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UNITED STATES SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549

FORM 10-Q

QUARTERLY REPORT PURSUANT TO SECTION 13 OR 15(D) OF
THE SECURITIES EXCHANGE ACT OF 1934

FOR QUARTERLY PERIOD ENDED JUNE 27, 2004
COMMISSION FILE NUMBER 1-12068

METALDYNE CORPORATION
(Exact name of registrant as specified in its charter)


Delaware 38-2513957
(State or other jurisdiction of
incorporation or organization)
(I.R.S. Employer
Identification No.)
47659 Halyard Drive, Plymouth, Michigan 48170-2429
(Address of principal executive offices) (Zip Code)

(734) 207-6200

(Registrant's telephone number)

Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.    Yes                 No      X   

Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Exchange Act).    Yes                 No      X   

There is currently no public market for the registrant's common stock.

Indicate the number of shares outstanding of each of the issuer's classes of common stock, as of the latest practical date.


Class Shares outstanding at
November 1, 2004
Common stock, par value $1 per share   42,844,760  

    




METALDYNE CORPORATION

INDEX


    Page No.
Part I. Financial Information
Item 1. Financial Statements
  Consolidated Balance Sheets – June 27, 2004 and December 28, 2003   2  
  Consolidated Statements of Operations for the Three and Six Months
    Ended June 27, 2004 and June 29, 2003
  3  
  Consolidated Statements of Cash Flows for the Three and Six Months
    Ended June 27, 2004 and June 29, 2003
  4  
  Notes to Consolidated Financial Statements   5-27  
Item 2. Management's Discussion and Analysis of Financial Condition and
    Results of Operations
  28-52  
Item 3. Quantitative and Qualitative Disclosure About Market Risk   52  
Item 4. Controls and Procedures   53-55  
Part II. Other Information and Signature   56-57  

1




PART I. FINANCIAL INFORMATION
ITEM 1. Financial Statements

METALDYNE CORPORATION
CONSOLIDATED BALANCE SHEET
June 27, 2004 and December 28, 2003
(Dollars In Thousands Except Per Share Amounts)


  June 27, 2004 December 28, 2003
  (Unaudited)  
ASSETS            
Current assets:            
Cash and cash equivalents $   $ 13,820  
Receivables:            
Trade, net of allowance for doubtful accounts   167,900     139,330  
TriMas   6,890     15,350  
Other   29,360     26,440  
Total receivables, net   204,150     181,120  
Inventories   113,870     83,680  
Deferred and refundable income taxes   8,120     9,110  
Prepaid expenses and other assets   44,470     36,280  
Total current assets   370,610     324,010  
Equity and other investments in affiliates   128,830     148,830  
Property and equipment, net   892,570     707,450  
Excess of cost over net assets of acquired companies   582,760     584,390  
Intangible and other assets   227,370     247,180  
Total assets $ 2,202,140   $ 2,011,860  
             
LIABILITIES AND SHAREHOLDERS' EQUITY            
             
Current liabilities:            
Accounts payable $ 280,900   $ 201,240  
Accrued liabilities   116,990     136,840  
Current maturities, long-term debt   8,580     10,880  
Total current liabilities   406,470     348,960  
Long-term debt   853,410     766,930  
Deferred income taxes   121,540     121,520  
Minority interest   800     800  
Other long-term liabilities   146,810     153,760  
Redeemable preferred stock, (aggregate liquidation value $149.4 million)   147,480      
Total liabilities   1,676,510     1,391,970  
             
Redeemable preferred stock, (aggregate liquidation value $76.0 million)       73,980  
             
Preferred stock (non-redeemable), $1 par, Authorized: 25 million;
Outstanding: None
       
Common stock, $1 par, Authorized: 250 million;
Outstanding: 42.8 million and 42.7 million shares, respectively
  42,830     42,730  
Paid-in capital   693,540     692,400  
Accumulated deficit   (243,170   (234,750
Accumulated other comprehensive income   32,430     45,530  
Total shareholders' equity   525,630     545,910  
Total liabilities, redeemable stock and shareholders' equity $ 2,202,140   $ 2,011,860  
             

See accompanying notes to the consolidated financial statements.

2




METALDYNE CORPORATION
CONSOLIDATED STATEMENT OF OPERATIONS
(Dollars In Thousands Except Per Share Data)


  Three Months Ended Six Months Ended
  (Unaudited) (Unaudited)
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
    (Restated)   (Restated)
Net sales $ 521,890   $ 390,540   $ 1,003,030   $ 772,460  
Cost of sales   (469,500   (340,710   (898,430   (681,590
Gross profit   52,390     49,830     104,600     90,870  
Selling, general and administrative expenses   (31,250   (27,630   (62,470   (57,280
Restructuring charges   (1,520   (2,330   (1,710   (3,860
Loss on disposition of manufacturing facilities           (7,600    
Operating profit   19,620     19,870     32,820     29,730  
                         
Other expense, net:
Interest expense
  (19,650   (17,280   (39,750   (35,200
Preferred stock dividends   (4,710       (8,970    
Non-cash gain on maturity of interest rate arrangements           6,590      
Equity gain (loss) from affiliates, net   2,980     (80   4,440     (2,710
Other, net   (1,040   (2,110   (3,420   (5,770
                         
Other expense, net   (22,420   (19,470   (41,110   (43,680
                         
Income (loss) before income taxes   (2,800   400     (8,290   (13,950
Income tax expense (benefit)   370     (660   130     (3,950
Net income (loss)   (3,170   1,060     (8,420   (10,000
Preferred stock dividends       2,280         4,500  
Loss attributable to common stock $ (3,170 $ (1,220 $ (8,420 $ (14,500
Basic and diluted loss per share attributable to common stock $ (0.07 $ (0.03 $ (0.20 $ (0.34

See accompanying notes to the consolidated financial statements.

3




METALDYNE CORPORATION
CONSOLIDATED STATEMENT OF CASH FLOWS
(Dollars in thousands)


  Six Months Ended
  (Unaudited)
  June 27,
2004
June 29,
2003
    (Restated)
Operating activities:                  
Net loss $ (8,420 $ (10,000
Adjustments to reconcile net loss to net cash provided by (used for) operating activities:                  
Depreciation and amortization   64,000     52,240  
Non-cash stock award expense   470     1,530  
Debt fee amortization   1,340     1,100  
Fixed asset losses   750     2,200  
Loss on disposition of manufacturing facilities   7,600      
Deferred income taxes   (70   3,100  
Preferred stock dividends   8,970      
Non-cash interest expense (interest accretion)       3,500  
Non-cash gain on maturity of interest rate arrangements   (6,590    
Equity (earnings) losses from affiliates, net of dividends   (4,440   2,710  
Other, net   (1,170   (1,610
Changes in assets and liabilities, net of acquisition/disposition of business:            
Receivables, net   (77,820   (3,920
Net proceeds (redemption) of accounts receivable securitization facility   47,000      
Inventories   (20,320   (3,600
Refundable income taxes       15,620  
Prepaid expenses and other assets   (8,780   (5,930
Accounts payable and accrued liabilities   49,320     (34,700
Net cash provided by operating activities   51,840     22,240  
Investing activities:            
Capital expenditures   (63,970   (54,370
Proceeds from sale/leaseback of fixed assets   72,530     8,460  
Proceeds on disposition of manufacturing facilities   (500   22,570  
Proceeds from sale of TriMas shares       20,000  
Acquisition of business   (217,850   (7,650
Proceeds on sale of joint venture   1,260      
Investment in joint venture       (20,000
Net cash used for investing activities   (208,530   (30,990
Financing activities:            
Principal payments of term loan facilities   (440   (500
Proceeds of revolving credit facility   117,090     180,000  
Principal payments of revolving credit facility   (64,790   (180,000
Proceeds of senior subordinated notes, due 2014   31,750      
Proceeds of other debt   780     1,420  
Principal payments of other debt   (5,970   (4,220
Issuance of Series A-1 preferred stock   64,450      
Net cash provided by (used for) financing activities   142,870     (3,300
Net decrease in cash   (13,820   (12,050
Cash and cash equivalents, beginning of period   13,820     19,130  
Cash and cash equivalents, end of period $   $ 7,080  
Supplementary cash flow information:            
Cash paid (refunded) for income taxes, net $ 6,780   $ (12,440
Cash paid for interest $ 37,680   $ 31,570  
                   

See accompanying notes to the consolidated financial statements.

4




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

1.    Business and Other Information

Metaldyne Corporation ("Metaldyne" or "the Company") is a leading global manufacturer of highly engineered metal components for the global light vehicle market. Our products include metal-formed and precision-engineered components and modular systems used in vehicle transmission, engine and chassis applications.

The Company maintains a fifty-two/fifty-three week fiscal year ending on the Sunday nearest to December 31. Fiscal years 2004 and 2003 each comprise fifty-two weeks and end on January 2, 2005 and December 28, 2003, respectively. All year and quarter references relate to the Company's fiscal year and fiscal quarters unless otherwise stated.

In the opinion of Company management, the unaudited financial statements contain all adjustments, including adjustments of a normal recurring nature, necessary to present fairly the financial position, results of operations and cash flows for the periods presented. These statements should be read in conjunction with the Company's financial statements included in the Annual Report on Form 10-K for the fiscal year ended December 28, 2003 (the "2003 Form 10-K"). The results of operations for the period ended June 27, 2004 are not necessarily indicative of the results for the full year.

Certain prior year amounts have been reclassified to reflect current year classification.

2.    Restatement

In September 2004, the Company announced the completion of an independent investigation into certain accounting matters ("Independent Investigation") and its determination that certain previously issued financial statements required restatement. The Company's financial statements for fiscal years 2001 and 2002 have been restated in the 2003 Form 10-K. In addition, the Company's quarterly financial information for the first three fiscal quarters of 2003 also has been restated to reflect adjustments to previously reported information on Form 10-Q, as described elsewhere herein.

The restatement arose primarily out of information obtained through an investigation conducted by a special committee of the board of directors which was comprised of one independent director of the Company. The special committee retained independent counsel, Sidley Austin Brown & Wood LLP ("Sidley"), and in turn Sidley retained Deloitte & Touche LLP ("D&T"), a firm with forensic accounting expertise, to assist Sidley in the investigation. The Independent Investigation was initiated as a result of certain admissions made by an employee of the Company and information obtained by the Company's internal audit staff. The investigation expanded beyond its initial focus on this employee's admissions of intentional overstatements and understatements of income at the Company's Sintered division into accounting practices in other areas of the Company concerning the smoothing of earnings through the use of accrual and allowance accounts and the recognition of tooling income. The restatement resulting from the Independent Investigation was limited to the periods from November 30, 2000 through 2003.

Specifically, a former Sintered division controller admitted that, following the acquisition of the Company in November 2000, income at the Sintered division from 2000 through 2003 was deliberately understated in an effort to disguise this employee's previous overstatements of income at the Sintered division during the period from 1996 through 1999. There were three primary admissions from the former Sintered divisional controller related to the period 1996 to 1999. During this time, he asserted that income was overstated by (1) overstating fixed assets, (2) understating liabilities (notably accounts payable), and (3) using a complex set of manual journal entries every month to "disguise" the effects of (1) and (2). The restatement adjustments reflect the Company's correction of these matters, based upon the findings of the Independent Investigation. The corrections of these Sintered division accounts indicate that cumulative net losses for the periods investigated were actually understated as a result of these intentional actions.

Based upon certain findings within the Sintered division, the investigation was expanded to encompass accounting practices in other areas of the Company concerning the use of accrual and

5




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

allowance accounts and the recognition of tooling income for the period from 2001 through 2003. This investigation involved an extensive review of journal entries of over a specified amount made over a three year period. As a result of the expanded investigation, the Company became aware of instances of inappropriate accounting relating to allowances and accruals, which had the effect of "smoothing" earnings for certain periods. Specifically, the Company concluded from the investigative findings that there were instances when accruals had been established to cover unanticipated expenses, accruals had been increased or decreased based upon performance, and/or accruals had been recorded different from estimated or analyzed amounts. The Company also identified from the investigative findings a few instances of incorrect timing in the recognition of tooling income. The investigation categorized journal entries from the relevant periods for analysis by the Company and review by the Company with its current and former independent auditors. The Company analyzed those categories of entries, which the investigation determined to be either potentially inaccurate (i.e., warranting further review) or unknown (i.e., insufficient documentation for third party evaluation).

The restatement adjustments address (1) inappropriate actions taken at the Sintered division by correcting overstated balances for property, plant and equipment, recognizing lower related depreciation expense and recognizing the continuing effect of adjustments made in prior periods on previously reported balances of other accounts such as accounts payable and accounts receivable; (2) the correction of certain journal entries, primarily relating to certain reserve and tooling accounts, identified as a result of the Independent Investigation; and (3) certain other adjustments not related to the Sintered investigation or the review of the accrual and tooling accounts.

Total Adjustments.    The following table presents the impact on net income of the restatement adjustments for the three and six months ended June 29, 2003:


  (In thousands)
  Three Months Ended
June 29, 2003
Six Months Ended
June 29, 2003
Net income (loss) as previously reported $ 480   $ (8,890
Sintered adjustments   1,000     (1,280
Tooling, accrual and allowance adjustmemts   90     (290
Other adjustments   (150   (220
Income tax effect   (360   680  
Restated net income (loss) $ 1,060   $ (10,000

6




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

The following table summarizes the impact on net income of the restatement adjustments on the consolidated statement of operations for the three and six months ended June 29, 2003:


      (In thousands)
  Three Months Ended June 29, 2003 Six Months Ended June 29, 2003
  As
Previously
Reported
Restate-
ments
As Restated As
Previously
Reported
Restate-
ments
As Restated
                                     
Net sales $ 390,290   $ 250   $ 390,540   $ 771,620   $ 840   $ 772,460  
Cost of goods sold   (340,780   70     (340,710   (680,580   (1,010   (681,590
Gross profit   49,510     320     49,830     91,040     (170   90,870  
                                     
Selling, general and administrative expenses   (27,630       (27,630   (57,280       (57,280
Restructuring charges   (2,330       (2,330   (3,860       (3,860
Operating profit   19,550     320     19,870     29,990     (170   29,730  
                                     
Other expense, net:                                    
Interest expense   (17,240   (40   (17,280   (35,120   (80   (35,200
Equity loss from affiliates, net   (80       (80   (2,710       (2,710
Other, net   (2,760   650     (2,110   (4,220   (1,550   (5,770
Other expense, net   (20,080   610     (19,470   (42,050   (1,630   (43,680
                                     
Income (loss) before income taxes   (530   930     400     (12,150   (1,800   (13,950
Income tax benefit   (1,010   350     (660   (3,260   690     (3,950
Net income (loss) $ 480   $ 580   $ 1,060   $ (8,890 $ (1,110 $ (10,000
                                     
Basic and diluted loss per share attributable to common stock $ (0.04 $ 0.01   $ (0.03 $ (0.31 $ (0.03 $ (0.34

7




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

The following table summarizes the impact on cash flow for the restatement adjustments for the six months ended June 29, 2003:


  (In thousands)
  As Previously
Reported
Restatements As Restated
                   
Cash flows from operating activities:                  
Net cash used for operating activities $ 23,900   $ (1,660 $ 22,240  
                   
Cash flows from investing activities:                  
Capital expenditures   (56,100   1,730     (54,370
Proceeds from sale/leaseback of fixed assets   8,460         8,460  
Disposition of businesses to a related party   22,570         22,570  
Proceeds form sale of TriMas shares   20,000         20,000  
Acquisition of business, net   (7,650       (7,650
Investment in joint venture   (20,000       (20,000
Net cash provided by (used for) investing activities   (32,720   1,730     (30,990
                   
Cash flows from financing activities:                  
Principal payments of term loan facilities   (500       (500
Proceeds of revolving credit facility   180,000         180,000  
Principal payments of revolving credit facility   (180,000       (180,000
Proceeds of other debt   1,420         1,420  
Principal payments of other debt   (4,150   (70   (4,220
Net cash provided by (used for) financing activities   (3,230   (70   (3,300
                   
Net increase (decrease) in cash   (12,050       (12,050
Cash and cash equivalents, beginning of period   19,130         19,130  
Cash and cash equivalents, end of period $ 7,080   $   $ 7,080  

3.    Stock Options and Awards

The following disclosure for the financial statements for the period ended June 27, 2004 is based on the Company continuing to account for stock-based employee compensation using the intrinsic value method under Accounting Principles Board ("APB") No. 25 and related interpretations.

The Company has one stock-based employee compensation plan. No stock-based employee compensation cost is reflected in net income, as all options granted under this plan had an exercise price equal to the market value of the underlying common stock on the date of grant. The following table illustrates the effect on net income and earnings per share if the Company had applied the fair value recognition provisions of SFAS No. 123, "Accounting for Stock-Based Compensation," to stock-based employee compensation.

8




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)


  (In thousands except per share amounts)
  Three Months Ended Six Months Ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
    (Restated)   (Restated)
Net loss attributable to common stock, as reported $ (3,170 $ 1,060   $ (8,420 $ (10,000
Deduct: Total stock-based employee compensation expense determined under fair value based method for all awards, net of related tax effects   (50   (470   (170   (940
Pro forma net loss attributable to common stock $ (3,220 $ 590   $ (8,590 $ (10,940
Loss per share:                        
Basic and diluted – as reported $ (0.07 $ (0.03 $ (0.20 $ (0.34
Basic and diluted – pro forma for stock-based compensation $ (0.07 $ (0.04 $ (0.20 $ (0.36
                         

Beginning in 2004, the Company offered eligible employees the opportunity to participate in a new Voluntary Stock Option Exchange Program (the "Program"), to exchange all of their outstanding options to purchase shares of the Company's common stock granted under the Long Term Equity Incentive Plan (the "Plan") for new stock options and restricted stock units to be granted under the Plan. Participation in the Program is voluntary; however, elections were required to be received by January 14, 2004, with new stock options to be granted on or after July 15, 2004 and restricted stock units granted on January 15, 2004. Non-eligible participants in the existing Plan and those eligible employees not electing to participate in the new Program will continue to be eligible to participate in the existing Plan. Stock compensation expense for the six months ended June 27, 2004 was $0.5 million.

