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These are the user uploaded subtitles that are being translated: 1 00:00:01,735 --> 00:00:03,135 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,137 --> 00:00:05,762 THE PORSCHE 918 SPYDER. 3 00:00:05,764 --> 00:00:08,291 IT'S MEAN, RARE, AND ECO-GREEN. 4 00:00:08,293 --> 00:00:11,360 -- Captions by VITAC -- www.vitac.com 5 00:00:11,362 --> 00:00:14,322 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,917 --> 00:00:27,511 PORSCHE'S 918 SPYDER HYBRID COMBINES THE ESSENTIALS 7 00:00:27,513 --> 00:00:31,773 OF MOTOR RACING WITH SUPERB FUEL ECONOMY. 8 00:00:31,775 --> 00:00:34,902 ORIGINALLY UNVEILED AS A CONCEPT CAR IN 2010, 9 00:00:34,904 --> 00:00:38,997 IT'S THE NEWEST BLUEPRINT FOR FUTURE PORSCHE SPORTS CARS. 10 00:00:38,999 --> 00:00:42,793 THE AUTOMAKERS' DESIGN TEAM STARTED WITH A CLEAN SLATE, 11 00:00:42,795 --> 00:00:46,656 NO CONSTRAINTS, OR COMPROMISES. 12 00:00:46,658 --> 00:00:51,119 THE GOAL WAS TO DEVELOP A HIGHLY FUEL-EFFICIENT SUPERCAR, 13 00:00:51,121 --> 00:00:55,282 SMARTLY BUILT AROUND A POWERFUL HYBRID DRIVE SYSTEM. 14 00:00:55,284 --> 00:01:00,746 THE 918 USES THE SAME V-8 ENGINE AS THE RS SPYDER RACECAR. 15 00:01:00,748 --> 00:01:03,139 THE ENGINE WAS DEVELOPED EXCLUSIVELY 16 00:01:03,141 --> 00:01:06,536 FOR THE ANNUAL 24-HOUR RACE IN LE MANS, FRANCE. 17 00:01:09,473 --> 00:01:13,434 IN 2013, THE 918 SPYDER HIT THE STREETS 18 00:01:13,436 --> 00:01:15,829 AS A LIMITED-PRODUCTION CAR. 19 00:01:15,831 --> 00:01:19,558 ITS APPEARANCE IS BEYOND ANY DRIVER'S WILDEST DREAM. 20 00:01:19,560 --> 00:01:22,085 THIS SUPERCAR HAS A ROLLING CHASSIS, 21 00:01:22,087 --> 00:01:25,755 A VEHICLE THAT CAN BE DRIVEN WITHOUT A STYLISTIC SHELL. 22 00:01:25,757 --> 00:01:29,351 THIS IS ONE OF THE AUTOMAKERS' ONGOING TRADITIONS. 23 00:01:35,643 --> 00:01:39,103 PRODUCTION STARTS WITH THE ASSEMBLY OF THE CHASSIS. 24 00:01:39,105 --> 00:01:40,571 IN THE FABRIC SHOP, 25 00:01:40,573 --> 00:01:42,799 MASSIVE SHEETS OF PREPREG COMPOSITE 26 00:01:42,801 --> 00:01:45,401 CARBON-FIBER-REINFORCED POLYMER 27 00:01:45,403 --> 00:01:48,463 ARE CUT INTO WIDE PATTERN PIECES WITH AN AUTOMATIC CUTTER. 28 00:01:48,465 --> 00:01:51,725 THE CUTTER USES A HIGH-SPEED OSCILLATING BLADE, 29 00:01:51,727 --> 00:01:55,521 WHICH ALTERNATES AT AROUND 18,000 STROKES PER MINUTE. 30 00:01:55,523 --> 00:02:00,350 THE SYSTEM ALSO VACUUMS AWAY ANY DUST DURING CUTTING. 