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These are the user uploaded subtitles that are being translated: 1 00:00:01,735 --> 00:00:03,268 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,270 --> 00:00:08,224 THE BUGATTI VEYRON, THE FASTEST WORK OF ART IN THE WORLD. 3 00:00:08,226 --> 00:00:11,494 ♪♪♪ 4 00:00:11,496 --> 00:00:14,555 -- Captions by VITAC -- www.vitac.com 5 00:00:14,557 --> 00:00:18,151 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,183 --> 00:00:24,975 Narrator: THE CITé DE L'AUTOMOBILE 7 00:00:24,977 --> 00:00:27,177 IN MULHOUSE, FRANCE, WAS FORMERLY KNOWN 8 00:00:27,179 --> 00:00:28,378 AS THE SCHLUMPF COLLECTION. 9 00:00:28,380 --> 00:00:30,706 IT HOUSES THE LARGEST COLLECTION 10 00:00:30,708 --> 00:00:32,800 OF CLASSIC BUGATTIS IN THE WORLD. 11 00:00:32,802 --> 00:00:35,569 WHILE MOST CAR COMPANIES WERE FOUNDED BY ENTREPRENEURS 12 00:00:35,571 --> 00:00:37,930 WITH A PURELY TECHNICAL BACKGROUND, 13 00:00:37,932 --> 00:00:40,198 BUGATTI'S CREATOR, ETTORE BUGATTI, 14 00:00:40,200 --> 00:00:44,595 CAME FROM A FAMILY OF WELL-KNOWN ITALIAN ARTISTS. 15 00:00:44,597 --> 00:00:47,190 THAT ARTISTIC HERITAGE PLAYED A VITAL ROLE 16 00:00:47,192 --> 00:00:50,051 IN THE DESIGN OF BUGATTI CARS, LONG CONSIDERED 17 00:00:50,053 --> 00:00:52,721 AMONG THE MOST BEAUTIFUL EVER MADE, 18 00:00:52,723 --> 00:00:55,882 BUT ART NEVER GOT IN THE WAY OF SPEED. 19 00:00:55,884 --> 00:00:58,744 IN FACT, BUGATTI BUILT ONE OF AUTOMOTIVE HISTORY'S 20 00:00:58,746 --> 00:01:03,274 MOST SUCCESSFUL RACE CARS -- THE TYPE 35. 21 00:01:03,276 --> 00:01:06,936 AFTER ETTORE AND HIS SON JEAN DIED, 22 00:01:06,938 --> 00:01:11,032 THE BUGATTI BRAND WENT DORMANT IN THE EARLY 1960s. 23 00:01:11,034 --> 00:01:13,893 BUT VOLKSWAGEN BOUGHT IT IN 1998, 24 00:01:13,895 --> 00:01:17,563 AND BUGATTI CAME ROARING BACK TO LIFE WITH THE VEYRON, 25 00:01:17,565 --> 00:01:20,659 THE FASTEST PRODUCTION CAR IN EXISTENCE. 26 00:01:22,688 --> 00:01:25,222 BUILT HERE AT ITS ANCESTRAL HEADQUARTERS 27 00:01:25,224 --> 00:01:27,849 IN MOLSHEIM, FRANCE, IT'S THE MOST POWERFUL 28 00:01:27,851 --> 00:01:30,811 AND EXPENSIVE PRODUCTION CAR IN THE WORLD. 29 00:01:32,581 --> 00:01:35,641 ♪♪♪ 30 00:01:35,643 --> 00:01:38,311 THE CARS ARE MADE HERE IN A BUILDING REFERRED TO 31 00:01:38,313 --> 00:01:40,237 AS THE ATELIER. 32 00:01:40,239 --> 00:01:43,132 THE PEOPLE AT BUGATTI THINK OF VEYRON 33 00:01:43,134 --> 00:01:45,001 AS MUCH MORE THAN JUST A CAR. 34 00:01:45,003 --> 00:01:48,396 TO THEM, IT'S AN AUTOMOTIVE WORK OF ART. 35 00:01:48,398 --> 00:01:52,526 EACH CAR BEGINS LIFE HERE IN THE DESIGN DEPARTMENT. 36 00:01:54,855 --> 00:01:57,189 AS FUTURISTIC AS THE VEYRON MAY LOOK, 37 00:01:57,191 --> 00:02:01,484 IT STILL FEATURES THE FAMOUS BUGATTI HORSESHOE-SHAPED GRILLE 38 00:02:01,486 --> 00:02:04,213 DEVELOPED BY ETTORE. 39 00:02:04,215 --> 00:02:06,549 ETTORE'S SON JEAN WAS A TALENTED STYLIST. 40 00:02:06,551 --> 00:02:09,544 HE CREATED SWEEPING CURVES THAT CAME TO DEFINE 41 00:02:09,546 --> 00:02:11,071 THE BUGATTI LOOK, 42 00:02:11,073 --> 00:02:14,941 AND THOSE CURVES REAPPEAR ON THE VEYRON. 43 00:02:14,943 --> 00:02:16,635 LIGHTWEIGHT AND STRONG, 44 00:02:16,637 --> 00:02:19,037 CARBON FIBER IS THE IDEAL MATERIAL 45 00:02:19,039 --> 00:02:21,898 FOR CONSTRUCTING A SUPERCAR LIKE THE VEYRON. 46 00:02:21,900 --> 00:02:25,694 HERE, A MACHINE CALLED A PLOTTER CUTS A SHEET OF CARBON FIBER 47 00:02:25,696 --> 00:02:27,228 INTO THE REQUIRED SHAPES. 