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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:02,736 --> 00:00:04,535
THE ARIEL ATOM 3S,
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00:00:04,536 --> 00:00:08,040
A SUPERCAR BUILT FOR THE TRACK
BUT COMFORTABLE ON THE ROAD.
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00:00:08,041 --> 00:00:11,041
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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♪♪
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THE 20,000-SQUARE-FOOT FACILITY
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LOCATED IN HALIFAX COUNTY,
VIRGINIA,
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HOUSES THE TMI
AUTOTECH HEADQUARTERS.
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00:00:31,596 --> 00:00:33,331
THIS IS WHERE
HIGHLY SKILLED WORKERS
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00:00:33,332 --> 00:00:37,102
ASSEMBLE THE ARIEL ATOM 3S.
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FOR THE FINAL ASSEMBLY STEP,
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EACH UNIT IS ASSIGNED
TO ONE TECHNICIAN
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00:00:41,341 --> 00:00:45,042
WHO COMPLETES THE MONTH-LONG
MANUFACTURING PROCESS.
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00:00:45,043 --> 00:00:48,311
TECHNICIANS WORK SIDE
BY SIDE ON FIVE UNITS
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00:00:48,312 --> 00:00:52,115
AT DIFFERENT STAGES
OF THE ASSEMBLY PROCESS.
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00:00:52,116 --> 00:00:53,518
IT TAKES ABOUT 4 WEEKS
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00:00:53,519 --> 00:00:55,853
TO GET FROM THE BARE,
POWDER-COATED CHASSIS
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TO THE ASSEMBLED EXOSKELETON
OF THE CAR,
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00:00:58,823 --> 00:01:02,560
WHICH IS FITTED
WITH A FIBERGLASS BASE.
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00:01:02,561 --> 00:01:06,129
THE BASE HOLDS A LAMINATED
SAFETY GLASS WINDSHIELD,
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00:01:06,130 --> 00:01:08,099
A FRONT-MOUNTED
ALUMINUM RADIATOR,
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00:01:08,100 --> 00:01:11,334
AND FIVE-SPOKE
RACE MOTOR SPORT WHEELS.
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00:01:11,335 --> 00:01:14,671
THIS 3S COMES EQUIPPED
WITH HIGH-OUTPUT HEADLIGHTS,
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00:01:14,672 --> 00:01:17,740
A PUSH-ROD AND ROCKER-ARM
REAR SUSPENSION SYSTEM,
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00:01:17,741 --> 00:01:21,111
SPECIAL 12-SPOKE RIMS,
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AND LOADED WITH
A 365-HORSEPOWER ENGINE.
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00:01:25,583 --> 00:01:27,418
THE TWO IN-FRONT
SUSPENSION DAMPERS
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ALLOW THE CAR
TO BEND INTO CURVES
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RATHER THAN DARTING INTO THEM.
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00:01:32,391 --> 00:01:35,525
♪♪
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A MECHANICAL ENGINEER REVIEWS
THE ATOM'S EXOSKELETON DESIGN,
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USING A CAD SOFTWARE
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00:01:40,834 --> 00:01:44,569
TO STUDY A 3-D MODEL
OF THE CHASSIS.
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00:01:44,570 --> 00:01:46,938
HE GOES OVER
THE WELDING SPECIFICATIONS
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FOR ALL 183 INDIVIDUAL PIECES
COMPRISING THE CHASSIS.
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A FABRICATION TECHNICIAN
ASSEMBLES THE CHASSIS
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00:01:55,781 --> 00:01:58,281
ON A MODULAR FIXTURE TABLE.
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00:01:58,282 --> 00:02:00,817
HE POSITIONS
THE MACHINED ALUMINUM JIG
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00:02:00,818 --> 00:02:03,153
AND SECURES IT IN PLACE.
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00:02:03,154 --> 00:02:05,189
THIS KEEPS
THE CHASSIS TUBE STABLE
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00:02:05,190 --> 00:02:08,191
DURING THE WELDING PROCESS.
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00:02:08,192 --> 00:02:10,394
THE TECHNICIAN BRINGS IN
A ROLLED STEEL TUBE,
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00:02:10,395 --> 00:02:13,565
WHICH WILL FORM THE RIGHT
UPPER SIDE RAIL OF THE CHASSIS.
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00:02:16,702 --> 00:02:19,904
HE PLACES THE TUBE FLUSH
AGAINST THE FRONT-END MODULE
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00:02:19,905 --> 00:02:25,108
BEFORE HE POSITIONS ANOTHER TUBE
ACROSS THE FRAME.
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00:02:25,109 --> 00:02:29,547
THE ENTIRE CHASSIS
IS BUILT USING MILD STEEL.
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THE ELECTRIC RESISTANCE
WELDING PROCESS
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00:02:31,850 --> 00:02:34,452
INCREASES THE STRENGTH
AND HARDNESS OF THE STEEL
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00:02:34,453 --> 00:02:37,922
WHILE DECREASING ITS DUCTILITY.
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THE ROLLED STEEL IS FORMED
INTO A ROUND TUBE
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00:02:40,794 --> 00:02:44,696
AND CLOSED USING
A FLASH BUTT WELDING TECHNIQUE.
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00:02:44,697 --> 00:02:47,064
THE TUBE IS THEN DRAWN
OVER A MANDREL
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00:02:47,065 --> 00:02:49,801
TO REMOVE THE WELD SEAM.
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00:02:49,802 --> 00:02:51,969
THIS PROCESS MAKES
THE CHASSIS STIFFER
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00:02:51,970 --> 00:02:53,470
AND MORE RESISTANT,
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00:02:53,471 --> 00:02:56,141
LEAVING THE TUBING
VIRTUALLY SEAMLESS.
