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These are the user uploaded subtitles that are being translated: 1 00:00:01,535 --> 00:00:03,935 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,937 --> 00:00:05,162 THE McLAREN 650S, 3 00:00:05,164 --> 00:00:08,224 A SUPERCAR FOR THE RACE TRACK OR THE OPEN ROAD. 4 00:00:17,218 --> 00:00:20,153 -- Captions by VITAC -- www.vitac.com 5 00:00:20,155 --> 00:00:23,247 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,249 --> 00:00:26,443 FAMED NEW ZEALAND DRIVER BRUCE McLAREN 7 00:00:26,445 --> 00:00:30,839 WON HIS FIRST RACE IN THE AUSTIN 7 ULSTER. 8 00:00:30,841 --> 00:00:34,968 HE FOUNDED BRUCE McLAREN RACING IN 1963. 9 00:00:34,970 --> 00:00:38,865 THE TEAM COMPETED AND WON IN THE FORMULA ONE, CAN-AM, 10 00:00:38,867 --> 00:00:41,859 INDY 500, AND LE MANS RACES. 11 00:00:41,861 --> 00:00:43,194 TODAY, McLAREN CARS 12 00:00:43,196 --> 00:00:47,991 ARE LEGENDARY FOR THEIR EXTRAORDINARY PERFORMANCE. 13 00:00:47,993 --> 00:00:52,453 IN 1992, THE CAR MAKER UNVEILED THE McLAREN F1, 14 00:00:52,455 --> 00:00:56,883 A ROAD CAR THAT REWROTE THE SUPERCAR RULE BOOK. 15 00:00:56,885 --> 00:00:59,011 WITH THE F1, McLAREN DISTILLED 16 00:00:59,013 --> 00:01:01,605 ITS UNPARALLELED SUCCESS ON THE TRACK 17 00:01:01,607 --> 00:01:04,141 INTO THE FASTEST NATURALLY-ASPIRATED 18 00:01:04,143 --> 00:01:06,269 PRODUCTION CAR IN THE WORLD. 19 00:01:08,740 --> 00:01:11,766 THE 650S CONTINUES THE TRADITION. 20 00:01:11,768 --> 00:01:14,027 IT IS A SERIES PRODUCTION SUPERCAR 21 00:01:14,029 --> 00:01:16,629 AVAILABLE AS A COUPE OR CONVERTIBLE. 22 00:01:16,631 --> 00:01:18,423 THE CAR'S TWIN-TURBO V8 23 00:01:18,425 --> 00:01:22,486 IS THE POWERHOUSE BEHIND A BLISTERING ACCELERATION PACE. 24 00:01:22,488 --> 00:01:25,955 IT HAS A TOP SPEED OF 207 MILES PER HOUR 25 00:01:25,957 --> 00:01:29,685 AND CAN GO FROM 0 TO 60 IN JUST THREE SECONDS. 26 00:01:35,643 --> 00:01:38,044 BACK IN 1981, 27 00:01:38,046 --> 00:01:42,039 McLAREN PIONEERED THE USE OF CARBON FIBER IN FORMULA ONE. 28 00:01:42,041 --> 00:01:45,001 AND IN 1992, THE McLAREN F1 29 00:01:45,003 --> 00:01:48,463 BECAME THE WORLD'S FIRST CARBON-FIBER ROAD CAR. 30 00:01:48,465 --> 00:01:50,791 THE 650S IS NO EXCEPTION. 31 00:01:50,793 --> 00:01:54,461 IT'S FITTED WITH A LIGHTWEIGHT CARBON-FIBER MONOCELL CHASSIS 32 00:01:54,463 --> 00:01:58,157 WITH ALUMINUM CRASH STRUCTURES BOLTED TO THE FRONT AND REAR. 33 00:02:00,486 --> 00:02:02,219 THE McLAREN PRODUCTION CENTRE 34 00:02:02,221 --> 00:02:05,213 IS LOCATED NEXT DOOR TO THE McLAREN TECHNOLOGY CENTRE 35 00:02:05,215 --> 00:02:07,208 IN SURREY, ENGLAND. 36 00:02:07,210 --> 00:02:08,943 AT THIS STATION, 37 00:02:08,945 --> 00:02:11,671 A TECHNICIAN ASSEMBLES THE FRONT AND REAR CRASH STRUCTURES 38 00:02:11,673 --> 00:02:15,567 ONTO THE CARBON-FIBER MONOCELL. 