All language subtitles for How.Its.Made.Dream.Cars.S02E09.KTM.X-Bow.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb_track3_[eng]

Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS"...

THE ULTRA-LIGHT
KTM X-BOW,

ALWAYS ROAD- AND RACE-READY.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

AS ONE OF THE LARGEST EUROPEAN
MOTORCYCLE MANUFACTURERS,

KTM IS MORE
THAN ALL-TERRAIN BIKES.

SINCE 1994, THE COMPANY
HAS MANUFACTURED AND DEVELOPED

RACE-READY OFF-ROAD
AND STREET MOTORCYCLES.

MOTORSPORTS HAS BEEN
THE MAIN FOCUS OF THE BRAND.

KTM'S RACING TEAM

HAS WON MORE THAN 200
WORLD CHAMPIONSHIP TITLES,

COUNTLESS NATIONAL TITLES,
AND 10 DAKAR RALLY TITLES.

KTM'S ONLY CAR SERIES,
THE X-BOW,

IS HEAVILY INFLUENCED
BY THE BRAND'S SUPERBIKES.

WITH A POWERFUL ENGINE,

SOLID CHASSIS,
AND BEAMING PRESENCE,

THE X-BOW IS RADICAL
IN THE SPORTS-CAR SEGMENT.

IT DEBUTED IN 2008 AT THE
INTERNATIONAL GENEVA MOTOR SHOW,

WITH STATE-OF-THE-ART
TECHNOLOGY FEATURES

AND A REVOLUTIONARY DESIGN.

WITH THE CONSTRUCTION ELEMENTS
LIKE CARBON FIBER,

AGGRESSIVE STYLING,
AND UNBELIEVABLE PERFORMANCE,

THE X-BOW
IS KTM'S ANSWER

TO EXTREME SPORTS
ON FOUR WHEELS.

THE KTM X-BOW
IS MANUFACTURED

AT A SPECIAL PLANT
IN GRAZ, AUSTRIA.

IN THE CONCEPT PHASE,
THE DESIGNERS TOYED

WITH VARIOUS CONSTRUCTION
METHODS AND SPECIALTY PARTS,

INCLUDING THE USE
OF A TUBULAR SPACE FRAME

MADE FROM
CHROME MOLYBDENUM STEEL.

THE X-BOW IS PRODUCED
IN 18 MONTHS

AND RELIES
ON MANY COLLABORATORS.

DESIGNERS USE
ADVANCED COMPUTER SOFTWARE

TO VISUALIZE THEIR IDEAS

IN VARIOUS PAINT COLORS
AND ROAD CONDITIONS

BEFORE PRODUCTION.

THEY THEN USE CLAY SCULPTURES
WITH FUNCTIONAL METAL PIECES

TO TEST THEIR IDEAS.

THE X-BOW'S COMPACT DESIGN

LEAVES A VERY POWERFUL
IMPRESSION.

IT DELIVERS AN INCREDIBLE LEVEL
OF DRIVING COMFORT

WITHOUT SACRIFICING
ANY RACING CHARM.

TO PRODUCE
THE FIBER-REINFORCED PARTS,

THEY PLACE CARBON-FIBER MATS
INTO A MOLD.

THE CLOTH MATS
ARE CHOSEN BASED ON STRENGTH

AND TORSIONAL-STIFFNESS
PROPERTIES.

THE CAR'S TWO-PART,
176-POUND CARBON MONOCOQUE

IS MADE UP OF FOUR LAYERS
INFUSED WITH EPOXY RESIN.

FOUR CEILING HUMIDIFIERS
DISPENSE A HYDRATING MIST,

KEEPING THE ROOM'S MOISTURE
LEVEL AT A CONSISTENT LEVEL.

THIS ENSURES GOOD AIR QUALITY
FOR STAFF AND MATERIALS.

WORKERS PLACE PRE-CUT ADHESIVE
SHEETS OF WOVEN CARBON FIBER

TO THE SEATING SECTION.

THIS PROCESS LAMINATES SINGLE
CARBON-FIBER LAYERS TOGETHER.