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00:02:58,709 --> 00:03:01,045
THE TECHNICIAN BRINGS IN
THE SIDE RAIL,
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00:03:01,046 --> 00:03:03,915
ALIGNS IT WITH THE LASER-NOTCHED
END OF THE MAIN TUBE,
60
00:03:03,916 --> 00:03:06,384
AND PLACES IT
ON THE FRONT-END MODULE.
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00:03:10,088 --> 00:03:12,857
IT TAKES ABOUT A DAY
TO TACK THE ENTIRE CHASSIS
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00:03:12,858 --> 00:03:15,127
BEFORE IT'S READY
FOR FINISH WELDING.
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00:03:18,197 --> 00:03:20,699
A WELDER STARTS ON THE BASE
OF A CHASSIS TUBE
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00:03:20,700 --> 00:03:22,499
USING A TIG WELDING TORCH
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00:03:22,500 --> 00:03:24,737
AND A SILICON BRONZE ROD.
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00:03:28,406 --> 00:03:31,108
NEXT, HE TAKES SMALL
LASER-CUT STEEL PARTS
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00:03:31,109 --> 00:03:34,712
THAT HAVE BEEN ENGINEERED
TO MAKE CHASSIS BRACKETS.
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00:03:34,713 --> 00:03:37,881
HE PLACES THE PIECES
ON A ROTATING WELDING FIXTURE,
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00:03:37,882 --> 00:03:39,215
CLAMPS THEM FIRMLY,
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00:03:39,216 --> 00:03:44,856
AND WELDS THEM USING
A SMALL SILICON BRONZE TIG ROD.
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00:03:44,857 --> 00:03:47,091
THE MELTING POINT
OF SILICON BRONZE
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00:03:47,092 --> 00:03:49,859
IS AROUND 1,800 DEGREES
FAHRENHEIT,
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00:03:49,860 --> 00:03:53,430
ABOUT 700 DEGREES BELOW
THE MELTING POINT OF STEEL.
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00:03:53,431 --> 00:03:56,299
SILICON BRONZE WELDING
REQUIRES LESS HEAT.
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00:03:56,300 --> 00:03:58,803
SO THERE'S LESS OF A CHANCE
THAT THE WELDER WILL MELT
76
00:03:58,804 --> 00:04:01,140
THE STEEL BASE METAL
INTO THE WELD,
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00:04:01,141 --> 00:04:03,975
WHICH COULD THEN BRITTLE
OR CRACK.
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00:04:03,976 --> 00:04:06,812
THE WELDER PUTS THE PIECE
ON AN ALUMINUM BLOCK
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00:04:06,813 --> 00:04:09,781
AND SECURES IT
WITH CUSTOMIZED FIXTURES.
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00:04:12,618 --> 00:04:15,955
HE PLACES ANOTHER LASER-CUT
STEEL PIECE ON THE BLOCK.
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00:04:18,556 --> 00:04:22,360
HE USES A FIXTURE
TO HOLD IT IN PLACE.
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00:04:24,629 --> 00:04:27,798
THIS TIME, HE USES
A STEEL FILLER ROD
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00:04:27,799 --> 00:04:29,834
BECAUSE THIS PARTICULAR
WELDING SEAM
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00:04:29,835 --> 00:04:32,138
WILL NOT BE VISIBLE
ON THE CHASSIS.
85
00:04:34,138 --> 00:04:37,507
THESE THREE-PIECE BRACKETS
FORM ROLL BAR MOUNTS.
86
00:04:37,508 --> 00:04:39,844
USING A LOCATOR FIXTURE
AND A SPACER,
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00:04:39,845 --> 00:04:43,548
THE WELDER POSITIONS THE BRACKET
ON THE FRAME.
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00:04:43,549 --> 00:04:47,084
HE SECURES THE FIXTURE IN PLACE
BY DRIVING ITS THREADED HEAD
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00:04:47,085 --> 00:04:51,455
THROUGH A HOLE
MACHINED INTO THE TUBING.
90
00:04:51,456 --> 00:04:52,789
USING A TIG TORCH,
91
00:04:52,790 --> 00:04:55,192
THE WELDER BRAZES
THE SILICON BRONZE FILLER,
92
00:04:55,193 --> 00:04:57,796
WHICH BONDS THE BRACKET
TO THE MAIN SIDE RAIL
93
00:04:57,797 --> 00:05:00,099
AND TO THE REAR
SUB-FRAME ASSEMBLY.
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00:05:02,600 --> 00:05:04,635
HE REMOVES THE LOCATOR FIXTURE,
95
00:05:04,636 --> 00:05:08,107
LEAVING THE ROLL BAR MOUNTS
SAFELY WELDED ONTO THE CHASSIS.
96
00:05:14,378 --> 00:05:19,382
THE CHASSIS RESTS ON A ROTATING
FIXTURE CALLED A ROTISSERIE.
97
00:05:19,383 --> 00:05:20,784
ON THIS WELDING JIG,
98
00:05:20,785 --> 00:05:24,955
THE CAR'S EXOSKELETON
CAN ROTATE A FULL 360 DEGREES.
99
00:05:24,956 --> 00:05:27,157
THIS ENSURES ACCURATE WELDING
100
00:05:27,158 --> 00:05:29,592
AND SAFE ACCESS
TO ALL WELDING POINTS.
101
00:05:29,593 --> 00:05:31,262
THE ASSEMBLED SPACE FRAME
102
00:05:31,263 --> 00:05:33,764
COMES WITH A DISTINCTIVE
AIR INTAKE HOOP
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00:05:33,765 --> 00:05:37,002
AND AN EMBEDDED STEERING COLUMN
WELDED INTO THE CHASSIS.
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00:05:37,003 --> 00:05:39,003
♪♪
105
00:05:40,705 --> 00:05:42,641
♪♪
106
00:05:43,300 --> 00:05:45,201
Narrator: THE COLD-ROLLED
STEEL FENDER STAY
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00:05:45,202 --> 00:05:48,138
IS A DISTINCTIVE PART
OF THE ARIEL ATOM.
