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These are the user uploaded subtitles that are being translated: 1 00:00:01,469 --> 00:00:03,602 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,604 --> 00:00:04,829 THE MORGAN 3 WHEELER -- 3 00:00:04,831 --> 00:00:08,290 A CAR WITH VINTAGE LOOKS AND 21st CENTURY POWER. 4 00:00:08,292 --> 00:00:11,560 -- Captions by VITAC -- www.vitac.com 5 00:00:11,562 --> 00:00:14,555 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,183 --> 00:00:25,241 Narrator: THE MORGAN MOTOR COMPANY 7 00:00:25,243 --> 00:00:27,711 HAS BEEN BUILDING CARS HERE AT MALVERN LINK 8 00:00:27,713 --> 00:00:30,038 ON PICKERSLEIGH ROAD IN MALVERN, ENGLAND, 9 00:00:30,040 --> 00:00:32,107 FOR OVER 100 YEARS. 10 00:00:33,236 --> 00:00:36,704 THE COMPANY WAS FOUNDED BY HENRY MORGAN IN 1910. 11 00:00:36,706 --> 00:00:39,198 THE FIRST CAR HE BUILT WAS A 3-WHEELED VEHICLE 12 00:00:39,200 --> 00:00:40,933 WHICH HE CALLED A RUNABOUT. 13 00:00:40,935 --> 00:00:44,629 THIS IS AN EXACT REPLICA OF THE FIRST PRODUCTION MODEL. 14 00:00:48,727 --> 00:00:52,254 THE CARS WERE SOON SO POPULAR THAT THE FACTORY IN MALVERN 15 00:00:52,256 --> 00:00:54,748 HAD TROUBLE MEETING DEMAND. 16 00:00:54,750 --> 00:00:57,542 THE 3 WHEELER WAS LIGHTWEIGHT, 17 00:00:57,544 --> 00:00:59,011 FUN, AND INEXPENSIVE, 18 00:00:59,013 --> 00:01:02,806 MAKING MOTORING MORE ACCESSIBLE TO THE GENERAL PUBLIC. 19 00:01:02,808 --> 00:01:04,341 IT WAS ALSO FAST. 20 00:01:04,343 --> 00:01:07,536 BY 1914, IT HAD ALREADY ESTABLISHED 21 00:01:07,538 --> 00:01:09,764 10 BRITISH AND WORLD RECORDS. 22 00:01:10,767 --> 00:01:13,501 THE NEW MORGAN 3 WHEELER IS BASED ON 23 00:01:13,503 --> 00:01:16,730 THE FAMOUS MORGAN SUPERSPORTS FROM THE 1930s. 24 00:01:21,160 --> 00:01:23,687 BUT WITH A HIGH POWER TO WEIGHT RATIO 25 00:01:23,689 --> 00:01:26,915 AND A TOP SPEED OF 115 MILES PER HOUR, 26 00:01:26,917 --> 00:01:29,084 THIS IS NO ANTIQUE. 27 00:01:35,577 --> 00:01:38,436 IN A MORGAN 3 WHEELER, THE SEATS ARE FIXED. 28 00:01:38,438 --> 00:01:40,304 THAT MEANS IF A DRIVER WANTS 29 00:01:40,306 --> 00:01:42,799 MORE COMFORTABLE ACCESS TO THE PEDALS, 30 00:01:42,801 --> 00:01:45,668 THEY ADJUST THE PEDALS, NOT THE SEAT. 31 00:01:45,670 --> 00:01:49,664 THIS CNC LASER DEVICE CUTS SLOTS IN THE STEEL FLOOR PANELS. 32 00:01:49,666 --> 00:01:52,859 THE SLOTS ALLOW FOR DIFFERENT PEDAL POSITIONS, 33 00:01:52,861 --> 00:01:55,120 DEPENDING ON THE HEIGHT OF THE DRIVER. 34 00:01:58,951 --> 00:02:00,884 THE MACHINE ALSO CUTS THE PANEL 35 00:02:00,886 --> 00:02:04,413 WHERE THE SEAT BELTS GET BOLTED DOWN BEHIND THE SEATS. 36 00:02:06,751 --> 00:02:09,743 A WORKER NOW USES A POWERFUL BENDING MACHINE 37 00:02:09,745 --> 00:02:11,203 TO FORM ANOTHER PART. 38 00:02:11,205 --> 00:02:13,306 THIS IS THE GEARBOX FIXING, 39 00:02:13,308 --> 00:02:16,701 WHICH WILL BE MOUNTED DIRECTLY TO THE CHASSIS. 40 00:02:16,703 --> 00:02:18,836 THE EARLY MORGAN 3 WHEELERS 41 00:02:18,838 --> 00:02:21,564 HAD JUST TWO GEARS AND NO REVERSE. 42 00:02:21,566 --> 00:02:23,759 WITH A REVERSE AND FIVE GEARS, 43 00:02:23,761 --> 00:02:27,455 THE MODERN DAY VERSION IS THOROUGHLY UP-TO-DATE. 44 00:02:29,091 --> 00:02:31,750 NO MONOCOQUE FOR THE MORGAN 3 WHEELER. 45 00:02:31,752 --> 00:02:35,354 HERE, THEY MAKE THE CHASSIS THE OLD-FASHIONED WAY. 46 00:02:35,356 --> 00:02:37,649 A WORKER USES A BENDING MACHINE 47 00:02:37,651 --> 00:02:40,910 TO SHAPE TUBES FOR THE MAIN CHASSIS RAILS. 