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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS" --
2
00:00:03,070 --> 00:00:06,430
THE LUCRA LC470,
A LIGHTWEIGHT SUPER CAR
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00:00:06,432 --> 00:00:08,290
WITH HEAVYWEIGHT POWER.
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00:00:08,292 --> 00:00:11,227
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:23,717 --> 00:00:27,043
Narrator: BELIEVE IT OR NOT,
EVEN THOUGH THE LUCRA LC470
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00:00:27,045 --> 00:00:29,304
HOUSES A POWERFUL V8 ENGINE,
8
00:00:29,306 --> 00:00:31,506
THANKS TO
CAREFUL DESIGN CHOICES,
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00:00:31,508 --> 00:00:36,303
IT WEIGHS
LESS THAN 2,000 POUNDS.
10
00:00:36,305 --> 00:00:38,931
ONE OF THOSE DESIGN CHOICES
WAS THE DECISION TO MAKE
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00:00:38,933 --> 00:00:41,526
THE ENTIRE BODY
OUT OF CARBON FIBER,
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00:00:41,528 --> 00:00:44,796
WHICH ONLY WEIGHS
ABOUT 200 POUNDS.
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00:00:46,925 --> 00:00:50,184
THE COMPONENTS OF THE LC470
ARE ALSO MADE OF
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00:00:50,186 --> 00:00:51,986
AVIATION GRADE MATERIAL,
15
00:00:51,988 --> 00:00:54,748
RIGHT DOWN TO THE WIRES
AND BOLTS.
16
00:00:54,750 --> 00:00:58,543
THIS RESULTS AT AN EXCEPTIONAL
COMBINATION OF LIGHTNESS,
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00:00:58,545 --> 00:01:00,646
STRENGTH, AND DURABILITY.
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00:01:03,075 --> 00:01:06,268
LUCRA CARS WAS FOUNDED BY
CAR ENTHUSIAST LUKE RICHARDS
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00:01:06,270 --> 00:01:08,137
IN 2006.
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00:01:08,139 --> 00:01:11,365
HIS GOAL WAS TO BUILD
THE PERFECT SPORTS CAR.
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00:01:11,367 --> 00:01:14,694
IN ESSENCE, HE WANTED TO FIND
A WAY TO COMBINE
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00:01:14,696 --> 00:01:17,497
THE AGILITY OF
EUROPEAN SPORTS CARS
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00:01:17,499 --> 00:01:21,692
WITH THE MUSCLE OF AMERICAN V8s.
24
00:01:21,694 --> 00:01:23,620
WHEN A CUSTOMER BUYS A LUCRA,
25
00:01:23,622 --> 00:01:25,421
RICHARD TAKES THEM
TO A RACE TRACK
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00:01:25,423 --> 00:01:28,150
TO INTRODUCE THE DRIVER
TO THE CAR.
27
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Narrator:
A CLEVER STRUCTURAL DESIGN
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ALLOWED RICHARDS AND HIS TEAM
TO PLACE THE ENGINE
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00:01:40,440 --> 00:01:42,106
NEAR THE CENTER OF THE CAR.
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00:01:42,108 --> 00:01:48,196
THIS ACHIEVED A WEIGHT BALANCE
OF 53% REAR AND 47% FRONT
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00:01:48,198 --> 00:01:52,058
FOR AN IDEAL COMBINATION
OF TRACTION AND HANDLING.
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00:01:52,060 --> 00:01:53,860
THE CHASSIS DESIGN IS THE KEY
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00:01:53,862 --> 00:01:57,122
TO THIS OPTIMAL
WEIGHT DISTRIBUTION.
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00:01:57,124 --> 00:01:58,949
KNOWN AS A PERIMETER CHASSIS,
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00:01:58,951 --> 00:02:00,751
INSTEAD OF RUNNING
UNDER THE ENGINE
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00:02:00,753 --> 00:02:03,946
AND THE PASSENGERS,
IT WRAPS AROUND THEM.
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00:02:07,109 --> 00:02:10,144
THIS MEANS THE DESIGNERS
COULD POSITION THE ENGINE BLOCK
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00:02:10,146 --> 00:02:11,871
AND THE SEATS
WHEREVER THEY WANTED
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00:02:11,873 --> 00:02:16,234
TO BEST ACCOMMODATE
THE DYNAMICS OF THE CAR.
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00:02:16,236 --> 00:02:20,964
THE CHASSIS IS CONSTRUCTED
OF D.O.M. STEEL TUBING.
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00:02:20,966 --> 00:02:24,092
LUCRA USES C.N.C. MACHINES
TO PRECISION CUT
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00:02:24,094 --> 00:02:28,222
AND BEND THE TUBING
BEFORE CLAMPING IT IN A JIG.
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00:02:28,224 --> 00:02:31,025
SINCE THE CHASSIS
IS THE FOUNDATION OF THE CAR,
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00:02:31,027 --> 00:02:33,886
IT MUST BE ABSOLUTELY FLAWLESS.
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00:02:33,888 --> 00:02:36,714
EVEN THE JIG WAS DIGITALLY
DESIGNED AND CUT
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00:02:36,716 --> 00:02:40,510
TO PREVENT MANUFACTURING ERRORS.
47
00:02:40,512 --> 00:02:43,379
THE WELDING PROCESS CAN WARP
A STRUCTURE OUT OF SHAPE
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00:02:43,381 --> 00:02:45,173
UNLESS IT'S SECURED.
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00:02:45,175 --> 00:02:47,775
THE JIG KEEPS EVERY COMPONENT
RIGIDLY IN PLACE
50
00:02:47,777 --> 00:02:49,803
AS THE WELDER WORKS.
