I was 12 and I got my first job working for him, the loose idea was to always build hot rods together. So, to be able to realize that and do it at the scale we do, it's such a blessing. We do what we love every day so it's not really work, though Serious66 is probably one of the most challenging things you could ever do."

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By Jack Haworth

Photography by Kyle Kuhnhausen

 

To make a name for yourself at the annual SEMA Show, you need to think, design and build beyond convention. Surface-level aesthetics may generate casual attention, but true credibility is earned with thoughtful engineering, precise execution and detailed craftsmanship.

Within the aftermarket community, Kyle Kuhnhausen is quickly becoming a household name.

In 2018, he showed up to the SEMA Show with his "InZanity" '72 Datsun 240z build, earning him a Top 4 spot and Top Young Gun Award in the SEMA Battle of the Builders (BOTB). In 2020, his Ballistic Beige '64 Corvette Stingray earned him a BOTB Top 12 spot, as well as the attention of a new client looking to build a nice Pro Touring car, but one that was "kind of the run-of-the-mill thing you'd see at Barrett-Jackson."

Five years and 10,000 hours of work later, that nice Pro Touring car was ready for its big debut -- at the 2025 SEMA Show in Las Vegas.

It was Kuhnhausen's most impressive and ambitious build yet -- "Serious66," a modernized '66 C2 Corvette masterpiece, "conceived to merge American heritage with European refinement."

"Five years of uncompromising work distilled into a singular vision: the essence of a '66 C2 elevated with modern engineering, bespoke craftsmanship and cohesive design," writes Kuhnhausen on his website. "Every surface, seam and system has been re-imagined from one-off body details and integrated glass, to an LT4/ZF8HP drivetrain and hand-built interior. Serious66 is not just restored, it's comprehensively re-engineered -- a study in restraint, innovation and execution."

Kuhnhausen said he dubbed his project Serious66 to reflect the nature of the build, "serious thought, serious hardware and serious execution." It wasn't the type of build that begs for cheap attention, but one that confidently unveils its brilliance through countless small details that add up to a serious achievement.

"Each decision balanced subtle restraint with bold execution, producing a Corvette that feels both instantly familiar and entirely new," he notes.

 

At first glance, the C2 silhouette does look familiar. But its refined finish disguises an engineering marvel, "one that preserves the midyear silhouette while advancing every other aspect to the highest standards of performance and craftsmanship."

Kuhnhausen's craftsmanship was acknowledged with a 2025 SEMA Best Engineered Vehicle of the Year Award -- a coveted accolade honoring a SEMA Show feature vehicle that demonstrates exceptional engineering throughout the entire vehicle, beyond just physical appearance.

According to Kuhnhausen, the success of Serious66 is best experienced behind the wheel.

"Driving this car is actually the greatest part of the whole experience. It truly drives like a new car with the 8HP transmission and the direct-injected LT4. The gearbox knows exactly what you want to do, the ride is plush but sporty, you can have a conversation in the cabin at freeway speeds. It really all comes together and as close as I've ever felt to driving a 911 GT3 Porsche is in this car."

EUROPEAN INSPIRATION

Kuhnhausen credits his client with shaping several of Serious66's distinctive design features, inspired by a visit to the Guggenheim Museum Bilbao and their exhibit of '60s European cars.

"He was sending me pictures day and night of all these key factors of iconic '60s European cars like the Ferrari 250 GTO, Jaguar E-Type and Mercedes 300SL Gullwing," said Kuhnhausen. "The common theme of those was they all had these smooth rockers, where the rocker seamlessly transitions to the ground and rolls under the car a little bit."

Integrating elements of European refinement into a classic American sports car would be a unique challenge, but Kuhnhausen was up for it.

 

"The guiding philosophy became refinement without erasure, to honor the C2's essence while elevating it with uninterrupted surfaces, integrated engineering, and timeless detail. More than 3,600 hours were dedicated to bodywork alone, with hundreds of one-off, CNC-machined and fabricated parts and vacuum-formed components developed to execute the vision."