39 00:02:15,569 --> 00:02:18,836 A SPECIALIZED FIXTURE HELPS HIM MANUALLY GUIDE THE STRUCTURES 40 00:02:18,838 --> 00:02:20,230 INTO PLACE. 41 00:02:20,232 --> 00:02:23,592 HE USES A WRENCH WITH A PRESET TORQUE SPECIFICATION 42 00:02:23,594 --> 00:02:26,228 TO TIGHTEN THE BOLTS. 43 00:02:26,230 --> 00:02:31,024 LIKE MANY SUPERCARS, THE 650S IS HAND-BUILT. 44 00:02:31,026 --> 00:02:33,085 EVEN THOUGH THERE ARE NO CONVEYER BELTS 45 00:02:33,087 --> 00:02:34,887 OR ROBOTS IN THIS FACILITY, 46 00:02:34,889 --> 00:02:38,983 McLAREN STILL MANAGES TO CONSTRUCT EIGHT CARS A DAY. 47 00:02:41,780 --> 00:02:43,779 THE TECHNICIAN MARKS EACH BOLT 48 00:02:43,781 --> 00:02:46,608 TO NOTE THAT IT'S BEEN TIGHTENED TO THE CORRECT TORQUE. 49 00:02:50,171 --> 00:02:52,997 A TWO-PART, HIGH-STRENGTH STRUCTURAL ADHESIVE 50 00:02:52,999 --> 00:02:55,667 IS APPLIED TO LARGE PARTS OF THE BODY STRUCTURE, 51 00:02:55,669 --> 00:02:57,795 LIKE THIS WINDSHIELD FRAME. 52 00:02:59,331 --> 00:03:01,590 THE TECHNICIANS CLAMP THE PART IN PLACE 53 00:03:01,592 --> 00:03:03,459 WITH THE HELP OF PRECISION SET PINS 54 00:03:03,461 --> 00:03:05,119 AND MYLARS. 55 00:03:10,819 --> 00:03:13,745 THESE POSITIONING TOOLS MUST BE INCREDIBLY ACCURATE 56 00:03:13,747 --> 00:03:16,414 SO THAT WHEN THE MONOCELL SLIDES INTO PLACE, 57 00:03:16,416 --> 00:03:19,977 THE PREBINDED COMPONENT CAN ROTATE DIRECTLY ONTO IT. 58 00:03:21,338 --> 00:03:24,205 A TECHNICIAN NOW TRANSFERS THE COMPLETED ASSEMBLY 59 00:03:24,207 --> 00:03:25,298 ONTO A DOLLY 60 00:03:25,300 --> 00:03:27,802 AND WHEELS IT TO THE NEXT STATION. 61 00:03:29,497 --> 00:03:31,897 HERE AT BODY ASSEMBLY STATION 90, 62 00:03:31,899 --> 00:03:34,491 TECHNICIANS BRING THE FINAL BODY PANELS 63 00:03:34,493 --> 00:03:37,153 TO A FIXTURE EQUIPPED WITH AN AIR VAC SYSTEM 64 00:03:37,155 --> 00:03:41,449 WHICH SUCTIONS THE PARTS IN PLACE. 65 00:03:41,451 --> 00:03:44,852 ONCE A TECHNICIAN SLIDES THE MONOCELL INTO THE STATION, 66 00:03:44,854 --> 00:03:47,714 IT'S CLAMPED SECURELY IN PLACE. 67 00:03:47,716 --> 00:03:52,378 TECHNICIANS THEN MANUALLY ROTATE THE PRELOADED PARTS ONTO IT. 68 00:03:52,380 --> 00:03:55,773 AN AUTOMATED CERAMIC HEATER SYSTEM WILL CURE THE ADHESIVE 69 00:03:55,775 --> 00:03:58,667 IN JUST 35 MINUTES. 70 00:03:58,669 --> 00:04:01,729 A MOTOR-POWERED MECHANICAL GATE ROTATES THE ROOF PANEL 71 00:04:01,731 --> 00:04:06,125 180 DEGREES ONTO THE TOP OF THE CAR BODY. 72 00:04:06,127 --> 00:04:08,461 THANKS TO THAT CERAMIC HEATER, 73 00:04:08,463 --> 00:04:11,456 TECHNICIANS CAN UNCLAMP THE FULLY CURED BODY PANELS 74 00:04:11,458 --> 00:04:13,951 AFTER JUST 35 MINUTES. 