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These are the user uploaded subtitles that are being translated: 1 00:00:01,802 --> 00:00:03,868 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS"... 2 00:00:03,870 --> 00:00:05,762 THE MORGAN AERO COUPE. 3 00:00:05,764 --> 00:00:08,191 CAN YOU BELIEVE THIS SUPERCAR IS MADE BY HAND? 4 00:00:08,193 --> 00:00:11,226 -- Captions by VITAC -- www.vitac.com 5 00:00:11,228 --> 00:00:14,155 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,383 --> 00:00:25,575 LOCATED IN THE HILLS OF MALVERN, ENGLAND, 7 00:00:25,577 --> 00:00:28,837 THE MORGAN MOTOR COMPANY IS ONE OF THE LAST TRULY BRITISH 8 00:00:28,839 --> 00:00:31,306 AND PRIVATELY OWNED AUTOMAKERS. 9 00:00:31,308 --> 00:00:32,800 FOUNDED IN 1910, 10 00:00:32,802 --> 00:00:36,570 THE MANUFACTURER TRADITIONALLY HANDCRAFTS LUXURIOUS ROAD CARS 11 00:00:36,572 --> 00:00:38,530 AND CARS FOR MOTOR SPORTS. 12 00:00:38,532 --> 00:00:40,666 THE INSPIRATION FOR ALL MORGAN CARS 13 00:00:40,668 --> 00:00:43,927 COMES FROM THE FOUNDERS LIVING IN THE HILLS OF MALVERN, 14 00:00:43,929 --> 00:00:46,122 WHERE THEY NEEDED POWERFUL VEHICLES 15 00:00:46,124 --> 00:00:49,250 THAT WERE ALSO ABOUT FAMILY COMFORT AND AMPLE CARGO SPACE. 16 00:00:49,252 --> 00:00:51,118 FOUNDER HENRY MORGAN 17 00:00:51,120 --> 00:00:54,481 GUIDED THE MORGAN MOTOR COMPANY FOR ALMOST 50 YEARS. 18 00:00:54,483 --> 00:00:56,617 THE INITIAL SUCCESS OF THE COMPANY 19 00:00:56,619 --> 00:00:59,677 WAS BASED ON THE ICONIC MORGAN THREE WHEELER. 20 00:00:59,679 --> 00:01:02,005 KNOWN AS THE CYCLE CAR, 21 00:01:02,007 --> 00:01:03,874 THIS BRILLIANT YET SIMPLE DESIGN 22 00:01:03,876 --> 00:01:06,936 BECAME ONE OF THE MOST SUCCESSFUL LIGHTWEIGHT CARS 23 00:01:06,938 --> 00:01:10,364 IN EARLY MOTOR HISTORY. 24 00:01:10,366 --> 00:01:11,833 FOLLOWING THE THREE WHEELER, 25 00:01:11,835 --> 00:01:13,893 THE TWO-SEAT RUNABOUT WAS DEVELOPED 26 00:01:13,895 --> 00:01:17,163 AND EQUIPPED WITH WHEEL STEERING AND EVEN A HOOD. 27 00:01:17,165 --> 00:01:21,293 INTRODUCED IN 1950, THE SHORT-LIVED MORGAN PLUS 4 28 00:01:21,295 --> 00:01:24,287 LED THE WAY TO THE MORE POPULAR MORGAN PLUS 8. 29 00:01:24,289 --> 00:01:28,250 PRODUCTION OF THE PLUS 8 LASTED FOR 36 YEARS. 30 00:01:30,780 --> 00:01:33,580 THE AERO COUPE WAS INTRODUCED IN 2001. 31 00:01:33,582 --> 00:01:36,041 IT IS ONE OF THE FIRST MORGAN CARS 32 00:01:36,043 --> 00:01:38,502 BUILT WITH AN ALUMINUM CHASSIS AND BODY, 33 00:01:38,504 --> 00:01:41,038 PAIRED WITH THE 4.8-LITER V8 ENGINE, 34 00:01:41,040 --> 00:01:44,367 MAKING A MIGHTY 367 HORSEPOWER. 35 00:01:49,599 --> 00:01:51,724 THE COMPANY RADSHAPE MANUFACTURES 36 00:01:51,726 --> 00:01:53,726 PRECISION SHEET-METAL PARTS 37 00:01:53,728 --> 00:01:56,689 INCLUDING THE BONDED CHASSIS FOR THE MORGAN AERO COUPE. 38 00:01:58,951 --> 00:02:01,352 COMPUTER-AIDED DESIGN AND MANUFACTURING 39 00:02:01,354 --> 00:02:04,613 MAKE BUILDING THE CHASSIS PARTS EASIER AND FASTER. 40 00:02:04,615 --> 00:02:08,276 THE SOFTWARE HELPS WORKERS CONTROL THE MACHINING TOOLS, 41 00:02:08,278 --> 00:02:12,005 WITH DUTIES SUCH AS ROUGHING, SEMI-FINISHING, FINISHING, 42 00:02:12,007 --> 00:02:15,634 AND CONTOUR MILLING. 43 00:02:15,636 --> 00:02:19,170 THIS PUNCH PRESS WORKS LIKE A HOLE PUNCH FOR PAPER. 44 00:02:19,172 --> 00:02:21,832 THE PUNCH PRESSES THE ALUMINUM SHEET 45 00:02:21,834 --> 00:02:23,359 AGAINST THE SUPPORT DIE 46 00:02:23,361 --> 00:02:24,693 AND INTO A ROUND OPENING 47 00:02:24,695 --> 00:02:27,688 WHERE THE SCRAP METAL IS COLLECTED IN A CONTAINER. 