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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,604 --> 00:00:04,829
THE MORGAN 3 WHEELER --
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00:00:04,831 --> 00:00:08,290
A CAR WITH VINTAGE LOOKS
AND 21st CENTURY POWER.
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00:00:08,292 --> 00:00:11,560
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
THE MORGAN MOTOR COMPANY
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HAS BEEN BUILDING CARS
HERE AT MALVERN LINK
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ON PICKERSLEIGH ROAD
IN MALVERN, ENGLAND,
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FOR OVER 100 YEARS.
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THE COMPANY WAS FOUNDED
BY HENRY MORGAN IN 1910.
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00:00:36,706 --> 00:00:39,198
THE FIRST CAR HE BUILT
WAS A 3-WHEELED VEHICLE
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00:00:39,200 --> 00:00:40,933
WHICH HE CALLED A RUNABOUT.
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00:00:40,935 --> 00:00:44,629
THIS IS AN EXACT REPLICA
OF THE FIRST PRODUCTION MODEL.
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00:00:48,727 --> 00:00:52,254
THE CARS WERE SOON SO POPULAR
THAT THE FACTORY IN MALVERN
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00:00:52,256 --> 00:00:54,748
HAD TROUBLE MEETING DEMAND.
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00:00:54,750 --> 00:00:57,542
THE 3 WHEELER WAS LIGHTWEIGHT,
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00:00:57,544 --> 00:00:59,011
FUN, AND INEXPENSIVE,
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00:00:59,013 --> 00:01:02,806
MAKING MOTORING MORE ACCESSIBLE
TO THE GENERAL PUBLIC.
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IT WAS ALSO FAST.
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00:01:04,343 --> 00:01:07,536
BY 1914,
IT HAD ALREADY ESTABLISHED
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00:01:07,538 --> 00:01:09,764
10 BRITISH AND WORLD RECORDS.
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00:01:10,767 --> 00:01:13,501
THE NEW MORGAN 3 WHEELER
IS BASED ON
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00:01:13,503 --> 00:01:16,730
THE FAMOUS MORGAN SUPERSPORTS
FROM THE 1930s.
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00:01:21,160 --> 00:01:23,687
BUT WITH A HIGH
POWER TO WEIGHT RATIO
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00:01:23,689 --> 00:01:26,915
AND A TOP SPEED
OF 115 MILES PER HOUR,
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00:01:26,917 --> 00:01:29,084
THIS IS NO ANTIQUE.
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IN A MORGAN 3 WHEELER,
THE SEATS ARE FIXED.
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THAT MEANS IF A DRIVER WANTS
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MORE COMFORTABLE ACCESS
TO THE PEDALS,
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THEY ADJUST THE PEDALS,
NOT THE SEAT.
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00:01:45,670 --> 00:01:49,664
THIS CNC LASER DEVICE CUTS SLOTS
IN THE STEEL FLOOR PANELS.
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00:01:49,666 --> 00:01:52,859
THE SLOTS ALLOW
FOR DIFFERENT PEDAL POSITIONS,
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00:01:52,861 --> 00:01:55,120
DEPENDING ON THE HEIGHT
OF THE DRIVER.
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THE MACHINE ALSO CUTS THE PANEL
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00:02:00,886 --> 00:02:04,413
WHERE THE SEAT BELTS GET
BOLTED DOWN BEHIND THE SEATS.
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00:02:06,751 --> 00:02:09,743
A WORKER NOW USES
A POWERFUL BENDING MACHINE
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TO FORM ANOTHER PART.
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THIS IS THE GEARBOX FIXING,
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00:02:13,308 --> 00:02:16,701
WHICH WILL BE MOUNTED
DIRECTLY TO THE CHASSIS.
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00:02:16,703 --> 00:02:18,836
THE EARLY MORGAN 3 WHEELERS
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HAD JUST TWO GEARS
AND NO REVERSE.
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WITH A REVERSE AND FIVE GEARS,
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THE MODERN DAY VERSION
IS THOROUGHLY UP-TO-DATE.
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00:02:29,091 --> 00:02:31,750
NO MONOCOQUE
FOR THE MORGAN 3 WHEELER.
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00:02:31,752 --> 00:02:35,354
HERE, THEY MAKE THE CHASSIS
THE OLD-FASHIONED WAY.
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00:02:35,356 --> 00:02:37,649
A WORKER USES A BENDING MACHINE
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TO SHAPE TUBES
FOR THE MAIN CHASSIS RAILS.
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00:02:40,912 --> 00:02:43,113
THESE TUBES ARE MADE
OF MILD STEEL,
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00:02:43,115 --> 00:02:45,573
ALSO KNOWN
AS PLAIN CARBON STEEL.
