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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 INDISTINCTLYOVER P.A. ]
29573
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