48 00:02:40,912 --> 00:02:43,113 THESE TUBES ARE MADE OF MILD STEEL, 49 00:02:43,115 --> 00:02:45,573 ALSO KNOWN AS PLAIN CARBON STEEL. 50 00:02:45,575 --> 00:02:48,435 FROM THE VERY BEGINNING, MORGAN 3 WHEELERS 51 00:02:48,437 --> 00:02:51,838 HAVE BEEN KNOWN FOR THEIR EXCEPTIONAL DURABILITY. 52 00:02:51,840 --> 00:02:54,332 COMPETING ON MUDDY, BUMPY COURSES 53 00:02:54,334 --> 00:02:57,060 IN RELIABILITY TRIALS DURING THE 1920s, 54 00:02:57,062 --> 00:03:00,322 THE LIGHTWEIGHT, RUGGED 3 WHEELERS WERE SO FAST 55 00:03:00,324 --> 00:03:03,459 RACE ORGANIZERS REQUIRED THAT THEY START A LAP BEHIND 56 00:03:03,461 --> 00:03:05,386 THEIR 4-WHEELED COMPETITION. 57 00:03:08,257 --> 00:03:10,216 A BLADE RISES FROM A TABLE 58 00:03:10,218 --> 00:03:13,144 TO CUT A TUBE THAT'S BEEN CLAMPED DOWN. 59 00:03:13,146 --> 00:03:15,614 THIS CUT, CALLED A SCALLOP END, 60 00:03:15,616 --> 00:03:18,342 WILL FIT TO ANOTHER TUBE AT AN ANGLE. 61 00:03:19,478 --> 00:03:21,203 WITH EACH COMPONENT OF THE CAR 62 00:03:21,205 --> 00:03:23,939 METICULOUSLY AND INDIVIDUALLY FORMED LIKE THIS, 63 00:03:23,941 --> 00:03:27,033 IT'S NO WONDER CUSTOMERS MUST WAIT AT LEAST A YEAR 64 00:03:27,035 --> 00:03:29,195 FOR THEIR ORDER TO BE FILLED. 65 00:03:34,760 --> 00:03:37,095 THE COMPONENTS FOR THE REAR SECTION OF THE CHASSIS 66 00:03:37,097 --> 00:03:39,989 HAVE BEEN FORMED AND PREPARED FOR ASSEMBLY. 67 00:03:42,653 --> 00:03:44,986 A TECHNICIAN NOW CLAMPS EACH PART 68 00:03:44,988 --> 00:03:46,380 IN A COMPLEX JIG SYSTEM 69 00:03:46,382 --> 00:03:50,375 AND TACK WELDS THEM IN PLACE AS HE GOES. 70 00:03:50,377 --> 00:03:54,037 THE REAR SECTION OF THE CHASSIS INCLUDES THE SEAT BELT MOUNTS, 71 00:03:54,039 --> 00:03:56,707 THE REAR FUEL TANK ATTACHMENT POINTS, 72 00:03:56,709 --> 00:03:58,734 MOUNTING FOR THE ROLL HOOP BARS, 73 00:03:58,736 --> 00:04:01,137 AND THE ATTACHMENT POINTS FOR THE REAR SWING ARM. 74 00:04:03,132 --> 00:04:06,726 SOME PARTS OF THE CHASSIS STRUCTURE WILL BE EXPOSED. 75 00:04:06,728 --> 00:04:09,529 THE MECHANICS OF THE VEHICLE ARE PART OF ITS APPEARANCE, 76 00:04:09,531 --> 00:04:12,190 SO IT'S EXTREMELY IMPORTANT THAT THE TECHNICIAN 77 00:04:12,192 --> 00:04:14,050 WELDS THE COMPONENTS TOGETHER 78 00:04:14,052 --> 00:04:18,813 WITH A FOCUS ON AESTHETIC APPEAL AS WELL AS STRUCTURAL INTEGRITY. 79 00:04:18,815 --> 00:04:22,476 IN THIS SENSE, THE 3 WHEELER RESEMBLES A MOTORCYCLE. 80 00:04:22,478 --> 00:04:25,612 IN FACT, 3 WHEELERS ARE OFFICIALLY CLASSED 81 00:04:25,614 --> 00:04:26,672 AS MOTORCYCLES 82 00:04:26,674 --> 00:04:29,575 AND EVEN USED TO BE CALLED CYCLE CARS. 83 00:04:36,701 --> 00:04:39,226 WITH THE REAR SECTION FULLY ASSEMBLED, 84 00:04:39,228 --> 00:04:42,723 IT'S NOW TIME TO UNITE IT WITH THE REST OF THE CHASSIS. 85 00:04:45,361 --> 00:04:47,886 THAT MEANS A BIGGER JIG. 86 00:04:47,888 --> 00:04:50,088 THE TECHNICIAN CLAMPS THE REAR SECTION 87 00:04:50,090 --> 00:04:52,349 AND THEN BEGINS TO ADD OTHER COMPONENTS. 88 00:04:54,319 --> 00:04:58,847 HERE'S THE FLOOR PANEL WITH THE DIFFERENT PEDAL POSITIONS. 89 00:04:58,849 --> 00:05:02,110 NEXT IS THE FRONT ROLL BAR. 90 00:05:02,112 --> 00:05:04,904 ONCE HE'S CLAMPED ALL THE COMPONENTS FIRMLY IN PLACE, 91 00:05:04,906 --> 00:05:06,105 HE BEGINS WELDING. 92 00:05:06,107 --> 00:05:08,199 NO LONGER TACK WELDING, 93 00:05:08,201 --> 00:05:12,062 HE USES A PENETRATIVE WELD TO FUSE THE JOINTS TOGETHER. 94 00:05:12,064 --> 00:05:14,330 THANKS TO A LOW CARBON CONTENT, 95 00:05:14,332 --> 00:05:16,792 MILD STEEL WELDS EASILY. 