48 00:02:27,230 --> 00:02:30,624 THE MATERIAL, WHICH IS STORED AT MINUS 4 DEGREES FAHRENHEIT 49 00:02:30,626 --> 00:02:32,285 TO PRESERVE ITS FORM, 50 00:02:32,287 --> 00:02:36,347 IS HEATED TO PLUS 64 DEGREES JUST PRIOR TO CUTTING. 51 00:02:37,984 --> 00:02:41,510 AND BUGATTI USES DIFFERENT KINDS OF FIBER DEPENDING ON 52 00:02:41,512 --> 00:02:43,646 WHAT PART OF THE CAR THEY'RE BUILDING. 53 00:02:43,648 --> 00:02:45,707 WHERE CERTAIN COMPONENTS REQUIRE FLEXIBILITY, 54 00:02:45,709 --> 00:02:48,235 OTHERS NEED RIGIDITY. 55 00:02:50,639 --> 00:02:54,533 A WORKER POSITIONS THE CARBON FIBER IN A MOLD. 56 00:02:54,535 --> 00:02:57,861 TO CREATE A PART, SHE MUST LAYER MULTIPLE SHEETS, OR PLIES, 57 00:02:57,863 --> 00:03:01,390 OF THE FIBER IN A SPECIFIED ORDER. 58 00:03:02,993 --> 00:03:05,786 THIS LAYERING PROCESS ADDS STRENGTH. 59 00:03:05,788 --> 00:03:08,448 TO AVOID CREATING ANY WRINKLES, SHE CAREFULLY CUTS 60 00:03:08,450 --> 00:03:12,577 AND OVERLAPS THE MATERIAL AT THE CORNERS. 61 00:03:12,579 --> 00:03:15,947 ALTHOUGH SHE MAKES IT LOOK EASY, THIS JOB REQUIRES 62 00:03:15,949 --> 00:03:18,875 AN ENORMOUS AMOUNT OF SKILL AND EXPERIENCE. 63 00:03:18,877 --> 00:03:21,603 EACH LAYER OF FIBER MUST BE CAREFULLY POSITIONED 64 00:03:21,605 --> 00:03:23,939 TO ENSURE MAXIMUM PERFORMANCE. 65 00:03:23,941 --> 00:03:27,835 THE PATTERN OF THE FIBERS MUST BE PERFECTLY ALIGNED. 66 00:03:31,966 --> 00:03:34,892 THE MOLD THEN COMES HERE TO THESE GIANT OVENS, 67 00:03:34,894 --> 00:03:36,694 WHICH ARE CALLED AUTOCLAVES. 68 00:03:36,696 --> 00:03:40,557 AUTOCLAVES APPLY A COMBINATION OF HEAT AND PRESSURE 69 00:03:40,559 --> 00:03:42,417 TO CURE THE CARBON FIBER. 70 00:03:43,920 --> 00:03:47,914 AFTER 4 HOURS OF BAKING AT 275 DEGREES FAHRENHEIT 71 00:03:47,916 --> 00:03:51,310 UNDER 87 PSI, THE PART IS READY. 72 00:03:51,312 --> 00:03:55,705 WORKERS REMOVE IT FROM THE MOLD. 73 00:03:55,707 --> 00:03:59,134 WHILE ALMOST ALL THE WORK OF CREATING A VEYRON 74 00:03:59,136 --> 00:04:01,003 IS ACCOMPLISHED BY HAND, 75 00:04:01,005 --> 00:04:03,664 SOMETIMES A ROBOT COMES IN HANDY. 76 00:04:03,666 --> 00:04:06,726 HERE A C.N.C. MACHINE TRIMS OFF EXCESS MATERIAL 77 00:04:06,728 --> 00:04:10,322 AND DRILLS ANY NECESSARY HOLES. 78 00:04:12,926 --> 00:04:15,685 NEXT, THE PARTS COME HERE, 79 00:04:15,687 --> 00:04:17,487 WHERE SKILLED CRAFTSMEN PREPARE THE SURFACE. 80 00:04:17,489 --> 00:04:21,016 THEY BEGIN BY SANDING WITH A HEAVY GRIT MATERIAL. 81 00:04:21,018 --> 00:04:24,678 THEY REPEAT THIS TIME-CONSUMING, PAINSTAKING PROCESS 82 00:04:24,680 --> 00:04:27,806 MULTIPLE TIMES WITH INCREASINGLY FINER GRITS 83 00:04:27,808 --> 00:04:31,302 UNTIL THE SURFACE IS PERFECTLY SMOOTH. 84 00:04:31,304 --> 00:04:32,903 THIS TECHNICIAN PERFORMS 85 00:04:32,905 --> 00:04:35,631 A HIGHLY DETAILED QUALITY CONTROL CHECK. 86 00:04:35,633 --> 00:04:38,760 SHE INSPECTS EVERY INCH OF THE SURFACE, 87 00:04:38,762 --> 00:04:42,296 MARKING ANY IMPERFECTIONS THAT NEED TO BE CORRECTED. 88 00:04:42,298 --> 00:04:43,890 THERE'S NO TIME RESTRAINT. 89 00:04:43,892 --> 00:04:48,820 EACH COMPONENT MUST BE ABSOLUTELY FLAWLESS. 90 00:04:48,822 --> 00:04:51,448 USING PRECISION CALIPERS, 91 00:04:51,450 --> 00:04:53,250 SHE CAREFULLY MEASURES THE DIAMETER OF THE HOLES 92 00:04:53,252 --> 00:04:56,679 TO ENSURE THEY'RE THE CORRECT SIZE. 93 00:04:59,909 --> 00:05:02,376 ONCE THE COMPONENTS HAVE PASSED INSPECTION, 94 00:05:02,378 --> 00:05:06,773 WORKERS MOUNT THEM ON A MONOCOQUE CHASSIS. 95 00:05:06,775 --> 00:05:09,334 LIKE TAILORS PUTTING TOGETHER A SUIT, 96 00:05:09,336 --> 00:05:12,495 THEY MAKE SURE THE PARTS FIT TOGETHER CORRECTLY. 