All language subtitles for How.Its.Made.Dream.Cars.S03E04.Zenvo.ST1.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb_track3_[eng]

Narrator:
TODAY ON "HOW IT'S MADE:
DREAM CARS," THE ZENVO ST1,

A DANISH HYPERCAR
THAT'S NOT JUST TURBOCHARGED,

IT'S ALSO SUPERCHARGED.

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

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

ZENVO WANTS YOU TO BE SCARED
WHEN YOU SEE AN ST1

DRIVING DOWN THE ROAD.

THE DESIGNER OF THE ST1 WAS TOLD
TO MAKE IT LOOK EVIL.

HE TURNED TO IMAGES OF WILD
PREDATORS FOR INSPIRATION.

THE SHOULDERS
OF A CROUCHING LIONESS

TRANSLATE
TO THE HYPERCAR'S FENDERS,

WHILE THE HEADLIGHTS
CONVEY AN EAGLE'S EYES.

THESE INFLUENCES HELP TO GIVE
THE ST1 ITS AGGRESSIVE STANCE.

THE CAR'S FREE-FLOWING
POSITIVE CURVES

CREATE THE IMPRESSION
OF DYNAMIC MOVEMENT,

EVEN WHEN THE CAR IS PARKED.

THIS DESIGN HELPS EXPRESS
THE ST1's MONSTROUS STRENGTH,

WITH A V8 ENGINE CAPABLE
OF PRODUCING 1,104 HORSEPOWER.

BUT AESTHETICS ALONE
DON'T MAKE A CAR BODY.

THE DESIGNER MUST ALSO
INCORPORATE KEY ELEMENTS

LIKE AERODYNAMICS AND DOWNFORCE
FOR MAXIMUM PERFORMANCE.

NO MATTER HOW SOPHISTICATED
THE DESIGN SOFTWARE IS,

THERE'S NO SUBSTITUTE
FOR SCULPTING THE CAR

IN THREE DIMENSIONS.

ZENVO ALSO MILLS
A FULL-SCALE VERSION

OF THE ST1 IN POLYSTYRENE.

THE FINAL PRODUCT
IS A TRUE SUPERCAR

THAT CAN ACCELERATE FROM ZERO
TO 60 IN THREE SECONDS FLAT

AND REACH A TOP SPEED OF
OVER 230 MILES PER HOUR.

THE SECRET INGREDIENT
AT THE HEART OF THE CAR

IS AN ENGINE
THAT HAS BOTH A TURBOCHARGER

AND A SUPERCHARGER.

ZENVO USES A COMBINATION
OF ALUMINUM AND STEEL

TO BUILD THE CHASSIS OF THE ST1.

THE STEEL IS ESPECIALLY
FORMULATED HIGH-STRENGTH TYPE.

THIS ALLOWS FOR THIN-WALLED
TUBING, A WEIGHT-SAVING DESIGN

THAT MAINTAINS STRONG
TORSIONAL RIGIDITY,

A CRUCIAL ASPECT
FOR ANY HIGH-PERFORMANCE CAR.

BECAUSE THE MANUFACTURER ONLY
MAKES FIVE OR SIX ST1s PER YEAR,

THEY CAN FOCUS ON CRAFTING
EVERY ASPECT OF THE CAR BY HAND.

HERE, A TECHNICIAN
CAREFULLY MEASURES

AND POSITIONS ALL THE COMPONENTS
OF THE REAR CHASSIS FRAME

IN PREPARATION FOR WELDING.

HE USES A FOLDING RULER
TO ENSURE THE GAPS

ARE PERFECTLY ALIGNED.

THEN HE TIG-WELDS
ALL THE COMPONENTS TOGETHER.

IT TAKES ABOUT A WEEK TO BUILD
THE REAR FRAME

AND ANOTHER WEEK
FOR THE FRONT FRAME.

ONCE COMPLETE, THE FRAMES
JOIN THE CENTRAL MONOCOQUE

TO CREATE THE FRAMEWORK
FOR THE HYPERCAR.

IT'S HARD TO BELIEVE
THAT THIS METAL FRAME

LIES UNDERNEATH THE SLEEK BODY
OF THE ST1.

