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These are the user uploaded subtitles that are being translated: 1 00:00:00,300 --> 00:00:02,735 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:02,736 --> 00:00:04,535 THE ARIEL ATOM 3S, 3 00:00:04,536 --> 00:00:08,040 A SUPERCAR BUILT FOR THE TRACK BUT COMFORTABLE ON THE ROAD. 4 00:00:08,041 --> 00:00:11,041 -- Captions by VITAC -- www.vitac.com 5 00:00:11,042 --> 00:00:14,044 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:14,045 --> 00:00:17,083 ♪♪ 7 00:00:23,020 --> 00:00:24,923 THE 20,000-SQUARE-FOOT FACILITY 8 00:00:24,924 --> 00:00:27,292 LOCATED IN HALIFAX COUNTY, VIRGINIA, 9 00:00:27,293 --> 00:00:31,595 HOUSES THE TMI AUTOTECH HEADQUARTERS. 10 00:00:31,596 --> 00:00:33,331 THIS IS WHERE HIGHLY SKILLED WORKERS 11 00:00:33,332 --> 00:00:37,102 ASSEMBLE THE ARIEL ATOM 3S. 12 00:00:37,103 --> 00:00:38,837 FOR THE FINAL ASSEMBLY STEP, 13 00:00:38,838 --> 00:00:41,340 EACH UNIT IS ASSIGNED TO ONE TECHNICIAN 14 00:00:41,341 --> 00:00:45,042 WHO COMPLETES THE MONTH-LONG MANUFACTURING PROCESS. 15 00:00:45,043 --> 00:00:48,311 TECHNICIANS WORK SIDE BY SIDE ON FIVE UNITS 16 00:00:48,312 --> 00:00:52,115 AT DIFFERENT STAGES OF THE ASSEMBLY PROCESS. 17 00:00:52,116 --> 00:00:53,518 IT TAKES ABOUT 4 WEEKS 18 00:00:53,519 --> 00:00:55,853 TO GET FROM THE BARE, POWDER-COATED CHASSIS 19 00:00:55,854 --> 00:00:58,822 TO THE ASSEMBLED EXOSKELETON OF THE CAR, 20 00:00:58,823 --> 00:01:02,560 WHICH IS FITTED WITH A FIBERGLASS BASE. 21 00:01:02,561 --> 00:01:06,129 THE BASE HOLDS A LAMINATED SAFETY GLASS WINDSHIELD, 22 00:01:06,130 --> 00:01:08,099 A FRONT-MOUNTED ALUMINUM RADIATOR, 23 00:01:08,100 --> 00:01:11,334 AND FIVE-SPOKE RACE MOTOR SPORT WHEELS. 24 00:01:11,335 --> 00:01:14,671 THIS 3S COMES EQUIPPED WITH HIGH-OUTPUT HEADLIGHTS, 25 00:01:14,672 --> 00:01:17,740 A PUSH-ROD AND ROCKER-ARM REAR SUSPENSION SYSTEM, 26 00:01:17,741 --> 00:01:21,111 SPECIAL 12-SPOKE RIMS, 27 00:01:21,112 --> 00:01:25,582 AND LOADED WITH A 365-HORSEPOWER ENGINE. 28 00:01:25,583 --> 00:01:27,418 THE TWO IN-FRONT SUSPENSION DAMPERS 29 00:01:27,419 --> 00:01:29,455 ALLOW THE CAR TO BEND INTO CURVES 30 00:01:29,456 --> 00:01:32,390 RATHER THAN DARTING INTO THEM. 31 00:01:32,391 --> 00:01:35,525 ♪♪ 32 00:01:35,526 --> 00:01:39,564 A MECHANICAL ENGINEER REVIEWS THE ATOM'S EXOSKELETON DESIGN, 33 00:01:39,565 --> 00:01:40,833 USING A CAD SOFTWARE 34 00:01:40,834 --> 00:01:44,569 TO STUDY A 3-D MODEL OF THE CHASSIS. 35 00:01:44,570 --> 00:01:46,938 HE GOES OVER THE WELDING SPECIFICATIONS 36 00:01:46,939 --> 00:01:53,043 FOR ALL 183 INDIVIDUAL PIECES COMPRISING THE CHASSIS. 37 00:01:53,044 --> 00:01:55,780 A FABRICATION TECHNICIAN ASSEMBLES THE CHASSIS 38 00:01:55,781 --> 00:01:58,281 ON A MODULAR FIXTURE TABLE. 39 00:01:58,282 --> 00:02:00,817 HE POSITIONS THE MACHINED ALUMINUM JIG 40 00:02:00,818 --> 00:02:03,153 AND SECURES IT IN PLACE. 41 00:02:03,154 --> 00:02:05,189 THIS KEEPS THE CHASSIS TUBE STABLE 42 00:02:05,190 --> 00:02:08,191 DURING THE WELDING PROCESS. 43 00:02:08,192 --> 00:02:10,394 THE TECHNICIAN BRINGS IN A ROLLED STEEL TUBE, 44 00:02:10,395 --> 00:02:13,565 WHICH WILL FORM THE RIGHT UPPER SIDE RAIL OF THE CHASSIS. 45 00:02:16,702 --> 00:02:19,904 HE PLACES THE TUBE FLUSH AGAINST THE FRONT-END MODULE 46 00:02:19,905 --> 00:02:25,108 BEFORE HE POSITIONS ANOTHER TUBE ACROSS THE FRAME. 