Intricate solutions are implemented throughout the car, helping to refine the vehicle's overall aesthetic and performance. For example, even the fuel fill unit has been completely redesigned.

"The fuel fill location is moved to display the central body line uninterrupted," says Kuhnhausen. "It is now packaged in a fully bespoke CNC-machined assembly under the rear emblem."

MILLIMETERS TO SPARE

Serious66 has been upgraded with all cutting-edge modern systems. This includes creature comforts like A/C and stereo and excellent Pro-Touring performance created by a direct injected dry-sump oiled LT4 and ZF8HP-70 eight-speed automatic transmission that seamlessly communicates with the engine ECU via CAN-bus network.

"Function is always the driving factor," says Kuhnhausen. "We don't build anything that isn't made to drive and use as intended. But to do that, you need substantially more hardware than most people put into these things."

The challenge lies with the platform itself; the C2 Corvette offers notoriously little room for even modest modifications.

"I've done a Datsun 240Z, which is a really small car, and I feel like it had a lot more room for stuff than a C2 Corvette," said Kuhnhausen. "C2s are one of the hardest packaging cars ever, when you start interjecting modern tech and you have five different computers. I had to get super creative."

To further intensify the challenge, he needed to fit a very tall driver into this very small car -- 6-ft. 5-in. tall.

 

"The firewall is completely custom and recessed 4 in. in the center for engine clearance and bellhousing access, along with the driver's footwell being protruded into the engine bay up to 6 in. over stock in portions and downwards to more comfortably accommodate the driver with full brake pedal swing."

Electronics were another major problem, but Kuhnhausen managed to solve it with creative solutions. He repurposed the glovebox as an electronics access point, with a custom steel liner to house the fuel pump PWM controller, engine harness fuse panel and diagnostic port, and TurboLamik transmission controller.

Additionally, he utilized one aspect of his client's vision for dual purpose.

"The suitcase was so instrumental in the vibe that the client wanted [it] based off the Mercedes Gullwing, just something really timeless and classy. But then I interjected and found a way to make it a functional piece of the car. So, it has a removable faux floor in a plaid covering, and that's where I hide a lot of the electronics."

Once it was time to put the car on the chassis, the clearances were minimal.

"We're talking millimeter-space constraints once it's all said and done because we didn't pull any punches on the performance aspect," Kuhnhausen explains. "That was very important to me; that we didn't build a show car."

THE GREAT EQUALIZER

Kuhnhausen created hundreds of one-off components to address packaging constraints, improve performance and refine the overall build. While fabrication remains his specialty, CAD programming and 3D printing has elevated the work to another level.

 

"I'm on the computer almost as much as I am behind a welding hood nowadays," says Kuhnhausen. "I'll 3D print the prototype in-house just to make sure the dimensions are right, and then I'll send it to SendCutSend and I'll get a metal part back in a few days. I don't have a million-dollar 12-kW fiber laser, but I get results like that and it doesn't slow up my workflow too much. It's really equalized the industry."

Kuhnhausen is well-skilled in the traditional methods of fabricating by hand. He built a C2 similar to Serious66 in 2019, using minimal CAD programming at the time.

"I've done it by hand, but now that I have all these tools at my disposal, there's no going back," asserts Kuhnhausen. "It just creates such a better product and gives me the ability to build off of the platform I just created. I have all those parts in CAD, so if I want to do another one, I don't have to start from zero."

Kuhnhausen's utilization of CAD and 3D printing began to increase around the time he launched the Serious66 project in 2020. Now he has four 3D printers that are "pretty much going 24 hours a day," building tools to sell online and prototyping his latest ideas.

"It just gets crazier every year. Now we can do 3D printing in metal and in engineering-grade materials. You can build anything you want to build and do it on a fairly reasonable budget. A 3D scanner is under $5,000 and you can get a good 3D printer for a $1,000. It's really scaled down to something that's utilizable."

As shops continue to expand their use of this technology, Kuhnhausen is seeing an explosion of creativity unleashed across the industry.

