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These are the user uploaded subtitles that are being translated: 1 00:00:01,135 --> 00:00:02,334 IT'S REACTIVE, UNRESTRAINED, 2 00:00:02,336 --> 00:00:03,668 AND ELECTRIFYING. 3 00:00:03,670 --> 00:00:05,362 MEET THE GINETTA G40, 4 00:00:05,364 --> 00:00:08,290 TODAY ON "HOW IT'S MADE: DREAM CARS." 5 00:00:08,292 --> 00:00:11,560 -- Captions by VITAC -- www.vitac.com 6 00:00:11,562 --> 00:00:14,555 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 7 00:00:23,116 --> 00:00:24,582 Narrator: BRITISH AUTO MAKER GINETTA 8 00:00:24,584 --> 00:00:28,579 AND TEAM LNT ARE SYNONYMOUS WITH RACING, 9 00:00:28,581 --> 00:00:32,107 MAKING HEADWAY IN AUTO RACING HISTORY FOR DECADES. 10 00:00:32,109 --> 00:00:35,703 SINCE ITS ACQUISITION BY LAWRENCE AUTOMOTIVE IN 2005, 11 00:00:35,705 --> 00:00:37,997 IT'S EXPANDED GREATLY. 12 00:00:37,999 --> 00:00:43,461 GINETTA RELEASE THE G40, ITS FIRST ROAD CAR IN 15 YEARS. 13 00:00:43,463 --> 00:00:47,590 FROM THE 1960s G10 AND THE LE MANS PROTOTYPE 14 00:00:47,592 --> 00:00:50,986 TO THIS 1964 G4 ROAD AND RACE CAR, 15 00:00:50,988 --> 00:00:54,147 AN IMPRESSIVE HISTORY. 16 00:00:54,149 --> 00:00:57,675 GINETTA WAS FOUNDED IN 1958 IN WOODBRIDGE, ENGLAND, 17 00:00:57,677 --> 00:01:00,145 BY THE WALKLETT BROTHERS. 18 00:01:00,147 --> 00:01:03,340 IN 1961, IT INTRODUCED THE G4, 19 00:01:03,342 --> 00:01:06,135 A ROAD CAR AND WEEKEND RACER. 20 00:01:06,137 --> 00:01:10,564 IN 2005, GINETTA WAS ACQUIRED BY LNT AUTOMOTIVE, 21 00:01:10,566 --> 00:01:12,967 REJUVENATING THE BRAND. 22 00:01:12,969 --> 00:01:16,362 THE G40 ROAD CAR DIFFERS FROM ITS RACING COUNTERPART 23 00:01:16,364 --> 00:01:18,222 BY USING AN AMERICAN ENGINE, 24 00:01:18,224 --> 00:01:20,492 A JAPANESE-INSPIRED GEARBOX, 25 00:01:20,494 --> 00:01:24,421 AND A ROAD-FRIENDLY INTERIOR. 26 00:01:24,423 --> 00:01:26,915 THE G40'S BIG ADVANTAGE IS SIMPLICITY 27 00:01:26,917 --> 00:01:29,918 AND LACK OF DRIVER AIDS LIKE POWER STEERING, 28 00:01:29,920 --> 00:01:32,546 TRACTION CONTROL, OR A.B.S. 29 00:01:35,577 --> 00:01:38,635 MANUFACTURED AT THE STATE-OF-THE-ART FACTORY 30 00:01:38,637 --> 00:01:40,438 LOCATED IN GARFORTH, LEEDS, 31 00:01:40,440 --> 00:01:44,067 THE FIRST G40 ROAD CAR WAS DRAFTED ON PAPER, 32 00:01:44,069 --> 00:01:46,794 VISUALIZED THROUGH 3-D COMPUTER RENDERING, 33 00:01:46,796 --> 00:01:50,599 AND HIT THE ROAD FOR TESTING IN UNDER A YEAR. 34 00:01:50,601 --> 00:01:52,659 AND BELOW THE STUNNING SURFACE 35 00:01:52,661 --> 00:01:55,854 IS A COLD DRAWN STEEL, SEAMLESS TUBE CHASSIS. 36 00:01:59,418 --> 00:02:02,486 AT ANOTHER LOCATION, A SUPPLIER PRODUCES AND STORES 37 00:02:02,488 --> 00:02:07,141 THE PRECUT STEEL TUBING FOR THE CHASSIS' ASSEMBLY. 38 00:02:07,143 --> 00:02:09,076 TWO WORKERS LIFT A TUBE 39 00:02:09,078 --> 00:02:12,472 INTO A 3-D LASER PIPE CUTTING CNC MACHINE 40 00:02:12,474 --> 00:02:14,274 FOR PRECISION CLIPPING. 41 00:02:15,836 --> 00:02:19,763 THIS CNC MACHINE CAN CUT TUBES WITH DIAMETERS FROM HALF AN INCH 42 00:02:19,765 --> 00:02:22,132 TO 8.5 INCHES. 43 00:02:25,029 --> 00:02:26,361 CUTTING IS MANAGED 44 00:02:26,363 --> 00:02:29,623 WITH AN AUTOMATIC LOADING AND TILTING SYSTEM. 45 00:02:30,960 --> 00:02:32,618 ONCE A PIECE IS CUT, 46 00:02:32,620 --> 00:02:36,380 IT'S AUTOMATICALLY UNLOADED ONTO A TRANSITION BELT. 47 00:02:36,382 --> 00:02:40,076 THEN THE PARTS ARE COLLECTED FOR FURTHER MACHINING. 