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00:02:55,069 --> 00:02:58,128
REMARKABLY, LUCRA BUILDS
THE MAIN BODY OF THE CAR
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00:02:58,130 --> 00:03:00,197
IN ONE SHOT.
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00:03:00,199 --> 00:03:03,325
THEY PLACE A 3-LAYER LAMINATE
OF CARBON FIBER
54
00:03:03,327 --> 00:03:07,221
INSIDE A ONE-PIECE MOLD
AND LET IT CURE.
55
00:03:10,285 --> 00:03:11,751
WHEN REMOVED FROM THE MOLD,
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00:03:11,753 --> 00:03:15,813
THE RESULT IS AN EXTRAORDINARILY
STRONG RIGID STRUCTURE
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00:03:15,815 --> 00:03:21,603
THAT COULD ALMOST FUNCTION AS
A MONOCOQUE CHASSIS ON ITS OWN.
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A TECHNICIAN PREPARES
TO CREATE APERTURES
59
00:03:23,474 --> 00:03:25,633
FOR THE DASHBOARD COMPONENTS
60
00:03:25,635 --> 00:03:29,828
BY ATTACHING A LASER CUT
ALUMINUM TEMPLATE.
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00:03:29,830 --> 00:03:32,632
HE THEN USES IT AS A GUIDE
TO CAREFULLY DRILL OUT
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00:03:32,634 --> 00:03:35,593
ALL THE NECESSARY HOLES
AND GUIDE POINTS.
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00:03:39,824 --> 00:03:42,918
NEXT, HE SCRIBES THE PERIMETER
OF ALL THE OPENINGS
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00:03:42,920 --> 00:03:44,553
WITH A SHARP POINT.
65
00:03:46,048 --> 00:03:50,642
THE FINISHED DASHBOARD
WILL FEATURE MINIMAL COMPONENTS.
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00:03:50,644 --> 00:03:52,845
THE LC470 HAS NONE OF
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00:03:52,847 --> 00:03:55,239
THOSE DISTRACTING
21st CENTURY ACCESSORIES
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00:03:55,241 --> 00:03:58,533
LIKE G.P.S. NAVIGATION,
BLUETOOTH CONNECTIVITY,
69
00:03:58,535 --> 00:04:02,262
OR U.S.B. PORTS.
70
00:04:02,264 --> 00:04:05,133
THE WORKER NOW UNSCREWS
THE ATTACHMENT POINTS
71
00:04:05,135 --> 00:04:06,659
AND REMOVES THE TEMPLATE,
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00:04:06,661 --> 00:04:10,388
REVEALING THE SCRIBE TRANSFER
OF THE DASHBOARD DESIGN.
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00:04:10,390 --> 00:04:13,984
IT'S READY FOR THE FINAL STEP.
74
00:04:13,986 --> 00:04:16,219
THE CENTER HOLES
THAT HE DRILLED EARLIER
75
00:04:16,221 --> 00:04:20,482
PROVIDE A GUIDE
FOR THE TECHNICIAN'S HOLE SAW.
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00:04:20,484 --> 00:04:22,676
THE CARBON FIBER
IS EXTREMELY HARD,
77
00:04:22,678 --> 00:04:27,139
SO HE MUST EXERT CONSIDERABLE
FORCE TO CUT EACH HOLE.
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00:04:27,141 --> 00:04:30,901
AT THE SAME TIME,
HE MUST BE EXTREMELY CAREFUL.
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00:04:30,903 --> 00:04:33,971
SINCE THE DASHBOARD IS PART
OF THE ONE-PIECE BODY,
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00:04:33,973 --> 00:04:37,200
HE'S ONLY GOT ONE SHOT
AT DOING IT RIGHT.
81
00:04:43,158 --> 00:04:45,559
NEXT,
THE BODY MEETS THE CHASSIS.
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00:04:45,561 --> 00:04:48,554
RATHER THAN
A FEW ATTACHMENT POINTS,
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00:04:48,556 --> 00:04:50,981
EVERY PART OF THE CHASSIS
PERIMETER BONDS DIRECTLY
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00:04:50,983 --> 00:04:54,785
TO THE CAR'S BODY.
85
00:04:54,787 --> 00:04:58,313
LUCRA STARTS BY RIVETING
THE CARBON FIBER TO THE STEEL,
86
00:04:58,315 --> 00:05:01,442
THEN WRAPS EVERY JOINT
IN MORE CARBON FIBER
87
00:05:01,444 --> 00:05:04,637
TO COMPLETELY FUSE THE BODY
TO THE CHASSIS.
88
00:05:12,786 --> 00:05:15,045
Narrator: TO MAKE
THE COMPLEX EXHAUST SYSTEM,
89
00:05:15,047 --> 00:05:17,647
LUCRA WORKS WITH A COMPANY
THAT SPECIALIZES
90
00:05:17,649 --> 00:05:19,107
IN DOING JUST THAT --
91
00:05:19,109 --> 00:05:22,311
MagnaFlow
OF OCEANSIDE, CALIFORNIA.
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00:05:22,313 --> 00:05:25,038
THE EXHAUST IS KEY
TO THE CAR'S PERFORMANCE,
93
00:05:25,040 --> 00:05:26,832
SO IT HAS TO BE DONE RIGHT.
94
00:05:28,369 --> 00:05:31,863
HERE, THEY USE PRECISION
EQUIPMENT DIGITALLY PROGRAMMED
95
00:05:31,865 --> 00:05:34,923
TO MAKE PERFECT BENDS
IN THE TUBING.
96
00:05:34,925 --> 00:05:37,393
MagnaFlow USES
STAINLESS STEEL TUBING
97
00:05:37,395 --> 00:05:41,188
TO MAKE THE LUCRA LC470
EXHAUST HEADER.