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00:05:48,139 --> 00:05:50,107
IT FEATURES A STOP WASHER
109
00:05:50,108 --> 00:05:52,441
SPOT WELDED
WITH A TIG STEEL FILLER
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00:05:52,442 --> 00:05:56,312
AND MIG-WELDED MOUNTING TABS
FOR BETTER RESISTANCE.
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00:05:56,313 --> 00:05:57,814
♪♪
112
00:05:57,815 --> 00:06:02,319
A WORKER FEEDS ROLLED STEEL
INTO A TUBE-BENDING MACHINE.
113
00:06:02,320 --> 00:06:04,453
THE WIPER DIE SYSTEM BOTH BENDS
114
00:06:04,454 --> 00:06:06,622
AND PUTS PRESSURE
ALL AROUND THE TUBE
115
00:06:06,623 --> 00:06:09,826
TO PREVENT IT FROM COLLAPSING
OR DEFORMING.
116
00:06:09,827 --> 00:06:12,162
AS THE NEXT TUBE SECTION
COMES OUT,
117
00:06:12,163 --> 00:06:14,932
THE BEND DIE RETURNS
TO ITS AXIS.
118
00:06:14,933 --> 00:06:16,600
THE CLAMP DIE AND PRESSURE DIE
119
00:06:16,601 --> 00:06:20,069
MOVE INTO POSITION
FOR THE SECOND BEND.
120
00:06:20,070 --> 00:06:21,504
IN LESS THAN ONE MINUTE,
121
00:06:21,505 --> 00:06:24,708
THE MULTI-RADIUS CNC
TUBE BENDING MACHINE
122
00:06:24,709 --> 00:06:27,177
AUTOMATICALLY MAKES
A SERIES OF FOUR BENDS
123
00:06:27,178 --> 00:06:29,646
TO FORM THE FENDER STAY.
124
00:06:29,647 --> 00:06:32,682
THIS CNC BENDER
ALLOWS FOR ACCURATE BENDS
125
00:06:32,683 --> 00:06:35,853
AS WELL AS REPEATABILITY
FOR FUTURE BUILDS.
126
00:06:38,123 --> 00:06:40,056
A WELDER NOW BRINGS
THE FENDER STAY
127
00:06:40,057 --> 00:06:44,026
FROM THE TUBE BENDING MACHINE
TO THE WELDING TABLE.
128
00:06:44,027 --> 00:06:46,929
HE MOUNTS TABS
ON A MACHINED ALUMINUM FIXTURE
129
00:06:46,930 --> 00:06:50,701
DESIGNED TO ENSURE
THE MOST ACCURATE WELDING.
130
00:06:50,702 --> 00:06:53,470
HE THEN INSERTS
AND ROUGHLY LOCATES WASHERS
131
00:06:53,471 --> 00:06:55,939
ON THE FENDER STAY TUBE.
132
00:06:55,940 --> 00:06:57,973
ONCE THE WASHERS ARE IN PLACE,
133
00:06:57,974 --> 00:07:01,377
THE WELDER POSITIONS
THE FENDER STAY ON THE FIXTURE.
134
00:07:01,378 --> 00:07:06,249
HE COMPLETES THE ASSEMBLY
WITH AN ADDITIONAL MOUNTING TAB.
135
00:07:06,250 --> 00:07:07,984
HE STARTS WELDING
THE MOUNTING TABS
136
00:07:07,985 --> 00:07:10,920
USING A MIG WELDING TORCH.
137
00:07:10,921 --> 00:07:12,855
WHILE CURRENT FLOWING
BETWEEN THE ELECTRODE
138
00:07:12,856 --> 00:07:15,158
AND THE METAL
CREATES AN ELECTRIC ARC,
139
00:07:15,159 --> 00:07:17,627
SHIELDING GASES BLOW
THROUGH THE TORCH.
140
00:07:17,628 --> 00:07:20,064
THIS PREVENTS
AMBIENT ATMOSPHERIC GASES
141
00:07:20,065 --> 00:07:23,133
FROM FLOWING INTO THE WELD.
142
00:07:23,134 --> 00:07:25,336
THE WELDER THEN SWITCHES BACK
TO TIG WELDING
143
00:07:25,337 --> 00:07:28,204
TO TACK-WELD
THE FENDER STOP WASHER.
144
00:07:28,205 --> 00:07:29,905
ONCE THE WELDING IS COMPLETE,
145
00:07:29,906 --> 00:07:33,143
THE WELDER UNFASTENS THE WORK
PIECE FROM THE FIXTURE
146
00:07:33,144 --> 00:07:35,312
AND TAKES IT
TO THE ASSEMBLY LINE.
147
00:07:38,182 --> 00:07:42,585
MEANWHILE, AN ENGINEER WORKS
ON THE UPRIGHT ASSEMBLY HOUSING.
148
00:07:42,586 --> 00:07:44,153
IN HIS 3-D CAD SYSTEM,
149
00:07:44,154 --> 00:07:46,590
HE STUDIES THE INTERACTION
OF THE PIECES,
150
00:07:46,591 --> 00:07:50,227
SUCH AS THE DRIVE FLANGES
AND THE WHEEL BEARING.
151
00:07:50,228 --> 00:07:52,263
HE CHECKS THE FIT
BETWEEN THE PIECES
152
00:07:52,264 --> 00:07:56,167
BEFORE THE UPRIGHT
FABRICATION BEGINS.
153
00:07:56,168 --> 00:07:59,436
A FABRICATION TECHNICIAN NOW
TAKES A WHEEL BEARING HOUSING
154
00:07:59,437 --> 00:08:02,939
AND MOUNTS IT
ON AN ALUMINUM JIG.
155
00:08:02,940 --> 00:08:05,876
HE INSERTS A LOCATING FIXTURE
THROUGH THE HOUSING
156
00:08:05,877 --> 00:08:10,681
TO ENSURE CORRECT PLACEMENT
OF THE PIECE IN THE ASSEMBLY.
