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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,137 --> 00:00:05,762
THE PORSCHE 918 SPYDER.
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00:00:05,764 --> 00:00:08,291
IT'S MEAN, RARE, AND ECO-GREEN.
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-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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PORSCHE'S 918 SPYDER HYBRID
COMBINES THE ESSENTIALS
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OF MOTOR RACING
WITH SUPERB FUEL ECONOMY.
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ORIGINALLY UNVEILED AS
A CONCEPT CAR IN 2010,
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IT'S THE NEWEST BLUEPRINT
FOR FUTURE PORSCHE SPORTS CARS.
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00:00:38,999 --> 00:00:42,793
THE AUTOMAKERS' DESIGN TEAM
STARTED WITH A CLEAN SLATE,
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00:00:42,795 --> 00:00:46,656
NO CONSTRAINTS, OR COMPROMISES.
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THE GOAL WAS TO DEVELOP A HIGHLY
FUEL-EFFICIENT SUPERCAR,
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SMARTLY BUILT AROUND
A POWERFUL HYBRID DRIVE SYSTEM.
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THE 918 USES THE SAME V-8 ENGINE
AS THE RS SPYDER RACECAR.
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00:01:00,748 --> 00:01:03,139
THE ENGINE WAS DEVELOPED
EXCLUSIVELY
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FOR THE ANNUAL 24-HOUR RACE
IN LE MANS, FRANCE.
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IN 2013,
THE 918 SPYDER HIT THE STREETS
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AS A LIMITED-PRODUCTION CAR.
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00:01:15,831 --> 00:01:19,558
ITS APPEARANCE IS BEYOND
ANY DRIVER'S WILDEST DREAM.
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00:01:19,560 --> 00:01:22,085
THIS SUPERCAR HAS
A ROLLING CHASSIS,
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00:01:22,087 --> 00:01:25,755
A VEHICLE THAT CAN BE DRIVEN
WITHOUT A STYLISTIC SHELL.
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00:01:25,757 --> 00:01:29,351
THIS IS ONE OF THE AUTOMAKERS'
ONGOING TRADITIONS.
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PRODUCTION STARTS WITH
THE ASSEMBLY OF THE CHASSIS.
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IN THE FABRIC SHOP,
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00:01:40,573 --> 00:01:42,799
MASSIVE SHEETS OF
PREPREG COMPOSITE
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CARBON-FIBER-REINFORCED POLYMER
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ARE CUT INTO WIDE PATTERN PIECES
WITH AN AUTOMATIC CUTTER.
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00:01:48,465 --> 00:01:51,725
THE CUTTER USES
A HIGH-SPEED OSCILLATING BLADE,
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00:01:51,727 --> 00:01:55,521
WHICH ALTERNATES AT AROUND
18,000 STROKES PER MINUTE.
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THE SYSTEM ALSO VACUUMS AWAY
ANY DUST DURING CUTTING.
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00:02:00,352 --> 00:02:02,978
THE SHEETS ARE FIT INTO MOLDS
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THAT PRODUCE
A TWO-PART INTERLOCKING CHASSIS,
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00:02:06,017 --> 00:02:08,876
A MONOCOQUE, AND A UNIT CARRIER.
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CARBON-FIBER-REINFORCED POLYMER
IS VERY THIN
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AND AFFORDS EXTREME
TORSIONAL RIGIDITY.
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WHEN THE CAR IS COMPLETE, IT
WEIGHS JUST UNDER 3,700 POUNDS,
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AN INCREDIBLY LOW WEIGHT
FOR A HYBRID SPORTS CAR.
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00:02:27,490 --> 00:02:29,556
THIS ALUMINUM HONEYCOMB LAYER
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KEEPS THE CAR'S CHASSIS
AT AN EVEN LOWER WEIGHT.
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00:02:35,489 --> 00:02:37,982
WITH A SMALL OFFSET TOOL,
THE SPECIALIST INSTALLS
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00:02:37,984 --> 00:02:42,011
THE HONEYCOMB SHEETS
INTO COMPLEX AREAS.
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00:02:49,238 --> 00:02:52,864
THIS RED FLUOROPOLYMER
RELEASE FILM HAS PERFORATIONS
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THAT ALLOW AIR AND EPOXY RESIN
TO FLOW THROUGH IT.
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THE FILM ALLOWS THE HONEYCOMB
CORES AND CARBON FIBER LAYERS
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00:02:59,665 --> 00:03:01,490
TO BIND TOGETHER.
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TECHNICIANS FIT MORE CARBON
FIBER SHEETS ONTO THE MOLD,
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00:03:06,923 --> 00:03:10,683
TRIMMING ANY EXCESS PIECES
WITH UTILITY KNIVES.
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00:03:10,685 --> 00:03:13,878
IN ADDITION TO CARBON-FIBER-
REINFORCED PLASTIC,
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00:03:13,880 --> 00:03:15,813
MAGNESIUM AND ALUMINUM ARE USED
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00:03:15,815 --> 00:03:20,769
TO KEEP THE CHASSIS WEIGHT DOWN
TO 3,615 POUNDS.
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00:03:24,834 --> 00:03:27,902
REMOVABLE WHITE COVERS
ARE FOR DE-MOLDING.