"Every big hot-rod shop now is building incredibly badass stuff that wasn't even something you could think about 10 years ago. Most shops now have a staff engineer versus fabricators. The precision has just gone through the roof, and the technology has followed to where we're building darn near aerospace-grade hot rods. It's just wild."

 

While a hot-rod space race may initially sound like a disadvantage for the small shops, that hasn't proven to be the case. Online fabrication services like SendCutSend have also helped even the playing field.

"SendCutSend just got into CNC five-axis milling. You can have a one-off part CNC five-axis milled and have it at your doorstep in under a week versus what used to be probably 10 times the cost and five times the lead time. It was basically priced out of being an option, whereas now it's the standard."

LIKE FATHER, LIKE SON

This new standard is unleashing the potential of talented builders like Kyle Kuhnhausen.

While his cars consistently attract attention at the SEMA Show, they are built alongside his father in a modest 1,200-sq.-ft. shop in rural Oregon. No large staff or million-dollar machines, just a father and son working together to produce some of the most innovative builds in the industry.

"My dad owned a mechanics and bodyshop, and he did a lot of drag racing on the weekends," said Kuhnhausen. "There are pictures of me at six months old sitting on the air cleaner of his drag car. I just recreated that with my daughter on top of the motor of Serious66, so it came full circle. It's just in my blood; I grew up fully immersed in it my whole life."

Kyle is only 34 years old, but the two have been working together for more than 20 years. He got his first job at his dad's shop when he was 12, the same age he learned to MIG weld. Today those roles are reversed. Kyle owns the shop -- Kuhnhausen Metal Concepts -- and his "semi-retired" dad is his only employee.

"My dad is my best friend and my mentor. Even back when I was 12 and I got my first job working for him, the loose idea was to always build hot rods together. So, to be able to realize that and do it at the scale we do, it's such a blessing. We do what we love every day so it's not really work, though Serious66 is probably one of the most challenging things you could ever do."

READ MORE LIKE THIS FOR FREE

SEMA magazine is now available to everyone--at no cost--online by claiming your complimentary subscription. Haven't claimed yours yet? Here's how:

• Claim your coupon voucher HERE
• Fill in the mandatory fields and questions regarding your automotive interests
• Subscribe
• Download the SEMA magazine app
• Sign in to access a year's worth of valuable industry knowledge
• Start reading!

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By Jack Haworth

Photography by Kyle Kuhnhausen

 

To make a name for yourself at the annual SEMA Show, you need to think, design and build beyond convention. Surface-level aesthetics may generate casual attention, but true credibility is earned with thoughtful engineering, precise execution and detailed craftsmanship.

Within the aftermarket community, Kyle Kuhnhausen is quickly becoming a household name.

In 2018, he showed up to the SEMA Show with his "InZanity" '72 Datsun 240z build, earning him a Top 4 spot and Top Young Gun Award in the SEMA Battle of the Builders (BOTB). In 2020, his Ballistic Beige '64 Corvette Stingray earned him a BOTB Top 12 spot, as well as the attention of a new client looking to build a nice Pro Touring car, but one that was "kind of the run-of-the-mill thing you'd see at Barrett-Jackson."

Five years and 10,000 hours of work later, that nice Pro Touring car was ready for its big debut -- at the 2025 SEMA Show in Las Vegas.

It was Kuhnhausen's most impressive and ambitious build yet -- "Serious66," a modernized '66 C2 Corvette masterpiece, "conceived to merge American heritage with European refinement."

"Five years of uncompromising work distilled into a singular vision: the essence of a '66 C2 elevated with modern engineering, bespoke craftsmanship and cohesive design," writes Kuhnhausen on his website. "Every surface, seam and system has been re-imagined from one-off body details and integrated glass, to an LT4/ZF8HP drivetrain and hand-built interior. Serious66 is not just restored, it's comprehensively re-engineered -- a study in restraint, innovation and execution."

Kuhnhausen said he dubbed his project Serious66 to reflect the nature of the build, "serious thought, serious hardware and serious execution." It wasn't the type of build that begs for cheap attention, but one that confidently unveils its brilliance through countless small details that add up to a serious achievement.