ZENVO BUILDS THE BODY
EXCLUSIVELY FROM CARBON FIBER.

A TECHNICIAN USES A PATTERN
TO CUT OUT THE CORRECT AMOUNT

OF CARBON FIBER NEEDED
TO CREATE THE CAR'S PANELING.

THANKS TO THE VERY DURABLE,
BUT INCREDIBLY LIGHTWEIGHT,

NATURE OF CARBON FIBER,

THE ZENVO ST1 WEIGHS IN
AT JUST OVER 3,000 POUNDS.

THE CAR'S LIGHT WEIGHT
ALSO HELPS IT MEET

THE VERY STRINGENT
EURO 5 EMISSIONS STANDARDS.

A REMARKABLE FEAT,

CONSIDERING THE AMOUNT
OF HORSEPOWER IT PUTS OUT.

HERE, A SPECIALIST BUILDS
A SECTION OF THE REAR SIDE PANEL

BY CAREFULLY HAND-LAYERING
CARBON FIBER INTO A MOLD.

USING CARBON FIBER
TO MAKE A CAR BODY

IS A METHOD OF CONSTRUCTION

THAT BLENDS TEXTILE WORK
WITH SCULPTING.

THIS PROCESS
IS PAINSTAKINGLY SLOW,

AND THE FIBER IS EXPENSIVE.

BUT WHEN YOU'RE HAND-BUILDING
A HIGHLY EXCLUSIVE DREAM CAR

IN SUCH SMALL NUMBERS,

YOU MUST USE
THE BEST MATERIALS AVAILABLE.

LOW-VOLUME,
MADE-TO-ORDER-GOODS PRODUCTION

IS ONE OF THE FEW INDUSTRIES

THAT STILL EMPLOYS
SKILLED CRAFTSPEOPLE.

NOW THE CRAFTSMAN PRESSES
A SHEET OF CARBON FIBER

IN A MOLD THAT IS SIMILAR,
BUT NOT IDENTICAL,

TO THE FIRST ONE.

THIS SECTION OF THE BODY PANEL

WILL HOUSE ZENVO'S
SIGNATURE GAS CAP,

SO IT MUST BE PREPARED
WITH THAT IN MIND.

ONCE THE TWO MOLDS ARE PREPARED,
A TECHNICIAN COVERS THEM

WITH A LAYER OF MATERIAL
CALLED BREATHER FABRIC.

THEN EVERYTHING IS SEALED
INSIDE A CLEAR PLASTIC BAG.

THE AIR IS VACUUMED OUT,
CREATING A TIGHT SEAL

THAT ENSURES PRECISE CONTROL
OVER THE CURING PROCESS.

TO CURE THE CARBON FIBER,
THE WORKER

TURNS ON AN ELECTRIC HEATING
SYSTEM EMBEDDED WITHIN THE MOLD.

IT TAKES ROUGHLY FIVE HOURS

TO DE-MOLD THIS TYPE
OF CARBON FIBER.

THEY LET IT SIT OVERNIGHT BEFORE
REMOVING IT FROM THE MOLD.

RELEASE AGENTS WERE APPLIED
TO THE FIBER

TO HELP
WITH THE DE-MOLDING PROCESS.

HOWEVER, THE TECHNICIANS MUST
STILL PROCEED VERY CAREFULLY

TO AVOID BREAKING OR CRACKING
THE PART AS THEY REMOVE IT.

HERE, A WORKER
IS USING A GRINDER

TO CUT AWAY EXCESS MATERIAL.

THIS REQUIRES A STEADY HAND.

NEXT, THE TECHNICIAN USES
A DIFFERENT HANDHELD POWER TOOL

TO CUT OUT THE GAS-CAP OPENING.

ONCE FINISHED,
HE SANDS THE EDGES SMOOTH.

THE FINISHED CARBON-FIBER
COMPONENTS COME HERE

TO A SEALED PAINTING STATION.

BUYERS CAN CHOOSE ANY FINISH
THEY WANT,

BUT MANY OPT FOR A CLEAR COATING
THAT PROTECTS THE SURFACE

BUT REVEALS
ITS DISTINCTIVE WEAVE.

HERE A SPECIALIST

SPRAYS THE PARTS WITH
AN AUTOMOTIVE-GRADE SEALANT.