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THEY USE PLASTIC BAGS
AND SUCTION HOSES
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00:03:31,899 --> 00:03:35,293
TO SEAL FIBROUS LAYERS
ONTO THE MOLD.
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00:03:37,555 --> 00:03:40,222
PERMEABLE LIGHTWEIGHT
POLYESTER SHEETS,
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00:03:40,224 --> 00:03:41,850
KNOWN AS BREATHER CLOTHS,
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00:03:41,852 --> 00:03:43,852
RECEIVE A SPRAY
OF ADHESIVE LIQUID
57
00:03:43,854 --> 00:03:46,847
TO BOND THEM INTO POSITION.
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00:03:46,849 --> 00:03:48,448
THE FABRIC ABSORBS EXCESS RESIN
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00:03:48,450 --> 00:03:50,376
AND ALLOWS AIR
TO FLOW FREELY
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00:03:50,378 --> 00:03:52,444
BETWEEN THE BAG
AND THE COMPOSITE
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00:03:52,446 --> 00:03:55,039
BEFORE IT ENTERS THE AUTOCLAVE.
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00:03:57,510 --> 00:03:59,468
NEXT, A THICK PLASTIC BAG
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CREATES A SECONDARY
AIRTIGHT COVER OVER THE MOLD.
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00:04:03,266 --> 00:04:07,761
THIS ALLOWS FOR EASY INSPECTION
OF THE LAMINATE AS IT CURES.
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00:04:10,256 --> 00:04:12,924
IN A PRESSURIZED OVEN
KNOWN AS AN AUTOCLAVE,
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00:04:12,926 --> 00:04:17,287
THE FIBROUS CHASSIS MATERIAL
CURES AT 248 DEGREES,
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00:04:17,289 --> 00:04:20,249
FORCING THE MATS TO RELEASE
THEIR IMPREGNATED RESIN.
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00:04:22,878 --> 00:04:26,739
AN INJECTOR PUMP USES HOSES
TO VACUUM OUT THE AIR,
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00:04:26,741 --> 00:04:30,109
THEN PRESSURIZES THE VESSEL
WITH INERT GAS.
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00:04:32,571 --> 00:04:34,764
FOR A 12-HOUR SOAK PERIOD,
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00:04:34,766 --> 00:04:38,367
THE AUTOCLAVE WILL USE HEAT
AND HIGH CONSOLIDATION PRESSURE
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TO CURE THE CARBON FIBER SHEETS
ONTO THE MOLD.
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00:04:41,765 --> 00:04:43,957
AFTER THE SOAK PERIOD,
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00:04:43,959 --> 00:04:46,159
A COOLING CYCLE
BRINGS THE TEMPERATURE DOWN,
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00:04:46,161 --> 00:04:50,088
DEPRESSURIZES THE VESSEL,
AND STOPS THE GAS.
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00:04:50,090 --> 00:04:53,250
ONCE IT'S COMPLETE,
THE TECHNICIANS
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REMOVE THE CHASSIS COMPONENTS
FROM THE MOLDS.
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00:04:58,516 --> 00:05:01,242
THE CHASSIS STILL NEEDS WORK.
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00:05:01,244 --> 00:05:03,769
IN THE FINISHING CHAMBER,
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00:05:03,771 --> 00:05:06,906
A ROBOTIC DRILL PRESS
PIERCES HOLES IN THE CHASSIS
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00:05:06,908 --> 00:05:09,668
FOR THE CAR'S
VARIOUS COMPONENTS.
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00:05:15,067 --> 00:05:17,259
NEXT, THE CHASSIS IS SUBJECTED
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00:05:17,261 --> 00:05:21,254
TO AN AGE-OLD NONDESTRUCTIVE
TEST USING A TAP HAMMER.
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00:05:22,525 --> 00:05:27,386
THIS EXAMINATION VERIFIES
NEAR-SURFACE DELIMITATIONS.
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00:05:29,815 --> 00:05:32,608
AN ACOUSTIC TRANSDUCER
CHECKS FOR LAMINATION QUALITY
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00:05:32,610 --> 00:05:35,745
THAT IS INVISIBLE
TO THE NAKED EYE.
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00:05:37,941 --> 00:05:41,300
A STERILE GEL COUPLING
PROVIDES AN ACOUSTIC SIGNAL
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00:05:41,302 --> 00:05:43,703
BETWEEN
THE ULTRASOUND TRANSDUCER
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00:05:43,705 --> 00:05:46,698
AND THE INSPECTION AREA.
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00:05:46,700 --> 00:05:49,760
THE TRANSDUCER SENDS AND
RECEIVES REFLECTIVE WAVE FORMS
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00:05:49,762 --> 00:05:52,488
TO DETECT IMPERFECTIONS.
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00:05:52,490 --> 00:05:56,917
THEIR INTENSITY AND DISTANCE ARE
SENT TO THE DIAGNOSTIC DISPLAY.
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00:05:56,919 --> 00:05:59,052
IN A LARGER SECTION
OF THE FACTORY,
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00:05:59,054 --> 00:06:01,915
PRODUCTION SPECIALISTS
PREPARE THE CHASSIS UNITS
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00:06:01,917 --> 00:06:04,383
FOR ENGINE PARTS AND MORE.