97 00:05:13,932 --> 00:05:19,787 THE WEAVE PATTERN MUST ALIGN, AND THEY EVEN MEASURE THE GAPS. 98 00:05:19,789 --> 00:05:23,583 BUGATTI DESIGNERS LOOK FOR INSPIRATION IN EVERYTHING, 99 00:05:23,585 --> 00:05:26,285 FROM PIGMENTS TO CHUNKS OF CRYSTAL. 100 00:05:26,287 --> 00:05:29,613 HERE, DESIGNERS WORK ON A BLUE-THEMED VEYRON, 101 00:05:29,615 --> 00:05:31,549 DECIDING HOW BEST TO MATCH 102 00:05:31,551 --> 00:05:34,210 DIFFERENT TINTS TO THE INTERIOR AND EXTERIOR COMPONENTS 103 00:05:34,212 --> 00:05:35,545 OF THE CAR. 104 00:05:36,607 --> 00:05:39,007 THEIR INSPIRATION IS THE RACING COLOR 105 00:05:39,009 --> 00:05:41,634 THAT ADORNED MANY EARLY BUGATTIS. 106 00:05:41,636 --> 00:05:45,230 CARS RACING IN THE FIRST HALF OF THE 20th CENTURY 107 00:05:45,232 --> 00:05:48,358 BORE THE RACING COLOR OF THEIR COUNTRY OF ORIGIN. 108 00:05:48,360 --> 00:05:50,627 THE FRENCH RACING COLOR WAS BLUE, 109 00:05:50,629 --> 00:05:55,891 AND BLUE HAS BECOME A DISTINCTIVE COLOR FOR BUGATTI. 110 00:05:55,893 --> 00:05:59,320 LIKE NEARLY EVERY OTHER STEP IN THE CREATION OF A VEYRON, 111 00:05:59,322 --> 00:06:03,783 THE PAINTING PROCESS IS ACCOMPLISHED BY HAND. 112 00:06:03,785 --> 00:06:07,378 AND ONCE AGAIN, SKILL AND EXPERIENCE ARE CRITICAL 113 00:06:07,380 --> 00:06:09,172 TO DOING THE JOB RIGHT. 114 00:06:09,174 --> 00:06:12,376 HERE, A PAINTER APPLIES LAYER UPON LAYER 115 00:06:12,378 --> 00:06:14,870 OF A CLEAR COAT. 116 00:06:14,872 --> 00:06:17,464 OFTEN, CUSTOMERS REQUEST A CLEAR FINISH 117 00:06:17,466 --> 00:06:21,661 THAT REVEALS THE CARBON FIBER STRUCTURE UNDERNEATH. 118 00:06:23,798 --> 00:06:27,925 BUT CUSTOMERS CAN ALSO CHOOSE ANY COLOR THEY DESIRE. 119 00:06:27,927 --> 00:06:33,022 IT COULD EVEN BE THE SHADE OF RED FOUND ON A FAVORITE TIE. 120 00:06:33,024 --> 00:06:34,882 TO GIVE THE COLOR DEPTH, 121 00:06:34,884 --> 00:06:38,812 THE PAINTER MAY APPLY AS MANY AS 10 OR MORE COATS. 122 00:06:42,276 --> 00:06:44,676 [ ENGINE REVS ] 123 00:06:46,344 --> 00:06:48,277 ♪♪♪ 124 00:06:48,279 --> 00:06:51,539 Narrator: ONE LOOK AT THIS COLOSSAL 16-CYLINDER ENGINE 125 00:06:51,541 --> 00:06:55,468 AND ITS 7-SPEED DIRECT SHIFT GEARBOX TRANSMISSION, 126 00:06:55,470 --> 00:06:57,470 AND YOU BEGIN TO UNDERSTAND WHY 127 00:06:57,472 --> 00:07:00,132 THE BUGATTI VEYRON HOLDS THE RECORD 128 00:07:00,134 --> 00:07:03,260 FOR THE FASTEST PRODUCTION CAR IN THE WORLD. 129 00:07:03,262 --> 00:07:04,795 ♪♪♪ 130 00:07:04,797 --> 00:07:06,822 VEYRON ENGINES ARE HAND-BUILT. 131 00:07:06,824 --> 00:07:10,418 TWO EXPERTS BUILD EACH ONE PIECE BY PIECE 132 00:07:10,420 --> 00:07:13,487 FROM A COMBINATION OF ALUMINUM, TITANIUM, 133 00:07:13,489 --> 00:07:15,748 STEEL, AND MAGNESIUM. 134 00:07:15,750 --> 00:07:17,683 THE PROCESS IS SO METICULOUS, 135 00:07:17,685 --> 00:07:21,546 IT TAKES TWO WEEKS TO BUILD A SINGLE ENGINE. 136 00:07:21,548 --> 00:07:24,440 HERE, THEY INSTALL THE CRANKSHAFT IN ITS HOUSING 137 00:07:24,442 --> 00:07:27,568 BEFORE BOLTING ON TEMPORARY SPACERS TO HOLD IT IN PLACE. 138 00:07:27,570 --> 00:07:30,964 THIS WILL ALLOW THEM TO ROTATE THE ENGINE BLOCK 139 00:07:30,966 --> 00:07:33,434 IN PREPARATION FOR THE NEXT STEP. 140 00:07:36,564 --> 00:07:38,689 IT'S NOW TIME TO INSTALL THE PISTONS, 141 00:07:38,691 --> 00:07:42,293 WHICH CAN ONLY BE INSERTED FROM ABOVE. 142 00:07:44,656 --> 00:07:47,315 THE CONNECTING RODS ARE MADE OF TITANIUM. 143 00:07:47,317 --> 00:07:50,385 ILLUSTRATING BUGATTI'S FAMOUS FLAIR FOR DETAIL, 144 00:07:50,387 --> 00:07:53,513 ETTORE BUGATTI'S INITIALS CAN EVEN BE FOUND HERE, 145 00:07:53,515 --> 00:07:56,308 WHERE THEY WILL BE INVISIBLE ONCE INSTALLED. 