Narrator: ST1 --
THE "S" STANDS FOR SUPERCHAGER,

THE "T" FOR TURBOCHARGER,

AND "1" INDICATES THAT THIS IS
THE COMPANY'S FIRST MODEL.

FEW CARS IN HISTORY
HAVE HAD BOTH TURBOCHARGER

AND SUPERCHARGER UNITED
IN A SINGLE ENGINE.

HAVING BOTH A SUPERCHARGER
AND A TURBOCHARGER

MEANS THAT THE CAR
HAS INSTANT THROTTLE RESPONSE,

NO MATTER HOW LOW OR HIGH
THE REVS.

HERE, A TECHNICIAN

MOUNTS THE CLUTCH
ONTO THE ALUMINUM ENGINE BLOCK.

THIS CLUTCH
IS AN ACCESSIBLE COMPONENT

THAT CAN BE EASILY REPLACED
IF NECESSARY.

ZENVO ADHERE
TO THIS SAME PHILOSOPHY

WHEN DESIGNING
THE CAR'S POWERTRAIN.

THEY USE HIGH-QUALITY
BUT CONVENTIONAL PARTS,

RATHER THAN EXOTIC,

DIFFICULT-TO-REPLACE COMPONENTS
WHEREVER POSSIBLE.

NEXT, THE WORKER

INSTALLS THE COMPRESSOR
FOR THE AIR-CONDITIONING.

EVEN WITH THIS ADDITION,

THE ENGINE
REMAINS REMARKABLY SMALL,

CONSIDERING HOW POWERFUL IT IS.

YET ANOTHER BENEFIT

OF COMBINING A TURBOCHARGER
WITH A SUPERCHARGER.

THE INTAKE MANIFOLD
OF THE ZENVO ST1

HOUSES
A LIQUID-TO-AIR INTERCOOLER.

THIS PROVIDES THE ENGINE
WITH COOL AIR

TO MAXIMIZE ITS EFFICIENCY.

THE CORES OF THE INTERCOOLER
ARE LONG CYLINDERS

MADE OF DOZENS OF EXTREMELY THIN
ALUMINUM DISCS STACKED TOGETHER.

THEY PROVIDE AN ENORMOUS AMOUNT
OF SURFACE AREA

IN A VERY SMALL SPACE.

AS THE WATER PUMP MOVES
COLD WATER THROUGH THOSE CORES,

THE DISCS ABSORB THE HEAT
FROM THE CHARGED AIR

AND DISPERSE IT.

COMBUSTION ENGINES NEED AIR
TO WORK.

A SUPERCHARGER IS ESSENTIALLY
A VERY SOPHISTICATED AIR PUMP.

IT BOOSTS THE PERFORMANCE
OF THE ENGINE

BY FORCING IN EXTRA AIR.

ZENVO'S ENGINE MANAGEMENT SYSTEM

WAS DEVELOPED ENTIRELY IN HOUSE
FROM SCRATCH.

AS A RESULT, THE MANUFACTURER

HAS COMPLETE CONTROL
OVER THE CAR'S PARAMETERS.

HERE, A METAL-CUTTING MACHINE

SAWS A LONG ALUMINUM ROD
INTO SMALL DISCS.

THANKS
TO ITS REMARKABLY LOW DENSITY,

ALUMINUM
CAN BE CUT EASILY AND QUICKLY.

HOWEVER, THE PROCESS
GENERATES HEAT FROM FRICTION.

TO KEEP THE SAW BLADE
FROM OVERHEATING,

A CONSTANT STREAM
OF LIQUID IS APPLIED.

THE ALUMINUM DISCS

THEN GO TO A HIGHLY SPECIALIZED
FIVE-AXIS MILLING MACHINE.

THE MACHINE
HAS MULTIPLE STATIONS,

ALLOWING IT TO WORK
ON MULTIPLE COMPONENTS

AT THE SAME TIME.

THIS MACHINE CAN SHAPE A ZENVO
FUEL CAP IN LESS THAN 10 MINUTES

WITH EXTREME PRECISION.