157
00:08:10,682 --> 00:08:13,551
NEXT, HE PICKS UP
A CAREFULLY MACHINED PART
158
00:08:13,552 --> 00:08:15,518
AND FITS IT
TO THE WHEEL BEARING HOUSING
159
00:08:15,519 --> 00:08:18,223
USING ANOTHER
SCREW-ON LOCATING FIXTURE.
160
00:08:20,457 --> 00:08:22,658
HE REPEATS THE OPERATION
ON THE OTHER SIDE
161
00:08:22,659 --> 00:08:24,261
TO FORM THE UPRIGHT.
162
00:08:27,430 --> 00:08:30,501
THE TECHNICIAN CLOSES
THE ASSEMBLY WITH METAL PLATES
163
00:08:30,502 --> 00:08:32,602
LASER-CUT
FOR A HIGH-PRECISION FIT
164
00:08:32,603 --> 00:08:36,372
AGAINST THE WHEEL BEARING
HOUSING.
165
00:08:36,373 --> 00:08:39,977
THE TECHNICIAN HAMMERS ANOTHER
LOCATING FIXTURE IN PLACE
166
00:08:39,978 --> 00:08:42,511
BEFORE HE POSITIONS
THE LASER-CUT STEEL PIECE
167
00:08:42,512 --> 00:08:46,482
TO COMPLETE
THE UPRIGHT ASSEMBLY.
168
00:08:46,483 --> 00:08:48,117
USING A MIG WELDING TORCH,
169
00:08:48,118 --> 00:08:50,420
HE STARTS WELDING
THE PARTS TOGETHER,
170
00:08:50,421 --> 00:08:51,955
FOLLOWING A CONSISTENT PATTERN
171
00:08:51,956 --> 00:08:55,125
TO ENSURE THAT ALL JOINTS
ARE WELDED PROPERLY.
172
00:08:55,126 --> 00:08:58,396
THE PROCESS TAKES
ABOUT 20 MINUTES TO COMPLETE.
173
00:09:01,132 --> 00:09:04,266
AFTER WELDING,
THE UPRIGHT GOES FOR MACHINING
174
00:09:04,267 --> 00:09:07,238
TO ENSURE THE CORRECT BORE SIZE
FOR THE BEARING.
175
00:09:09,339 --> 00:09:11,373
MOUNTED ON A CNC LATHE,
176
00:09:11,374 --> 00:09:14,611
THE PIECE STARTS TURNING
COUNTERCLOCKWISE.
177
00:09:14,612 --> 00:09:16,380
A COOLING SPRAY
PREVENTS THE PIECE
178
00:09:16,381 --> 00:09:18,850
FROM OVERHEATING
WHILE THE HIGH-SPEED LATHE
179
00:09:18,851 --> 00:09:22,819
BORES A SOCKET FOR THE BEARING
INSIDE THE HOUSING.
180
00:09:22,820 --> 00:09:26,056
THE MACHINED UPRIGHT IS READY
FOR POWDER COATING.
181
00:09:28,158 --> 00:09:31,728
A TECHNICIAN ASSEMBLES
THE POWDER-COATED UPRIGHT.
182
00:09:31,729 --> 00:09:33,697
HE PLACES THE BEARING
IN THE HOUSING
183
00:09:33,698 --> 00:09:36,367
AND ACTIVATES
THE HYDRAULIC PRESS.
184
00:09:36,368 --> 00:09:37,736
THE POWER HEAD OF THE PRESS
185
00:09:37,737 --> 00:09:41,170
SLOWLY PUSHES THE BEARING
INTO THE HOUSING.
186
00:09:41,171 --> 00:09:44,274
THE PRESS IS EQUIPPED
WITH A CUSTOM ALUMINUM TOOLING,
187
00:09:44,275 --> 00:09:47,144
PRESSING ONLY ON THE OUTER
PORTION OF THE BEARING.
188
00:09:47,145 --> 00:09:49,979
IT USES LOW PRESSURE
TO AVOID DEFORMATION
189
00:09:49,980 --> 00:09:51,749
OF THE BEARING OR HOUSING.
190
00:09:54,286 --> 00:09:56,386
THE TECHNICIAN
TAKES A RETAINING RING
191
00:09:56,387 --> 00:09:58,288
DESIGNED TO SECURE THE BEARING
192
00:09:58,289 --> 00:10:01,657
AND INSERTS IT MANUALLY
INTO THE HOUSING.
193
00:10:01,658 --> 00:10:05,027
USING AN L-KEY TOOL,
HE PUSHES THE SPIRAL LOCK RING
194
00:10:05,028 --> 00:10:07,897
INTO THE HOUSING.
195
00:10:07,898 --> 00:10:10,733
CONTRARY TO SELF-LOCKING
RETAINING RINGS,
196
00:10:10,734 --> 00:10:12,501
THE SPIRAL RING SIMPLY POPS
197
00:10:12,502 --> 00:10:15,639
INTO A MACHINED GROOVE
IN THE HOUSING.
198
00:10:15,640 --> 00:10:17,675
♪♪
199
00:10:23,314 --> 00:10:25,482
ONCE THE BEARING IS LOCKED IN
FROM THE BACK
200
00:10:25,483 --> 00:10:26,882
WITH THE RETAINING RING,
201
00:10:26,883 --> 00:10:29,085
THE TECHNICIAN PLACES
THE BEARING SEAL
202
00:10:29,086 --> 00:10:31,722
ON THE FRONT SIDE
OF THE ASSEMBLY.
203
00:10:31,723 --> 00:10:34,924
HE POSITIONS AN ALUMINUM TOOLING
ON THE BEARING SEAL
204
00:10:34,925 --> 00:10:37,294
AND USES AN ARBOR PRESS
TO FIT IT TIGHTLY
205
00:10:37,295 --> 00:10:39,397
INTO THE UPRIGHT
ASSEMBLY HOUSING.