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00:06:04,385 --> 00:06:07,312
WITH THE AID OF A SERVICE
CONSOLE AND TORQUE WRENCH,
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00:06:07,314 --> 00:06:10,506
A TECHNICIAN INSTALLS
CUSTOM ALUMINUM MOUNTING INSERTS
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00:06:10,508 --> 00:06:12,935
IN PREDRILLED OPENINGS.
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00:06:15,472 --> 00:06:18,465
THE SUPPORT BRACKET WILL LINK
SUSPENSION CONTROL ARMS
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00:06:18,467 --> 00:06:20,201
TO THE ENGINE FRAME.
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00:06:26,859 --> 00:06:29,485
THESE SUPPORT UNITS
ARE MADE FROM CAST ALUMINUM.
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00:06:29,487 --> 00:06:32,154
THEY SECURE THE ATTACHMENT
OF THE DRIVETRAIN
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00:06:32,156 --> 00:06:34,482
AND THE SUSPENSION
TO THE CHASSIS.
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00:06:34,484 --> 00:06:38,278
THE CARBON FIBER AIR BOXES THAT
FEED THE V-8 ENGINE CLEAN AIR
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00:06:38,280 --> 00:06:39,880
ARE PART OF THE CHASSIS.
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00:06:39,882 --> 00:06:41,607
THIS DESIGN FEATURE IS BOTH
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00:06:41,609 --> 00:06:44,209
ENERGY-EFFICIENT
AND A SPACE SAVER.
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00:06:50,099 --> 00:06:53,559
Narrator: THE PORSCHE
918 SPYDER'S V-8 ENGINE
109
00:06:53,561 --> 00:06:56,420
IS COUPLED
TO DYNAMIC HYBRID MODULES.
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00:06:56,422 --> 00:06:59,023
THEY NOT ONLY ALLOW THE CAR
TO OPERATE ELECTRICALLY,
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00:06:59,025 --> 00:07:01,317
THEY ALSO CONVERT
KINETIC BRAKING ENERGY
112
00:07:01,319 --> 00:07:04,246
INTO REUSABLE ELECTRICITY.
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00:07:05,849 --> 00:07:07,783
ASSEMBLING A HYBRID MODULE
114
00:07:07,785 --> 00:07:10,844
STARTS WITH A MAGNET
AC SYNCHRONOUS MOTOR
115
00:07:10,846 --> 00:07:13,639
MADE UP OF A STATOR AND A ROTOR.
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00:07:15,376 --> 00:07:16,867
THE STATOR CONSISTS OF
117
00:07:16,869 --> 00:07:19,470
WOUND CONDUCTORS
AND ARMATURE FRAMEWORK,
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00:07:19,472 --> 00:07:22,131
SELECT SMALL COILS
WITH COPPER WINDING WIRES
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00:07:22,133 --> 00:07:24,759
ATTACHED TO
THE CIRCULAR ARMATURE.
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00:07:26,463 --> 00:07:29,255
EACH COIL MOUNTS
ONTO THE LAMINATION STACK,
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00:07:29,257 --> 00:07:32,984
WHICH INCLUDES THE STATOR
AND ROTOR CORE.
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00:07:32,986 --> 00:07:36,746
EVERY COIL IS MADE OF 50
WINDINGS OF COPPER WIRE,
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00:07:36,748 --> 00:07:39,816
PLASTIC END CAPS,
AND ISOLATION PAPER.
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00:07:41,145 --> 00:07:44,939
EACH COIL AUTOMATICALLY BECOMES
PART OF THE ROTATED STACK.
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00:07:44,941 --> 00:07:47,541
THE COILS MOUNT PRECISELY
TO THE STACK
126
00:07:47,543 --> 00:07:49,802
TO GENERATE
THE NECESSARY CHARGE.
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00:07:49,804 --> 00:07:52,605
WHEN COMPLETE,
THE LAMINATION STACK
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00:07:52,607 --> 00:07:55,500
CONSISTS OF
OVER 200 SHEETS OF METAL.
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00:07:59,898 --> 00:08:03,825
THE ARMATURE MOVES SLOWLY
INTO A BRAZING STATION.
130
00:08:03,827 --> 00:08:06,086
COPPER WIRE ENDS JOIN
THE INNER CONNECTORS
131
00:08:06,088 --> 00:08:09,089
THROUGH A HIGH-TEMPERATURE
FUSION PROCESS.
132
00:08:11,652 --> 00:08:14,178
THE ELECTRIC INTERCONNECTION
OF THE COILS
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IS ESTABLISHED BY BRAZING THE
TWO COPPER WIRES OF EACH COIL
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AT ALMOST 800 DEGREES.
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00:08:22,171 --> 00:08:24,639
PLASMA-ACTIVATED SILICONE
IS APPLIED
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00:08:24,641 --> 00:08:27,467
TO SECURELY INSULATE
THE INNER CONNECTION.
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00:08:27,469 --> 00:08:29,069
TO ENSURE ITS COHESION,
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00:08:29,071 --> 00:08:32,330
AN AUTOMATED DEVICE DELIVERS
LOW-TEMPERATURE PLASMA,
139
00:08:32,332 --> 00:08:35,092
CREATING A THERMOPLASTIC LAYER.
