Original subtitles

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.