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

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GERMANY'S
MOST ICONIC SPORTS CAR --

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THE PORSCHE 911.

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

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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

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THE SIXTH LARGEST CITY
IN GERMANY -- STUTTGART --

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IS KNOWN AS THE CRADLE
OF THE AUTOMOBILE.

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HERE, THE PORSCHE FAMILY
DESIGNS AND ASSEMBLES

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SOME OF THE MOST FAMOUS
SPORTS CARS ON THE PLANET.

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3,000 EMPLOYEES WORK
TO MANUFACTURE

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PORSCHE'S MOST CELEBRATED CAR --
THE 911 COUPE.

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IN 1963,
FERDINAND ALEXANDER PORSCHE

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DESIGNED THE ORIGINAL 911
TO BE CALLED THE 901,

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BUT THERE WAS A LITTLE
COMPETITION --

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AN EXISTING MODEL
FROM A COMPETING AUTOMAKER

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FORCED PORSCHE
TO RENAME THE CAR THE 911.

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BY 1964, THE PORSCHE 911

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WAS THE MOST DYNAMIC SPORTS CAR
OF THE PERIOD.

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THIS CAR IS THE RESULT
OF A LONG HISTORY,

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WITH THE CREATION
OF THE 1939 TYPE 64 --

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A MODEL WITH
AN ALL-ALUMINUM CHASSIS

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WHOSE FINAL VERSION
NEVER EMERGED.

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PORSCHE CONSIDERS IT

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THE GRANDFATHER
OF ALL THEIR CARS.

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SINCE THE BEGINNING, THE COMPANY
HAS CREATED SPORTS CARS

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AND CARS SPECIFICALLY
FOR MOTOR SPORTS.

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THIS 911 IS THE MOST
SOPHISTICATED MODEL EVER BUILT,

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WITH FUTURISTIC DESIGN,
ADVANCED TECHNOLOGIES,

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IMPROVED ENGINE PERFORMANCE,
AND A LIGHTWEIGHT BODY.

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IT'S A SUPERCAR THAT EPITOMIZES

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TRADITION, INNOVATION,
AND A RACING PEDIGREE.

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THE 911 STARTS WITH
THE BODYSHELL ASSEMBLY,

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WHERE THE CHASSIS IS MADE
WITH MILD STEEL AND ALUMINUM.

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PRODUCTION ISLANDS WITH
WELD-AND-TRANSFER ROBOTS

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PUT TOGETHER
THE LARGEST PARTS --

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NOTABLY, THE BASE
OF THE ENGINE BAY.

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THE THREE ROBOTS
ARE PROGRAMMED TO WORK ON

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ALL VARIANTS OF THE MODEL.

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TWO WORKERS VERIFY THE QUALITY
OF THE SPOT WELDING.

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INSPECTING EACH WELD,
THEY EXECUTE NECESSARY CHANGES,

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AS WELL AS MEASURE THE DISTANCE
BETWEEN THE PARTS.

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WHEN THE WORKERS COMPLETE
THEIR ASSESSMENT,

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ROBOTS MOVE THE PARTS
TO ANOTHER WORKSTATION.

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THE CAR'S BODYSHELL SIDE PANELS

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MOVE VIA A CONVEYOR LIFT
TO A WELDING STATION.

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A WORKER INSTALLS THE PANELS
INTO A SECURE SECTION

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WHERE ROBOTS WELD THE PARTS
WITH PRECISION.

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SINCE THE CAR'S CHASSIS
IS A MonoKote STRUCTURE

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RATHER THAN
A TRADITIONAL CHASSIS,

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THE SIDE PANELS ARE ATTACHED
WITH THE BASE ALREADY COMPLETE.

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AUTOMATED GUIDES
HOLD THE PANELS IN PLACE

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WHILE THEY ARE WELDED
TO THE BASE.

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THE BODYSHELL ASSEMBLY LINE
DELIVERS THE DOORS,

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AND WELD ROBOTS SECURE THEM

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BY PRECISELY WELDING
THE HINGES TO THE BODY.

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HOWEVER, IT'S ONLY TEMPORARY,

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SINCE THE DOORS WILL BE TAKEN
AWAY AFTER THE PAINTING PROCESS,

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ONLY TO BE REATTACHED
ON THE VEHICLE ASSEMBLY LINE.

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OTHER FRAME PARTS
IN THE CAR'S ROOFTOP

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ARE WELDED
TO THE VEHICLE PLATFORM

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IN THIS AUTOMATED
ASSEMBLY SECTION.