48 00:02:27,690 --> 00:02:30,090 CHASSIS PARTS REQUIRE NIBBLING, 49 00:02:30,092 --> 00:02:33,085 WHERE PUNCH HOLES OVERLAP FORMING ANY SHAPE. 50 00:02:33,087 --> 00:02:36,113 THE PUNCHING MACHINE HAS TO DELIVER MORE STROKES 51 00:02:36,115 --> 00:02:41,444 ALONG THE PUNCHED PATH, CREATING A SMOOTHER EDGE. 52 00:02:41,446 --> 00:02:45,173 PRODUCED IN GERMANY BY ALUMINUM MANUFACTURER ALCAN, 53 00:02:45,175 --> 00:02:48,302 THE THIN SHEET PLIES ARE ALSO COATED WITH PT2, 54 00:02:48,304 --> 00:02:51,237 AN ORGANIC COMPOUND WHICH INCREASES THE STRENGTH 55 00:02:51,239 --> 00:02:56,127 OF THE BONDS FORMED WHEN THE PARTS ARE GLUED TOGETHER. 56 00:03:02,260 --> 00:03:04,652 ONCE THE PUNCH MACHINE OUTPUTS THE PIECES, 57 00:03:04,654 --> 00:03:07,588 A WORKER SHAPES THEM FURTHER WITH A MECHANICAL FOLDING, 58 00:03:07,590 --> 00:03:11,117 COINING, AND AIR-BENDING MACHINE CALLED A PRESS BRAKE. 59 00:03:18,143 --> 00:03:21,403 AIR BENDING THE ALUMINUM MEANS EACH SHEET IS BENT BY A BRAKE. 60 00:03:21,405 --> 00:03:23,005 IT STRIKES THE ALUMINUM 61 00:03:23,007 --> 00:03:25,299 WITH A PRESET PRESSURE INTO THE DIE 62 00:03:25,301 --> 00:03:30,496 WITHOUT PRESSING IT AGAINST THE MATRIX WALLS. 63 00:03:30,498 --> 00:03:34,292 THE CAR'S CHASSIS CONSISTS OF 32 PARTS, 64 00:03:34,294 --> 00:03:36,961 EACH PIECE FOLDED WITH PRECISION. 65 00:03:36,963 --> 00:03:40,690 THIS PROCESS TAKES FOUR HOURS PER CHASSIS. 66 00:03:40,692 --> 00:03:44,185 IN THE CLEAN ROOM FOR RECENTLY MACHINED PARTS, 67 00:03:44,187 --> 00:03:46,913 EACH PART IS STACKED ACCORDING TO THEIR PATTERN GROUP. 68 00:03:46,915 --> 00:03:48,982 THEY WILL SOON INTERSECT 69 00:03:48,984 --> 00:03:51,777 AND BECOME THE INTERNAL FRAMEWORK OF THE CAR. 70 00:03:51,779 --> 00:03:54,438 WITHIN THE CLEAN-ROOM ENVIRONMENT, 71 00:03:54,440 --> 00:03:56,573 SEALED AT THE ENTRANCES AND EXITS 72 00:03:56,575 --> 00:03:58,400 TO ENSURE THE UTMOST QUALITY, 73 00:03:58,402 --> 00:04:02,529 TWO WORKERS DELIVER THE MIDSECTION ONTO A WORK CART. 74 00:04:02,531 --> 00:04:03,931 HAVING ALREADY ASSEMBLED 75 00:04:03,933 --> 00:04:06,326 SOME OF THE LARGER PIECES OF THE CHASSIS, 76 00:04:06,328 --> 00:04:07,994 THEY WILL CONTINUE TO BOND AND RIVET 77 00:04:07,996 --> 00:04:10,655 THE MAIN PARTS TOGETHER. 78 00:04:10,657 --> 00:04:14,217 THE WORKERS DELIVER THE FRONT-END BASE COMPONENT, 79 00:04:14,219 --> 00:04:16,753 WHICH HAS STRUCTURAL EPOXY ADHESIVE. 80 00:04:16,755 --> 00:04:18,280 THE GEL'S ORANGE COLOR 81 00:04:18,282 --> 00:04:21,683 HELPS TO HIGHLIGHT ITS PLACEMENT DURING ASSEMBLY. 82 00:04:21,685 --> 00:04:25,612 PUSHING THE CHASSIS PARTS CLOSER TOGETHER TO MATCHING SECTIONS, 83 00:04:25,614 --> 00:04:28,007 THE WORKERS HAMMER A METAL CYLINDRICAL SHAFT 84 00:04:28,009 --> 00:04:31,369 INTO PUNCHED HOLES TO AVOID ANY BUILDING ERRORS 85 00:04:31,371 --> 00:04:33,571 WHILE OTHER HOLES ARE INJECTED WITH RIVETS 86 00:04:33,573 --> 00:04:35,598 TO FASTEN THE CHASSIS. 87 00:04:38,828 --> 00:04:40,762 TO SOLIDIFY THE RIVETS, 88 00:04:40,764 --> 00:04:43,023 THE WORKERS USE SERVO-DRIVEN TOOLS. 89 00:04:43,025 --> 00:04:46,226 THIS ENABLES CONTROL OF THE RIVET-SETTING PROCESS 90 00:04:46,228 --> 00:04:48,287 FOR UNCOMPROMISED REPEATABILITY 91 00:04:48,289 --> 00:04:52,183 AND QUALITY OF WATER-TIGHT JOINTS. 92 00:04:52,185 --> 00:04:54,584 THIS PROCESS INCREASES PRODUCTIVITY 93 00:04:54,586 --> 00:04:58,714 AND SAVES TIME IN ATTACHING THE CHASSIS PARTS. 