206
00:10:41,699 --> 00:10:44,132
THE SEAL KEEPS CONTAMINANTS
OUT OF THE BEARING
207
00:10:44,133 --> 00:10:47,104
TO ENSURE
MAXIMAL ROTATION SPEED.
208
00:10:49,272 --> 00:10:52,376
THE TECHNICIAN PLACES
THE DRIVE FLANGE ON THE JIG
209
00:10:52,377 --> 00:10:55,210
AND INSTALLS
THE UPRIGHT ON TOP.
210
00:10:55,211 --> 00:10:57,814
HE LOWERS THE POWER HEAD
AGAINST THE BEARING
211
00:10:57,815 --> 00:10:59,183
AND USES THE ARBOR PRESS
212
00:10:59,184 --> 00:11:02,718
TO PUSH THE DRIVE FLANGE
INTO THE WHEEL BEARING.
213
00:11:02,719 --> 00:11:05,021
THE TECHNICIAN THEN
REMOVES THE UPRIGHT ASSEMBLY
214
00:11:05,022 --> 00:11:06,791
FROM THE JIG.
215
00:11:08,825 --> 00:11:10,993
HERE,
YOU CAN SEE THE AXLE SPLINES
216
00:11:10,994 --> 00:11:12,396
DRIVEN THROUGH THE WHEEL BEARING
217
00:11:12,397 --> 00:11:16,299
BEFORE THE BEARING SEAL
IS INSTALLED.
218
00:11:16,300 --> 00:11:18,972
♪♪
♪♪
219
00:11:21,200 --> 00:11:24,734
Narrator: ASSEMBLING
AN ARIEL ATOM 3S STARTS
220
00:11:24,735 --> 00:11:27,271
WITH THE DOUBLE WISHBONE
FRONT SUSPENSION.
221
00:11:27,272 --> 00:11:29,208
THE AIR INTAKE HOOP
IS INTEGRATED
222
00:11:29,209 --> 00:11:31,309
INTO THE EXOSKELETON CHASSIS
223
00:11:31,310 --> 00:11:35,278
AS IS THE REAR SUBFRAME
HOUSING MODULE FOR THE ENGINE.
224
00:11:35,279 --> 00:11:38,049
♪♪
225
00:11:38,050 --> 00:11:40,651
AT THE TMI AUTOTECH
HEADQUARTERS,
226
00:11:40,652 --> 00:11:42,185
TWO ASSEMBLY TECHNICIANS
227
00:11:42,186 --> 00:11:45,023
SLIDE THE FIBERGLASS TUB
UNDERNEATH THE CHASSIS.
228
00:11:48,427 --> 00:11:50,695
THEY LIFT IT UP
AGAINST THE SIDE RAILS
229
00:11:50,696 --> 00:11:52,363
AND USE PRE-WELDED TABS
230
00:11:52,364 --> 00:11:55,734
TO MOUNT IT ON THE CHASSIS
WITH ASSEMBLY NUTS AND BOLTS.
231
00:12:00,239 --> 00:12:02,506
THE TECHNICIANS FIT
THE ALUMINUM FUEL TANK
232
00:12:02,507 --> 00:12:04,042
RIGHT BEHIND THE SEAT.
233
00:12:06,644 --> 00:12:08,912
THEY MAKE SURE
THE FUEL TANK IS LEVELED
234
00:12:08,913 --> 00:12:12,684
AND TAKE MEASUREMENTS TO ENSURE
THAT THE ENGINE FITS PROPERLY.
235
00:12:16,021 --> 00:12:17,253
USING MASKING TAPE
236
00:12:17,254 --> 00:12:19,924
TO AVOID SCRATCHING
THE POWDER-COATED CHASSIS,
237
00:12:19,925 --> 00:12:24,661
THEY FINE-TUNE
THE FUEL TANK'S POSITION.
238
00:12:24,662 --> 00:12:27,665
THEY THEN DRIVE ASSEMBLY BOLTS
THROUGH THE MOUNTING TABS
239
00:12:27,666 --> 00:12:29,432
TO HOLD THE TANK IN PLACE
240
00:12:29,433 --> 00:12:32,604
BEFORE USING A RATCHET
AND WRENCH TO TORQUE THE NUTS.
241
00:12:40,479 --> 00:12:43,513
NEXT, TECHNICIANS INSTALL
THE CHASSIS LOOM.
242
00:12:43,514 --> 00:12:45,315
IT'S AN ELECTRICAL HARNESS
THAT CONNECTS
243
00:12:45,316 --> 00:12:50,121
ALL THE ELECTRONIC COMPONENTS
TO A FUSE BOX.
244
00:12:50,122 --> 00:12:54,791
A TECHNICIAN INSTALLS
THE CHASSIS LOOM ON THE CAR.
245
00:12:54,792 --> 00:12:56,127
HE PLACES THE FUSE BOX
246
00:12:56,128 --> 00:12:59,829
IN THE FIBERGLASS BATTERY BOX
AT THE FRONT.
247
00:12:59,830 --> 00:13:02,566
HE THEN ROUTES THE HARNESS
ALONG THE CHASSIS
248
00:13:02,567 --> 00:13:06,304
USING PRE-WELDED LOCATIONAL TABS
AND TIE WRAPS.
249
00:13:23,755 --> 00:13:25,989
THE HARNESS ENDS
AT THE DASHBOARD,
250
00:13:25,990 --> 00:13:27,324
WHERE THE LOOM WILL CONNECT
251
00:13:27,325 --> 00:13:32,329
WITH THE DIGITAL DISPLAY UNIT
CONTROLLERS AND MONITORS.
252
00:13:32,330 --> 00:13:34,866
THE TECHNICIAN FASTENS
THE HARNESS TO THE CHASSIS
253
00:13:34,867 --> 00:13:36,635
WITH A TIE WRAP.