48 00:02:42,046 --> 00:02:43,646 BACK AT THE MAIN FACTORY 49 00:02:43,648 --> 00:02:46,440 WITHIN THE CHASSIS FABRICATION DEPARTMENT, 50 00:02:46,442 --> 00:02:48,501 A MACHINIST TWISTS ALUMINUM TUBING 51 00:02:48,503 --> 00:02:50,837 TO CREATE THE RADIATOR'S COOLANT PIPE, 52 00:02:50,839 --> 00:02:53,999 A HARD PIPE WHICH CARRIES COOLANT FROM THE ENGINE BLOCK 53 00:02:54,001 --> 00:02:56,994 TO THE RADIATOR. 54 00:02:56,996 --> 00:02:59,930 THIS PORTABLE BENCHTOP TUBE AND PIPE BENDER 55 00:02:59,932 --> 00:03:02,525 FUNCTIONS WITH A SINGLE BENDING SPEED. 56 00:03:02,527 --> 00:03:05,786 THIS ALLOWS THE PIPE TO BE CAREFULLY FASHIONED 57 00:03:05,788 --> 00:03:08,982 TO MEET UNIQUE MANUFACTURING SPECIFICATIONS. 58 00:03:15,015 --> 00:03:18,141 EVENTUALLY, THE CAR'S INTERNAL CHASSIS FRAMEWORK 59 00:03:18,143 --> 00:03:19,743 WILL CONSISTENT OF 60 00:03:19,745 --> 00:03:23,539 262 SEGMENTS OF BENT AND STRAIGHT LASER-CUT TUBES. 61 00:03:23,541 --> 00:03:25,632 AT A PRIMARY WORKSTATION, 62 00:03:25,634 --> 00:03:29,495 A TECHNICIAN PLACES THE REAR ROLL HOOP STRUCTURE 63 00:03:29,497 --> 00:03:31,230 ONTO THE CHASSIS JIG. 64 00:03:31,232 --> 00:03:33,491 IT'S POSITIONED USING A TAPE MEASURE 65 00:03:33,493 --> 00:03:36,561 ALONG WITH A RUBBER MALLET FOR KEY PLACEMENT. 66 00:03:41,652 --> 00:03:43,385 PIECES ARE WELDED USING 67 00:03:43,387 --> 00:03:46,580 A METAL INERT GAS WELDING UNIT, OR MIG GUN. 68 00:03:48,917 --> 00:03:50,241 AT ANOTHER WORKSHOP, 69 00:03:50,243 --> 00:03:52,978 A TECHNICIAN PLACES A PRECUT PLATE OF STEEL 70 00:03:52,980 --> 00:03:54,838 ONTO A TRADITIONAL PIECE OF EQUIPMENT 71 00:03:54,840 --> 00:03:57,040 CALLED A FLY PRESS. 72 00:03:57,042 --> 00:03:59,535 THIS MANUALLY PRESSES AND SHAPES THE MATERIAL 73 00:03:59,537 --> 00:04:02,263 INTO WHAT IS KNOWN AS A GUSSET. 74 00:04:05,401 --> 00:04:07,260 THE GUSSETS ARE LARGE BRACKETS 75 00:04:07,262 --> 00:04:10,655 THAT CONNECT AND STRENGTHEN CROSSMEMBERS OF THE CHASSIS. 76 00:04:10,657 --> 00:04:12,924 ONCE A GUSSET IS MACHINED, 77 00:04:12,926 --> 00:04:15,619 THE PART IS WELDED TO THE STEEL BASE FRAME 78 00:04:15,621 --> 00:04:16,720 WITH A MIG GUN. 79 00:04:21,084 --> 00:04:23,677 ADDING MORE OF THE LASER-CUT STEEL TUBES, 80 00:04:23,679 --> 00:04:27,006 THE WELDING TECHNICIAN SNAPS AND LOCKS THE UPPER COMPONENTS 81 00:04:27,008 --> 00:04:28,774 INTO THE CHASSIS JIG. 82 00:04:30,770 --> 00:04:32,704 NOW HE'S BUILDING THE BOX SECTION, 83 00:04:32,706 --> 00:04:36,499 WHERE AREAS LIKE THE PASSENGER AND DRIVER SIDE CHASSIS TUBES 84 00:04:36,501 --> 00:04:38,367 ARE ALIGNED. 85 00:04:38,369 --> 00:04:40,895 NEXT, HE MOVES ON TO WELD, 86 00:04:40,897 --> 00:04:44,691 FORMING A LARGER, SOLIDIFIED STRUCTURE. 87 00:04:44,693 --> 00:04:48,153 IN TOTAL, 103 TUBES ARE INSTALLED 88 00:04:48,155 --> 00:04:50,022 TO FORM THE BOX SECTION. 89 00:04:55,113 --> 00:04:56,245 THE INSTALLATION OF 90 00:04:56,247 --> 00:04:58,113 THE DRIVER SIDE FOOTWELL AND BULKHEAD 91 00:04:58,115 --> 00:05:02,977 ARE EASILY APPLIED DUE TO THE 3-D COMPUTER-AIDED DESIGN. 92 00:05:05,306 --> 00:05:07,599 NOW POSITIONED ON A CHASSIS ROLLER, 93 00:05:07,601 --> 00:05:11,336 THE PRELIMINARY SPACE FRAME IS ROTATED TO DIFFERENT ANGLES. 94 00:05:11,338 --> 00:05:14,197 THIS HELPS TO FINALIZE SPECIFIC WELDS 95 00:05:14,199 --> 00:05:17,059 BELOW AND AROUND THE BASE OF THE FRAME. 96 00:05:19,063 --> 00:05:21,322 WHEN FINISHED, THE CHASSIS IS 97 00:05:21,324 --> 00:05:24,383 ELECTROSTATICALLY POWDER-COATED BLACK. 