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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS" --
2
00:00:03,470 --> 00:00:06,096
THE CHEVROLET CORVETTE STINGRAY,
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00:00:06,098 --> 00:00:08,357
A LEGEND REINVENTED.
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00:00:08,359 --> 00:00:11,293
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:23,183 --> 00:00:25,776
Narrator: IN 1981,
GENERAL MOTORS MOVED
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ITS CHEVROLET CORVETTE
ASSEMBLY PLANT
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00:00:28,247 --> 00:00:29,971
TO BOWLING GREEN, KENTUCKY,
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00:00:29,973 --> 00:00:33,700
WHICH IS ALSO HOME TO
THE NATIONAL CORVETTE MUSEUM.
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00:00:33,702 --> 00:00:39,064
HERE, A BUST PAYS TRIBUTE
TO ZORA ARKUS-DUNTOV,
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00:00:39,066 --> 00:00:41,726
THE MAN KNOWN AS
THE FATHER OF THE CORVETTE.
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00:00:41,728 --> 00:00:44,996
THE FIRST CORVETTE DESIGN
WAS LED BY
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00:00:44,998 --> 00:00:50,184
GENERAL MOTORS HEAD OF DESIGN
HARLEY EARL IN 1953.
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00:00:50,186 --> 00:00:51,453
NOT LONG AFTER,
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00:00:51,455 --> 00:00:54,614
ZORA ARKUS-DUNTOV
SAW THAT ORIGINAL CAR
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00:00:54,616 --> 00:00:56,617
AT A NEW YORK
MOTORAMA EXHIBITION
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00:00:56,619 --> 00:00:59,944
AND FELL IN LOVE
WITH THE CORVETTE LOOK.
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00:00:59,946 --> 00:01:01,872
BY THE 1960S,
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00:01:01,874 --> 00:01:04,942
HE HELPED CREATE
THE FAMOUS CORVETTE STINGRAY,
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00:01:04,944 --> 00:01:08,204
A STYLISH AND POWERFUL
SPORTS CAR.
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00:01:08,206 --> 00:01:11,232
CHEVROLET STOPPED USING
THE STINGRAY NAME ON CORVETTES
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00:01:11,234 --> 00:01:13,827
AFTER 1976.
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00:01:13,829 --> 00:01:16,496
BUT WITH THE SEVENTH GENERATION
OF THE CORVETTE,
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00:01:16,498 --> 00:01:19,491
STINGRAY RIDES AGAIN.
25
00:01:19,493 --> 00:01:20,625
IT INCORPORATES
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00:01:20,627 --> 00:01:22,686
ALUMINUM AND CARBON FIBER
MATERIALS TOGETHER
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WITH STATE-OF-THE-ART
POWER TRAIN TECHNOLOGY.
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00:01:25,491 --> 00:01:28,116
THIS CAR HAS BEEN
COMPLETELY REDESIGNED
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00:01:28,118 --> 00:01:30,511
TO CREATE A FAST,
LIGHTWEIGHT UPDATE
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00:01:30,513 --> 00:01:32,580
TO THE AUTOMOTIVE LEGEND.
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00:01:35,643 --> 00:01:40,071
HERE, A ROBOT POSITIONS
COMPONENTS OF THE STINGRAY FRAME
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00:01:40,073 --> 00:01:44,066
IN A JIG, KNOWN AS
A GEOMETRY SETTING TOOL.
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00:01:44,068 --> 00:01:46,135
WITH THE FIRST COMPONENT
IN PLACE,
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00:01:46,137 --> 00:01:50,131
A WORKER LOADS IN A PART CALLED
THE SEAT BACK BEAM,
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00:01:50,133 --> 00:01:52,059
FOLLOWED BY THE SEAT BACK PANELS
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00:01:52,061 --> 00:01:55,053
AND THE TUNNEL SIDE PANELS.
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00:01:55,055 --> 00:01:56,522
THESE ARE ALL PART
OF A COMPONENT
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SIMPLY CALLED THE TUNNEL.
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00:02:01,020 --> 00:02:02,219
ONCE THE SETTING TOOL HAS
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00:02:02,221 --> 00:02:04,547
CLAMPED EVERYTHING
FIRMLY IN PLACE,
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00:02:04,549 --> 00:02:07,016
THE WALL BEHIND IT
PIVOTS ON ITS AXIS
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00:02:07,018 --> 00:02:09,810
AND SWIVELS 180 DEGREES,
43
00:02:09,812 --> 00:02:12,639
REVEALING
A RECENTLY WELDED TUNNEL.
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00:02:14,810 --> 00:02:16,567
ON THE OTHER SIDE OF THAT WALL,
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00:02:16,569 --> 00:02:20,030
A PAIR OF ROBOTS BEGIN
WELDING THE PARTS.
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00:02:23,234 --> 00:02:25,828
JUST 155 SECONDS LATER,
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00:02:25,830 --> 00:02:29,089
THE TUNNEL IS WELDED
AND READY FOR THE NEXT STEP.
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00:02:29,091 --> 00:02:33,018
A ROBOT PREPARES
THE BODY LIFE RAILS.
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00:02:33,020 --> 00:02:35,621
A SECOND ROBOT LOADS THE TUNNEL
BETWEEN THE RAILS
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00:02:35,623 --> 00:02:37,649
ON THE TOOLING FIXTURE.
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00:02:37,651 --> 00:02:40,043
THE CAR BODY
BEGINS TO TAKE SHAPE
52
00:02:40,045 --> 00:02:43,446
AS THE FRONT AND REAR BUMPERS
GO ON.