98
00:05:41,190 --> 00:05:44,050
THIS IS BECAUSE STAINLESS STEEL
IS RUSTPROOF,
99
00:05:44,052 --> 00:05:46,978
EASY TO KEEP CLEAN,
AND CAPABLE OF ENDURING
100
00:05:46,980 --> 00:05:50,315
THE SUPER HOT TEMPERATURES OF
THE EXHAUST GASES.
101
00:05:53,079 --> 00:05:55,271
SPECIALIZED GAUGES TEST
EVERY PARAMETER
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00:05:55,273 --> 00:05:59,734
OF EACH SECTION OF TUBING
TO ENSURE IT'S FLAWLESS.
103
00:05:59,736 --> 00:06:03,329
FOR THE LC470,
MagnaFlow BUILDS A COMPONENT
104
00:06:03,331 --> 00:06:07,492
KNOWN AS AN EXHAUST HEADER
RATHER THAN A MANIFOLD.
105
00:06:08,428 --> 00:06:11,162
A HEADER IS DESIGNED TO MAKE
THE EXHAUST GASES FLOW
106
00:06:11,164 --> 00:06:15,951
AT A SPEED THAT HELPS OPTIMIZE
THE OUTPUT OF THE ENGINE.
107
00:06:15,953 --> 00:06:19,154
IN A SENSE, THE EXHAUST HEADER
HELPS THE ENGINE BREATHE
108
00:06:19,156 --> 00:06:20,848
MORE EFFICIENTLY.
109
00:06:24,912 --> 00:06:27,045
A LASER CUTTING MACHINE
QUICKLY ETCHES OUT
110
00:06:27,047 --> 00:06:29,840
THE FLANGES FOR THE HEADER.
111
00:06:29,842 --> 00:06:32,001
THE HOLES IN THE FLANGES
MUST PRECISELY MATCH
112
00:06:32,003 --> 00:06:34,904
THE DIAMETER OF THE TUBES.
113
00:06:34,906 --> 00:06:37,165
IN FACT, THE DIAMETER OF
THE HEADER PIPE
114
00:06:37,167 --> 00:06:39,901
IS A KEY TO ITS PERFORMANCE.
115
00:06:39,903 --> 00:06:43,663
THE DESIGNERS MATCH THE DIAMETER
TO THE ENGINE'S CAPACITY.
116
00:06:43,665 --> 00:06:45,324
THE OPTIMAL DIAMETER,
117
00:06:45,326 --> 00:06:47,659
TOGETHER WITH THE SMOOTH BENDS
IN THE PIPES,
118
00:06:47,661 --> 00:06:50,988
HELP MAXIMIZE AIRFLOW.
119
00:06:50,990 --> 00:06:53,649
BUT PERHAPS EVEN MORE IMPORTANT
TO THE AIRFLOW
120
00:06:53,651 --> 00:06:55,650
IS THE FACT THAT
WITH THE HEADER,
121
00:06:55,652 --> 00:06:58,246
EACH CYLINDER HAS ITS OWN PIPE.
122
00:07:03,878 --> 00:07:07,005
A SKILLED WELDER CLAMPS
THE PIPES INTO A CUSTOM JIG
123
00:07:07,007 --> 00:07:09,332
AND GOES TO WORK.
124
00:07:09,334 --> 00:07:13,228
THIS STYLE OF HEADER IS KNOWN
AS AN EQUAL LENGTH HEADER.
125
00:07:13,230 --> 00:07:14,630
THAT MEANS THAT
EACH OF THE PIPES
126
00:07:14,632 --> 00:07:17,357
IS EXACTLY THE SAME LENGTH.
127
00:07:17,359 --> 00:07:19,626
THIS FEATURE ENSURES
THAT ALL THE CYLINDERS
128
00:07:19,628 --> 00:07:21,887
WORK WITH EQUAL EFFICIENCY.
129
00:07:26,686 --> 00:07:30,580
MAKING SURE THAT ALL THOSE PIPES
HAVE EXACTLY THE SAME LENGTH,
130
00:07:30,582 --> 00:07:34,042
AND SIMULTANEOUSLY FIT AROUND
EACH OTHER IN A TIGHT SPACE,
131
00:07:34,044 --> 00:07:38,037
IS NO EASY FEAT.
132
00:07:38,039 --> 00:07:39,906
OF COURSE,
THE HEADER IS JUST ONE COMPONENT
133
00:07:39,908 --> 00:07:42,434
OF THE EXHAUST SYSTEM.
134
00:07:42,436 --> 00:07:43,902
IN THIS SECTION
OF THEIR FACILITY,
135
00:07:43,904 --> 00:07:46,796
MagnaFlow CONSTRUCTS MUFFLERS
FROM GIANT ROLLS
136
00:07:46,798 --> 00:07:52,061
OF STAINLESS STEEL SHEETING.
137
00:07:52,063 --> 00:07:54,121
A MASSIVE PRESS
PRESTAMPS THE STEEL
138
00:07:54,123 --> 00:07:58,851
WITH THE MagnaFlow COMPANY LOGO
AT REGULAR INTERVALS.
139
00:07:58,853 --> 00:08:00,919
THIS CONTINUOUS SHEET
WILL BE USED TO FORM
140
00:08:00,921 --> 00:08:03,648
THE VISIBLE ELEMENT OF
THE MUFFLERS.
141
00:08:05,751 --> 00:08:09,345
NEXT, A POWERFUL CUTTING MACHINE
EASILY CHOPS THE SHEET
142
00:08:09,347 --> 00:08:11,440
TO THE REQUIRED SIZE.
143
00:08:13,944 --> 00:08:17,137
A CAREFULLY CALIBRATED
ROLLING DEVICE FORMS THE SHEETS
144
00:08:17,139 --> 00:08:21,400
TO EXACTLY THE RIGHT
CURVE DIAMETER TWO AT A TIME.