75 00:04:15,554 --> 00:04:16,820 IN THE CONTROLLED ENVIRONMENT 76 00:04:16,822 --> 00:04:19,214 OF GEOMETRIC AND SURFACE VALIDATION, 77 00:04:19,216 --> 00:04:21,617 A COORDINATE MEASURING MACHINE, OR CCM, 78 00:04:21,619 --> 00:04:23,611 GOES TO WORK. 79 00:04:23,613 --> 00:04:26,147 THE CCM HAS TWO AUTOMATED ARMS 80 00:04:26,149 --> 00:04:28,140 THAT TRAVEL THE LENGTH OF THE BODY, 81 00:04:28,142 --> 00:04:31,836 MEASURING EVERY ELEMENT OF THE ASSEMBLY. 82 00:04:31,838 --> 00:04:34,830 EXTENDING FROM THE END OF EACH ARM IS A SMALLER ARM 83 00:04:34,832 --> 00:04:37,567 THAT CAN ROTATE 360 DEGREES. 84 00:04:37,569 --> 00:04:39,360 THIS ROTATION ALLOWS THE ARM 85 00:04:39,362 --> 00:04:42,563 TO ACCURATELY GAUGE THE ENTIRE SURFACE AREA. 86 00:04:42,565 --> 00:04:43,890 PRECISION PROBES 87 00:04:43,892 --> 00:04:46,760 MOUNTED WITH A RUBY AT THE TIPS OF THE SMALLER ARMS 88 00:04:46,762 --> 00:04:48,153 TOUCH THE CAR BODY 89 00:04:48,155 --> 00:04:51,582 AT 304 DIFFERENT SURFACE AND GEOMETRIC POINTS. 90 00:04:51,584 --> 00:04:53,851 THE PROBES RECORD EACH POSITION 91 00:04:53,853 --> 00:04:57,013 AND COMPARE IT TO THE DESIGN SPECIFICATIONS. 92 00:04:59,508 --> 00:05:03,236 NEXT, PAINTERS SPRAY EACH CAR BODY BY HAND. 93 00:05:03,238 --> 00:05:07,298 McLAREN WORKS WITH AKZONOBEL TO FORMULATE PAINT COLORS 94 00:05:07,300 --> 00:05:11,928 USING A WATER-BASED SYSTEM THAT REDUCES SOLVENT EMISSIONS. 95 00:05:11,930 --> 00:05:13,596 IN THIS CASE, THE PAINTERS 96 00:05:13,598 --> 00:05:16,792 ARE APPLYING THE HERITAGE McLAREN ORANGE. 97 00:05:16,794 --> 00:05:21,388 BRUCE McLAREN HIMSELF CHOSE THIS PAINT FOR HIS EARLY RACE CARS. 98 00:05:21,390 --> 00:05:22,923 A CLEVER BUSINESSMAN, 99 00:05:22,925 --> 00:05:27,219 McLAREN KNEW THAT THIS COLOR WOULD SET HIS RACE TEAM APART. 100 00:05:27,221 --> 00:05:30,147 HE HAD NOTICED THAT, EVEN ON THE BLACK-AND-WHITE TV SCREENS 101 00:05:30,149 --> 00:05:31,683 OF THE 1960s, 102 00:05:31,685 --> 00:05:34,677 ORANGE SHOWED UP AS A DIFFERENT SHADE OF GRAY. 103 00:05:39,676 --> 00:05:42,803 THERE ARE 30 DIFFERENT STATIONS IN THE PAINT PROCESS. 104 00:05:44,364 --> 00:05:47,966 ONCE COATED, A CAR BODY MOVES THROUGH AN OVEN. 105 00:05:47,968 --> 00:05:51,561 THE OVEN BAKES THE PAINT AT A LOW TEMPERATURE TO CURE IT. 106 00:05:51,563 --> 00:05:53,956 THEN, TECHNICIANS POLISH THE SURFACES 107 00:05:53,958 --> 00:05:57,752 BEFORE INSPECTORS EXAMINE THE PAINT FOR ANY FLAWS. 108 00:06:06,712 --> 00:06:10,506 Narrator: McLAREN DEVELOPED THE AWARD-WINNING M838T ENGINE 109 00:06:10,508 --> 00:06:12,800 FOR ITS NEW LINE OF SUPERCARS. 110 00:06:12,802 --> 00:06:15,937 RICARDO, ANOTHER U.K.-BASED TECHNOLOGY COMPANY, 111 00:06:15,939 --> 00:06:18,465 ASSEMBLES THIS EIGHT-CYLINDER POWERHOUSE, 112 00:06:18,467 --> 00:06:20,726 WHICH FEATURES TWIN TURBOCHARGERS. 