4.    Accounts Receivable Securitization and Factoring Agreements

The Company has entered into an arrangement to sell, on an ongoing basis, the trade accounts receivable of substantially all domestic business operations to MTSPC, Inc. ("MTSPC"), a wholly owned subsidiary of the Company. MTSPC from time to time may sell an undivided fractional ownership interest in the pool of receivables up to approximately $150 million to a third party multi-seller receivables funding company. The net proceeds of sale are less than the face amount of accounts receivable sold by an amount that approximates the purchaser's financing costs, which amounted to a total of $2.3 million and $2.0 million for the six months ended June 27, 2004 and June 29, 2003 (as restated), respectively, and is included in other expense, net in the Company's consolidated statement of operations. At June 27, 2004, the Company's funding under the facility was $47.0 million with $44.5 million available but not utilized. The discount rate at June 27, 2004 was 2.24% compared to 2.14% at December 28, 2003. The usage fee under the facility is 1.5%. In addition, the Company is required to pay a fee of 0.5% on the unused portion of the facility. This facility expires in November 2005.

The Company has entered into agreements with international invoice factoring companies to sell customer accounts receivable of Metaldyne foreign locations in France, Germany, Spain, United Kingdom and Mexico on a non-recourse basis. As of June 27, 2004, the Company had available approximately $67 million from these commitments, and approximately $57.8 million of receivables were sold under these programs. The Company pays a commission to the factoring company plus interest from the date the receivables are sold to the date of customer payment. Commission expense related to these agreements are recorded in other expense, net on the Company's consolidated statement of operations.

To facilitate the collection of funds from operating activities, the Company has entered into accelerated payment collection programs with its largest customers. At June 27, 2004, the Company

9




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

received approximately $57 million under the accelerated collection programs. The Company was recently notified that a portion of this program would expire in 2004, with the majority of the program expiring in 2005. While the impact of the discontinuance of these programs may be partially offset by a greater utilization of the accounts receivable securitization facility, the Company is examining other alternative programs in the marketplace, as well as enhanced terms directly from its customers. However, the Company may not be able to reach a favorable resolution in a timely manner, and the new arrangements may be less advantageous to the Company. If the Company is unable to replace these arrangements, it could adversely affect its liquidity and future covenant compliance under its senior secured credit facility. In addition, if the Company fails to renew its accounts receivable securitization agreement, which expires in November 2005, it could have adverse effects on the Company's liquidity and future covenant compliance. However, the Company had approximately $87 million of undrawn and available commitments on its revolving credit facility at June 27, 2004.

5.    Inventories

Inventories by component are as follows:


  (In thousands)
  June 27, 2004 December 28, 2003
Finished goods $ 32,630   $ 25,710  
Work in process   27,260     29,480  
Raw materials   53,980     28,490  
  $ 113,870   $ 83,680  

6.    Goodwill and Other Intangible Assets

At June 27, 2004, the goodwill balance was approximately $583 million. For purposes of testing this goodwill for potential impairment, fair values were determined based upon the discounted cash flows of the reporting units using a 9.5% discount rate as of December 28, 2003. This assessment was completed for the year ended December 28, 2003, which indicated that the fair value of these units exceeded their carrying values.

10




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Acquired Intangible Assets

The change in the gross carrying amount of acquired intangible assets is primarily attributable to the exchange impact from foreign currency.


  (In thousands, except weighted average life)
  As of June 27, 2004 As of December 28, 2003
  Gross
Carrying
Amount
Accumulated
Amortization
Weighted
Average
Life
Gross
Carrying
Amount
Accumulated
Amortization
Weighted
Average
Life
Amortized Intangible Assets:                            
Customer Contracts $ 93,700   $ (36,010 8.2 years $ 94,420   $ (31,050 8.2 years
Technology and Other   163,870     (40,440 14.9 years   165,280     (35,290 14.9 years
Total $ 257,570   $ (76,450 13.6 years $ 259,700   $ (66,340 13.6 years
                             
Aggregate Amortization Expense (Included in Cost of Sales):                            
For the six months ended
June 27, 2004
      $ 11,890                  
                             
Estimated Amortization Expense:                            
For the year ending
January 2, 2005
        23,500                  
For the year ending December 31, 2005         23,100                  
For the year ending December 31, 2006         23,100                  
For the year ending December 31, 2007         22,300                  
For the year ending December 31, 2008         21,600                  

Goodwill

The changes in the carrying amount of goodwill for the six months ended June 27, 2004 are as follows:


  (In thousands)
  Chassis Driveline Engine Total
Balance as of December 28, 2003   61,630     371,010     151,750     584,390  
Exchange impact from foreign currency       (1,290   (340   (1,630
Balance as of June 27, 2004 $ 61,630   $ 369,720   $ 151,410   $ 582,760  

7.    Derivative Financial Instruments

The Company manages its exposure to changes in interest rates through the use of interest rate protection agreements. These interest rate derivatives are designated as cash flow hedges. The effective portion of each derivative's gain or loss is initially reported as a component of other comprehensive income (loss) and subsequently reclassified into earnings when the forecasted transaction affects earnings. The Company does not use derivatives for speculative purposes.

In February 2001, the Company entered into interest rate protection agreements with various financial institutions to hedge a portion of its interest rate risk related to the term loan borrowings under

11




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

its credit facility. These agreements include two interest rate collars with a term of three years, a total notional amount of $200 million as of December 28, 2003, and a three-month LIBOR interest rate cap and floor of 7% and approximately 4.5%, respectively. The agreements also include four interest rate caps at a three-month LIBOR interest rate of 7% with a total notional amount of $301 million as of December 28, 2003.

All of the Company's interest rate protection arrangements matured in February 2004 and, as a result of their maturity, a cumulative pre-tax non-cash gain of $6.6 million was recorded and is reflected as a non-cash gain on maturity of interest rate arrangements in the Company's consolidated statement of operations for the six months ended June 27, 2004. Prior to their maturity, $6.6 million was included in accumulated other comprehensive income related to these arrangements. Prior to the expiration of these agreements, the Company recognized additional interest expense of $1.1 million during the six months ended June 27, 2004.

8.    Segment Information

The Company has defined a segment as a component with business activity resulting in revenue and expense that has separate financial information evaluated regularly by the Company's chief operating decision maker and its board of directors in determining resource allocation and assessing performance.

The Company has established Adjusted Earnings Before Interest Taxes Depreciation and Amortization ("Adjusted EBITDA") as a key indicator of financial operating performance and as a measure of cash generating capability. The Company defines Adjusted EBITDA as net income (loss) before cumulative effect of accounting change and before interest, taxes, depreciation, amortization, asset impairment, non-cash losses on sale-leaseback of property and equipment and non-cash restricted stock award expense. Adjusted EBITDA is a non-GAAP measure and therefore caution must be exercised in using Adjusted EBITDA as an analytical tool and should not be used in isolation or as a substitute for analysis of our results as reported under GAAP. In evaluating Adjusted EBITDA, management deems it important to consider the quality of the Company's underlying earnings by separately identifying certain costs undertaken to improve the Company's results, such as costs related to consolidating facilities and businesses in an effort to eliminate duplicative costs or achieve efficiencies, costs related to integrating acquisitions and restructuring costs related to expense reduction efforts.

The Company is comprised of three reportable segments: Chassis, Driveline and Engine. In 2003, the Company moved one of its European operations that had historically been part of the Chassis segment to the Engine segment, and moved one of its domestic operations that had historically been part of the Driveline segment to the Engine segment. In 2004, the Company moved one of its North American operations that had historically been part of the Engine segment to the Chassis segment. The prior year amounts have been restated to reflect these changes for comparison purposes.

CHASSIS — Manufactures components, modules and systems used in a variety of engineered chassis applications, including fittings, wheel-ends, axle shaft, knuckles and mini-corner assemblies. This segment utilizes a variety of processes including hot, warm and cold forging, powder metal forging and machinery and assembly.

DRIVELINE — Manufactures components, modules and systems, including precision shafts, hydraulic controls, hot and cold forgings and integrated program management used in a broad range of transmission applications. These applications include transmission and transfer case shafts, transmission valve bodies, cold extrusion and Hatebur hot forgings.

ENGINE — Manufactures a broad range of engine components, modules and systems, including sintered metal, powder metal, forged and tubular fabricated products used for a variety of applications. These applications include balance shaft modules and front cover assemblies.

12




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Segment activity for the three and six months ended June 27, 2004 and June 29, 2003 (as restated) is as follows:


  (In thousands)
  Three Months Ended Six Months Ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
    (Restated)   (Restated)
Sales
Chassis $ 155,930   $ 37,600   $ 284,250   $ 77,470  
Driveline   202,810     202,860     398,240     403,180  
Engine   163,150     150,080     320,540     291,810  
Total sales $ 521,890   $ 390,540   $ 1,003,030   $ 772,460  
Adjusted EBITDA                        
Chassis $ 15,340   $ 3,780   $ 24,610   $ 7,470  
Driveline   18,110     22,690     40,380     41,480  
Engine   27,080     25,040     54,160     44,620  
Operating EBITDA   60,530     51,510     119,150     93,570  
Centralized resources ("Corporate")   (7,770   (4,860   (13,860   (12,290
Total Adjusted EBITDA   52,760     46,650     105,290     81,280  
Depreciation & amortization   (32,470   (27,290   (64,000   (52,240
Non-cash stock award expense   (240   (630   (470   (1,530
Loss on disposition of manufacturing facilities           (7,600    
Other, net included in Adjusted EBITDA   (430   1,140     (400   2,220  
Operating profit $ 19,620   $ 19,870   $ 32,820   $ 29,730  

  (In thousands)
  June 27, 2004 December 28, 2003
Total Assets            
Chassis $ 392,430   $ 121,260  
Driveline   987,010     953,520  
Engine   759,130     733,920  
Corporate(1)   64,020     203,160  
Total $ 2,202,590   $ 2,011,860  

  Six Months Ended
  June 27, 2004 June 29, 2003
Capital Expenditures            
Chassis $ 21,710   $ 7,890  
Driveline   17,090     29,210  
Engine   24,710     14,290  
Corporate   1,000     2,980  
Total $ 63,970   $ 54,370  

Intercompany sales for the quarter ended June 27, 2004 were $2.1 million and $0.6 million for the Driveline and Engine segment, respectively. Intercompany sales for the quarter ended June 29, 2003 were $0.8 million for the Engine segment. Intercompany sales for the six months ended June 27, 2004 were $4 million and $1.5 million for the Driveline and Engine segments, respectively. Intercompany sales for the six months ended June 29, 2003 were $1.6 million for the Engine segment.

(1) Corporate total assets reflect the obligations associated with the Accounts Receivable Securitization program as discussed in Note 4, Accounts Receivable Securitization and Factoring Agreements.

13




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

9.    Acquisitions

In the first quarter of 2004, effective December 31, 2003, the Company completed a transaction with DaimlerChrysler Corporation ("DaimlerChrysler") that transferred full ownership of the New Castle Machining and Forge ("New Castle") manufacturing operations to Metaldyne. Since January 2003, New Castle has been managed as a joint venture between Metaldyne and DaimlerChrysler; at December 28, 2003, the Company's investment in this joint venture was approximately $22 million. The New Castle facility manufactures suspension and powertrain components for Chrysler, Jeep and Dodge vehicles; additionally, Metaldyne has launched initiatives to expand the customer base beyond DaimlerChrysler. The New Castle manufacturing operations are part of the Company's Chassis segment.

As part of the New Castle transaction, Metaldyne acquired Class A and Class B units representing DaimlerChrysler's entire joint venture interest in New Castle. In exchange, Metaldyne delivered to DaimlerChrysler $215 million (before fees and expenses of approximately $5 million), comprised of $118.8 million in cash; $31.7 million in aggregate principal amount of a new issue of its 10% senior subordinated notes; and $64.5 million in aggregate liquidation preference of its Series A-1 preferred stock. Included in the $5 million fees and expenses is a $2.4 million transaction fee paid to Heartland Industrial Partners ("Heartland") pursuant to the acquisition of New Castle. The cash portion of the consideration was funded in part by the net cash proceeds of approximately $65 million from the sale-leaseback of certain machinery and equipment with a third-party lessor, with the remainder funded through Metaldyne's revolving credit facility.

The assets and liabilities of New Castle at December 31, 2003 consisted of the following (in thousands):


Current assets $ 13,370  
Property and equipment, net   240,720  
Total assets   254,090  
Total liabilities   14,110  
Net assets $ 239,980  

The above assets and liabilities at the acquisition date, and are subject to change based upon the final valuation and allocation of purchase price.

On May 30, 2003, the Company acquired a facility in Greensboro, North Carolina, from Dana Corporation ("Dana") for approximately $7.7 million at closing and agreed to pay an additional $1.4 million in cash over a period of time ending on December 31, 2004. The Company may also be obligated to pay up to an additional $1.4 million in cash on December 31, 2004 depending upon the extent of new business awards at the facility. The Greensboro facility became part of the Driveline segment's Transmission and Program Management division. The Greensboro operation, which employs approximately 150 people, machines cast iron and aluminum castings, including various steering knuckles and aluminum carriers for light truck applications. The results of operations of the facility have been included in the consolidated financial statements since that date.

As part of the agreement with Dana, the Company agreed to obtain a third party buyer of the Greensboro facility and agreed to sign a lease agreement with this party. If the Company failed to obtain a third party buyer for this property within 60 days of the acquisition, it agreed to pay Dana $10 million to purchase the facility. To secure this arrangement, the Company gave Dana a letter of credit of $10 million. On July 14, 2003, the Company subsequently entered in a long-term lease agreement with a third party, thereby releasing the Company from the $10 million letter of credit.

In addition, the Company signed a seven-year supply agreement with Dana covering all existing business at Greensboro, including a right of last refusal on successor programs, as well as a commitment to award $20 million of new forging business to the Company. Dana has also issued purchase orders, to

14




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

be satisfied at other of our facilities, for incremental other tube, gear and carrier business for a number of platforms. In September 2004, the Company terminated the supply agreement with Dana.

10.    Asset Impairments and Restructuring Related Integration Actions

In fiscal 2003, the Company entered into several restructuring arrangements whereby it incurred approximately $13.1 million of costs associated with severance and facility closures. These actions include the completion of the Engine segment's European operation reorganization that was initiated in fiscal 2002 and completed in the first quarter of 2003 and actions within the Driveline segment's forging operations and administrative departments to eliminate redundant headcount and adjust costs to reflect the decline in the Company's forging revenue in 2003. Also included in this charge are the severance costs to replace certain members of the Company's executive management team and the costs to restructure several departments in the Company's corporate office, including the sales, human resources and information technology departments. Restructuring costs incurred for the six months ended June 27, 2004 are as follows: Driveline Group $1.1 million; Chassis Group $0.1 million; and Corporate $0.5 million. The Company expects to realize additional savings from these restructuring actions in 2004 as reductions in employee-related expenses recognized in both cost of goods sold and selling, general and administrative expense.

In the fourth quarter of 2003, the Company performed its FAS 144 long-lived asset impairment test and recorded a pre-tax, non-cash impairment write-down of $4.9 million. This charge was recorded to reduce the net book value of two facilities with negative operating performance to their current fair market value. These two facilities were sold on February 1, 2004 to an independent third party of whom this sales price was used to determine the fair market value of these two facilities. This assessment did not result in any asset impairment for the remaining Metaldyne locations (see Note 11).

The below amounts represent total estimated cash payments, of which $5.4 million and $6.6 million are recorded in accrued liabilities, with $1.3 million (which will primarily be paid out in 2005) and $2.6 million recorded in other long-term liabilities in the Company's consolidated balance sheet at June 27, 2004 and December 28, 2003, respectively. This table provides a rollforward of the restructuring accrual related to the above restructuring actions as of June 27, 2004.


      (In thousands)
  Acquisition Related
  Severance
Costs
2002
Additional
Severance
and Other
Exit Costs
2003
Additional
Severance
and Other
Exit Costs
2004
Additional
Severance
and Other
Exit Costs
Total
Balance at December 28, 2003 $ 1,380   $ 360   $ 7,310   $   $ 9,050  
Charges to expense               1,710     1,710  
Cash payments   (250   (230   (2,920   (580   (3,980 )) 
Reversal of unutilized amounts   (80               (80
Balance at June 27, 2004 $ 1,050   $ 130   $ 4,390   $ 1,130   $ 6,700  

11.    Dispositions

On February 1, 2004, the Company sold its ownership of its Bedford Heights, Ohio and Rome, Georgia manufacturing operations to Lester PDC, a Kentucky-based aluminum die casting and machining company. These two plants had combined 2003 sales of approximately $62 million and an operating loss of approximately $14 million. For the first six months of 2003, these plants had sales of approximately $32 million and an operating loss of approximately $3 million. The Company retained an interest in approximately $5.6 million in working capital (principally accounts receivable). Cash paid in the transaction to buy out the remaining portion of the equipment that had previously been sold under an operating lease arrangement by the Company was approximately $6.1 million, net of proceeds from Lester PDC of $4.1 million. The buyer also agreed to sub-lease both the Bedford Heights, Ohio and the

15




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Rome, Georgia facilities from the Company for an annual lease payment of approximately $600,000. Both manufacturing operations were part of the Company's Driveline segment. In connection with the disposition of these manufacturing facilities, the Company recognized a charge of $7.6 million on the Company's consolidated statement of operations as of June 27, 2004. The charge represents the book value of approximately $12 million in fixed assets and deferred financing fees offset by the $4.1 million in cash consideration paid by Lester PDC for the assets.