254
00:13:42,340 --> 00:13:44,108
USING AN OVERHEAD HOIST,
255
00:13:44,109 --> 00:13:46,578
TWO TECHNICIANS CAREFULLY LOWER
THE DRIVE TRAIN
256
00:13:46,579 --> 00:13:50,215
INTO THE ENGINE COMPARTMENT
OF THE REAR SUB-FRAME.
257
00:13:53,451 --> 00:13:55,085
WITH A HANDHELD TOOL,
258
00:13:55,086 --> 00:13:57,021
A TECHNICIAN DRIVES
AN ENDLESS SCREW
259
00:13:57,022 --> 00:14:00,291
TO ACTIVATE THE SPECIAL
TILTING MECHANISM OF THE HOIST.
260
00:14:00,292 --> 00:14:02,193
THIS SYSTEM
ALLOWS THE TECHNICIANS
261
00:14:02,194 --> 00:14:04,830
TO POSITION THE ENGINE
IN THE FRAME.
262
00:14:09,268 --> 00:14:11,136
ONCE THE DRIVE TRAIN
IS IN POSITION,
263
00:14:11,137 --> 00:14:13,138
THEY REMOVE THE HOIST.
264
00:14:15,441 --> 00:14:17,241
A TECHNICIAN
CONNECTS THE EXHAUST
265
00:14:17,242 --> 00:14:19,078
AND FORCED-INDUCTION
TURBOCHARGER
266
00:14:19,079 --> 00:14:23,248
TO THE SINGLE PORT MANIFOLD
OF THE ENGINE.
267
00:14:23,249 --> 00:14:25,382
HE BOLTS IT ONTO THE BACK
OF THE ENGINE
268
00:14:25,383 --> 00:14:29,353
USING A TORQUE WRENCH
TO TIGHTEN THE NUTS.
269
00:14:29,354 --> 00:14:34,257
HE NOW ASSEMBLES THE UPRIGHT
TO THE SUSPENSION.
270
00:14:34,258 --> 00:14:36,194
HE INSERTS BOLTS
THROUGH THE ROD ENDS
271
00:14:36,195 --> 00:14:38,161
OF THE LOWER SUSPENSION ARM.
272
00:14:38,162 --> 00:14:41,165
THE BOLTS ACT AS FIRM
AND PRECISE ATTACHMENT POINTS
273
00:14:41,166 --> 00:14:43,533
FOR THE UPRIGHT ASSEMBLY.
274
00:14:43,534 --> 00:14:46,103
THESE LOWER ROD ENDS
WILL ALSO AID IN THE ALIGNMENT
275
00:14:46,104 --> 00:14:47,840
OF THE VEHICLE SUSPENSION.
276
00:14:51,944 --> 00:14:54,179
THE TECHNICIAN NOW
TAKES THE DRIVE AXLE
277
00:14:54,180 --> 00:14:56,382
AND CONNECTS IT
TO THE TRANSMISSION.
278
00:14:59,951 --> 00:15:02,052
HE LOCKS THE AXLE IN
WITH A SNAP RING
279
00:15:02,053 --> 00:15:04,956
BEFORE CONNECTING THE UPRIGHT
TO THE DRIVE AXLE.
280
00:15:09,527 --> 00:15:12,061
THE TECHNICIAN THEN SCREWS ON
THE AXLE NUT
281
00:15:12,062 --> 00:15:13,631
AND COMPLETES THE ASSEMBLY
282
00:15:13,632 --> 00:15:16,635
BY BOLTING THE UPRIGHT
TO THE UPPER WISHBONE.
283
00:15:22,641 --> 00:15:25,110
NEXT, THE TECHNICIAN POSITIONS
THE FENDER STAY
284
00:15:25,111 --> 00:15:27,210
IN THE SUSPENSION ASSEMBLY,
285
00:15:27,211 --> 00:15:29,180
ALIGNING
THE PRE-WELDED MOUNTING TABS
286
00:15:29,181 --> 00:15:31,316
OF THE FENDER STAY
WITH THE UPRIGHT.
287
00:15:34,119 --> 00:15:36,052
HE THEN INSERTS ASSEMBLY BOLTS
288
00:15:36,053 --> 00:15:38,923
AND USES AN ELECTRIC
TORQUE WRENCH TO TIGHTEN THEM.
289
00:15:46,063 --> 00:15:47,732
THE TECHNICIAN NOW INSERTS
290
00:15:47,733 --> 00:15:49,601
THE VENTILATED
AND FLOATING BRAKE DISK
291
00:15:49,602 --> 00:15:50,869
ON THE WHEEL HUB.
292
00:15:53,004 --> 00:15:54,504
HE BOLTS A WHEEL NUT IN PLACE
293
00:15:54,505 --> 00:15:57,709
TO FACILITATE THE INSTALLATION
OF THE BRAKE CALIPER.
294
00:16:00,277 --> 00:16:01,478
NEXT, HE MOUNTS
295
00:16:01,479 --> 00:16:04,147
THE FOUR-PISTON BRAKE CALIPER
ON THE BRAKE DISK
296
00:16:04,148 --> 00:16:06,652
AND ATTACHES IT
TO THE UPRIGHT ASSEMBLY.
297
00:16:08,753 --> 00:16:10,988
THE TECHNICIAN INSERTS
A PAIR OF BRAKE PADS
298
00:16:10,989 --> 00:16:13,258
BETWEEN THE CALIPER
AND THE DISK.
299
00:16:16,728 --> 00:16:18,496
HE POSITIONS A BRACKET
300
00:16:18,497 --> 00:16:20,765
AND INSERTS A LOCK PIN
THROUGH THE CALIPER,
301
00:16:20,766 --> 00:16:23,369
SECURING THE BRAKE PADS
IN PLACE.
302
00:16:30,374 --> 00:16:33,444
THE TECHNICIAN FINALLY INSTALLS
THE PARKING BRAKE CALIPER
303
00:16:33,445 --> 00:16:36,047
ON THE REARWARD SIDE
OF THE BRAKE DISK.