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AN AUTOMATED LIFT MOVES
THE SKELETAL BODY OF THE CAR

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TO ANOTHER STATION
FOR TREATMENT AND INSPECTION.

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WORKERS INSPECT THE BODY

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AND VERIFY THE STRENGTH AND
QUALITY OF THE MACHINED WELDS.

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AFTERWARD,
THE STRUCTURE IS TAKEN

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BY AN OVERHEAD CONVEYOR LIFT

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TO ANOTHER ASSEMBLY LINE
FOR PARTS AND CLEANING.

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AT THIS STAGE,
WORKERS INSTALL THE HOOD COVER

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AND CARRY OUT MANUAL CLEANING.

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USING SOFT CLOTHS
AND SPECIAL CLEANING AGENTS,

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WORKERS ELIMINATE
ANY CONSTRUCTION DUST

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ALONG THE BODY'S SURFACE.

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THE FRAME,
WEIGHING 80 POUNDS LESS

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THAN THE PREVIOUS GENERATION'S
CHASSIS,

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IS MOVED BY A TRANSFER LIFTER
TO THE PAINT SHOP.

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THE PAINTING PROCESS BEGINS
BY DIPPING THE BODY

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INTO A BATH
OF CATHODIC DIP PRIMER.

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CATHODIC PAINT ENHANCES

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THE CORROSION RESISTANCE
OF THE CAR'S STRUCTURE,

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BRINGING THE BODY CLOSER
TO AN IMMUNE STATE.

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NEXT, A HIGH-PRESSURE SHOWER
RINSES THE FRAME

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TO REMOVE ANY EXCESS PAINT

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BEFORE THE FRAME DIPS INTO
THE PRIMER TREATMENT AGAIN.

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SEVEN CONSECUTIVE
PRIMER BATHS ARE EMPLOYED

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TO SHIELD THE CAR'S BODYSHELL
FROM RUST

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AND OTHER ENVIRONMENTAL DAMAGE.

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BY FLIPPING AND RETURNING
THE BODY INTO THE BASIN,

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THE PRIMER PAINT
IS GUARANTEED TO REACH

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EVERY CAVITY AND CORNER.

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IT ALSO ELIMINATES ANY STREAKS

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THAT MIGHT DEVELOP
AT INTERSECTIONS.

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AFTER THE PAINT IS CURED
IN A 30-MINUTE DRYING PROCEDURE,

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THE STRUCTURE MOVES
INTO ANOTHER ROOM

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WHERE PAINT ROBOTS UNDERSEAL
WITH SEAM-SEALING PAINT,

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WHICH CONSISTS OF A PVC COATING.

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THIS LAYER OF PROTECTION
WATERPROOFS ALL SEALS

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AND ELIMINATES ADDITIONAL
POSSIBILITIES OF CORROSION.

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IN ANOTHER PAINT ROOM, THE BODY
RECEIVES A FILLER COATING.

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PAINT ROBOTS
APPLY THIS BASE COAT,

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WHICH SERVES TO PROTECT THE BODY
FROM FLYING STONES.

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THE FILLER-COATING COLOR
IS SELECTED BY THE CUSTOMER.

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ALL PAINT COLORS CAN BE
REPRODUCED AT AN ADDED COST.

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THE STRUCTURE
REQUIRES EIGHT LAYERS

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OF THE ENVIRONMENT-FRIENDLY,
WATER-BASED FILLER COATING

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FOR FULL COVERAGE.

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ONCE THE PAINT IS CURED,

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THE BODYSHELL MOVES
TO ANOTHER AREA

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WHERE ROBOTS APPLY
TWO SOLVENT-BASED CLEAR COATS

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TO PROVIDE PROTECTION
AGAINST SCRAPES AND SCRATCHES.

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A WORKER WEARING
PROTECTIVE GLOVES

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TO AVOID ANY CONTACT
WITH THE NEW PAINT

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INSTALLS THE COMPANY'S CREST
ON THE HOOD

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WITH A SPECIALLY CRAFTED CLAMP,

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REVEALING THE SYMBOL
OF STUTTGART'S PRIDE.

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Narrator:
THE APPEAL OF THE PORSCHE 911
IS THE SILHOUETTE,

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BUT THE EXCITEMENT IS FROM
A SIX-CYLINDER FLAT ENGINE

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PRODUCING 350 HORSEPOWER --

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MORE THAN ENOUGH DRIVING FORCE
FOR ANY ROAD.

