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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,270 --> 00:00:08,224
THE BUGATTI VEYRON, THE FASTEST
WORK OF ART IN THE WORLD.
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00:00:08,226 --> 00:00:11,494
♪♪♪
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00:00:11,496 --> 00:00:14,555
-- Captions by VITAC --
www.vitac.com
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00:00:14,557 --> 00:00:18,151
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:23,183 --> 00:00:24,975
Narrator:
THE CITé DE L'AUTOMOBILE
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IN MULHOUSE, FRANCE,
WAS FORMERLY KNOWN
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AS THE SCHLUMPF COLLECTION.
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00:00:28,380 --> 00:00:30,706
IT HOUSES THE LARGEST COLLECTION
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00:00:30,708 --> 00:00:32,800
OF CLASSIC BUGATTIS
IN THE WORLD.
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00:00:32,802 --> 00:00:35,569
WHILE MOST CAR COMPANIES
WERE FOUNDED BY ENTREPRENEURS
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00:00:35,571 --> 00:00:37,930
WITH A PURELY TECHNICAL
BACKGROUND,
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00:00:37,932 --> 00:00:40,198
BUGATTI'S CREATOR,
ETTORE BUGATTI,
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00:00:40,200 --> 00:00:44,595
CAME FROM A FAMILY OF
WELL-KNOWN ITALIAN ARTISTS.
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00:00:44,597 --> 00:00:47,190
THAT ARTISTIC HERITAGE
PLAYED A VITAL ROLE
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00:00:47,192 --> 00:00:50,051
IN THE DESIGN OF BUGATTI CARS,
LONG CONSIDERED
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00:00:50,053 --> 00:00:52,721
AMONG THE MOST BEAUTIFUL
EVER MADE,
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00:00:52,723 --> 00:00:55,882
BUT ART NEVER GOT IN THE WAY
OF SPEED.
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00:00:55,884 --> 00:00:58,744
IN FACT, BUGATTI BUILT ONE
OF AUTOMOTIVE HISTORY'S
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00:00:58,746 --> 00:01:03,274
MOST SUCCESSFUL RACE CARS --
THE TYPE 35.
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00:01:03,276 --> 00:01:06,936
AFTER ETTORE
AND HIS SON JEAN DIED,
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00:01:06,938 --> 00:01:11,032
THE BUGATTI BRAND WENT DORMANT
IN THE EARLY 1960s.
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00:01:11,034 --> 00:01:13,893
BUT VOLKSWAGEN BOUGHT IT
IN 1998,
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00:01:13,895 --> 00:01:17,563
AND BUGATTI CAME ROARING BACK
TO LIFE WITH THE VEYRON,
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THE FASTEST PRODUCTION CAR
IN EXISTENCE.
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BUILT HERE
AT ITS ANCESTRAL HEADQUARTERS
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IN MOLSHEIM, FRANCE,
IT'S THE MOST POWERFUL
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AND EXPENSIVE PRODUCTION CAR
IN THE WORLD.
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♪♪♪
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THE CARS ARE MADE HERE
IN A BUILDING REFERRED TO
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AS THE ATELIER.
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THE PEOPLE AT BUGATTI THINK
OF VEYRON
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AS MUCH MORE THAN JUST A CAR.
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TO THEM,
IT'S AN AUTOMOTIVE WORK OF ART.
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EACH CAR BEGINS LIFE HERE
IN THE DESIGN DEPARTMENT.
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00:01:54,855 --> 00:01:57,189
AS FUTURISTIC
AS THE VEYRON MAY LOOK,
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IT STILL FEATURES THE FAMOUS
BUGATTI HORSESHOE-SHAPED GRILLE
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DEVELOPED BY ETTORE.
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00:02:04,215 --> 00:02:06,549
ETTORE'S SON JEAN WAS
A TALENTED STYLIST.
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00:02:06,551 --> 00:02:09,544
HE CREATED SWEEPING CURVES
THAT CAME TO DEFINE
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00:02:09,546 --> 00:02:11,071
THE BUGATTI LOOK,
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00:02:11,073 --> 00:02:14,941
AND THOSE CURVES REAPPEAR
ON THE VEYRON.
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00:02:14,943 --> 00:02:16,635
LIGHTWEIGHT AND STRONG,
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CARBON FIBER IS
THE IDEAL MATERIAL
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00:02:19,039 --> 00:02:21,898
FOR CONSTRUCTING A SUPERCAR
LIKE THE VEYRON.
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HERE, A MACHINE CALLED A PLOTTER
CUTS A SHEET OF CARBON FIBER
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00:02:25,696 --> 00:02:27,228
INTO THE REQUIRED SHAPES.
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THE MATERIAL, WHICH IS STORED
AT MINUS 4 DEGREES FAHRENHEIT
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00:02:30,626 --> 00:02:32,285
TO PRESERVE ITS FORM,
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00:02:32,287 --> 00:02:36,347
IS HEATED TO PLUS 64 DEGREES
JUST PRIOR TO CUTTING.
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00:02:37,984 --> 00:02:41,510
AND BUGATTI USES DIFFERENT KINDS
OF FIBER DEPENDING ON
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WHAT PART OF THE CAR
THEY'RE BUILDING.
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WHERE CERTAIN COMPONENTS
REQUIRE FLEXIBILITY,
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OTHERS NEED RIGIDITY.
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A WORKER POSITIONS
THE CARBON FIBER IN A MOLD.