98 00:05:30,294 --> 00:05:35,055 Narrator: THE G40'S INEXPENSIVE, 1.8-LITER AMERICAN ENGINE 99 00:05:35,057 --> 00:05:37,516 IS THE SAME ENGINE BLOCK FOUND 100 00:05:37,518 --> 00:05:41,045 IN OLDER VERSIONS OF FORD'S COMPACT CARS, 101 00:05:41,047 --> 00:05:44,240 LIKE THE FOCUS, ESCORT, AND FIESTA. 102 00:05:45,810 --> 00:05:47,743 THIS PARTICULAR ENGINE ASSEMBLY 103 00:05:47,745 --> 00:05:50,671 STARTS WITH A TECHNICIAN INSTALLING THE INTAKE 104 00:05:50,673 --> 00:05:53,133 AND EXHAUST CAMSHAFT CYLINDRICAL RODS, 105 00:05:53,135 --> 00:05:56,128 WHICH RUN THE LENGTH OF THE CYLINDER BANK. 106 00:05:57,731 --> 00:06:01,425 A FRICTION-REDUCING CAMSHAFT ASSEMBLY LUBRICANT 107 00:06:01,427 --> 00:06:05,621 IS THEN APPLIED TO ENSURE THE PART'S OPERATIONAL DEMANDS. 108 00:06:05,623 --> 00:06:07,889 AS PART OF THE CAMSHAFT UNITS, 109 00:06:07,891 --> 00:06:11,819 BALL BEARINGS ARE FASTENED AT BOTH ENDS OF EACH BAR. 110 00:06:11,821 --> 00:06:14,347 THIS WILL REDUCE ROTATIONAL FRICTION 111 00:06:14,349 --> 00:06:16,808 AND SUPPORT THE CYLINDRICAL RODS. 112 00:06:19,312 --> 00:06:22,839 WORKING WITH THE CYLINDER BANK TO HOUSE THE CAMSHAFT RODS 113 00:06:22,841 --> 00:06:27,035 ARE 10 CAMSHAFT BRACKETS AND THEIR FASTENING BOLTS. 114 00:06:27,037 --> 00:06:30,030 THEY HELP THE CAMSHAFT UNITS TO REMAIN IN POSITION 115 00:06:30,032 --> 00:06:33,326 FOR THEIR PROPER SYNCHRONIZATION WITH THE CRANKSHAFT. 116 00:06:37,123 --> 00:06:39,524 USING AN IMPACT DRIVER, 117 00:06:39,526 --> 00:06:41,718 EACH SUPPORT CLAMP AND FASTENING BOLT 118 00:06:41,720 --> 00:06:44,988 IS PRECISELY INSTALLED. 119 00:06:50,912 --> 00:06:53,313 A DESIGNATED AMOUNT OF TORQUE IS APPLIED 120 00:06:53,315 --> 00:06:56,775 IN ORDER TO AVOID ANY DAMAGE TO THE HARDWARE. 121 00:06:59,204 --> 00:07:01,997 USING A SPECIALIZED PAINT PEN WITH BLUE INK, 122 00:07:01,999 --> 00:07:03,732 KNOWN AS TORQUE PAINT, 123 00:07:03,734 --> 00:07:06,994 EACH BOLT IS MARKED FOR QUALITY INSURANCE. 124 00:07:09,398 --> 00:07:13,026 NEXT, THE TECHNICIAN ATTACHES THE CAMSHAFT SPROCKETS, 125 00:07:13,028 --> 00:07:15,487 WHICH ARE RESPONSIBLE FOR MAINTAINING 126 00:07:15,489 --> 00:07:18,682 THE TIMING BETWEEN THE CAMSHAFT AND THE CRANKSHAFT. 127 00:07:18,751 --> 00:07:22,744 TO ENSURE THE SPROCKETS ARE EXACTLY ADJUSTED, 128 00:07:22,746 --> 00:07:27,107 A MANUAL TORQUE WRENCH IS USED TO FASTEN THE BOLTS. 129 00:07:27,109 --> 00:07:29,243 AGAIN, TORQUE PAINT IS APPLIED TO MARK 130 00:07:29,245 --> 00:07:32,638 IF THE PART HAS TAMPERED WITH OR BECOMES LOOSE. 131 00:07:35,768 --> 00:07:37,501 THE TENSIONER PULLEY AND IDLER PULLEY 132 00:07:37,503 --> 00:07:40,029 REGULATE THE SYSTEM'S TIMING BELT. 133 00:07:40,031 --> 00:07:42,565 THEY ARE ALSO ADJUSTED, FASTENED, 134 00:07:42,567 --> 00:07:44,926 AD FINALLY MARKED WITH TORQUE PAINT. 135 00:07:46,196 --> 00:07:49,923 ATTACHED TO THREE SPECIFIC AREAS OF THE CRANKSHAFT SPROCKET 136 00:07:49,925 --> 00:07:52,450 ARE THICK PIECES OF DOUBLE-SIDED TAPE. 137 00:07:52,452 --> 00:07:54,186 THEY TEMPORARILY SUPPORT 138 00:07:54,188 --> 00:07:56,914 A METALLIC PRECISION CAM DEGREE WHEEL, 139 00:07:56,916 --> 00:07:58,782 WHICH ACCURATELY SETS THE CAMSHAFT TIMING 140 00:07:58,784 --> 00:08:01,744 WHILE ALSO CHECKING THE VALVE TIMING. 141 00:08:04,007 --> 00:08:07,233 IN THIS STEP OF THE ENGINE BUILDING PROCESS, 142 00:08:07,235 --> 00:08:11,004 HE IS USING A CAM DEGREEING KIT, WHICH LETS HIM CHECK 143 00:08:11,006 --> 00:08:14,933 THE PISTON-TO-VALVE CLEARANCE WITH ACCURACY. 