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A WORKER DELIVERS
PRE-PICKED ENGINE COMPONENTS

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SUCH AS THE CRANKCASE,
THE CRANKSHAFT, AND PISTONS.

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USING A ROD-CONNECTING MACHINE,

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A WORKER ASSEMBLES PISTON RODS
TO HEADS FOR A PERFECT MATCH.

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A LEAK-PROOF RING
SURROUNDS EACH PISTON HEAD.

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THE WORKER GENTLY SLIDES
THE COMBINED UNIT

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INTO THE CYLINDER BLOCK
OF THE CRANKCASE.

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ONCE ALL THE PISTONS ARE SET,

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THE CYLINDER BLOCK
MOVES TO A NEW WORKSTATION.

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WITH THE AID
OF A LIFTING DEVICE,

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A WORKER LOWERS THE CRANKSHAFT
ONTO A WORKTABLE.

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USING LUBRICATED CLAMPS,
HE INSTALLS AND FASTENS

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THE CONNECTING RODS OF EACH
PISTON TO THE CRANKSHAFT

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USING AN AIR-IMPACT SCREWDRIVER.

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AFTER SECURING THE PISTON RODS,

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THE WORKER ADDS METAL TIMING
CHAINS TO THE CRANKSHAFT.

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TOO HEAVY TO HANDLE MANUALLY,
USING A MECHANIZED LIFTER,

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A WORKER LOWERS THE CRANKSHAFT

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INTO THE CASING
OF THE CRANKCASE,

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FIRMLY ATTACHING IT
INTO POSITION.

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HE ALSO CHECKS THAT
ALL MOVING PARTS ARE FUNCTIONAL.

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AS THE TWO SEPARATE CASES
OF THE CRANKCASE

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ROLL INTO A CONTAINMENT ROOM,

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TRANSFER ROBOTS RAISE ONE PART
ONTO THE OTHER.

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THE TWO PARTS ARE
PRECISELY ALIGNED AND LINKED.

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THE SIX PISTONS ARE NOW IN

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HORIZONTALLY OPPOSITE POSITIONS
OF ONE ANOTHER.

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A WORKER SHIFTS
THE NEW ENGINE BLOCK

148
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INTO A CARRIER
CALLED A CROSSMEMBER,

149
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WHICH TRANSPORTS THE ENGINE
TO SELECT STATIONS

150
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FOR FURTHER ASSEMBLY.

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IN THE NEXT CIRCUIT, A WORKER
INSTALLS A CYLINDER HEAD GASKET

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ONTO THE ENGINE BLOCK,

153
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WHICH WILL EXIST BETWEEN
THE TWO HOUSING PARTS.

154
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THE ACCOMPANYING
CYLINDER-HEAD SECTION,

155
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WHICH HOUSES THE CAMSHAFT,

156
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IS PRECISELY FASTENED INTO PLACE
WITH AN AIR-IMPACT WRENCH.

157
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THE WORKER
ROTATES THE ENGINE BLOCK

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AND INSTALLS
A SECOND CYLINDER HEAD GASKET

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ONTO THE OTHER END
OF THE ENGINE BLOCK.

160
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HE LOWERS ANOTHER LARGE PIECE
OF THE ENGINE BLOCK

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WITH THE HELP
OF A LIFTING DEVICE.

162
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THE WORKER ALSO PUTS LARGE BOLTS
INTO SPECIFIC POSITIONS

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BEFORE SENDING
THE NEAR-COMPLETE ENGINE

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TO ANOTHER SECTION
INVOLVING MORE AUTOMATION.

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ON THE CROSSMEMBER,

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THE ENGINE BLOCK SHUTTLES
TO A NEW WORKSTATION.

167
00:10:04,458 --> 00:10:08,053
AFTER THE DOUBLE-OVERHEAD
CAMSHAFT IS COMPLETE,

168
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A ROBOT INSTALLS
AND FASTENS A COVER.

169
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EACH SCREW IS CAREFULLY
PUT INTO PLACE

170
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AND TURNED
BY A MEASURED ROTATION.

171
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THE TURNING POWER
IS EXTREMELY PRECISE

172
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FOR A WELL-SEALED COMPLETION,

173
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AVOIDING ANY UNNECESSARY
TIGHTNESS OR DAMAGE.

174
00:10:30,336 --> 00:10:33,496
THE ENTIRE ENGINE ASSEMBLY
ROTATES

175
00:10:33,498 --> 00:10:35,156
AND IS SET TO A NEW POSITION

176
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BEFORE ENTERING A CABINET
FOR A COLD TEST.