94 00:04:58,716 --> 00:05:00,908 USING A CARTRIDGE APPLICATOR, 95 00:05:00,910 --> 00:05:04,103 A WORKER APPLIES MORE ADHESIVE TO THE CHASSIS CLEANLY 96 00:05:04,105 --> 00:05:06,305 AND WITH A MINIMUM OF WASTE. 97 00:05:06,307 --> 00:05:08,866 THIS HIGH-STRENGTH ADHESIVE HAS BEEN IN USE 98 00:05:08,868 --> 00:05:10,735 SINCE WORLD WAR II 99 00:05:10,737 --> 00:05:13,697 AND WAS DESIGNED FOR AIR AND SEA SHIP BUILDING. 100 00:05:25,019 --> 00:05:27,620 MORE GEL AND ADDITIONAL PARTS IN THE CENTER 101 00:05:27,622 --> 00:05:30,348 CREATE A SUB FRAME OF THE COCKPIT. 102 00:05:41,236 --> 00:05:44,429 THE CHASSIS STANDS IN A CURING ROOM FOR 25 MINUTES 103 00:05:44,431 --> 00:05:48,893 TO DRY THE ADHESIVE AT 375 DEGREES FAHRENHEIT. 104 00:05:48,895 --> 00:05:51,829 A WORKER APPLIES TEST SAMPLES TO THE CHASSIS 105 00:05:51,831 --> 00:05:55,090 WITH THE SAME BATCH OF ALUMINUM AND ADHESIVE. 106 00:05:55,092 --> 00:05:58,786 THE SAMPLES ARE PEELED APART BY A TENSILE-TESTING MACHINE, 107 00:05:58,788 --> 00:06:03,315 APPLYING BETWEEN 230 TO 670 POUNDS OF FORCE 108 00:06:03,317 --> 00:06:05,977 IN ORDER TO VERIFY THE STRENGTH OF THE BOND. 109 00:06:05,979 --> 00:06:07,979 AFTER 13 HOURS OF ASSEMBLY, 110 00:06:07,981 --> 00:06:10,574 RADSHAPE GIVES THEIR SEAL OF APPROVAL 111 00:06:10,576 --> 00:06:14,870 AND SENDS THE CHASSIS TO BECOME THE START OF THE AERO COUPE. 112 00:06:21,811 --> 00:06:25,638 Narrator: THE AERO COUPE IS NO EXCEPTION TO MORGAN'S TRADITION 113 00:06:25,640 --> 00:06:27,965 OF HAVING THEIR CARS BUILT AROUND A WOOD FRAME 114 00:06:27,967 --> 00:06:29,300 AND METAL CHASSIS. 115 00:06:29,302 --> 00:06:32,829 THE WOOD DELIVERS STRENGTH, FLEXIBILITY, 116 00:06:32,831 --> 00:06:35,891 AND SAFETY IN ANY COLLISION. 117 00:06:37,461 --> 00:06:39,920 THE AUTO MAKER USES A LARGE AMOUNT OF LUMBER 118 00:06:39,922 --> 00:06:43,524 FROM ASH TREES IN THE CRAFTSMANSHIP OF THEIR CARS. 119 00:06:43,526 --> 00:06:46,986 A WORKER USES A SERIES OF PRE-DESIGNED ROUTER JIGS 120 00:06:46,988 --> 00:06:49,580 TO HELP SCULPT PARTS OF THE WOODEN FRAME 121 00:06:49,582 --> 00:06:52,408 ON A SPECIALIZED TABLE SAW. 122 00:06:52,410 --> 00:06:55,278 KNOWN AS THE WOOD-FRAME PROCESS, 123 00:06:55,280 --> 00:06:58,673 PARTS ARE CUT INTO PATTERNED PIECES IN THE FACTORY'S MILL. 124 00:06:58,675 --> 00:07:01,668 ONCE THE PIECES ARE PRECISELY CUT, 125 00:07:01,670 --> 00:07:03,069 THEY ARE SANDED AND SHAVED 126 00:07:03,071 --> 00:07:05,097 TO MEET THE PROPER SIZING AND WEIGHT. 127 00:07:10,896 --> 00:07:12,321 AT ANOTHER WORK TABLE, 128 00:07:12,323 --> 00:07:15,891 A WORKER PLACES A HIGH-STRENGTH ADHESIVE ON WOODEN PANELS, 129 00:07:15,893 --> 00:07:19,153 BRUSHING THE GLUE FROM ONE END TO ANOTHER, 130 00:07:19,155 --> 00:07:22,849 CERTIFYING THE PIECES ARE FULLY COATED ON ONE SIDE. 131 00:07:34,971 --> 00:07:37,564 MOUNTING THE TWO PIECES BACK-TO-BACK, 132 00:07:37,566 --> 00:07:39,700 THE WORKER MOVES THE UNIFIED SHEET 133 00:07:39,702 --> 00:07:43,496 INTO A PREDEFINED JIG THAT'S MORE THAN 60 YEARS OLD. 134 00:07:43,498 --> 00:07:45,322 THIS CLAMP PRESSURE TECHNIQUE 135 00:07:45,324 --> 00:07:47,892 MOLDS THE WOOD TO REMAIN A SPECIFIC SHAPE. 136 00:07:53,191 --> 00:07:55,250 WITH A RUBBER MALLET, 137 00:07:55,252 --> 00:07:57,644 THE WORKER HAMMERS THE PIECES INTO PLACE 138 00:07:57,646 --> 00:08:00,179 WITH THE HELP OF A PROTECTIVE WOOD GUIDE. 