On May 9, 2003, the Company sold its Chassis Group's Fittings division to TriMas Corporation ("TriMas") for $22.6 million plus the assumption of an operating lease. This transaction was accounted for as a sale of entities under common control, due to common ownership between TriMas and the Company. Therefore, the proceeds, in excess of the book value, amounting to $6.3 million were recorded as equity and other investments in affiliates in the Company's consolidated balance sheet as of December 28, 2003. The Fittings division, which is a leading manufacturer of specialized fittings and cold-headed parts used in automotive and industrial applications, became part of the TriMas Fastening Systems Group.

In April 2003, TriMas exercised its right to repurchase 1 million shares of its common stock from the Company at $20 per share, the same price that it was valued on June 6, 2002, the date of the Company's sale of TriMas. As a result of this repurchase by TriMas, and as a result of acquisitions performed by TriMas in 2003, the Company's ownership in TriMas decreased to 5.75 million shares or approximately 28% of TriMas as of June 27, 2004.

12.    Mandatorily Redeemable Preferred Stock

As part of the New Castle transaction, Metaldyne issued 644,540 shares of $64.5 million in liquidation value of redeemable Series A-1 preferred stock in exchange for interests in New Castle held by DaimlerChrysler Corporation. The redeemable Series A-1 preferred shares are mandatorily redeemable on December 31, 2013. The Series A-1 preferred stockholders are entitled to receive, when, as and if declared by the Company's Board of Directors, cumulative quarterly cash dividends at a rate of 11% per annum plus 2% per annum for any period for which there are any accrued and unpaid dividends. The preferred stock issued was valued at $64.5 million as a preliminary estimate of the fair value of this security, pending the final valuation.

The Company has outstanding 361,001 shares of $36.1 million in liquidation value ($34.1 million estimated carrying value for accounting purposes) of Series A preferred stock par value $1 and authorized 370,000 shares to Masco Corporation. The Company will accrete from the carrying value to the liquidation value ratably over the twelve-year period. The preferred stock is mandatorily redeemable on December 31, 2012. Series A preferred stockholders are entitled to receive, when, as and if declared by the Company's board of directors, cumulative quarterly cash dividends at a rate of 13% per annum for periods ending on or prior to December 31, 2005 and 15% per annum for periods after December 31, 2005 plus 2% per annum for any period for which there are any accrued and unpaid dividends.

The Company has outstanding 184,153 shares valued at $18.5 million of redeemable Series B preferred stock in exchange for interests in GMTI. The redeemable Series B preferred shares issued are mandatory redeemable on June 15, 2013. The Series B preferred stockholders are entitled to receive, when, as and if declared by the Company's Board of Directors, cumulative semi-annual cash dividends at a rate of 11.5% per annum. On December 31, 2003, Heartland Industrial Partners, L.P., Metaldyne's parent company, purchased all of the outstanding 184,153 shares of redeemable Series B preferred stock from former GMTI shareholders.

Preferred stock dividends were $9.0 million and $4.7 million, while dividend cash payment were zero, for the six months ended June 27, 2004 and June 29, 2003, respectively. Thus, unpaid accrued dividends were $30.4 million and $18.4 million as of June 27, 2004 and December 28, 2003, respectively. Redeemable preferred stock, consisting of outstanding shares and unpaid dividends, was $147.5 million and $74.0 million in the Company's consolidated balance sheet at June 27, 2004 and December 28, 2003, respectively. As a result of the Company's implementation of SFAS No. 150, "Accounting for Certain

16




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Financial Instruments with Characteristics of both Liabilities and Equity," redeemable preferred stock has been reclassified as a long-term liability effective beginning in 2004.

13.    Earnings Per Share

The following reconciles the numerators and denominators used in the computations of basic and diluted earnings per common share:


  (In thousands except per share amounts)
  Three Months Ended Six Months Ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
    (Restated)   (Restated)
                         
Weighted average number of shares outstanding   42,800     42,730     42,800     42,730  
                         
Net income (loss) $ (3,170 $ 1,060   $ (8,420 $ (10,000
Less: Preferred stock dividends       2,280         4,500  
Loss used for basic and diluted earnings per share computation $ (3,170 $ (1,220 $ (8,420 $ (14,500
                         
Basic loss per share attributable to common stock $ (0.07 $ (0.03 $ (0.20 $ (0.34
Total shares used for basic earnings per share computation   42,800     42,730     42,800     42,730  
Contingently issuable shares                
Total shares used for diluted earnings per share computation   42,800     42,730     42,800     42,730  
                         
Diluted loss per share attributable to common stock $ (0.07 $ (0.03 $ (0.20 $ (0.34

Excluded from the calculation of diluted loss per share are stock options representing 911,700 and 2,570,000 of common shares as they are anti-dilutive at June 27, 2004 and June 29, 2003 (as restated), respectively.

Contingently issuable shares, representing approximately 50,000 and 920,000 restricted common shares, have an anti-dilutive effect on earnings per share for the three and six months ended June 27, 2004 and June 29, 2003 (as restated), respectively.

14.    Comprehensive Income (Loss)

The Company's total comprehensive income (loss) for the period was as follows:


  (In thousands)
  Three Months Ended Six Months Ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
    (Restated)   (Restated)
Net income (loss) $ (3,170 $ 1,060   $ (8,420 $ (10,000
Other comprehensive income (loss):                        
Foreign currency translation adjustment   (1,560   20,810     (6,510   27,510  
Interest rate agreements fair value adjustments (realized in 2004)       90     (6,590   390  
Total other comprehensive income (loss)   (1,560   20,900     (13,100   27,900  
Total comprehensive income (loss) $ (4,730 $ 21,960   $ (21,520 $ 17,900  

17




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

15.    Employee Benefit Plans

Pension Benefits:


  (In thousands)
  For the three months ended For the six months ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
Components of Net Periodic Benefit Cost                        
Service cost $ 780   $ 800   $ 1,560   $ 1,600  
Interest cost   4,340     4,280     8,680     8,560  
Expected return on plan assets   (4,350   (4,140   (8,700   (8,280
Amortization of prior service cost   40     30     80     60  
Amortization of net (gain) loss   620     170     1,240     340  
Curtailment (gain) loss   (1,470       (1,470    
Net periodic benefit cost $ (40 $ 1,140   $ 1,390   $ 2,280  

Other Benefits:


  (In thousands)
  For the three months ended For the six months ended
  June 27, 2004 June 29, 2003 June 27, 2004 June 29, 2003
Components of Net Periodic Benefit Cost                        
Service cost $ 300   $ 260   $ 600   $ 520  
Interest cost   780     750     1,560     1,500  
Expected return on plan assets                
Amortization of prior service cost   (60   (30   (120   (60
Amortization of net (gain) loss   140     70     280     140  
Curtailment (gain) loss   (480       (480    
Net periodic benefit cost $ 680   $ 1,050   $ 1,840   $ 2,100  

The curtailment gain of $1.5 million relates to the disposition of the manufacturing facilities discussed in Note 11 to the consolidated financial statements.

Employer Contributions

Metaldyne previously disclosed in its financial statements for the year ended December 28, 2003, that it expected to contribute $17.5 million to its defined benefit pension plans in 2004. As of June 27, 2004, approximately $5 million of contributions have been made.

The Company also disclosed in its financial statements for the year ended December 28, 2003, that it expected to contribute approximately $9.1 million to its defined contribution (profit-sharing and 401(k) matching contribution) plans in 2004. The Company contributed approximately $1.7 million to its defined contribution plans as of June 27, 2004.

16.    Commitments and Contingencies

The Company is subject to claims and litigation in the ordinary course of its business, but does not believe that any such claim or litigation will have a material adverse effect on its financial position or results of operation.

There are no material pending legal proceedings, other than ordinary routine litigation incidental to the Company's business, to which it is aware that would have a material adverse effect on the Company's financial position or results of operations.

17.    New Accounting Pronouncements

In May 2003, the FASB issued SFAS No. 150, "Accounting for Certain Financial Instruments with Characteristics of both Liabilities and Equity." This Statement establishes standards for how an issuer classifies and measures certain financial instruments with characteristics of both liabilities and equity. This

18




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Statement is effective for financial instruments entered into or modified after May 31, 2003, and otherwise is effective at the beginning of the first interim period beginning after June 15, 2003, except for mandatorily redeemable financial instruments of nonpublic entities, for which it is effective for the first fiscal period beginning after December 15, 2003. Due to the Company being a nonpublic entity as defined in SFAS No. 150, it has adopted this Statement effective for the quarter ended March 28, 2004. As a result of the Company's adoption of SFAS No. 150, the Company's redeemable preferred stock is classified as a long-term liability on the Company's consolidated balance sheet effective as of the quarter ended March 28, 2004, and preferred stock dividends associated with this redeemable preferred stock are classified as other expense, net on the Company's consolidated statement of operations beginning with the quarter ended March 28, 2004.

18.    Subsequent Event

In July 2004, the Company received an IRS tax refund of $27 million that resulted from a claim filed in 2002. This claim was based on a 2002 change in the US Treasury Regulations that permitted the Company to utilize a previously disallowed capital loss that primarily resulted from the sale of a subsidiary in 2000. The amount received in excess of the refund previously recorded will be considered in the tax provision for the third quarter of 2004.

19.    Condensed Consolidating Financial Statements of Guarantors of Senior Subordinated Notes

The following condensed consolidating financial information presents:

(1)  Condensed consolidating financial statements as of June 27, 2004 and December 28, 2003, and for the three and six months ended June 27, 2004 and June 29, 2003 (as restated) of (a) Metaldyne Corporation, the parent and issuer, (b) the guarantor subsidiaries, (c) the non-guarantor subsidiaries and (d) the Company on a consolidated basis, and
(2)  Elimination entries necessary to consolidate Metaldyne Corporation, the parent, with guarantor and non-guarantor subsidiaries.

The condensed consolidating financial statements are presented on the equity method. Under this method, the investments in subsidiaries are recorded at cost and adjusted for the Company's share of the subsidiaries' cumulative results of operations, capital contributions, distributions and other equity changes. The principal elimination entries eliminate investments in subsidiaries and intercompany balances and transactions.

All investments in non-domestic subsidiaries are held directly at Metaldyne Company LLC, a wholly owned subsidiary of Metaldyne Corporation and the guarantor subsidiaries. Equity in non-domestic subsidiary investees is included in the guarantor column of the accompanying consolidating financial information.

19




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Balance Sheets June 27, 2004
(Unaudited)


(In thousands)  
  Parent Guarantor Non-Guarantor Eliminations Consolidated
Assets                              
Current assets:                              
Cash and cash equivalents $   $ (2,450 $ 2,450   $   $  
Total receivables, net       124,570     79,580         204,150  
Inventories       84,170     29,700         113,870  
Deferred and refundable income taxes       6,950     1,170         8,120  
Prepaid expenses and other assets       35,390     9,080         44,470  
Total current assets       248,630     121,980         370,610  
Equity investments in affiliates   128,830                 128,830  
Property and equipment, net       667,460     225,110         892,570  
Excess of cost over net assets of acquired companies       442,700     140,060         582,760  
Investment in subsidiaries   544,280     229,990         (774,270    
Intangible and other assets       207,240     20,130         227,370  
Total assets $ 673,110   $ 1,796,020   $ 507,280   $ (774,270 $ 2,202,140  
Liabilities And Shareholders' Equity                        
Current liabilities:                              
Accounts payable $   $ 207,600   $ 73,300   $   $ 280,900  
Accrued liabilities       82,770     34,220         116,990  
Current maturities, long-term debt       4,060     4,520         8,580  
Total current liabilities       294,430     112,040         406,470  
Long-term debt   431,750     416,450     5,210         853,410  
Deferred income taxes       100,000     21,540         121,540  
Minority interest           800         800  
Other long-term liabilities       140,200     6,610         146,810  
Redeemable preferred stock   147,480                 147,480  
Intercompany accounts, net   (431,750   300,660     131,090          
Total liabilities   147,480     1,251,740     277,290         1,676,510  
Shareholders' equity:                              
Preferred stock                    
Common stock   42,830                 42,830  
Paid-in capital   693,540                 693,540  
Accumulated deficit   (243,170               (243,170
Accumulated other comprehensive income   32,430                 32,430  
Investment by Parent/Guarantor       544,280     229,990     (774,270    
Total shareholders' equity   525,630     544,280     229,990     (774,270   525,630  
Total liabilities, redeemable stock and shareholders' equity $ 673,110   $ 1,796,020   $ 507,280   $ (774,270 $ 2,202,140  

20




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS   

Guarantor/Non-Guarantor
Condensed Consolidating Balance Sheets December 28, 2003

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Assets                              
Current assets:                              
Cash and cash equivalents $   $ 10,750   $ 3,070   $   $ 13,820  
Total receivables, net       151,940     29,180         181,120  
Inventories       54,080     29,600         83,680  
Deferred and refundable income taxes       7,900     1,210         9,110  
Prepaid expenses and other assets       27,880     8,400         36,280  
Total current assets       252,550     71,460         324,010  
Equity and other investments in affiliates   148,830                 148,830  
Property and equipment, net       478,760     228,690         707,450  
Excess of cost over net assets of acquired companies       441,920     142,470         584,390  
Investment in subsidiaries   471,060     229,590         (700,650    
Intangible and other assets       225,400     21,780         247,180  
Total assets $ 619,890   $ 1,628,220   $ 464,400   $ (700,650 $ 2,011,860  
Liabilities And Shareholders' Equity                              
Current liabilities:                              
Accounts payable $   $ 128,960   $ 72,280   $   $ 201,240  
Accrued liabilities       96,040     40,800         136,840  
Current maturities, long-term debt       4,820     6,060         10,880  
Total current liabilities       229,820     119,140         348,960  
Long-term debt   400,000     360,740     6,190         766,930  
Deferred income taxes       95,530     25,990         121,520  
Minority interest           800         800  
Other long-term liabilities       148,620     5,140         153,760  
Intercompany accounts, net   (400,000   322,450     77,550          
Total liabilities       1,157,160     234,810         1,391,970  
Redeemable preferred stock   73,980                 73,980  
Shareholders' equity:                              
Preferred stock                    
Common stock   42,730                 42,730  
Paid-in capital   692,400                 692,400  
Accumulated deficit   (234,750               (234,750
Accumulated other comprehensive income   45,530                 45,530  
Investment by Parent/Guarantor       471,060     229,590     (700,650    
Total shareholders' equity $ 545,910   $ 471,060   $ 229,590   $ (700,650 $ 545,910  
Total liabilities, redeemable stock and shareholders' equity $ 619,890   $ 1,628,220   $ 464,400   $ (700,650 $ 2,011,860  

21




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Operations
Three Months Ended June 27, 2004
(Unaudited)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Net sales $   $ 416,350   $ 105,540   $   $ 521,890  
Cost of sales       (386,290   (83,210       (469,500
Gross profit       30,060     22,330         52,390  
Selling, general and administrative
expenses
      (25,790   (5,460       (31,250
Restructuring charges       (660   (860       (1,520
Operating profit       3,610     16,010         19,620  
Other expense, net:                              
Interest expense       (17,310   (2,340       (19,650
Preferred stock dividends   (4,710               (4,710
Equity income (loss) from affiliates, net   2,980                 2,980  
Other, net       (2,360   1,320         (1,040
Other expense, net   (1,730   (19,670   (1,020       (22,420
Income (loss) before income taxes   (1,730   (16,060   14,990         (2,800
Income tax expense (benefit)       (3,840   4,210         370  
Equity in net income of subsidiaries   (1,440   10,780         (9,340    
Earnings (loss) attributable to common
stock
$ (3,170 $ (1,440 $ 10,780   $ (9,340 $ (3,170

22




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Operations
Three Months Ended June 29, 2003
(Unaudited)
(Restated)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Net sales $   $ 300,090   $ 90,450   $   $ 390,540  
Cost of sales       (268,880   (71,830       (340,710
Gross profit       31,210     18,620         49,830  
Selling, general and administrative
expenses
      (25,930   (1,700       (27,630
Restructuring charges       (2,330           (2,330
Operating profit       2,950     16,920         19,870  
Other expense, net:                              
Interest expense       (16,910   (370       (17,280
Equity income (loss) from affiliates, net   (80               (80
Other, net       (850   (1,260       (2,110
Other income (expense), net   (80   (17,760   (1,630       (19,470
Income (loss) before income taxes   (80   (14,810   15,290         400  
Income tax expense (benefit)       (4,790   4,130         (660
Equity in net income of subsidiaries   1,140     11,160         (12,300    
Net income (loss) $ 1,060   $ 1,140   $ 11,160   $ (12,300 $ 1,060  
Preferred stock dividends   2,280                 2,280  
Earnings (loss) attributable to common
stock
$ (1,220 $ 1,140   $ 11,160   $ (12,300 $ (1,220

