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These are the user uploaded subtitles that are being translated: 1 00:00:01,601 --> 00:00:03,068 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 3 00:00:06,432 --> 00:00:08,290 WITH HEAVYWEIGHT POWER. 4 00:00:08,292 --> 00:00:11,227 -- Captions by VITAC -- www.vitac.com 5 00:00:11,229 --> 00:00:14,255 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,717 --> 00:00:27,043 Narrator: BELIEVE IT OR NOT, EVEN THOUGH THE LUCRA LC470 7 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, 9 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 11 00:00:38,933 --> 00:00:41,526 THE ENTIRE BODY OUT OF CARBON FIBER, 12 00:00:41,528 --> 00:00:44,796 WHICH ONLY WEIGHS ABOUT 200 POUNDS. 13 00:00:46,925 --> 00:00:50,184 THE COMPONENTS OF THE LC470 ARE ALSO MADE OF 14 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, 17 00:00:58,545 --> 00:01:00,646 STRENGTH, AND DURABILITY. 18 00:01:03,075 --> 00:01:06,268 LUCRA CARS WAS FOUNDED BY CAR ENTHUSIAST LUKE RICHARDS 19 00:01:06,270 --> 00:01:08,137 IN 2006. 20 00:01:08,139 --> 00:01:11,365 HIS GOAL WAS TO BUILD THE PERFECT SPORTS CAR. 21 00:01:11,367 --> 00:01:14,694 IN ESSENCE, HE WANTED TO FIND A WAY TO COMBINE 22 00:01:14,696 --> 00:01:17,497 THE AGILITY OF EUROPEAN SPORTS CARS 23 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 26 00:01:25,423 --> 00:01:28,150 TO INTRODUCE THE DRIVER TO THE CAR. 27 00:01:35,643 --> 00:01:37,643 Narrator: A CLEVER STRUCTURAL DESIGN 28 00:01:37,645 --> 00:01:40,438 ALLOWED RICHARDS AND HIS TEAM TO PLACE THE ENGINE 29 00:01:40,440 --> 00:01:42,106 NEAR THE CENTER OF THE CAR. 30 00:01:42,108 --> 00:01:48,196 THIS ACHIEVED A WEIGHT BALANCE OF 53% REAR AND 47% FRONT 31 00:01:48,198 --> 00:01:52,058 FOR AN IDEAL COMBINATION OF TRACTION AND HANDLING. 32 00:01:52,060 --> 00:01:53,860 THE CHASSIS DESIGN IS THE KEY 33 00:01:53,862 --> 00:01:57,122 TO THIS OPTIMAL WEIGHT DISTRIBUTION. 34 00:01:57,124 --> 00:01:58,949 KNOWN AS A PERIMETER CHASSIS, 35 00:01:58,951 --> 00:02:00,751 INSTEAD OF RUNNING UNDER THE ENGINE 36 00:02:00,753 --> 00:02:03,946 AND THE PASSENGERS, IT WRAPS AROUND THEM. 37 00:02:07,109 --> 00:02:10,144 THIS MEANS THE DESIGNERS COULD POSITION THE ENGINE BLOCK 38 00:02:10,146 --> 00:02:11,871 AND THE SEATS WHEREVER THEY WANTED 39 00:02:11,873 --> 00:02:16,234 TO BEST ACCOMMODATE THE DYNAMICS OF THE CAR. 40 00:02:16,236 --> 00:02:20,964 THE CHASSIS IS CONSTRUCTED OF D.O.M. STEEL TUBING. 41 00:02:20,966 --> 00:02:24,092 LUCRA USES C.N.C. MACHINES TO PRECISION CUT 42 00:02:24,094 --> 00:02:28,222 AND BEND THE TUBING BEFORE CLAMPING IT IN A JIG. 43 00:02:28,224 --> 00:02:31,025 SINCE THE CHASSIS IS THE FOUNDATION OF THE CAR, 44 00:02:31,027 --> 00:02:33,886 IT MUST BE ABSOLUTELY FLAWLESS. 45 00:02:33,888 --> 00:02:36,714 EVEN THE JIG WAS DIGITALLY DESIGNED AND CUT 46 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 48 00:02:43,381 --> 00:02:45,173 UNLESS IT'S SECURED. 49 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. 51 00:02:55,069 --> 00:02:58,128 REMARKABLY, LUCRA BUILDS THE MAIN BODY OF THE CAR 52 00:02:58,130 --> 00:03:00,197 IN ONE SHOT. 53 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, 56 00:03:11,753 --> 00:03:15,813 THE RESULT IS AN EXTRAORDINARILY STRONG RIGID STRUCTURE 57 00:03:15,815 --> 00:03:21,603 THAT COULD ALMOST FUNCTION AS A MONOCOQUE CHASSIS ON ITS OWN. 58 00:03:21,605 --> 00:03:23,472 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. 61 00:03:29,830 --> 00:03:32,632 HE THEN USES IT AS A GUIDE TO CAREFULLY DRILL OUT 62 00:03:32,634 --> 00:03:35,593 ALL THE NECESSARY HOLES AND GUIDE POINTS. 63 00:03:39,824 --> 00:03:42,918 NEXT, HE SCRIBES THE PERIMETER OF ALL THE OPENINGS 64 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. 66 00:03:50,644 --> 00:03:52,845 THE LC470 HAS NONE OF 67 00:03:52,847 --> 00:03:55,239 THOSE DISTRACTING 21st CENTURY ACCESSORIES 68 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, 72 00:04:06,661 --> 00:04:10,388 REVEALING THE SCRIBE TRANSFER OF THE DASHBOARD DESIGN. 73 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. 76 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. 78 00:04:27,141 --> 00:04:30,901 AT THE SAME TIME, HE MUST BE EXTREMELY CAREFUL. 79 00:04:30,903 --> 00:04:33,971 SINCE THE DASHBOARD IS PART OF THE ONE-PIECE BODY, 80 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. 82 00:04:45,561 --> 00:04:48,554 RATHER THAN A FEW ATTACHMENT POINTS, 83 00:04:48,556 --> 00:04:50,981 EVERY PART OF THE CHASSIS PERIMETER BONDS DIRECTLY 84 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. 92 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 102 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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