All language subtitles for How.Its.Made.Dream.Cars.S04E01.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb

Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"

THE BENTLEY MULSANNE,

AN OPULENT PALACE ON WHEELS.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

BENTLEY HAS BEEN
BUILDING POWERFUL, LUXURIOUS,

HANDMADE CARS SINCE 1919.

AT THE COMPANY'S FACTORY
HEADQUARTERS IN CREWE, ENGLAND,

THE LEGENDARY BRAND
CONTINUES ITS LONG TRADITION.

THE 41/2-LITER BLOWER OF 1930

IS ONE OF THE RAREST AND MOST
VALUABLE BENTLEYS IN THE WORLD.

IT'S A CELEBRATED VETERAN
OF LE MANS AND MANY OTHER RACES.

ROLLS-ROYCE BOUGHT BENTLEY
IN 1931.

IN 1933, THE COMPANY INTRODUCED
THE 31/2-LITER BENTLEY DERBY,

MARKING A SHIFT
IN FOCUS FROM SPEED TO ELEGANCE.

THE CAR WAS NAMED
FOR THE ROLLS-ROYCE FACTORY

IN DERBY, ENGLAND,
WHERE IT WAS BUILT.

THE FABLED 1928 BENTLEY SPEED 6

BEAT THE BLUE TRAIN FROM CANNES
TO CALAIS IN 1930.

THE BENTLEY MULSANNE SPEED FUSES
THOSE TWO TRADITIONS TOGETHER,

BUT LATER BECAME SYNONYMOUS
WITH REFINED ELEGANCE.

IT'S NAMED AFTER
THE RENOWNED SECTION

OF THE LE MANS 24-HOUR RACE
CALLED THE MULSANNE STRETCH.

THIS SUPER CAR CAN ROCKET
UP TO 190 MILES PER HOUR

IN LUXURIOUS STYLE.

A CRANE LOWERS THE REAR SECTION

OF THE GALVANIZED STEEL
MONOCOQUE ONTO A JIG.

NEXT THE CRANE BRINGS THE CENTER
FLOOR AND FRONT END SECTION

INTO POSITION.

WORKERS CLAMP THEM IN PLACE

TO PREPARE THEM FOR
THE NEXT PHASE OF PRODUCTION.

THEY ADD SMALLER COMPONENTS,
LIKE THE SILL INSERT.

THEN WORKERS USE PORTABLE
RESISTANCE SPOT-WELDERS

TO MELT THE METAL.

THE WELDERS USE AN ELECTRIC
CURRENT TO JOIN THE SHEETS

IN A LOCAL SPOT.

THIS TECHNIQUE GENERATES
LESS HEAT

THAN OTHER FUSION-WELDING
METHODS.

THE MULSANNE HAS ROUGHLY
5,800 SPOT-WELDS.

THE ROOF AND THE CAR SIDES

HAVE BEEN PRE-ASSEMBLED
IN ANOTHER PART OF THE FACILITY.

A CRANE JOINS THIS SUB-ASSEMBLY
TO THE UNDERFRAME.

THE MULSANNE ROOF
HAS A CLAMSHELL STRUCTURE,

MEANING IT EXTENDS
DOWN INTO THE DOORFRAMES.

THE WORKERS BEGIN A PROCESS
CALLED BRAZING,

WHICH CREATES A SEAMLESS SURFACE

FROM ONE SIDE OF THE CAR
TO THE OTHER.

THEY USE A SPECIAL CLAMP

TO KEEP THE STEEL PANELS
PROPERLY ALIGNED.

THE CLAMP ALSO CONDUCTS HEAT
AWAY FROM THE JOINT

AS IT'S BEING WELDED.

THIS HELPS REDUCE DISTORTION
IN THE METAL.

A WORKER BEGINS THE LONG PROCESS
OF SMOOTHING OUT THE JOINT.