144 00:08:14,935 --> 00:08:16,293 IT ENSURES THAT 145 00:08:16,295 --> 00:08:19,955 THE ENGINE VALVES ARE OPENING AT THE CORRECT POINT 146 00:08:19,957 --> 00:08:23,158 AND THE PISTONS CYCLE WITHIN THE CYLINDERS. 147 00:08:23,160 --> 00:08:27,813 ANY ERROR IN THE SETTINGS CAN CAUSE THE PARTS TO MALFUNCTION, 148 00:08:27,815 --> 00:08:31,483 CAUSING DAMAGE TO THE ENGINE. 149 00:08:31,485 --> 00:08:33,244 TIMING IS ALSO VERIFIED 150 00:08:33,246 --> 00:08:37,774 TO ENSURE THE CRANKSHAFT AND CAMSHAFTS ARE ALIGNED. 151 00:08:41,104 --> 00:08:43,838 NEXT IS THE 4-CYLINDER EXHAUST MANIFOLD 152 00:08:43,840 --> 00:08:46,366 THAT COLLECTS AIR AND FUEL MIXTURES, 153 00:08:46,368 --> 00:08:48,560 WHICH ASSIST THE SERIES OF SMALL EXPLOSIONS 154 00:08:48,562 --> 00:08:50,896 WITHIN THE ENGINE'S COMBUSTION CHAMBER. 155 00:08:54,860 --> 00:08:57,319 THE TECHNICIAN ATTACHES THE EXHAUST MANIFOLD 156 00:08:57,321 --> 00:08:58,988 WITH STUDS AND NUTS, 157 00:08:58,990 --> 00:09:03,050 USING AN IMPACT DRIVER FOR TORQUE FORCE PRECISION. 158 00:09:07,716 --> 00:09:08,873 COVERAGE IS ADDED, 159 00:09:08,875 --> 00:09:11,876 LIKE THE ALUMINUM BACKING PLATE FOR THE AIR-BOX. 160 00:09:11,878 --> 00:09:16,072 A PLASTIC CAMSHAFT COVER FOLLOWS, 161 00:09:16,074 --> 00:09:19,534 ALONG WITH THE ALUMINUM TIMING BELT COVER, 162 00:09:19,536 --> 00:09:21,328 THE WATER PUMP PULLEY, 163 00:09:21,330 --> 00:09:24,198 AND A PLASTIC CAMSHAFT SPROCKET COVER. 164 00:09:24,200 --> 00:09:27,827 THE ENGINE BLOCK IS READY FOR THE ROAD AND TRACK. 165 00:09:33,683 --> 00:09:35,875 Narrator: THE G40'S DASHBOARD, 166 00:09:35,877 --> 00:09:39,137 TRANSMISSION PROP TUNNEL, AND INTERIOR SIDE TRIM 167 00:09:39,139 --> 00:09:42,106 ARE MADE OF CHOPPED STRAND MAT FIBERGLASS 168 00:09:42,108 --> 00:09:45,169 WITH A POLYESTER RESIN AND A GEL-COAT FINISH. 169 00:09:45,171 --> 00:09:47,696 LOOKING STELLAR STARTS ON THE INSIDE. 170 00:09:48,966 --> 00:09:54,227 ESPECIALLY USEFUL ON NEW MOLDS IS A LAYER OF MOLD RELEASE WAX, 171 00:09:54,229 --> 00:09:56,989 WHICH IS FORMULATED FOR THE EASY REMOVAL OF A PART 172 00:09:56,991 --> 00:09:58,491 FROM A TEMPLATE. 173 00:10:03,256 --> 00:10:06,583 FOLLOWING THE IMPLEMENTATION OF THE RELEASE WAX, 174 00:10:06,585 --> 00:10:09,978 A JET BLACK GEL COAT OF A HIGH QUALITY RESIN FINISH 175 00:10:09,980 --> 00:10:12,072 IS SPREAD ACROSS THE SURFACE. 176 00:10:12,074 --> 00:10:15,409 ONCE THE GEL COAT IS APPLIED, 177 00:10:15,411 --> 00:10:17,936 THE MOLD IS SHUTTERED TO ANOTHER AREA 178 00:10:17,938 --> 00:10:19,872 FOR CURING AT ROOM TEMPERATURE. 179 00:10:21,333 --> 00:10:24,068 GEL COAT WILL NOT CURE ADEQUATELY 180 00:10:24,070 --> 00:10:26,195 BELOW 59 DEGREES FAHRENHEIT, 181 00:10:26,197 --> 00:10:29,691 AND IN TEMPERATURES ABOVE 86 DEGREES, 182 00:10:29,693 --> 00:10:31,959 IT WILL CURE TOO QUICKLY. 183 00:10:31,961 --> 00:10:34,153 AFTER THE DRYING PROCESS, 184 00:10:34,155 --> 00:10:37,015 AN EPOXY EMULSION IS PAINTED ONTO THE SURFACE. 185 00:10:37,017 --> 00:10:40,944 IT IS NOW READY TO RECEIVE CHOPPED STRANDS OF FIBERGLASS 186 00:10:40,946 --> 00:10:45,007 THAT ARE MIXED WITH MORE OF THE HIGH STRENGTH BONDING GLUE. 187 00:10:47,244 --> 00:10:48,835 THESE STRANDS ARE MADE 188 00:10:48,837 --> 00:10:51,638 BY CHOPPING CONTINUOUS GLASS FILAMENTS 189 00:10:51,640 --> 00:10:55,367 COATED WITH A CHEMICAL SIZING INTO A SPECIFIED LENGTH. 