THE WORKERS
USE PUTTY KNIVES

TO CONFORM THE FIBER'S FILMS
AND REMOVE AIR POCKETS.

ADDITIONAL CARBON-FIBER PIECES
ARE ADDED TO SPECIFIC AREAS

TO ENSURE A FINE AND
WELL-PRODUCED OVERALL STRUCTURE.

THIS PROCESS ENSURES

THAT THE CAR IS BOTH VERY RIGID
AND EXTREMELY LIGHTWEIGHT.

NEXT, WORKERS PLACE
A THICK PROTECTIVE COVERING

OVER THE MOLD.

COUPLINGS CONNECTED
TO AIR-SUCTION HOSES

REMOVE AIR AND APPLY
GRAVITATIONAL PRESSURE,

FORCING THE LAYERS
OF CARBON FIBER

TO SHAPE AGAINST THE MOLD.

IN A PRESSURIZED OVEN,

THE FIBROUS MATERIAL
CURES AT 248 DEGREES.

THIS FORCES THE MATS
TO RELEASE THE RESIN.

THE MONOCOQUE
IS A TWO-PART CONSTRUCTION.

THE FIRST PART IS THE BASE.

THE SECOND, LARGER PART

COMPLETES
THE REST OF THE CHASSIS.

THE PARTS ARE FASTENED TOGETHER

WITH A HIGH-STRENGTH
EPOXY RESIN.

AN AUTOMATIC MATERIAL FEEDER

MOVES THE TOP PORTION
OF THE MONOCOQUE

INTO A FINISHING CHAMBER

FOR DE-FLASHING, DRILLING,
AND PROCESSING.

WHILE IN THE FINISHING CHAMBER,

A ROBOT DRILLS HOLES
IN THE MONOCOQUE.

THE HOLES
ARE FOR VARIOUS COMPONENTS

THAT WILL BE ATTACHED LATER.

ALUMINUM INSERTS
INSIDE THE CARBON-FIBER CHASSIS

ARE DRILLED FOR THE ADDITION
OF OTHER ELEMENTS LATER.

AT ANOTHER STATION,

WORKERS ADD A BONDING GLUE
CALLED DP490

TO THE FRAME OF THE WINDSHIELD.

THE TWO-COMPONENT EPOXY ADHESIVE
IS DESIGNED FOR HIGH STRENGTH

AND ENVIRONMENTAL RESISTANCE.

THEY PLACE THE EPOXY
OVER AS MUCH SURFACE AS POSSIBLE

FOR MAXIMUM ADHESION.

ONCE THE EPOXY
IS EVENLY DISTRIBUTED,

THE CASING MOVES TO
THE COCKPIT SHELL FOR ASSEMBLY.

"F" CLAMPS SECURE THE STRUCTURE
INTO POSITION.

BONDING TAKES FOUR TO SIX HOURS,
DRYING AT ABOUT 74 DEGREES.

THE CAR'S
CARBON-FIBER BODY PANELS

ARE MADE IN A SERIES
OF SIMPLE STEPS,

LIKE DESIGN, CONSTRUCTION,
CURING, AND SANDING.

COMPONENTS ARE PAINTED
WITH A PROTECTIVE PRIMER

AND FINISHED WITH A CLEAR COAT
OF PAINT AND DECALS.

Narrator: THE KTM X-BOW'S
FASHIONABLE DESIGN

IS SURE TO TURN HEADS,

ESPECIALLY
ITS REAR STRUCTURAL UNIT.

IT ILLUSTRATES THEIR UNEQUIVOCAL
PASSION FOR RACING FLAIR.

NEXT, THE STEERING-COLUMN
ASSEMBLY.

A TECHNICIAN SPRAYS LUBRICANT
ONTO THE STEERING-COLUMN SHAFT.

HE THEN FITS A LIGHTWEIGHT,
NON-MAGNETIC SPACER

OVER THE SHAFT AND INSERTS IT
INTO THE ADJUSTOR.