96 00:05:16,794 --> 00:05:21,655 ONCE COMPLETE, THE CHASSIS IS READY FOR A BATH. 97 00:05:21,657 --> 00:05:23,123 10 BATHS, IN FACT. 98 00:05:23,125 --> 00:05:27,553 THIS IS A RUST-PROOFING PROCESS CALLED AUTOPHORETIC COATING. 99 00:05:27,555 --> 00:05:32,008 FIRST, THE CHASSIS MUST UNDERGO A THOROUGH CLEANING PROCESS 100 00:05:32,010 --> 00:05:33,943 BEFORE FINALLY DIPPING INTO 101 00:05:33,945 --> 00:05:36,671 A VAT OF PVDC RESIN-BASED LIQUID. 102 00:05:36,673 --> 00:05:41,300 THIS MATERIAL PROTECTS EVERY NOOK AND CRANNY OF THE STEEL. 103 00:05:41,302 --> 00:05:44,162 FINALLY, A TECHNICIAN WEARING A FULL BODY SUIT 104 00:05:44,164 --> 00:05:46,899 AND EQUIPPED WITH AN INDEPENDENT AIR SUPPLY 105 00:05:46,901 --> 00:05:49,493 SPRAYS THE CHASSIS WITH A COATING OF BLACK PAINT. 106 00:05:49,495 --> 00:05:52,296 BRIGHT MULTIDIRECTIONAL LIGHTING 107 00:05:52,298 --> 00:05:54,857 ENSURES HE DOESN'T MISS ANYTHING. 108 00:05:56,786 --> 00:06:00,580 THE CHASSIS IS NOW READY FOR THE NEXT STEP. 109 00:06:06,389 --> 00:06:08,481 Narrator: THERE AREN'T MANY CARS THAT REQUIRE 110 00:06:08,483 --> 00:06:10,684 A FULLY OPERATIONAL WOODSHOP 111 00:06:10,686 --> 00:06:12,945 AND THE TECHNICAL SKILLS OF A TRAINED CARPENTER. 112 00:06:12,947 --> 00:06:17,374 THE HANDCRAFTED ASH WOOD FRAME OF A MORGAN 3 WHEELER 113 00:06:17,376 --> 00:06:20,436 IS ONE OF ITS SIGNATURE ELEMENTS. 114 00:06:21,973 --> 00:06:24,040 A CRAFTSMAN BEGINS THE PROCESS 115 00:06:24,042 --> 00:06:26,701 OF LAMINATING TOGETHER SECTIONS OF ASH. 116 00:06:26,703 --> 00:06:29,962 ASH IS THE WOOD THAT MORGAN HAS TRADITIONALLY USED 117 00:06:29,964 --> 00:06:32,357 TO CREATE ITS CAR FRAMES. 118 00:06:32,359 --> 00:06:36,295 THAT'S BECAUSE IT'S TOUGH, STRONG, AND LIGHTWEIGHT. 119 00:06:36,297 --> 00:06:39,523 THE WOODWORKER LAYERS FIVE PLIES OF ASH. 120 00:06:39,525 --> 00:06:41,917 HE PUTS GLUE BETWEEN EACH LAYER, 121 00:06:41,919 --> 00:06:45,046 ENSURING THE ADHESIVE IS EVENLY SPREAD. 122 00:06:45,048 --> 00:06:47,248 ONCE IT'S GLUED TOGETHER, 123 00:06:47,250 --> 00:06:50,710 HE PLACES THE 5-LAYER LAMINATE ON A FORM. 124 00:06:50,712 --> 00:06:53,204 HE BENDS IT TO MATCH THE FORM SHAPE 125 00:06:53,206 --> 00:06:55,106 AND SECURES IT FIRMLY IN PLACE WITH STRAPS. 126 00:06:58,470 --> 00:07:01,863 HE INSERTS THE FORM AND LAMINATE INTO A LARGE VACUUM BAG 127 00:07:01,865 --> 00:07:03,398 AND SEALS IT. 128 00:07:04,868 --> 00:07:07,260 A PUMP SUCKS THE AIR OUT OF THE BAG, 129 00:07:07,262 --> 00:07:10,288 SQUEEZING THE LAMINATE TIGHTLY TO THE FORM. 130 00:07:10,290 --> 00:07:13,818 THIS ENSURES THE PLIES WILL CURE IN THE EXACT SHAPE OF THE FORM. 131 00:07:20,017 --> 00:07:21,284 THE CRAFTSMAN CREATES 132 00:07:21,286 --> 00:07:23,611 EACH OF THE COMPONENTS OF THE WOODEN FRAME 133 00:07:23,613 --> 00:07:26,473 WITH PAINSTAKING ATTENTION TO DETAIL. 134 00:07:27,910 --> 00:07:31,836 THE WOODWORKER NOW BEGINS THE ASSEMBLY PROCESS -- 135 00:07:31,838 --> 00:07:33,104 DRILLING, GLUING, 136 00:07:33,106 --> 00:07:35,966 CLAMPING, AND SCREWING THE PIECES TOGETHER. 137 00:07:35,968 --> 00:07:39,094 HE CAREFULLY AND METHODICALLY BUILDS THE FRAME. 138 00:07:39,096 --> 00:07:41,363 WHILE THE CURVED WOODEN STRUCTURE 139 00:07:41,365 --> 00:07:43,457 IS REMINISCENT OF BOAT BUILDING, 140 00:07:43,459 --> 00:07:47,186 THE DESIGNERS OF THE 3 WHEELER ACTUALLY LOOKED TO AVIATION 141 00:07:47,188 --> 00:07:48,454 FOR INSPIRATION. 142 00:07:48,456 --> 00:07:50,181 AND THE COMPLETED CAR 143 00:07:50,183 --> 00:07:53,918 DOES LOOK A BIT LIKE AN OLD-FASHIONED AIRPLANE. 