177
00:10:42,224 --> 00:10:45,751
THIS ASSESSMENT DEVICE CHECKS
THE NEW ENGINE WITH A LEAK TEST,

178
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FLOW TEST, AND PRESSURE TEST

179
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BY SIMULATING ITS FUNCTION
WITH THE ASSISTANCE

180
00:10:51,075 --> 00:10:52,174
OF AN AUTOMATED AIR PUMP.

181
00:10:55,638 --> 00:10:57,838
WHEN THE TESTS ARE SUCCESSFUL,

182
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THE CENTRAL PART
OF THE FLAT ENGINE IS COMPLETE.

183
00:11:02,437 --> 00:11:05,163
THE INSTALLATION OF TUBING
IS NEXT.

184
00:11:05,165 --> 00:11:06,897
PLACEMENT
OF THE INTAKE MANIFOLD,

185
00:11:06,899 --> 00:11:09,259
FOLLOWED BY EXHAUST MANIFOLD,

186
00:11:09,261 --> 00:11:13,155
COMPLETE THE 3.4-LITER
V6 ENGINE ASSEMBLY.

187
00:11:17,986 --> 00:11:20,246
AT THE END OF THE LINE,

188
00:11:20,248 --> 00:11:23,582
A WORKER TRANSFERS THE MOTOR
TO A ROBOTIC CART.

189
00:11:23,584 --> 00:11:26,477
USING GUIDANCE SIGNALS,
THE CART TRAVELS

190
00:11:26,479 --> 00:11:29,305
TO THE PORSCHE 911
VEHICLE ASSEMBLY LINE.

191
00:11:39,758 --> 00:11:44,786
Narrator:
THE INTERIOR OF THE PORSCHE 911
IS IMPRESSIVELY SOPHISTICATED,

192
00:11:44,788 --> 00:11:48,581
SUITED WITH THE FINEST LEATHER
IN A VARIETY OF COLORS.

193
00:11:48,583 --> 00:11:52,111
THE CAR'S INTERIOR IS DESIGNED
TO SUIT ANY CUSTOMER'S TASTE.

194
00:11:54,807 --> 00:11:56,941
IN THE UPHOLSTERY SHOP,

195
00:11:56,943 --> 00:12:00,269
LEATHER COLOR IS CHOSEN
ACCORDING TO CUSTOMER CHOICE.

196
00:12:00,271 --> 00:12:02,663
MANUFACTURER-APPROVED COWHIDE,

197
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BOUGHT FROM CERTIFIED
CATTLE HERDS,

198
00:12:04,667 --> 00:12:07,126
SITS ON
AN OPTICAL SCANNING TABLE

199
00:12:07,128 --> 00:12:08,928
WHICH REMOVES ANY WRINKLES.

200
00:12:08,930 --> 00:12:13,358
WITHIN SECONDS, RECOGNITION
BY A HIGH-DEFINITION CAMERA

201
00:12:13,360 --> 00:12:17,154
ASSESSES THE LEATHER'S SIZE,
HOLES, AND MARKS IN DETAIL.

202
00:12:17,156 --> 00:12:22,209
USING A SPECIAL MOUSE,
THE WORKER MARKS DEFECTS

203
00:12:22,211 --> 00:12:25,746
AND TRACES THOSE AREAS
FOR FURTHER RECOGNITION.

204
00:12:25,748 --> 00:12:28,107
THIS ELIMINATES ANY
IMPERFECTIONS

205
00:12:28,109 --> 00:12:31,369
AND IS ESSENTIAL TO CUTTING
THE LEATHER INTO PIECES.

206
00:12:31,371 --> 00:12:34,764
THE CAR INTERIOR REQUIRES
THE LEATHER OF FIVE COWS,

207
00:12:34,766 --> 00:12:39,961
AND IN THIS PROCESS,
40% OF THE LEATHER IS DISCARDED.

208
00:12:45,060 --> 00:12:49,854
ONCE COMPLETE, THE WORKER
PLACES A CODE ON THE SKIN

209
00:12:49,856 --> 00:12:53,784
FOR IDENTIFICATION
IN THE NEXT PROCESS.

210
00:12:53,786 --> 00:12:58,180
A WORKER SPREADS THE LEATHER
ON AN AUTOMATED CUTTING TABLE.

211
00:12:58,182 --> 00:13:00,208
WITH THE IDENTIFICATION CODE,

212
00:13:00,210 --> 00:13:04,604
THE LEATHER WILL BE CUT
INTO PATTERNED PIECES.