139 00:08:00,181 --> 00:08:04,676 THE JIG ALSO HAS VARIOUS CLOSURE SUPPORTS 140 00:08:04,678 --> 00:08:07,738 THAT REQUIRE BOLTING AND SECURING WITH A RATCHET, 141 00:08:07,740 --> 00:08:10,198 ENSURING THE WOOD PLANKS SHAPE CORRECTLY 142 00:08:10,200 --> 00:08:13,135 AND ARE EQUAL IN SYMMETRY. 143 00:08:17,959 --> 00:08:19,492 COMPLETELY SECURE, 144 00:08:19,494 --> 00:08:22,219 THE WOOD SITS IN THE ANTIQUE JIG FOR ONE HOUR, 145 00:08:22,221 --> 00:08:24,755 UNTIL THE GLUE IS FULLY ABSORBED INTO THE WOOD 146 00:08:24,757 --> 00:08:27,284 AND COMPLETELY DRY. 147 00:08:30,022 --> 00:08:32,347 USING THE RUBBER MALLET TO LOOSEN THE PLANK, 148 00:08:32,349 --> 00:08:36,310 THE WORKER REMOVES THE NEWLY SHAPED COMPONENT. 149 00:08:41,975 --> 00:08:43,434 WITHIN THE WORKSHOP, 150 00:08:43,436 --> 00:08:46,104 A WORKER SHAVES THE EDGES OF A FRAME PIECE. 151 00:08:46,106 --> 00:08:50,625 USING A HAND PLANE, HE SHAPES THE LUMBER AS NECESSARY. 152 00:08:50,627 --> 00:08:53,128 PLANING PRODUCES HORIZONTAL, VERTICAL, 153 00:08:53,130 --> 00:08:55,722 OR INCLINED FLAT SURFACES. 154 00:08:55,724 --> 00:08:58,124 A SANDING BLOCK IS ALSO PUT TO USE 155 00:08:58,126 --> 00:09:02,913 TO SMOOTH ALL EDGE CARVINGS FROM THE HAND PLANE. 156 00:09:02,915 --> 00:09:06,650 THE WORKER PLACES THE FINISHED PIECE NEXT TO THE OTHER PARTS. 157 00:09:06,652 --> 00:09:09,678 THE WORK DONE IN THE WOOD SHOP IS VERY TIME-SENSITIVE. 158 00:09:09,680 --> 00:09:13,341 IT TAKES THREE DAYS TO BUILD THE ASH WOOD FRAME 159 00:09:13,343 --> 00:09:17,270 BEFORE IT IS FITTED ONTO THE CAR'S CHASSIS. 160 00:09:17,272 --> 00:09:20,531 THE WORKER ASSEMBLES THE PARTS 161 00:09:20,533 --> 00:09:23,693 BY PLACING A HIGH-STRENGTH WOOD GLUE IN CERTAIN AREAS 162 00:09:23,695 --> 00:09:25,829 AS WELL AS STAINLESS-STEEL SCREWS 163 00:09:25,831 --> 00:09:29,157 INTO PRE-DRILLED HOLES USING A CORDLESS SCREWDRIVER. 164 00:09:29,159 --> 00:09:32,419 THE MANUFACTURER CALLS THIS PROCESS 165 00:09:32,421 --> 00:09:34,554 21st CENTURY COACH BUILDING. 166 00:09:34,556 --> 00:09:38,283 THIS LAYER OF ASH HARDWOOD WILL BE SANDWICHED 167 00:09:38,285 --> 00:09:41,445 BETWEEN THE ALUMINUM OUTER-BODY PANELS 168 00:09:41,447 --> 00:09:44,040 AND THE RIGID INTERNAL ALUMINUM CHASSIS. 169 00:09:48,905 --> 00:09:52,065 CLAMPS ARE ALSO USED TO HOLD THE WOOD IN POSITION 170 00:09:52,067 --> 00:09:55,035 WHILE THE STAINLESS-STEEL SCREWS ARE INSTALLED. 171 00:09:59,633 --> 00:10:02,993 ONCE THE HARDWOOD FRAME IS COMPLETELY ASSEMBLED, 172 00:10:02,995 --> 00:10:04,787 TWO WORKERS MOVE THE SUBSTRUCTURE 173 00:10:04,789 --> 00:10:06,922 ONTO THE ALUMINUM CHASSIS FOR FITTING. 174 00:10:06,924 --> 00:10:09,117 ADDING MORE TO THE REAR OF THE CHASSIS, 175 00:10:09,119 --> 00:10:10,985 THE WORKER PLACES A FENDER SUPPORT 176 00:10:10,987 --> 00:10:13,379 AND SCREWS IT INTO PLACE. 177 00:10:16,610 --> 00:10:19,944 A CORE STRENGTH WITHIN THE FACTORY IS WOOD WORK. 178 00:10:19,946 --> 00:10:22,071 THE CAR'S WOOD FRAME 179 00:10:22,073 --> 00:10:25,867 EXEMPLIFIES TRADITIONAL SKILLS AND EXCELLENT CRAFTSMANSHIP. 180 00:10:25,869 --> 00:10:28,470 THE FACTORY WOOD SHOP IS VERY SMALL. 181 00:10:28,472 --> 00:10:30,598 EVERY ELEMENT OF THE WOODEN FRAME 182 00:10:30,600 --> 00:10:33,558 IS FINE TUNED WITH COMMON AND TRADITIONAL TOOLS. 183 00:10:33,560 --> 00:10:38,823 VARIOUS MODEL FRAMES ARE BUILT AT THE SAME TIME. 184 00:10:38,825 --> 00:10:41,417 TWO WORKERS MOVE THE WOODEN SUB FRAME 185 00:10:41,419 --> 00:10:44,287 TO A STATION FOR DIP TREATMENT. 