144 00:07:53,920 --> 00:07:57,581 THIS NOD TO AVIATION HAS HISTORIC SIGNIFICANCE 145 00:07:57,583 --> 00:07:58,606 FOR MORGAN. 146 00:07:58,608 --> 00:08:00,342 DURING THE WORLD WAR I, 147 00:08:00,344 --> 00:08:03,203 A FLYING ACE NAMED CAPTAIN ALBERT BALL 148 00:08:03,205 --> 00:08:06,206 DROVE A CUSTOM-MADE GRAND PRIX 3 WHEELER. 149 00:08:06,208 --> 00:08:09,067 HE SAID TO DRIVE THIS CAR WAS THE NEAREST THING TO FLYING 150 00:08:09,069 --> 00:08:11,996 WITHOUT LEAVING THE GROUND. 151 00:08:11,998 --> 00:08:15,224 TRAGICALLY, CAPTAIN BALL WAS SHOT DOWN AND KILLED. 152 00:08:15,226 --> 00:08:16,692 TO COMMEMORATE HIM, 153 00:08:16,694 --> 00:08:19,688 MORGAN CALLED THEIR NEXT MODEL THE AERO. 154 00:08:24,086 --> 00:08:27,679 HERE, WE SEE THE FRAME BEGIN TO TAKE SHAPE. 155 00:08:27,681 --> 00:08:29,280 THE CRAFTSMAN PLACES THE BOTTOM SECTION 156 00:08:29,282 --> 00:08:33,043 IN A PURPOSE BUILD JIG AND WEDGES IT INTO PLACE. 157 00:08:33,045 --> 00:08:37,239 HE THEN ATTACHES A STABILIZING BAR TO THE FRONT SECTION. 158 00:08:37,241 --> 00:08:42,303 THIS STABILIZER TEMPORARILY MAINTAINS THE FORM OF THE FRAME. 159 00:08:42,305 --> 00:08:45,431 IT WILL LATER BE REMOVED WHEN THE FINISHED FRAMEWORK AND BODY 160 00:08:45,433 --> 00:08:47,425 ARE FITTED TO THE CAR. 161 00:08:52,524 --> 00:08:54,724 WITH THE BOTTOM SECTION COMPLETE, 162 00:08:54,726 --> 00:08:57,519 IT'S NOW TIME FOR THE WOODWORKER TO BEGIN ADDING 163 00:08:57,521 --> 00:08:59,187 THE TOP AND SIDES. 164 00:09:01,517 --> 00:09:03,776 NEXT, HE INSTALLS A CURVED SECTION 165 00:09:03,778 --> 00:09:06,244 THAT WILL SUPPORT THE FRONT BULKHEAD. 166 00:09:06,246 --> 00:09:08,672 HE WILL INSTALL A SECOND CURVED SECTION 167 00:09:08,674 --> 00:09:11,409 WHICH WILL FORM PART OF WHAT THE MANUFACTURERS CALL 168 00:09:11,411 --> 00:09:13,136 THE REAR CLAMSHELL. 169 00:09:17,133 --> 00:09:19,934 THE FRAME NEEDS A SKIN. 170 00:09:19,936 --> 00:09:22,862 HERE, WORKERS FORM THE ALUMINUM BODY PANELS 171 00:09:22,864 --> 00:09:24,489 FOR THE 3 WHEELER. 172 00:09:24,491 --> 00:09:26,959 THIS DEVICE USES THREE ROLLERS 173 00:09:26,961 --> 00:09:28,952 THAT HAVE BEEN CALIBRATED TO BEND A PANEL 174 00:09:28,954 --> 00:09:30,921 TO A SPECIFIED CURVE. 175 00:09:33,818 --> 00:09:36,611 NEXT, A WORKER USES A HAND-POWERED TOOL 176 00:09:36,613 --> 00:09:40,248 TO CREATE A SHARPER CURVE AT ONE END OF THE PIECE. 177 00:09:42,978 --> 00:09:46,170 THIS SIDE PANEL WILL WRAP AROUND ONE SIDE OF THE CAR, 178 00:09:46,172 --> 00:09:49,266 FROM THE FRONT TO THE TAIL. 179 00:09:51,769 --> 00:09:54,095 BEFORE THE PANELS CAN BE ATTACHED, 180 00:09:54,097 --> 00:09:57,858 A CRAFTSMAN APPLIES A SPECIAL ADHESIVE TO THE WOOD FRAME. 181 00:09:57,860 --> 00:10:00,661 IT'S A 2-PART LIQUID RESIN POWDER HARDENER, 182 00:10:00,663 --> 00:10:04,523 SPECIFICALLY FORMULATED FOR LAMINATING CURVED PANELS. 183 00:10:07,053 --> 00:10:09,645 LIKE SQUIRES PUTTING ARMOR ON A KNIGHT, 184 00:10:09,647 --> 00:10:12,582 TWO TECHNICIANS BEGIN CAREFULLY INSTALLING THE ALUMINUM PANELS 185 00:10:12,584 --> 00:10:14,475 ON THE FRAME. 186 00:10:14,477 --> 00:10:17,604 THIS IS THE MAIN PART OF THE BODY. 187 00:10:17,606 --> 00:10:19,205 TO ENSURE A TIGHT BOND, 188 00:10:19,207 --> 00:10:21,474 THEY SECURE THE METAL TO THE WOOD 189 00:10:21,476 --> 00:10:23,201 WITH CLOSELY SPACED CLAMPS. 190 00:10:26,398 --> 00:10:30,559 TAKING NO CHANCES, THEY ALSO SCREW THE PANELS IN PLACE. 191 00:10:30,561 --> 00:10:32,161 THIS HELPS TIGHTEN THE BOND 192 00:10:32,163 --> 00:10:34,922 BETWEEN WOOD, ADHESIVE, AND METAL. 