190 00:10:55,369 --> 00:10:59,030 THESE STRANDS ENSURE THE COMPATIBILITY WITH THE RESIN 191 00:10:59,032 --> 00:11:01,925 TO REINFORCE THE PLASTIC-LIKE STRUCTURE 192 00:11:01,927 --> 00:11:04,527 AND PROVIDE ACOUSTICAL INSULATION. 193 00:11:08,058 --> 00:11:11,985 THE WORKERS APPLY SEVERAL LAYERS OF CONTINUOUS FILAMENT MATS 194 00:11:11,987 --> 00:11:14,580 THAT PROVIDE RIGIDITY, CONFORMABILITY, 195 00:11:14,582 --> 00:11:16,314 AND TENSILE STRENGTH. 196 00:11:16,316 --> 00:11:19,943 THE CONTINUOUS FILAMENT MATS ARE A NONWOVEN MAT 197 00:11:19,945 --> 00:11:22,205 MADE FROM FIBERGLASS FILAMENTS. 198 00:11:22,207 --> 00:11:24,940 THEY CONSIST OF CONTINUOUS FIBERS 199 00:11:24,942 --> 00:11:27,902 RANDOMLY ORIENTED IN MULTIPLE LAYERS. 200 00:11:30,532 --> 00:11:34,059 THE GLASS FIBER IS BONDED WITH A SILANE COUPLING AGENT, 201 00:11:34,061 --> 00:11:37,729 AND THE LAYERS ARE HELD TOGETHER WITH A SUITABLE BINDER. 202 00:11:42,419 --> 00:11:45,287 FINALLY, A SMALL FIBERGLASS RESIN ROLLER, 203 00:11:45,289 --> 00:11:48,882 CONSISTING OF THIN, PARALLEL FINS WITH DEEP GROOVES, 204 00:11:48,884 --> 00:11:50,017 ELIMINATES AIR 205 00:11:50,019 --> 00:11:52,744 ON THE FLAT SURFACES AND GRADUAL CURVES 206 00:11:52,746 --> 00:11:55,240 BEFORE THE PART IS CURED. 207 00:11:59,571 --> 00:12:02,038 THE IMPRESSION OF THE TRANSMISSION PROP TUNNEL 208 00:12:02,040 --> 00:12:03,965 IS SEPARATED FROM THE MOLD 209 00:12:03,967 --> 00:12:08,495 USING PLASTIC WEDGES AND SUBTLE ARM STRENGTH. 210 00:12:08,497 --> 00:12:10,364 IF MORE FORCE IS REQUIRED, 211 00:12:10,366 --> 00:12:13,258 WORKERS USE A WHITE HEAD RUBBER MALLET 212 00:12:13,260 --> 00:12:14,493 TO TAP THE MOLD. 213 00:12:16,055 --> 00:12:18,881 BUT THE PROCESS DOESN'T END HERE. 214 00:12:21,051 --> 00:12:24,845 IN A SECURE ROOM, WEARING PROTECTIVE GLOVES AND A MASK, 215 00:12:24,847 --> 00:12:28,541 THE MACHINIST REMOVES ANY AND ALL EXCESS FIBROUS MATERIALS 216 00:12:28,543 --> 00:12:29,876 WITH AN ANGLE GRINDER 217 00:12:29,878 --> 00:12:33,405 TO PREPARE THE PART FOR A PROPER, SMOOTH FINISH. 218 00:12:36,669 --> 00:12:38,735 WITHIN THE TRANSMISSION PROP TUNNEL 219 00:12:38,737 --> 00:12:40,862 IS THE OPEN PORTION THAT IS ALLOCATED TO 220 00:12:40,864 --> 00:12:46,226 THE GEARBOX, GEARSHIFTER, AND PARKING BRAKE COMPONENTS. 221 00:12:46,228 --> 00:12:50,022 USING A SMALL RECIPROCATING SAW DESIGNED FOR MICROCUTTING, 222 00:12:50,024 --> 00:12:52,883 HE PLUNGES THE HAND TOOL INTO THE PANEL, 223 00:12:52,885 --> 00:12:55,745 MAKING ACCURATE CUTS ALONG THE PERIMETER. 224 00:12:57,949 --> 00:13:02,243 TO FOLLOW UP, THE CUT EDGES ARE SHAPED, SMOOTHED, AND FINISHED. 225 00:13:02,245 --> 00:13:04,905 HE EXERTS PRESSURE TO THE FIBERGLASS 226 00:13:04,907 --> 00:13:07,440 WITH AN AIR SANDER AND A BELT SANDER 227 00:13:07,442 --> 00:13:10,703 FOR PRECISION QUALITY AND ULTIMATE CLEANLINESS. 228 00:13:14,901 --> 00:13:17,793 AT ANOTHER WORKTABLE, HE TREATS THE PART'S EXTERIOR 229 00:13:17,795 --> 00:13:19,996 WITH A POLISHING COMPOUND 230 00:13:19,998 --> 00:13:24,058 IN ORDER TO CREATE A COSMETICALLY DYNAMIC FINISH 231 00:13:24,060 --> 00:13:25,652 AND SURFACE SHINE. 232 00:13:25,654 --> 00:13:29,981 ALTOGETHER, THIS PROCESS REMOVES ANY FLASHLINES CREATED 233 00:13:29,983 --> 00:13:34,177 WHEN THE SHAPING MOLD AND FINISH COMPONENT SEPARATED. 