31 00:02:00,352 --> 00:02:02,978 THE SHEETS ARE FIT INTO MOLDS 32 00:02:02,980 --> 00:02:06,015 THAT PRODUCE A TWO-PART INTERLOCKING CHASSIS, 33 00:02:06,017 --> 00:02:08,876 A MONOCOQUE, AND A UNIT CARRIER. 34 00:02:11,080 --> 00:02:14,274 CARBON-FIBER-REINFORCED POLYMER IS VERY THIN 35 00:02:14,276 --> 00:02:17,302 AND AFFORDS EXTREME TORSIONAL RIGIDITY. 36 00:02:17,304 --> 00:02:22,099 WHEN THE CAR IS COMPLETE, IT WEIGHS JUST UNDER 3,700 POUNDS, 37 00:02:22,101 --> 00:02:25,994 AN INCREDIBLY LOW WEIGHT FOR A HYBRID SPORTS CAR. 38 00:02:27,490 --> 00:02:29,556 THIS ALUMINUM HONEYCOMB LAYER 39 00:02:29,558 --> 00:02:32,919 KEEPS THE CAR'S CHASSIS AT AN EVEN LOWER WEIGHT. 40 00:02:35,489 --> 00:02:37,982 WITH A SMALL OFFSET TOOL, THE SPECIALIST INSTALLS 41 00:02:37,984 --> 00:02:42,011 THE HONEYCOMB SHEETS INTO COMPLEX AREAS. 42 00:02:49,238 --> 00:02:52,864 THIS RED FLUOROPOLYMER RELEASE FILM HAS PERFORATIONS 43 00:02:52,866 --> 00:02:56,193 THAT ALLOW AIR AND EPOXY RESIN TO FLOW THROUGH IT. 44 00:02:56,195 --> 00:02:59,663 THE FILM ALLOWS THE HONEYCOMB CORES AND CARBON FIBER LAYERS 45 00:02:59,665 --> 00:03:01,490 TO BIND TOGETHER. 46 00:03:03,261 --> 00:03:06,921 TECHNICIANS FIT MORE CARBON FIBER SHEETS ONTO THE MOLD, 47 00:03:06,923 --> 00:03:10,683 TRIMMING ANY EXCESS PIECES WITH UTILITY KNIVES. 48 00:03:10,685 --> 00:03:13,878 IN ADDITION TO CARBON-FIBER- REINFORCED PLASTIC, 49 00:03:13,880 --> 00:03:15,813 MAGNESIUM AND ALUMINUM ARE USED 50 00:03:15,815 --> 00:03:20,769 TO KEEP THE CHASSIS WEIGHT DOWN TO 3,615 POUNDS. 51 00:03:24,834 --> 00:03:27,902 REMOVABLE WHITE COVERS ARE FOR DE-MOLDING. 52 00:03:29,564 --> 00:03:31,897 THEY USE PLASTIC BAGS AND SUCTION HOSES 53 00:03:31,899 --> 00:03:35,293 TO SEAL FIBROUS LAYERS ONTO THE MOLD. 54 00:03:37,555 --> 00:03:40,222 PERMEABLE LIGHTWEIGHT POLYESTER SHEETS, 55 00:03:40,224 --> 00:03:41,850 KNOWN AS BREATHER CLOTHS, 56 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. 58 00:03:46,849 --> 00:03:48,448 THE FABRIC ABSORBS EXCESS RESIN 59 00:03:48,450 --> 00:03:50,376 AND ALLOWS AIR TO FLOW FREELY 60 00:03:50,378 --> 00:03:52,444 BETWEEN THE BAG AND THE COMPOSITE 61 00:03:52,446 --> 00:03:55,039 BEFORE IT ENTERS THE AUTOCLAVE. 62 00:03:57,510 --> 00:03:59,468 NEXT, A THICK PLASTIC BAG 63 00:03:59,470 --> 00:04:03,264 CREATES A SECONDARY AIRTIGHT COVER OVER THE MOLD. 64 00:04:03,266 --> 00:04:07,761 THIS ALLOWS FOR EASY INSPECTION OF THE LAMINATE AS IT CURES. 65 00:04:10,256 --> 00:04:12,924 IN A PRESSURIZED OVEN KNOWN AS AN AUTOCLAVE, 66 00:04:12,926 --> 00:04:17,287 THE FIBROUS CHASSIS MATERIAL CURES AT 248 DEGREES, 67 00:04:17,289 --> 00:04:20,249 FORCING THE MATS TO RELEASE THEIR IMPREGNATED RESIN. 