193 00:10:36,892 --> 00:10:38,951 NEXT, THEY ADD THE FRONT SECTION, 194 00:10:38,953 --> 00:10:41,254 WHERE THE ENGINE WILL EVENTUALLY SIT. 195 00:10:42,949 --> 00:10:45,616 THE TECHNICIANS INSTALL THE SIDE PANELS 196 00:10:45,618 --> 00:10:47,043 IN THE SAME MANNER. 197 00:10:47,045 --> 00:10:50,772 THE PANELS FEATURE THREE LOUVERS ON EACH SIDE. 198 00:10:50,774 --> 00:10:52,907 THESE LOUVERS ARE DECORATIVE FEATURES 199 00:10:52,909 --> 00:10:56,804 WHICH RESEMBLE THE LOOK OF THE EARLIER MORGAN 3 WHEELERS. 200 00:10:58,373 --> 00:11:01,033 THE WORKER BRINGS THE REAR TRUNK LID TO THE CAR 201 00:11:01,035 --> 00:11:04,462 AND ATTACHES IT. 202 00:11:04,464 --> 00:11:06,856 THEN IT'S TIME TO INSTALL THE HOOD, 203 00:11:06,858 --> 00:11:09,292 WHICH HAS A FRONTPIECE CALLED A COWL. 204 00:11:11,320 --> 00:11:13,722 THE WINGED MORGAN 3 WHEELER EMBLEM 205 00:11:13,724 --> 00:11:16,683 IS THE FINISHING TOUCH. 206 00:11:22,583 --> 00:11:25,542 Narrator: EVERY DETAIL OF THE MORGAN 3 WHEELER 207 00:11:25,544 --> 00:11:27,010 HAS BEEN CONSIDERED. 208 00:11:27,012 --> 00:11:30,273 NOT ONLY DOES THE CAR LOOK LIKE A SMALL AIRPLANE ON WHEELS, 209 00:11:30,275 --> 00:11:33,667 THE LEATHER USED TO UPHOLSTER IT COMES FROM A MANUFACTURER 210 00:11:33,669 --> 00:11:36,596 THAT SUPPLIES THE AVIATION INDUSTRY. 211 00:11:37,932 --> 00:11:40,826 A CRAFTSMAN BEGINS THE PROCESS 212 00:11:40,828 --> 00:11:43,495 OF CREATING THE COVER FOR THE UPPER SEAT BACK. 213 00:11:45,357 --> 00:11:48,884 USING A TEMPLATE, HE CUTS OUT THE SHAPE REQUIRED. 214 00:11:52,549 --> 00:11:56,016 NEXT, HE STARTS MARKING OUT A QUILTING PATTERN. 215 00:11:56,018 --> 00:11:58,778 WHEN CUSTOMERS ORDER THEIR 3 WHEELERS, 216 00:11:58,780 --> 00:12:03,107 THEY CAN CHOOSE FROM A VARIETY OF DIFFERENT UPHOLSTERY OPTIONS. 217 00:12:03,109 --> 00:12:06,102 NOT ONLY CAN THEY SPECIFY THE COLOR THEY WANT, 218 00:12:06,104 --> 00:12:09,364 THEY CAN REQUEST SPECIAL STITCHING PATTERNS. 219 00:12:09,366 --> 00:12:12,033 QUILTED LEATHER IS A POPULAR CHOICE. 220 00:12:12,035 --> 00:12:15,061 EVEN THOUGH THE 3 WHEELER IS A TINY CAR, 221 00:12:15,063 --> 00:12:20,192 IT TAKES TWO HIDES TO FULLY UPHOLSTER ONE VEHICLE. 222 00:12:20,194 --> 00:12:22,386 MORGAN SOURCES A PORTION OF THEIR LEATHER 223 00:12:22,388 --> 00:12:24,388 FROM A COMPANY COMMITTED TO MANUFACTURING 224 00:12:24,390 --> 00:12:27,449 WITH A LOW CARBON FOOTPRINT. 225 00:12:27,451 --> 00:12:31,546 THEY PROCESS THE HIDES LEFT OVER FROM COMMERCIAL ABATTOIRS 226 00:12:31,548 --> 00:12:32,747 AND USE WASTE PRODUCTS 227 00:12:32,749 --> 00:12:34,941 THAT WOULD OTHERWISE GO INTO A LANDFILL 228 00:12:34,943 --> 00:12:38,002 TO GENERATE HEAT AND STEAM FOR DRYING LEATHER 229 00:12:38,004 --> 00:12:40,805 AND HEATING WATER. 230 00:12:40,807 --> 00:12:44,702 THEY ALSO TURN SKIN GREASE BYPRODUCT INTO FUEL OIL. 231 00:12:52,762 --> 00:12:55,488 TO QUILT LEATHER, YOU NEED A GOOD BACKING. 232 00:12:55,490 --> 00:12:58,682 THE CRAFTSMAN PLACES THE PIECE OF LEATHER 233 00:12:58,684 --> 00:13:01,419 OVER A PIECE OF THIN FOAM BACKING. 234 00:13:01,421 --> 00:13:02,913 HE WILL THEN SPRAY AN ADHESIVE 235 00:13:02,915 --> 00:13:04,714 ON THE UNFINISHED SIDE OF THE LEATHER 236 00:13:04,716 --> 00:13:06,308 IN ORDER TO GLUE IT TO THE FOAM. 237 00:13:08,245 --> 00:13:10,637 LEATHER IS THE MATERIAL OF CHOICE 238 00:13:10,639 --> 00:13:12,172 FOR UPHOLSTERING CARS, 239 00:13:12,174 --> 00:13:15,901 THANKS TO ITS UNIQUE QUALITIES OF COMFORT AND DURABILITY. 