186 00:10:44,289 --> 00:10:47,148 HOOKED ONTO PULLEYS, THE WORKERS LOWER THE ASH FRAME 187 00:10:47,150 --> 00:10:50,109 INTO A TANK OF INSECTICIDAL WOOD-CARE CHEMICAL 188 00:10:50,111 --> 00:10:52,913 DESIGNED TO PROTECT AND PRESERVE THE TIMBER. 189 00:10:58,104 --> 00:11:01,371 AFTER THE WOOD ABSORBS ENOUGH OF THE CHEMICAL, 190 00:11:01,373 --> 00:11:03,565 THE FRAME IS REMOVED FROM THE TANK 191 00:11:03,567 --> 00:11:06,360 TO STAND ON SLATS WHERE IT DRIP-DRIES. 192 00:11:12,727 --> 00:11:15,119 THIS IS JUST THE ORGANIC BEGINNING 193 00:11:15,121 --> 00:11:17,622 OF THE AERO COUPE SUPERCAR. 194 00:11:25,683 --> 00:11:29,176 Narrator: THE AERO COUPE IS A MIX OF RACING SENSIBILITIES, 195 00:11:29,178 --> 00:11:32,906 ENVIRONMENTAL RESPONSIBILITY, AND A HIGH LEVEL OF SAFETY. 196 00:11:32,908 --> 00:11:35,366 IT'S ALSO ONE OF THE ONLY SUPER CARS 197 00:11:35,368 --> 00:11:38,236 ORIGINALLY DESIGNED WITH SIGNIFICANT TRUNK SPACE 198 00:11:38,238 --> 00:11:40,930 FOR LONG-DISTANCE DRIVING. 199 00:11:40,932 --> 00:11:43,925 SINCE 1910, TRADITIONAL CRAFTSMANSHIP 200 00:11:43,927 --> 00:11:46,194 HAS BEEN KEY IN ALMOST EVERY WAY. 201 00:11:46,196 --> 00:11:48,055 BEFORE BECOMING A ROAD REALITY, 202 00:11:48,057 --> 00:11:49,789 DESIGNERS AND ENGINEERS 203 00:11:49,791 --> 00:11:53,319 CONCEPTUALIZE THIS CAR AND OTHER CARS FROM SCRATCH, 204 00:11:53,321 --> 00:11:56,481 USING AGE-OLD TOOLS LIKE PENCIL AND PAPER. 205 00:11:56,483 --> 00:12:01,010 BUT THE COMPANY ISN'T LIVING IN THE DARK AGES. 206 00:12:01,012 --> 00:12:02,945 FROM PAPER TO 3-D RENDERING, 207 00:12:02,947 --> 00:12:05,340 DESIGNERS USE A COMPUTER SOFTWARE 208 00:12:05,342 --> 00:12:08,268 WHICH ALLOWS THEM TO VISUALIZE THEIR IDEAS 209 00:12:08,270 --> 00:12:10,804 IN VARIOUS COLORS AND ENVIRONMENTS 210 00:12:10,806 --> 00:12:13,865 BEFORE THE EVENTUAL CONSTRUCTION OF THE CAR. 211 00:12:13,867 --> 00:12:17,695 MAKING THIS CAR LOOK AS GOOD AS IT DOES IN 3-D RENDERINGS 212 00:12:17,697 --> 00:12:21,290 REQUIRES SOME BENDING AND TWISTING. 213 00:12:21,292 --> 00:12:24,552 ALTHOUGH SOME PARTS OF THE CAR'S BODY ARE SUPERFORMED, 214 00:12:24,554 --> 00:12:27,822 OTHERS, LIKE THE HOOD PANELS, REQUIRE A PERSONAL TOUCH. 215 00:12:27,824 --> 00:12:31,151 THE HOOD PANELS ARE CUT FROM SINGLE SHEETS OF ALUMINUM 216 00:12:31,153 --> 00:12:33,711 AND SHAPED BY HAND. 217 00:12:33,713 --> 00:12:36,515 USING A MANUAL SLIP-ROLL MACHINE, 218 00:12:36,517 --> 00:12:40,243 WORKERS PLACE THE UNBENT ALUMINUM SHEET INTO THE BENDER, 219 00:12:40,245 --> 00:12:43,505 BRINGING THE BACK OF THE ROLL UP TO THE DESIRED POSITION, 220 00:12:43,507 --> 00:12:46,333 AND START THE BEND. 221 00:12:50,130 --> 00:12:53,925 IN NO TIME, FRONTAL ELEMENTS THAT ADD TO THE CAR'S ALLURE 222 00:12:53,927 --> 00:12:55,659 ARE MADE TO MEASURE. 223 00:12:55,661 --> 00:13:00,523 THIS CAR COMPANY IS ALL ABOUT DETAILS, 224 00:13:00,525 --> 00:13:02,851 AND EVERYTHING GETS HANDS-ON ATTENTION, 225 00:13:02,853 --> 00:13:04,719 DOWN TO THE FUEL-DOOR COVER. 226 00:13:04,721 --> 00:13:08,281 A WORKER MOUNTS A SMALL, CIRCULAR PIECE OF ALUMINUM 227 00:13:08,283 --> 00:13:09,875 INTO A MOLD. 228 00:13:09,877 --> 00:13:13,471 HE APPLIES A METAL STAMP AND HAMMERS THE EDGES. 