146 00:07:59,805 --> 00:08:01,738 THE WORKER ROTATES THE PISTON RINGS 147 00:08:01,740 --> 00:08:04,867 TO PREVENT KNOCKING AND TO EFFECTIVELY SEAL OFF 148 00:08:04,869 --> 00:08:08,595 THE COMBUSTION CHAMBER FROM THE CRANKSHAFT. 149 00:08:08,597 --> 00:08:11,064 THE WORKER THEN OILS THE PISTON BY HAND 150 00:08:11,066 --> 00:08:15,620 TO PREPARE IT FOR INSTALLATION. 151 00:08:15,622 --> 00:08:18,022 A CLAMPING DEVICE UNIQUELY DESIGNED TO HOLD PISTONS 152 00:08:18,024 --> 00:08:20,617 ALLOWS HIM TO CAREFULLY SITUATE THE COMPONENT 153 00:08:20,619 --> 00:08:23,420 BEFORE SINKING IT INTO POSITION. 154 00:08:28,744 --> 00:08:30,210 ROTATING THE ENGINE BLOCK, 155 00:08:30,212 --> 00:08:32,237 HE REMOVES THE TEMPORARY EXTENSIONS 156 00:08:32,239 --> 00:08:34,974 TO PREPARE FOR THE NEXT STEP OF ATTACHING THE RODS 157 00:08:34,976 --> 00:08:36,801 TO THE CRANKSHAFT. 158 00:08:39,439 --> 00:08:42,498 THIS PART IS CALLED THE CONNECTING ROD CAP. 159 00:08:42,500 --> 00:08:44,166 AFTER APPLYING GREASE, 160 00:08:44,168 --> 00:08:47,428 THE TECHNICIAN BOLTS THE CAP ONTO THE CONNECTING ROD, 161 00:08:47,430 --> 00:08:49,623 SECURING IT AROUND THE CRANK PIN. 162 00:08:51,793 --> 00:08:53,518 HE THEN USES A HAND TOOL 163 00:08:53,520 --> 00:08:56,747 TO LOOSELY FASTEN THE BOLTS IN PLACE. 164 00:08:59,385 --> 00:09:02,578 THEN A CUSTOM-MADE DEVICE FINISHES UP THE JOB, 165 00:09:02,580 --> 00:09:04,939 SIMULTANEOUSLY TIGHTENING THE FASTENERS 166 00:09:04,941 --> 00:09:09,035 TO THE PRECISE TORQUE SPECIFIED BY THE ENGINEERS. 167 00:09:10,738 --> 00:09:12,604 A MONITORING SYSTEM KEEPS TRACK, 168 00:09:12,606 --> 00:09:17,593 ENSURING THAT ALL BOLTS ARE CORRECTLY TIGHTENED. 169 00:09:17,595 --> 00:09:20,397 NOW THE TECHNICIANS CAREFULLY LOWER THE BEARING CASE 170 00:09:20,399 --> 00:09:23,825 ONTO THE CRANK CASE, SEALING IN THE CRANKSHAFT. 171 00:09:23,827 --> 00:09:27,421 THE FINISHED 8-LITER, 16-CYLINDER ENGINE WILL PRODUCE 172 00:09:27,423 --> 00:09:32,818 1,200 HORSEPOWER AT 6,400 R.P.M., 173 00:09:32,820 --> 00:09:36,013 AND IT WILL HAVE A TORQUE OF 1,100 FOOT POUNDS 174 00:09:36,015 --> 00:09:40,242 BETWEEN 3,000 AND 5,000 R.P.M. 175 00:09:40,244 --> 00:09:42,436 FIRST, THE TECHNICIANS HAVE TO INSTALL 176 00:09:42,438 --> 00:09:45,306 THE LOWER INTAKE MANIFOLD. 177 00:09:45,308 --> 00:09:48,501 THERE ARE TWO UPPER SECTIONS OF THE INTAKE MANIFOLD, 178 00:09:48,503 --> 00:09:50,762 EACH FEEDING 8 CYLINDERS. 179 00:09:50,764 --> 00:09:55,092 LIKE THE BULK OF THE ENGINE, THESE COMPONENTS ARE ALUMINUM. 180 00:09:57,796 --> 00:10:00,189 LOOK CLOSELY, AND YOU CAN SEE A TINY VERSION 181 00:10:00,191 --> 00:10:04,451 OF ETTORE BUGATTI'S INITIALS ON THE HEADS OF THE ALUMINUM BOLTS 182 00:10:04,453 --> 00:10:06,412 THAT SECURE THE MANIFOLD. 183 00:10:09,184 --> 00:10:10,675 THE ENGINE IS NOW COMPLETE. 184 00:10:10,677 --> 00:10:13,411 IT'S TIME TO TRANSFER IT TO THE TESTING FACILITY 185 00:10:13,413 --> 00:10:15,071 AND START IT UP. 186 00:10:18,402 --> 00:10:22,204 THE ENGINE SPENDS EIGHT HOURS ON THE TESTING RIG, 187 00:10:22,206 --> 00:10:24,731 AS TECHNICIANS REV IT UP TO ITS FULL POWER AND TORQUE 188 00:10:24,733 --> 00:10:27,526 IN MULTIPLE CYCLES. 189 00:10:27,528 --> 00:10:29,261 WHILE MONITORING THE PERFORMANCE, 190 00:10:29,263 --> 00:10:32,356 THE TECHNICIANS ALSO RUN IN THE ENGINE. 191 00:10:32,358 --> 00:10:33,624 THERE'LL BE NO NEED 192 00:10:33,626 --> 00:10:36,952 FOR CUSTOMERS TO BREAK IT IN SLOWLY. 