23




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Operations
Six Months Ended June 27, 2004
(Unaudited)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Net sales $   $ 794,860   $ 208,170   $   $ 1,003,030  
Cost of sales       (732,850   (165,580       (898,430
Gross profit       62,010     42,590         104,600  
Selling, general and administrative
expenses
      (51,520   (10,950       (62,470
Restructuring charges       (850   (860       (1,710
Proceeds on disposition of manufacturing facilities       (7,600           (7,600
Operating profit       2,040     30,780         32,820  
Other expense, net:                              
Interest expense       (35,300   (4,450       (39,750
Preferred stock dividends   (8,970               (8,970
Non-cash gain on interest rate arrangements upon maturity       6,590             6,590  
Equity income (loss) from affiliates, net   4,440                 4,440  
Other, net       (2,170   (1,250       (3,420
Other expense, net   (4,530   (30,880   (5,700       (41,110
Income (loss) before income taxes   (4,530   (28,840   25,080         (8,290
Income tax expense (benefit)       (7,200   7,330         130  
Equity in net income of subsidiaries   (3,890   17,750         (13,860    
Earnings (loss) attributable to common
stock
$ (8,420 $ (3,890 $ 17,750   $ (13,860 $ (8,420

24




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Operations
Six Months Ended June 29, 2003
(Unaudited)
(Restated)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Net sales $   $ 595,560   $ 176,900   $   $ 772,460  
Cost of sales       (541,320   (140,270       (681,590
Gross profit       54,240     36,630         90,870  
Selling, general and administrative
expenses
      (51,760   (5,520       (57,280
Restructuring charges       (2,330   (1,530       (3,860
Operating profit       150     29,580         29,730  
Other expense, net:                              
Interest expense       (34,340   (860       (35,200
Equity income (loss) from affiliates, net   (2,710               (2,710
Other, net       (530   (5,240       (5,770
Other income (expense), net   (2,710   (34,870   (6,100       (43,680
Income (loss) before income taxes   (2,710   (34,720   23,480         (13,950
Income tax expense (benefit)       (13,210   9,260         (3,950
Equity in net income of subsidiaries   (7,290   14,220         (6,930    
Net income (loss) $ (10,000 $ (7,290 $ 14,220   $ (6,930 $ (10,000
Preferred stock dividends   4,500                 4,500  
Earnings (loss) attributable to common
stock
$ (14,500 $ (7,290 $ 14,220   $ (6,930 $ (14,500

25




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONTINUED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Cash Flows
Six Months Ended June 27, 2004
(Unaudited)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Cash flows from operating activities:                              
Net cash provided by (used for) operating activities $   $ 94,210   $ (42,370 $   —   $ 51,840  
Cash flows from investing activities:                              
Capital expenditures       (49,290   (14,680       (63,970
Proceeds from sale/leaseback of fixed assets       72,530             72,530  
Proceeds on disposition of manufacturing facilities       (500           (500
Acquisition of business       (217,850           (217,850
Disposition of joint venture       1,260             1,260  
Net cash used for investing activities       (193,850   (14,680       (208,530
                               
Cash flows from financing activities:                              
Principal payments of term loan facilities       (440           (440
Proceeds of revolving credit facility       117,090             117,090  
Principal payments of revolving credit facility       (64,790           (64,790
Proceeds of senior subordinated notes,
due 2014
  31,750                 31,750  
Proceeds of other debt           780         780  
Principal payments of other debt       (2,660   (3,310       (5,970
Issuance of Series A-1 preferred stock   64,450                 64,450  
Change in intercompany accounts   (96,200   39,690     56,510          
Net cash provided by financing activities       88,890     53,980         142,870  
Net increase (decrease) in cash       (10,750   (3,070       (13,820
Cash and cash equivalents, beginning of
period
      10,750     3,070         13,820  
Cash and cash equivalents, end of period $   $   $   $   $  

26




METALDYNE CORPORATION
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS    (CONCLUDED)

Guarantor/Non-Guarantor
Condensed Consolidating Statement Of Cash Flows
Six Months Ended June 29, 2003
(Unaudited)
(Restated)

(In thousands)


  Parent Guarantor Non-Guarantor Eliminations Consolidated
Cash flows from operating activities:                              
Net cash provided by (used for) operating activities $   $ 41,300   $ (19,060 $   —   $ 22,240  
Cash flows from investing activities:                              
Capital expenditures       (42,040   (12,330       (54,370
Proceeds from sale/leaseback of fixed assets       8,460             8,460  
Disposition of businesses           22,570         22,570  
Proceeds from sale of TriMas shares   20,000                 20,000  
Acquisition of business, net of cash received       (7,650           (7,650
Investment in joint venture       (20,000           (20,000
Net cash provided by (used for) investing activities   20,000     (61,230   10,240         (30,990
Cash flows from financing activities:                              
Principal payments of term loan facilities       (500           (500
Proceeds of revolving credit facility       180,000             180,000  
Principal payments of revolving credit facility       (180,000           (180,000
Proceeds of other debt           1,420         1,420  
Principal payments of other debt       (1,920   (2,300       (4,220
Change in intercompany accounts   (20,000   14,610     5,390          
Net cash provided by (used for) financing activities   (20,000   12,190     4,510         (3,300
Net increase (decrease) in cash       (7,740   (4,310       (12,050
Cash and cash equivalents, beginning of
period
      14,610     4,520         19,130  
Cash and cash equivalents, end of period $   $ 6,870   $ 210   $   $ 7,080  

27




ITEM 2.  MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS

Executive Summary

We are a leading global manufacturer of highly engineered metal components for the global light vehicle market with 2003 sales of approximately $1.5 billion. We operate three segments focused on the global light vehicle market. The Chassis, Driveline and Engine segments manufacture, design, engineer and assemble metal-formed and precision-engineered components and modular systems used in the transmissions, engines and chassis of vehicles. We serve approximately 200 automotive and industrial customers and our top ten customers represent approximately 65% of total 2003 sales. Prior to November 2000, we were a public company. Since we were acquired in November 2000 by a private investor group, we have actively pursued opportunities for internal growth and strategic acquisitions that were unavailable to us when the majority of our shares were publicly traded. Since November 2000, we have completed four acquisitions — Simpson in December 2000, GMTI effective January 2001, Dana Corporation's Greensboro, NC operation in May 2003, and DaimlerChrysler's New Castle operation at the beginning of our fiscal 2004. Each of these acquisitions has added to the full service, integrated metal supply capabilities of our automotive operations. Additionally we split off our non-automotive operations, divesting our former TriMas subsidiary in June 2002 and our Fittings operation in April 2003.

As discussed elsewhere in this filing or in our 2003 Form 10K, an independent investigation into certain accounting matters at the Company was completed in late September 2004. The Company's quarterly financial information for the first three fiscal quarters of 2003 have been restated to reflect adjustments to the Company's previously reported financial information on Form 10-Q for the first three fiscal quarters of 2003. The restatement arose primarily out of information obtained through an independent investigation. The investigation was initiated as a result of certain allegations made by an employee of the Company and information obtained by the Company's internal audit staff. This investigation expanded beyond its initial allegations into overstatements and understatements of income at the Company's Sintered Division into accounting practices in other areas of the Company concerning the use of reserves and accrual accounts and the recognition of tooling income. Refer to Item 4 for a discussion of the investigation, its findings and actions taken and to be taken by the Company in response thereto.

Key Factors Affecting our Reported Results

We operate in extremely competitive markets. Our customers select us based upon numerous factors including technology, quality and price. Supplier selection is generally finalized several years prior to the start of vehicle production, and as a result business that we win will generally not start production for two years or beyond. In addition, our results are heavily dependent on global vehicle production, and in particular the North American vehicle production of the Big 3 domestic manufacturers (GM, Ford, and DaimlerChrysler). Our customers generally require that we offer annual productivity and efficiency related price decreases on products we sell them. Critical factors to be successful in this market include global low cost production facilities, leading service and parts quality, and differentiated product and process technology. Thus, we focus on managing our global manufacturing footprint in line with our customer needs and local market manufacturing cost differences, improving operating efficiency and production quality of our plants, fixing or eliminating unprofitable facilities and reducing our overall material costs. In addition, we spend considerable time and resources developing new technology and products to enhance performance and/or decrease cost of the products we sell to our customers. See "Results of Operations" for more details as to the factors that drive year over year performance.

The rise in material costs, especially steel, continues to negatively impact our results. This and other increases in our raw material costs increased our cost of goods sold by approximately $16 million through the second quarter of 2004 (approximately $11 million related to steel increases). Note that the steel price increases primarily relate to our Forging operations within the Driveline Group while the remaining increases are spread across all of our other businesses and is related to numerous raw material increases such as energy, Molybdenum and casting components we purchase. Raw material costs have continued to

28




increase throughout the year and we currently expect these costs to increase our cost of goods sold by approximately $50 million in 2004. However, we currently anticipate recovering approximately $30 million of this increase through steel scrap sales, steel resourcing efforts and negotiated or contractual price recovery from our customers. However, our ability to fully execute this recovery is not guaranteed. Additionally, it appears that raw material costs will continue to increase in 2005 and although we have initiatives in place to offset these expected increases, there is no guarantee that these efforts will be successful.

Our strategy is centered on growth through new business awards and acquisitions. We have a significant new project backlog and have completed several recent acquisitions that we believe will enable us to better serve our customer base and provide enhanced returns for our stakeholders. In order to finance a large portion of this activity, we incurred significant issuance of new debt. As such, we have significant leverage and are constrained by various covenant limitations (see "— Financial Covenants" for more details surrounding these covenants). As we continue to invest in the resources to produce our new business backlog and thus grow our business, a significant portion of our operating cash flow will be used to buy new capital equipment, expand production capacity and invest in new technology in addition to servicing principal and interest payments on our debt obligations. Therefore, we are focused on our cash generation ability (we monitor this internally through "Adjusted EBITDA." See discussion below in "Non GAAP Financial Measures" for explanation), and working capital and fixed asset efficiency to assess our ability to profitably finance our new business backlog.

Net sales for the first six months of 2004 net sales were $1,003 million versus $772 for the first six months of 2003 (as restated). The primary driver of the increase in our 2004 sales was our New Castle acquisition, which contributed $212 million in the first six months of 2004. In addition, we had approximately $37 million in additional volume related to new product launches and ramp up of existing programs as well as a $17 million benefit from foreign exchange movements. However, these increases were partially offset by approximately $32 million related to our divestiture of two aluminum die casting facilities within our Driveline segment and a 2.9% decrease in North American vehicles production from our three largest customers (Ford, GM and DaimlerChrysler). Operating profit for the first six months increased from $29.7 million in 2003 (as restated) to $32.8 million in 2004. The increase in 2004 operating profit is primarily the result of an approximate $13 million contribution from our New Castle acquisition, which was offset by approximately $7 million in fees and expenses relating to the Independent Investigation described in Note 2 to the consolidated financial statements included herein and a $7.6 million charge taken in connection with our divestiture of two manufacturing facilities within our Driveline segment. The net remaining increase is primarily driven by the decrease in our selling, general and administrative costs in 2004.

Key Indicators of Performance (Non-GAAP Financial Measures)

In evaluating our business, our management considers Adjusted EBITDA as a key indicator of financial operating performance and as a measure of cash generating capability.

We define Adjusted EBITDA as net income (loss) before cumulative effect of accounting change and before interest, taxes, depreciation, amortization, asset impairment, preferred stock dividends, non-cash losses on sale-leaseback of property and equipment and non-cash restricted stock award expense. In evaluating Adjusted EBITDA, our management deems it important to consider the quality of our underlying earnings by separately identifying certain costs undertaken to improve our results, such as costs related to consolidating facilities and business in an effort to eliminate duplicative costs or achieve efficiencies, costs related to integrating acquisitions and restructuring costs related to expense reduction efforts. Although our consolidation, restructuring and integration efforts are continuing and driven in part by our acquisition activity, our management eliminates these costs to evaluate underlying business performance. Caution must be exercised in eliminating these items as they include substantially (but not necessarily entirely) cash costs and there can be no assurance that we will ultimately realize the benefits of these efforts. Moreover, even if the anticipated benefits are realized, they may be offset by other business performance or general economic issues.

By selecting Adjusted EBITDA, management believes that it is the best indicator (together with a careful review of the aforementioned items) of our ability to service and/or incur indebtedness as we are

29




a highly leveraged company. We use Adjusted EBITDA as a key performance measure because we believe it facilitates operating performance comparisons from period to period and company to company by backing out potential differences caused by variations in capital structures (affecting interest expense), tax positions (such as the impact on periods or companies of changes in effective tax rates or net operating losses) and the impact of purchase accounting and SFAS No. 142 (affecting depreciation and amortization expense). Because Adjusted EBITDA facilitates internal comparisons of our historical operating performance on a more consistent basis, we also use Adjusted EBITDA for business planning purposes, to incent and compensate our management personnel, in measuring our performance relative to that of our competitors and in evaluating acquisition opportunities. In addition, we believe Adjusted EBITDA or similar measures are widely used by investors, securities analysts, ratings agencies and other interested parties as a measure of financial performance and debt-service capabilities. Our use of Adjusted EBITDA has limitations as an analytical tool, and you should not consider it in isolation or as a substitute for analysis of our results as reported under GAAP. Some of these limitations are:

•  It does not reflect our cash expenditures for capital equipment or contractual commitments;
•  Although depreciation and amortization are non-cash charges, the assets being depreciated and amortized may have to be replaced in the future, and Adjusted EBITDA does not reflect cash requirements for such replacements;
•  It does not reflect changes in, or cash requirements for, our working capital needs;
•  It does not reflect the interest expense or the cash requirements necessary to service interest or principal payments on our indebtedness;
•  It includes amounts resulting from matters we consider not to be indicative of underlying performance of our fundamental business operations, as discussed in "Management's Discussion and Analysis of Financial Condition and Results of Operations"; and
•  Other companies, including companies in our industry, may calculate these measures differently than we do, limiting their usefulness as a comparative measure.

Because of these limitations, Adjusted EBITDA should not be considered a measure of discretionary cash available to us to invest in the growth of our business. We compensate for these limitations by relying primarily on our GAAP results and using Adjusted EBITDA only supplementally. We carefully review our operating profit margins (operating profit as a percentage of net sales) at a segment level, which are discussed in detail in our year-to-year comparison of operating results.

The following is a reconciliation of our Adjusted EBITDA to net income (loss) for the three and six months ended June 27, 2004 and June 29, 2003 (as restated):


  (In thousands)
  Three Months Ended Six Months Ended
  2004 2003 2004 2003
    (Restated)   (Restated)
Net income (loss) $ (3,170 $ 1,060   $ (8,420 $ (10,000
Income tax expense (benefit)   370     (660   130     (3,950
Interest expense   19,650     17,280     39,750     35,200  
Depreciation and amortization in operating profit   32,470     27,290     64,000     52,240  
Non-cash stock award expense   240     630     470     1,530  
Preferred stock dividends   4,710         8,970      
Non-cash gain on maturity of interest rate arrangements           (6,590    
Loss on disposition of manufacturing facilities           7,600      
Equity (gain) loss from affiliates   (2,980   80     (4,440   2,710  
Certain items within Other, Net(1)   1,470     970     3,820     3,550  
Adjusted EBITDA $ 52,760   $ 46,650   $ 105,290   $ 81,280  

30




(1)    Reconciliation of Other Expense


  (In thousands)
  Three Months Ended Six Months Ended
  2004 2003 2004 2003
    (Restated)   (Restated)
Items deducted from net loss in determining Adjusted EBITDA (amortization of financing fees and A/R securitization fees) $ 1,470   $ 970   $ 3,820   $ 3,550  
Items included in determining Adjusted EBITDA (includes foreign currency, royalties and interest income)   (430   1,140     (400   2,220  
Total other, net $ 1,040   $ 2,110   $ 3,420   $ 5,770  

The following details certain items relating to our consolidation, restructuring and integration efforts and other charges not eliminated in determining Adjusted EBITDA, but that we would eliminate in evaluating the quality of our Adjusted EBITDA:


  (In thousands)
  Three Months Ended Six Months Ended
  2004 2003 2004 2003
    (Restated)   (Restated)
Restructuring charges $ (1,520 $ (2,330 $ (1,710 $ (3,860
Fixed asset disposal losses   (430   (990   (750   (2,200
Foreign currency losses   (290   (200   (720   (1,430
Independent Investigation fees   (5,260       (6,430    

Results of Operations

Quarter Ended June 27, 2004 versus June 29, 2003 (As Restated)

Net Sales.    Net sales by segment and in total for the three months ended June 27, 2004 and June 29, 2003 (as restated) were:


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 155,930   $ 37,600  
Driveline Segment   202,810     202,860  
Engine Segment   163,150     150,080  
    Total Company $ 521,890   $ 390,540  

Our second quarter 2004 net sales were $522 million versus second quarter 2003 (as restated) net sales of $391 million. The primary driver of the increase in our 2004 automotive sales was our New Castle acquisition, which contributed $119 million in the second quarter of 2004. In addition we had approximately $20 million in additional volume related to new product launches and ramp up of existing programs as well as a $5 million benefit from foreign exchange movements. However, these increases were partially offset by an approximate $17 million decrease related to our divestiture of two aluminum die casting facilities within our Driveline segment and a 1.3% decrease in North American vehicles production from our three largest customers (Ford, General Motors and DaimlerChrysler). The specific sales differences are further explained in the segment information section.

31




Gross profit.    Gross profit by segment and in total for the three months ended June 27, 2004 and June 29, 2003 (as restated) were:


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 12,510   $ 3,720  
Driveline Segment   16,460     24,630  
Engine Segment   26,900     24,470  
Corporate/centralized resources   (3,480   (2,990
    Total Company $ 52,390   $ 49,830  

Our gross profit was $52.4 million, or 10.0% of net sales for 2004 compared to $49.8 million, or 12.8% of net sales for 2003 (as restated). The $2.6 million increase was primarily due to the sales increase noted above. The 2.8% margin decline is primarily explained by a $10 million year over year decline in our North American forging operation (primarily related to an approximate $9 million increase in steel prices during the second quarter), which is part of our Driveline segment, and a $3 million one-time payment made to a customer relating to the award of a future business contract. Both these items are explained further in our segment discussion for the Driveline Group.