WORKING FROM THE TOP
DOWN, THE CUTTING TOOL SCULPTS

THE ALUMINUM SO EASILY IT LOOKS
LIKE IT'S CARVING A MATERIAL

THAT'S AS SOFT AS WAX.

THE MACHINE MILLS THE FUEL CAP

FOLLOWING
A COMPUTER-AIDED DESIGN...

...WHILE MONITORS DISPLAY
ITS SWIFT AND PRECISE MOTIONS.

THE MILLING MACHINE

AUTOMATICALLY SELECTS THE TOOLS
IT NEEDS.

HERE IT'S USING ONE
OF THE THINNEST BITS

TO ETCH OUT THE COMPANY'S NAME.

THIS MACHINE HAS A CUTTING TOOL

THAT'S THINNER
THAN A HUMAN HAIR.

IN ABOUT EIGHT MINUTES,
THE MILLING MACHINE

CAN TRANSFORM
A SIMPLE ALUMINUM DISC

INTO A SLEEK COMPONENT
OF A HIGH-PERFORMANCE SUPERCAR.

Narrator:
WHEN IT COMES TO A HYPERCAR
AS EXCLUSIVE AS THE ZENVO ST1,

THE INTERIOR MUST BE
AS LUXURIOUS AND FLAWLESS

AS THE EXTERIOR.

THAT'S WHY THE CAR MAKER

CUSTOMIZES THE UPHOLSTERY
FOR EACH BUYER,

RIGHT DOWN
TO THE STITCHING PATTERN.

IT TAKES FIVE COW HIDES
TO UPHOLSTER A SINGLE ST1.

HERE, SPECIALLY TRAINED
CRAFTSMEN UNFOLD A HIDE

ON A CUTTING TABLE.

THEY BEGIN BY INSPECTING
THE SURFACE FOR ANY FLAWS.

NEXT, THEY
LAY THE CUTTING PATTERNS OUT.

THEY USE SMALL METAL WEIGHTS
TO KEEP THE PATTERNS IN PLACE

AS THEY WORK.

THESE CUTTING PATTERNS

WERE CREATED
BY THE UPHOLSTERY SPECIALIST

AND THE CAR'S DESIGNER.

THE CRAFTSMEN TRACE
THE OUTLINE OF THE PATTERNS,

TRANSFERRING THE CUTTING PLAN
TO THE COW HIDE.

THEY MUST PAY CLOSE ATTENTION

TO THE POSITION
OF EACH PATTERN ON THE HIDE.

THE LEATHER CLOSEST
TO THE SPINE OF THE COW

IS THE BEST-QUALITY MATERIAL.

THE LEATHER BECOMES THINNER
AND FLAWED NEAR THE BELLY AREA

OF THE COW HIDE.

NOW THE UPHOLSTERY SPECIALIST
BEGINS CUTTING OUT THE SEGMENTS.

THESE PIECES WILL BE USED
TO UPHOLSTER PARTS OF THE SEATS

AND DOORS.

IT TAKES BOTH TRAINING
AND PRACTICE TO BE ABLE TO CUT

WITH THIS COMBINATION
OF SPEED AND PRECISION.

ONCE THE PATTERNS ARE CUT,

IT'S TIME
TO PUT THEM ALL TOGETHER.

A CRAFTSMAN USES A SEWING
MACHINE TO JOIN TWO PIECES

WITH A CLOSED STITCH.

LEATHER
IS AN UNFORGIVING MATERIAL,

SO THE WORKER
MUST PROCEED WITH GREAT CARE.

WHILE YOU CAN BE TRAINED

TO BECOME AN AUTOMOTIVE
UPHOLSTERY SPECIALIST

IN LESS THAN A YEAR,

TRUE MASTERY TAKES MUCH LONGER.

THIS TECHNICIAN'S EXPERTISE

MAKES THE PROCESS LOOK
MUCH EASIER THAN IT ACTUALLY IS.

NOW HE USES A MACHINE THAT SEWS
A DOUBLE-STITCH PATTERN.

THE CUSTOMER CAN CHOOSE
THIS DECORATIVE FEATURE

IN ANY COLOR THEY WISH.

SEWING LEATHER REQUIRES
SPECIALIZED SEWING MACHINES,

NEEDLES, AND THREAD,

AS WELL AS CAREFUL ADJUSTMENT
OF THE THREAD TENSION.