"Each decision balanced subtle restraint with bold execution, producing a Corvette that feels both instantly familiar and entirely new," he notes.

 

At first glance, the C2 silhouette does look familiar. But its refined finish disguises an engineering marvel, "one that preserves the midyear silhouette while advancing every other aspect to the highest standards of performance and craftsmanship."

Kuhnhausen's craftsmanship was acknowledged with a 2025 SEMA Best Engineered Vehicle of the Year Award -- a coveted accolade honoring a SEMA Show feature vehicle that demonstrates exceptional engineering throughout the entire vehicle, beyond just physical appearance.

According to Kuhnhausen, the success of Serious66 is best experienced behind the wheel.

"Driving this car is actually the greatest part of the whole experience. It truly drives like a new car with the 8HP transmission and the direct-injected LT4. The gearbox knows exactly what you want to do, the ride is plush but sporty, you can have a conversation in the cabin at freeway speeds. It really all comes together and as close as I've ever felt to driving a 911 GT3 Porsche is in this car."

EUROPEAN INSPIRATION

Kuhnhausen credits his client with shaping several of Serious66's distinctive design features, inspired by a visit to the Guggenheim Museum Bilbao and their exhibit of '60s European cars.

"He was sending me pictures day and night of all these key factors of iconic '60s European cars like the Ferrari 250 GTO, Jaguar E-Type and Mercedes 300SL Gullwing," said Kuhnhausen. "The common theme of those was they all had these smooth rockers, where the rocker seamlessly transitions to the ground and rolls under the car a little bit."

Integrating elements of European refinement into a classic American sports car would be a unique challenge, but Kuhnhausen was up for it.

 

"The guiding philosophy became refinement without erasure, to honor the C2's essence while elevating it with uninterrupted surfaces, integrated engineering, and timeless detail. More than 3,600 hours were dedicated to bodywork alone, with hundreds of one-off, CNC-machined and fabricated parts and vacuum-formed components developed to execute the vision."

Intricate solutions are implemented throughout the car, helping to refine the vehicle's overall aesthetic and performance. For example, even the fuel fill unit has been completely redesigned.

"The fuel fill location is moved to display the central body line uninterrupted," says Kuhnhausen. "It is now packaged in a fully bespoke CNC-machined assembly under the rear emblem."

MILLIMETERS TO SPARE

Serious66 has been upgraded with all cutting-edge modern systems. This includes creature comforts like A/C and stereo and excellent Pro-Touring performance created by a direct injected dry-sump oiled LT4 and ZF8HP-70 eight-speed automatic transmission that seamlessly communicates with the engine ECU via CAN-bus network.

"Function is always the driving factor," says Kuhnhausen. "We don't build anything that isn't made to drive and use as intended. But to do that, you need substantially more hardware than most people put into these things."

The challenge lies with the platform itself; the C2 Corvette offers notoriously little room for even modest modifications.

"I've done a Datsun 240Z, which is a really small car, and I feel like it had a lot more room for stuff than a C2 Corvette," said Kuhnhausen. "C2s are one of the hardest packaging cars ever, when you start interjecting modern tech and you have five different computers. I had to get super creative."

To further intensify the challenge, he needed to fit a very tall driver into this very small car -- 6-ft. 5-in. tall.

 

"The firewall is completely custom and recessed 4 in. in the center for engine clearance and bellhousing access, along with the driver's footwell being protruded into the engine bay up to 6 in. over stock in portions and downwards to more comfortably accommodate the driver with full brake pedal swing."

Electronics were another major problem, but Kuhnhausen managed to solve it with creative solutions. He repurposed the glovebox as an electronics access point, with a custom steel liner to house the fuel pump PWM controller, engine harness fuse panel and diagnostic port, and TurboLamik transmission controller.

Additionally, he utilized one aspect of his client's vision for dual purpose.

"The suitcase was so instrumental in the vibe that the client wanted [it] based off the Mercedes Gullwing, just something really timeless and classy. But then I interjected and found a way to make it a functional piece of the car. So, it has a removable faux floor in a plaid covering, and that's where I hide a lot of the electronics."