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00:08:36,862 --> 00:08:40,389
THIS IS THE SILICONE
IN ITS LIQUID STATE.
141
00:08:40,391 --> 00:08:45,686
THE NEXT PART OF THE PROCESS
IS CALLED TRICKLE IMPREGNATION.
142
00:08:45,688 --> 00:08:50,208
THE ARMATURE REVOLVES ON
AN AUTO-CENTERING CHUCK.
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00:08:50,210 --> 00:08:53,077
AS IT ROTATES,
A SERIES OF DRIPPERS
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00:08:53,079 --> 00:08:56,840
APPLY INSULATING RESIN TO THE
WINDINGS AT CONTROLLED RATES.
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00:09:03,232 --> 00:09:06,166
IN THE FINAL STAGES
OF THE MOTOR'S ASSEMBLY,
146
00:09:06,168 --> 00:09:09,227
THE ARMATURE, THE ELECTRIC
METAL SHEETS, AND COILS
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00:09:09,229 --> 00:09:11,555
MOUNT ONTO A BASE CARRIER.
148
00:09:11,557 --> 00:09:14,091
ONCE THEY LOCK INTO POSITION,
149
00:09:14,093 --> 00:09:18,320
THE AIR-GUIDE FRAME
LOWERS INTO THE ARMATURE.
150
00:09:18,322 --> 00:09:20,848
THE OUTER FRAME AIDS
IN THE AIR VENTILATION PATHS
151
00:09:20,850 --> 00:09:25,078
BETWEEN PARTS AND SOUNDPROOF
ENCLOSURE DURING OPERATION.
152
00:09:29,977 --> 00:09:33,003
THE CURRENT-CONNECTING
SLIP RINGS AND COVER
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00:09:33,005 --> 00:09:37,032
COMPLETES THE MANUFACTURING
OF THE STATOR UNIT.
154
00:09:40,529 --> 00:09:44,524
A SMALL CEILING ROBOT ACCURATELY
POSITIONS AND DISPENSES RESIN
155
00:09:44,526 --> 00:09:46,592
ONTO THE ROTOR'S ENCASEMENT.
156
00:09:46,594 --> 00:09:50,221
IT CAN CONTROL ALL ASPECTS
OF APPLICATION PARAMETERS
157
00:09:50,223 --> 00:09:53,783
SUCH AS FLUID FLOW
AND SPEED PROPORTIONAL CONTROL.
158
00:09:55,879 --> 00:09:58,547
ONE AT A TIME,
A SPECIALIST PLACES MAGNETS
159
00:09:58,549 --> 00:10:03,076
INTO THE MAIN CLUTCH
OF A POSITIONING JIG.
160
00:10:03,078 --> 00:10:06,938
THE JIG'S COMPRESSION VICE
ALIGNS AND FIRMLY ATTACHES
161
00:10:06,940 --> 00:10:10,668
THE MAGNET TO THE HEAVY-DUTY
RESIN ON THE ROTOR CASE.
162
00:10:19,562 --> 00:10:21,421
WITHIN AC SYNCHRONOUS MOTORS,
163
00:10:21,423 --> 00:10:24,850
MAGNETIC FIELDS FORM IN BOTH
THE ROTOR AND THE STATOR,
164
00:10:24,852 --> 00:10:27,619
PRODUCING A TORQUE
ON THE MOTOR SHAFT.
165
00:10:30,048 --> 00:10:33,142
THIS IS THE UNION
OF THE ROTOR AND THE STATOR.
166
00:10:35,046 --> 00:10:37,171
THIS BEARING BRACKET
CREATES A CLEARANCE GAP
167
00:10:37,173 --> 00:10:38,972
BETWEEN THE TWO ELEMENTS.
168
00:10:38,974 --> 00:10:41,266
THE BRACKET
MAINTAINS EVEN SPACING
169
00:10:41,268 --> 00:10:45,330
BETWEEN THE PARTS THROUGH
THE 360 DEGREES OF ROTATION.
170
00:10:49,528 --> 00:10:54,256
THE SPECIALIST ADDS THE HOUSING,
POWER TERMINAL, AND CABLES.
171
00:10:54,258 --> 00:10:56,324
THE TERMINAL MANAGES
THE POWER FIELD
172
00:10:56,326 --> 00:11:00,220
AS ELECTRICITY FLOWS FROM THE
BATTERY TO THE ELECTRIC MOTOR.
173
00:11:00,222 --> 00:11:02,213
LIKE MOST ELECTRIC
AND HYBRID CARS
174
00:11:02,215 --> 00:11:04,617
WITH A HIGH-VOLTAGE
ELECTRICAL SYSTEM,
175
00:11:04,619 --> 00:11:06,944
CABLES AND CONNECTORS
ARE COLORED BRIGHT ORANGE
176
00:11:06,946 --> 00:11:09,013
FOR SAFETY.
177
00:11:15,888 --> 00:11:18,915
Narrator:
THE PORSCHE 918 SPYDER'S
178
00:11:18,917 --> 00:11:24,279
4.6-LITER, 8-CYLINDER ENGINE
PRODUCES 608 HORSEPOWER,
179
00:11:24,281 --> 00:11:26,206
THE HIGHEST POWER OUTPUT
PER LITER
180
00:11:26,208 --> 00:11:30,002
OF ANY PORSCHE
NATURALLY-ASPIRATED ENGINE.