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00:02:45,575 --> 00:02:48,435
FROM THE VERY BEGINNING,
MORGAN 3 WHEELERS
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00:02:48,437 --> 00:02:51,838
HAVE BEEN KNOWN FOR
THEIR EXCEPTIONAL DURABILITY.
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00:02:51,840 --> 00:02:54,332
COMPETING ON
MUDDY, BUMPY COURSES
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00:02:54,334 --> 00:02:57,060
IN RELIABILITY TRIALS
DURING THE 1920s,
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THE LIGHTWEIGHT, RUGGED
3 WHEELERS WERE SO FAST
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00:03:00,324 --> 00:03:03,459
RACE ORGANIZERS REQUIRED
THAT THEY START A LAP BEHIND
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THEIR 4-WHEELED COMPETITION.
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A BLADE RISES FROM A TABLE
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00:03:10,218 --> 00:03:13,144
TO CUT A TUBE
THAT'S BEEN CLAMPED DOWN.
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00:03:13,146 --> 00:03:15,614
THIS CUT,
CALLED A SCALLOP END,
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00:03:15,616 --> 00:03:18,342
WILL FIT TO ANOTHER TUBE
AT AN ANGLE.
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WITH EACH COMPONENT OF THE CAR
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METICULOUSLY AND INDIVIDUALLY
FORMED LIKE THIS,
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IT'S NO WONDER CUSTOMERS MUST
WAIT AT LEAST A YEAR
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00:03:27,035 --> 00:03:29,195
FOR THEIR ORDER TO BE FILLED.
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00:03:34,760 --> 00:03:37,095
THE COMPONENTS FOR
THE REAR SECTION OF THE CHASSIS
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00:03:37,097 --> 00:03:39,989
HAVE BEEN FORMED AND PREPARED
FOR ASSEMBLY.
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00:03:42,653 --> 00:03:44,986
A TECHNICIAN NOW CLAMPS
EACH PART
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IN A COMPLEX JIG SYSTEM
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00:03:46,382 --> 00:03:50,375
AND TACK WELDS THEM IN PLACE
AS HE GOES.
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00:03:50,377 --> 00:03:54,037
THE REAR SECTION OF THE CHASSIS
INCLUDES THE SEAT BELT MOUNTS,
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00:03:54,039 --> 00:03:56,707
THE REAR FUEL TANK
ATTACHMENT POINTS,
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00:03:56,709 --> 00:03:58,734
MOUNTING FOR THE ROLL HOOP BARS,
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00:03:58,736 --> 00:04:01,137
AND THE ATTACHMENT POINTS
FOR THE REAR SWING ARM.
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00:04:03,132 --> 00:04:06,726
SOME PARTS OF THE CHASSIS
STRUCTURE WILL BE EXPOSED.
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00:04:06,728 --> 00:04:09,529
THE MECHANICS OF THE VEHICLE
ARE PART OF ITS APPEARANCE,
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00:04:09,531 --> 00:04:12,190
SO IT'S EXTREMELY IMPORTANT
THAT THE TECHNICIAN
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WELDS THE COMPONENTS TOGETHER
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00:04:14,052 --> 00:04:18,813
WITH A FOCUS ON AESTHETIC APPEAL
AS WELL AS STRUCTURAL INTEGRITY.
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00:04:18,815 --> 00:04:22,476
IN THIS SENSE, THE 3 WHEELER
RESEMBLES A MOTORCYCLE.
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00:04:22,478 --> 00:04:25,612
IN FACT, 3 WHEELERS ARE
OFFICIALLY CLASSED
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AS MOTORCYCLES
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AND EVEN USED TO BE CALLED
CYCLE CARS.
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WITH THE REAR SECTION
FULLY ASSEMBLED,
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IT'S NOW TIME TO UNITE IT
WITH THE REST OF THE CHASSIS.
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00:04:45,361 --> 00:04:47,886
THAT MEANS A BIGGER JIG.
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THE TECHNICIAN CLAMPS
THE REAR SECTION
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00:04:50,090 --> 00:04:52,349
AND THEN BEGINS TO ADD
OTHER COMPONENTS.
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HERE'S THE FLOOR PANEL WITH
THE DIFFERENT PEDAL POSITIONS.
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NEXT IS THE FRONT ROLL BAR.
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00:05:02,112 --> 00:05:04,904
ONCE HE'S CLAMPED ALL
THE COMPONENTS FIRMLY IN PLACE,
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00:05:04,906 --> 00:05:06,105
HE BEGINS WELDING.