HE CAREFULLY WORKS THE WELD
FROM ONE SIDE TO THE OTHER

USING PROGRESSIVELY FINER GRIT
FINISHING SURFACES.

HE COMPLETES THE JOB BY HAND.

WHEN THE BODY
GOES TO THE PAINT SHOP,

ANY REMAINING SCRATCHES
ARE SO FINE

THAT THE PAINT JOB
WILL COVER THEM COMPLETELY.

A WORKER USES A LIFT ASSIST

TO BRING ONE
OF THE MULSANNE'S FOUR DOORS

INTO POSITION.

UNLIKE THE STEEL MONOCOQUE
AND ROOF,

THE DOORS ARE MADE OF ALUMINUM.

USING SETTING AIDS AND GAUGES,
A WORKER INSTALLS THE HOOD.

HE RAISES AND LOWERS IT
TO CONFIRM THE FIT.

THE HOOD IS ALSO MADE
OF ALUMINUM.

THE TRUNK LID IS MADE
OF SHEET-MOLDED COMPOSITE.

THE COMPLETED CAR BODY IS SENT
TO THE INSPECTION AREA.

AN EXPERT THOROUGHLY
CHECKS THE SURFACES.

HE USES A SPECIAL FINE-GRAINED
STONE TO IDENTIFY ANY DEFECTS

WITHOUT COMPROMISING
THE OVERALL SURFACE QUALITY.

THE HIGHLIGHT FLUID
IS APPLIED IN LOCAL AREAS

TO MIMIC THE LOOK OF PAINT.

WITH THE HELP
OF SPECIAL LIGHTING,

THE INSPECTOR CAN SEE ANY FLAWS
ON THE SURFACE.

ONCE THE BODY PASSES INSPECTION,
IT TRAVELS TO THE PAINT SHOP.

CUSTOMERS CAN CHOOSE
FROM MORE THAN 100 COLORS

OR MATCH THE PAINT JOB
TO ANYTHING,

FROM A FAVORITE TIE

TO A PARTICULAR SHADE
OF LIPSTICK.

Narrator:
BENTLEY'S BRAWNY V8 ENGINE

IS A CORNERSTONE
OF THE COMPANY'S BRAND.

FOR THE NEW MULSANNE,
THEY'VE RE-ENGINEERED

THE FAMED 63/4-LITER
POWERHOUSE,

PUSHING THE PEAK TORQUE
TO 811 FOOT-POUNDS.

A TECHNICIAN USES A HOIST

TO CAREFULLY LOWER THE
CRANKSHAFT INTO THE CRANK CASE.

HE USES THE MAIN BEARING CAPS
TO ATTACH THE PARTS.

HE SECURES THE CAPS WITH BOLTS.

THEN CONFIRMS
THAT THE CRANKSHAFT

CAN SPIN FREELY IN ITS BEARING.

A TECHNICIAN SLOWLY DROPS THE
CAMSHAFT INTO THE ENGINE BLOCK.

HE MAKES SURE THE BLOCK DOESN'T
DAMAGE THE CAMSHAFT LOBES

AS THEY GO IN.

HE ADDS SEALING RINGS
TO THE END OF THE CAMSHAFT

BEFORE HE INSTALLS
THE TOP PLATE.

THE RINGS KEEP THE CAMSHAFT
END FLOAT WITHIN PARAMETERS.

USING A PISTON CHECKING GAUGE,
AN OPERATOR

ENSURES THE COMPONENTS' CIRCLIPS
ARE IN PLACE

BEFORE SEPARATING THE CAP
FROM THE ROD.

THIS ALLOWS HIM TO EASILY
INSTALL THE CON ROD BEARINGS

AND CAP BEARINGS.

HE ATTACHES TWO NYLON RODS
TO THE PISTON

AND COMPRESSES THE PISTON RINGS
IN A SPECIALIZED TOOL.

HE BRINGS THE PISTON
TO THE ENGINE BLOCK

AND INSERTS IT
INTO ITS ASSIGNED BORE.