240 00:13:22,335 --> 00:13:24,126 WHEN CUTTING THE BACKING, 241 00:13:24,128 --> 00:13:27,455 HE LEAVES A MARGIN THAT WILL BE TRIMMED LATER. 242 00:13:27,457 --> 00:13:29,991 ONCE HE'S FINISHED THIS OPERATION, 243 00:13:29,993 --> 00:13:32,185 THE MATERIAL WILL BE READY TO HEAD TO THE SEWING AREA, 244 00:13:32,187 --> 00:13:34,454 WHERE QUILTING CAN BEGIN. 245 00:13:39,679 --> 00:13:43,873 THIS CRAFTSMAN STITCHES THE PATTERN OUTLINED IN WHITE. 246 00:13:43,875 --> 00:13:46,475 WORKING BY EYE, HE MUST TAKE CARE 247 00:13:46,477 --> 00:13:48,836 NOT TO DEVIATE FROM THE DESIGN. 248 00:13:51,074 --> 00:13:52,932 BESIDES COMFORT AND DURABILITY, 249 00:13:52,934 --> 00:13:55,360 LEATHER HAS A LONG LIST OF PROPERTIES 250 00:13:55,362 --> 00:13:58,229 THAT MAKE IT POPULAR WITH CAR MANUFACTURERS. 251 00:13:58,231 --> 00:14:01,157 NOT ONLY DOES IT HAVE A HIGH TENSILE STRENGTH, 252 00:14:01,159 --> 00:14:04,419 IT'S ALSO RESISTANT TO TEARING, PUNCTURE, ABRASION, 253 00:14:04,421 --> 00:14:06,555 FIRE, AND MILDEW. 254 00:14:06,557 --> 00:14:09,416 IT'S WARM IN WINTER AND COOL IN SUMMER. 255 00:14:09,418 --> 00:14:13,312 THANKS TO ITS ABILITY TO HOLD LARGE QUANTITIES OF WATER, 256 00:14:13,314 --> 00:14:17,175 IT CAN ABSORB PERSPIRATION AND LATER LET IT DISSIPATE. 257 00:14:20,571 --> 00:14:22,905 WHEN THE STITCHING PROCESS IS COMPLETE, 258 00:14:22,907 --> 00:14:25,233 THE QUILTED LEATHER PIECE RETURNS HERE. 259 00:14:25,235 --> 00:14:27,902 THE CRAFTSMAN PREPARES THE STRUCTURAL COMPONENT 260 00:14:27,904 --> 00:14:31,331 OF THE UPPER SEAT BACK. 261 00:14:31,333 --> 00:14:33,859 LIKE THE REST OF THE MORGAN 3 WHEELER FRAME, 262 00:14:33,861 --> 00:14:36,453 IT'S MADE OF WOOD. 263 00:14:36,455 --> 00:14:38,655 THE WORKER SPRAYS AN ADHESIVE ON THE WOOD, 264 00:14:38,657 --> 00:14:41,183 WHICH WILL ALLOW HIM TO ATTACH A PIECE OF SEAT FOAM 265 00:14:41,185 --> 00:14:42,685 FOR CUSHIONING. 266 00:14:47,217 --> 00:14:49,408 HE THEN CAREFULLY TRIMS THE FOAM 267 00:14:49,410 --> 00:14:53,271 SO THAT IT CONFORMS TO THE SHAPE OF THE WOOD'S SUBSTRATE. 268 00:14:53,273 --> 00:14:54,939 THIS CUTOUT IN THE HEADREST 269 00:14:54,941 --> 00:14:57,434 WILL ACCOMMODATE THE SEAT BELT SYSTEM. 270 00:15:01,965 --> 00:15:04,499 IT'S NOW TIME FOR THE FINAL STEP 271 00:15:04,501 --> 00:15:08,629 OF MOUNTING THE QUILTED LEATHER ONTO THE SUBSTRATE. 272 00:15:08,631 --> 00:15:10,222 MARKING THE BACKING TO ENSURE 273 00:15:10,224 --> 00:15:13,091 THAT IT REMAINS PERFECTLY ALIGNED WITH THE WOOD, 274 00:15:13,093 --> 00:15:16,220 THE CRAFTSMAN SLOWLY AND CAREFULLY ATTACHES THE LEATHER 275 00:15:16,222 --> 00:15:19,048 WITH DOZENS OF STAPLES. 276 00:15:19,050 --> 00:15:23,178 FOR THIS TASK, HE USES A GUN POWERED BY COMPRESSED AIR. 277 00:15:25,382 --> 00:15:27,841 IT TAKES APPROXIMATELY NINE HOURS 278 00:15:27,843 --> 00:15:32,370 TO FULLY PREPARE THE UPHOLSTERY FOR A MORGAN 3 WHEELER. 279 00:15:32,372 --> 00:15:34,731 THE LEATHER WORKER NEEDS 2 1/2 HOURS 280 00:15:34,733 --> 00:15:37,668 JUST TO CUT ALL THE PIECES OUT. 281 00:15:37,670 --> 00:15:40,862 THE SEWING AND STITCHING REQUIRES ANOTHER 4 HOURS, 282 00:15:40,864 --> 00:15:43,591 FOLLOWED BY 3 1/2 HOURS FOR THIS FINAL STEP 283 00:15:43,593 --> 00:15:46,286 OF MOUNTING THE LEATHER ON THE SUBSTRATE. 284 00:15:52,986 --> 00:15:55,812 THE CORNERS DEMAND SPECIAL ATTENTION 285 00:15:55,814 --> 00:15:59,007 AND A SPECIAL TECHNIQUE. 286 00:15:59,009 --> 00:16:01,009 THIS ENTIRE OPERATION 287 00:16:01,011 --> 00:16:04,972 CALLS FOR PATIENCE, SKILL, AND CONCENTRATION. 