THE THREAD MUST BE MADE
OF UPHOLSTERY-WEIGHT POLYESTER

OR RAYON, OR IT
COULD EASILY BREAK WHEN SEWING.

HERE A CRAFTSMAN INSTALLS A
SECTION OF THE DOOR UPHOLSTERY.

THIS CENTERPIECE
HAS BEEN QUILTED

WITH AN EMBROIDERY MACHINE.

IT TAKES 2 1/2 HOURS

TO EMBROIDER THE PATTERN
ON THIS PARTICULAR SECTION.

HE CAREFULLY INSTALLS
THE ARM REST,

ENSURING
THE TIGHTEST POSSIBLE FIT.

THE EMBROIDERED QUILTING

ABOVE THE ARM REST
IS A HEXAGONAL PATTERN.

THIS DESIGN MOTIF
IS FOUND THROUGHOUT THE ST1.

EVEN THE CAR'S GRILLE FEATURES
HEXAGONS.

THE TECHNICIAN CAREFULLY
INSPECTS EVERY INCH

OF THE UPHOLSTERY SURFACE
TO ENSURE IT'S FLAWLESS.

A CRAFTSMAN WILL FOLLOW
THE SAME PROCEDURE

FOR EACH OF THE CAR'S
INTERIOR ELEMENTS.

THIS INSPECTION PROCESS
PLAYS A LARGE ROLE

IN WHY IT TAKES ROUGHLY 10
MONTHS TO BUILD A SINGLE ST1.

Narrator:
FINAL ASSEMBLY OF THE ST1

TAKES PLACE AT THIS PLANT
IN ZEALAND, DENMARK.

IT TAKES ABOUT FOUR MONTHS

FOR TECHNICIANS TO TAKE
THE VARIOUS SUBASSEMBLIES

AND TRANSFORM THEM

INTO A COMPLETE
HIGH-PERFORMANCE HYPERCAR.

SOME OF THE SUBASSEMBLIES
OF THIS ST1

HAVE BEEN HERE FOR TWO MONTHS.

WORKERS CAREFULLY BUILD
THEM PIECE BY PIECE.

HERE TWO TECHNICIANS INSTALL
THE LEFT DOOR TO THE FRAME.

NOW IT'S TIME TO ADD THE PIECE

THAT WILL HOUSE THE GAS CAP
AND FEED PIPE.

FLANGES ON THE TOP

AND BOTTOM OF THE PART
PROVIDE ATTACHMENT POINTS.

THE TECHNICIAN LINES EVERYTHING
UP AND SCREWS IT IN PLACE.

THE CARBON-FIBER WEAVE
IS CLEARLY VISIBLE ON THIS PART.

THIS WAS DONE
FOR AESTHETIC EFFECT.

THE WORKER LINES UP THE MOUTH
OF THE GAS PIPE AND ATTACHES IT.

ONCE IT'S SECURELY IN PLACE,

HE INSTALLS ZENVO'S SIGNATURE
ALUMINUM GAS CAP.

THIS NEXT PART
SERVES THREE FUNCTIONS.

IT HOUSES THE TAILLIGHTS,

PROVIDES A SUPPORT FRAME
FOR THE EXHAUST PIPE,

AND HAS A GRILLE THAT VENTS
HOT AIR FROM THE ENGINE.

THE PART IS MADE
OF ANODIZED ALUMINUM,

RATHER THAN PLASTIC,

TO PROTECT IT
FROM THE HIGH TEMPERATURES

GENERATED BY THE ENGINE
AND EXHAUST PIPE.

IT'S TIME TO INSTALL
THE REAR WINDSHIELD FRAME,

WHICH IS ALSO MADE OF ALUMINUM.

TECHNICIANS ATTACH THE GLASS
IN THE TOP PORTION OF THE FRAME.

THE BOTTOM THIRD REMAINS OPEN,

PROVIDING ANOTHER VENT
FOR THE HOT ENGINE AIR.

THE GRILLE OF THE VENT FEATURES
THE SAME HEXAGONAL DESIGN MOTIF

REPEATED THROUGHOUT THE CAR.