Selling, General and Administrative.    Selling, general and administrative expenses were $31.3 million or 6.0% of net sales for 2004 compared to $27.6 million, or 7.1% of net sales for 2003 The $3.7 million increase from 2003 to 2004 is primarily related to approximately $5 million of expense associated with the Independent Investigation described in Note 2 to the consolidated financial statements included herein. The reduction in selling, general and administrative expenses as a percentage of net sales reflects the benefits from restructuring efforts initiated in 2003 and the fact that the New Castle facility was able to integrate into our operation without significant additional investment in these activities.

Depreciation and Amortization.    Depreciation and amortization expense by segment and in total for the three months ended June 27, 2004 and June 29, 2003 (as restated) were:


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 6,610   $ 1,820  
Driveline Segment   14,600     12,870  
Engine Segment   10,060     10,690  
Corporate/centralized resources   1,200     1,910  
    Total Company $ 32,470   $ 27,290  

The net increase in depreciation and amortization of approximately $5.2 million is principally explained by $4.7 million of depreciation and amortization expense associated with our New Castle acquisition.

Restructuring Charges.    We incurred $1.5 million of restructuring charges in the second quarter of 2004 compared to $2.3 million incurred in the second quarter of 2003. Of the 2004 charges, approximately $0.9 million related to our Driveline segment, where the majority of the charge related to the closure of a facility in Europe. An additional $0.5 million relates to costs to reduce headcount in our Corporate center, and the remaining $0.1 million relates to headcount reductions in our Chassis segment. Net restructuring activity in the second quarter of 2004 is as follows:

32





  (In thousands)
  Severance
Costs
Balance March 28, 2004 $ 5,860  
Charges to expense   1,520  
Cash payments   (1,730
Balance at June 27, 2004 $ 5,650  

Operating Profit.    Operating profit was $19.6 million, or 3.8% of sales, for the second quarter of 2004 compared to $19.9 million, or 5.1% of sales, for the same period in 2003 (as restated). The $0.3 million decrease is principally explained by an $10 million contribution from our New Castle acquisition (before corporate expense allocations to the segments relating to services performed at Corporate for the benefit of the operations), approximately $0.8 million decrease in restructuring expense, $1.5 million pension curtailment gain, and $6 million from new launches and ramp up from existing programs. However, these improvements were offset by $10 million of issues surrounding our forging operations (primarily related to an approximate $9 million increase in steel prices during the second quarter), a $3 million one-time payment to a customer relating to the launch of an upcoming program, and approximately $5 million in fees and expenses for professional services provided related to the Independent Investigation and restatement described in Note 2 to the consolidated financial statements included herein. These items are further explained in the sections above and in the segment discussion that follows. Operating profit by segment for the three months ended June 27, 2004 and June 29, 2003 (as restated) is as follows:


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 8,730   $ 1,960  
Driveline Segment   3,510     9,820  
Engine Segment   17,020     14,350  
Corporate/centralized resources   (9,640   (6,260
    Total Company $ 19,620   $ 19,870  

Adjusted EBITDA.    Management reviews our segment operating results based upon the Adjusted EBITDA definition as discussed in the "Key Indicators of Performance (Non-GAAP Financial Measures)" section. Accordingly, we have separately presented such amounts in the table below. Adjusted EBITDA increased to $52.8 million in 2004 from $46.7 million in 2003 (as restated). The primary drivers of this increase are explained above in the operating profit and depreciation and amortization discussions, and will be further detailed in the segment detail that follows. Additionally, in "— Segment Information" below, we provide a reconciliation between Adjusted EBITDA and operating profit.


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 15,340   $ 3,780  
Driveline Segment   18,110     22,690  
Engine Segment   27,080     25,040  
Corporate/centralized resources   (7,770   (4,860
Total Company $ 52,760   $ 46,650  
             
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 430   $ 990  
Memo: Other, net (income) loss included in calculation of Adjusted EBITDA $ (430 $ 1,140  

33




Interest Expense.    Interest expense increased from $17.3 million in the second quarter of 2003 (as restated) to approximately $19.7 million in 2004. The increase is principally due to $0.8 million in interest arising from the 10% senior subordinated notes from our New Castle acquisition and $3.8 million in interest arising from our 10% senior notes issued in October 2003. These increases were offset by a decrease of $1.1 million in interest expense related to the redemption of the $98.5 million outstanding balance on the 4.5% subordinated debentures and a decrease of $0.6 million in interest expense related to the repayment of $46.6 million of term loan debt in the fourth quarter of 2003.

Equity Loss from Affiliates.    Equity earnings (loss) from affiliates were $3.0 million in the second quarter of 2004. The improvement versus our second quarter 2003 loss of $0.1 million reflects the improved operating results of our equity affiliates.

Other, Net.    Other, net decreased to a loss of $1.0 million in the second quarter of 2004 versus a loss of approximately $2.1 million in the second quarter of 2003 (as restated). This decrease is due primarily to a $1.2 million gain recognized on the disposition of a joint venture in Korea in the second quarter of 2004.

Preferred Stock Dividends.    Preferred stock dividends were $4.7 million in the second quarter of 2004 as compared to $2.3 million for the same period in 2003. This increase is due to dividends on the $64.5 million of preferred stock issued in connection with the New Castle acquisition and compounded interest on preexisting preferred stock. Due to our adoption of SFAS No. 150, "Accounting for Certain Financial Instruments with Characteristics of both Liabilities and Equity" in the first quarter of 2004, preferred stock dividends are included as other expense, net on our consolidated statement of operations beginning in 2004.

Taxes.     The provision for income taxes for the second quarter of 2004 was an expense of $0.5 million as compared with a benefit of $0.7 million for the second quarter of 2003 (as restated). The primary reasons for the Company's effective tax rate being different from its statutory rate are non-deductible preferred stock dividends, foreign losses for which losses are not recognized and foreign tax rates in excess of the U.S. rate as well as the provision for unremitted earnings of a foreign subsidiary.

Segment Information

Chassis Segment.    Sales for our Chassis Segment increased in the second quarter of 2004 to $155.9 million versus $37.6 million in the prior period (as restated). The primary driver of the approximate $118 million increase in sales was the New Castle acquisition, which contributed $119 million during the period. Adjusted EBITDA for the segment increased from $3.8 million in the second quarter of 2003 (as restated) to $15.3 million in 2004. The increase is primarily due to an approximate $14 million increase from our New Castle acquisition (results are net of approximately $2.5 million in operating leases used to finance the acquisition), offset partially by approximately $0.5 million from the divestiture of our Fittings operation, $1.5 million of customer pricing concessions and commodity price increases, and $0.5 million of additional lease expense related to sale leaseback activities completed in 2003 and first quarter of 2004. Operating profit increased by $6.8 million in the second quarter of 2004 due to the above factors but was offset by an increase of $4.7 million in depreciation and amortization expense that primarily relates to the New Castle acquisition.

34





  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Chassis Segment
Sales $ 155,930   $ 37,600  
             
Operating profit $ 8,730   $ 1,960  
Depreciation and amortization   6,610     1,820  
Adjusted EBITDA $ 15,340   $ 3,780  
             
Memo: Fixed asset gains included in calculation of both operating profit and Adjusted EBITDA $ (530 $  

Driveline Segment.    Sales for our Driveline segment were $202.8 million in the second quarter of 2004 versus $202.9 million in 2003 (as restated). Sales decreased $17 million related to the divestiture of two aluminum die casting facilities but was primarily offset by a $3 million benefit in foreign exchange fluctuations and a $9 million benefit from new launches and ramp up of existing business. Adjusted EBITDA for the segment decreased to $18.1 million from $22.7 million in the prior year. Approximately $10 million of the decrease relates to our forging operation's issues surrounding steel price increases (approximate $9 million increase during the second quarter), lost business and the full year impact of customer productivity concessions agreed to in 2003. Additionally, $3 million of the decrease relates to a one-time payment made to a customer in return for a contract award launching in 2005. This program award is for production of two key modules in a new six-speed transmission and has annual peak sales of approximately $35 million. Somewhat offsetting these decreases were approximately $2.5 million in additional profits from the launching and ramp up sales described above, approximately $4.5 million from cost reduction activities, and approximately $0.5 million related to foreign exchange fluctuations. Operating profit decreased from $9.8 million in 2003 (as restated) to $3.5 million in 2004. In addition to the factors discussed above influencing Adjusted EBITDA, the decrease is primarily attributable to a $1.7 million increase in depreciation and amortization expense.


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Driveline Segment
Sales $ 202,810   $ 202,860  
             
Operating profit $ 3,510   $ 9,820  
Depreciation and amortization   14,600     12,870  
Adjusted EBITDA $ 18,110   $ 22,690  
Memo: Fixed asset gains included in calculation of both operating profit and Adjusted EBITDA $ (50 $ (10

Engine Segment.    Sales for our Engine Segment increased to $163.2 million in the second quarter of 2004 or 8.7% over 2003 (as restated) sales of $150.1 million. The $13.1 million increase primarily reflects approximately $11 million in additional volume from new product launches and a $2.5 million benefit related to foreign exchange movements. Adjusted EBITDA increased from $25.0 million in the first quarter of 2003 (as restated) to $27.1 million in 2004. The increase primarily relates to profit from additional sales volume, but is also aided by an approximate $0.5 million benefit related to foreign exchange movements. Operating profit increased to $17.0 million in the second quarter of 2004 from $14.4 million in 2003 (as restated). In addition to the factors discussed above, operating profit was positively affected by a $0.6 million reduction in depreciation and amortization expense.

35





  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Engine Segment
Sales $ 163,150   $ 150,080  
             
Operating profit $ 17,020   $ 14,350  
Depreciation and amortization   10,060     10,690  
Adjusted EBITDA $ 27,080   $ 25,040  
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 80   $ 1,000  

Corporate/Centralized Resources.    Adjusted EBITDA for Corporate/Centralized Resources was a loss of $7.8 million in the second quarter of 2004 versus a loss of $4.9 million in the prior period (as restated). This increased loss is primarily attributable to the approximate $5 million in fees incurred in the quarter surrounding the Independent Investigation described in Note 2 to the consolidated financial statements included herein. After adjusting for these one-time fees, Corporate expenses decreased by approximately $2 million. This reduction is principally explained by restructuring activities initiated in 2003 and a reduction of approximately $1.6 million in other expense, net, primarily related to a gain on the disposition of a joint venture in Korea during the second quarter of 2004 but is offset by approximately $0.9 million increase in fixed asset losses). Operating profit decreased by $3.4 million in 2004, which is also explained by the factors described above.


  (In thousands)
  Three Months Ended Three Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Corporate/Centralized Resources
Operating profit $ (9,640 $ (6,260
             
Non-cash stock award expense   240     630  
Depreciation and amortization   1,200     1,910  
Other, net   430     (1,140
Adjusted EBITDA $ (7,770 $ (4,860
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 930   $  
Memo: Other, net (income) loss included in calculation of Adjusted EBITDA $ (430 $ 1,140  

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Six Months Ended June 27, 2004 versus June 29, 2003 (As Restated)

Net Sales.    Net sales by segment and in total for the six months ended June 27, 2004 and June 29, 2003 (as restated) were:


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 284,250   $ 77,470  
Driveline Segment   398,240     403,180  
Engine Segment   320,540     291,810  
    Total Company $ 1,003,030   $ 772,460  

Net sales for the first six months of 2004 were $1,003 million versus $772 for the first six months of 2003 (as restated). The primary driver of the increase in our 2004 automotive sales was our New Castle acquisition, which contributed $212 million in the first six months of 2004. In addition we had approximately $37 million in additional volume related to new product launches and ramp up of existing programs as well as a $17 million benefit from foreign exchange movements. However, these increases were partially offset by approximately $32 million related to our divestiture of two aluminum die casting facilities within our Driveline segment, and a 2.9% decrease in North American vehicle production from our three largest customers (Ford, General Motors and DaimlerChrysler).

Gross profit.    Gross margin by segment and in total for the six months ended June 27, 2004 and June 29, 2003 (as restated) were:


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 19,840   $ 7,850  
Driveline Segment   37,150     43,310  
Engine Segment   55,420     46,510  
Corporate/centralized resources   (7,810   (6,800
    Total Company $ 104,600   $ 90,870  

Our gross profit was $104.6 million, or 10.4% of net sales, for 2004 compared to $90.9 million or 11.8% of net sales for 2003 (as restated). The increase of $13.7 million was primarily due to the sales increase noted above. The 1.4% margin decline is primarily explained by two issues within our Driveline segment. The first issue surrounds a $10 million decline in our forging operations (primarily relates to an $11 million increase in steel cost during the first six months of 2004) and the second issue involves a $3 million one-time payment made to one of our customers relating to a new business award. Both these items are further explained in the segment discussion that follows.

Selling, General and Administrative.    Selling, general and administrative expenses were $62.5 million, or 6.2% of net sales, for 2004 compared to $57.3 million or 7.4% of sales in 2003 . The $5.2 million increase from 2003 to 2004 is primarily explained by the approximately $6 million in fees relating to the Independent Investigation described in Note 2 to the consolidated financial statements included herein. The reduction in selling, general and administrative expenses as a percentage of net sales additionally reflects the fact that the New Castle facility was able to integrate into our operation without significant additional investment in these activities, and reflects the benefits of our restructuring activity initiatives in late 2003

Depreciation and Amortization.    Depreciation and amortization expense by segment and in total for the six months ended June 27, 2004 and June 29, 2003 (as restated) were:

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  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 12,800   $ 3,700  
Driveline Segment   27,950     25,780  
Engine Segment   18,910     18,940  
Corporate/centralized resources   4,340     3,820  
    Total Company $ 64,000   $ 52,240  

The net increase in depreciation and amortization of approximately $11.8 million is principally explained by $9.2 million of depreciation and amortization expense associated with our New Castle acquisition. Additionally, for the past several years capital spending has been in excess of our depreciation expense. Thus, the additional capital spending accounts for the remaining increase in depreciation expense.

Restructuring Charges.    We incurred $1.7 million of additional restructuring charges in the first six months of 2004 compared to $3.9 million incurred in the first six months of 2003. Of the 2004 charges, approximately $1.1 million relates to our Driveline segment, where the majority of the charge relates to the closure of a facility in Europe. An additional $0.5 million relates to costs to reduce headcount in our Corporate center, and the remaining $0.1 million relates to headcount reductions in our Chassis segment. Net restructuring activity in the first six months of 2004 is as follows:


  (In thousands)
  Severance
Costs
Balance December 28, 2003 $ 7,670  
Charges to expense   1,710  
Cash payments   (3,730
Balance at June 27, 2004 $ 5,650  

Disposition of Manufacturing Facilities.    In connection with our sale of two aluminum die casting facilities in our Driveline segment, we incurred a $7.6 million charge in the first six months of 2004. This charge represents approximately a book value of $12 million in fixed assets and deferred financing fees offset by the $4.1 million in cash consideration paid by Lester PDC for the assets. See Note 11 to the consolidated financial statements included herein.

Operating Profit.    Operating profit was $32.8 million, or 3.3% of sales, for the first six months of 2004 compared to $29.7 million, or 3.9% of sales, for the same period in 2003 (as restated). This includes a $7.6 million charge relating to the disposition of two manufacturing facilities discussed above from 2004. This resulting increase is principally explained by the significant increase in sales and the decrease in selling, general and administrative expenses as a percentage of sales. The makeup of each of these differences is discussed in greater detail above and in the segment discussion that follows. Operating profit by segment for the six months ended June 27, 2004 and June 29, 2003 (as restated) is as follows:


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 11,810   $ 3,770  
Driveline Segment   4,830     15,700  
Engine Segment   35,250     25,680  
Corporate/centralized resources   (19,070   (15,420
    Total Company $ 32,820   $ 29,730  

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Adjusted EBITDA.    Management reviews our segment operating results based upon the Adjusted EBITDA definition as discussed in the "Key Indicators of Performance (Non-GAAP Financial Measures)" section. Accordingly, we have separately presented such amounts in the table below. Adjusted EBITDA increased to $105.3 million in 2004 from $81.3 million in 2003 (as restated) The primary drivers of this increase are explained above in the operating profit and depreciation and amortization discussions, and will be further detailed in the segment detail that follows. Additionally, in "— Segment Information" below, we provide a reconciliation between Adjusted EBITDA and operating profit.


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Segment
Chassis Segment $ 24,610   $ 7,470  
Driveline Segment   40,380     41,480  
Engine Segment   54,160     44,620  
Corporate/centralized resources   (13,860   (12,290
    Total Company $ 105,290   $ 81,280  
             
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 750   $ 2,200  
Memo: Other, net (income) loss included in calculation of Adjusted EBITDA $ (400 $ 2,220  

Interest Expense.    Interest expense increased from $35.2 million in the first six months of 2003 (as restated) to approximately $39.8 million in 2004. The increase is principally due to $1.6 million in interest arising from the 10% senior subordinated notes from our New Castle acquisition and $7.5 million in interest arising from our 10% senior notes issued in October 2003. These increases were offset by a decrease of $2.2 million in interest expense related to the redemption of the $98.5 million outstanding balance on the 4.5% subordinated debentures and a decrease of approximately $1.3 million in interest expense related to the repayment of $46.6 million of term loan debt in the fourth quarter of 2004.

Equity Loss from Affiliates.    Equity earnings (loss) from affiliates were $4.4 million in the first six months of 2004. The improvement versus our 2003 loss of $2.7 million reflects the improved operating results of our equity affiliates.