304
00:16:40,417 --> 00:16:42,020
HE COMPLETES THE BRAKE ASSEMBLY
305
00:16:42,021 --> 00:16:44,488
BY BOLTING THE PARKING BRAKE
ON THE UPRIGHT
306
00:16:44,489 --> 00:16:47,792
USING AN ELECTRIC IMPACT WRENCH
TO TORQUE THE BOLTS.
307
00:16:52,163 --> 00:16:54,232
THE TECHNICIAN
NOW PREPARES TO INSTALL
308
00:16:54,233 --> 00:16:56,434
THE REAR SUSPENSION DAMPER.
309
00:16:56,435 --> 00:16:58,435
HE INSTALLS A FASTENER TO ATTACH
310
00:16:58,436 --> 00:17:01,439
THE UPPER PORTION OF THE DAMPER
TO THE CHASSIS
311
00:17:01,440 --> 00:17:04,743
AND INSERTS SPACERS ON THE LOWER
PORTION OF THE DAMPER.
312
00:17:07,544 --> 00:17:10,048
HE ATTACHES THE DAMPER
TO THE BELL CRANK,
313
00:17:10,049 --> 00:17:11,816
WHICH CONNECTS
THE SUSPENSION DAMPER
314
00:17:11,817 --> 00:17:14,051
TO THE LOWER WISHBONE ARM.
315
00:17:14,052 --> 00:17:17,420
FINALLY, HE INSTALLS
THE FIBERGLASS FENDER
316
00:17:17,421 --> 00:17:19,557
OVER THE UPRIGHT ASSEMBLY.
317
00:17:21,693 --> 00:17:23,696
♪♪
318
00:17:25,200 --> 00:17:27,101
♪♪
319
00:17:27,102 --> 00:17:30,571
Narrator: THE ATOM 3S FEATURES
A DISTINCTIVE AIR INTAKE SNORKEL
320
00:17:30,572 --> 00:17:31,738
EMBEDDED IN THE CHASSIS,
321
00:17:31,739 --> 00:17:33,306
TWO SIDE RADIATORS
322
00:17:33,307 --> 00:17:36,409
INTEGRATED WITH A TURBOCHARGER
INTERCOOLING SYSTEM
323
00:17:36,410 --> 00:17:37,512
AND A STAINLESS STEEL,
324
00:17:37,513 --> 00:17:41,347
CUSTOM-FABRICATED,
REPACKABLE EXHAUST.
325
00:17:41,348 --> 00:17:42,582
♪♪
326
00:17:42,583 --> 00:17:44,351
THE FABRICATION TECHNICIAN
327
00:17:44,352 --> 00:17:47,554
MOUNTS A FIVE-SPOKE MOTOR SPORT
WHEEL ON THE DRIVE FLANGE.
328
00:17:47,555 --> 00:17:48,822
HE TIGHTENS THE NUTS
329
00:17:48,823 --> 00:17:52,325
WITH AN ELECTRIC IMPACT
TORQUE WRENCH.
330
00:17:52,326 --> 00:17:55,696
A FIBERGLASS ENGINE COVER
PROTECTS THE ENGINE BLOCK.
331
00:17:55,697 --> 00:17:58,934
IT ALSO SERVES AS A BASE
FOR THE ENGINE COOLANT RESERVOIR
332
00:17:58,935 --> 00:18:00,567
AND THE WASHABLE AIR FILTER,
333
00:18:00,568 --> 00:18:05,072
WHICH IS SEALED
WITH THE INTAKE SNORKEL.
334
00:18:05,073 --> 00:18:07,274
THE TECHNICIAN INSTALLS
THE FRONT RADIATOR
335
00:18:07,275 --> 00:18:10,579
AND FAN ASSEMBLY
ON THE FRONT SUB-FRAME MODULE.
336
00:18:12,913 --> 00:18:14,081
HE MOUNTS THE RADIATOR
337
00:18:14,082 --> 00:18:16,315
ON BONDED RUBBER
INSULATION MOUNTS
338
00:18:16,316 --> 00:18:19,788
DESIGNED TO ABSORB
VIBRATIONS FROM THE ROAD.
339
00:18:24,624 --> 00:18:28,063
HE THEN CONNECTS THE RADIATOR
TO THE MAIN ELECTRICAL HARNESS.
340
00:18:30,597 --> 00:18:31,898
TWO TECHNICIANS INSTALL
341
00:18:31,899 --> 00:18:34,235
THE CUSTOM-MOLDED,
UPHOLSTERED SEAT COVER
342
00:18:34,236 --> 00:18:37,205
ON TOP OF THE FIBERGLASS BUCKET.
343
00:18:38,807 --> 00:18:41,908
THE COVER HAS BUILT-IN SLOTS
FOR THE GEAR SHIFT LEVER
344
00:18:41,909 --> 00:18:44,345
AND FOR THE HARNESS
ANCHOR POINTS.
345
00:18:46,647 --> 00:18:48,548
AT LAST,
A TECHNICIAN BRINGS IN
346
00:18:48,549 --> 00:18:51,317
THE AERODYNAMIC
FIBERGLASS SIDE POD
347
00:18:51,318 --> 00:18:55,087
AND POSITIONS IT ON TOP
OF THE SIDE RADIATOR.
348
00:18:55,088 --> 00:18:57,556
THE TECHNICIANS
FINALIZE THE ASSEMBLY
349
00:18:57,557 --> 00:18:59,092
WITH THE WIND SCREEN,
350
00:18:59,093 --> 00:19:00,994
THE FIBERGLASS NOSE AND HOOD,
351
00:19:00,995 --> 00:19:04,032
ALONG WITH THE FRONT WHEELS
AND FENDERS.