288 00:16:07,135 --> 00:16:08,600 THE LEATHER MUST FOLLOW 289 00:16:08,602 --> 00:16:11,095 THE CONTOURS OF THE SUBSTRATE PERFECTLY. 290 00:16:11,097 --> 00:16:14,098 NO CREASES OR BULGES ALLOWED. 291 00:16:24,245 --> 00:16:26,805 Narrator: SEEN WITHOUT ITS WHEELS OR ENGINE, 292 00:16:26,807 --> 00:16:28,406 THE MORGAN 3 WHEELER LOOKS LIKE 293 00:16:28,408 --> 00:16:31,602 THE COCKPIT OF A WORLD WAR I FIGHTER PLANE, 294 00:16:31,604 --> 00:16:33,136 AND THAT'S NO ACCIDENT. 295 00:16:33,138 --> 00:16:36,198 COMING UP, WE'LL SEE ALL THE CUSTOM COMPONENTS 296 00:16:36,200 --> 00:16:38,493 BROUGHT TOGETHER TO FORM A FINISHED CAR. 297 00:16:39,829 --> 00:16:43,089 STARTING WITH THE CHASSIS, A TECHNICIAN BEGINS INSTALLING 298 00:16:43,091 --> 00:16:45,557 ALL OF THE ELECTRICAL COMPONENTS. 299 00:16:45,559 --> 00:16:49,421 THIS INCLUDES THE LEADS TO THE COIL PACK AND SPARK PLUGS, 300 00:16:49,423 --> 00:16:53,083 AS WELL AS THE WIRING LOOM, FUSE BOX, AND MAIN FUSE. 301 00:16:53,085 --> 00:16:55,243 MORGAN HAS ENGINEERED THE 3 WHEELER 302 00:16:55,245 --> 00:16:56,578 TO START IMMEDIATELY, 303 00:16:56,580 --> 00:17:00,907 EVEN AFTER LONG STRETCHES PARKED IN A GARAGE. 304 00:17:00,909 --> 00:17:04,837 THE TECHNICIAN NOW INSTALLS THE ENGINE AND TRANSMISSION. 305 00:17:04,839 --> 00:17:08,566 THE ENGINE IS A V-TWIN X-WEDGE FROM S&S, 306 00:17:08,568 --> 00:17:12,662 A LEGENDARY MANUFACTURER OF MOTORCYCLE ENGINES. 307 00:17:12,664 --> 00:17:15,657 WITH A TOP SPEED OF 115 MILES PER HOUR, 308 00:17:15,659 --> 00:17:18,852 IT HAS A MAXIMUM TORQUE OF 103 FOOT-POUNDS 309 00:17:18,854 --> 00:17:21,588 AT 3,250 RPMs. 310 00:17:24,184 --> 00:17:29,479 THE POWERFUL BATTERY WILL HOLD ITS CHARGE FOR MONTHS. 311 00:17:29,481 --> 00:17:32,808 LIKE A MOTORCYCLE, THE 3 WHEELER HAS SOMETHING CALLED 312 00:17:32,810 --> 00:17:34,543 REAR SWINGARM SUSPENSION. 313 00:17:34,545 --> 00:17:38,072 THIS SYSTEM GRIPS THE AXLE OF THE REAR WHEEL 314 00:17:38,074 --> 00:17:39,866 AND PIVOTS UP AND DOWN 315 00:17:39,868 --> 00:17:43,136 AT THE POINT WHERE IT ATTACHES TO THE STRUCTURE OF THE VEHICLE. 316 00:17:46,466 --> 00:17:49,025 ONCE THE SWINGARM AND WHEEL ARE IN PLACE, 317 00:17:49,027 --> 00:17:52,020 THE TECHNICIAN INSTALLS THE REAR KEVLAR DRIVE BELT 318 00:17:52,022 --> 00:17:53,989 ON THE ALUMINUM SPROCKET. 319 00:17:55,226 --> 00:17:58,485 THIS SYSTEM ALSO CLOSELY RESEMBLES A MOTORCYCLE. 320 00:17:58,487 --> 00:18:02,648 ROTATING THE BACK WHEEL TURNS THE BEVEL BOX AND PROP SHAFT. 321 00:18:05,779 --> 00:18:09,171 NEXT, IT'S TIME FOR THE PEDAL BOX ASSEMBLY -- 322 00:18:09,173 --> 00:18:11,640 THE ACCELERATOR, CLUTCH, AND BRAKE. 323 00:18:11,642 --> 00:18:14,502 ONCE THEY'RE IN, THE TECHNICIAN CONNECTS THEIR HOSES 324 00:18:14,504 --> 00:18:18,065 AND TESTS THEM TO MAKE SURE THEY'RE MOVING CORRECTLY. 325 00:18:21,328 --> 00:18:24,388 NOW THE LEATHER UPHOLSTERED GEARBOX COVER 326 00:18:24,390 --> 00:18:27,858 GOES OVER THE 5-SPEED MAZDA SPORTS TRANSMISSION. 327 00:18:27,860 --> 00:18:29,652 THE TECHNICIAN WORKS THE STICK SHIFT 328 00:18:29,654 --> 00:18:32,388 THROUGH ITS SLEEVE AND ADDS THE KNOB. 329 00:18:34,517 --> 00:18:38,411 THE NEXT UPHOLSTERED COMPONENT COVERS THE PROP SHAFT. 330 00:18:38,413 --> 00:18:40,480 THEN THE DOOR PANELS GO ON, 331 00:18:40,482 --> 00:18:44,868 FOLLOWED BY THE LOWER AND UPPER SEAT BACKING AND CUSHIONS. 332 00:18:44,870 --> 00:18:47,404 THE DETAILED, TIME-CONSUMING WORK 333 00:18:47,406 --> 00:18:50,398 DONE IN THE LEATHER DEPARTMENT IS FINALLY ON DISPLAY. 