Other, Net.    Other, net expense decreased to a $3.4 million loss in the first six months of 2004 versus a loss of approximately $5.8 million in the first six months of 2003 (as restated). This decrease is primarily due to a reduction in foreign currency losses in 2004 versus 2003 and a $1.2 million gain on the disposition of a joint venture in Korea during the second quarter of 2004.

Preferred Stock Dividends.    Preferred stock dividends were $9.0 million in the first six months of 2004 as compared to $4.5 million for the same period in 2003 . This increase is due to dividends on the $64.5 million of preferred stock issued in connection with the New Castle acquisition and compounded interest on preexisting preferred stock. Due to our adoption of SFAS No. 150, "Accounting for Certain Financial Instruments with Characteristics of both Liabilities and Equity" as of the first quarter of 2004, preferred stock dividends are included as "other expense, net" on our consolidated statement of operations beginning in 2004.

Taxes.    The tax provision for the first six months of 2004 was an expense of $0.2 million as compared to $4.0 million for the same period of 2003 (as restated). The primary reasons for the Company's effective tax rate being different from its statutory rate are non-deductible preferred stock dividends, foreign losses for which losses are not recognized and foreign tax rates in excess of the U.S. rate as well as the provision for unremitted earnings of a foreign subsidiary.

In July 2004, the Company received a $27 million tax refund from the IRS that resulted from a claim filed by the Company in 2002. This claim was based on a 2002 change in the U.S. Treasury Regulations,

39




which permitted the Company to utilize a previously disallowed capital loss that primarily resulted from the sale of a subsidiary in 2000. The amount received in excess of the refund previously recorded will be considered in the tax provision for the third quarter of 2004.

Segment Information

Chassis Segment.    Sales for our Chassis Segment increased in the first six months of 2004 to $284.3 million versus $77.5 million in the prior period (as restated). The primary driver of the approximate $206.8 million increase in sales is a $212 million increase from the acquisition of New Castle offset by $6 million decrease due to the divestiture of our Fittings operation in April 2003. Adjusted EBITDA for the segment increased from $7.5 million in the first six months of 2003 (as restated) to $24.6 million in 2004. The increase is primarily due to an approximate $21 million increase from our New Castle acquisition (results are net of approximately $5 in operating leases used to finance the acquisition), offset partially by approximately $1.5 million from the divestiture of our Fittings operation, $2 million in customer price concessions, and approximately $1 million of additional lease expense related to sale leaseback activities completed in 2003. Operating profit increased by $8 million in the first six months of 2004 due to the above factors but was offset by an increase of $9.1 million in depreciation and amortization expense primarily relating to the New Castle acquisition.


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Chassis Segment
Sales $ 284,250   $ 77,470  
             
Operating profit $ 11,810   $ 3,770  
Depreciation and amortization   12,800     3,700  
Adjusted EBITDA $ 24,610   $ 7,470  
Memo: Fixed asset (gains) losses included in calculation of both operating profit and Adjusted EBITDA $ (530 $ 140  

Driveline Segment.    Sales for our Driveline segment were $398.2 million in the first six months of 2004 versus $403.2 million in 2003 (as restated). Sales decreased $32 million related to the divestiture of two aluminum die casting facilities but were offset by a $9 million benefit in foreign exchange fluctuations and a $16 million benefit from new launches and ramp up of existing business. Adjusted EBITDA for the segment decreased $1.1 million to $40.4 million as compared with the prior year (as restated). Cost savings and profits from new business primarily offset issues within the Forging operation (primary issue was an approximate $11 million increase in the price to procure steel during the first six months of 2004 compared to the same period in 2003). Operating profit decreased from $15.7 million in 2003 (as restated) to $4.8 million in 2004. This decrease is primarily attributable to the $7.6 million disposition of two manufacturing facilities discussed earlier and approximately $2.2 million of incremental depreciation and amortization expense.

40





  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Driveline Segment
Sales $ 398,240   $ 403,180  
             
Operating profit $ 4,830   $ 15,700  
Asset impairment   7,600      
Depreciation and amortization   27,950     25,780  
Adjusted EBITDA $ 40,380   $ 41,480  
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 190   $ 10  

Engine Segment.    Sales for our Engine Segment increased to $320.5 million in the first six months of 2004 or 9.8% over 2003 (as restated) sales of $291.8 million. The $28.7 million increase primarily reflects $25 million in additional volume from new product launches and a $8 million benefit related to foreign exchange movements. Adjusted EBITDA increased from $44.6 million in the first six months of 2003 (as restated) to $54.2 million in 2004. The increase primarily relates to additional sales volume, but is also aided by an approximate $0.5 million benefit related to foreign exchange movements. Operating profit increased to $35.2 million in the first six months of 2004 from $25.7 million in 2003 (as restated). The explanations for this change are described above.


  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Engine Segment
Sales $ 320,540   $ 291,810  
             
Operating profit $ 35,250   $ 25,680  
Depreciation and amortization   18,910     18,940  
Adjusted EBITDA $ 54,160   $ 44,620  
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 160   $ 1,170  

Corporate/Centralized Resources.    Adjusted EBITDA for Corporate/Centralized Resources was a loss of $13.9 million in the first six months of 2004 versus a loss of $12.3 million in the prior period. We incurred $6 million of expenses associated with our Independent Investigation discussed in Note 2 to the consolidated financial statements contained herein. After adjusting for these one time expenses, corporate expenses decreased by approximately $4.4 million. The remaining reduction is principally explained by restructuring activities initiated in 2003, a pension curtailment gain of approximately $1.5 million recognized in the second quarter of 2004 and a decrease of $2.6 million in Other, Net. Operating profit decreased by $3.7 million in 2004, which is also explained by the factors described above.

41





  (In thousands)
  Six Months Ended Six Months Ended
  June 27, 2004 June 29, 2003
    (Restated)
Corporate/Centralized Resources
Operating profit $ (19,070 $ (15,420
             
Non-cash stock award expense   470     1,530  
Depreciation and amortization   4,340     3,820  
Other, net   400     (2,220
Adjusted EBITDA $ (13,860 $ (12,290
Memo: Fixed asset losses included in calculation of both operating profit and Adjusted EBITDA $ 930   $ 900  
Memo: Other, net (income) loss included in calculation of Adjusted EBITDA $ (400 $ 2,220  

Liquidity and Capital Resources

Overview of Capital Structure.    Our objective is to appropriately finance our business through a mix of long-term and short-term debt and to ensure that we have adequate access to liquidity. Our principal sources of liquidity are cash flow from operations, our revolving credit facility and our accounts receivable securitization facility. We have significant unutilized capacity under our revolving credit facility that may be utilized for acquisitions, investments or capital expenditure needs. Our cash flows during the year are impacted by the volume and timing of vehicle production, which includes a halt in our North American customers for approximately two weeks in July and one week in December and reduced production in July and August for certain European customers. We believe that our liquidity and capital resources including anticipated cash flow from operations will be sufficient to meet debt service, capital expenditure and other short-term and long-term obligations and needs, but we are subject to unforeseeable events and the risk that we are not successful in implementing our business strategies.

To facilitate the collection of funds from operating activities, we have sold receivables under our accounts receivable facility and have entered into accelerated payment collection programs with our largest customers. If these additional liquidity sources were to become unavailable or limited by customer concentration, credit quality or otherwise, we would require additional borrowing capacity through similar means or other lines of credit. At June 27, 2004, we received approximately $57 million under the accelerated collection programs. We were recently notified that a portion of this program will expire in 2004, with the majority of the program expiring in 2005. While the impact of the discontinuance of these programs may be partially offset by a greater utilization of our accounts receivable securitization facility, we are examining other alternative programs in the marketplace, as well as enhanced terms directly from our customers. However, we may not be able to reach a favorable resolution in a timely manner, and the new arrangements may be less advantageous to the Company. If we are unable to replace these arrangements, it could adversely affect our liquidity and future covenant compliance under our senior secured credit facility. In addition, if we fail to renew our accounts receivable securitization agreement, which expires in November 2005, we could have adverse effects on our liquidity and future covenant compliance. However, we had $87 million of undrawn and available commitments on our revolving credit facility at June 27, 2004.

Our capital planning process is focused on ensuring that we use our cash flow generated from our operations in ways that enhance the value of our company. Historically, we have used our cash for a mix of activities focused on revenue growth, cost reduction and balance sheet strengthening. In the first six months of 2004, we have used our cash primarily to service our debt obligations, fund our capital expenditure requirements, and make the New Castle acquisition.

42




Liquidity.    At June 27, 2004, we had approximately $87 million and $52 of undrawn and available commitments from our revolving credit facility and accounts receivable facility, respectively. Thus, our total liquidity including revolver and accounts receivable facilities was approximately $139 million at June 27, 2004.

Effect of Independent Investigation on Covenants and Liquidity.    Due to the delay in filing our financial statements, as a result of the Independent Investigation and the restatement (see Note 2 to the consolidated financial statements included herein), we were required to seek a waiver from our senior bank group, accounts receivable financing providers and certain lessors under sale-leaseback arrangements. Furthermore, prior to this filing, we did not comply with a covenant related to the deliver of financial statements for our 11% senior subordinated notes due in 2012 and the 10% subordinated notes due in 2013. However, we have not received a notice of default from either the trustee or the holders of such notes for either of these two securities. During this time period, we have continued to have adequate access to our accounts receivable securitization and revolving credit facilities. Upon completion and delivery of our financial statement with the SEC (2003 Form 10-K and 2004 Form 10-Q for the first and second quarters), we will no longer require extensions of these waivers, or be in violation of any covenants on our notes discussed above.

TriMas Common Stock.    As of June 27, 2004, our remaining shares outstanding in TriMas were 5.75 million, representing a book value of $121.5 million that are recorded as "equity and other investments in affiliates" in the Company's consolidated balance sheet as of June 27, 2004. We continue to monitor opportunities to liquidate all or a portion of this interest to assist in funding operations, repaying debt and making strategic investments and/or acquisitions.

Debt, Capitalization and Available Financing Sources.    On October 20, 2003, we issued $150 million of 10% senior notes due 2013 in a private placement under Rule 144A and Regulation S of the Securities Act of 1933, as amended. As these notes were not registered within 210 days from the closing date, the annual interest rate increased by 1% and will remain so until the registration statement is declared effective. The net proceeds from this offering were used to redeem the balance of the $98.5 million aggregate principal amount of the outstanding 4.5% subordinated debentures that were due in December 2003 and to repay $46.6 million of term loan debt under our credit facility. As a result of this term loan repayment, our semi-annual principal installments on the term loan facility were decreased to $0.4 million with the remaining outstanding balance due December 31, 2009. Due to this financing, we agreed with our banks to decrease our revolver facility to $200 million.


  (In millions)
  June 27, 2004 June 29, 2003
Senior credit facilities:            
    Term loan $ 352   $ 352  
    Revolving credit facility   52      
Total senior credit facility $ 404   $ 352  
11% senior subordinated notes, with interest payable semi-annually, due 2012   250     250  
10% senior notes, with interest payable semi-annually, due 2013   150     150  
10% senior subordinated notes, with interest payable semi-annually, due 2014   32      
Other debt   26     26  
Total $ 862   $ 778  
Less current maturities   9     11  
Long-term debt $ 853   $ 767  

At June 29, 2004, we were contingently liable for standby letters of credit totaling $61.3 million issued on our behalf by financial institutions. These letters of credit are used for a variety of purposes, including meeting requirements to self-insure workers' compensation claims.

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Our senior credit facility contains covenants and requirements affecting us and our subsidiaries, including a financial covenant requirement for an EBITDA to cash interest expense coverage ratio to exceed 2.25 through July 3, 2005; and a debt to EBITDA leverage ratio not to exceed 5.00 and 4.75 for the quarters ended June 27, 2004 and October 3, 2004, respectively. The accounts receivable facility is included in computing debt for the purposes of these covenant calculations. We were in compliance with the preceding financial covenants throughout the quarter and obtained waivers associated with the timely submission of financial statements and associated representations and warranties through November 15, 2004. Our most restrictive covenant is the leverage ratio. The permitted leverage ratio (as modified on September 30, 2004) becomes more restrictive in future periods, is 5.00 in the second fiscal quarter of 2004, declining to 4.75 in the third fiscal quarter of 2004, 4.50 in the first fiscal quarter of 2005, 4.25 in the third fiscal quarter of 2005, 3.75 in the fourth fiscal quarter of 2005, 3.00 in the first fiscal quarter of 2006 and 2.75 in the fourth fiscal quarter of 2006 and thereafter.

New Castle Acquisition.    We successfully completed our purchase of DaimlerChrysler's common and preferred interests in NC-M Chassis ("New Castle") on December 31, 2003 (subsequent to our 2003 year end of December 28th). We financed this acquisition with $118.8 million in cash, $31.7 million in aggregate principal amount of a new issue of 10% senior subordinated notes and $64.5 million in aggregate liquidation preference Series A-1 redeemable preferred stock. The cash portion of the consideration was funded in part with the net cash proceeds of approximately $65 million from the sale to and subsequent leaseback of certain equipment from General Electric Capital Corporation, and the remainder was funded through the Company's revolving credit facility.

Interest Rate Hedging Arrangements.    In February 2001, we entered into interest rate protection agreements with various financial institutions to hedge a portion of our interest rate risk related to the term loan borrowings under our credit facility. These agreements included two interest rate collars with a term of three years, a total notional amount of $200 million and a three month LIBOR interest rate cap and floor of 7% and 4.5%, respectively, and four interest rate caps at a three month LIBOR interest rate of 7% with a total notional amount of $301 million. As a result of our early retirement of our term loans in June 2002, we recorded a cumulative non-cash loss of $7.5 million, which is included in our consolidated statement of operations for the year ended December 29, 2002. The two interest rate collars and two of the interest rate caps totaling $200 million were immediately redesignated to our new term loan borrowings in June 2002. The remaining two interest rate caps totaling $101 million no longer qualify for hedge accounting. Therefore, any unrealized gain or loss is recorded as other income or expense in the consolidated statement of operations beginning June 20, 2002.

The two interest rate collars expired in the first quarter of 2004, and accordingly we recognized a pre-tax non-cash gain of approximately $6.6 million, which reflects the reversal of the majority of the non-realized charge reflected in our 2002 results and explained in the above paragraph. Prior to the expiration of these interest rate collars, we recognized approximately $1.1 million as additional interest expense in 2004. Prior to their maturity, $6.6 million was included in accumulated other comprehensive income related to these arrangements.

Off-Balance Sheet Arrangements

Our Receivables Facility.    We have entered into an agreement to sell, on an ongoing basis, the trade accounts receivable of certain business operations to a bankruptcy-remote, special purposes subsidiary, MTSPC, wholly owned by us. MTSPC has sold and, subject to certain conditions, may from time to time sell an undivided fractional ownership interest in the pool of domestic receivables, up to approximately $150 million, to a third party multi-seller receivables funding company, or conduit. Upon sale to the conduit, MTSPC holds a subordinated retained interest in the receivables. Under the terms of the agreement, new receivables are added to the pool as collections reduce previously sold receivables. We service, administer and collect the receivables on behalf of MTSPC and the conduit. The facility is an important source of liquidity to the Company. The receivables facility resulted in net expense of $2.3 million in 2004.

The facility is subject to customary termination events, including, but not limited to, breach of representations or warranties, the existence of any event that materially adversely affects the collectibility

44




of receivables or performance by a seller and certain events of bankruptcy or insolvency. At June 27, 2004, we had utilized $47 million of the facility with $44.5 million available but not utilized. The proceeds of sale are less than the face amount of accounts receivable sold by an amount that approximates the purchaser's financing costs. The agreement expires in November 2005. If we are unable to renew or replace this facility, it could adversely affect our liquidity and capital resources.

We have entered into agreements with international invoice factoring companies to sell customer accounts receivable of Metaldyne foreign locations in France, Germany, Spain, United Kingdom and Mexico on a non-recourse basis. As of June 27, 2004, we had available approximately $67 million from these commitments, and approximately $57.8 million of receivables were sold under these programs. We pay a commission to the factoring company plus interest from the date the receivables are sold to the date of customer payment. Commission expense related to these agreements are recorded in other expense, net on the Company's consolidated statement of operations. The net expense of this program for six months amounted to approximately $2.3 million through June 27, 2004.

Certain Other Commitments.    We have other cash commitments not relating to debt as well, such as those in respect of leases and redeemable preferred stock.

Sale-Leaseback Arrangements.    On June 17, 2004, the Company entered into a sale-leaseback transaction for machinery and equipment with a third party lessor. The Company received $7.5 million cash as part of this transaction. In the first quarter of 2004, we entered into two sale-leaseback arrangements. On December 31, 2003 we entered into a sale-leaseback with proceeds of approximately $4.5 million. This lease was accounted for as a capital lease and the present value of our lease payments is therefore reflected in our debt balance. We also entered into a $65 million sale-leaseback on December 31, 2003, as part of our financing related to the purchase of New Castle. This lease for New Castle equipment is accounted for as an operating lease and the annual lease expense is approximately $10 million.

In March 2003, we entered into a sale-leaseback transaction with respect to certain manufacturing equipment for proceeds of approximately $8.5 million, and in October 2003, we entered into a sale-leaseback transaction for machinery and equipment for additional proceeds of $8.5 million. In July 2003, we entered into an approximate $10 million operating lease associated with the acquisition of our Greensboro, North Carolina facility. The proceeds from this lease were used to finance a portion of the acquisition of this facility from Dana Corporation. All of these leases are accounted for as operating leases. The sale-leasebacks initiated in 2003 contribute an additional $3.8 million in annualized lease expense going forward, which is included in our "Contractual Cash Obligations," below. We continue to look to sale-leaseback and other leasing opportunities as a source of cash for debt reduction and other uses. Our total obligations under lease agreements are summarized in the Contractual Cash Obligation table that follows.