68 00:04:22,878 --> 00:04:26,739 AN INJECTOR PUMP USES HOSES TO VACUUM OUT THE AIR, 69 00:04:26,741 --> 00:04:30,109 THEN PRESSURIZES THE VESSEL WITH INERT GAS. 70 00:04:32,571 --> 00:04:34,764 FOR A 12-HOUR SOAK PERIOD, 71 00:04:34,766 --> 00:04:38,367 THE AUTOCLAVE WILL USE HEAT AND HIGH CONSOLIDATION PRESSURE 72 00:04:38,369 --> 00:04:41,763 TO CURE THE CARBON FIBER SHEETS ONTO THE MOLD. 73 00:04:41,765 --> 00:04:43,957 AFTER THE SOAK PERIOD, 74 00:04:43,959 --> 00:04:46,159 A COOLING CYCLE BRINGS THE TEMPERATURE DOWN, 75 00:04:46,161 --> 00:04:50,088 DEPRESSURIZES THE VESSEL, AND STOPS THE GAS. 76 00:04:50,090 --> 00:04:53,250 ONCE IT'S COMPLETE, THE TECHNICIANS 77 00:04:53,252 --> 00:04:56,479 REMOVE THE CHASSIS COMPONENTS FROM THE MOLDS. 78 00:04:58,516 --> 00:05:01,242 THE CHASSIS STILL NEEDS WORK. 79 00:05:01,244 --> 00:05:03,769 IN THE FINISHING CHAMBER, 80 00:05:03,771 --> 00:05:06,906 A ROBOTIC DRILL PRESS PIERCES HOLES IN THE CHASSIS 81 00:05:06,908 --> 00:05:09,668 FOR THE CAR'S VARIOUS COMPONENTS. 82 00:05:15,067 --> 00:05:17,259 NEXT, THE CHASSIS IS SUBJECTED 83 00:05:17,261 --> 00:05:21,254 TO AN AGE-OLD NONDESTRUCTIVE TEST USING A TAP HAMMER. 84 00:05:22,525 --> 00:05:27,386 THIS EXAMINATION VERIFIES NEAR-SURFACE DELIMITATIONS. 85 00:05:29,815 --> 00:05:32,608 AN ACOUSTIC TRANSDUCER CHECKS FOR LAMINATION QUALITY 86 00:05:32,610 --> 00:05:35,745 THAT IS INVISIBLE TO THE NAKED EYE. 87 00:05:37,941 --> 00:05:41,300 A STERILE GEL COUPLING PROVIDES AN ACOUSTIC SIGNAL 88 00:05:41,302 --> 00:05:43,703 BETWEEN THE ULTRASOUND TRANSDUCER 89 00:05:43,705 --> 00:05:46,698 AND THE INSPECTION AREA. 90 00:05:46,700 --> 00:05:49,760 THE TRANSDUCER SENDS AND RECEIVES REFLECTIVE WAVE FORMS 91 00:05:49,762 --> 00:05:52,488 TO DETECT IMPERFECTIONS. 92 00:05:52,490 --> 00:05:56,917 THEIR INTENSITY AND DISTANCE ARE SENT TO THE DIAGNOSTIC DISPLAY. 93 00:05:56,919 --> 00:05:59,052 IN A LARGER SECTION OF THE FACTORY, 94 00:05:59,054 --> 00:06:01,915 PRODUCTION SPECIALISTS PREPARE THE CHASSIS UNITS 95 00:06:01,917 --> 00:06:04,383 FOR ENGINE PARTS AND MORE. 96 00:06:04,385 --> 00:06:07,312 WITH THE AID OF A SERVICE CONSOLE AND TORQUE WRENCH, 97 00:06:07,314 --> 00:06:10,506 A TECHNICIAN INSTALLS CUSTOM ALUMINUM MOUNTING INSERTS 98 00:06:10,508 --> 00:06:12,935 IN PREDRILLED OPENINGS. 99 00:06:15,472 --> 00:06:18,465 THE SUPPORT BRACKET WILL LINK SUSPENSION CONTROL ARMS 100 00:06:18,467 --> 00:06:20,201 TO THE ENGINE FRAME. 