181
00:11:32,873 --> 00:11:35,332
ON THE COMBUSTION ENGINE'S
ASSEMBLY LINE,
182
00:11:35,334 --> 00:11:38,160
THE ENGINE BLOCK SHIFTS
TO A LIGHTWEIGHT TROLLEY.
183
00:11:38,162 --> 00:11:40,429
IT USES
A VERTICALLY-MOUNTED SLEW RING,
184
00:11:40,431 --> 00:11:44,492
WHICH CONNECTS TO A BRACKET ON
THE BLOCK'S CRANKSHAFT HOUSING.
185
00:11:44,494 --> 00:11:47,753
WHEN THE ENGINE BLOCK
LOCKS INTO PLACE,
186
00:11:47,755 --> 00:11:52,817
IT CAN ROTATE 360 DEGREES,
ALLOWING FOR COMPLETE ACCESS.
187
00:11:55,714 --> 00:11:58,240
THE CRANKSHAFT
AND ITS CONTAINMENT CLAMPS
188
00:11:58,242 --> 00:11:59,441
ARE LOCKED IN PLACE
189
00:11:59,443 --> 00:12:02,243
TO KEEP THE REVOLVING
ENGINE PART IN POSITION.
190
00:12:02,245 --> 00:12:03,770
THEN A TECHNICIAN USES
191
00:12:03,772 --> 00:12:06,399
A MICROCHIP-CONTROLLED
TORQUE WRENCH
192
00:12:06,401 --> 00:12:08,968
TO TEST THE JOINTS,
ADJUST THE TORQUE,
193
00:12:08,970 --> 00:12:11,462
AND EXAMINE THE ENGINE LIMITS.
194
00:12:21,258 --> 00:12:23,182
THEY USE A DIAL BORE GAUGE
195
00:12:23,184 --> 00:12:27,179
TO ASSESS THE INSIDE DIAMETER
OF CONNECTING ROD BOLTS.
196
00:12:31,276 --> 00:12:33,877
CYLINDER HEAD BOLTS
ARE THE CONNECTING ELEMENTS
197
00:12:33,879 --> 00:12:36,472
BETWEEN THE ENGINE BLOCK,
CYLINDER HEAD GASKET,
198
00:12:36,474 --> 00:12:38,340
AND CYLINDER HEAD.
199
00:12:38,342 --> 00:12:41,468
THE BOLT-TIGHTENING FORCE
IS AN IMPORTANT FACTOR
200
00:12:41,470 --> 00:12:44,530
FOR THE MUTUAL SEALING
OF THE COMBUSTION CHAMBER,
201
00:12:44,532 --> 00:12:48,193
OIL AND COOLANT CHANNELS,
AS WELL AS THE AMBIENT AIR.
202
00:12:52,891 --> 00:12:56,752
NEXT, ALREADY-INSTALLED CAMSHAFT
BRACKETS LOCK INTO POSITION
203
00:12:56,754 --> 00:13:00,314
WITH THEIR PROPER FASTENING
BOLTS BY A POWER DRIVER.
204
00:13:07,940 --> 00:13:10,241
PIPING KNOWN AS
FUEL INJECTION RAIL
205
00:13:10,243 --> 00:13:12,434
IS INSTALLED
WITH A TORQUE WRENCH.
206
00:13:12,436 --> 00:13:15,171
THE RAIL SUPPLIES
PRESSURIZED FUEL
207
00:13:15,173 --> 00:13:18,299
TO INDIVIDUAL INJECTORS
WITHIN THE ENGINE.
208
00:13:22,798 --> 00:13:26,325
THE ENGINE'S HANDMADE
WIRING HARNESS IS CRUCIAL.
209
00:13:28,262 --> 00:13:31,121
THE WIRES ARE BOUND TOGETHER
BY CABLE TIES
210
00:13:31,123 --> 00:13:33,915
TO SAVE SPACE
AND MINIMIZE THE EFFECTS
211
00:13:33,917 --> 00:13:37,211
OF VIBRATIONS, ABRASIONS,
AND MOISTURE.
212
00:13:41,075 --> 00:13:42,808
THE ALUMINUM ENGINE BLOCK,
213
00:13:42,810 --> 00:13:45,203
FINALIZED
WITH THE REAR ELECTRIC MOTOR,
214
00:13:45,205 --> 00:13:48,799
IS READY TO JOIN
THE 7-SPEED TRANSMISSION BLOCK.
215
00:13:55,766 --> 00:13:58,758
NEXT, A SPECIALIST
PLACES THE 7-SPEED GEARBOX
216
00:13:58,760 --> 00:14:02,020
INTO POSITION WHERE IT WILL JOIN
THE DRIVESHAFT.
217
00:14:02,022 --> 00:14:06,951
THE GEARBOX PROVIDES THE
CONTROLLED APPLICATION OF POWER
218
00:14:06,953 --> 00:14:09,512
TO THE WHEELS.
219
00:14:09,514 --> 00:14:13,048
THEN THE DRIVESHAFT
AND LINKAGE ARMS ARE CONNECTED
220
00:14:13,050 --> 00:14:16,644
TO THE GEARBOX OF
THE FRONT ELECTRIC DRIVE SYSTEM.