229 00:13:18,069 --> 00:13:20,002 WHAT'S LEFT IS THE GATEWAY 230 00:13:20,004 --> 00:13:23,231 TO WHERE GASOLINE MEETS THE CAR'S GAS TANK. 231 00:13:25,168 --> 00:13:27,426 THE CAR CONTINUES TO TAKE SHAPE, 232 00:13:27,428 --> 00:13:29,954 AS A WORKER ATTACHES THE ALUMINUM SKIN PARTS 233 00:13:29,956 --> 00:13:31,489 TO THE WOODEN FRAME, 234 00:13:31,491 --> 00:13:35,819 INCLUDING THE SIDE PANELS, AS WELL AS THE ROOFING AND MORE. 235 00:13:35,821 --> 00:13:39,415 ALL PANELS ARE INSPECTED FOR PERFECT POSITIONING. 236 00:13:41,252 --> 00:13:44,311 FROM PROCESS TO PROGRESS -- 237 00:13:44,313 --> 00:13:46,905 THE WORKER MOUNTS MORE PIECES TO THE MAIN HULL 238 00:13:46,907 --> 00:13:51,969 TO FORM WHAT BEGINS TO LOOK LIKE A MODERN YET CLASSIC SUPER CAR. 239 00:13:56,000 --> 00:13:57,867 WITH MOST OF THE CAR'S BODY PANELS 240 00:13:57,869 --> 00:13:59,794 FITTED INTO THEIR RESPECTIVE PLACES, 241 00:13:59,796 --> 00:14:01,997 IT'S TIME FOR THE NEXT PHASE 242 00:14:01,999 --> 00:14:04,323 IN SHAPING THIS SUPER CAR'S IDENTITY. 243 00:14:04,325 --> 00:14:06,393 AND, SINCE THE ASSEMBLY LINE 244 00:14:06,395 --> 00:14:10,122 HAS NEVER INVOLVED ANY ROBOTS OR CONVEYOR BELTS, 245 00:14:10,124 --> 00:14:14,977 THE BODY IS PULLED ON A CART BY MUSCLE TO THE PAINT SHOP. 246 00:14:14,979 --> 00:14:16,946 IN A SOPHISTICATED PAINT SHOP, 247 00:14:16,948 --> 00:14:19,607 A WORKER MISTS THE PANELS INDIVIDUALLY 248 00:14:19,609 --> 00:14:21,075 WITH A WATER-BASED PAINT, 249 00:14:21,077 --> 00:14:24,537 WHICH OFFERS PROTECTION AND POLISH. 250 00:14:24,539 --> 00:14:30,334 THE PAINTING PROCESS OF THE ENTIRE CAR TAKES THREE DAYS. 251 00:14:30,336 --> 00:14:32,362 FOR MORE THAN 100 YEARS, 252 00:14:32,364 --> 00:14:35,031 THE MANUFACTURER HAS PAID ATTENTION 253 00:14:35,033 --> 00:14:38,360 TO THE SMALLEST AND LAST DETAILS. 254 00:14:38,362 --> 00:14:40,888 THE LEATHER INTERIOR IS NO EXCEPTION. 255 00:14:40,890 --> 00:14:44,283 USING A UNIQUE BRAND OF LOW-CARBON SCOTTISH LEATHER, 256 00:14:44,285 --> 00:14:48,246 THE INTERIOR CABIN REQUIRES FOUR COW HIDES. 257 00:14:48,248 --> 00:14:52,108 ALL LEATHER WORK IS DONE USING TWIN-NEEDLE CONTRAST STITCHING, 258 00:14:52,110 --> 00:14:55,378 AFFORDING AN EXTREMELY EXCLUSIVE YET SPORTY FEEL, 259 00:14:55,380 --> 00:14:58,607 NOT TO MENTION STURDY AND RELIABLE QUALITY. 260 00:15:00,769 --> 00:15:04,196 A WORKER SLIDES A LEATHER CASING OF A FRONT SEAT 261 00:15:04,198 --> 00:15:05,464 ONTO THE SEAT BACK, 262 00:15:05,466 --> 00:15:08,959 ENSURING THE FIT IS PERFECTLY ALIGNED WITH THE FRAME. 263 00:15:12,390 --> 00:15:15,725 COMBING OVER THE SURFACE FOR COMPLETE SMOOTHNESS 264 00:15:15,727 --> 00:15:17,584 AND USING HOG RING PLIERS, 265 00:15:17,586 --> 00:15:23,550 HE PULLS THE LEATHER REPEATEDLY TO MATCH THE FRAME. 266 00:15:23,552 --> 00:15:26,077 THE WORKER INSERTS THE CHAIR'S BOTTOM CUSHION 267 00:15:26,079 --> 00:15:29,139 INTO THE SEAT BACK'S LOWER FRAME. 268 00:15:29,141 --> 00:15:31,608 HE SPREADS THE LEATHER AND PULLS IT INTO PLACE 269 00:15:31,610 --> 00:15:34,169 BEFORE ATTACHING IT TO THE FRAME. 270 00:15:39,302 --> 00:15:41,893 THE WORKER HOLDS THE MATERIAL IN PLACE 271 00:15:41,895 --> 00:15:46,090 WHILE USING A NAIL GUN TO AFFIX THE CUSHIONING INTO POSITION. 272 00:15:46,092 --> 00:15:48,159 SMALL, METAL CLAMPS ARE INSTALLED 273 00:15:48,161 --> 00:15:50,620 TO BIND THE LEATHER TO THE SEAT'S FRAME 274 00:15:50,622 --> 00:15:53,848 BEFORE THE WORKER SMOOTHES THE LEATHER ACROSS THE CUSHION 275 00:15:53,850 --> 00:15:56,050 FOR AN EVEN DRESSING. 