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00:02:43,448 --> 00:02:45,707
ALL OF THE COMPONENTS
ARE MADE OF ALUMINUM,
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00:02:45,709 --> 00:02:50,604
WHICH OFFERS RUST-FREE RIGIDITY,
LIGHTNESS, AND DURABILITY.
55
00:02:53,934 --> 00:02:57,328
ONCE ALL THE COMPONENTS OF
THE FRAME ARE CLAMPED IN PLACE,
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00:02:57,330 --> 00:02:59,530
A ROBOT QUICKLY WELDS THE JOINTS
57
00:02:59,532 --> 00:03:02,291
BEFORE THE FRAMES HEADS TO
THE NEXT STATION.
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00:03:05,054 --> 00:03:07,388
BY THE TIME THE STINGRAY
IS FINISHED,
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00:03:07,390 --> 00:03:10,884
IT'LL HAVE
ROUGHLY 350 RESISTANT SPOT WELDS
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00:03:10,886 --> 00:03:13,612
AND ABOUT 70 LASER WELDS.
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00:03:13,614 --> 00:03:17,207
THAT'S MORE THAN 36 FEET
OF LASER WELDS.
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00:03:19,144 --> 00:03:21,937
WHILE THE FRAME IS
A VITAL ELEMENT OF THE CORVETTE,
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00:03:21,939 --> 00:03:26,633
THE BODY PANELS CREATE
THE STINGRAY'S DISTINCTIVE LOOK.
64
00:03:26,635 --> 00:03:30,563
HERE, A WORKER LOADS
A SET OF PANELS ONTO A CARRIER.
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00:03:30,565 --> 00:03:32,364
THE CARRIER MOVES AT A SPEED
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00:03:32,366 --> 00:03:35,660
PROGRAMMED TO KEEP UP WITH
THE PACE OF PRODUCTION.
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00:03:40,158 --> 00:03:41,583
AT THE PRIMING BOOTH ENTRANCE,
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00:03:41,585 --> 00:03:43,785
A READER SCANS
THE UNIQUE BAR CODE
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00:03:43,787 --> 00:03:45,912
LOCATED ON EACH CARRIER
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00:03:45,914 --> 00:03:48,715
AND SENDS THE INFORMATION
TO A COMPUTER,
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00:03:48,717 --> 00:03:50,775
WHICH TELLS THE ROBOTS
WHAT TO DO.
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00:03:50,777 --> 00:03:52,577
IN JUST 2 1/2 MINUTES,
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00:03:52,579 --> 00:03:55,372
THEY PRIME THE ENTIRE SET
OF PANELS.
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00:03:57,935 --> 00:04:01,203
THE PANELS THEN HEAD ACROSS
THE HALL INTO A GIANT OVEN,
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00:04:01,205 --> 00:04:03,464
WHERE THEY WILL BAKE
FOR 30 MINUTES
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00:04:03,466 --> 00:04:06,993
AT A TEMPERATURE
OF 260 DEGREES FAHRENHEIT.
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00:04:10,991 --> 00:04:13,591
AFTER THAT, THE PANELS WILL
RECEIVE A BASE COAT
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00:04:13,593 --> 00:04:17,954
IN ONE OF 10 DIFFERENT COLORS,
FOLLOWED BY A CLEAR COAT.
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00:04:17,956 --> 00:04:19,882
FINALLY, THEY ARRIVE HERE,
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00:04:19,884 --> 00:04:22,409
WHERE A TEAM OF TECHNICIANS
INSPECT THE SURFACES
81
00:04:22,411 --> 00:04:26,439
AND CORRECT ANY DEFECTS
WITH SANDERS AND POLISHERS.
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00:04:30,011 --> 00:04:32,437
THE PAINT SHOP ALSO HANDLES
ANOTHER PROCESS
83
00:04:32,439 --> 00:04:35,231
CALLED SONIC WELDING.
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00:04:35,233 --> 00:04:37,233
HERE, A WORKER POSITIONS
THE CORVETTE EMBLEM
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00:04:37,235 --> 00:04:38,560
IN A FIXTURE,
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00:04:38,562 --> 00:04:41,696
THEN LAYS THE CAR'S FASCIA
ON TOP.
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00:04:41,698 --> 00:04:45,692
HE INSERTS COMPOSITE BRACKETS
INTO THE FASCIA.
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00:04:45,694 --> 00:04:48,620
THE FASCIA AND THE BRACKETS,
WHICH ARE MADE OF A MATERIAL
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00:04:48,622 --> 00:04:51,781
CALLED THERMOPLASTIC POLYOLEFIN,
OR T.P.O.,
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00:04:51,783 --> 00:04:54,050
FORM THE NOSE OF THE CAR.
91
00:04:54,052 --> 00:04:56,445
THESE BRACKETS WILL PROVIDE
LOCATING POINTS
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00:04:56,447 --> 00:04:59,440
FOR THE HEADLIGHT INSTALLATION.
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00:04:59,442 --> 00:05:04,103
ONCE THEY'RE INSTALLED,
THE WORKER CLAMPS THEM IN PLACE.
94
00:05:04,105 --> 00:05:08,466
A ROBOTIC ARM BEGINS
THE ULTRASONIC WELDING PROCESS.
95
00:05:08,468 --> 00:05:11,595
THIS MEANS IT USES
HIGH FREQUENCY SOUND WAVES
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00:05:11,597 --> 00:05:13,796
TO MELT THE BRACKET
ON TO THE FASCIA
97
00:05:13,798 --> 00:05:16,391
AT SPECIFIED WELD POINTS.
98
00:05:16,393 --> 00:05:19,061
THESE SOUND WAVES ARE INAUDIBLE.
99
00:05:21,257 --> 00:05:24,684
THERE ARE 25 WELD POINTS
FOR THIS PART.