THE TECHNICIAN REMOVES

THE PROTECTIVE NYLON RODS
FROM THE BORE,

THEN HE INSTALLS THE CAPS,
AND TORQUES THEM IN PLACE.

HE FINISHES THE INSTALLATION

AND THEN TURNS THE CRANKSHAFT.

HE RUNS THE PISTONS
UP AND DOWN THE BORES

TO MAKE SURE
THEY CAN MOVE FREELY.

A TECHNICIAN INSTALLS
THE CRANKSHAFT FLEX PLATE.

THE FLEX PLATE IS PART OF THE
COMPONENT THAT TURNS THE GEARBOX

AND PROVIDES DRIVE.

THEN HE PLACES THE SECOND PLATE
ON TOP

BEFORE POSITIONING A
PLASTIC TORQUE TIGHTENING GUIDE.

THE TECHNICIAN FOLLOWS
THREE PRESCRIBED STEPS

IN TORQUING THE BOLTS.

THE BOLTS
MUST BE TIGHTENED TO A TORQUE

SPECIFIED BY THE ENGINEERS
WHO DESIGNED THE ENGINE.

A WORKER BRINGS
THE LIGHTWEIGHT ALUMINUM HEADS

TO THE ENGINE BLOCK

AND USES A SET OF LOCATOR PINS
TO POSITION THEM.

THE TECHNICIAN ADDS A PAIR
OF GASKETS.

AND THEN DROPS
THE MANIFOLD INTO POSITION.

HE FOLLOWS
THE TORQUING SPECIFICATIONS

TO RUN DOWN THE BOLTS.

HE INSTALLS THE FUEL RAILS
ON EITHER SIDE

OF THE MANIFOLD BASE.

THE TECHNICIAN CAREFULLY
PLACES AN OILED BALL BEARING

ON TOP OF EACH
OF THE ENGINE'S 16 PUSH RODS.

THEN HE USES FIVE LOCATOR STUDS
TO INSTALL THE ROCKER SHAFT.

HE TORQUES DOWN THE NUTS
WITH A THREE-STAGE PROCESS

THAT GENTLY
COMPRESSES THE PUSH RODS

WITHOUT BENDING
THE ROCKER SHAFT.

AFTER PRE-OILING
THE ROCKER SHAFT,

THE TECHNICIAN
ADDS THE ROCKER COVER.

THEN A WORKER STAMPS
ON THE ENGINE'S NUMBER.

HE HAMMERS A UNIQUE COMBINATION

OF LETTERS AND NUMBERS
INTO THE SIDE OF THE BLOCK.

THAT NUMBER INCREASES
BY ONE WITH EACH NEW ENGINE.

FINALLY, A WORKER INSTALLS
THE TURBO AND EXHAUST MANIFOLD.

HE USES BRASS NUTS
TO HOLD IT IN PLACE

BECAUSE BRASS IS RESISTANT
TO HEAT EXPANSION.

THE COMPLETELY ASSEMBLED
V8 ENGINE

IS NOW READY TO POWER
A BENTLEY MULSANNE

FROM ZERO TO 60 MILES PER HOUR
IN JUST 4.9 SECONDS.

Narrator: WOOD IS A TRADEMARK
ELEMENT OF BENTLEY CARS,

AND THE MULSANNE
HAS A LOT OF IT.

THE WOOD PANELING BELOW THE DOOR
WINDOW IS CALLED THE WAIST RAIL.

BUILDING IT REQUIRES
FINE MATERIALS

AND EVEN FINER CRAFTSMANSHIP.

ARTISANS START THE PROCESS

BY MACHINING A PAIR
OF MATCHING TONGUES AND GROOVES

IN TWO PIECES OF WOOD.

IN THIS CASE, THE WOOD
IS AMERICAN BLACK WALNUT,

BUT CUSTOMERS CAN CHOOSE
FROM A VARIETY OF OPTIONS.