276 00:15:56,052 --> 00:15:58,444 USING HOG PLIERS, 277 00:15:58,446 --> 00:16:01,314 THE WORKER PULLS THE LEATHER EDGES FOR THE BEST FIT, 278 00:16:01,316 --> 00:16:04,576 COMPLETING THE CAR'S RACING-INSPIRED BUCKET SEAT. 279 00:16:06,438 --> 00:16:08,305 A PROMINENT FEATURE OF ANY CAR 280 00:16:08,307 --> 00:16:11,734 IS THE FRONT-END SIGNATURE GRILLE. 281 00:16:11,736 --> 00:16:13,795 A WORKER HAND-CRAFTS THE GRILLE 282 00:16:13,797 --> 00:16:16,931 USING PRE-CUT PARTS THAT ARE WELDED TOGETHER. 283 00:16:20,528 --> 00:16:22,053 ONCE THE WELDS COOL, 284 00:16:22,055 --> 00:16:25,389 THE WORKER GRINDS AWAY ANY UNWANTED MATERIAL 285 00:16:25,391 --> 00:16:28,085 AND SMOOTHES THE LINKED AREAS. 286 00:16:34,543 --> 00:16:38,012 A SMOOTH, CLEAN LOOK IS ALL PART OF THE AERO COUPE 287 00:16:38,014 --> 00:16:41,741 THAT MAKES IT STAND OUT IN ANY CROWD. 288 00:16:49,773 --> 00:16:52,967 Narrator: THE AERO COUPE IS FASHIONED FROM RESEARCH, 289 00:16:52,969 --> 00:16:56,696 TAKEN FROM THE RACE TRACK TO THE COMPANY'S LABORATORIES. 290 00:16:56,698 --> 00:16:59,557 ADVANCED COMPUTER SOFTWARE ALSO ALLOWS ENGINEERS 291 00:16:59,559 --> 00:17:03,987 TO CONCEPTUALIZE A FULL, WORKING CAR IN JUST A FEW CLICKS. 292 00:17:05,323 --> 00:17:09,117 THE HEART OF THIS CAR IS THE 4.8-LITER V8 ENGINE 293 00:17:09,119 --> 00:17:12,512 SUPPLIED BY GERMAN LUXURY AUTO MAKER BMW. 294 00:17:12,514 --> 00:17:15,716 THE SAME ENGINE WAS FORMERLY USED 295 00:17:15,718 --> 00:17:19,511 IN BMW's LUXURY CROSSOVER, THE X6. 296 00:17:19,513 --> 00:17:22,339 WITH THE ULTRA-STIFF ALUMINUM CHASSIS COMPLETE, 297 00:17:22,341 --> 00:17:24,667 A WORKER DELIVERS THE ENGINE 298 00:17:24,669 --> 00:17:27,670 WITH THE HELP OF A PNEUMATIC HOIST. 299 00:17:27,672 --> 00:17:31,733 THE 8-CYLINDER ENGINE REACHES 367 HORSEPOWER, 300 00:17:31,735 --> 00:17:34,994 ALLOWING THIS CAR TO GO FROM ZERO TO 60 MILES AN HOUR 301 00:17:34,996 --> 00:17:36,955 IN 4.5 SECONDS. 302 00:17:38,659 --> 00:17:40,617 MOVING FROM THE FRONT END 303 00:17:40,619 --> 00:17:42,753 TO THE BACK OF THE ALUMINUM CHASSIS, 304 00:17:42,755 --> 00:17:46,415 THE WORKER SLOWLY HOISTS THE REAR TRANSAXLE INTO POSITION 305 00:17:46,417 --> 00:17:47,883 AND SECURES IT PROPERLY 306 00:17:47,885 --> 00:17:50,811 BEFORE THE CAR RECEIVES MORE MAJOR COMPONENTS. 307 00:17:55,076 --> 00:17:58,103 IN ANOTHER SECTION, THE CAR'S UNDERCARRIAGE STANDS 308 00:17:58,105 --> 00:18:00,771 WITH THE ADDITION OF THE STEERING, WHEELS, 309 00:18:00,773 --> 00:18:02,832 AND MORE ELECTRICAL COMPONENTS. 310 00:18:02,834 --> 00:18:06,228 RUNNING SEVERAL TESTS, A WORKER VERIFIES 311 00:18:06,230 --> 00:18:08,964 THAT THE POWER STEERING IS FULLY FUNCTIONAL 312 00:18:08,966 --> 00:18:11,291 AND THAT WHEEL ALIGNMENT IS CORRECT. 313 00:18:11,293 --> 00:18:15,120 USING ROUTINE SCREENINGS AND THE LATEST COMPUTER SOFTWARE, 314 00:18:15,122 --> 00:18:16,321 THE WORKER CAN ASSESS 315 00:18:16,323 --> 00:18:18,983 THAT THE CAR'S ALIGNMENT AND HANDLING CHARACTERISTICS 316 00:18:18,985 --> 00:18:21,444 ARE COMPLETELY SATISFACTORY. 317 00:18:26,176 --> 00:18:29,043 IF THE WHEELS REQUIRE ANY ADJUSTING, 318 00:18:29,045 --> 00:18:31,538 THE WORKER ADMINISTERS THE CHANGES 319 00:18:31,540 --> 00:18:33,999 IN CONJUNCTION WITH COMPUTER SOFTWARE, 320 00:18:34,001 --> 00:18:37,761 CERTIFYING THE CAR MEETS THE AUTOMAKER'S STANDARDS. 321 00:18:46,956 --> 00:18:49,223 ASSUMING MORE OF A COMPLETE STANCE 322 00:18:49,225 --> 00:18:52,085 WITH THE MAJORITY OF ESSENTIAL PARTS INTACT, 323 00:18:52,087 --> 00:18:55,413 THERE IS STILL THE NEED FOR COVERAGE. 