234 00:13:37,541 --> 00:13:39,674 HE USES A VARIABLE SPEED POLISHER 235 00:13:39,676 --> 00:13:42,937 EQUIPPED WITH A WOOL POLISHING BONNET 236 00:13:42,939 --> 00:13:47,333 THAT ROTATES FROM 600 TO 3,000 REVOLUTIONS PER MINUTE. 237 00:13:47,335 --> 00:13:49,894 HE CONDITIONS THE SURFACE OF THE PART, 238 00:13:49,896 --> 00:13:53,523 GIVING IT A HIGH GLOSS FINISH AND REFLECTIVE IMPRESSION. 239 00:13:59,823 --> 00:14:01,348 WITH AN IMPACT DRIVER, 240 00:14:01,350 --> 00:14:03,617 THE TECHNICIAN DRILLS THE COMPONENT, 241 00:14:03,619 --> 00:14:07,012 CREATING THE NECESSARY HOLES FOR SOON-TO-BE-INSTALLED SCREWS, 242 00:14:07,014 --> 00:14:09,573 BOLTS, AND OTHER FASTENERS. 243 00:14:09,575 --> 00:14:11,975 CONTROL ELEMENTS IN THE CAR'S COCKPIT, 244 00:14:11,977 --> 00:14:13,970 LIKE THE GEARSHIFTER AND PARKING BRAKE, 245 00:14:13,972 --> 00:14:18,499 WILL BE LINKED TO THE TRANSMISSION PROP TUNNEL. 246 00:14:18,501 --> 00:14:21,035 A LEATHER TRIM WILL ALSO WORK IN TANDEM 247 00:14:21,037 --> 00:14:22,328 WITH THESE SECTIONS. 248 00:14:25,701 --> 00:14:28,727 THE TECHNICIAN APPLIES A POLYURETHANE ADHESIVE, 249 00:14:28,729 --> 00:14:33,390 WHICH SECURES NUT PLATES TO THE UNDERSIDE OF THE COMPONENT. 250 00:14:33,392 --> 00:14:37,920 IT ALLOWS THE TRIM SURROUNDING THE GEAR STICK TO BOLT ON. 251 00:14:37,922 --> 00:14:40,981 THIS ADHESIVE ALSO ALLOWS FOR A LITTLE FLEXIBILITY, 252 00:14:40,983 --> 00:14:44,777 NEVER CRACKING OVER TIME DUE TO VIBRATIONS. 253 00:14:46,606 --> 00:14:49,607 BOLTS SECURE THE NUT PLATES DURING CURING. 254 00:14:51,803 --> 00:14:55,263 INSTRUMENTAL TO THE COCKPIT AND THE DRIVER'S SATISFACTION 255 00:14:55,265 --> 00:14:57,132 IS THE DASHBOARD, 256 00:14:57,134 --> 00:14:59,759 WHICH SHARES A NUMBER OF CHARACTERISTICS 257 00:14:59,761 --> 00:15:01,662 WITH THE G40'S RACING SIBLING. 258 00:15:02,956 --> 00:15:05,557 THE OVERALL PANEL, FUNCTION BUTTONS, 259 00:15:05,559 --> 00:15:07,350 AND OPERATIONS INDICATORS 260 00:15:07,352 --> 00:15:10,121 TRANSLATE PERFECTLY ONTO THIS ROAD CAR. 261 00:15:16,818 --> 00:15:19,577 Narrator: STUNNING STYLING AND EXCELLENT PERFORMANCE 262 00:15:19,579 --> 00:15:21,111 ARE IN EVERY GINETTA CAR, 263 00:15:21,113 --> 00:15:25,241 FROM THE ELECTRIC G50 TO THIS 1960s G10 264 00:15:25,243 --> 00:15:27,302 TO THE G60 SUPERCAR, 265 00:15:27,304 --> 00:15:31,031 AND THE G40 IS AN UNDENIABLE ADDITION. 266 00:15:32,301 --> 00:15:35,994 70 STAFF MEMBERS PRODUCE 300 CARS A YEAR. 267 00:15:35,996 --> 00:15:39,924 WITH EACH VEHICLE TAKING FOUR WEEKS TO BUILD. 268 00:15:43,254 --> 00:15:46,055 DELIVERED USING A HYDRAULIC ELEVATING CART, 269 00:15:46,057 --> 00:15:47,248 THE FIRST COMPONENT 270 00:15:47,250 --> 00:15:49,117 IN THIS STEP-BY-STEP MARRIAGE OF ELEMENTS 271 00:15:49,119 --> 00:15:51,745 IS THE REAR DIFFERENTIAL. 272 00:15:51,747 --> 00:15:54,480 IT'S DESIGNED TO DRIVE A PAIR OF WHEELS 273 00:15:54,482 --> 00:15:57,843 WHILE ALLOWING THEM TO ROTATE AT DIFFERENT SPEEDS. 274 00:16:03,334 --> 00:16:06,202 NEXT ARE THE REAR UPPER SUSPENSION WISHBONES, 275 00:16:06,204 --> 00:16:09,297 WHICH CONTROL THE VERTICAL MOVEMENT OF THE WHEEL 276 00:16:09,299 --> 00:16:11,198 THROUGHOUT SUSPENSION TRAVEL. 277 00:16:14,696 --> 00:16:17,689 TWO HALF AXLES CONNECT TO THE GEARBOX AND DIFFERENTIAL 278 00:16:17,691 --> 00:16:20,683 ON EITHER SIDE. 279 00:16:20,685 --> 00:16:24,179 THIS IS A FUEL CELL BLADDER. 280 00:16:24,181 --> 00:16:25,513 IT'S A GASOLINE TANK 281 00:16:25,515 --> 00:16:28,575 ENCASED IN A FABRICATED ALUMINUM HOUSING CASE 282 00:16:28,577 --> 00:16:31,345 AND SECURED WITH METALLIC STRAPS. 