213
00:13:04,606 --> 00:13:07,999
THE COMPUTERIZED SYSTEM CONFIRMS
THE CUTTING OF ALL PIECES

214
00:13:08,001 --> 00:13:11,328
WITH PRECISE CUSTOMIZATION.

215
00:13:11,330 --> 00:13:14,665
ON THE CUTTING TABLE,
A VERY SMALL ecoJET

216
00:13:14,667 --> 00:13:16,758
SPRAYS WATER AT A HIGH PRESSURE,

217
00:13:16,760 --> 00:13:19,887
REPEATEDLY CREATING
CONTOURS AND OUTLINES

218
00:13:19,889 --> 00:13:22,957
WITHOUT TEARING
OR DAMAGING THE LEATHER.

219
00:13:33,044 --> 00:13:36,504
THE WORKER REMOVES
ANY RESIDUE OR REMAINS,

220
00:13:36,506 --> 00:13:38,039
KEEPING THE PATTERNED PIECES

221
00:13:38,041 --> 00:13:41,568
SLICED BY THE ecoJET
LEATHER CUTTER.

222
00:13:41,570 --> 00:13:43,369
WEARING WHITE GLOVES
AND USING A SPATULA

223
00:13:43,371 --> 00:13:46,030
TO AVOID ANY WEAR
ON THE MATERIAL,

224
00:13:46,032 --> 00:13:48,926
HE STACKS EACH NEW PIECE
WITH OTHERS

225
00:13:48,928 --> 00:13:52,488
TO SEND TO THE SEWING ROOM.

226
00:13:55,860 --> 00:13:58,986
USING INDUSTRIAL
SEWING MACHINES,

227
00:13:58,988 --> 00:14:02,515
SKILLED GARMENT WORKERS STITCH
THE PIECES OF LEATHER TOGETHER

228
00:14:02,517 --> 00:14:05,443
WITH HIGH-STRENGTH
NEEDLES AND THREAD.

229
00:14:05,445 --> 00:14:07,845
THE THREAD COLORS
OFTEN MATCH OR CONTRAST

230
00:14:07,847 --> 00:14:10,807
THE PIGMENT
OF THE LEATHER CUTOUTS.

231
00:14:12,478 --> 00:14:15,537
A WORKER PLACES
THE UPPER UNIT OF THE DASHBOARD

232
00:14:15,539 --> 00:14:17,331
AND ITS LEATHER COUNTERPARTS,

233
00:14:17,333 --> 00:14:19,733
INFUSED WITH HIGH-STRENGTH
BONDING GLUE,

234
00:14:19,735 --> 00:14:21,994
ONTO A CASTING UNIT.

235
00:14:21,996 --> 00:14:23,863
LOWERING A PRESSING DEVICE,

236
00:14:23,865 --> 00:14:27,225
IT ESTABLISHES
A MARRIAGE OF THE MATERIALS.

237
00:14:27,227 --> 00:14:30,219
ENSURING THAT EACH SECTION OF
THE LEATHER IS PROPERLY FITTED,

238
00:14:30,221 --> 00:14:34,149
THE WORKER PULLS THE MATERIAL
TO SMOOTH IT ON ALL SIDES,

239
00:14:34,151 --> 00:14:37,944
MATCHING THE SEAMS TO THE FRAME.

240
00:14:37,946 --> 00:14:41,573
PRECISION FINISHING TOOLS,
LIKE A DIRECTIONAL HEATER,

241
00:14:41,575 --> 00:14:44,642
CERTIFY THAT THE LEATHER
IS PERFECTLY JOINED

242
00:14:44,644 --> 00:14:47,304
INTO EVERY CAVITY OF THE
DASHBOARD FRAME

243
00:14:47,306 --> 00:14:49,599
WITHOUT OVERLOOKING
ANY IMPERFECTIONS.

244
00:14:52,170 --> 00:14:54,628
THE WORKER PLACES
THE DASHBOARD PART

245
00:14:54,630 --> 00:14:58,658
INTO A SPECIAL KILN
TO FULLY DRY THE ADHESIVE

246
00:14:58,660 --> 00:15:00,426
AND PERFECTLY JOIN
THE MATERIALS.

247
00:15:02,989 --> 00:15:07,317
WHEN DRIED, THE UNIT TRAVELS
TO A NEW WORKSTATION.