113 00:06:22,929 --> 00:06:25,522 RICARDO ASSEMBLES THE ENGINES AT THIS FACILITY 114 00:06:25,524 --> 00:06:29,017 IN SHOREHAM, U.K. 115 00:06:29,019 --> 00:06:31,487 THE ENGINE MOVES THROUGH 10 DIFFERENT STATIONS 116 00:06:31,489 --> 00:06:34,147 DURING THE MANUFACTURING PROCESS. 117 00:06:34,149 --> 00:06:35,349 AT THIS STATION, 118 00:06:35,351 --> 00:06:38,211 A TECHNICIAN APPLIES A LUBRICANT TO THE EIGHT PISTONS 119 00:06:38,213 --> 00:06:41,940 BEFORE INSTALLING THEM IN THE ALUMINUM ENGINE BLOCK. 120 00:06:41,942 --> 00:06:44,008 A GUIDE PLACED OVER THE CYLINDER OPENINGS 121 00:06:44,010 --> 00:06:46,136 HELPS THEM WITH THE INSTALLATION. 122 00:06:50,433 --> 00:06:53,427 ONCE THE TECHNICIAN FINISHES INSTALLING THE PISTONS, 123 00:06:53,429 --> 00:06:56,096 HE ROTATES THE ENGINE TO GAIN ACCESS TO THE BOTTOM 124 00:06:56,098 --> 00:06:57,223 OF THE CONNECTING RODS, 125 00:06:57,225 --> 00:06:59,491 OR CON RODS. 126 00:06:59,493 --> 00:07:03,854 HE ADDS BEARINGS AND ATTACHES THE PISTONS TO THE CRANKSHAFT. 127 00:07:03,856 --> 00:07:05,782 A TESTAMENT TO McLAREN'S COMMITMENT 128 00:07:05,784 --> 00:07:07,583 TO HANDCRAFTED PRECISION, 129 00:07:07,585 --> 00:07:11,913 THE BEARINGS ARE INDIVIDUALLY SIZED FOR EACH CON ROD. 130 00:07:11,915 --> 00:07:16,376 WHEN TURNING, THE CRANKSHAFT WILL CHURN OUT 616 HORSEPOWER 131 00:07:16,378 --> 00:07:19,838 WITH THE ENGINE DISPLACING JUST 3.8 LITERS. 132 00:07:23,402 --> 00:07:25,927 ONCE THE PISTONS HAVE BEEN FULLY INSTALLED, 133 00:07:25,929 --> 00:07:28,264 A COMPUTER NUMERICAL CONTROL MACHINE, 134 00:07:28,266 --> 00:07:29,465 OR CNC, 135 00:07:29,467 --> 00:07:33,920 APPLIES BONDING ADHESIVE TO THE TOP SECTION OF THE BLOCK. 136 00:07:33,922 --> 00:07:35,321 DESPITE ITS POWER, 137 00:07:35,323 --> 00:07:39,284 THE ENGINE IS SURPRISINGLY COMPACT AND LIGHTWEIGHT. 138 00:07:39,286 --> 00:07:40,685 A SET OF GUIDE RODS 139 00:07:40,687 --> 00:07:43,580 HELPS THE TECHNICIAN LOCATE THE PART ON THE BLOCK. 140 00:07:47,344 --> 00:07:49,611 THE TECHNICIAN FURTHER STRENGTHENS THE BLOCK 141 00:07:49,613 --> 00:07:51,405 WITH BOLTS. 142 00:07:53,276 --> 00:07:57,169 NEXT, A WORKER POSITIONS THE CYLINDER HEADS ON TOP. 143 00:07:57,171 --> 00:08:02,433 THE TWO CYLINDER HEADS HAVE DOUBLE OVERHEAD CAMSHAFTS. 144 00:08:02,435 --> 00:08:05,694 TECHNICIANS USE PRECISION TOOLS TO TIGHTEN EACH OF THE BOLTS 145 00:08:05,696 --> 00:08:07,989 TO ACHIEVE OPTIMUM CLAMP LOAD. 146 00:08:13,454 --> 00:08:16,848 A WORKER FITS THE DRIVETRAINS TO THE FRONT OF THE ENGINE. 147 00:08:16,850 --> 00:08:18,784 THESE WILL DRIVE THE FOUR CAMSHAFTS 148 00:08:18,786 --> 00:08:21,177 AND ENGINE ANCILLARIES. 149 00:08:21,179 --> 00:08:23,505 McLAREN AND RICARDO HAVE WORKED TOGETHER 150 00:08:23,507 --> 00:08:28,268 TO OPTIMIZE EVERY DETAIL OF THE M838T ENGINE. 