283 00:16:35,575 --> 00:16:38,636 TRANSMITTING POWER FROM THE GEARBOX TO THE DIFFERENTIAL 284 00:16:38,638 --> 00:16:42,397 IS THE ONE-PIECE UNIVERSAL JOINT CALLED A TORQUE TUBE, 285 00:16:42,399 --> 00:16:44,859 OR BETTER KNOWN AS THE DRIVESHAFT. 286 00:16:47,931 --> 00:16:50,456 MORE WIRING AND TUBING IS ATTACHED 287 00:16:50,458 --> 00:16:52,551 WITH TWIST TAIL CABLE TIES. 288 00:16:54,254 --> 00:16:57,214 THIS WIRING IS FOR THE POWER OF THE INTAKE FUEL PUMP 289 00:16:57,216 --> 00:17:01,143 AND A FUEL HOSE THAT FEEDS TO THE ENGINE'S FUEL RAIL. 290 00:17:04,481 --> 00:17:07,340 AFTER MOST ESSENTIALS ARE AFFIXED TO THE CHASSIS, 291 00:17:07,342 --> 00:17:11,137 COCKPIT COMPONENTS LIKE THE FIBERGLASS REAR BULKHEAD TRIM, 292 00:17:11,139 --> 00:17:12,805 WHICH SEPARATES THE CABIN 293 00:17:12,807 --> 00:17:15,667 FROM THE FUEL TANK AND REAR SUSPENSION UNITS, 294 00:17:15,669 --> 00:17:16,601 GET ADDED. 295 00:17:18,697 --> 00:17:21,622 FOLLOWING THE ADDITION OF THE REAR UNDERSIDE, 296 00:17:21,624 --> 00:17:23,558 IS THE SIDE CEILING TRIM PANEL, 297 00:17:23,560 --> 00:17:26,386 WHICH SECURELY CLOSES THE CABIN FROM THE EXTERIOR. 298 00:17:27,489 --> 00:17:29,748 USING AN AIR HYDRAULIC RIVET GUN, 299 00:17:29,750 --> 00:17:32,017 THE TECHNICIAN SETS THE MECHANICAL FASTENERS 300 00:17:32,019 --> 00:17:35,046 INTO THEIR PROPER LOCKING POSITIONS. 301 00:17:38,843 --> 00:17:40,443 AS THE PRODUCTION OF THIS CAR 302 00:17:40,445 --> 00:17:42,971 GETS CLOSER AND CLOSER TO THE FINISH LINE, 303 00:17:42,973 --> 00:17:45,699 WORKERS DELIVER THE MAIN FIBERGLASS BODY SHELL 304 00:17:45,701 --> 00:17:48,935 THAT SNAPS EASILY ONTO THE CHASSIS FRAME. 305 00:17:51,931 --> 00:17:55,092 THE DOORS ARE MOUNTED WITH CONVENTIONAL HINGES. 306 00:17:57,530 --> 00:17:59,988 NEXT, THE WORKERS USE AN AIR HOIST 307 00:17:59,990 --> 00:18:03,116 TO DROP IN TWO OF THE MOST ESSENTIAL ITEMS -- 308 00:18:03,118 --> 00:18:05,252 A COMPLETELY FRAME-FITTING ENGINE 309 00:18:05,254 --> 00:18:08,114 AND THE GEARBOX ASSEMBLY. 310 00:18:12,545 --> 00:18:14,145 IN THIS WORK AREA, 311 00:18:14,147 --> 00:18:17,340 A TECHNICIAN SLIDES A SHEET OF CORRUGATED ALUMINUM 312 00:18:17,342 --> 00:18:19,734 INTO A MANUAL GUILLOTINE SHEARER. 313 00:18:19,736 --> 00:18:21,536 USING THE PNEUMATIC FOOT PEDAL, 314 00:18:21,538 --> 00:18:23,963 THIS MACHINE SHEARS THE SHEET QUICKLY 315 00:18:23,965 --> 00:18:26,299 WITH A HEAVY DESCENDING BLADE. 316 00:18:26,301 --> 00:18:30,095 AFTER CUTTING, IT'S MOVED FOR BENDING 317 00:18:30,097 --> 00:18:34,091 TO A COUNTERBALANCE BOX AND PAN FOLDER. 318 00:18:34,093 --> 00:18:36,018 THE SHEET IS CLAMPED INTO PLACE, 319 00:18:36,020 --> 00:18:39,814 AND THE COUNTERWEIGHT GENERATES THE FORCE TO BEND THE METAL. 320 00:18:44,379 --> 00:18:47,705 CREATED USING THE BOX FOLDER IS THE HEAT SHIELD, 321 00:18:47,707 --> 00:18:50,108 WHICH SURROUNDS THE CATALYTIC CONVERTER, 322 00:18:50,110 --> 00:18:52,302 A VEHICLE EMISSIONS CONTROL DEVICE 323 00:18:52,304 --> 00:18:55,798 THAT REDUCES TOXIC POLLUTANTS AND EXHAUST GAS. 324 00:18:57,401 --> 00:18:59,927 THE HEAT SHIELD ALSO PROTECTS THE BULKHEAD, 325 00:18:59,929 --> 00:19:01,662 BODYWORK, AND CABIN 326 00:19:01,664 --> 00:19:04,724 FROM THE HIGH HEAT GENERATED BY THE CONVERTER. 