193 00:10:36,954 --> 00:10:39,280 [ WHIRRING ] 194 00:10:39,282 --> 00:10:42,617 THE EXHAUST MANIFOLDS AND TURBOCHARGERS GLOW RED-HOT, 195 00:10:42,619 --> 00:10:44,677 THEIR SURFACE TEMPERATURES REACHING 196 00:10:44,679 --> 00:10:47,973 UP TO 1,470 DEGREES FAHRENHEIT, 197 00:10:47,975 --> 00:10:52,236 WITH EXHAUST GASES AT 1,800 DEGREES. 198 00:10:52,238 --> 00:10:57,166 THE ENGINE IS NOW COMPLETELY ASSEMBLED, TESTED, AND RUN IN. 199 00:10:57,168 --> 00:11:00,293 A TECHNICIAN PERFORMS THE FINAL QUALITY CHECK 200 00:11:00,295 --> 00:11:03,030 AND PREPARES IT FOR TRANSPORT. 201 00:11:03,032 --> 00:11:05,858 THIS QUAD-TURBOCHARGED 8-LITER BEHEMOTH 202 00:11:05,860 --> 00:11:09,921 PRODUCES 1,200 HORSEPOWER. 203 00:11:09,923 --> 00:11:14,717 UNIQUE AMONG PRODUCTION ENGINES, IT HAS 64 VALVES. 204 00:11:14,719 --> 00:11:16,377 BUT THANKS TO CAREFUL ENGINEERING, 205 00:11:16,379 --> 00:11:19,381 IT ONLY NEEDS FOUR CAMSHAFTS. 206 00:11:19,383 --> 00:11:21,074 AT ITS TOP SPEED, 207 00:11:21,076 --> 00:11:25,537 THE ENGINE INHALES 53,000 LITERS OF AIR PER MINUTE -- 208 00:11:25,539 --> 00:11:29,400 AS MUCH AS YOU BREATHE OVER FIVE DAYS. 209 00:11:29,402 --> 00:11:31,702 ♪♪♪ 210 00:11:35,222 --> 00:11:36,747 Narrator: NEARLY EVERY INCH 211 00:11:36,749 --> 00:11:40,016 OF A BUGATTI VEYRON INTERIOR IS COVERED IN LEATHER. 212 00:11:40,018 --> 00:11:42,277 WITH HUNDREDS OF PIECES OF LEATHER TO PREPARE, 213 00:11:42,279 --> 00:11:46,140 IT TAKES 12 TO 15 COWHIDES TO UPHOLSTER A VEYRON, 214 00:11:46,142 --> 00:11:49,302 AND OF COURSE, IT'S ALL DONE BY HAND. 215 00:11:49,304 --> 00:11:50,569 ♪♪♪ 216 00:11:50,571 --> 00:11:53,430 ETTORE BUGATTI ONCE SAID OF HIS CARS, 217 00:11:53,432 --> 00:11:57,360 "NOTHING IS TOO BEAUTIFUL, AND NOTHING IS TOO EXPENSIVE." 218 00:11:57,362 --> 00:12:00,830 HIS SON JEAN AGREED, BELIEVING TAILOR-MADE SERVICE 219 00:12:00,832 --> 00:12:04,960 SHOULD BE ONE OF BUGATTI'S HIGHEST PRIORITIES. 220 00:12:04,962 --> 00:12:07,387 CUSTOMERS CAN CHOOSE FROM ONE 221 00:12:07,389 --> 00:12:10,516 OF MORE THAN ROUGHLY 45 COLORS OF LEATHER. 222 00:12:10,518 --> 00:12:12,518 BUGATTI SOURCES THESE HIDES 223 00:12:12,520 --> 00:12:17,314 FROM COWS RAISED HIGH IN THE MOUNTAINS OF AUSTRIA. 224 00:12:17,316 --> 00:12:20,710 THAT ENVIRONMENT IS FREE OF MOSQUITOES AND BARBED WIRE, 225 00:12:20,712 --> 00:12:23,938 SO THE COWHIDES ARE NEARLY FLAWLESS. 226 00:12:23,940 --> 00:12:28,535 BUT INEVITABLY, THERE WILL BE A FEW IRREGULARITIES. 227 00:12:28,537 --> 00:12:32,531 THIS ARTISAN SPREADS A HIDE ON A SPECIALIZED TABLE, 228 00:12:32,533 --> 00:12:36,059 WHICH USES A CLAMPING DEVICE TO STRETCH THE LEATHER TIGHT, 229 00:12:36,061 --> 00:12:38,854 ALLOWING FOR CLOSE INSPECTION OF THE SURFACE. 230 00:12:42,218 --> 00:12:44,752 A BRIGHT, EVEN LIGHT HELPS THE WORKER 231 00:12:44,754 --> 00:12:47,947 METICULOUSLY EXAMINE EVERY INCH OF THE HIDE. 232 00:12:47,949 --> 00:12:51,009 WHEREVER SHE FINDS EVEN THE TINIEST FLAW, 233 00:12:51,011 --> 00:12:53,678 SHE CIRCLES IT WITH A SPECIAL PENCIL. 234 00:12:55,173 --> 00:12:57,040 WHILE THE FLAWS MAY SIMPLY BE 235 00:12:57,042 --> 00:12:59,701 NATURALLY OCCURRING WRINKLES OR DENTS, 236 00:12:59,703 --> 00:13:02,137 THEY MUST BE MARKED AND AVOIDED. 237 00:13:06,727 --> 00:13:08,427 STEERING CLEAR OF THE MARKED FLAWS, 238 00:13:08,429 --> 00:13:12,389 THE CRAFTSWOMAN LAYS A SET OF STENCILS ON THE LEATHER. 239 00:13:12,391 --> 00:13:13,924 THESE REPRESENT THE LEATHER REQUIRED 240 00:13:13,926 --> 00:13:15,785 TO UPHOLSTER A DOOR. 241 00:13:15,787 --> 00:13:17,720 SHE CAREFULLY TRACES 242 00:13:17,722 --> 00:13:21,549 THE OUTLINES OF EACH STENCIL ON THE HIDE. 243 00:13:23,578 --> 00:13:26,513 SHE THEN REMOVES THE STENCILS TO CLEAR OFF THE LEATHER 244 00:13:26,515 --> 00:13:29,975 AND MAKE ROOM FOR HER SCISSORS. 