248
00:15:07,319 --> 00:15:11,446
A WORKER PLACES
A REAR PLASTIC PANEL

249
00:15:11,448 --> 00:15:14,307
ONTO THE INSIDE OF
THE LEATHER-BOUND DASHBOARD.

250
00:15:14,309 --> 00:15:17,011
AN AUTOMATED COVER
CONTAINS THE AREA

251
00:15:17,013 --> 00:15:21,473
WHILE A BONDING DEVICE BRACES
THE PARTS WITH FASTENING TIES.

252
00:15:21,475 --> 00:15:24,134
THE SHAPE AND CONSTRUCTION
OF THE UPPER DASHBOARD

253
00:15:24,136 --> 00:15:27,730
MAKE INSTALLING THE CAR'S
DIALS AND SWITCHES EASY.

254
00:15:31,361 --> 00:15:35,221
ONCE THE FULLY UPHOLSTERED
DASHBOARD IS PARTIALLY EQUIPPED,

255
00:15:35,223 --> 00:15:38,091
WORKERS SECURELY INSTALL IT
INTO THE COCKPIT

256
00:15:38,093 --> 00:15:41,987
USING A MECHANICAL LIFTER
AND AIR-IMPACT SCREWDRIVERS.

257
00:15:43,616 --> 00:15:47,509
THE CAR'S BODY MOVES ALONG
THE VEHICLE ASSEMBLY LINE,

258
00:15:47,511 --> 00:15:49,779
PROTECTED BY VINYL COVERINGS.

259
00:15:51,974 --> 00:15:53,974
AND WITHOUT THE DOORS,

260
00:15:53,976 --> 00:15:57,503
INTERIOR INSTALLATION WORK
IS MUCH EASIER TO EXECUTE,

261
00:15:57,505 --> 00:15:59,931
LIKE PLACING A GLASS SUNROOF.

262
00:16:01,634 --> 00:16:04,127
TWO WINDOW-ASSEMBLY ROBOTS
ARE RESPONSIBLE

263
00:16:04,129 --> 00:16:07,990
FOR THE INSTALLATION OF
THE FRONT AND REAR WINDSHIELDS.

264
00:16:07,992 --> 00:16:10,058
THE FIRST ROBOT
APPLIES AN ADHESIVE PASTE

265
00:16:10,060 --> 00:16:11,986
AROUND THE GLASS EDGES

266
00:16:11,988 --> 00:16:16,248
AS THE SECOND ROBOT GENTLY
ALIGNS THE WINDOW INTO POSITION

267
00:16:16,250 --> 00:16:20,277
USING INFRARED SENSORS
FOR ACCURACY.

268
00:16:20,279 --> 00:16:23,214
AS A NEXT-LEVEL SPORTS CAR,
THE CONSTRUCTION

269
00:16:23,216 --> 00:16:27,277
OF THE PORSCHE 911
CONTINUES ON MULTIPLE STORIES --

270
00:16:27,279 --> 00:16:30,705
ALL WITHIN THE SAME BUILDING.

271
00:16:36,622 --> 00:16:39,616
Narrator: THE PORSCHE 911
ENGINE, TRANSMISSION, AND AXLES

272
00:16:39,618 --> 00:16:42,411
ARE MOUNTED BY A SYNCHRONOUS
ELEVATING PLATFORM,

273
00:16:42,413 --> 00:16:44,613
WHERE THE PARTS ARE INSERTED
INTO THE BODY.

274
00:16:44,615 --> 00:16:47,074
WORKERS CAN ALSO INSTALL
CUSTOMIZED VARIANTS

275
00:16:47,076 --> 00:16:49,076
LIKE ALL-WHEEL DRIVE,
CERAMIC BRAKES,

276
00:16:49,078 --> 00:16:50,636
OR A SPORTS CHASSIS.

277
00:16:51,706 --> 00:16:56,033
ADDING TO THE CAR'S ASSEMBLY,
A WORKER AFFIXES THE GEARBOX

278
00:16:56,035 --> 00:17:00,730
TO THE 3.4-LITER
V6 ENGINE BLOCK.

279
00:17:02,626 --> 00:17:06,227
BOTH PARTS ARE LOWERED
WITH A HOIST ONTO A WORKSTATION

280
00:17:06,229 --> 00:17:08,255
WHERE SYSTEMS, INCLUDING
THE DRIVETRAIN AND SUSPENSION,

281
00:17:08,257 --> 00:17:10,590
WILL JOIN THE MACHINERY.

282
00:17:10,592 --> 00:17:15,512
WORKERS ATTACH AND ALIGN
THE EXHAUST SYSTEM.