Once it was time to put the car on the chassis, the clearances were minimal.

"We're talking millimeter-space constraints once it's all said and done because we didn't pull any punches on the performance aspect," Kuhnhausen explains. "That was very important to me; that we didn't build a show car."

THE GREAT EQUALIZER

Kuhnhausen created hundreds of one-off components to address packaging constraints, improve performance and refine the overall build. While fabrication remains his specialty, CAD programming and 3D printing has elevated the work to another level.

 

"I'm on the computer almost as much as I am behind a welding hood nowadays," says Kuhnhausen. "I'll 3D print the prototype in-house just to make sure the dimensions are right, and then I'll send it to SendCutSend and I'll get a metal part back in a few days. I don't have a million-dollar 12-kW fiber laser, but I get results like that and it doesn't slow up my workflow too much. It's really equalized the industry."

Kuhnhausen is well-skilled in the traditional methods of fabricating by hand. He built a C2 similar to Serious66 in 2019, using minimal CAD programming at the time.

"I've done it by hand, but now that I have all these tools at my disposal, there's no going back," asserts Kuhnhausen. "It just creates such a better product and gives me the ability to build off of the platform I just created. I have all those parts in CAD, so if I want to do another one, I don't have to start from zero."

Kuhnhausen's utilization of CAD and 3D printing began to increase around the time he launched the Serious66 project in 2020. Now he has four 3D printers that are "pretty much going 24 hours a day," building tools to sell online and prototyping his latest ideas.

"It just gets crazier every year. Now we can do 3D printing in metal and in engineering-grade materials. You can build anything you want to build and do it on a fairly reasonable budget. A 3D scanner is under $5,000 and you can get a good 3D printer for a $1,000. It's really scaled down to something that's utilizable."

As shops continue to expand their use of this technology, Kuhnhausen is seeing an explosion of creativity unleashed across the industry.

"Every big hot-rod shop now is building incredibly badass stuff that wasn't even something you could think about 10 years ago. Most shops now have a staff engineer versus fabricators. The precision has just gone through the roof, and the technology has followed to where we're building darn near aerospace-grade hot rods. It's just wild."

 

While a hot-rod space race may initially sound like a disadvantage for the small shops, that hasn't proven to be the case. Online fabrication services like SendCutSend have also helped even the playing field.

"SendCutSend just got into CNC five-axis milling. You can have a one-off part CNC five-axis milled and have it at your doorstep in under a week versus what used to be probably 10 times the cost and five times the lead time. It was basically priced out of being an option, whereas now it's the standard."

LIKE FATHER, LIKE SON

This new standard is unleashing the potential of talented builders like Kyle Kuhnhausen.

While his cars consistently attract attention at the SEMA Show, they are built alongside his father in a modest 1,200-sq.-ft. shop in rural Oregon. No large staff or million-dollar machines, just a father and son working together to produce some of the most innovative builds in the industry.

"My dad owned a mechanics and bodyshop, and he did a lot of drag racing on the weekends," said Kuhnhausen. "There are pictures of me at six months old sitting on the air cleaner of his drag car. I just recreated that with my daughter on top of the motor of Serious66, so it came full circle. It's just in my blood; I grew up fully immersed in it my whole life."

Kyle is only 34 years old, but the two have been working together for more than 20 years. He got his first job at his dad's shop when he was 12, the same age he learned to MIG weld. Today those roles are reversed. Kyle owns the shop -- Kuhnhausen Metal Concepts -- and his "semi-retired" dad is his only employee.

"My dad is my best friend and my mentor. Even back when I was 12 and I got my first job working for him, the loose idea was to always build hot rods together. So, to be able to realize that and do it at the scale we do, it's such a blessing. We do what we love every day so it's not really work, though Serious66 is probably one of the most challenging things you could ever do."

READ MORE LIKE THIS FOR FREE

SEMA magazine is now available to everyone--at no cost--online by claiming your complimentary subscription. Haven't claimed yours yet? Here's how:

• Claim your coupon voucher HERE
• Fill in the mandatory fields and questions regarding your automotive interests
• Subscribe
• Download the SEMA magazine app
• Sign in to access a year's worth of valuable industry knowledge
• Start reading!