WITH THE HELP OF LUBRICANT,

THE TECHNICIAN ATTACHES
PART OF THE UPPER STEERING SHIFT

BY TWISTING IT INTO POSITION.

THE UNIVERSAL JOINT IS INSERTED
INTO THE INTERMEDIATE SHAFT.

IT TRANSMITS STEERING DATA

TO AND FROM THE COCKPIT
AND THE WHEELS

VIA AN INFRARED TRANSMITTER.

THE UNIVERSAL JOINT IS SECURED

WITH A LOCKING WASHER
AND SCREWS.

THEN THE TECHNICIAN INSTALLS
A PLASTIC COLUMN RING

CONTAINING ELECTRICAL WIRING
THAT RELAYS NAVIGATIONAL ORDERS

AND OTHER FUNCTIONS
WITHIN THE SYSTEM.

HE DELICATELY MELTS THE CABLING

USING A HANDHELD HEAT GUN
TO SHRINK-WRAP THE RUBBER COVER.

HE ALSO WRAPS
CLOTH-BASED ADHESIVE TAPE

ON THE OUTER COLUMN.

TO FINALIZE THE ADJUSTABLE
STEERING COLUMN'S CONSTRUCTION,

THE TECHNICIAN SLIDES
THE INNER POST

OVER TOP OF THE OUTER COLUMN.

THE STEERING COLUMN
ALSO PROVIDES THE MOUNTING

FOR SWITCHES
AND OTHER INSTRUMENTS.

ASSEMBLING THE REAR STRUCTURAL
UNIT STARTS WITH THE MAINFRAME,

WHICH INCLUDES
THE LICENSE-PLATE HOLDER.

THE TECHNICIAN
SLIDES THE MUFFLER COVER

INTO PRE-EXISTING SLITS.

HARDWARE IS ADDED
TO SECURE IT IN PLACE.

THE LICENSE-PLATE LIGHTS
ARE INSTALLED IN THE FRAME

AND FASTENED WITH SCREWS.

SUPPORT ARMS ARE ADDED, AS WELL.

THE TECHNICIAN ATTACHES EACH OF
THE UNIQUELY DESIGNED TAILLIGHTS

WITH SCREWS
AND AN IMPACT DRIVER.

THE TAILLIGHT WIRING SYSTEM
IS SIMPLE.

IN THE COCKPIT IS A SWITCH.

WHEN THE DRIVER PRESSES DOWN
ON THE BRAKE PEDAL,

THE CIRCUIT IS COMPLETE,

TRIGGERING THE TAILLIGHTS
TO TURN ON.

THE WIRES ARE HELD TO THE WING'S
FRAMEWORK WITH CABLE TIES.

ANY EXCESS PIECES FROM THE TIES
ARE REMOVED WITH CUTTING PLIERS.

THE REAR STRUCTURAL UNIT
IS FINISHED

AND READY TO JOIN THE CHASSIS.

BRAKE ASSEMBLY BEGINS
WHEN A SPECIALIST INSERTS

THE PRIMARY WHEEL CARRIERS
INTO VICES.

NEXT, THE COUPLING
OF THE WHEEL HUB IS ADDED.

THE WORKER SECURES IT
WITH A TORQUE WRENCH

TO MEET
THE VEHICLE'S SPECIFICATIONS.

NOW THE BRAKE-DUST SHIELDS
ARE ADDED.

THEY PREVENT DIRT AND DEBRIS

FROM ACCUMULATING
IN THE BRAKING SYSTEM.

ONE OF THE MOST IMPORTANT PARTS
OF THE BRAKE SYSTEM

IS THE ROTOR.

IT RECEIVES A HOLDING BOLT
FOR POSITIONING.

THE WORKER ADJUSTS
THE HOLDING JIG

TO A SECONDARY POSITION
AND INSTALLS THE CALIPERS.

THEY PERFORM THE MECHANICAL
ASPECT OF THE BRAKING ACTION.

SEPARATE CALIPERS ARE INSTALLED

FOR THE HAND BRAKE
ON THE REAR-WHEEL CARRIERS.

