BIG RAPIDS — Ferris State University Associate Professor Mark Prosser participated in the Fuller Moto FLEETWOOD 5-Day Builder Challenge, a project aimed at creating a custom aluminum car body from a wooden frame in less than a week.
The challenge, held in Atlanta, Georgia, brought together 22 expert craftsmen, including renowned automobile designer Chip Foose, to build a 19-foot Fleetwood vehicle powered by a custom V16 engine using a 3D-printed chassis.
“What makes a project like this so special is that it brings together so many of the disciplines we teach at Ferris State,” said Prosser. “Design, engineering, machining, welding, metal shaping, and flawless execution — this build is a showcase of those skills at the highest level.”
Bryan Fuller, owner of Fuller Moto and a longtime automotive television personality, organized the challenge to push the boundaries of innovation and craftsmanship. Fuller Moto specializes in unique, hand-built vehicles and aims to inspire automotive enthusiasts worldwide through events and collaborations.
Prosser, a faculty member in the School of Design and Manufacturing within Ferris State’s College of Engineering Technology, was chosen for his expertise and teaching ability. “Mark is one of the very best welding instructors out there,” Fuller said. “He’s very personable, but he can also educate people without intimidating them.”
The project involved creating a wooden “buck” frame, designed by a Fuller Moto engineering intern, which was used to shape 48 aluminum panels. These panels were then merged into a seamless body over five days, requiring nearly 1,000 hours of craftsmanship.
Ferris State’s College of Engineering Technology was a top sponsor of the event, with Dean Kate O’Connor and Associate Dean Bill Koepf traveling to Atlanta to witness the build. “Mark’s excitement was always about how this experience could serve Ferris State and the students,” O’Connor said.
Prosser’s involvement in the challenge not only showcased his skills but also provided valuable lessons for his students, emphasizing the real-world applications of their education.
“It’s important for students to understand that building anything isn’t just about technology or theory — it’s about hard work, skill development, and applying what they learn to something real,” he said.