145
00:08:21,402 --> 00:08:24,295
MagnaFlow WILL USE THESE
NEWLY FORMED CYLINDERS
146
00:08:24,297 --> 00:08:27,757
TO MAKE THE OUTER LAYER
OF THE MUFFLERS.
147
00:08:32,289 --> 00:08:34,981
AS THE CYLINDERS LEAVE
THE ROLLING MACHINE,
148
00:08:34,983 --> 00:08:37,817
A WELDING HEAD TRAVELS ALONG
THE TRACK UNDERNEATH THEM
149
00:08:37,819 --> 00:08:40,345
TO FUSE THEM SHUT
WITH THE WELDED SEAM.
150
00:08:43,075 --> 00:08:45,842
A CONVEYOR SYSTEM THEN ARRIVES
TO WHISK THEM AWAY
151
00:08:45,844 --> 00:08:47,670
TO THE NEXT STAGE OF PRODUCTION.
152
00:08:51,634 --> 00:08:54,368
AT THE CORE OF THE MUFFLER
IS A PERFORATED LENGTH
153
00:08:54,370 --> 00:08:56,262
OF STAINLESS STEEL PIPE.
154
00:08:56,264 --> 00:08:58,464
A WORKER PLACES ONE
IN A SPINNING DEVICE
155
00:08:58,466 --> 00:09:01,593
THAT TURNS THE CORE
ON ITS AXIS.
156
00:09:01,595 --> 00:09:03,920
THIS ALLOWS THE WORKER
TO QUICKLY AND EASILY
157
00:09:03,922 --> 00:09:06,690
WRAP THE LENGTH
IN STAINLESS STEEL MESH.
158
00:09:13,349 --> 00:09:14,948
AT THE NEXT STATION,
159
00:09:14,950 --> 00:09:18,811
A WORKER SURROUNDS THE WRAPPED
CORE IN A LAYER OF MINERAL WOOL.
160
00:09:18,813 --> 00:09:21,072
BOTH THE MINERAL WOOL
AND THE STEEL MESH
161
00:09:21,074 --> 00:09:24,667
CAN WITHSTAND HIGH MUFFLER
TEMPERATURES.
162
00:09:24,669 --> 00:09:28,229
A COMPRESSION DEVICE SQUEEZES
THE WOOL AROUND THE CORE,
163
00:09:28,231 --> 00:09:31,933
AND THEN INSERTS THE ASSEMBLY
INSIDE THE EXTERIOR CYLINDER.
164
00:09:35,564 --> 00:09:39,558
A WORKER THEN SLIDES THE HEAVY
GAUGE STAINLESS STEEL END CAPS
165
00:09:39,560 --> 00:09:40,951
OVER THE SECTIONS OF THE CORE
166
00:09:40,953 --> 00:09:43,887
THAT EXTEND BEYOND
THE OUTER CYLINDER.
167
00:09:43,889 --> 00:09:48,217
HE USES A METAL WORKING HAMMER
TO TAP THEM GENTLY INTO PLACE.
168
00:09:54,109 --> 00:09:56,968
HE THEN REMOVES
THE PROTECTIVE FILM OF PLASTIC
169
00:09:56,970 --> 00:09:58,837
TO PREPARE
THE NEWLY FORMED MUFFLER
170
00:09:58,839 --> 00:10:01,131
FOR THE FINAL WELDING PROCESS.
171
00:10:02,668 --> 00:10:07,195
A ROBOT TRANSFERS THE MUFFLER
TO THE FINAL WELDING STATION.
172
00:10:07,197 --> 00:10:09,389
TO DAMPEN SOUND,
CONVENTIONAL MUFFLERS
173
00:10:09,391 --> 00:10:13,252
USE A HIGHLY EFFICIENT TECHNIQUE
CALLED REFLECTION,
174
00:10:13,254 --> 00:10:17,347
WHICH ROUTES THE EXHAUST
THROUGH A SYSTEM OF BAFFLES.
175
00:10:17,349 --> 00:10:20,817
BUT REFLECTION ALSO SLOWS DOWN
THE ESCAPING GASES
176
00:10:20,819 --> 00:10:23,012
CAUSING SOMETHING KNOWN AS
BACK PRESSURE,
177
00:10:23,014 --> 00:10:26,607
WHICH DIMINISHES
ENGINE PERFORMANCE.
178
00:10:26,609 --> 00:10:30,269
SO FOR A SUPER CAR
LIKE THE LUCRA LC470,
179
00:10:30,271 --> 00:10:34,066
MagnaFlow USES A DIFFERENT
TECHNIQUE CALLED ABSORPTION.
180
00:10:34,068 --> 00:10:37,335
THE SOUND PENETRATES THROUGH
THE PERFORATED STEEL CORE
181
00:10:37,337 --> 00:10:39,630
AND IS PARTIALLY ABSORBED
BY THE STEEL MESH
182
00:10:39,632 --> 00:10:42,691
AND MINERAL WOOL.
183
00:10:42,693 --> 00:10:45,160
WHILE THE EXHAUST NODE
TENDS TO BE LOUDER,
184
00:10:45,162 --> 00:10:49,257
THERE'S LITTLE BACK PRESSURE
TO DIMINISH ENGINE PERFORMANCE.
185
00:10:56,432 --> 00:10:58,925
Narrator:
IN 21st CENTURY CARS,
186
00:10:58,927 --> 00:11:01,728
THE WIRING IS AS IMPORTANT
AS THE POWER TRAIN.
187
00:11:01,730 --> 00:11:05,823
RECOGNIZING THIS,
THE DESIGNERS OF THE LUCRA LC470
188
00:11:05,825 --> 00:11:07,951
CHOSE TO USE
MILITARY SPECIFICATION
189
00:11:07,953 --> 00:11:10,479
AVIATION GRADE MATERIAL.