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00:05:06,107 --> 00:05:08,199
NO LONGER TACK WELDING,
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00:05:08,201 --> 00:05:12,062
HE USES A PENETRATIVE WELD
TO FUSE THE JOINTS TOGETHER.
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00:05:12,064 --> 00:05:14,330
THANKS TO A LOW CARBON CONTENT,
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00:05:14,332 --> 00:05:16,792
MILD STEEL WELDS EASILY.
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00:05:16,794 --> 00:05:21,655
ONCE COMPLETE, THE CHASSIS
IS READY FOR A BATH.
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00:05:21,657 --> 00:05:23,123
10 BATHS, IN FACT.
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00:05:23,125 --> 00:05:27,553
THIS IS A RUST-PROOFING PROCESS
CALLED AUTOPHORETIC COATING.
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00:05:27,555 --> 00:05:32,008
FIRST, THE CHASSIS MUST UNDERGO
A THOROUGH CLEANING PROCESS
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BEFORE FINALLY DIPPING INTO
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00:05:33,945 --> 00:05:36,671
A VAT OF
PVDC RESIN-BASED LIQUID.
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00:05:36,673 --> 00:05:41,300
THIS MATERIAL PROTECTS EVERY
NOOK AND CRANNY OF THE STEEL.
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00:05:41,302 --> 00:05:44,162
FINALLY, A TECHNICIAN WEARING
A FULL BODY SUIT
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00:05:44,164 --> 00:05:46,899
AND EQUIPPED WITH
AN INDEPENDENT AIR SUPPLY
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00:05:46,901 --> 00:05:49,493
SPRAYS THE CHASSIS WITH
A COATING OF BLACK PAINT.
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00:05:49,495 --> 00:05:52,296
BRIGHT MULTIDIRECTIONAL LIGHTING
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00:05:52,298 --> 00:05:54,857
ENSURES HE DOESN'T MISS
ANYTHING.
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00:05:56,786 --> 00:06:00,580
THE CHASSIS IS NOW READY
FOR THE NEXT STEP.
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Narrator: THERE AREN'T MANY CARS
THAT REQUIRE
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A FULLY OPERATIONAL WOODSHOP
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00:06:10,686 --> 00:06:12,945
AND THE TECHNICAL SKILLS
OF A TRAINED CARPENTER.
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00:06:12,947 --> 00:06:17,374
THE HANDCRAFTED ASH WOOD FRAME
OF A MORGAN 3 WHEELER
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00:06:17,376 --> 00:06:20,436
IS ONE OF
ITS SIGNATURE ELEMENTS.
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00:06:21,973 --> 00:06:24,040
A CRAFTSMAN BEGINS THE PROCESS
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00:06:24,042 --> 00:06:26,701
OF LAMINATING TOGETHER
SECTIONS OF ASH.
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00:06:26,703 --> 00:06:29,962
ASH IS THE WOOD THAT MORGAN
HAS TRADITIONALLY USED
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00:06:29,964 --> 00:06:32,357
TO CREATE ITS CAR FRAMES.
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THAT'S BECAUSE IT'S TOUGH,
STRONG, AND LIGHTWEIGHT.
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00:06:36,297 --> 00:06:39,523
THE WOODWORKER LAYERS
FIVE PLIES OF ASH.
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00:06:39,525 --> 00:06:41,917
HE PUTS GLUE BETWEEN EACH LAYER,
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00:06:41,919 --> 00:06:45,046
ENSURING THE ADHESIVE
IS EVENLY SPREAD.
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00:06:45,048 --> 00:06:47,248
ONCE IT'S GLUED TOGETHER,
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00:06:47,250 --> 00:06:50,710
HE PLACES THE 5-LAYER LAMINATE
ON A FORM.
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00:06:50,712 --> 00:06:53,204
HE BENDS IT TO MATCH
THE FORM SHAPE
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00:06:53,206 --> 00:06:55,106
AND SECURES IT FIRMLY IN PLACE
WITH STRAPS.
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00:06:58,470 --> 00:07:01,863
HE INSERTS THE FORM AND LAMINATE
INTO A LARGE VACUUM BAG
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00:07:01,865 --> 00:07:03,398
AND SEALS IT.
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00:07:04,868 --> 00:07:07,260
A PUMP SUCKS THE AIR
OUT OF THE BAG,
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00:07:07,262 --> 00:07:10,288
SQUEEZING THE LAMINATE
TIGHTLY TO THE FORM.
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00:07:10,290 --> 00:07:13,818
THIS ENSURES THE PLIES WILL CURE
IN THE EXACT SHAPE OF THE FORM.