100
00:05:24,686 --> 00:05:27,945
THE ROBOT COMPLETES ITS TASK
IN JUST 3 MINUTES,
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00:05:27,947 --> 00:05:32,709
PERFECTLY BONDING THE BRACKETS
AND THE EMBLEM TO THE PANEL.
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00:05:38,481 --> 00:05:40,506
Narrator: AT THE HEART
OF EVERY CORVETTE
103
00:05:40,508 --> 00:05:43,242
IS A CLASSIC
AMERICAN V8 POWERHOUSE.
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00:05:43,244 --> 00:05:48,264
THE STINGRAY'S ENGINE IS
6.2 LITERS, 461 HORSEPOWER,
105
00:05:48,266 --> 00:05:52,560
AND HAS A TOP SPEED OF
190 MILES PER HOUR.
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00:05:54,197 --> 00:05:55,996
THE ENGINES ARE MADE HERE
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00:05:55,998 --> 00:05:58,191
AT THE G.M. TONAWANDA
ENGINE PLANT
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00:05:58,193 --> 00:06:00,193
IN BUFFALO, NEW YORK.
109
00:06:00,821 --> 00:06:04,748
THEY START WITH A PRECISION
SAND CAST ALUMINUM BLOCK.
110
00:06:04,750 --> 00:06:07,951
HERE, A TEAM OF ROBOTS
CONDUCTS A SERIES OF TESTS,
111
00:06:07,953 --> 00:06:10,212
INCLUDING
THE WATER JACKET LEAK TEST
112
00:06:10,214 --> 00:06:12,381
AND BLOCKAGE TESTS.
113
00:06:13,943 --> 00:06:15,275
A CAMERA CHECKS
FOR THE PRESENCE
114
00:06:15,277 --> 00:06:17,837
OF ALL THE NECESSARY
THREADED HOLES
115
00:06:17,839 --> 00:06:19,238
THAT WILL PROVIDE
ATTACHMENT POINTS
116
00:06:19,240 --> 00:06:22,600
DURING THE ASSEMBLY OF THE CAR
AT BOWLING GREEN.
117
00:06:26,030 --> 00:06:27,430
A DATA BOLT,
118
00:06:27,432 --> 00:06:30,091
WHICH IS AN ACTUAL BOLT
THAT CONTAINS A COMPUTER CHIP,
119
00:06:30,093 --> 00:06:33,253
RECORDS THE ENGINE'S PROGRESS
AS IT MOVES THROUGH PRODUCTION
120
00:06:33,255 --> 00:06:34,655
AT TONAWANDA.
121
00:06:38,986 --> 00:06:42,513
HERE, A WORKER PREPARES
TO INSTALL THE CRANKSHAFT.
122
00:06:42,515 --> 00:06:44,848
HE PLACES A SPECIALIZED GUIDE
IN THE BLOCK
123
00:06:44,850 --> 00:06:47,376
TO PREVENT ANY DAMAGE
TO THE CRANKCASE
124
00:06:47,378 --> 00:06:50,805
AS HE LOWERS THE PRE-OILED
CRANKSHAFT INTO POSITION.
125
00:06:53,936 --> 00:06:58,196
THESE POWDERED METAL PISTON RODS
ARE KNOWN AS FRACTURED RODS.
126
00:06:58,198 --> 00:07:00,465
THAT'S BECAUSE THE SUPPLIER
ACTUALLY BREAKS THEM
127
00:07:00,467 --> 00:07:04,661
AT THE POINT WHERE THEY WILL
ENCIRCLE THE CRANKSHAFT.
128
00:07:04,663 --> 00:07:07,022
THE IRREGULARITY
OF THE FRACTURE SURFACES
129
00:07:07,024 --> 00:07:09,224
ALLOW THE TECHNICIANS
AT TONAWANDA
130
00:07:09,226 --> 00:07:12,987
TO REALIGN THE RODS PERFECTLY
DURING INSTALLATION.
131
00:07:14,748 --> 00:07:18,543
NOW A TECHNICIAN USES A DEVICE
CALLED A PISTON CUP
132
00:07:18,545 --> 00:07:22,372
TO COMPRESS THE PISTON RINGS
AT TAPERING ANGLE.
133
00:07:22,374 --> 00:07:24,974
THIS MAKES IT EASIER
TO SLIDE THE PISTON ASSEMBLY
134
00:07:24,976 --> 00:07:27,301
INTO THE CYLINDER.
135
00:07:27,303 --> 00:07:30,763
THE SECOND WORKER USES
A BLUE TOOL CALLED A GUIDEFORK
136
00:07:30,765 --> 00:07:33,634
TO GUIDE THE ROD IN WITHOUT
DAMAGING THE PISTON LINER
137
00:07:33,636 --> 00:07:36,896
OR THE CRANKSHAFT.
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00:07:44,455 --> 00:07:47,582
THIS IS THE OIL PAN RTV STATION.
139
00:07:47,584 --> 00:07:52,244
RTV STANDS FOR "ROOM-TEMPERATURE
VULCANIZATION."
140
00:07:52,246 --> 00:07:55,707
WITH THE BOTTOM SECTION OF
THE OIL PAN CLAMPED UPSIDE DOWN,
141
00:07:55,709 --> 00:07:58,776
THE MACHINE SQUEEZES
A THIN BEAD OF RTV
142
00:07:58,778 --> 00:08:01,672
AROUND ITS PERIMETER.
143
00:08:01,674 --> 00:08:05,934
A CAMERA VERIFIES THAT
THE ORIENTATION IS CORRECT.