NOW WORKERS
INSTALL THE REAR HOOD.

THEY INSPECT THE GAPS
BETWEEN PANELS

TO ENSURE
THEY'RE CORRECTLY ALIGNED.

THE GAPS ON THE ST1
ARE RELATIVELY NARROW,

COMPARED TO OTHER HANDMADE,
LOW-VOLUME PRODUCTION CARS.

THE CAREFULLY DESIGNED
REAR SPOILER

WILL KEEP THE ST1
ON THE GROUND,

EVEN WHEN IT HITS
THOSE HIGH SPEEDS.

THE TECHNICIANS HAVE LEFT
THE REAR CONSTRUCTION OPEN

SO THEY CAN EASILY INSTALL
THE ENGINE.

THEY USE A HYDRAULIC
CRANE SYSTEM

TO HELP THEM CORRECTLY
POSITION THE V8 POWERHOUSE

BEFORE BOLTING IT IN.

THANKS TO THE ENGINE'S LOCATION,
THE CAR'S WEIGHT DISTRIBUTION

IS 56% IN THE REAR
AND 44% IN THE FRONT.

NEXT, WORKERS
INSTALL THE SUPERCHARGER,

WHICH SITS ON TOP
OF THE INTAKE MANIFOLD.

INSIDE THE MANIFOLD

IS ONE OF THE INTERCOOLER WE
SAW BEING CONSTRUCTED EARLIER.

NOW A TECHNICIAN
ADDS THE ENGINE'S NUMBER PLATE.

ON THE PLATE
IS THE SERIAL NUMBER ST1009

BECAUSE THIS IS CAR NUMBER 9.

INSULATION ON THE TURBINE SIDE
OF THE TURBOCHARGER

IMPROVES EFFICIENCY

AND HELPS PREVENT OVERHEATING
IN THE ENGINE COMPARTMENT.

ZENVO'S MADE-TO-ORDER
ENGINE-MANAGEMENT SYSTEM

WILL CONTROL EVERY ASPECT
OF THE CAR'S PERFORMANCE.

ONCE THE ST1 IS FULLY ASSEMBLED,

IT'S READY FOR THE ALL-IMPORTANT
DYNO TESTING PHASE.

IT TAKES AN ENTIRE DAY
TO COMPLETE THIS STEP,

AS ZENVO ADJUSTS
ALL THE PARAMETERS

OF THE CAR'S SOPHISTICATED
ELECTRONICS.

SINCE THE CAR
IS BLUETOOTH-ENABLED,

THERE'S NO NEED
TO HOOK UP ANY CABLES

TO MONITOR
THE CAR'S PERFORMANCE.

DUCTS SITUATED
DIRECTLY BEHIND THE TAIL PIPES

VENT THE CAR'S EXHAUST OUTDOORS
WHILE IT'S BEING TESTED.

ONCE IT'S PASSED
THE DYNO STATION TESTING STAGE,

THIS ST1 IS READY
FOR MANDATORY ROAD TESTING.

THANKS TO THE DESIGN
OF ITS EXTERIOR LINES,

EVEN WHEN PARKED, THE CAR
LOOKS LIKE IT'S READY TO POUNCE.

A SLEEK MOLDED HEAT SHIELD

COVERS THE TURBOCHARGER
UNDER THE REAR HOOD.

INSIDE, ZENVO'S SIGNATURE
HEXAGONAL PATTERN

CAN BE FOUND THROUGHOUT THE CAR,

FROM THE MAIN INSTRUMENT
DISPLAY GRAPHICS

TO THE INFOTAINMENT CONSOLE
AND UPHOLSTERY.

IN THE SCANDINAVIAN DESIGN
TRADITION,

FORM IS ALWAYS SUPPOSED
TO FOLLOW FUNCTION.

THE FUNCTION OF THE ST1
IS TO TERRIFY THE COMPETITION

AND LOOK GOOD WHILE DOING IT.

WITH ITS PREDATORY CURVES
COVERING A SUPERCHARGED TURBO V8

CAPABLE OF PUNCHING THE CAR

FROM ZERO TO 60
IN JUST THREE SECONDS,

THIS DANISH HYPERCAR
IS ACTUALLY QUITE TRADITIONAL.