HE ENSURES THAT ALL BOLTS
ARE PRECISELY ADJUSTED

USING AN ELECTRONIC
MEASURING WRENCH

CONTROLLED BY
A BUILT-IN MICROPROCESSOR.

AT ANOTHER WORK STATION,

THE TECHNICIAN SECURES
THE UNFINISHED BRAKE SYSTEM

INTO A HOLDING UNIT.

HE ADDS THE CONTROL ARMS
AND LOCKS THEM IN POSITION

WITH AN ELECTRIC TORQUE WRENCH.

THE CONCLUSION --

ULTIMATE
SHORT-RANGE BRAKING POWER.

Narrator:
KTM'S AUTOMOTIVE FACTORY

IS NEXT DOOR TO THE
MOTORCYCLE-PRODUCTION FACILITY.

IT'S COMPRISED
OF 10 SPECIAL WORK STATIONS.

ROUGHLY 100 CARS ARE PRODUCED

IN THIS STATE-OF-THE-ART FACTORY
EVERY YEAR.

HEADQUARTERED
IN MATTIGHOFEN, AUSTRIA,

WORKERS BUILD 80,000 KTM ORANGE
MOTORCYCLES EVERY YEAR.

THE COMPANY MAY EVEN
BE THE FIRST

TO PRODUCE
AN ELECTRIC OFF-ROAD BIKE.

BUT FOR NOW, NEW TERRITORY COMES
WITH THE X-BOW.

IN THIS ROOM, THE CHASSIS
AND RUNNING PARTS COME TOGETHER.

USING AN OVERHEAD LIFT,

A TECHNICIAN LOWERS
THE MONOCOQUE

ONTO A SERIES OF ASSEMBLY JIGS.

NEXT, WORKERS GLIDE THE REAR
SECTION OF THE SPACE FRAME

TOWARD THE CARBON-FIBER
MONOCOQUE,

ATTACHING IT
TO THE LIGHTWEIGHT CHASSIS.

THIS PART OF THE BASE FRAME

CONTAINS THE REAR SUSPENSION
AND DRIVESHAFT UNITS.

THIS PART ALSO SUPPORTS
THE ENGINE

AND GEARBOX ASSEMBLY UNITS.

AT ANOTHER WORK STATION,

THE TURBOCHARGER INTERCOOLER
IS READIED.

IT'S USED TO COOL
THE TURBOCHARGER

DURING THE SEMI-ADIABATIC
COMPRESSION PROCESS.

THE INTERCOOLER IS ATTACHED
TO THE FIRE WALL,

WHICH PROVIDES A SAFETY BARRIER
BETWEEN THE ENGINE AND COCKPIT.

NEXT, THE INTERCOOLER
AND FIRE WALL

ARE CONNECTED TO
THE INTERCOOLING PUMP SYSTEM.

THE SMALL AUDI ENGINE PRODUCES
285 HORSEPOWER

AND ACCELERATES FROM ZERO TO 60
IN JUST OVER FOUR SECONDS.

USING AN AIR HOIST,
THE WORKERS LOWER

THE FUEL-INJECTED POWER UNIT
AND GEARBOX

INTO THE SPACE FRAME.

WHILE MOST MANUFACTURERS MOUNT

A CAR'S RUNNING GEAR VERTICALLY
WITH A CHASSIS...

...THE X-BOW'S COMPONENTS
ARE MOUNTED HORIZONTALLY.

NEXT, WORKERS ATTACH

THE RACING-INSPIRED
PUSH-ROD SPRINGS AND DAMPERS.

THESE ENSURE THE VEHICLE HAS
OPTIMUM CONTACT WITH THE ROAD.

GRABBING THE RIGHT-FRONT
SUSPENSION COMPONENT

BY THE CONTROL ARMS,

A TECHNICIAN BOLTS THE UNIT
INTO FOUR SPECIFIC INSERTS

WITHIN THE TWIN-WALL
CARBON-FIBER MONOCOQUE.

ATTACHING ADDITIONAL PARTS
IS QUICK

BECAUSE HOLES AND BODY SECTIONS
ARE MACHINED IN ADVANCE.