283
00:17:17,250 --> 00:17:19,508
RAISED AND TRANSPORTED
BY A SUSPENDED CONVEYOR LIFT,

284
00:17:19,510 --> 00:17:22,577
WORKERS SLOWLY LOWER THE BODY

285
00:17:22,579 --> 00:17:24,939
TO ENSURE THE ENGINE BLOCK,
DAMPERS, AND SUSPENSION

286
00:17:24,941 --> 00:17:28,668
SLIDE DIRECTLY INTO
THEIR DESIGNATED LOCATIONS

287
00:17:28,670 --> 00:17:31,529
WITHOUT ANY COMPLICATIONS.

288
00:17:31,531 --> 00:17:34,532
COMMONLY KNOWN
AS THE MARRIAGE OF ELEMENTS,

289
00:17:34,534 --> 00:17:36,726
WORKERS BOLT
THE DRIVETRAIN AND CHASSIS

290
00:17:36,728 --> 00:17:40,355
TO THE BODY OF THE CAR.

291
00:17:46,888 --> 00:17:49,681
ADDING TO THE CAR'S
FLAIR AND SAFETY,

292
00:17:49,683 --> 00:17:52,342
TWO WORKERS MOUNT THE BUMPERS.

293
00:17:52,344 --> 00:17:54,612
ANOTHER WORKER,
USING A PRESET MOLD,

294
00:17:54,614 --> 00:17:59,142
ATTACHES THE LEGENDARY NAMEPLATE
WITH CARE AND PRECISION.

295
00:18:00,704 --> 00:18:03,304
A SIMPLE ADHESIVE
AND FINISHING ROLLER

296
00:18:03,306 --> 00:18:04,464
KEEP IT TOGETHER.

297
00:18:06,702 --> 00:18:11,096
AND A QUICK WIPE-DOWN ADDS TO
THE SHINE OF THE CAR'S IDENTITY.

298
00:18:12,725 --> 00:18:15,058
THE CAR NOW ENTERS
THE FINAL STATIONS

299
00:18:15,060 --> 00:18:17,786
OF THE VEHICLE ASSEMBLY LINE.

300
00:18:17,788 --> 00:18:19,321
USING A LIFTING DEVICE,

301
00:18:19,323 --> 00:18:22,984
A WORKER MOUNTS THE TIRES
AND RIMS ONTO EACH WHEEL PLATE.

302
00:18:22,986 --> 00:18:25,778
THE COMPANY'S ASSEMBLY PLANNING

303
00:18:25,780 --> 00:18:29,507
USES THE COST-EFFECTIVE
"JUST IN TIME" STRATEGY,

304
00:18:29,509 --> 00:18:32,510
WHICH AVOIDS KEEPING ANY
INVENTORY OF PARTS IN OVERSTOCK.

305
00:18:32,512 --> 00:18:38,266
AT THIS STATION,
THE CAR REGAINS ITS DOORS.

306
00:18:38,268 --> 00:18:42,729
MANUFACTURED OFFSITE BY RECARO,
A NAME SYNONYMOUS WITH RACING,

307
00:18:42,731 --> 00:18:46,359
THE SPORTY, LEATHER BUCKET SEATS
ARE FIT INTO THE CABIN.

308
00:18:50,223 --> 00:18:52,690
AFTER BODY
AND ELECTRICAL ADJUSTMENTS

309
00:18:52,692 --> 00:18:54,017
ON THE VEHICLE'S ASSEMBLY LINE,

310
00:18:54,019 --> 00:18:57,153
THE CAR WILL UNDERGO
DRIVING TESTS.

311
00:19:00,017 --> 00:19:03,209
A WORKER DRIVES THE CAR
ONTO TEST ROLLERS.

312
00:19:03,211 --> 00:19:06,170
COMPUTERIZED LASER SENSORS SCAN
LABELS ON EACH WHEEL

313
00:19:06,172 --> 00:19:08,172
AND MONITOR THEIR MOVEMENT

314
00:19:08,174 --> 00:19:12,102
FOR ALIGNMENT, TIRE BALANCE,
AND HANDLING QUALITIES.

315
00:19:17,927 --> 00:19:23,656
AT ANOTHER WORKSTATION, A WORKER
SHAKES THE WHEELS LATERALLY

316
00:19:23,658 --> 00:19:25,525
TO MANUALLY CHECK
THE AXLE ALIGNMENT.