A WOODWORKER APPLIES GLUE
TO THE TONGUES

AND AN ACTIVATOR COMPOUND
TO THE GROOVES.

THEN HE CAREFULLY FITS THE TWO
PIECES OF WOOD TOGETHER.

A HYDRAULIC PRESS
PROVIDES JUST ENOUGH PRESSURE

TO FORCE THE GLUE
ALONG THE GROOVE LINES,

ENSURING THERE ARE NO GAPS.

AFTER 20 MINUTES,

THE GLUE IS HARD ENOUGH
TO START SHAPING THE MATERIAL.

WORKING FREEHAND,

A CRAFTSMAN USES A BAND SAW
TO CUT OFF SURPLUS WOOD,

LEAVING THE ROUGH SHAPE
OF A WAIST RAIL.

EACH MULSANNE HAS FOUR
WAIST RAILS, ONE PER DOOR.

AN OPERATOR LOADS ALL FOUR
ONTO A FIXTURE

USING A VACUUM SYSTEM
TO HOLD THEM IN PLACE.

THE FIXTURE SLIDES
INTO A FIVE-AXIS CNC MACHINE.

THE MACHINE USES A SET
OF FORMING TOOLS

TO CUT THE SURFACE DETAILING.

IN THIS CASE, IT'S WORKING
ON WHAT'S CALLED THE "B" SIDE

OF THE WAIST RAIL.

THIS SIDE,
WHICH WON'T BE VISIBLE,

INCLUDES ALL
THE ATTACHMENT POINTS.

OPERATORS FLIP THE WOOD OVER

TO LET THE CNC MACHINE
FINISH THE "A" SIDE.

TO ACHIEVE THE SIGNATURE BENTLEY
LOOK, THE COMPANY USES

HIGH-QUALITY SOURCES
LIKE CALIFORNIA BURL WALNUT.

THE BURL COMES FROM THE ROOT
OF THE TREE.

THE VENEER SUPPLIER

SHAVE THE BURL INTO LEAVES
JUST A HALF A MILLIMETER THICK

AND PACKAGE THEM IN BUNDLES.

HERE, A CRAFTSMAN
CAREFULLY FLICKS A SET OF LEAVES

TO MAKE SURE THE KNOTS
LINE UP PERFECTLY.

HE PLACES TWO LEAVES END TO END,

WITH THE KNOT PATTERNS
MIRRORING EACH OTHER PRECISELY.

A NICK ENSURES THEY
CAN BE EASILY REALIGNED.

THEN HE FLIPS THE LEAVES OVER

AND CAREFULLY TAPES
THEM TOGETHER.

THE NICK HELPS HIM LINE THEM
BACK UP QUICKLY.

HE APPLIES LIGHT,
SMOOTH PRESSURE TO THE LEAVES

TO MAKE SURE
THE TAPE ADHERES COMPLETELY.

THE LEAVES OF THE WALNUT VENEER
ARE EXTREMELY FRAGILE.

TO PROTECT THEM FROM CRACKING
AND SPLITTING,

THE WORKER COVERS ONE SIDE
WITH SPECIALIZED TAPE.

THEN HE CUTS THE VENEER
TO THE SHAPE REQUIRED.

NOW HE'S READY TO ATTACH THE
VENEER TO THE WALNUT WAIST RAIL.

FIRST THE CRAFTSMAN APPLIES
A HEAT-ACTIVATED LIQUID GLUE

TO THE SURFACE.

HE PLACES THE WAIST RAIL ON
A FIXTURE THAT WILL PROTECT IT

DURING THE NEXT PHASE
OF PRODUCTION.

HE POSITIONS THE VENEER ON TOP

AND, WITH THE HELP OF A SECOND
WORKER, SECURES IT IN PLACE.

THEY COVER EVERYTHING
WITH A SHEET OF PLASTIC

AND SEND IT INTO A MACHINE
CALLED A MEMBRANE PRESS.