144
00:08:05,936 --> 00:08:08,795
THE MACHINE FLIPS THE BOTTOM
SECTION OF THE OIL PAN
145
00:08:08,797 --> 00:08:10,731
180 DEGREES
146
00:08:10,733 --> 00:08:13,259
AND BRINGS THE TOP SECTION
UP TO MEET IT.
147
00:08:13,261 --> 00:08:15,261
THE TURNTABLE THEN SWIVELS,
148
00:08:15,263 --> 00:08:17,021
DELIVERING THE NEXT OIL PAN
149
00:08:17,023 --> 00:08:19,649
WHILE ALLOWING THE WORKER
TO TRANSFER THE FINISHED ONE
150
00:08:19,651 --> 00:08:22,419
ONTO AN INVERTED ENGINE BLOCK.
151
00:08:24,814 --> 00:08:27,082
THIS PROCESS MUST
BE ACCOMPLISHED QUICKLY
152
00:08:27,084 --> 00:08:29,777
BEFORE THE RTV HAS A CHANCE
TO CURE.
153
00:08:32,106 --> 00:08:35,774
16 SPINDLES DESCEND
TO TIGHTEN THE OIL PAN FASTENERS
154
00:08:35,776 --> 00:08:38,302
TO THE PRECISE TORQUE REQUIRED.
155
00:08:40,965 --> 00:08:43,432
HERE AT
THE HEAD SUB ASSEMBLY STATION,
156
00:08:43,434 --> 00:08:47,095
THIS MACHINE INSTALLS BOTH
THE EXHAUST AND INTAKE VALVES
157
00:08:47,097 --> 00:08:51,991
AT THE RATE OF 48 PARTS
IN JUST 40 SECONDS.
158
00:08:51,993 --> 00:08:54,786
ONE OF THE ARMS GRABS
A SET OF VALVE COMPONENTS,
159
00:08:54,788 --> 00:08:57,648
DIPS THEM IN OIL,
AND INSERTS THEM.
160
00:08:57,650 --> 00:08:59,382
THE MACHINE FLIPS THE HEAD,
161
00:08:59,384 --> 00:09:02,911
THEN THE SECOND ARM INSTALLS
A SERIES OF SPRINGS,
162
00:09:02,913 --> 00:09:05,606
COMPRESSING THEM SLIGHTLY
163
00:09:05,608 --> 00:09:08,075
AND DROPPING A KEY
DOWN INSIDE THEM.
164
00:09:08,077 --> 00:09:10,136
AS THE SPRING DECOMPRESSES,
165
00:09:10,138 --> 00:09:14,032
THE KEY LOCKS,
HOLDING THE SPRING IN PLACE.
166
00:09:18,063 --> 00:09:19,863
A TECHNICIAN POSITIONS
A COMPONENT
167
00:09:19,865 --> 00:09:22,356
CALLED A CYLINDER HEAD GASKET
ON THE ENGINE
168
00:09:22,358 --> 00:09:24,960
BEFORE INSTALLING THE HEAD.
169
00:09:24,962 --> 00:09:28,555
THIS GASKET IS A HIGH TECH,
MULTILAYER STEEL COMPONENT
170
00:09:28,557 --> 00:09:33,085
THAT MUST SEAL IN OIL, COOLANT,
AND COMBUSTION.
171
00:09:33,087 --> 00:09:35,146
THE CYLINDER HEAD'S
INTEGRATIVE FUEL RAIL TO
172
00:09:35,148 --> 00:09:38,374
ACCOMMODATE THE DIRECT INJECTION
FUEL SYSTEM.
173
00:09:40,911 --> 00:09:44,171
TWO WORKERS INSERT
THE 16 PUSH RODS
174
00:09:44,173 --> 00:09:48,301
THAT WILL TRANSMIT MOTION FROM
THE CAM SHAFT TO THE VALVES.
175
00:09:48,303 --> 00:09:50,495
ONCE THE RODS ARE IN PLACE,
176
00:09:50,497 --> 00:09:54,124
THE WORKERS INSTALL COMPONENTS
CALLED ROCKER ARMS.
177
00:09:54,126 --> 00:09:57,861
THE MOTION OF THE CAM SHAFT WILL
TRANSFER THROUGH THE PUSH RODS
178
00:09:57,863 --> 00:10:00,789
TO THE ROCKER ARMS
AND THEN TO THE VALVES.
179
00:10:05,922 --> 00:10:08,447
THE WORKERS HAVE ONLY PARTIALLY
SCREWED THE ROCKER ARMS
180
00:10:08,449 --> 00:10:10,407
IN PLACE.
181
00:10:10,409 --> 00:10:12,810
AT THIS STATION,
A SPECIALIZED DEVICE
182
00:10:12,812 --> 00:10:15,939
ORIENTS THE ENGINE
SO THAT NO VALVES ARE OPEN
183
00:10:15,941 --> 00:10:20,201
BEFORE TIGHTENING THE BOLTS
TO THE NECESSARY TORQUE.
184
00:10:20,203 --> 00:10:23,864
THIS OPERATION IS CALLED
THE ROCKER ARM RUNDOWN.
185
00:10:27,060 --> 00:10:30,529
A TECHNICIAN INSTALLS
THE ROCKER COVER AND COIL PACKS.
186
00:10:30,531 --> 00:10:32,890
THE ROCKER COVER
SEALS THE VALVE TRAIN,
187
00:10:32,892 --> 00:10:35,151
WHILE THE COIL PACKS
SUPPLY IGNITION ENERGY
188
00:10:35,153 --> 00:10:39,079
TO THE SPARK PLUGS.