221
00:14:16,646 --> 00:14:19,506
THE SUSPENSION CONTROL ARMS
ARE INSTALLED.
222
00:14:19,508 --> 00:14:22,033
THEY MANAGE THE MOTION
OF THE WHEELS
223
00:14:22,035 --> 00:14:25,170
AS THE CAR REBOUNDS OR DROOPS
ON THE ROAD.
224
00:14:26,732 --> 00:14:29,600
NEXT IS THE
AIR-CONDITIONING COMPRESSOR,
225
00:14:29,602 --> 00:14:32,194
THE HEART OF THE A.C. SYSTEM.
226
00:14:32,196 --> 00:14:36,857
IT TAKES THE REFRIGERANT GAS
AND PRESSURIZES IT TO COOL AIR.
227
00:14:36,859 --> 00:14:40,486
IT'S RUN BY AN ENGINE BELT AND
ELECTRICALLY-OPERATED CLUTCH.
228
00:14:44,184 --> 00:14:47,611
A WORKER ADDS
THE SUSPENSION SHOCKS.
229
00:14:47,613 --> 00:14:50,080
THEY ARE PART OF
AN ADAPTIVE SHOCK ABSORBER
230
00:14:50,082 --> 00:14:52,207
AND REAR-AXLE STEERING SYSTEM,
231
00:14:52,209 --> 00:14:55,602
WHICH PROVIDES ELECTROMECHANICAL
WHEEL ADJUSTMENT.
232
00:14:55,604 --> 00:14:58,205
WITH A TORQUE WRENCH,
233
00:14:58,207 --> 00:15:01,533
A SPECIALIST INSTALLS
AND FASTENS THE FINAL BOLTS
234
00:15:01,535 --> 00:15:04,128
TO COMPLETE THE RUNNING GEAR.
235
00:15:09,293 --> 00:15:11,619
IN PURELY ELECTRIC MODE,
236
00:15:11,621 --> 00:15:16,082
THE 918 SPYDER ATTAINS
ZERO TO 60 IN SIX SECONDS
237
00:15:16,084 --> 00:15:19,577
AND A TOP SPEED
OF 93 MILES PER HOUR.
238
00:15:19,579 --> 00:15:22,114
DEFINITELY ELECTRIFYING.
239
00:15:29,039 --> 00:15:32,298
Narrator:
THE 918 SPYDER'S ARRANGEMENT
OF INNOVATIVE DESIGN
240
00:15:32,300 --> 00:15:35,995
AND HYBRID TECHNOLOGY
RIVALS ANY RACECAR.
241
00:15:35,997 --> 00:15:37,529
WITH REVOLUTIONARY COMPONENTS
242
00:15:37,531 --> 00:15:39,590
AND HIGH-RECUPERATION
PERFORMANCE,
243
00:15:39,592 --> 00:15:43,186
IT IS THE SUPERCAR
OF THE FUTURE.
244
00:15:44,456 --> 00:15:46,122
ON AN ENGINE CRADLE DOLLY,
245
00:15:46,124 --> 00:15:48,449
TECHNICIANS BRING
THE CARRIER UNIT
246
00:15:48,451 --> 00:15:50,185
TO THE DRIVE-SYSTEM ELEMENTS.
247
00:15:50,187 --> 00:15:54,547
THIS INCLUDES THE V-8 ENGINE,
AN ELECTRIC DRIVE, AND GEARBOX.
248
00:15:54,549 --> 00:15:57,876
TUBING TO THE AIR FILTER
AND THE ENGINE'S EXHAUST
249
00:15:57,878 --> 00:16:00,204
ARE SUBSEQUENTLY FIT.
250
00:16:01,940 --> 00:16:05,000
THE CARRIER UNIT HAS
THREE SPECIFIC MOUNTING POINTS
251
00:16:05,002 --> 00:16:06,401
FOR THE DRIVE SYSTEM --
252
00:16:06,403 --> 00:16:09,430
TWO POINTS IN THE FRONT
OF THE CARBON FIBER UNIT
253
00:16:09,432 --> 00:16:12,158
AND ANOTHER IN THE REAR SECTION.
254
00:16:12,160 --> 00:16:15,820
IN THE FRONT, TWO LIGHTWEIGHT
GRAY CAST IRON MOUNTING BRACKETS
255
00:16:15,822 --> 00:16:20,283
ARE ATTACHED WITH A POWER DRIVER
TO HOLD THE MOTOR IN POSITION.
256
00:16:25,249 --> 00:16:26,647
THE OVAL-SHAPED AIR FILTERS
257
00:16:26,649 --> 00:16:29,242
PROTECT THE FUEL-INJECTION
AND AIR-INTAKE SYSTEMS
258
00:16:29,244 --> 00:16:32,938
FROM DUST AND DEBRIS THAT CAN
BE SUCKED IN DURING OPERATION.
259
00:16:37,569 --> 00:16:39,970
TECHNICIANS CONNECT
THE POWER TERMINAL
260
00:16:39,972 --> 00:16:43,900
AND HIGH-VOLTAGE CABLES
TO THE LITHIUM-ION BATTERY.
261
00:16:46,663 --> 00:16:50,123
THE BATTERY THEN SHUTTLES
TO A FINISHED MONOCOQUE.