190
00:11:11,815 --> 00:11:15,543
AIRPLANES HAVE TO WITHSTAND
THE TOUGHEST CONDITIONS.
191
00:11:15,545 --> 00:11:18,271
NOT ONLY DO THEIR COMPONENTS
NEED TO BE ABLE TO ENDURE
192
00:11:18,273 --> 00:11:20,439
THE HOT TARMAC OF RUNWAYS,
193
00:11:20,441 --> 00:11:22,107
SHORTLY AFTER TAKEOFF,
194
00:11:22,109 --> 00:11:25,903
THEY CAN ENCOUNTER FRIGID
TEMPERATURES IN THE JET STREAM.
195
00:11:25,905 --> 00:11:29,232
RAPID TEMPERATURE FLUCTUATIONS
AND CONSTANT VIBRATION
196
00:11:29,234 --> 00:11:33,228
ARE ENORMOUS CHALLENGES
FOR ANY MATERIAL.
197
00:11:33,230 --> 00:11:34,787
MILITARY SPECIFICATION
198
00:11:34,789 --> 00:11:37,524
OR MIL-SPEC
AVIATION GRADE WIRING,
199
00:11:37,526 --> 00:11:42,454
IS DESIGNED TO FUNCTION
EFFICIENTLY IN ANY ENVIRONMENT.
200
00:11:42,456 --> 00:11:46,784
THE WIRES ARE INDIVIDUALLY CODED
WITH A FLUORINE-BASED PLASTIC
201
00:11:46,786 --> 00:11:48,844
CALLED
ETHYLENE TETRAFLUOROETHYLENE,
202
00:11:48,846 --> 00:11:50,713
OR E.T.F.E.
203
00:11:50,715 --> 00:11:54,742
E.T.F.E. IS INCREDIBLY
CORROSION RESISTANT.
204
00:11:54,744 --> 00:11:57,670
TESTS SIMULATING ACCELERATED
EXPOSURE TO WEATHER
205
00:11:57,672 --> 00:12:03,460
HAVE SHOWN ALMOST NO SIGNS
OF DETERIORATION AFTER 30 YEARS.
206
00:12:03,462 --> 00:12:06,529
NOT ONLY THAT,
COATING THE INDIVIDUAL WIRES
207
00:12:06,531 --> 00:12:10,759
WITH E.T.F.E. HELPS PREVENT
OTHER PROBLEMS.
208
00:12:10,761 --> 00:12:12,819
WHEN WIRES ARE BUNDLED TOGETHER,
209
00:12:12,821 --> 00:12:15,622
THEIR SIGNALS CAN INTERFERE
WITH EACH OTHER.
210
00:12:15,624 --> 00:12:18,751
THE E.T.F.E. COATING EFFECTIVELY
INSULATES THE WIRES
211
00:12:18,753 --> 00:12:21,746
FROM EACH OTHER
ELIMINATING THIS PROBLEM.
212
00:12:27,445 --> 00:12:29,237
AND THERE'S YET ANOTHER
IMPORTANT BENEFIT
213
00:12:29,239 --> 00:12:32,032
TO USING
AVIATION GRADE WIRING --
214
00:12:32,034 --> 00:12:34,100
IT'S LIGHTWEIGHT.
215
00:12:34,102 --> 00:12:36,361
THE WIRES IN A PASSENGER JET,
FOR INSTANCE,
216
00:12:36,363 --> 00:12:37,963
CAN WEIGH MANY TONS,
217
00:12:37,965 --> 00:12:41,725
SO IT'S IMPORTANT TO MAKE THEM
AS LIGHT AS POSSIBLE.
218
00:12:41,727 --> 00:12:45,054
EVEN THE CONNECTORS USED
IN THE LUCRA LC470
219
00:12:45,056 --> 00:12:48,516
ARE MIL-SPEC AVIATION GRADE,
220
00:12:48,518 --> 00:12:51,119
SPECIALLY DESIGNED TO HANDLE
CONSTANT VIBRATION
221
00:12:51,121 --> 00:12:53,313
AND EXPOSURE TO CORROSIVES.
222
00:12:53,315 --> 00:12:56,974
THE PLUGS HAVE BEEN GIVEN
A COATING OF GOLD
223
00:12:56,976 --> 00:13:00,145
DUE TO THE METAL'S
CORROSION RESISTANT PROPERTIES.
224
00:13:03,808 --> 00:13:05,266
ONCE COMPLETED,
225
00:13:05,268 --> 00:13:07,402
THE TECHNICIAN LAYS OUT
EACH SET OF WIRES
226
00:13:07,404 --> 00:13:11,932
ON A WIRING DESIGN.
227
00:13:11,934 --> 00:13:14,993
DRAWN UP
BY ELECTRICAL ENGINEERS,
228
00:13:14,995 --> 00:13:19,490
THE DESIGN PROVIDES A PRECISE
GUIDE TO THE LUCRA SYSTEM.
229
00:13:19,492 --> 00:13:23,019
THE TECHNICIAN USES A HEAT GUN
TO INSTALL A PROTECTIVE SLEEVE
230
00:13:23,021 --> 00:13:27,348
AROUND EACH BUNDLE OF WIRES.
231
00:13:27,350 --> 00:13:29,675
THE HEAT GUN, BLOWING HOT AIR
AT A MINIMUM TEMPERATURE
232
00:13:29,677 --> 00:13:33,906
OF 212 DEGREES FAHRENHEIT,
SHRINKS THE TUBING IN PLACE.
233
00:13:33,908 --> 00:13:38,234
THIS TUBING PROTECTS THE WIRES
FROM ABRASION AND CORROSION.