189
00:10:39,081 --> 00:10:42,283
A PIECE OF FOAM SOUND INSULATION
GOES OVER THE ENGINE
190
00:10:42,285 --> 00:10:44,010
BEFORE A TECHNICIAN POSITIONS
191
00:10:44,012 --> 00:10:49,174
THE HIGH DENSITY COMPOSITE
PLASTIC INTAKE MANIFOLD ON TOP.
192
00:10:49,176 --> 00:10:50,575
LAST BUT NOT LEAST,
193
00:10:50,577 --> 00:10:52,769
A MACHINE ATTACHES
THE EXHAUST MANIFOLD
194
00:10:52,771 --> 00:10:54,704
TOGETHER WITH ITS GASKET.
195
00:10:54,706 --> 00:10:59,167
MADE OF CAST STAINLESS STEEL
FOR STRENGTH AND DURABILITY,
196
00:10:59,169 --> 00:11:01,896
THE EXHAUST MANIFOLD FEATURES
EQUAL LENGTH RUNNERS
197
00:11:01,898 --> 00:11:05,158
FOR OPTIMAL ENGINE PERFORMANCE.
198
00:11:11,058 --> 00:11:13,383
Narrator: FROM START TO FINISH,
199
00:11:13,385 --> 00:11:15,118
THE NEW
CHEVROLET CORVETTE STINGRAY
200
00:11:15,120 --> 00:11:19,181
WILL TRAVEL SEVEN MILES
ON A NETWORK OF CONVEYOR SYSTEMS
201
00:11:19,183 --> 00:11:20,875
AS WORKERS TRANSFORM
THE COMPONENTS
202
00:11:20,877 --> 00:11:22,209
INTO A COMPLETE CAR
203
00:11:22,211 --> 00:11:25,004
OVER THE COURSE
OF THREE AND A HALF DAYS.
204
00:11:26,340 --> 00:11:28,340
SINCE 1981,
205
00:11:28,342 --> 00:11:31,802
ALL CORVETTES HAVE BEEN MADE
HERE IN BOWLING GREEN, KENTUCKY,
206
00:11:31,804 --> 00:11:33,997
AT THE BOWLING GREEN
ASSEMBLY PLANT,
207
00:11:33,999 --> 00:11:36,833
WHICH COVERS
1,000,000 SQUARE FEET.
208
00:11:39,562 --> 00:11:42,823
TO BUILD THE CAR, WORKERS RELY
ON A SPECIAL CONVEYOR SYSTEM
209
00:11:42,825 --> 00:11:45,317
KNOWN AS A TOWVEYOR.
210
00:11:45,319 --> 00:11:49,154
THIS CONSISTS OF TOW CARTS WHICH
MOVE AT PRECISELY TIME SPEEDS
211
00:11:49,156 --> 00:11:52,283
ALONG TRACKS SET IN THE FLOOR.
212
00:11:52,285 --> 00:11:55,111
THIS ALLOWS WORKERS TO MOUNT
COMPONENTS ON THE CHASSIS
213
00:11:55,113 --> 00:11:59,340
AS IT MOVES, ENSURING SMOOTH,
TIMELY ASSEMBLY.
214
00:12:02,704 --> 00:12:05,697
HERE, A WORKER USES A HOIST
TO SETTLE THE TRANSMISSION
215
00:12:05,699 --> 00:12:09,033
INTO ITS CRADLE,
WHERE THEY WILL SECURE IT.
216
00:12:09,035 --> 00:12:12,396
THE NEW STINGRAY COMES WITH
TWO TRANSMISSION OPTIONS --
217
00:12:12,398 --> 00:12:14,123
AN 8-SPEED
AUTOMATIC TRANSMISSION
218
00:12:14,125 --> 00:12:16,124
WITH PADDLE SHIFTING,
219
00:12:16,126 --> 00:12:20,755
OR A 7-SPEED MANUAL TRANSMISSION
WITH ACTIVE REV MATCH.
220
00:12:23,384 --> 00:12:25,585
AS THE CHASSIS MOVES ALONG,
221
00:12:25,587 --> 00:12:28,880
THE ENGINE TRAVELS
A PARALLEL ASSEMBLY LINE.
222
00:12:28,882 --> 00:12:32,075
THE TWO LINES MEET
AT PRECISELY THE RIGHT TIME.
223
00:12:32,077 --> 00:12:35,337
WORKERS TRANSFER THE FINISHED
ENGINE TO THE CHASSIS
224
00:12:35,339 --> 00:12:37,706
AND LOWER IT INTO POSITION.
225
00:12:42,204 --> 00:12:45,664
WORKERS NOW CONNECT A LONG
CYLINDER CALLED A TORQUE TUBE,
226
00:12:45,666 --> 00:12:47,357
WHICH WILL TRANSFER
THE ENGINE'S TORQUE
227
00:12:47,359 --> 00:12:49,160
TO THE TRANSMISSION.
228
00:12:51,556 --> 00:12:53,956
AND, OF COURSE, THE TRANSMISSION
WILL BE CONTROLLED
229
00:12:53,958 --> 00:12:56,284
FROM THE STINGRAY'S
HIGH TECH COCKPIT,
230
00:12:56,286 --> 00:12:59,012
WHICH IS READY FOR INSTALLATION.
231
00:12:59,014 --> 00:13:02,815
ALL THE JOINTS GET
A PROTECTIVE COATING OF URETHANE
232
00:13:02,817 --> 00:13:07,304
BEFORE A ROBOT LOWERS
THE COCKPIT ONTO THE CAR FRAME.
233
00:13:07,306 --> 00:13:11,233
32 BOLTS ON EACH SIDE
SECURE IT IN POSITION.