245 00:13:29,977 --> 00:13:32,336 IT'S THE SAME PROCEDURE A SEAMSTRESS USES 246 00:13:32,338 --> 00:13:34,737 TO MAKE A DRESS, BUT IN THIS CASE, 247 00:13:34,739 --> 00:13:37,366 IT'S A CAR DOOR THAT'S GETTING AN OUTFIT. 248 00:13:38,669 --> 00:13:41,128 GIVEN BUGATTI'S EMPHASIS ON CUSTOM WORK, 249 00:13:41,130 --> 00:13:45,425 IT'S NO SURPRISE THE ARTISAN DOES HER CUTTING BY HAND. 250 00:13:50,489 --> 00:13:53,349 CLIPPING DIVOTS AT INTERVALS ALONG THE EDGES 251 00:13:53,351 --> 00:13:57,479 WILL MAKE IT EASIER TO ALIGN THE LEATHER PROPERLY. 252 00:13:57,481 --> 00:13:59,548 IT'S IMPORTANT THAT ALL THE PIECES 253 00:13:59,550 --> 00:14:03,610 BE PRECISELY THE SAME THICKNESS. 254 00:14:03,612 --> 00:14:06,504 THIS DEVICE SHAVES THE UNDERSIDE OF THE LEATHER 255 00:14:06,506 --> 00:14:08,699 TO THE SAME PRESCRIBED DEPTH -- 256 00:14:08,701 --> 00:14:11,669 IN THIS CASE, NEARLY HALF THE ORIGINAL THICKNESS. 257 00:14:14,365 --> 00:14:17,292 TO PREVENT BULKINESS WHERE THE PIECES OVERLAP, 258 00:14:17,294 --> 00:14:19,960 AN OPERATOR USES A PURPOSE-BUILT MACHINE 259 00:14:19,962 --> 00:14:23,055 TO SHAVE THE EDGES OF THE LEATHER DOWN EVEN FURTHER. 260 00:14:23,057 --> 00:14:27,985 THIS PROCESS, KNOWN AS SKIVING, IS JUST ONE PRECISION ELEMENT 261 00:14:27,987 --> 00:14:31,714 OF FINE LEATHER CRAFTSMANSHIP. 262 00:14:31,716 --> 00:14:34,176 ETTORE BUGATTI WAS KNOWN TO HAVE 263 00:14:34,178 --> 00:14:37,071 A GREAT PASSION FOR LEATHERWORK. 264 00:14:42,203 --> 00:14:46,864 THE MACHINE THIS ARTISAN USES SIMULTANEOUSLY STITCHES 265 00:14:46,866 --> 00:14:49,191 AND TRIMS THE PIECES AS SHE WORKS. 266 00:14:49,193 --> 00:14:52,729 BUGATTI'S ATTENTION TO DETAIL IN UPHOLSTERING THE VEYRON 267 00:14:52,731 --> 00:14:56,024 IS A THROWBACK TO THE EARLY DAYS OF CAR MANUFACTURE, 268 00:14:56,026 --> 00:14:58,085 WHEN SPECIALIZED COACH BUILDERS 269 00:14:58,087 --> 00:15:00,854 MADE CUSTOM INTERIORS FOR EACH CAR. 270 00:15:03,550 --> 00:15:05,150 AS SHE WORKS, 271 00:15:05,152 --> 00:15:09,538 THE INTERIOR OF THE CAR DOOR BEGINS TO TAKE SHAPE. 272 00:15:09,540 --> 00:15:12,441 WITH A STEADY HAND, A SKILLED CRAFTSWOMAN 273 00:15:12,443 --> 00:15:15,904 APPLIES A DECORATIVE STITCH USING A PALE BLUE THREAD 274 00:15:15,906 --> 00:15:18,765 ON DARK BLUE LEATHER TO CREATE CONTRAST. 275 00:15:18,767 --> 00:15:20,566 A POPULAR CUSTOMER CHOICE, 276 00:15:20,568 --> 00:15:23,562 THIS STITCHING TECHNIQUE IS CALLED QUILTING. 277 00:15:26,592 --> 00:15:29,792 A FINISHED EXAMPLE OF THIS STYLE OF DECORATIVE STITCHING 278 00:15:29,794 --> 00:15:35,983 WILL COVER AN ARMREST THAT FORMS PART OF THE CENTER CONSOLE. 279 00:15:35,985 --> 00:15:37,985 WHEN IT COMES TO LEATHERWORK, 280 00:15:37,987 --> 00:15:40,313 THE POSSIBILITIES ARE NEARLY ENDLESS. 281 00:15:40,315 --> 00:15:43,240 CUSTOMERS CAN EVEN CHOOSE A WOVEN PATTERN 282 00:15:43,242 --> 00:15:44,709 FOR THEIR UPHOLSTERY. 283 00:15:46,604 --> 00:15:49,873 A WORKER NOW BEGINS THE PAINSTAKING PROCESS 284 00:15:49,875 --> 00:15:53,001 OF ATTACHING THE LEATHER TO ITS SUBSTRUCTURE. 285 00:15:53,003 --> 00:15:54,727 HE BEGINS BY CAREFULLY 286 00:15:54,729 --> 00:16:00,258 AND THOROUGHLY WEDGING A SECTION OF SEAM INTO A SLOT. 287 00:16:00,260 --> 00:16:04,421 NEXT, HE BRUSHES A GLUE ONTO THE SUBSTRUCTURE 288 00:16:04,423 --> 00:16:06,423 AND CAREFULLY BRINGS THE LEATHER OVER IT. 289 00:16:06,425 --> 00:16:09,952 THIS GLUE IS A POLYURETHANE-BASED ADHESIVE 290 00:16:09,954 --> 00:16:15,608 THAT REMAINS FLEXIBLE EVEN AFTER IT CURES. 