234
00:13:38,236 --> 00:13:40,904
IT'S ESPECIALLY DESIGNED
TO ONLY SHRINK ONE WAY
235
00:13:40,906 --> 00:13:43,565
ALONG ITS DIAMETER.
236
00:13:43,567 --> 00:13:45,634
IN OTHER WORDS,
IT WON'T GET SHORTER
237
00:13:45,636 --> 00:13:48,930
WHEN EXPOSED TO HEAT --
JUST TIGHTER.
238
00:13:52,394 --> 00:13:57,389
THE FULLY ASSEMBLED WIRING
IS CALLED A WIRING HARNESS.
239
00:13:57,391 --> 00:14:00,684
IT'S NOW TIME TO MOVE ON TO
THE NEXT STAGE OF PRODUCTION.
240
00:14:04,782 --> 00:14:08,208
LUCRA CONDUCTS RIGOROUS TESTS
OF EVERY WIRING HARNESS
241
00:14:08,210 --> 00:14:10,369
THAT GOES INTO ONE OF ITS CARS.
242
00:14:10,371 --> 00:14:13,605
TECHNICIANS USE A COMPUTER
TO RUN THE TEST,
243
00:14:13,607 --> 00:14:14,665
CHECKING TO MAKE SURE
244
00:14:14,667 --> 00:14:17,335
ALL THE WIRES
ARE CONDUCTING PROPERLY.
245
00:14:19,864 --> 00:14:23,491
THEY ALSO DO LOAD TESTING,
CHECK FOR CONTINUITY,
246
00:14:23,493 --> 00:14:27,888
AN ENSURE THAT THE WIRES AREN'T
INTERFERING WITH EACH OTHER.
247
00:14:27,890 --> 00:14:30,816
THE TECHNICIAN EVALUATES
THE SYSTEMS THAT MONITOR
248
00:14:30,818 --> 00:14:34,486
THE CAR'S FLUID LEVELS
AND THE CONTROLS FOR THE LIGHTS.
249
00:14:34,488 --> 00:14:36,813
IN ADDITION TO
THESE TYPICAL FUNCTIONS,
250
00:14:36,815 --> 00:14:40,776
THE WIRING HARNESS ALSO CONTROLS
THE POWER-OPERATED TRUNK LID
251
00:14:40,778 --> 00:14:42,177
AND DOORS,
252
00:14:42,179 --> 00:14:44,705
THE PRE AND POST CATALYTIC
CONVERTER LAMBDA SENSORS,
253
00:14:44,707 --> 00:14:47,167
AND THE DRIVE-BY WIRE THROTTLE.
254
00:14:49,971 --> 00:14:52,297
THE HARNESS IS
SO CAREFULLY DESIGNED,
255
00:14:52,299 --> 00:14:56,993
IT ONLY TAKES TWO HOURS
TO HOOK EVERYTHING UP.
256
00:15:02,732 --> 00:15:06,726
Narrator: THE LUCRA LC470
BARES A CLOSE RESEMBLANCE
257
00:15:06,728 --> 00:15:11,656
TO A LEGENDARY 1950s RACE CAR
KNOWN AS THE LISTER JAGUAR.
258
00:15:11,658 --> 00:15:14,251
BUT UNDER THAT SLEEK,
OLD SCHOOL BODY,
259
00:15:14,253 --> 00:15:17,079
IS A STATE-OF-THE-ART
21st CENTURY SUPER CAR.
260
00:15:19,216 --> 00:15:23,077
DUE TO THE LC470'S
UNUSUALLY LIGHT CURB WEIGHT,
261
00:15:23,079 --> 00:15:26,472
THE DESIGNERS PAID SPECIAL
ATTENTION TO THE SUSPENSION.
262
00:15:26,474 --> 00:15:28,541
THE LIGHTER THE CAR,
263
00:15:28,543 --> 00:15:31,736
THE MORE IT'S AFFECTED BY
ITS WHEEL WEIGHT.
264
00:15:31,738 --> 00:15:34,831
THIS TECHNICIAN INVERTS
THE FORGED ALUMINUM SUSPENSION
265
00:15:34,833 --> 00:15:37,559
WHEN ATTACHING IT IN ORDER TO
KEEP THE COMPONENTS
266
00:15:37,561 --> 00:15:41,488
WEIGHT-ORIENTED TO THE CHASSIS
RATHER THAN THE WHEEL.
267
00:15:41,490 --> 00:15:44,491
THAT WAY, WHEN THE WHEEL GOES
OVER A BUMP,
268
00:15:44,493 --> 00:15:47,286
IT DOESN'T DESTABILIZE THE CAR.
269
00:15:51,583 --> 00:15:54,243
NEXT, THE TECHNICIAN ATTACHES
THE HIGH-PERFORMANCE
270
00:15:54,245 --> 00:15:59,641
WILWOOD BRAKES
WHICH HAVE SIX PISTON CALIPERS.
271
00:15:59,643 --> 00:16:02,569
THE FLORESCENT GREEN OBJECT
TO THE LEFT OF THE BRAKE
272
00:16:02,571 --> 00:16:05,171
IS PART OF A HIGH-TECH
ANTI-ROLL BAR
273
00:16:05,173 --> 00:16:07,966
THAT STRETCHES THROUGH
TO THE OTHER SIDE OF THE CAR.
274
00:16:10,329 --> 00:16:11,861
THE WORKERS NOW INSTALL
275
00:16:11,863 --> 00:16:16,325
A TREMEC TKO 600 RR
5-SPEED TRANSMISSION
276
00:16:16,327 --> 00:16:18,920
AND BOLT IT IN PLACE
ON THE ENGINE.