47 00:02:25,109 --> 00:02:29,547 THE ENTIRE CHASSIS IS BUILT USING MILD STEEL. 48 00:02:29,548 --> 00:02:31,849 THE ELECTRIC RESISTANCE WELDING PROCESS 49 00:02:31,850 --> 00:02:34,452 INCREASES THE STRENGTH AND HARDNESS OF THE STEEL 50 00:02:34,453 --> 00:02:37,922 WHILE DECREASING ITS DUCTILITY. 51 00:02:37,923 --> 00:02:40,793 THE ROLLED STEEL IS FORMED INTO A ROUND TUBE 52 00:02:40,794 --> 00:02:44,696 AND CLOSED USING A FLASH BUTT WELDING TECHNIQUE. 53 00:02:44,697 --> 00:02:47,064 THE TUBE IS THEN DRAWN OVER A MANDREL 54 00:02:47,065 --> 00:02:49,801 TO REMOVE THE WELD SEAM. 55 00:02:49,802 --> 00:02:51,969 THIS PROCESS MAKES THE CHASSIS STIFFER 56 00:02:51,970 --> 00:02:53,470 AND MORE RESISTANT, 57 00:02:53,471 --> 00:02:56,141 LEAVING THE TUBING VIRTUALLY SEAMLESS. 58 00:02:58,709 --> 00:03:01,045 THE TECHNICIAN BRINGS IN THE SIDE RAIL, 59 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. 61 00:03:10,088 --> 00:03:12,857 IT TAKES ABOUT A DAY TO TACK THE ENTIRE CHASSIS 62 00:03:12,858 --> 00:03:15,127 BEFORE IT'S READY FOR FINISH WELDING. 63 00:03:18,197 --> 00:03:20,699 A WELDER STARTS ON THE BASE OF A CHASSIS TUBE 64 00:03:20,700 --> 00:03:22,499 USING A TIG WELDING TORCH 65 00:03:22,500 --> 00:03:24,737 AND A SILICON BRONZE ROD. 66 00:03:28,406 --> 00:03:31,108 NEXT, HE TAKES SMALL LASER-CUT STEEL PARTS 67 00:03:31,109 --> 00:03:34,712 THAT HAVE BEEN ENGINEERED TO MAKE CHASSIS BRACKETS. 68 00:03:34,713 --> 00:03:37,881 HE PLACES THE PIECES ON A ROTATING WELDING FIXTURE, 69 00:03:37,882 --> 00:03:39,215 CLAMPS THEM FIRMLY, 70 00:03:39,216 --> 00:03:44,856 AND WELDS THEM USING A SMALL SILICON BRONZE TIG ROD. 71 00:03:44,857 --> 00:03:47,091 THE MELTING POINT OF SILICON BRONZE 72 00:03:47,092 --> 00:03:49,859 IS AROUND 1,800 DEGREES FAHRENHEIT, 73 00:03:49,860 --> 00:03:53,430 ABOUT 700 DEGREES BELOW THE MELTING POINT OF STEEL. 74 00:03:53,431 --> 00:03:56,299 SILICON BRONZE WELDING REQUIRES LESS HEAT. 75 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, 77 00:04:01,141 --> 00:04:03,975 WHICH COULD THEN BRITTLE OR CRACK. 78 00:04:03,976 --> 00:04:06,812 THE WELDER PUTS THE PIECE ON AN ALUMINUM BLOCK 79 00:04:06,813 --> 00:04:09,781 AND SECURES IT WITH CUSTOMIZED FIXTURES. 80 00:04:12,618 --> 00:04:15,955 HE PLACES ANOTHER LASER-CUT STEEL PIECE ON THE BLOCK. 81 00:04:18,556 --> 00:04:22,360 HE USES A FIXTURE TO HOLD IT IN PLACE. 82 00:04:24,629 --> 00:04:27,798 THIS TIME, HE USES A STEEL FILLER ROD 83 00:04:27,799 --> 00:04:29,834 BECAUSE THIS PARTICULAR WELDING SEAM 84 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, 87 00:04:39,845 --> 00:04:43,548 THE WELDER POSITIONS THE BRACKET ON THE FRAME. 88 00:04:43,549 --> 00:04:47,084 HE SECURES THE FIXTURE IN PLACE BY DRIVING ITS THREADED HEAD 89 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. 94 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 103 00:05:33,765 --> 00:05:37,002 AND AN EMBEDDED STEERING COLUMN WELDED INTO THE CHASSIS. 104 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 107 00:05:45,202 --> 00:05:48,138 IS A DISTINCTIVE PART OF THE ARIEL ATOM. 108 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 110 00:05:52,442 --> 00:05:56,312 AND MIG-WELDED MOUNTING TABS FOR BETTER RESISTANCE. 111 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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