262
00:16:50,125 --> 00:16:52,917
WITH THE ASSISTANCE
OF AN ELECTRIC DRIVE STACKER,
263
00:16:52,919 --> 00:16:56,054
THE MONOCOQUE SHELL
HOVERS ABOVE THE BATTERY.
264
00:17:00,745 --> 00:17:03,612
THE POWER SOURCE
RAISES TO ITS NEW HOME
265
00:17:03,614 --> 00:17:06,774
BELOW THE FUEL TANK
AND BEHIND THE COCKPIT.
266
00:17:08,611 --> 00:17:12,004
THE LIQUID-COOLED 6.8-KILOWATT-
AN-HOUR BATTERY PACK
267
00:17:12,006 --> 00:17:14,732
HAS 312 INDIVIDUAL CELLS
268
00:17:14,734 --> 00:17:18,494
AND DISCHARGES 220 KILOWATTS
OF PEAK POWER.
269
00:17:18,496 --> 00:17:20,763
TWO TECHNICIANS INSTALL
270
00:17:20,765 --> 00:17:24,226
THE 18-GALLON ALUMINUM
HYBRID-PRESSURE FUEL TANK.
271
00:17:24,228 --> 00:17:27,888
THE TANK SITS INSIDE
THE MONOCOQUE BEHIND THE SEATS.
272
00:17:33,913 --> 00:17:35,512
AFTER THE FUEL CELL,
273
00:17:35,514 --> 00:17:38,574
THEY ADD A LOW-MASS
ALUMINUM HEAT-RESISTANT PANEL
274
00:17:38,576 --> 00:17:41,177
ALONG WITH PROTECTED CABLING.
275
00:17:41,179 --> 00:17:44,705
THIS ALUMINUM SHELL
REDUCES THE TRANSMISSION OF HEAT
276
00:17:44,707 --> 00:17:47,133
AND VIBRATIONS TO THE COCKPIT.
277
00:17:48,970 --> 00:17:51,396
NEXT, TECHNICIANS
ADD THE CARRIER UNIT
278
00:17:51,398 --> 00:17:53,665
MOUNTED
WITH THE ENGINE COMPONENTS
279
00:17:53,667 --> 00:17:55,926
TO THE MONOCOQUE
COCKPIT SECTION.
280
00:17:55,928 --> 00:17:59,655
TECHNICIANS USE TORQUE WRENCHES
TO ADJUST THE BOLTS THAT JOIN
281
00:17:59,657 --> 00:18:03,117
THE INTERLOCKING CARBON FIBER
RESIN POLYMER STRUCTURES
282
00:18:03,119 --> 00:18:04,385
TOGETHER.
283
00:18:08,950 --> 00:18:11,942
THIS IS THE EXHAUST SYSTEM
WITH TOP PIPES.
284
00:18:11,944 --> 00:18:15,939
IT IS MADE OF EXTREME HEAT
AND PRESSURE-RESISTANT STEEL.
285
00:18:15,941 --> 00:18:17,940
THE SYSTEM IS ALSO WRAPPED
286
00:18:17,942 --> 00:18:21,536
IN THIN-WALLED HEAT-
AND NOISE-BARRIER SHIELDS.
287
00:18:21,538 --> 00:18:25,165
BELOW THE EXHAUST
IS A TEMPORARY TARPAULIN SHEET
288
00:18:25,167 --> 00:18:28,527
TO PROTECT THE ENGINE CRADLE
AND OTHER PARTS.
289
00:18:31,758 --> 00:18:33,690
A TECHNICIAN
ATTACHES THE RUNNING GEAR
290
00:18:33,692 --> 00:18:35,484
TO THE REAR SECTION
OF THE CHASSIS.
291
00:18:35,486 --> 00:18:39,781
A LIFT ELEVATES THE DRIVETRAIN,
THE SUSPENSION SYSTEM,
292
00:18:39,783 --> 00:18:42,183
AND BRAKING UNITS INTO POSITION.
293
00:18:46,114 --> 00:18:48,973
THE RUNNING GEAR
IS BOLTED TO THE CARRIER UNIT
294
00:18:48,975 --> 00:18:50,976
USING A POWER DRIVER.
295
00:18:58,001 --> 00:19:01,395
HERE, THE CAR'S STYLISH SILLS
MEET THE CHASSIS,
296
00:19:01,397 --> 00:19:04,424
INCLUDING THE RIGHT PANEL
WITH THE FUEL CAP.
297
00:19:06,727 --> 00:19:08,319
USING A FEELER GAGE,
298
00:19:08,321 --> 00:19:10,788
THE MEASUREMENT OF THE CLEARANCE
IN GAP WIDTH
299
00:19:10,790 --> 00:19:15,085
BETWEEN THE TWO PARTS
IS TAKEN FOR ACCURACY.
300
00:19:15,087 --> 00:19:18,480
NEXT, MORE ULTRALIGHT
CARBON FIBER PANELS
301
00:19:18,482 --> 00:19:21,275
ARE ADDED TO THE BODY
OF THE CAR.