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00:07:20,017 --> 00:07:21,284
THE CRAFTSMAN CREATES
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00:07:21,286 --> 00:07:23,611
EACH OF THE COMPONENTS
OF THE WOODEN FRAME
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00:07:23,613 --> 00:07:26,473
WITH PAINSTAKING ATTENTION
TO DETAIL.
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00:07:27,910 --> 00:07:31,836
THE WOODWORKER NOW BEGINS
THE ASSEMBLY PROCESS --
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00:07:31,838 --> 00:07:33,104
DRILLING, GLUING,
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00:07:33,106 --> 00:07:35,966
CLAMPING, AND SCREWING
THE PIECES TOGETHER.
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00:07:35,968 --> 00:07:39,094
HE CAREFULLY AND METHODICALLY
BUILDS THE FRAME.
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00:07:39,096 --> 00:07:41,363
WHILE
THE CURVED WOODEN STRUCTURE
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00:07:41,365 --> 00:07:43,457
IS REMINISCENT OF BOAT BUILDING,
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00:07:43,459 --> 00:07:47,186
THE DESIGNERS OF THE 3 WHEELER
ACTUALLY LOOKED TO AVIATION
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00:07:47,188 --> 00:07:48,454
FOR INSPIRATION.
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00:07:48,456 --> 00:07:50,181
AND THE COMPLETED CAR
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00:07:50,183 --> 00:07:53,918
DOES LOOK A BIT LIKE
AN OLD-FASHIONED AIRPLANE.
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00:07:53,920 --> 00:07:57,581
THIS NOD TO AVIATION HAS
HISTORIC SIGNIFICANCE
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00:07:57,583 --> 00:07:58,606
FOR MORGAN.
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00:07:58,608 --> 00:08:00,342
DURING THE WORLD WAR I,
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00:08:00,344 --> 00:08:03,203
A FLYING ACE NAMED
CAPTAIN ALBERT BALL
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00:08:03,205 --> 00:08:06,206
DROVE A CUSTOM-MADE
GRAND PRIX 3 WHEELER.
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00:08:06,208 --> 00:08:09,067
HE SAID TO DRIVE THIS CAR WAS
THE NEAREST THING TO FLYING
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00:08:09,069 --> 00:08:11,996
WITHOUT LEAVING THE GROUND.
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00:08:11,998 --> 00:08:15,224
TRAGICALLY, CAPTAIN BALL
WAS SHOT DOWN AND KILLED.
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TO COMMEMORATE HIM,
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MORGAN CALLED THEIR NEXT MODEL
THE AERO.
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00:08:24,086 --> 00:08:27,679
HERE, WE SEE THE FRAME
BEGIN TO TAKE SHAPE.
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00:08:27,681 --> 00:08:29,280
THE CRAFTSMAN PLACES
THE BOTTOM SECTION
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00:08:29,282 --> 00:08:33,043
IN A PURPOSE BUILD JIG
AND WEDGES IT INTO PLACE.
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00:08:33,045 --> 00:08:37,239
HE THEN ATTACHES A STABILIZING
BAR TO THE FRONT SECTION.
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00:08:37,241 --> 00:08:42,303
THIS STABILIZER TEMPORARILY
MAINTAINS THE FORM OF THE FRAME.
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00:08:42,305 --> 00:08:45,431
IT WILL LATER BE REMOVED WHEN
THE FINISHED FRAMEWORK AND BODY
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00:08:45,433 --> 00:08:47,425
ARE FITTED TO THE CAR.
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00:08:52,524 --> 00:08:54,724
WITH THE BOTTOM SECTION
COMPLETE,
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00:08:54,726 --> 00:08:57,519
IT'S NOW TIME FOR THE WOODWORKER
TO BEGIN ADDING
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THE TOP AND SIDES.
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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.
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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.
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00:09:19,936 --> 00:09:22,862
HERE, WORKERS FORM
THE ALUMINUM BODY PANELS
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00:09:22,864 --> 00:09:24,489
FOR THE 3 WHEELER.
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00:09:24,491 --> 00:09:26,959
THIS DEVICE USES THREE ROLLERS
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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.
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00:09:42,978 --> 00:09:46,170
THIS SIDE PANEL WILL WRAP AROUND
ONE SIDE OF THE CAR,
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00:09:46,172 --> 00:09:49,266
FROM THE FRONT TO THE TAIL.
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00:09:51,769 --> 00:09:54,095
BEFORE THE PANELS
CAN BE ATTACHED,
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00:09:54,097 --> 00:09:57,858
A CRAFTSMAN APPLIES A SPECIAL
ADHESIVE TO THE WOOD FRAME.
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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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