352
00:19:06,500 --> 00:19:08,568
BEFORE LEAVING
THE ASSEMBLY AREA,
353
00:19:08,569 --> 00:19:10,770
EACH CAR UNDERGOES
A SERIES OF TESTS
354
00:19:10,771 --> 00:19:13,605
ON A CHASSIS DYNAMOMETER,
OR DYNO.
355
00:19:13,606 --> 00:19:14,975
[ ENGINE REVS ]
356
00:19:14,976 --> 00:19:18,245
THE DYNO USES WHAT IS CALLED
THE SALVISBERG ROLLER
357
00:19:18,246 --> 00:19:21,081
TO MONITOR VARIOUS ASPECTS
OF THE CAR'S PERFORMANCE,
358
00:19:21,082 --> 00:19:24,518
SUCH AS ENGINE SPEED
AND LOAD CONTROL.
359
00:19:25,487 --> 00:19:26,888
IN A CONTROLLED ENVIRONMENT,
360
00:19:26,889 --> 00:19:29,856
THE ROLLERS ALLOW THE TECHNICIAN
TO FIRE UP THE ENGINE,
361
00:19:29,857 --> 00:19:33,427
BRINGING IT FROM IDLE
TO ALMOST 8,000 RPM.
362
00:19:38,531 --> 00:19:41,901
A DRIVER NOW TAKES THE FINISHED
CAR TO A TEST TRACK.
363
00:19:41,902 --> 00:19:43,804
THE DRIVER PAYS
SPECIAL ATTENTION
364
00:19:43,805 --> 00:19:47,406
TO THE CAR'S ACCELERATION,
BRAKING, AND CORNERING.
365
00:19:47,407 --> 00:19:49,575
HE ALSO LISTENS
FOR UNUSUAL SOUNDS
366
00:19:49,576 --> 00:19:52,446
OR ABNORMAL VIBRATIONS.
367
00:19:52,447 --> 00:19:55,917
THE TEST TRACK IS DESIGNED
TO PUT THE CAR TO THE TEST,
368
00:19:55,918 --> 00:19:59,352
WITH SHARP TURNS EXERTING
VERY HIGH CORNERING FORCES
369
00:19:59,353 --> 00:20:02,691
AND LONG, STRAIGHT STRETCHES
TO ASSESS THE ACCELERATION.
370
00:20:05,460 --> 00:20:07,060
AFTER A SERIES OF LAPS,
371
00:20:07,061 --> 00:20:10,797
THE CAR PULLS OFF THE ROAD
FOR A PIT STOP.
372
00:20:10,798 --> 00:20:12,833
TECHNICIANS VISUALLY INSPECT
THE CAR
373
00:20:12,834 --> 00:20:18,171
FOR LEAKS, LOOSE PARTS,
OR ANY AREAS OF CONCERN.
374
00:20:18,172 --> 00:20:20,774
THE TECHNICIANS ALSO MANUALLY
INSPECT THE CAR
375
00:20:20,775 --> 00:20:24,144
TO MAKE SURE NOTHING HAS COME
LOOSE DURING THE TEST LAPS.
376
00:20:26,279 --> 00:20:27,881
WITH THE TECHNICIANS' APPROVAL,
377
00:20:27,882 --> 00:20:29,681
THE DRIVER
HEADS BACK TO THE TRACK
378
00:20:29,682 --> 00:20:31,752
FOR A LAST TEST DRIVE.
379
00:20:35,021 --> 00:20:38,458
THIS ROAD-READY ATOM 3S FEATURES
A FRONT AIR FOIL
380
00:20:38,459 --> 00:20:39,825
FOR LIFT REDUCTION,
381
00:20:39,826 --> 00:20:42,229
SPECIAL 12-SPOKE WHEELS,
382
00:20:42,230 --> 00:20:44,498
AND A HONDA 2.4-LITER ENGINE
383
00:20:44,499 --> 00:20:48,402
TIGHTLY PACKED
UNDER A FIBERGLASS COVER.
384
00:20:48,403 --> 00:20:50,437
EQUIPPED
WITH A SIX-POINT HARNESS,
385
00:20:50,438 --> 00:20:52,040
A REMOVABLE STEERING WHEEL,
386
00:20:52,041 --> 00:20:53,774
AND TWO-PIECE SPRING DAMPERS,
387
00:20:53,775 --> 00:20:56,244
THIS HIGH-PERFORMANCE,
ROAD-LEGAL CAR
388
00:20:56,245 --> 00:20:58,478
HAS SEVERAL
RACE-INSPIRED FEATURES,
389
00:20:58,479 --> 00:21:00,980
SUCH AS
THE AERODYNAMIC SIDE PODS
390
00:21:00,981 --> 00:21:05,585
AND THE REAR AIR FOIL
FOR DRAG REDUCTION.
391
00:21:05,586 --> 00:21:07,120
A DRIVER NOW TAKES THE CAR
392
00:21:07,121 --> 00:21:10,390
FOR A TOUR
ON SMALL COUNTRY ROADS.
393
00:21:10,391 --> 00:21:11,658
ON A FLAT ROAD SURFACE,
394
00:21:11,659 --> 00:21:13,358
THE CAR IS WELL-BALANCED
395
00:21:13,359 --> 00:21:16,296
AND BITES SMOOTHLY
INTO THE CURVES.
396
00:21:16,297 --> 00:21:17,730
THIS CAR IS NOT DESIGNED
397
00:21:17,731 --> 00:21:20,200
FOR REGULAR,
INNER-CITY COMMUTERS.
398
00:21:20,201 --> 00:21:22,469
THE ARIEL ATOM 3S IS A CAR
399
00:21:22,470 --> 00:21:25,838
FOR DRIVING ENTHUSIASTS
TO ENJOY ON AN OPEN ROAD,
400
00:21:25,839 --> 00:21:27,841
WHERE THE FULL POTENTIAL
OF THIS SUPERCAR
401
00:21:27,842 --> 00:21:30,045
CAN BE PUT TO GOOD USE.
31343
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