Redeemable Preferred Stock.    We have outstanding $147 million in aggregate liquidation value of Series A, B and A-1 redeemable preferred stock in respect of which we have the option to pay cash dividends, subject to the terms of our debt instruments, at rates of 13%, 11.5% and 11%, respectively, per annum initially and to effect a mandatory redemption in December 2012, June 2013 and December 2013, respectively. For periods that we do not pay cash dividends on the Series A and Series A-1 preferred stock, an additional 2% per annum of dividends is accrued. No cash dividends were paid in 2003 or 2004. In the event of a change in control or certain qualified equity offerings, we may be required to make an offer to repurchase our outstanding preferred stock. We may not be permitted to do so and may lack the financial resources to satisfy these obligations. Consequently, upon these events, it may become necessary to recapitalize our company or secure consents.

Saturn-Related Obligations.    In the November 2000 recapitalization of the Company, our shares were converted into the right to receive $16.90 in cash plus additional cash amounts based upon the net proceeds of the disposition of the stock of Saturn Electronics & Engineering Inc. held by Metaldyne. We hold 1,796,800 shares of Class A common stock and 1,796,800 shares of Class B common stock of Saturn, a privately held corporation. As such, there is no readily available market value of these shares. However, the value of this investment as recorded on the Company's books was $6.0 million as of December 28, 2003 and $7.3 million at June 27, 2004. We have not identified any indicators of impairment.

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Although no disposition of the stock of Saturn was made prior to the recapitalization or has been made to date, former holders of our common stock as of the merger will be entitled to amounts based upon the net proceeds, if any, from any future disposition of that stock if and when a disposition is completed. The amount which will be paid to such former stockholders will equal the proceeds in excess of $18 million and less than or equal to $40 million, any proceeds in excess of $55.7 million and less than or equal to $56.7 million as well as 60% of any such proceeds in excess of $56.7 million. We are not responsible to disburse any funds to the previous holders of the Company's common stock if the sale proceeds are less than $18 million. Any sale of the stock of Saturn requires approval from a committee representing the interests of the former shareholders of the Company. Thus, the Company does not control the timing of the sale of the stock of Saturn. Therefore, it is possible that the Company may choose to agree to accept an amount less than that indicated above in order to accelerate a disposition of the holdings of the stock of Saturn.

Credit Rating.    Metaldyne is rated by Standard & Poor's and Moody's Ratings. We currently have long-term ratings of BB/B2 on our senior credit facility, B/B3 on our 10% senior notes due 2013 and B/Caa1 on our 11% senior subordinated notes due 2012. Our goal is to decrease our total leverage and thus improve our credit ratings. In the event of a credit downgrade, we believe we would continue to have access to additional credit sources. However, our borrowing costs would further increase and our ability to tap certain financial markets may be limited.

Capital Expenditures.    Our capital expenditure program promotes our growth-oriented business strategy by investing in our core areas, where efficiencies and profitability can be enhanced. Capital expenditures by product segment for the periods presented were:


  (In thousands)
  June 27, 2004 June 29, 2003
    (Restated)
Capital Expenditures:            
Chassis $ 21,170   $ 7,890  
Driveline   17,090     29,210  
Engine   24,710     14,290  
Corporate   1,000     2,980  
    Total $ 63,970   $ 54,370  

Cash Flows

Operating activities — Net cash provided by operating activities totaled $51.8 million for the six months ended June 27, 2004, compared to a $22.2 million increase in 2003 (as restated). Adjusting 2004 results by the $47 million increased use of the accounts receivable securitization facility, the 2004 operating cash flow would have approximated a $5 million inflow, or an approximate $17 million decrease versus 2003 (as restated). The primary driver of this decline is improved operational performance offset by an approximate $25 million increase in investment in working capital (excluding accounts receivable securitization facility). This increase in working capital is explained by the 30% increase in sales in 2004 (driven largely by the New Castle Acquisition), higher inventory levels (largely driven by the increase in raw material pricing combined with higher safety stock to compensate for the decrease in supply) and an increase in our accounts receivable (due to the increase in our sales, slower payment practices from our customers, and an approximate $5 million decline in our ability to use our accelerated payment collection programs).

Investing activities — Cash flows used in investing activities totaled $208.5 million for the six months ended June 27, 2004, compared to a use of cash of $31.0 million in 2003 (as restated). Capital expenditures were higher in 2004 by approximately $9.6 million than in 2003 (as restated) primarily related to increased new business launch activity. Additionally, we acquired the New Castle facility in 2004 for approximately $218 million including fees and offset by proceeds from a sale-leaseback of approximately $65 million on New Castle's equipment. In 2003, we invested $20 million in NC-M Chassis Systems, LLC, a joint venture with DaimlerChrysler Corporation. Proceeds from sale-leaseback transactions with respect to equipment and real property represented a source of cash of $8.5 million in 2003.

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Financing activities — Cash flows from financing activities totaled $142.9 million for the six months ended June 27, 2004, compared to a use of cash of $3.3 million in 2003 (as restated). In 2004, we issued $96 million in new debt and preferred stock to acquire New Castle and ended the quarter with approximately $52 million outstanding on our revolving credit facility versus zero outstanding at December 28, 2003.

Outlook

Automotive vehicle production in 2004 is expected to be slightly below 2003 production levels in North America and slightly higher in Europe, but there are several factors that could alter this outlook, including a change in interest rates or an increase in vehicle incentives offered to consumers.

Our principal use of funds from operating activities and borrowings for the next several years are expected to fund interest and principal payments on our indebtedness, growth related capital expenditures and working capital increases, strategic acquisitions and lease expense. Management believes cash flow from operations and debt financing and refinancing that occurred in October 2003 will provide us with adequate sources of liquidity for the foreseeable future. However, our sources of liquidity may be inadequate if we are unable to obtain operating targets, which would cause us to seek covenant relief from existing lenders in the near future. In addition, matters affecting the credit quality of our significant customers could adversely impact the availability of our receivables arrangements and our liquidity. We continue to explore other sources of liquidity, including additional debt, but existing debt instruments may limit our ability to incur additional debt. Therefore, we may be unable to secure equity or other financing. We were recently notified that a portion of the accelerated accounts receivable programs with our largest customers will expire in 2004, while the majority will expire in 2005. These programs accelerated approximately $57 million at June 27, 2004. We are actively working to find substitutes to replace these programs, but there is no certainty that we will be successful. However, we had $87 million of undrawn and available commitments on our revolving credit facility at June 27, 2004.

On December 31, 2003, we completed our acquisition of DaimlerChrysler's New Castle facility. Based on our new, more favorable agreement with the UAW and the supply contract with Daimler Chrysler, we anticipate 2004 Adjusted EBITDA for this facility of between $35 and $40 million, net of approximately $10 million in operating lease expense associated with a $65 million sale-leaseback of New Castle equipment used to finance the acquisition.

Two of our largest suppliers have recently declared bankruptcy and are in the process of reorganizing. The effect on the Company from these bankruptcies is unknown, but they could result in the Company paying higher prices, having less favorable payment terms and/or having interrupted supply of parts.

Consistent with operating in the global vehicle industry, we anticipate competitive pressures and thus expect to face significant price reduction pressures from our customer base. In 2003, though, we invested significantly in automation and underwent restructuring activities to help offset these pricing pressures. In addition, we are facing significant increases in the cost to procure certain materials utilized in our manufacturing processes such as steel, energy, Molybdenum and nickel. In general, steel prices have recently risen by as much as 60-100% and have thus created significant tension between steel producers, suppliers and end customers. Based on current prices, our steel costs could increase approximately $50 million in 2004. However, we anticipate several initiatives such as steel scrap sales, steel resourcing efforts, contractual steel surcharge pass through agreements with customers and reducing or eliminating 2004 scheduled price downs to our customers will offset approximately $30 million of these increased costs. Additionally, we are actively working with our customers to 1) obtain additional business to help offset these prices through better utilization of our capacity, 2) negotiate a surcharge to reflect the increased material costs, and/or 3) resource certain of our products made unprofitable by these increases in material costs. We will actively work to mitigate the effect of these steel increases throughout 2004.

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Contractual Cash Obligations

Under various agreements, we are obligated to make future cash payments in fixed amounts. These include payments under our long-term debt agreements, rent payments required under lease agreements and various severance obligations undertaken. The following table summarizes our fixed cash obligations over various future periods as of June 27, 2004.


  (In millions)
    Payments Due by Periods
  Total Less Than
One Year
1-3
Years
3-5
Years
After
5 Years
                               
Long-term debt $ 404   $ 1   $ 2   $ 54   $ 347  
11% Senior subordinated notes due 2012   250                 250  
10% Senior notes due 2013   150                 150  
10% Senior subordinated notes due 2014   32                 32  
Other debt   14     3     3         8  
Capital lease obligations   12     5     5     1     1  
Operating lease obligations (1)   336     47     83     76     130  
Redeemable preferred stock, including accrued dividends   147                 147  
Pension contributions (data available through 2004)   17     17              
Contractual severance   5     4     1          
Total contractual obligations (2) $ 1,367   $ 77   $ 94   $ 131   $ 1,065  
(1) Operating lease expense is included in the determination of Adjusted EBITDA.
(2) Total contractual obligations exclude accounts payable and accrued liabilities.

At June 27, 2004, we were contingently liable for standby letters of credit totaling $61.3 million issued on our behalf by financial institutions. We are also contingently liable for future product warranty claims. We believe that our product warranty exposure is immaterial; however, it is continuously monitored for potential warranty implications of new and current business.

Critical Accounting Policies

The expenses and accrued liabilities or allowances related to certain policies are initially based on our best estimates at the time of original entry in our accounting records. Adjustments are recorded when our actual experience differs from the expected experience underlying the estimates. We make frequent comparisons of actual versus expected experience to mitigate the likelihood of material adjustments.

Goodwill.    In June 2001, the Financial Accounting Standards Board ("FASB") approved Statement of Financial Accounting Standards ("SFAS") No. 142 "Goodwill and Other Intangible Assets" which was effective for us on January 1, 2002. Under SFAS No. 142, we ceased the amortization of goodwill. Beginning in 2002, we test goodwill for impairment on an annual basis, unless conditions exist which would require a more frequent evaluation. In assessing the recoverability of goodwill, projections regarding estimated future cash flows and other factors are made to determine the fair value of the respective assets. We may be required to record impairment charges for goodwill if these estimates or related projections change in the future.

At adoption and again during 2002 and 2003, we determined that our goodwill was not impaired as fair values continue to exceed their carrying value. Fair value of our goodwill is determined based upon the discounted cash flows of the reporting units using a 9.5% discount. Assuming an increase in the discount rate to 12%, fair value would continue to exceed the respective carrying value of each automotive segment.

Receivables And Revenue Recognition.

The Company recognizes revenue when there is evidence of a sale, the delivery has occurred or services have been rendered, the sales price is fixed or determinable and the collectibility of receivables

48




is reasonably assured. Consequently, sales are generally recorded upon shipment of product to customers and transfer of title under standard commercial terms. Significant retroactive price adjustments are recognized in the period in which such amounts become probable.

Valuation of Long-Lived Assets.    Metaldyne periodically evaluates the carrying value of long-lived assets to be held and used including intangible assets, when events or circumstances warrant such a review. The carrying value of a long-lived asset to be held and used is considered impaired when the anticipated separately identifiable undiscounted cash flows from such an asset are less than the carrying value of the asset. In that event, a loss is recognized based on the amount by which the carrying value exceeds that fair value of the long-lived asset. Fair value is determined primarily using the anticipated cash flows discounted at a rate commensurate with the risk involved. Impairment losses on long-lived assets are held for sale are determined in a similar manner, except that fair values are reduced for the cost to dispose of the assets.

Pension and Postretirement Benefits Other Than Pensions.    The determination of our obligation and expense for our pension and postretirement benefits, such as retiree healthcare and life insurance, is dependent on our selection of certain assumptions used by actuaries in calculating such amounts. These assumptions are described in Note 25, Employee Benefit Plans, of our consolidated financial statements for the year ended December 28, 2003, which include, among others, discount rate, expected long-term rate of return on plan assets and rate of increase in compensation and health care costs. While we believe that our assumptions are appropriate, significant differences in our actual experience or assumptions may materially affect our pension and postretirement benefits other than benefits and our future expense. Our actual return on pension plan assets was 6.5% for the year ended December 28, 2003. In comparison, our expected long-term return on pension plan assets was 8.96% for the year ended December 28, 2003. The expected return on plan assets was established by analyzing the long-term returns for similar assets, and as such, no revisions have been made to adjust to actual performance of the plan assets.

New Accounting Pronouncements.

In May 2003, the FASB issued SFAS No. 150, "Accounting for Certain Financial Instruments with Characteristics of both Liabilities and Equity." This Statement establishes standards for how an issuer classifies and measures certain financial instruments with characteristics of both liabilities and equity. This Statement is effective for financial instruments entered into or modified after May 31, 2003, and otherwise is effective at the beginning of the first interim period beginning after June 15, 2003, except for mandatorily redeemable financial instruments of nonpublic entities, for which it is effective for the first fiscal period beginning after December 15, 2003. Due to the Company being a nonpublic entity as defined in SFAS No. 150, we adopted this Statement effective for the quarter ended March 28, 2004. As a result of the Company's adoption of SFAS No. 150, the Company's redeemable preferred stock is classified as a long-term liability on the Company's consolidated balance sheet effective as of the quarter ended March 28, 2004, and preferred stock dividends associated with this redeemable preferred stock are classified as other expense, net on the Company's consolidated statement of operations beginning with the quarter ended March 28, 2004.

On December 8, 2003, the Medicare Prescription Drug, Improvement and Modernization Act was signed into law. This law provides for a federal subsidy to sponsors of retiree health care benefit plans that provide a benefit that is at least actuarially equivalent to the benefit established by the law. The Company provides retiree drug benefits that exceed the value of the benefits that will be provided by Medicare Part D, and the Company's eligible retirees generally pay a premium for this benefit that is less than the Part D premium. Therefore, the Company has concluded that these benefits are at least actuarially equivalent to the Part D program so that Metaldyne will be eligible for the basic Medicare Part D subsidy.

In the second quarter of 2004, a Financial Accounting Board (FASB) Staff Position (FSP FAS 106-2, "Accounting and Disclosure Requirements Related to the Medicare Prescription Drug Improvement and Modernization Act of 2003") was issued providing guidance on the accounting for the effects of the Act for employers that sponsor postretirement health care plans that provide prescription drug benefits. The FSP is effective for the first interim or annual period beginning after June 15, 2004. The Company estimates the federal subsidy included in the law will ultimately result in an approximate $4.5 million to

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$6.0 million reduction in Metaldyne's postretirement benefit obligation. However, the reduction is not reflected in the Company's postretirement benefit obligation at the balance sheet date, since this information is as of the Company's September 30, 2003 measurement date. For 2004, the Company expects a net reduction in our postretirement expense when compared to 2003. This decrease reflects the favorable impact of the Medicare legislation and changes to the plans that eliminated some coverage, offset by a 50 basis point decline in the discount rate and adverse experience in health care trends.

Other Matters

Fiscal Year

Our fiscal year will end on the Sunday nearest to December 31.

Caution Concerning Forward Looking Statements and Certain Risks Related to Our Business and Our Company — Safe Harbor Statements

This report contains statements reflecting the Company's views about its future performance, its financial condition, its markets and many other matters that constitute "forward-looking statements." These views involve risks and uncertainties that are difficult to predict and may cause the Company's actual results and/or expectations about various matters to differ significantly from those discussed in such forward-looking statements. All statements, other than statements of historical fact included in this quarterly report, regarding our strategy, future operations, financial condition, expected results and costs, new business, estimated revenues and losses, prospects and plans are forward-looking statements. When used in this quarterly report, the words "will," "believe," "anticipate," "intend," "estimate," "expect," "project" and similar expressions are intended to identify forward-looking statements, although not all forward-looking statements contain such identifying words. You should not place undue reliance on these forward-looking statements. All forward-looking statements speak only as of the date of this quarterly report and we undertake no obligation to update such information. Readers should consider that various factors may affect whether actual results and experience correspond with our forward-looking statements and that many of these factors also represent risks attendant to owning securities in the Company, including the following:

•  Dependence on Automotive Industry and Industry Cyclicality — The industries in which we operate depend upon general economic conditions and are highly cyclical. Our performance is affected particularly by new vehicle sales, which can be highly sensitive to changes in interest rates, consumer confidence and fuel costs. We experience sales declines during the third calendar quarter as a result of scheduled OEM shutdowns.
•  Customer Concentration — Our base of customers is concentrated among original equipment manufacturers in North America, particularly the large automotive manufacturers, and the loss of business from a major customer, the discontinuance of particular vehicle models or a change in regulations or auto consumer preferences could materially adversely affect us.
•  Ability to Finance Capital Requirements — Our business is capital intensive. We have made substantial capital investments to improve capacity and productivity and to meet customer requirements. More investment is required to maintain and expand our future business awards. If we are unable to meet future capital requirements, our business may be materially adversely affected.
•  Increases in Costs Due to Our Supply Base and Raw Materials — Increases in our raw material or energy costs or the loss of a substantial number of our suppliers could negatively affect our financial health and results. In particular, we have been recently adversely impacted by steel costs, which we have been unable to wholly mitigate. In addition, certain of our suppliers have suffered financial distress, which may materially adversely impact us as well in terms of the potential for interrupted supply, unfavorable payment terms and/or higher prices. Specifically, two of our largest suppliers have recently declared bankruptcy, and are in the process of reorganizing. The effect on the Company from these bankruptcies is unknown, but they could result in the Company paying higher prices, having less favorable payment terms and/or having interrupted supply of parts.