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TO CREATE A PART, SHE MUST LAYER
MULTIPLE SHEETS, OR PLIES,
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00:02:57,863 --> 00:03:01,390
OF THE FIBER
IN A SPECIFIED ORDER.
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00:03:02,993 --> 00:03:05,786
THIS LAYERING PROCESS
ADDS STRENGTH.
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00:03:05,788 --> 00:03:08,448
TO AVOID CREATING ANY WRINKLES,
SHE CAREFULLY CUTS
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00:03:08,450 --> 00:03:12,577
AND OVERLAPS THE MATERIAL
AT THE CORNERS.
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00:03:12,579 --> 00:03:15,947
ALTHOUGH SHE MAKES IT LOOK EASY,
THIS JOB REQUIRES
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00:03:15,949 --> 00:03:18,875
AN ENORMOUS AMOUNT OF SKILL
AND EXPERIENCE.
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00:03:18,877 --> 00:03:21,603
EACH LAYER OF FIBER MUST BE
CAREFULLY POSITIONED
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00:03:21,605 --> 00:03:23,939
TO ENSURE MAXIMUM PERFORMANCE.
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00:03:23,941 --> 00:03:27,835
THE PATTERN OF THE FIBERS
MUST BE PERFECTLY ALIGNED.
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00:03:31,966 --> 00:03:34,892
THE MOLD THEN COMES HERE
TO THESE GIANT OVENS,
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00:03:34,894 --> 00:03:36,694
WHICH ARE CALLED AUTOCLAVES.
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AUTOCLAVES APPLY A COMBINATION
OF HEAT AND PRESSURE
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TO CURE THE CARBON FIBER.
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00:03:43,920 --> 00:03:47,914
AFTER 4 HOURS OF BAKING
AT 275 DEGREES FAHRENHEIT
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00:03:47,916 --> 00:03:51,310
UNDER 87 PSI,
THE PART IS READY.
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00:03:51,312 --> 00:03:55,705
WORKERS REMOVE IT FROM THE MOLD.
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00:03:55,707 --> 00:03:59,134
WHILE ALMOST ALL THE WORK
OF CREATING A VEYRON
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00:03:59,136 --> 00:04:01,003
IS ACCOMPLISHED BY HAND,
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00:04:01,005 --> 00:04:03,664
SOMETIMES A ROBOT
COMES IN HANDY.
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00:04:03,666 --> 00:04:06,726
HERE A C.N.C. MACHINE TRIMS OFF
EXCESS MATERIAL
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00:04:06,728 --> 00:04:10,322
AND DRILLS ANY NECESSARY HOLES.
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00:04:12,926 --> 00:04:15,685
NEXT, THE PARTS COME HERE,
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00:04:15,687 --> 00:04:17,487
WHERE SKILLED CRAFTSMEN
PREPARE THE SURFACE.
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00:04:17,489 --> 00:04:21,016
THEY BEGIN BY SANDING
WITH A HEAVY GRIT MATERIAL.
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00:04:21,018 --> 00:04:24,678
THEY REPEAT THIS TIME-CONSUMING,
PAINSTAKING PROCESS
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00:04:24,680 --> 00:04:27,806
MULTIPLE TIMES WITH
INCREASINGLY FINER GRITS
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00:04:27,808 --> 00:04:31,302
UNTIL THE SURFACE
IS PERFECTLY SMOOTH.
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00:04:31,304 --> 00:04:32,903
THIS TECHNICIAN PERFORMS
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00:04:32,905 --> 00:04:35,631
A HIGHLY DETAILED
QUALITY CONTROL CHECK.
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00:04:35,633 --> 00:04:38,760
SHE INSPECTS EVERY INCH
OF THE SURFACE,
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00:04:38,762 --> 00:04:42,296
MARKING ANY IMPERFECTIONS
THAT NEED TO BE CORRECTED.
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THERE'S NO TIME RESTRAINT.
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00:04:43,892 --> 00:04:48,820
EACH COMPONENT MUST BE
ABSOLUTELY FLAWLESS.
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00:04:48,822 --> 00:04:51,448
USING PRECISION CALIPERS,
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00:04:51,450 --> 00:04:53,250
SHE CAREFULLY MEASURES
THE DIAMETER OF THE HOLES
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00:04:53,252 --> 00:04:56,679
TO ENSURE
THEY'RE THE CORRECT SIZE.
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00:04:59,909 --> 00:05:02,376
ONCE THE COMPONENTS
HAVE PASSED INSPECTION,
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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,
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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.
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00:05:19,789 --> 00:05:23,583
BUGATTI DESIGNERS LOOK FOR
INSPIRATION IN EVERYTHING,
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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
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00:05:34,212 --> 00:05:35,545
OF THE CAR.
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00:05:36,607 --> 00:05:39,007
THEIR INSPIRATION
IS THE RACING COLOR
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00:05:39,009 --> 00:05:41,634
THAT ADORNED
MANY EARLY BUGATTIS.
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00:05:41,636 --> 00:05:45,230
CARS RACING IN THE FIRST HALF
OF THE 20th CENTURY
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00:05:45,232 --> 00:05:48,358
BORE THE RACING COLOR
OF THEIR COUNTRY OF ORIGIN.
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00:05:48,360 --> 00:05:50,627
THE FRENCH RACING COLOR
WAS BLUE,
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00:05:50,629 --> 00:05:55,891
AND BLUE HAS BECOME
A DISTINCTIVE COLOR FOR BUGATTI.
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00:05:55,893 --> 00:05:59,320
LIKE NEARLY EVERY OTHER STEP
IN THE CREATION OF A VEYRON,
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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 ]
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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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