324 00:18:55,415 --> 00:18:57,615 THIS RIGID, ALUMINUM-BASED CAR IS ALSO INSPIRED 325 00:18:57,617 --> 00:19:00,743 BY AUTOMAKERS GT3 AERO, 326 00:19:00,745 --> 00:19:04,639 WHICH ENJOYED A NUMBER OF RACING VICTORIES. 327 00:19:04,641 --> 00:19:06,967 CONTRIBUTING TO THE EXTERNAL LOOK, 328 00:19:06,969 --> 00:19:09,903 A WORKER ADDS COSMETIC PARTS LIKE A REAR FENDER 329 00:19:09,905 --> 00:19:13,432 WITHOUT THE HELP OF ANY LARGE MACHINERY OR ROBOTS. 330 00:19:13,434 --> 00:19:15,359 AND, AS YOU CAN SEE, 331 00:19:15,361 --> 00:19:18,529 THE CAR GETS CLOSER TO MOTOR PERFECTION WITH EVERY TWIST. 332 00:19:26,389 --> 00:19:28,514 THE MECHANICAL ASSEMBLY BAY 333 00:19:28,516 --> 00:19:32,577 EMPLOYS BOTH YOUNG AND EXPERIENCED PERSONALITIES. 334 00:19:32,579 --> 00:19:37,474 ONLY 175 WORKERS CONTRIBUTE TO THE SCULPTURAL CAR. 335 00:19:37,476 --> 00:19:41,137 EVEN ASSEMBLING VARIOUS MODELS IN THE SAME AREA. 336 00:19:41,139 --> 00:19:43,597 EACH CAR IS ASSEMBLED TO DEMONSTRATE 337 00:19:43,599 --> 00:19:45,132 A DISTINCT COMBINATION 338 00:19:45,134 --> 00:19:50,396 OF HIGH PERFORMANCE AND TRADITIONAL AUTOMOTIVE FASHION. 339 00:19:50,398 --> 00:19:52,790 LOOKING SET TO ROLL OUT OF THE FACTORY, 340 00:19:52,792 --> 00:19:55,752 THIS CAR IS NOT QUITE READY FOR THE OPEN ROAD. 341 00:19:55,754 --> 00:19:59,881 TWO WORKERS GIVE THE LUXURY SPORTS CAR SOME FINAL ATTENTION 342 00:19:59,883 --> 00:20:03,018 BY BUFFING THE BODY PANELS WITH A POLISHING CHEMICAL 343 00:20:03,020 --> 00:20:05,212 AND SOME FIRM CLEANING WITH CARE. 344 00:20:06,749 --> 00:20:10,742 A VARIABLE-SPEED POLISHER AND A NON-ABRASIVE LEATHER CLOTH 345 00:20:10,744 --> 00:20:14,905 ARE ALSO USED TO HIGHLIGHT THE PAINT FINISH. 346 00:20:14,907 --> 00:20:17,834 ADMIRABLY TAILORED, CAREFULLY CRAFTED, 347 00:20:17,836 --> 00:20:20,328 AND DESIGNED TO GO THE DISTANCE, 348 00:20:20,330 --> 00:20:23,431 THIS FLAGSHIP SUPER CAR, THE AERO COUPE, 349 00:20:23,433 --> 00:20:26,426 IS NOW READY TO ROAM THE COUNTRYSIDE ROADS. 350 00:20:30,256 --> 00:20:32,515 MANUFACTURED WITH THE HIGHEST QUALITY 351 00:20:32,517 --> 00:20:35,985 OF WOOD, ALUMINUM, AND PLASTIC MATERIALS, 352 00:20:35,987 --> 00:20:39,381 THIS CAR IS AN EXAMPLE OF THE DESIGN AND HAND ASSEMBLY 353 00:20:39,383 --> 00:20:44,178 BY MEN AND WOMEN WORKING AT THE FOOT OF THE MALVERN HILLS. 354 00:20:44,180 --> 00:20:46,538 THE AERO CONTINUES TO REPRESENT 355 00:20:46,540 --> 00:20:48,675 THE UNIQUE AUTOMOTIVE ENGINEERING 356 00:20:48,677 --> 00:20:53,129 OF A WELL-DRESSED CLASSIC WITH AN EXTREME EDGE. 357 00:20:53,131 --> 00:20:55,464 WHETHER IN MOTION... 358 00:20:55,466 --> 00:20:57,000 OR STANDING STILL, 359 00:20:57,002 --> 00:20:59,994 IT IS A BOLD AUTOMOTIVE SCULPTURE. 360 00:20:59,996 --> 00:21:03,623 LIKE THE OUTER SHELL, THE REFINED COCKPIT 361 00:21:03,625 --> 00:21:07,019 IS FITTED WITH THE LUXURIOUS TRIMMINGS OF ASH HARDWOOD, 362 00:21:07,021 --> 00:21:12,216 PREMIUM SCOTTISH LEATHER, AND UNCOMPROMISED QUALITY. 363 00:21:12,218 --> 00:21:17,772 MANUFACTURED BY HAND AND MADE LIKE A FUTURISTIC CONCEPT CAR, 364 00:21:17,774 --> 00:21:20,574 THIS SUPER CAR IS VERY REAL. 365 00:21:20,576 --> 00:21:23,369 EXTREMELY LIGHTWEIGHT AND VERY MANEUVERABLE, 366 00:21:23,371 --> 00:21:26,231 IT'S A STELLAR MODEL OF THE ONGOING COMMITMENT 367 00:21:26,233 --> 00:21:31,028 TO MORE THAN 100 YEARS OF UNFORGETTABLE SPORTS CARS. 29651

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