101 00:06:26,859 --> 00:06:29,485 THESE SUPPORT UNITS ARE MADE FROM CAST ALUMINUM. 102 00:06:29,487 --> 00:06:32,154 THEY SECURE THE ATTACHMENT OF THE DRIVETRAIN 103 00:06:32,156 --> 00:06:34,482 AND THE SUSPENSION TO THE CHASSIS. 104 00:06:34,484 --> 00:06:38,278 THE CARBON FIBER AIR BOXES THAT FEED THE V-8 ENGINE CLEAN AIR 105 00:06:38,280 --> 00:06:39,880 ARE PART OF THE CHASSIS. 106 00:06:39,882 --> 00:06:41,607 THIS DESIGN FEATURE IS BOTH 107 00:06:41,609 --> 00:06:44,209 ENERGY-EFFICIENT AND A SPACE SAVER. 108 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. 110 00:06:56,422 --> 00:06:59,023 THEY NOT ONLY ALLOW THE CAR TO OPERATE ELECTRICALLY, 111 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. 113 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. 116 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, 118 00:07:19,472 --> 00:07:22,131 SELECT SMALL COILS WITH COPPER WINDING WIRES 119 00:07:22,133 --> 00:07:24,759 ATTACHED TO THE CIRCULAR ARMATURE. 120 00:07:26,463 --> 00:07:29,255 EACH COIL MOUNTS ONTO THE LAMINATION STACK, 121 00:07:29,257 --> 00:07:32,984 WHICH INCLUDES THE STATOR AND ROTOR CORE. 122 00:07:32,986 --> 00:07:36,746 EVERY COIL IS MADE OF 50 WINDINGS OF COPPER WIRE, 123 00:07:36,748 --> 00:07:39,816 PLASTIC END CAPS, AND ISOLATION PAPER. 124 00:07:41,145 --> 00:07:44,939 EACH COIL AUTOMATICALLY BECOMES PART OF THE ROTATED STACK. 125 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. 127 00:07:49,804 --> 00:07:52,605 WHEN COMPLETE, THE LAMINATION STACK 128 00:07:52,607 --> 00:07:55,500 CONSISTS OF OVER 200 SHEETS OF METAL. 129 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 133 00:08:14,180 --> 00:08:17,707 IS ESTABLISHED BY BRAZING THE TWO COPPER WIRES OF EACH COIL 134 00:08:17,709 --> 00:08:20,109 AT ALMOST 800 DEGREES. 135 00:08:22,171 --> 00:08:24,639 PLASMA-ACTIVATED SILICONE IS APPLIED 136 00:08:24,641 --> 00:08:27,467 TO SECURELY INSULATE THE INNER CONNECTION. 137 00:08:27,469 --> 00:08:29,069 TO ENSURE ITS COHESION, 138 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. 140 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. 143 00:08:50,210 --> 00:08:53,077 AS IT ROTATES, A SERIES OF DRIPPERS 144 00:08:53,079 --> 00:08:56,840 APPLY INSULATING RESIN TO THE WINDINGS AT CONTROLLED RATES. 145 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 147 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 153 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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