291 00:16:15,610 --> 00:16:18,812 TO WORK PROPERLY, THE GLUE MUST BE THERMALLY ACTIVATED. 292 00:16:18,814 --> 00:16:22,941 HERE THE UPHOLSTERER USES A HEAT GUN TO DO THE JOB. 293 00:16:25,237 --> 00:16:28,363 A FLAT HANDHELD DEVICE REMOVES ANY AIR POCKETS 294 00:16:28,365 --> 00:16:30,765 THAT WOULD COMPROMISE THE ADHESION 295 00:16:30,767 --> 00:16:34,862 AND ENSURES THAT THE LEATHER HUGS THE SUBSTRUCTURE TIGHTLY. 296 00:16:38,192 --> 00:16:42,120 THE DOOR PANEL HAS BEEN FULLY UPHOLSTERED AND TRIMMED. 297 00:16:42,122 --> 00:16:44,314 BUT WILL IT FIT? 298 00:16:44,316 --> 00:16:46,582 TO ENSURE THAT ALL THE DIMENSIONS ARE CORRECT, 299 00:16:46,584 --> 00:16:49,977 A WORKER ATTACHES THE PANEL TO A MOCK-UP DOOR. 300 00:16:49,979 --> 00:16:52,939 A QUALITY CONTROL INSPECTOR THEN VERIFIES 301 00:16:52,941 --> 00:16:56,769 THAT ALL LEVERS AND KNOBS ARE IN PERFECT WORKING ORDER. 302 00:17:01,534 --> 00:17:04,326 SHE ALSO USES A SPACER TO EXAMINE THE DIVIDE 303 00:17:04,328 --> 00:17:06,662 BETWEEN THE UPHOLSTERY COMPONENTS. 304 00:17:06,664 --> 00:17:10,725 THESE GAPS MUST BE UNIFORMLY THE SAME WIDTH. 305 00:17:12,028 --> 00:17:14,354 [ ENGINE REVS ] 306 00:17:15,943 --> 00:17:17,875 ♪♪♪ 307 00:17:17,877 --> 00:17:20,070 Narrator: BUGATTI MAKES 308 00:17:20,072 --> 00:17:22,339 JUST 40 VEYRONS PER YEAR ON AVERAGE. 309 00:17:22,341 --> 00:17:24,733 AND LIKE OTHER WORKS OF ART, 310 00:17:24,735 --> 00:17:27,361 THIS SUPERCAR IS A LIMITED EDITION. 311 00:17:27,363 --> 00:17:32,124 ONLY 450 OF THEM WILL EVER BE MADE. 312 00:17:32,126 --> 00:17:33,392 ♪♪♪ 313 00:17:33,394 --> 00:17:34,526 BUGATTI CALLS 314 00:17:34,528 --> 00:17:36,921 ITS 1,100-SQUARE-FOOT PRODUCTION FACILITY 315 00:17:36,923 --> 00:17:38,389 THE ATELIER. 316 00:17:38,391 --> 00:17:40,684 INSTEAD OF A TYPICAL ASSEMBLY LINE 317 00:17:40,686 --> 00:17:44,612 FOUND IN MOST CAR FACTORIES, THE VEYRON IS ASSEMBLED 318 00:17:44,614 --> 00:17:47,808 AT INDIVIDUAL STATIONS. 319 00:17:47,810 --> 00:17:51,477 HERE, A TECHNICIAN UNITES THE TRANSMISSION WITH THE ENGINE 320 00:17:51,479 --> 00:17:53,806 AND CAREFULLY BOLTS THEM TOGETHER 321 00:17:53,808 --> 00:17:56,033 WITH A HANDHELD RATCHET. 322 00:17:56,035 --> 00:17:59,036 THE MECHANICAL COMPONENTS OF THE CAR'S REAR SECTION 323 00:17:59,038 --> 00:18:01,297 HAVE ALL BEEN ASSEMBLED. 324 00:18:03,434 --> 00:18:05,826 TECHNICIANS PUSH THE BACK END ALONG A TRACK 325 00:18:05,828 --> 00:18:07,629 TO MEET THE FRONT. 326 00:18:07,631 --> 00:18:13,117 THE TRACK SITS BELOW THE FLOOR AND IS COVERED BY METAL PLATES 327 00:18:13,119 --> 00:18:15,186 THAT OPEN AND CLOSE AROUND THE TROLLEY FEET 328 00:18:15,188 --> 00:18:17,181 AS THEY MOVE. 329 00:18:20,711 --> 00:18:22,244 THE WORKERS JOIN THE TWO SECTIONS 330 00:18:22,246 --> 00:18:25,306 WITH JUST 14 TITANIUM BOLTS. 331 00:18:25,308 --> 00:18:27,775 ONCE AGAIN, THEY USE HANDHELD RATCHETS 332 00:18:27,777 --> 00:18:30,269 RATHER THAN POWER TOOLS. 333 00:18:31,339 --> 00:18:34,599 THE POWERFUL MECHANICS OF THE VEYRON HAVE BEEN ASSEMBLED, 334 00:18:34,601 --> 00:18:39,129 BUT A BUGATTI IS NOT A BUGATTI WITHOUT ITS SCULPTED EXTERIOR. 335 00:18:41,458 --> 00:18:45,285 TO BRING THE VEYRON TO ITS ARTFUL CONCLUSION, 336 00:18:45,287 --> 00:18:47,020 TECHNICIANS WEAR WHITE GLOVES 337 00:18:47,022 --> 00:18:50,081 SO AS NOT TO MAR THE SURFACE WITH FINGERPRINTS. 338 00:18:50,083 --> 00:18:52,284 THEY INSTALL EACH COMPONENT 339 00:18:52,286 --> 00:18:56,080 WITH THE SAME CARE AND PRECISION USED THROUGHOUT. 