302
00:19:21,277 --> 00:19:23,743
FOR THOSE WHO WANT TO KEEP THE
CAR AS LIGHTWEIGHT AS POSSIBLE,
303
00:19:23,745 --> 00:19:26,939
A PRICY WEIGHT-REDUCING COATING
IS AVAILABLE
304
00:19:26,941 --> 00:19:29,366
INSTEAD OF METALLIC PAINT.
305
00:19:29,368 --> 00:19:31,769
DURING THE FINAL STAGES
OF ASSEMBLY,
306
00:19:31,771 --> 00:19:34,430
EACH CAR'S VARIOUS
AESTHETIC COMPONENTS,
307
00:19:34,432 --> 00:19:36,957
INCLUDING
THE EXTERIOR ACCESSORIES,
308
00:19:36,959 --> 00:19:40,820
LIGHTS, AND INTERIOR TRIM
ARE PAINSTAKINGLY FIT.
309
00:19:40,822 --> 00:19:43,289
THIS IS ONE
OF VERY FEW SUPERCARS
310
00:19:43,291 --> 00:19:46,918
THAT EMPLOYS A MODERN
YET HANDCRAFTED PRODUCTION LINE.
311
00:19:48,713 --> 00:19:50,314
A SPECIALIST ATTACHES
312
00:19:50,316 --> 00:19:54,643
THE ADJUSTABLE, AERODYNAMIC,
THREE-SETTING RETRACTABLE WING
313
00:19:54,645 --> 00:19:58,438
AND MEASURES IT WITH A FEELER
GAGE FOR A PRECISION FIT.
314
00:19:58,440 --> 00:20:00,933
HE ALSO CHECKS THE HYDRAULIC
OPERATION OF THE WING
315
00:20:00,935 --> 00:20:02,902
TO ENSURE
THAT THE MECHANICAL LINKAGE,
316
00:20:02,904 --> 00:20:05,596
ADJUSTING CYLINDERS,
AND GUIDANCE
317
00:20:05,598 --> 00:20:08,332
ALL OPERATE WITHIN
DESIRABLE LIMITS.
318
00:20:08,334 --> 00:20:13,188
HE CALCULATES THE GAP WIDTH TO
ENSURE THE FIT OF THE SPOILER.
319
00:20:13,190 --> 00:20:15,323
TECHNICIANS INSTALL
320
00:20:15,325 --> 00:20:18,252
THE STAINLESS-STEEL
EXHAUST SYSTEM COVER PLATE.
321
00:20:19,855 --> 00:20:23,349
THIS COCKPIT IS CLEARLY IMAGINED
WITH THE DRIVER IN MIND.
322
00:20:23,351 --> 00:20:27,077
THE CONTROLS ARE GROUPED AROUND
A MULTIFUNCTION STEERING WHEEL,
323
00:20:27,079 --> 00:20:30,740
MERGING WITH THREE LARGE,
ROUND INSTRUMENT PANELS.
324
00:20:30,742 --> 00:20:33,209
IT IS POLISHED OFF
WITH AN INFOTAINMENT BLOCK
325
00:20:33,211 --> 00:20:35,537
IN AN ELEVATED CENTER CONSOLE.
326
00:20:37,899 --> 00:20:41,034
AS A PLUG-IN HYBRID,
THIS AUTOMOBILE COMBINES
327
00:20:41,036 --> 00:20:44,296
THE DRIVING DYNAMICS
OF A PERFORMANCE RACECAR
328
00:20:44,298 --> 00:20:48,425
WITH A LOW THIRST FOR FUEL,
MAKING THE DRIVE FUN AND LONG.
329
00:20:48,427 --> 00:20:51,153
IF THINGS
ARE KEPT PURELY ELECTRIC,
330
00:20:51,155 --> 00:20:54,715
A DRIVE RANGE OF 18 MILES
IS ACHIEVABLE.
331
00:20:54,717 --> 00:20:58,778
TWO REMOVABLE ROOF PANELS
OFFER A PREMIUM VIEW.
332
00:20:58,780 --> 00:21:00,846
CONTROL PANELS
FOR CLIMATE CONTROL,
333
00:21:00,848 --> 00:21:02,774
WING ADJUSTMENT,
AND COMMUNICATIONS
334
00:21:02,776 --> 00:21:06,177
CONNECT THE DRIVER TO THE CAR.
335
00:21:06,179 --> 00:21:10,039
NO LONGER JUST A CONCEPT CAR
MADE FOR SHOWROOMS,
336
00:21:10,041 --> 00:21:13,335
THE PORSCHE 918 SPYDER
IS A LIVING DREAM.
337
00:21:13,337 --> 00:21:16,129
IT CONTRIBUTES TO
A LONG-STANDING TRADITION
338
00:21:16,131 --> 00:21:18,264
OF EXCEPTIONAL SUPERCARS.
339
00:21:18,266 --> 00:21:21,860
A SPORTS CAR UNLIKE ANY OTHER,
IT BREAKS THE BOUNDARIES
340
00:21:21,862 --> 00:21:25,322
OF STYLE, PERFORMANCE,
AND TECHNOLOGY,
341
00:21:25,324 --> 00:21:27,617
DEFIANT IN DESIGN
TO INSPIRE GENERATIONS
342
00:21:27,619 --> 00:21:32,080
OF ENGINEERS, ENTHUSIASTS,
AND HYBRID SUPERCARS TO COME.
28067
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