327 00:19:04,726 --> 00:19:06,792 ONCE THE SHIELD IS INSTALLED, 328 00:19:06,794 --> 00:19:09,453 THE TECHNICIAN CAN FINALLY INSTALL 329 00:19:09,455 --> 00:19:11,356 THE RADIATOR'S WATER PIPE. 330 00:19:14,152 --> 00:19:18,413 DRESSING THE CAR'S COCKPIT WITH ROAD AND RACE-WORTHY DYNAMICS 331 00:19:18,415 --> 00:19:20,807 CONTINUES AS THE WORKERS FIRMLY INSTALL 332 00:19:20,809 --> 00:19:23,610 THE JET BLACK FIBERGLASS TRANSMISSION 333 00:19:23,612 --> 00:19:25,271 AND PROP SHAFT COVER. 334 00:19:27,408 --> 00:19:28,965 NEXT IS THE ADDITION OF 335 00:19:28,967 --> 00:19:32,036 THE MINIMALISTIC RACING-INSPIRED DASHBOARD PANEL, 336 00:19:32,038 --> 00:19:35,164 WITH ITS VERY FEW METALLIC CONTROL BUTTONS 337 00:19:35,166 --> 00:19:37,325 AND OPERATIONS INSTRUMENTATION. 338 00:19:39,296 --> 00:19:40,953 MORE CONTROL IS ADDED 339 00:19:40,955 --> 00:19:44,090 WITH THE STEERING COLUMN SWITCH CLUSTER, 340 00:19:44,092 --> 00:19:45,683 A GAGE PANEL, 341 00:19:45,685 --> 00:19:48,353 AND THE RACING-INSPIRED STEERING WHEEL. 342 00:19:50,849 --> 00:19:54,376 UNLIKE MOST SPORTS CARS, THE FRONT BONNET IS COMPOSED OF 343 00:19:54,378 --> 00:19:55,778 THE BUMPER, HEAD LAMPS, 344 00:19:55,780 --> 00:19:58,072 FENDERS, AND HOOD AS A WHOLE UNIT. 345 00:19:59,908 --> 00:20:01,834 THIS FRONTAL KIT SNAPS INTO PLACE 346 00:20:01,836 --> 00:20:04,170 WITH A FLICK OF THE HOOD LATCHES, 347 00:20:04,172 --> 00:20:07,565 CLAMPS COMMONLY USED ON RACE CARS. 348 00:20:09,594 --> 00:20:12,261 THE RACING WORLD HAS ALWAYS BEEN PRIORITY NUMBER ONE 349 00:20:12,263 --> 00:20:14,656 TO THE AUTOMAKER -- 350 00:20:14,658 --> 00:20:17,383 EVEN MORE SO TO THE COMPANY'S CHAIRMAN, 351 00:20:17,385 --> 00:20:19,118 A FORMER RACING CHAMPION. 352 00:20:19,120 --> 00:20:21,413 THE TEAM ALWAYS ROLLS WITH A TRUCK EQUIPPED 353 00:20:21,415 --> 00:20:23,282 WITH A PORTABLE DYNAMOMETER, 354 00:20:23,284 --> 00:20:24,883 ALLOWING TESTING FROM HEADQUARTERS. 355 00:20:24,885 --> 00:20:27,344 [ REVS ENGINE ] 356 00:20:27,346 --> 00:20:30,339 THE FACTORY DYNO VERIFIES THE ENGINE POWER 357 00:20:30,341 --> 00:20:34,135 AND DRIVETRAIN PERFORMANCE OF NEW CARS SOLD TO CUSTOMERS, 358 00:20:34,137 --> 00:20:37,272 WHILE THE PORTABLE SYSTEM PREPS TEAM CARS FOR RACE DAY. 359 00:20:39,835 --> 00:20:41,567 IT'S NOT ESSENTIAL TO BE A MILLIONAIRE 360 00:20:41,569 --> 00:20:43,161 TO GET BEHIND THE WHEEL OF 361 00:20:43,163 --> 00:20:46,823 THIS BRITISH, HANDCRAFTED, STREET LEGAL RACE CAR. 362 00:20:46,825 --> 00:20:49,226 THE G40 IS DESIGNED WITH THE BUDGET-CONSCIOUS, 363 00:20:49,228 --> 00:20:52,421 ENTRY LEVEL RACING ENTHUSIAST IN MIND. 364 00:20:54,717 --> 00:20:57,985 AND WHERE IT REALLY THRIVES IS AT THE TRACK, 365 00:20:57,987 --> 00:21:01,848 LIKE HERE AT THE WORLD-RENOWNED SILVERSTONE CIRCUIT. 366 00:21:01,850 --> 00:21:05,643 WITH AN AUTOMOTIVE HERITAGE FORMED BY FOUR BROTHERS 367 00:21:05,645 --> 00:21:09,105 AND REJUVENATED BY A COMPANY UNLIKE ANY OTHER, 368 00:21:09,107 --> 00:21:11,199 GINETTA HAS ALWAYS BEEN ABOUT 369 00:21:11,201 --> 00:21:14,136 RACING'S ADRENALINE-PUMPING DISCIPLINE. 370 00:21:14,138 --> 00:21:18,265 AS A PAVEMENT-HUGGING ROAD CAR THAT FLOURISHES ON THE TRACK, 371 00:21:18,267 --> 00:21:21,794 YET AFFORDS INEXPENSIVE, DEPENDABLE, FUN RACING, 372 00:21:21,796 --> 00:21:24,789 THE G40 IS MORE THAN JUST A FANTASY. 373 00:21:24,791 --> 00:21:27,884 IT'S A DREAM CAR THAT PROVES IT. 374 00:21:27,886 --> 00:21:32,046 [ MAN SPEAKING INDISTINCTLY OVER P.A. ] 29573

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