317
00:19:25,527 --> 00:19:29,520
SENSORS AND COMPUTER SOFTWARE
HELP PERFECT THE ADJUSTMENTS.

318
00:19:29,522 --> 00:19:32,182
NEXT, A WORKER
ASSESSES THE ORIENTATION

319
00:19:32,184 --> 00:19:35,777
OF THE CAR'S OPTICAL BLOCKS
AND LIGHT UNITS.

320
00:19:35,779 --> 00:19:40,407
A WORKER DRIVES THE CAR ONTO
ANOTHER SET OF TEST ROLLERS.

321
00:19:40,409 --> 00:19:44,469
IN THIS EXERCISE, WHILE
THE ACCELERATOR IS PRESSED,

322
00:19:44,471 --> 00:19:47,598
A DEVICE CALLED A DYNAMOMETER
RECORDS MOTOR PERFORMANCE.

323
00:19:47,600 --> 00:19:49,801
IT MEASURES
THE POWER AND TORQUE OUTPUT

324
00:19:49,803 --> 00:19:54,956
DELIVERED BY THE 3.4-LITER
FLAT 6-CYLINDER ENGINE.

325
00:19:54,958 --> 00:19:58,693
A WATER-LEAKAGE TEST
USES MID-PRESSURE SHOWERS

326
00:19:58,695 --> 00:20:02,622
AS A WORKER SEARCHES FOR LEAKS
IN THE CABIN USING A FLASHLIGHT.

327
00:20:04,618 --> 00:20:08,812
WHEN THE EXTENSIVE DRIVE TESTS
ARE SUCCESSFUL,

328
00:20:08,814 --> 00:20:10,613
THE CAR IS READY
TO EXIT THE PLANT.

329
00:20:10,615 --> 00:20:14,176
THE FACTORY IN THE ZUFFENHAUSEN
DISTRICT OF STUTTGART, GERMANY,

330
00:20:14,178 --> 00:20:17,771
PRODUCES MORE THAN
40,000 CARS PER YEAR --

331
00:20:17,773 --> 00:20:21,100
TWICE THE AMOUNT
SINCE THE EARLY '90s.

332
00:20:21,102 --> 00:20:23,561
ONLY VARIANTS OF THIS MODEL
AND ANOTHER MODEL

333
00:20:23,563 --> 00:20:25,563
ARE ASSEMBLED HERE.

334
00:20:25,565 --> 00:20:27,165
INSTANTLY RECOGNIZABLE

335
00:20:27,167 --> 00:20:30,059
AND ORIGINALLY ENGINEERED
FOR THE RACETRACK,

336
00:20:30,061 --> 00:20:34,055
THIS CAR CONTINUES TO STIR
EMOTION AND GARNER ATTENTION,

337
00:20:34,057 --> 00:20:37,717
JUST AS IT DID
IN ITS ORIGINAL YEAR.

338
00:20:37,719 --> 00:20:42,247
WITH A PERFECT LEATHER INTERIOR,
ADVANCED TECHNOLOGY,

339
00:20:42,249 --> 00:20:45,843
AND A POWERFUL 3.4-LITER
V6 ENGINE,

340
00:20:45,845 --> 00:20:48,137
THIS CAR IS ONE OF
THE MOST CAPTIVATING SPORTS CARS

341
00:20:48,139 --> 00:20:51,540
IN THE ENTIRE WORLD.

342
00:20:51,542 --> 00:20:56,730
ALTHOUGH A GRAND DEPARTURE
FROM THE FIRST 911,

343
00:20:56,732 --> 00:21:00,859
THIS CAR STILL RETAINS
A LOT OF THE ORIGINAL STYLING

344
00:21:00,861 --> 00:21:02,995
WITH A MODERN EDGE

345
00:21:02,997 --> 00:21:06,956
AND THE GIFT
OF NEW AERODYNAMICS.

346
00:21:06,958 --> 00:21:09,251
THIS CAR IS NO EXCEPTION
TO THE RULE...

347
00:21:11,088 --> 00:21:14,615
...WHICH HAS MADE IT
CLASSICALLY APPEALING

348
00:21:14,617 --> 00:21:16,417
FOR MORE THAN 40 YEARS.

349
00:21:19,213 --> 00:21:21,706
DREAM CARS --
THE COMPACT PORSCHE 911

350
00:21:21,708 --> 00:21:25,501
IS POWERFULLY AGILE
AND VISUALLY LEGENDARY

351
00:21:25,503 --> 00:21:28,605
WITHOUT COMPROMISE.