277
00:16:18,922 --> 00:16:22,381
LUCRA IS SO COMMITTED TO
KEEPING THE CAR'S WEIGHT DOWN,
278
00:16:22,383 --> 00:16:24,717
THAT IT EVEN SOURCES
THE 12-SIDED BOLTS THEY USE
279
00:16:24,719 --> 00:16:27,812
FOR ASSEMBLY
FROM THE AEROSPACE INDUSTRY.
280
00:16:30,808 --> 00:16:34,535
CUSTOMERS CAN CHOOSE FROM ONE OF
THREE ENGINE OPTIONS --
281
00:16:34,537 --> 00:16:38,498
THE MERCEDES AMG 6.3 V8,
282
00:16:38,500 --> 00:16:42,336
THE 6.3-LITER GM LS3,
283
00:16:42,338 --> 00:16:45,630
OR THE 7-LITER GM LS7,
284
00:16:45,632 --> 00:16:50,361
THE LEGENDARY ENGINE
IN THE CORVETTE ZO7.
285
00:16:50,363 --> 00:16:52,621
A TECHNICIAN THREADS
THE STEERING SHAFT
286
00:16:52,623 --> 00:16:54,757
THROUGH THE DASHBOARD
AS A SECOND TECHNICIAN
287
00:16:54,759 --> 00:16:56,885
ATTACHES IT TO THE PINION.
288
00:16:56,887 --> 00:16:59,112
THE STEERING SHAFT
IS A TELESCOPING ROD
289
00:16:59,114 --> 00:17:03,174
THAT COLLAPSES ON IMPACT,
PREVENTING INJURY TO THE DRIVER.
290
00:17:03,176 --> 00:17:05,243
S.F.I. RATED FOR RACING,
291
00:17:05,245 --> 00:17:07,771
THIS COMPONENT IS USED
IN NASCAR EVENTS.
292
00:17:11,177 --> 00:17:13,836
THE CUSTOM BUILT HEADER
FROM MagnaFlow
293
00:17:13,838 --> 00:17:15,796
NOW GOES ON THE ENGINE.
294
00:17:15,798 --> 00:17:17,731
THANKS TO CAREFUL DESIGN,
295
00:17:17,733 --> 00:17:22,327
THE PIPES CURVE UP AND OVER
THE STEERING SHAFT.
296
00:17:22,329 --> 00:17:25,123
BEFORE THE EXHAUST GASES
REACH THE MUFFLER,
297
00:17:25,125 --> 00:17:28,385
CATALYTIC CONVERTERS HELP
LOWER TOXIC EMISSIONS
298
00:17:28,387 --> 00:17:32,280
BY CATALYZING A REACTION
CALLED REDOX.
299
00:17:32,282 --> 00:17:33,949
HERE, A WORKER ATTACHES
300
00:17:33,951 --> 00:17:38,077
THE MagnaFlow CATALYTIC
CONVERTER TO THE HEADER.
301
00:17:38,079 --> 00:17:41,473
A TECHNICIAN NOW PLUGS IN
ALL THE WIRING IN THE ENGINE,
302
00:17:41,475 --> 00:17:44,402
INCLUDING AN OXYGEN SENSOR.
303
00:17:44,404 --> 00:17:46,203
THIS SENSOR MEASURES
THE EXHAUST GASES
304
00:17:46,205 --> 00:17:48,164
FOR OXYGEN LEVEL
305
00:17:48,166 --> 00:17:54,361
AND HELPS THE ENGINE TUNE ITSELF
FOR OPTIMAL PERFORMANCE.
306
00:17:54,363 --> 00:17:57,023
TWO WORKERS INSTALL
THE REAR DIFFUSER.
307
00:17:57,025 --> 00:18:00,752
THIS IS AN IMPORTANT PART
OF THE CAR'S AERODYNAMICS.
308
00:18:00,754 --> 00:18:04,022
AS THE CAR DRIVES,
IT SPLITS THE AIR.
309
00:18:04,024 --> 00:18:07,450
THE DIFFUSER HELPS REUNITE
THE AIR MOVING UNDER THE CAR
310
00:18:07,452 --> 00:18:09,478
WITH THE AIR MOVING OVER IT.
311
00:18:13,308 --> 00:18:16,769
THE FRONT DIFFUSER ALSO HOUSES
THE CAR'S OIL CORES,
312
00:18:16,771 --> 00:18:21,566
MAKING EFFICIENT USE
OF THE AIRFLOW AROUND THE CAR.
313
00:18:21,568 --> 00:18:23,501
IT ALSO DRAWS AIR OVER
THE BRAKES
314
00:18:23,503 --> 00:18:26,730
TO HELP KEEP THEM COOL.
315
00:18:26,732 --> 00:18:29,257
BUT THE CHIEF GOAL
OF THE DIFFUSER SYSTEM
316
00:18:29,259 --> 00:18:32,126
IS TO SLOW AND PRESSURIZE
THE AIRFLOW
317
00:18:32,128 --> 00:18:34,787
BEFORE RELEASING IT BACK
INTO THE CAR'S SLIPSTREAM,
318
00:18:34,789 --> 00:18:38,517
LEAVING AS LITTLE DISTURBED AIR
IN ITS WAKE AS POSSIBLE.
319
00:18:45,218 --> 00:18:47,476
A WORKER INSTALLS THE SEATS.
320
00:18:47,478 --> 00:18:50,137
HE CAN DO IT EASILY BY HIMSELF
BECAUSE THESE ARE
321
00:18:50,139 --> 00:18:53,733
LIGHTWEIGHT ALUMINUM
RACING SEATS.
322
00:18:53,735 --> 00:18:57,663
THESE STRONG, FORM-FITTING SEATS
ARE MADE IN CANADA.