For step-by-step instructions on how to claim your free SEMA magazine subscription, click HERE.

By SEMA News Editors

Air Lift Company

ProSeries Air Spring Kit for '24-'25 Ford Ranger 4WD

 

Air Lift Company has released its new ProSeries Air Spring Kit for the '24-'25 Ford Ranger 4WD (all trims except Raptor) to deliver up to 5,000 lbs. or load-leveling support. The ProSeries system features double-bellow air springs with upper and lower roll plates, as well as ultra-high-strength nylon end caps. The kit works in conjunction with the Ranger's factory suspension to reduce rear-end sag, improve steering response, correct headlight aim, and minimize body roll and bottoming out when the vehicle is fully loaded, according to the company.

airliftcompany.com

 

Synergy Manufacturing

Jeep JL/JLU/JT Titan Series Tie Rod

 

Synergy Manufacturing recently announced the release of its new Jeep JL/JLU/JT Titan Series Tie Rod. Engineered for off-road and daily-driver applications, the steering upgrade features 1.75-in. heat-treated chromoly construction and metal-on-metal tie-rod ends. Bolts to factory locations and is fully adjustable while installed in the vehicle.

synergymfg.com

 

 

Westin Automotive

Power Retractable Tonneau Cover

 

Westin has announced its new Power Retractable Tonneau Cover Is now available, offering all-weather protection and a low-profile OE look, according to the company. Built from heavy-duty aluminum, the tonneau cover supports up to 500 lbs. of evenly distributed weight and opens and closes remotely with a key fob. A compact roll-up canister conserves bed space while integrated T-slot channels allow for accessory mounting and a built-in LED bed light provides extra visibility.

westinautomotive.com

By SEMA News Editors

New this year, exhibitors must activate or create an account in our new CRM before submitting their 2026 SEMA Show Exhibit Space Rental Application (ESRA).

 

SEMA has launched a new customer management system ahead of this year's SEMA Show, November 3-6, 2026, in Las Vegas.

To improve how SEMA engages with exhibitors and serves the industry year-round, the association has migrated to a new customer management system powered by Salesforce.

What This Means for 2026 SEMA Show Exhibitors

New this year, exhibitors must activate or create an account in our new customer relationship management (CRM) system before submitting their 2026 SEMA Show Exhibit Space Rental Application (ESRA). Once an account is set up, industry members will be able to:

• Reserve exhibit space.
• Download invoices, complete online payments and access exhibitor resources.

How to Get Started

Getting set up in the new SEMA Show exhibitor platform is simple:

• Visit services.semashow.com.
• Returning exhibitors:
  • Enter the email you've used to purchase a SEMA Show booth before to receive a password reset link (click here).
• New exhibitors or returning exhibitors using a new email: 
  • Create a new account (click here)

Once logged in, exhibitors are ready to reserve an exhibit space.

Having Issues Reserving Your Exhibit Space? 

If you're not receiving a password reset email or can't set up a new account, it's possible your record has more than one email address on file. In that case, our team will need to assist you with setting up your account.

SEMA is providing hands-on support to ensure a smooth transition for every exhibitor. 

Call: 240-ASK-SEMA (240-275-7362)

Email: customercare@sema.org

SEMA's stellar customer care team will walk you through account setup, password resets or answer any question

Note: updating your account does not affect exhibitors' account history or SEMA Show seniority.

We're excited to share what we've been working on--and we look forward to helping you make the most of it.

---

In related news, SEMA has opened registration for the 2026 Exhibitor Summit, a must-attend and complimentary event for all exhibitors, including first-timers and long-timers. Learn more about that here.

The 2026 SEMA Show is set for November 3-6, in Las Vegas. Interested exhibitors can buy a booth and learn more at semashow.com/exhibitor. Attendee and buyer registration opens in Spring 2026; to sign up for notifications, visit here. For more information, visit semashow.com. 

 

Image courtesy of Shutterstock | DC Studio