THE TECHNICIAN VERIFIES
THE SUSPENSION UNIT IS SECURE

BY MANUALLY LIFTING
AND PULLING THE UNIT.

THEN HE INSTALLS
THE PEDAL ASSEMBLY.

IT UTILIZES THREE,
LIGHTWEIGHT ALUMINUM PEDALS

THAT CONTROL THE BRAKE, CLUTCH,
AND THROTTLE.

THE PEDALS ARE ATTACHED
TO A RAIL

SO THEY CAN BE ADJUSTED
TO ACCOMMODATE ANY DRIVER.

NEXT, THE TECHNICIAN CONNECTS
THE ELECTRICAL WIRING

OF THE LIGHTWEIGHT,
ALUMINUM SHIFT CONSOLE

AND GEAR-LEVER GUIDE.

THESE COMPONENTS HELP DELIVER

SHORT AND ULTRA-PRECISE
GEAR CHANGES.

UNLIKE OTHER SPORTS CARS,

THIS VEHICLE USES AN ATYPICAL,
SINGULAR MULTI-FUNCTION DISPLAY.

THE DISPLAY IS SIMILAR
TO THE COMPANY'S SUPERBIKES,

WHICH DELIVER OPERATIONAL
FEEDBACK AND TRIP INFORMATION.

THE ENGINE'S PROTECTIVE COVER
GOES OVER THE VALVE COMPONENTS.

THE REMAINING ENGINE TUBING
AND PIPING

IS CONNECTED TO THE PROPER DUCTS
AFTER THE LID IS ADDED.

IN CASE OF A CRASH,
THESE PROTECTIVE STEEL ROLL BARS

CAN WITHSTAND LOADS OF UP
TO 2.5 TIMES THE CAR'S WEIGHT.

NOW THE REAR BUMPER
AND LIGHTING SYSTEMS

ARE SECURELY INSTALLED
ONTO THE REAR SPACE FRAME.

A DEEP-SOUNDING EXHAUST
IS A MUST FOR ANY SPORTS CAR.

THIS METALLIC EXHAUST SYSTEM
IS A SIMPLISTIC SILENCING BLOCK.

IT ADDS A DISTINCT LOOK
AND TONE TO THE VEHICLE.

WORKERS CAREFULLY REMOVE
A TWO-PIECE, ALUMINUM HARNESS.

THIS HARNESS HELPS MOVE

THE FRONT WINDSHIELD
AND SIDE WINDOWS

ONTO THE CAR'S MAIN BODY
FOR INSTALLATION.

THE PERFORMANCE WHEELS
ARE 18 INCHES IN THE FRONT

AND 19 IN THE REAR.

NOW THAT THE MAJOR RUNNING
COMPONENTS ARE INSTALLED,

THE CAR IS READY FOR A ROAD TEST
TO GUARANTEE PERFORMANCE.

Narrator:
WITH FINE-TUNED PERFORMANCE

AND NEAR-LIMITLESS
VEHICLE CUSTOMIZATION,

THE KTM X-BOW
IS A GENUINE SPORTS CAR

OF THE PUREST VARIETY.

AT THE FILLING STATION,

EACH AND EVERY CAR RECEIVES
THE NECESSARY RUNNING FLUIDS

REQUIRED FOR THE VEHICLE'S
OVERALL PERFORMANCE.

FIRST, THE ENGINE COOLANT.

IT IS DESIGNED TO REMOVE
EXCESS HEAT FROM THE ENGINE.

OTHER COMPLIMENTARY CHEMICALS

INCLUDE PREMIUM GASOLINE
AND ENGINE OIL.

THE ENGINE OIL LUBRICATES

VARIOUS INTERNAL PARTS
OF THE ENGINE.

ALSO, FLUIDS ARE ADDED
FOR BRAKING, TRANSMISSION,

WINDSHIELD WASHING,
AND POWER STEERING.

AT THE NEXT STATION,
A TECHNICIAN ADJUSTS THE WHEELS

USING AN ELITE ALIGNMENT SYSTEM.