234
00:13:15,498 --> 00:13:16,764
AT THIS STATION,
235
00:13:16,766 --> 00:13:18,833
A ROBOT APPLIES
A URETHANE ADHESIVE
236
00:13:18,835 --> 00:13:21,327
ON A COMPONENT CALLED
THE WHEELHOUSE,
237
00:13:21,329 --> 00:13:25,156
AS A CART DOCKS THE CAR
IN A PRECISE LOCATION.
238
00:13:30,455 --> 00:13:33,848
AUTOMATED LIFTS INSTALL
THE WHEELHOUSES ON THE CAR
239
00:13:33,850 --> 00:13:35,942
AND HOLD THEM THERE
FOR 90 SECONDS
240
00:13:35,944 --> 00:13:38,011
AS THE ADHESIVE CURES.
241
00:13:55,365 --> 00:13:59,158
A WORKER BRINGS THE LEFT REAR
QUARTER PANEL TO THE CAR
242
00:13:59,160 --> 00:14:02,086
AND ATTACHES IT
WITH SEVERAL SCREWS ON THE TOP
243
00:14:02,088 --> 00:14:04,222
AND SEVERAL IN THE DOORFRAME.
244
00:14:07,620 --> 00:14:10,513
NEXT, SHE INSTALLS
THE FUEL NOZZLE.
245
00:14:10,515 --> 00:14:12,314
WITH THE NEW CORVETTE STINGRAY,
246
00:14:12,316 --> 00:14:14,909
YOU'LL NEVER ACCIDENTALLY
LEAVE YOUR GAS CAP BEHIND
247
00:14:14,911 --> 00:14:16,577
AT THE SERVICE STATION.
248
00:14:16,579 --> 00:14:19,438
THAT'S BECAUSE
THERE IS NO GAS CAP.
249
00:14:19,440 --> 00:14:21,900
THANKS TO A CLEVER,
SPRING-LOADED MECHANISM,
250
00:14:21,902 --> 00:14:25,362
THE NOZZLE SELF-SEALS
WHEN YOU FINISH FUELING UP.
251
00:14:27,199 --> 00:14:31,727
NEXT, TECHNICIANS USE HOISTS
TO INSTALL THE SEATS.
252
00:14:31,729 --> 00:14:33,854
THERE ARE TWO DIFFERENT
SEATS OPTIONS --
253
00:14:33,856 --> 00:14:37,850
THE STANDARD GT
AND THE COMPETITION SPORT.
254
00:14:37,852 --> 00:14:40,586
A PROTECTIVE RING AROUND THE
PERIMETER OF THE DOOR OPENING
255
00:14:40,588 --> 00:14:44,215
ENSURES THIS PROCESS
WON'T DAMAGE THE CAR BODY.
256
00:14:46,277 --> 00:14:48,144
A WORKER REMOVES THE BACKING
257
00:14:48,146 --> 00:14:51,072
FROM A SELF-ADHESIVE
CORVETTE EMBLEM.
258
00:14:51,074 --> 00:14:52,607
HE USES A JIG TO MAKE SURE
259
00:14:52,609 --> 00:14:54,601
THE EMBLEM IS
PERFECTLY POSITIONED
260
00:14:54,603 --> 00:14:57,929
BEFORE ADHERING IT TO
THE REAR FASCIA OF THE CAR.
261
00:15:00,934 --> 00:15:03,093
WHILE THERE, HE ALSO
TAKES THE OPPORTUNITY
262
00:15:03,095 --> 00:15:07,289
TO TEST THE REAR L.E.D. LIGHTS.
263
00:15:07,291 --> 00:15:11,618
HE NOW ROTATES THE PANEL
TO THE UPRIGHT POSITION.
264
00:15:11,620 --> 00:15:14,088
ALTHOUGH THE REAR FASCIA
IS LIGHTWEIGHT,
265
00:15:14,090 --> 00:15:15,414
CORVETTE MANDATES
266
00:15:15,416 --> 00:15:18,543
THAT TWO WORKERS SHOULD
WALK THE PART TO THE CAR.
267
00:15:19,980 --> 00:15:21,646
THIS HELPS PREVENT
DAMAGE BEING DONE
268
00:15:21,648 --> 00:15:23,906
TO EITHER THE PART OR THE CAR
269
00:15:23,908 --> 00:15:27,202
AS THE WORKERS
CAREFULLY INSTALL IT TOGETHER.
270
00:15:31,700 --> 00:15:33,834
THE POWER TRAIN AND THE CAR BODY
HAVE BEEN ASSEMBLED
271
00:15:33,836 --> 00:15:36,261
ON TWO SEPARATE CONVEYOR LINES
272
00:15:36,263 --> 00:15:39,190
THAT ARE PRECISELY TIMED
TO CONVERGE HERE.
273
00:15:40,726 --> 00:15:44,253
THE OVERHEAD CONVEYOR
SLOWLY LOWERS THE BODY,
274
00:15:44,255 --> 00:15:47,515
AS THE TOWVEYOR RAISES
THE POWER TRAIN TO MEET IT.
275
00:15:50,653 --> 00:15:51,945
ONCE TECHNICIANS HAVE
276
00:15:51,947 --> 00:15:54,948
BOLTED THE BODY
AND ITS POWER TRAIN TOGETHER,
277
00:15:54,950 --> 00:15:56,675
WORKERS INSTALL THE HOOD,
278
00:15:56,677 --> 00:15:59,937
WHICH IS MADE OF STRONG,
LIGHTWEIGHT CARBON FIBER.
279
00:16:01,807 --> 00:16:05,000
A TECHNICIAN THEN USES SPACERS,
OR GAP TOOLS,
280
00:16:05,002 --> 00:16:06,535
TO MAKE SURE THE GAP BETWEEN
281
00:16:06,537 --> 00:16:08,295
THE HOOD AND THE REST
OF THE CAR BODY
282
00:16:08,297 --> 00:16:10,131
IS THE CORRECT WIDTH.