PRESSURE FROM THE PRESS BONDS
THE VENEER TO THE WAIST RAIL.

AFTER 20 MINUTES IN THE PRESS,

THE TWO WOOD COMPONENTS ARE
FIRMLY ADHERED TO EACH OTHER.

NOW A MEMBER OF THE SANDING TEAM
GOES TO WORK ON THE WAIST RAIL.

HE STARTS WITH A RELATIVELY
COURSE GRIT OF SAND PAPER

TO REMOVE ANY GLUE RESIDUE
OR SCRATCHES.

HE FINISHES WITH 120-GRIT PAPER.

THIS WAIST RAIL
HAS ALREADY RECEIVED

FIVE COATS OF POLYESTER LACQUER,

AND IT'S READY FOR POLISHING.

A WORKER APPLIES
A POLISHING COMPOUND

TO A DEVICE CALLED THE MOP.

THEN HE POLISHES
THE WAIST RAIL'S COATING

TO A SMOOTH, HIGH GLOSS.

THE FINISHED WAIST RAIL

WILL FORM PART OF THE FINELY
CRAFTED WOOD PANELING

THAT CIRCLES THE INTERIOR
OF THE MULSANNE.

Narrator: THE MULSANNE BODY
IS READY FOR FINAL ASSEMBLY.

THE CAR IS BARE BONES NOW,

BUT BENTLEY IS RIGHTLY FAMOUS

FOR ITS CARS'
LUXURIOUS INTERIORS,

SO THERE'S A LOT OF WORK
TO BE DONE.

TWO WORKERS LOAD A BAG
FULL OF WIRING INTO THE CAR.

THIS PREASSEMBLED WIRING IS
CALLED THE MAIN HARNESS OR LOOM.

IT'S BEEN HEATED
TO 136 DEGREES FAHRENHEIT

TO MAKE IT FLEXIBLE
AND EASY TO MANIPULATE.

THE INSTALLERS FEED
A SECTION OF THE WIRING

THROUGH A OPENING
INTO THE TRUNK.

THE HARNESS
INCLUDES FIBER OPTIC CABLES

TO RUN THE ENTERTAINMENT SYSTEM

AND AIR LINES
FOR THE SUSPENSION.

IT'S EXTREMELY IMPORTANT

NONE OF THESE ARE KINKED
DURING INSTALLATION.

A WORKER POSITIONS
THE INDICATOR SIDE LIGHTS

AND THEN ADDS THE HEADLIGHTS.

OPERATORS
USE SPECIALIZED MACHINERY

TO ADJUST THE DIRECTION
OF THE HEADLIGHT BEAMS.

INSTALLERS LOAD THE DASHBOARD,

WHICH BENTLEY WORKERS ASSEMBLED

AT AN ADJACENT STATION
ON THE PRODUCTION LINE.

WITH THE CAR ELEVATED ON A LIFT,

WORKERS
INSTALL THE EXHAUST SYSTEM.

IT WAS ALSO ASSEMBLED
PARALLEL TO THE PRODUCTION LINE.

THE POWER TRAIN, WHICH
INCLUDES THE ENGINE, GEARBOX,

PROP SHAFT,
REAR DIFFERENTIAL, AND BRAKES,

SITS ON A FIXTURE
CALLED THE MARRIAGE BED.

IT'S READY TO JOIN
THE CAR'S BODY.

THE MARRIAGE, AS IT'S CALLED,

IS AN EXTREMELY
INTENSIVE PROCESS.

THE MARRIAGE BED
FLOATS ON A BEARING,

ALLOWING OPERATORS

TO MANUALLY ALIGN
THE TWO SUB-ASSEMBLIES

AS THEY COME TOGETHER.

THE RADIATOR SHELL
CAN BE PAINTED OR FULLY CHROMED

ACCORDING
TO CUSTOMER PREFERENCE.