334 00:18:50,400 --> 00:18:53,627 THE SEATING DESIGN IS SNUG BUT COMFORTABLE. 335 00:18:55,297 --> 00:18:58,757 THEN IT'S TIME TO PUT TOGETHER THE DASHBOARD. 336 00:18:58,759 --> 00:19:01,418 THE DISPLAYS AND SWITCHES HERE ARE DIRECTLY INSPIRED 337 00:19:01,420 --> 00:19:04,655 BY OLD-FASHIONED AIRPLANE COCKPITS. 338 00:19:06,217 --> 00:19:08,751 TO FASTEN THE BODY TO THE STRUCTURE, 339 00:19:08,753 --> 00:19:10,845 THEY WILL DRILL THROUGH THE ALUMINUM PANELS 340 00:19:10,847 --> 00:19:13,473 TO THE STEEL CHASSIS TUBING, 341 00:19:13,475 --> 00:19:15,842 USING JUST TWO ATTACHMENT POINTS IN THE FRONT, 342 00:19:15,844 --> 00:19:18,169 TWO IN THE BACK, 343 00:19:18,171 --> 00:19:19,938 AND FOUR ON EACH SIDE. 344 00:19:23,703 --> 00:19:25,169 EACH SIDE OF THE 3 WHEELER 345 00:19:25,171 --> 00:19:27,697 FEATURES AN EXPOSED EXHAUST PIPE. 346 00:19:29,133 --> 00:19:32,360 THE TECHNICIAN MOUNTS THE OIL TANK IN ITS BRACKETS. 347 00:19:34,389 --> 00:19:37,924 THEN HE INSTALLS THE FRONT WHEEL ON ITS HUB ASSEMBLY. 348 00:19:39,252 --> 00:19:41,119 THE WIRE SPOKES AND SINGLE WHEEL NUT 349 00:19:41,121 --> 00:19:44,881 MAY RESEMBLE THE STYLE OF MORGAN'S ORIGINAL 3 WHEELERS, 350 00:19:44,883 --> 00:19:46,741 BUT THEY FUNCTION AS DURABLE, 351 00:19:46,743 --> 00:19:49,077 THOROUGHLY UP-TO-DATE COMPONENTS. 352 00:19:51,273 --> 00:19:53,674 NOW IT'S TIME FOR THE STEEL ROLL HOOPS 353 00:19:53,676 --> 00:19:55,735 WITH THEIR LEATHER HEADRESTS. 354 00:19:57,071 --> 00:19:59,797 THE ROUNDED HOOD WITH ITS SIGNATURE FRONT COWL 355 00:19:59,799 --> 00:20:01,032 IS THE NEXT COMPONENT. 356 00:20:03,561 --> 00:20:05,894 THIS IS THE LINER FOR THE SMALL TRUNK AREA 357 00:20:05,896 --> 00:20:07,789 JUST ABOVE THE FUEL TANK. 358 00:20:09,760 --> 00:20:12,285 HERE IN THE FINISHING DEPARTMENT, 359 00:20:12,287 --> 00:20:16,481 A WORKER USES A ROTARY POLISHER TO BUFF THE SURFACE OF THE CAR. 360 00:20:16,483 --> 00:20:20,110 THE CAR IS PAINTED THE FAMOUS RACING GREEN, 361 00:20:20,112 --> 00:20:22,446 ONCE SEEN ON ALL BRITISH CARS 362 00:20:22,448 --> 00:20:25,841 COMPETING IN EUROPEAN SPORTING EVENTS. 363 00:20:25,843 --> 00:20:29,903 GIVEN HOW MANY RACES THE ORIGINAL 3 WHEELERS WON, 364 00:20:29,905 --> 00:20:33,733 IT'S NO WONDER THIS COLOR IS A POPULAR CHOICE. 365 00:20:37,997 --> 00:20:41,057 WITH A MAXIMUM TORQUE OF 103 FOOT-POUNDS 366 00:20:41,059 --> 00:20:43,685 AT 3,250 RPMs, 367 00:20:43,687 --> 00:20:47,781 THE MORGAN 3 WHEELER IS A POWERFUL CAR FOR ITS SIZE, 368 00:20:47,783 --> 00:20:51,944 BUT IT ONLY WEIGHS IN AT 1,160 POUNDS, 369 00:20:51,946 --> 00:20:55,807 A FACTOR THAT CONTRIBUTES TO ITS IMPRESSIVE FUEL EFFICIENCY 370 00:20:55,809 --> 00:20:57,675 OF 25 MILES PER GALLON. 371 00:20:59,971 --> 00:21:03,339 IN OTHER WORDS, DESPITE ITS VINTAGE APPEAL, 372 00:21:03,341 --> 00:21:05,733 THIS IS A THOROUGHLY MODERN SPORTS CAR 373 00:21:05,735 --> 00:21:07,668 BUILT FOR THE 21st CENTURY. 374 00:21:07,670 --> 00:21:11,231 BUT THEN AGAIN, MAYBE HENRY MORGAN'S CLEVER IDEA 375 00:21:11,233 --> 00:21:13,959 JUST NEVER GOT OLD. 376 00:21:13,961 --> 00:21:16,487 FITTING A MOTORCYCLE ENGINE AND A TRANSMISSION 377 00:21:16,489 --> 00:21:18,955 ONTO A LIGHTWEIGHT CHASSIS WITH THREE WHEELS 378 00:21:18,957 --> 00:21:22,484 MIGHT BE ONE OF THE BEST WAYS OF COMBINING FUEL EFFICIENCY 379 00:21:22,486 --> 00:21:27,281 WITH THE CAR LOVER'S DREAM OF FLYING ON THE ROAD. 30154

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