THIS SYSTEM USES HIGH-RESOLUTION
CAMERAS AND OPTICAL LASERS

TO PROVIDE
ALIGNMENT MEASUREMENTS

WITH PINPOINT ACCURACY.

WHEEL-MOUNTED SENSORS
WITH TRIANGULAR REFLECTORS

DELIVER THE INFORMATION
TO THE CAMERA.

THE CAMERA TRANSFERS
THAT INFORMATION

TO THE MAIN COMPUTER CONSOLE.

THIS ALLOWS THE TECHNICIAN TO
MAKE ADJUSTMENTS AS NEEDED

FOR CAMBER,
WHEEL LOADS, TOW SET,

AND STEERING-WHEEL POSITIONING.

THIS IS THE FIRST TIME
THE ENGINE IS CYCLED.

TO TEST ITS POWERFUL DRIVING
DYNAMICS,

KTM USES
A DYNAMOMETER TEST ROOM.

ONCE THE CAR
IS ON A SET OF TEST ROLLERS,

A REAR SECURITY ROAD BLOCKER
RAISES INTO PLACE

AND THE TRIAL RUN BEGINS.

DURING THIS ROLLING ROAD TEST,

THE SOFTWARE RECORDS AND
ANALYZES

THE PERFORMANCE OF THE MOTOR'S
POWER AND TORQUE OUTPUT.

THE FRONT SPLITTER, MAIN BODY,
AND REAR DIFFUSER

CAN GENERATE OVER 400 POUNDS
OF DOWNFORCE AT HIGH SPEEDS.

THE MAIN UNDER-FLOOR
AND REAR DIFFUSER ARE MOUNTED.

THEN A CARBON EXHAUST COVER
IS ADDED,

OFFERING A PROTECTIVE AESTHETIC.

THE CRASH BOX OFFERS
COLLISION SAFETY,

AIRFLOW OPTIMIZATION,
AND REDUCES UNDERSTEER.

A LIGHTING SYSTEM,
LICENSE-PLATE HOLDER,

FRONT SPLITTER,
AND AERODYNAMIC FRONT FINS

ARE ALL ATTACHED
TO THE CRASH BOX.

WORKERS SECURE
THE COMPLETED CRASH BOX

TO THE REST OF THE CHASSIS
WITH IMPACT DRIVERS.

IN A HEAD-ON COLLISION,
WHERE THE CAR IS TRAVELING

AT SPEEDS OF AROUND
40 MILES PER HOUR OR LESS,

THE CRASH BOX WILL ABSORB
THE ENERGY OF THE IMPACT,

LEAVING THE MONOCOQUE FRONT
VIRTUALLY UNHARMED.

AT THE FINAL STATION,

CARBON-FIBER BODY PANELS
ARE INSTALLED

TO COMPLETE THE CAR'S
SHARP, OUTER AESTHETIC.

WITH ITS ROOFLESS STANCE
AND PERFORMANCE POSTURE,

THE X-BOW IS PERFECT FOR
SUNNY DAYS AND WINDING ROADS.

BUT IN THE CASE OF RAIN,

THE CROSS TOP CAN BE MOUNTED.

INSTALLATION TAKES
LESS THAN FIVE MINUTES

AND NEVER COMPROMISES
A DRIVER'S ABILITY

TO GET IN OR OUT OF THE CAR.

THE COVER IS MADE

OF A WATER- AND DIRT-REPELLANT
SYNTHETIC FABRIC.

IT IS STORED
IN THE PASSENGER FOOTWELL.

FROM ESTEEMED MOTORCYCLE
ORIGINS,

THE X-BOW IS A RIVETING
SPORTS CAR.

FUSING ELEMENTS LIKE
A SUPER-STIFF CHASSIS,

A TURBOCHARGED ENGINE,

SUPERB STEERING
AND BRAKING POWER,

KTM'S X-BOW IS MADE TO BE DRIVEN
WITH BOLD CONVICTION

ON ANY ROAD OR TRACK.