283
00:16:13,761 --> 00:16:15,495
AFTER FASTENING THE HOOD
TO THE CAR
284
00:16:15,497 --> 00:16:17,422
AT ITS ATTACHMENT POINTS,
285
00:16:17,424 --> 00:16:21,618
HE DOUBLE-CHECKS THE WIDTH
WITH A SET OF GAUGES.
286
00:16:21,620 --> 00:16:25,313
SATISFIED,
HE REMOVES THE GAP TOOLS.
287
00:16:27,584 --> 00:16:30,711
A WORKER NOW INSTALLS
THE HEADLIGHTS.
288
00:16:30,979 --> 00:16:35,641
THE CORVETTE STINGRAY FEATURES
AMBER L.E.D. TURN SIGNALS,
289
00:16:35,643 --> 00:16:37,969
FRAMING THE BI-XENON,
FROSTED, INDIRECT,
290
00:16:37,971 --> 00:16:40,463
H.I.D. HIGH AND LOW BEAM
HEADLIGHTS.
291
00:16:45,595 --> 00:16:50,757
THERE ARE ALSO WHITE L.E.D.
D.R.L. UNDER EACH PROJECTOR.
292
00:16:58,617 --> 00:17:00,350
WITH THE LIGHTS FULLY INSTALLED,
293
00:17:00,352 --> 00:17:03,612
TWO WORKERS CAN NOW CARRY
THE FRONT FENDER TO THE CAR
294
00:17:03,614 --> 00:17:06,140
AND POSITION IT
FOR INSTALLATION.
295
00:17:06,142 --> 00:17:09,268
THE FENDER INCLUDES THE
STINGRAY'S DISTINCTIVE GRILLE
296
00:17:09,270 --> 00:17:13,731
AND THE CORVETTE'S
FAMOUS EMBLEM.
297
00:17:13,733 --> 00:17:14,933
A TECHNICIAN USES A HOIST
298
00:17:14,935 --> 00:17:18,361
TO POSITION THE WHEELS
FOR INSTALLATION.
299
00:17:18,363 --> 00:17:19,562
THE WHEELS FEATURE
300
00:17:19,564 --> 00:17:21,556
MICHELIN PILOT
SUPER SPORT TIRES,
301
00:17:21,558 --> 00:17:25,519
SPECIFICALLY DESIGNED
FOR THE STINGRAY.
302
00:17:31,246 --> 00:17:32,804
Narrator: A FULLY DECKED OUT
303
00:17:32,806 --> 00:17:35,539
SEVENTH GENERATION
CORVETTE STINGRAY
304
00:17:35,541 --> 00:17:37,667
FEATURES MAGNETIC
SELECTIVE ROD CONTROL,
305
00:17:37,669 --> 00:17:39,269
HEAD-UP DISPLAY,
306
00:17:39,271 --> 00:17:41,262
A 10-SPEAKER AUDIO SYSTEM,
307
00:17:41,264 --> 00:17:45,492
AND A DRIVER MODE SELECTOR
WITH FIVE DIFFERENT OPTIONS.
308
00:17:46,762 --> 00:17:50,089
THESE CORVETTES ARE
COMPLETELY ASSEMBLED.
309
00:17:50,091 --> 00:17:52,892
AN OVERHEAD CONVEYOR SYSTEM
SLOWLY LOWERS THEM
310
00:17:52,894 --> 00:17:56,820
UNTIL THE WHEELS TOUCH
THE GROUND FOR THE FIRST TIME.
311
00:17:56,822 --> 00:18:01,576
THE CAR HAS A DRY WEIGHT
OF 3,159 POUNDS.
312
00:18:01,578 --> 00:18:02,910
WITH ALL ITS FLUIDS,
313
00:18:02,912 --> 00:18:06,373
THE CURB WEIGHT WILL BE
3,302 POUNDS.
314
00:18:07,642 --> 00:18:10,168
HERE, BRIGHT SIDE LIGHTING
ALLOWS TECHNICIANS
315
00:18:10,170 --> 00:18:14,898
TO CAREFULLY INSPECT THE CAR
FOR ANY FLAWS IN THE PAINT JOB
316
00:18:14,900 --> 00:18:17,368
OR THE GAPS BETWEEN
THE BODY PANELS.
317
00:18:19,330 --> 00:18:22,657
A WORKER THEN STARTS THE CAR UP
FOR THE FIRST TIME
318
00:18:22,659 --> 00:18:24,391
AND DRIVES IT OVER
A RUMPLE STRIP
319
00:18:24,393 --> 00:18:26,386
TO AN ALIGNMENT STATION.
320
00:18:26,388 --> 00:18:29,188
HERE, TECHNICIANS WILL USE
PRECISION EQUIPMENT
321
00:18:29,190 --> 00:18:30,514
TO PERFECTLY ALIGN
322
00:18:30,516 --> 00:18:33,151
THE STEERING SYSTEM
AND THE HEADLIGHTS.
323
00:18:37,149 --> 00:18:39,607
IN A PIT
UNDER THE ALIGNMENT STATION,
324
00:18:39,609 --> 00:18:42,936
A WORKER CAREFULLY ADJUSTS
THE WHEELS.
325
00:18:42,938 --> 00:18:45,872
THE STEERING WHEEL MUST BE
NO MORE THAN 5 MILLIMETERS
326
00:18:45,874 --> 00:18:47,533
OFF ITS CENTER POSITION
327
00:18:47,535 --> 00:18:50,136
WHEN THE WHEELS ARE POINTED
STRAIGHT AHEAD.
