The Aero 8’s design evolved through traditional Morgan principles of form following function, with key contributions from Chris Lawrence, Charles Morgan, and the Morgan Engineering Team, alongside Norman Kent of Survirn Engineering Ltd. Radshape and Superform were heavily involved in the chassis and body panel production respectively. Announced in 2000, the Aero 8 marked a departure for Morgan, being the first to use an aluminium chassis and frame, unlike previous models with aluminium-skinned wooden bodies on steel chassis. It also notably lacked anti-roll bars.
The first Aero 8s were powered by a 4.4 L BMW M62 V8 engine mated to a 6-speed Getrag transmission. In 2007, the Series 4 Aero 8 received an upgraded 4.8 L BMW N62 V8 engine, with an optional ZF automatic transmission becoming available. Production at Morgan’s Malvern Link factory was capable of up to 14 cars per week, including both Aero models and traditional Morgans.
The Aero 8 Series 1, unveiled at the 2000 Geneva Motor Show by Charles Morgan, was described as "the result of the biggest development project ever undertaken by the Morgan Motor Company." The car’s structure comprised pre-formed bonded aluminium elements, assembled with a significant degree of handcrafting. The chassis incorporated elements of an ash frame, linking it to traditional Morgan construction. Design features included in-board shock absorbers, double wishbones, a flat floor, and rose-jointed suspension, improving handling over previous models.
Producing 286 bhp at 5500 rpm and 322 lbf·ft of torque at 3750 rpm, the Series 1 achieved a 0 to 62 mph time of 4.8 seconds and a top speed of 160 mph. The interior featured a turned aluminium dashboard, an asymmetric design, and a custom Mulberry glovebox, alongside modern conveniences like cruise control, air-conditioning, and a heated windscreen. The car’s performance was comparable to contemporary supercars from Ferrari, Porsche, and TVR.
The Series 1 Aero 8 became known for its distinctive “cross-eyed” appearance, resulting from the reversed VW Beetle headlamps. This design choice was initially justified for aerodynamic benefits. From 2005 (Series 3 onwards), Morgan replaced the VW Beetle headlights with those from the Mini.
In 2004, Morgan released the limited-edition Aero 8 GTN, featuring a 4.6L Alpina BMW engine producing 330 bhp, a 0-60 mph time of 4.3 seconds, and a top speed of 175 mph. Just eleven GTNs were produced, all in a two-tone BMW blue/silver colour scheme. They included a carbon fibre roof, carbon fibre interior, and other enhancements. Richard Hammond of Top Gear featured the GTN in Season 5 Episode 5 and later became a Morgan owner.
The Aero 8 Series 2, launched at the 2004 Los Angeles Motor Show, was the first Aero model available for sale in North America. It featured a repositioned fuel tank to comply with US rear impact regulations, a raised boot lid for improved aerodynamics and storage, and a “pram style” folding roof. The Series 2 was powered by a BMW N62B44 4.4L V8 engine producing 333 bhp at 6,100 rpm and 331 lb-ft of torque at 3,600 rpm, achieving a top speed of 160 mph and a 0-62 mph time of 4.8 seconds. Around 60 Series 2 cars were produced in both left- and right-hand drive configurations.
The Aero 8 Series 3 (2005–2007) largely addressed the “cross-eyed” appearance by adopting new Mini headlamps and revised front panels, while retaining the interior and mechanical platform of the Series 2. Approximately 200 Series 3 models were produced.
In 2009, Morgan participated in the FIA GT3 series with the Aero Supersports, designed for improved aerodynamics. The AutoGT team, sponsored by Banque Baring Sturdza, achieved pole position and race wins at Silverstone. The car’s distinctive sound came from its lower-revving V8 and side exhaust layout.
The Aero 8 Series 4 (2007–2010) introduced the BMW 4.8L V8 engine (N62B48), producing 362 bhp and 370 lb/ft of torque, a 13% power increase. It also offered an optional ZF 6HP26 six-speed automatic transmission. Other changes included a repositioned fuel tank, revised instrumentation, increased luggage space, and revised air vents.
The AeroMax, initially presented at the 2005 Geneva Motor Show, was a bespoke car built for Prince Eric Sturdza. Due to public interest, a limited production run of approximately 100 cars was agreed upon, commencing in 2008 and completing in 2009. The design, created by Matt Humphries, drew comparisons to classic Bugattis. It was the first Morgan to exceed a retail price of £100,000, selling for £110,000.
The Aero Supersports (2009–2016) was a targa-roofed derivative of the AeroMax platform, sharing the same chassis, engine, and transmission as the Aero 8 Series 4. The Aero Coupe (2012–2016) featured a fixed roof mirroring the targa panels of the Supersports.
The Plus 8 (2012–2019) utilized the Aero 8 platform, 4.8L engine, and manual or automatic gearbox, but with bodywork styled to resemble traditional Morgan models. The Plus 8 was the lightest V8 passenger car compliant with European safety standards. A special edition, the Plus 8 Speedster (2014), evoked a traditional café racer aesthetic.
The Aero 8 Series 5 (2016–2018) reintroduced a soft top, retaining the BMW 4.8L V8 engine. It featured updated interior finishes and a revised rear design with Lancia Thesis taillights. The Series 5 also incorporated a new front and rear suspension with anti-roll bars. A final run of 8 Aero GTs were released with further design enhancements.
In 2021, Morgan produced the Plus 8 GTR, a special project using nine chassis sourced from the assets of Bristol Cars, tuned to 375 bhp. The Aero 8 has competed in the 24 Hours of Le Mans twice (2002, 2004), the FIA GT series, and the British GT Series.