323
00:18:57,665 --> 00:19:01,166
IN FACT, NEARLY EVERY COMPONENT
OF THE LUCRA LC470,
324
00:19:01,168 --> 00:19:05,162
IS MADE IN NORTH AMERICA.
325
00:19:05,164 --> 00:19:08,757
A TEAM OF TECHNICIANS NOW BLEEDS
ANY RESIDUAL AIR BUBBLES
326
00:19:08,759 --> 00:19:10,418
OUT OF THE BRAKE LINES.
327
00:19:10,420 --> 00:19:14,447
THIS IS NECESSARY
WITH A HYDRAULIC BRAKE SYSTEM
328
00:19:14,449 --> 00:19:17,383
BECAUSE WHILE BRAKE FLUID
CANNOT BE COMPRESSED,
329
00:19:17,385 --> 00:19:20,111
AIR CAN BE.
330
00:19:20,113 --> 00:19:22,972
THAT MEANS THAT THE PRESENCE
OF AIR BUBBLES CAN REDUCE
331
00:19:22,974 --> 00:19:25,575
THE RESPONSIVENESS
OF THE BRAKES.
332
00:19:25,577 --> 00:19:27,502
ONE PERSON PUMPS
THE BRAKE PEDAL
333
00:19:27,504 --> 00:19:29,971
AND THEN HOLDS IT
TO MAINTAIN PRESSURE,
334
00:19:29,973 --> 00:19:32,699
WHILE THE OTHERS RELEASE
ANY BUBBLES THAT SHOW UP.
335
00:19:38,399 --> 00:19:40,725
THE CAR IS NEARLY COMPLETE.
336
00:19:40,727 --> 00:19:44,120
THE WORKERS DOUBLE-CHECK
ALL THE PLUGS AND ATTACHMENTS.
337
00:19:44,122 --> 00:19:47,748
LUCRA'S COMMITMENT
TO WEIGHT BALANCE IS PROFOUND.
338
00:19:47,750 --> 00:19:50,151
THEY EVEN MOUNTED THE BATTERY
IN THE TRUNK
339
00:19:50,153 --> 00:19:53,079
ON THE PASSENGER'S SIDE
TO BALANCE THE WEIGHT
340
00:19:53,081 --> 00:19:57,809
OF THE PERSON
BEHIND THE STEERING WHEEL.
341
00:19:57,811 --> 00:20:00,670
THE WHEEL ARE ONE-PIECE
ALUMINUM MONOBLOCK,
342
00:20:00,672 --> 00:20:03,632
FORGED UNDER PRESSURE
TO CREATE A DENSE, HARD,
343
00:20:03,634 --> 00:20:09,297
LIGHT COMPONENT THAT REDUCES
THE CAR'S UNSPRUNG WEIGHT.
344
00:20:09,299 --> 00:20:11,365
FINALLY,
IT'S TIME TO TEST OUT
345
00:20:11,367 --> 00:20:15,686
THE NEWLY CREATED CAR'S
DYNAMICS.
346
00:20:15,688 --> 00:20:18,422
HAVING PARKED THE REAR WHEELS
ON A PAIR OF ROLLERS
347
00:20:18,424 --> 00:20:21,251
AND HOOKED THE CAR'S SENSORS
UP TO A COMPUTER,
348
00:20:21,253 --> 00:20:23,979
A DRIVER PUTS IT THROUGH
ITS PACES.
349
00:20:23,981 --> 00:20:27,182
AS HE REVS THE ENGINE
TO FULL SPEED,
350
00:20:27,184 --> 00:20:29,242
THE COMPUTER RUNS
DOZENS OF TESTS
351
00:20:29,244 --> 00:20:32,438
ENSURING THE CAR IS LEAK-FREE,
PERFECTLY TUNED,
352
00:20:32,440 --> 00:20:34,907
AND MEETS ALL DESIGN PARAMETERS.
353
00:20:38,738 --> 00:20:41,397
BUILDING A RACE CAR IS
CHALLENGING.
354
00:20:41,399 --> 00:20:44,325
IN SOME WAYS, BUILDING A GARDEN
VARIETY STREET CAR
355
00:20:44,327 --> 00:20:46,794
IS EVEN MORE DIFFICULT.
356
00:20:46,796 --> 00:20:49,856
BUT FUSING A RACE CAR
WITH A STREET CAR
357
00:20:49,858 --> 00:20:52,058
MAY BE THE HARDEST OF ALL.
358
00:20:52,060 --> 00:20:56,513
FOR ONE THING, RACE CARS DON'T
NEED FUNCTIONING DOORS.
359
00:20:56,515 --> 00:20:59,349
FOR ANOTHER, STREET CARS DON'T
NEED TO BE ABLE TO ACCELERATE
360
00:20:59,351 --> 00:21:04,279
FROM 0 TO 60 MILES PER HOUR
IN UNDER 4 SECONDS.
361
00:21:04,281 --> 00:21:07,875
SUPER CARS DO.
362
00:21:07,877 --> 00:21:09,469
[ ENGINE REVS ]
363
00:21:09,471 --> 00:21:12,271
Narrator: SINCE THE BRAWNY
V8 ENGINE HAS ONLY 2,000 POUNDS
364
00:21:12,273 --> 00:21:13,831
OF CAR TO MOVE,
365
00:21:13,833 --> 00:21:19,362
THE LUCRA LC470 CAN EXPLODE
FROM 0 TO 60 MILES PER HOUR
366
00:21:19,364 --> 00:21:22,958
IN JUST THREE SECONDS.
367
00:21:22,960 --> 00:21:26,353
WITH A TOP SPEED OF
OVER 200 MILES PER HOUR,
368
00:21:26,355 --> 00:21:30,416
IT'S A LIGHTWEIGHT DREAM CAR
WITH A HEAVYWEIGHT PUNCH.
29821
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