328
00:18:54,500 --> 00:18:55,691
SIMULTANEOUSLY,
329
00:18:55,693 --> 00:18:57,627
AN OPTICAL SENSOR MOVES
BACK AND FORTH
330
00:18:57,629 --> 00:18:59,220
IN FRONT OF THE CAR
331
00:18:59,222 --> 00:19:01,923
TO GAUGE THE POSITION
OF THE HEADLIGHTS.
332
00:19:04,352 --> 00:19:07,812
AT A DISTANCE OF 25 FEET,
THE MIDDLE OF THE HEADLIGHT BEAM
333
00:19:07,814 --> 00:19:10,716
CAN BE NO MORE THAN
5 MILLIMETERS OFF CENTER.
334
00:19:23,498 --> 00:19:28,126
THE CAR IS NOW READY FOR
THE DYNAMIC VEHICLE TEST.
335
00:19:28,128 --> 00:19:31,128
HERE, A DRIVER TRIES OUT
EVERY SWITCH
336
00:19:31,130 --> 00:19:34,591
WHILE REVVING THE CAR
UP TO 80 MILES PER HOUR,
337
00:19:34,593 --> 00:19:38,853
AS A COMPUTER RUNS OVER
800 TESTS IN JUST 2 MINUTES.
338
00:19:39,590 --> 00:19:42,048
IT CHECKS EVERYTHING
FROM THE ENGINE CYLINDERS
339
00:19:42,050 --> 00:19:45,377
TO TRANSMISSION SHIFTING
AND EMISSION LEVELS.
340
00:19:48,608 --> 00:19:51,275
ONCE PAST
THE DYNAMIC VEHICLE TEST,
341
00:19:51,277 --> 00:19:55,137
THE CAR MUST ENDURE A POWERFUL,
SIMULATED TROPICAL STORM.
342
00:19:55,206 --> 00:19:58,199
THIS IS KNOWN AS THE WATER TEST.
343
00:19:59,069 --> 00:20:00,893
FOR 2 SOLID MINUTES,
344
00:20:00,895 --> 00:20:03,029
HIGH PRESSURE JETS
HAMMER THE CAR
345
00:20:03,031 --> 00:20:05,890
WITH 12 GALLONS PER SECOND.
346
00:20:05,892 --> 00:20:08,886
THE DRIVER USES A FLASHLIGHT
TO EXAMINE THE INTERIOR
347
00:20:08,888 --> 00:20:11,422
FOR ANY SIGNS OF LEAKAGE.
348
00:20:12,024 --> 00:20:14,216
UNDER SUCH AN INTENSE BARRAGE,
349
00:20:14,218 --> 00:20:17,345
THE SMALLEST CRACK WILL SHOW UP.
350
00:20:20,775 --> 00:20:22,041
THE DRIVER NOW TAKES THE CAR
351
00:20:22,043 --> 00:20:24,902
OVER SOMETHING CALLED
THE SQUEAK AND RATTLE TRACK,
352
00:20:24,904 --> 00:20:28,173
WHICH SIMULATES
DIFFERENT ROAD CONDITIONS.
353
00:20:28,175 --> 00:20:31,768
AS HE DRIVES, HE LISTENS
CAREFULLY FOR...WHAT ELSE?
354
00:20:31,770 --> 00:20:33,729
SQUEAKS AND RATTLES.
355
00:20:37,059 --> 00:20:38,525
THE NEW STINGRAY IS THE LATEST
356
00:20:38,527 --> 00:20:42,054
IN A LONG LINE
OF FAMOUS CORVETTES.
357
00:20:42,056 --> 00:20:43,456
IN FACT, CHEVROLET HAS MADE
358
00:20:43,458 --> 00:20:46,116
MORE THAN 1.5 MILLION OF THEM
IN TOTAL.
359
00:20:46,118 --> 00:20:49,612
IN PRODUCTION SINCE 1953,
360
00:20:49,614 --> 00:20:52,214
THE CORVETTE IS THE WORLD'S
LONGEST RUNNING,
361
00:20:52,216 --> 00:20:55,343
CONTINUOUSLY PRODUCED
PASSENGER CAR.
362
00:20:55,345 --> 00:20:59,005
THE ORIGINAL 1960 STINGRAY
TOOK MORNING THAN JUST ITS NAME
363
00:20:59,007 --> 00:21:01,900
FROM THAT HYDRODYNAMIC FISH.
364
00:21:03,937 --> 00:21:07,698
THE DESIGN OF BOTH THE OLD
AND THE NEW CORVETTE STINGRAY
365
00:21:07,700 --> 00:21:09,633
FEATURES
SMOOTHLY CURVING TRANSITIONS
366
00:21:09,635 --> 00:21:11,493
FROM SURFACE TO SURFACE,
367
00:21:11,495 --> 00:21:14,956
ENABLING AIR TO FLOW OVER
AND AROUND IT AT HIGH SPEED.
368
00:21:14,958 --> 00:21:16,958
THIS DESIGN FEATURE,
369
00:21:16,960 --> 00:21:20,687
TAKEN TOGETHER WITH THE NEW
STINGRAY'S POWERFUL V8 ENGINE,
370
00:21:20,689 --> 00:21:24,148
HIGH TECH TRANSMISSION,
AND LIGHTWEIGHT CONSTRUCTION,
371
00:21:24,150 --> 00:21:26,776
MAKE IT A TRUE CORVETTE,
372
00:21:26,778 --> 00:21:29,045
PAYING TRIBUTE TO
A CELEBRATED PAST
373
00:21:29,047 --> 00:21:31,640
WHILE ROARING INTO THE FUTURE.
29636
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