340 00:18:58,476 --> 00:19:00,409 BUT BEFORE REACHING THIS STAGE, 341 00:19:00,411 --> 00:19:03,237 AN EXPERT TESTS THE CAR'S SYSTEMS 342 00:19:03,239 --> 00:19:05,373 AT THIS ROLLING TEST STATION. 343 00:19:05,375 --> 00:19:09,102 THESE COMPONENTS ARE A PART OF THE REAR WING ASSEMBLY. 344 00:19:10,297 --> 00:19:12,564 AT HIGH SPEEDS, THE REAR WING EXTENDS 345 00:19:12,566 --> 00:19:15,024 AND PROVIDES MASSIVE DOWNWARD FORCE 346 00:19:15,026 --> 00:19:18,653 TO KEEP THE CAR FIRMLY ON THE GROUND. 347 00:19:18,655 --> 00:19:21,790 AND WHEN THE DRIVER BRAKES, IT IMMEDIATELY FLIPS 348 00:19:21,792 --> 00:19:23,050 TO A VERTICAL POSITION, 349 00:19:23,052 --> 00:19:25,252 ADDING THE BRAKING POWER OF A HATCHBACK 350 00:19:25,254 --> 00:19:29,182 TO THE CAR'S POWERFUL CERAMIC DISCS. 351 00:19:29,184 --> 00:19:32,210 [ WHIRRING ] 352 00:19:34,180 --> 00:19:36,806 HERE, A SPECIALIST PREPARES THE CAR 353 00:19:36,808 --> 00:19:38,533 FOR ITS FINAL INSPECTION. 354 00:19:38,535 --> 00:19:42,003 THE CAR WILL SPEND TWO ENTIRE DAYS AT THIS STATION, 355 00:19:42,005 --> 00:19:45,666 AS HE PAINSTAKINGLY BUFFS AND POLISHES THE CAR 356 00:19:45,668 --> 00:19:46,858 TO SHINING PERFECTION. 357 00:19:46,860 --> 00:19:48,594 HE MUST ENSURE 358 00:19:48,596 --> 00:19:50,395 THAT EVERY INCH OF THE SURFACE 359 00:19:50,397 --> 00:19:53,057 IS ABSOLUTELY FLAWLESS. 360 00:19:55,352 --> 00:20:00,014 IF THERE ARE ANY IMPERFECTIONS, THIS MAN WILL FIND THEM. 361 00:20:00,016 --> 00:20:04,010 IT'S HIS JOB TO GIVE EACH VEYRON ITS FINAL INSPECTION. 362 00:20:04,012 --> 00:20:08,740 NO BUGATTI LEAVES THIS FACILITY WITHOUT HIS APPROVAL. 363 00:20:08,742 --> 00:20:11,143 SURROUNDED BY FULL-SPECTRUM LIGHTS, 364 00:20:11,145 --> 00:20:13,971 THE CAR UNDERGOES A METICULOUS EXAMINATION. 365 00:20:13,973 --> 00:20:16,098 IF THE INSPECTOR DISCOVERS ANY FLAWS, 366 00:20:16,100 --> 00:20:19,493 HE WILL SEND THE CAR BACK TO THE PREVIOUS STATION 367 00:20:19,495 --> 00:20:21,429 FOR MORE POLISHING. 368 00:20:24,426 --> 00:20:27,093 BEFORE A VEYRON GOES THROUGH FINAL INSPECTION 369 00:20:27,095 --> 00:20:29,987 AND SIGN-OFF, AN ENGINEER TAKES THE CAR 370 00:20:29,989 --> 00:20:33,783 OUT TO A TEST TRACK AND DRIVES IT 185 MILES 371 00:20:33,785 --> 00:20:38,246 FOR A FINAL DYNAMIC APPROVAL TEST. 372 00:20:38,248 --> 00:20:41,975 THE BUGATTI VEYRON HAS SET TWO WORLD RECORDS -- 373 00:20:41,977 --> 00:20:44,069 ONE FOR THE FASTEST PRODUCTION ROAD CAR 374 00:20:44,071 --> 00:20:48,032 AND ONE FOR THE FASTEST CONVERTIBLE WITH THE ROOF DOWN. 375 00:20:48,034 --> 00:20:49,800 THIS ORANGE AND BLACK 376 00:20:49,802 --> 00:20:53,663 BUGATTI VEYRON 16.4 GRAND SPORT VITESSE 377 00:20:53,665 --> 00:20:55,531 IS THE CAR THAT SET THAT SECOND RECORD 378 00:20:55,533 --> 00:20:59,727 BY GOING 253 MILES PER HOUR WITH ITS TOP DOWN. 379 00:20:59,729 --> 00:21:03,623 AND TRUE TO THE BUGATTI LEGACY, 380 00:21:03,625 --> 00:21:05,417 IT LOOKED GOOD DOING IT. 381 00:21:09,481 --> 00:21:12,808 YOU'D NEED TO GO 93 MILES AN HOUR JUST TO GET THIS CAR 382 00:21:12,810 --> 00:21:14,876 OUT OF SECOND GEAR. 383 00:21:14,878 --> 00:21:18,305 IT ACCELERATES FROM ZERO TO 60 MILES PER HOUR 384 00:21:18,307 --> 00:21:19,706 IN 2.6 SECONDS, 385 00:21:19,708 --> 00:21:21,767 FROM ZERO TO 120 IN 7.1, 386 00:21:21,769 --> 00:21:26,564 AND FROM ZERO TO 180 IN 16 FLAT. 387 00:21:26,566 --> 00:21:27,765 IT'S NO WONDER THE VEYRON HAS ACHIEVED 388 00:21:27,767 --> 00:21:31,328 ICONIC STATUS AMONG SUPERCARS AT WARP SPEED. 30742

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