CUSTOMERS CAN OPT FOR THE
BENTLEY TWO-DIMENSIONAL BADGE

OR FOR ITS FAMOUS FLYING "B"
HOOD ORNAMENT.

THE "B" HAS BEEN DESIGNED TO
RETRACT AT THE SLIGHTEST TOUCH.

BENTLEY ARTISANS
MAKE THEIR CAR SEATS ON SITE,

CUSTOMIZING ALL UPHOLSTERY,
TRIM,

AND OTHER SPECIAL FEATURES TO
THE CUSTOMER'S SPECIFICATIONS.

THIS PARTICULAR MODEL

FEATURES A SCREEN EMBEDDED
IN THE BACK OF THE HEADREST.

OTHERS COME WITH INTEGRATED
TABLETS AND KEYBOARDS.

THE MULSANNE STEERING WHEELS
ARE ALSO CUSTOM-MADE ON SITE.

WHEELS CAN COME HEATED,

MADE OF WOOD,
FULLY UPHOLSTERED IN LEATHER,

OR A COMBINATION OF ALL THREE.

A WORKER BUILDS A DOOR PARALLEL
TO THE ASSEMBLY LINE.

WITH THE WOODEN WAIST RAIL
ALREADY CLAMPED IN PLACE,

HE ADDS THE CASING
AROUND THE SPEAKER SYSTEM.

BUILDING COMPONENTS
NEXT TO THE ASSEMBLY LINE

REDUCES THE RISK OF DAMAGE
DURING TRANSIT.

LIKE EVERY OTHER ELEMENT
OF THE MULSANNE,

THE DOORS' INTERIOR MATERIALS,
COLOR SCHEME,

AND EVEN UPHOLSTERY STITCHING
PATTERN ARE CUSTOM-MADE.

AN INSTALLER USES A LIFT ASSIST

TO TRANSFER THE DOOR
TO ITS MATCHING CAR

AND ALIGN THE HINGES
FOR ATTACHMENT.

A SYSTEM OF BAR CODES
AND SCANNERS ENSURES WORKERS

ASSEMBLE THE RIGHT PARTS
TO THE RIGHT CAR.

THE TREAD PLATE BADGE

CAN FEATURE THE NAME
OF AN INDIVIDUAL, A COMPANY,

OR ANYTHING ELSE
A CUSTOMER REQUESTS.

AN INSPECTOR STARTS
AT ONE CORNER

AND WORKS HER WAY
AROUND THE MULSANNE

IN A PRESCRIBED PATTERN.

SHE EXAMINES THE CAR FOR FLAWS

AND ENSURES THAT IT'S BUILT
TO THE CUSTOMER'S REQUIREMENTS.

WITH ITS LONG, GRACEFUL LINES
AND SMOOTH, POLISHED SURFACES,

THE EXTERIOR
OF THE MULSANNE SPEED

RECALLS THE OLD-SCHOOL ELEGANCE
OF CARS LIKE THE 1933 DERBY.

EVEN THE WHEELS LOOK GRACEFUL.

INSIDE, BENTLEY'S FLAIR
FOR LUXURY IS ON FULL DISPLAY.

THE REFINED STYLE
BARELY CONCEALS THE POWERHOUSE

THAT GENERATES BENTLEY'S
FAMOUS WAVE OF TORQUE,

MAKING IT MORE POWERFUL
THAN ANY MUSCLE CAR.

THE BENTLEY MULSANNE IS 13%
MORE EFFICIENT

THAN PREVIOUS MODELS,

GIVING IT
A SMALLER CARBON FOOTPRINT

AND EXTENDING ITS RANGE
BY 50 MILES.

HANDMADE FROM TOP TO BOTTOM,

THE MULSANNE SPEED
CALLS ON BOTH STRANDS

OF ITS BRAND'S
HISTORICAL TRADITIONS,

FUSING SPEED AND STRENGTH

WITH THE OPULENCE OF
THE MOST LUXURIOUS LIMOUSINE.