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•  Our Industries are Highly Competitive — Continuing trends among our customers will increase competitive pressures in our businesses. Certain of our competitors have greater financial resources and, in some cases, we compete with our own customers. The continuing trend towards limiting outside suppliers involves significant risks, as well as opportunities, and has increased competition. We have experienced and may continue to experience adverse pricing pressures as a result.
•  Changing Technology — Our products are subject to changing technology, which could place us at a competitive disadvantage relative to alternative products introduced by competitors. We may require significant ongoing and recurring additional capital expenditures and investment in research and development, manufacturing and other areas to remain competitive.
•  Challenges of Acquisition Strategy — We intend to actively pursue acquisitions and/or joint ventures but we may not be able to identify attractive acquisition and/or joint venture candidates, successfully integrate our acquired operations or realize the intended benefits of our acquisitions and/or joint ventures, particularly with respect to any acquisitions outside North America.
•  Dependence on Key Personnel and Relationships — We depend on the services of key individuals, particularly our executive officers, and our relationship with our controlling stockholder. The loss of any key individual or change in our relationship with our controlling stockholder could materially and adversely harm us.
•  Labor Stoppages Affecting OEMs — We may be subject to work stoppages at our facilities or those of our principal customers or suppliers, which could materially and adversely harm us.
•  Outsourcing Trend — Our strategies may not succeed if anticipated outsourcing among automotive manufacturers fails to materialize to the extent we have assumed. Principal risks to continued outsourcing are union/labor considerations and objections.
•  International Sales — A growing portion of our revenue may be derived from international sources, which exposes us to certain risks, such as foreign trade restrictions, government embargoes, tariffs, foreign currency risks, expatriation risks and political instability.
•  Product Liabilityand Warranty Claims -- We may incur material losses and costs as a result of product liability and warranty claims that may be brought against us in the event that the use of our current and formerly manufactured or sold products results, or is alleged to result, in bodily injury and/or property damage. In addition, claims may be asserted against us in respect of formerly owned operations, such as TriMas, for which we are indemnified. In the event of financial difficulties, TriMas may be unable to satisfy indemnification claims.
•  Environmental Matters — Our business may be materially and adversely affected by compliance obligations and liabilities under environmental laws and regulations.
•  Control by Principal Stockholder — We are controlled by Heartland, whose interests in our business may be different than other investors in the Company.
•  Terms of Stockholders Agreement — Provisions of a stockholders agreement among the majority of our stockholders impose significant operating and financial restrictions on our business without certain stockholder agreement. In the event our significant stockholders are unable to agree on certain actions, we may be materially and adversely impacted.
•  Leverage; Ability to Service Debt — We may not be able to manage our business as we might otherwise do so due to our high degree of leverage. Our high degree of leverage means that we must dedicate significant cash flow to debt service. By doing so, we will have greater difficulty in meeting other important commercial and financial obligations or in pursuing various strategies and opportunities.
•  Substantial Restrictions and Covenants — Restrictions in our debt instruments limit our ability to take certain actions, including to incur further debt, finance capital expenditures, pay dividends and sell or acquire assets or businesses. These restrictions may prevent us from taking actions in the interests of our securityholders. In addition, our ability to comply with our financial

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  covenants in our debt instruments may be impacted by numerous matters, including matters beyond our control. In the event, we are in default, we may be materially and adversely impacted.
•  Implementation of Control Improvements — We have not yet completed implementation of our current plans to improve our internal controls and may be unable to remedy certain internal control weaknesses identified by our independent auditors and take other actions to meet our 2005 compliance deadline for Section 404 of the Sarbanes-Oxley Act of 2002.
•  Impact of Restatement — The disclosure of the restatement and weaknesses in our internal control over financial reporting may adversely impact the confidence of those with whom we have commercial or financial relationships. Our conclusions and actions relative to the restatement and our control weaknesses is subject to scrutiny in the future, including review by the Securities and Exchange Commission in connection with its ordinary course review of our public filings and disclosures or otherwise.

We undertake no obligation to update publicly any forward-looking statements, whether as a result of new information, future events or otherwise.

There are few published independent sources for data related to the markets for many of our products. To the extent we are able to obtain or derive data from independent sources, we have done so. In particular, we used a report produced by the Ducker Research Company, Inc. profiling North American Forging, Foundry and Machinery Industries prepared in 2000 for Heartland Industrial Partners, L.P., our largest shareholder. To the extent information in the Ducker Report is dated, we have expressed our belief by extrapolating data from the Ducker Report using other publicly available information about the competitors and products addressed in the Ducker Report. To the extent information is otherwise not obtained or derived from independent sources, we have expressed our belief based on our own internal analyses and estimates of our and our competitors' products and capabilities. We note that many of the industries in which we compete are characterized by competition among a small number of large suppliers. Industry publications and surveys and forecasts that we have used generally state that the information contained therein has been obtained from sources believed to be reliable. We have not independently verified any of the data from third-party sources nor have we ascertained the underlying assumptions or bases for any such information. In general, when we say we are a "leader" or a "leading" manufacturer or make similar statements about ourselves, we are expressing our belief that we formulated principally from our estimates and experiences in, and knowledge of, the markets in which we compete. In some cases, we possess independent data to support our position, but that data may not be sufficient in isolation for us to reach the conclusions that we have reached without our knowledge of our markets and businesses.

In addition to the foregoing, readers of this quarterly report are cautioned that, prior to the announcement of the Independent Investigation referred to herein, the Commission provided the Company with comments in the ordinary course on its filings under the Securities Exchange Act of 1934 as amended. The Company believes that it has supplementally or in this report adequately responded to the Staff's comments on the Company's filings. However, it is entirely possible that disclosure may change as a result of the Commission's review of this filing and the Company's responses to those comments. Further, the Company has not included certain historical selected financial data in its Annual Report, and the Commission may comment that the Company's Form 10-K must be amended for the inclusion of such information.

ITEM 3.    QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

In the normal course of business, we are exposed to market risk associated with fluctuations in foreign exchange rates. We are also subject to interest risk as it relates to long-term debt. See "Management's Discussion and Analysis of Financial Condition and Results of Operations" for details about our primary market risks, and the objectives and strategies used to manage these risks. Also see Note 15 "Long-Term Debt" in the notes to the consolidated financial statements for additional information in our 2003 Form 10-K.

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ITEM 4.    CONTROLS AND PROCEDURES

The Company's quarterly financial information has been restated to reflect adjustments to the Company's previously reported financial information on Form 10-Q for the first three fiscal quarters of 2003. Reference is made to Note 2 to the Company's financial statements, and Note 2 to our 2003 Form 10K, for greater detail on the restatement adjustments.

The restatement arose primarily out of information obtained through an investigation conducted by an independent director of the Company, Marshall Cohen, with the assistance of an independent counsel, Sidley Austin Brown & Wood LLP, and the forensic accounting group of Deloitte & Touche LLP. The investigation was initiated as a result of certain allegations made by an employee of the Company and information obtained by the Company's internal audit staff. As discussed below, the Company has implemented, or adopted plans to implement, a number of measures intended to address matters of concern that have been identified through the investigation and is continuing to consider further measures.

In 2003, a plant controller at the Sintered division's St. Mary's, Pennsylvania facility encountered difficulties in understanding certain accounting practices and documentation. In December 2003, he notified the Company's independent auditors, KPMG LLP, that, among other things, he was unable to reconcile certain of the plant's general ledger accounts and to find appropriate documentation for certain entries and indicated that he had concerns regarding the division controller. The Company's Chief Financial Officer initiated an immediate review by the Company's internal audit department of accounting procedures and financial accounting at the domestic plants within the Sintered division. Shortly thereafter, the Company and its Board of Directors authorized the independent investigation into certain accounting practices at the Sintered division from 2001 through 2003.

During the initial stages of the investigation, the Company was made aware of errors with respect to the recording of certain entries which it attempted to analyze. While the Company was performing these analyses, in February 2004, the Sintered division controller made the following allegations concerning actions in which he admittedly participated. He alleged that, following the acquisition of the Company in November 2000, income at the Sintered division from 2000 through 2003 was deliberately understated by up to approximately $10 million in the aggregate. He alleged that these understatements were part of an effort to disguise previous overstatements of income by approximately $20 million in aggregate at the Sintered division during the period from 1996 through 1999, which was prior to the acquisition. There were three primary allegations from the former Sintered divisional controller related to the period 1996 to 1999. During this time, he stated income was overstated by (1) overstating fixed assets, (2) understating liabilities (notably accounts payable), and (3) using a complex set of manual journal entries every month to "disguise" the effects of (1) and (2). Following the acquisition in late 2000, he stated that income was understated through similar actions. The Company concluded that the Sintered division controller's allegations concerning these actions were correct, although the amounts impacted by the actions following the Acquisition vary from the allegations. The Sintered division investigation revealed deficiencies, circumventions and breakdowns that occurred in controls and procedures at the Company.

Based upon certain findings within the Sintered division, the investigation was expanded to encompass accounting practices in other areas of the Company concerning the use of reserves and accrual accounts and the recognition of tooling income for the period from 2001 through 2003. This investigation involved an extensive review by those conducting the investigation of journal entries of over a specified amount made over a three year period. As a result of the expanded investigation, the Company became aware of instances of inappropriate accounting relating to reserves and accruals, which had the effect of "smoothing" earnings for certain periods. Specifically, the Company concluded from the investigative findings that there were instances when reserves had been established to cover unanticipated expenses, reserves had been increased or decreased based upon performance, and/or accruals or reserves had been recorded different from estimated or analyzed amounts. The Company also identified from the investigative findings a few instances of incorrect timing in the recognition of tooling income. The investigation categorized journal entries from the relevant periods for analysis by the Company and review by the Company with its current and former independent auditors. The Company analyzed those categories of entries which the investigation determined to be either potentially inaccurate (i.e.,

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warranting further review) or unknown (i.e., insufficient documentation for third party evaluation). Based upon the Company's review of these categories of entries, the Company believes that the net impact on pretax earnings of the entries determined to be inappropriate and the tooling income issue discussed above was less than $0.6 million in 2003 and no quarter was affected by more than that amount.

Through the work of the investigation, a number of concerns with financial controls and procedures have been identified. Control concerns specifically identified by those conducting the investigation include, but are not limited to, instances of disregard for, or lack of understanding of, proper accrual accounting under GAAP, particularly in relation to reserve accounts; inconsistent policies and procedures concerning the recognition of tooling income; inadequate training of personnel within key accounting and operations functions; undue pressure on certain accounting personnel relative to operating results; issues in properly reviewing internal reporting packages and questionnaires; a failure to properly account for fixed assets; a lack of timely and adequate monitoring of intercompany balances, management review of general ledger, account reconciliation and manual journal entries; and insufficient information systems safeguards and security controls.

In October 2004, KPMG advised the Company that the following items constituted material weaknesses: management's focus on internal controls, specifically referencing those control issues identified by the investigation; the extent to which manual journal entries were able to be made without appropriate review or supporting documentation; the extent to which manual corporate level adjustments were required in the consolidation and financial reporting/close process; the need to improve controls to limit access to accounts payable and vendor files; and the need to enhance controls related to fixed and leased assets to ensure, among other things, timely asset classifications. These material weaknesses, if unaddressed, could result in material errors in the Company's financial statements. In addition, KPMG advised the Company that it had identified reportable conditions relating to intercompany account reconciliation; the need to reduce decentralization relative to international subsidiaries; and the need to devote greater resources to income tax accounting. KPMG has made a number of business recommendations relating to the above-referenced reportable conditions and material weaknesses. The Company has implemented several remedial measures to compensate for these weaknesses, including additional oversight, centralized reconciliations and personnel reassignments.

The Company believes that certain of the issues highlighted by the investigation derive from the Company's history of acquisitions and the attendant employment of personnel from different predecessor companies who continued prior accounting practices. In some instances, the Company believes control issues have been exacerbated by the predecessor companies' previously highly decentralized structure which current management has been addressing over time since the acquisition.

The Company has devoted substantial resources to the improvement and review of its control processes and procedures and such review is ongoing. Those conducting the investigation have made observations concerning corrective actions based on the matters that have come to their attention, which the Company has reviewed. The Company has taken actions or considered actions to address concerns and issues referred to above, and intends to continue taking actions as necessary to further address such concerns and issues, by (1) making personnel and organizational changes; (2) improving communications and internal reporting; (3) simplifying and making consistent various accounting policies and procedures and enhancing related documentation; (4) significantly expanding its training programs for both accounting and non-accounting employees related to accounting matters; (5) increasing management's focus on internal controls and improving the extent and timing of management oversight in a number of areas; and (6) implementing processes and procedures to reduce manual interventions and adjustments and more appropriately limit access to certain files and systems. The Company's Audit Committee and its Board of Directors have reviewed the actions undertaken to date in response to the findings arising from the investigation and authorized other actions to improve control processes and procedures. Specific remedial actions have been undertaken since the beginning of 2004 and include the following:

•  the termination or resignation of seven employees;
•  the upgrading of various personnel, including hiring a new Sintered division controller, a new corporate controller and a new fixed asset manager;

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•  substantial additional training of accounting personnel and non-accounting personnel in accounting matters;
•  revised incentive compensation system to eliminate plant specific performance criteria in favor of division-wide criteria;
•  instituted a number of fixed asset inventory and construction-in-progress analysis improvements;
•  improved corporate accounting policies and procedures documentation;
•  enhanced validation of intercompany balances;
•  separated assignments, responsibility and access between the accounts payable group and central procurement group;
•  expanded review processes of information supplied by plant and division level personnel; and
•  improved procedures and review of relative to plant manual journal entries.

The Company will continue to evaluate the effectiveness of its controls and procedures on an ongoing basis, including consideration of internal control weaknesses and business recommendations identified by its auditors and suggestions made by those that conducted the investigation, and, consequently, intends to implement further actions in its continuing efforts to strengthen the control process.

In addition, the Company is undertaking a thorough review of its internal controls, including information technology systems and financial reporting as part of the Company's preparation for compliance with the requirements of Section 404 of the Sarbanes-Oxley Act. Given the need to fully remedy the internal control weaknesses identified by KPMG, there can be no assurance that the Company will be able to remedy these weaknesses and take other actions required for compliance with Section 404 of the Sarbanes-Oxley Act by the required compliance date, the filing date for its fiscal 2005 audit in early 2006.

Disclosure Controls and Procedures

The evaluation and investigation described above included an evaluation by management with the participation of our Chief Executive Officer and Chief Financial Officer, of the effectiveness of our disclosure controls and procedures (as such term is defined in Rule 13a-15(e) and Rule 15d-15(e) of the Securities Exchange Act of 1934) pursuant to Rule 13a-15 of the Exchange Act. Our disclosure controls and procedures are designed only to provide reasonable assurance that they will meet their objectives. Based upon that evaluation, and the investigation, the Chief Executive Officer and Chief Financial Officer concluded that (a) as of June 27, 2004, the Company's disclosure controls and procedures were not effective to provide reasonable assurance that they would meet their objectives, and (b) taking into account the remedial measures implemented by the Company, as of November 10, 2004, notwithstanding the material weaknesses and reportable conditions summarized above, the Company's disclosure controls and procedures are effective to provide reasonable assurance that they will meet their objectives.

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PART II. OTHER INFORMATION

METALDYNE CORPORATION

Items 1, 2, 3, 4 and 5 are not applicable.

Item 6. Exhibits.


Exhibit 3.1 Restated Certificate of Incorporation of MascoTech, Inc.(1)
Exhibit 3.2 Bylaws of Metaldyne Corporation.(2)
Exhibit 12 Computation of Ratio of Earnings to Combined Fixed Charges and Preferred Stock Dividends.
Exhibit 31.1 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.
Exhibit 31.2 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.
Exhibit 32.1 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.
Exhibit 32.2 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.
(1)  Incorporated by reference from the Exhibits filed with Metaldyne Corporation's Annual Report on Form 10-K for the year ended December 31, 2000.
(2)  Incorporated by reference from the Exhibits filed with MascoTech, Inc.'s (now known as Metaldyne Corporation) Registration Statement on Form S-1 filed December 27, 2000.

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SIGNATURE

Pursuant to the requirements of the Securities Exchange Act of 1934, the registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto duly authorized.

METALDYNE CORPORATION
(Registrant)

Date: November 10, 2004

BY:    /s/ Jeffrey M. Stafeil                
Jeffrey M. Stafeil
Executive Vice President and Chief Financial Officer
(Chief Accounting Officer and Authorized Signatory)

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METALDYNE CORPORATION

EXHIBIT INDEX


Exhibit  
Exhibit 3.1 Restated Certificate of Incorporation of MascoTech, Inc.(1)
Exhibit 3.2 Bylaws of Metaldyne Corporation.(2)
Exhibit 12 Computation of Ratio of Earnings to Combined Fixed Charges and Preferred Stock Dividends.
Exhibit 31.1 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.
Exhibit 31.2 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.
Exhibit 32.1 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.
Exhibit 32.2 Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.
(1) Incorporated by reference from the Exhibits filed with Metaldyne Corporation's Annual Report on Form 10-K for the year ended December 31, 2000.
(2) Incorporated by reference from the Exhibits filed with MascoTech, Inc.'s (now known as Metaldyne Corporation) Registration Statement on Form S-1 filed December 27, 2000.

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