151 00:08:28,270 --> 00:08:30,071 THEIR WORK HAS BEEN RECOGNIZED 152 00:08:30,073 --> 00:08:32,732 WITH THE PRESTIGIOUS ENGINE OF THE YEAR AWARD 153 00:08:32,734 --> 00:08:34,000 FOR TWO YEARS RUNNING 154 00:08:34,002 --> 00:08:35,794 IN THE 3- TO 4-LITER CATEGORY. 155 00:08:39,458 --> 00:08:44,886 DESPITE A POWER OUTPUT OF 616 HORSEPOWER AT 7,500 RPMs, 156 00:08:44,888 --> 00:08:48,749 THE ENGINE HAS THE LOWEST CO2 EMISSIONS IN ITS CLASS. 157 00:08:53,481 --> 00:08:56,406 THE TECHNICIAN HAS INSTALLED ALL OF THE COMPONENTS, 158 00:08:56,408 --> 00:08:59,477 BUT BEFORE HE CAN TEST THAT THE ENGINE WILL TURN OVER CORRECTLY, 159 00:08:59,479 --> 00:09:01,971 HE MUST ENSURE THAT HE HAS APPLIED 160 00:09:01,973 --> 00:09:03,907 THE CORRECT LEVEL OF TENSION. 161 00:09:06,702 --> 00:09:11,098 HE NOW FITS THE SPARK PLUGS TO THE EIGHT CYLINDERS. 162 00:09:11,100 --> 00:09:14,026 THE ENGINE DESIGNERS FOUND WEIGHT-SAVING POSSIBILITIES 163 00:09:14,028 --> 00:09:17,054 IN EVERY CORNER OF THE ASSEMBLY. 164 00:09:17,056 --> 00:09:20,391 EVEN THE WALLS OF THE SPARK PLUG TUBES HAVE BEEN THINNED, 165 00:09:20,393 --> 00:09:23,652 REDUCING THEIR WEIGHT BY 5 1/2 POUNDS. 166 00:09:26,115 --> 00:09:27,715 WITH EVERYTHING IN PLACE, 167 00:09:27,717 --> 00:09:29,776 THE FRONT COVER AND CYLINDER HEAD COVERS 168 00:09:29,778 --> 00:09:31,310 ARE INSTALLED, 169 00:09:31,312 --> 00:09:33,938 COMPLETING THIS STAGE OF THE ENGINE ASSEMBLY. 170 00:09:35,408 --> 00:09:37,067 HERE AT STATION EIGHT, 171 00:09:37,069 --> 00:09:40,270 TECHNICIANS FIT THE EXHAUST MANIFOLD AND TWIN TURBOS 172 00:09:40,272 --> 00:09:43,465 TOGETHER WITH THE REQUIRED COOLANT AND LUBRICATION PIPES. 173 00:09:45,394 --> 00:09:48,996 THERE ARE SOME TRICKY ELEMENTS TO THE INSTALLATION PROCESS. 174 00:09:48,998 --> 00:09:50,322 DESPITE THIS, 175 00:09:50,324 --> 00:09:53,684 WORKERS MUST KEEP PACE WITH THE PRODUCTION SPEED. 176 00:09:53,686 --> 00:09:56,620 SPECIALIZED TOOLS HELP THEM QUICKLY TIGHTEN BOLTS 177 00:09:56,622 --> 00:09:59,582 TO THE CORRECT TORQUE AT DIFFICULT ANGLES. 178 00:10:03,146 --> 00:10:04,879 THE LIGHTWEIGHT INTAKE MANIFOLD 179 00:10:04,881 --> 00:10:07,340 IS ONE OF THE LAST PARTS TO BE FITTED. 180 00:10:12,039 --> 00:10:15,365 NEXT, THE TECHNICIAN INSTALLS THE FUEL RAIL. 181 00:10:15,367 --> 00:10:19,228 THE ENGINE'S FUEL CONSUMPTION IS 24 MILES PER GALLON. 182 00:10:19,230 --> 00:10:22,890 THIS IS EXTREMELY EFFICIENT FOR A V8 SUPERCAR. 183 00:10:25,494 --> 00:10:26,785 THE FULLY BUILT ENGINES 184 00:10:26,787 --> 00:10:28,587 ARE TRANSFERRED FROM THE PRODUCTION LINE 185 00:10:28,589 --> 00:10:32,384 TO SPECIALLY DESIGNED PALLETS. 186 00:10:32,386 --> 00:10:33,918 FROM HERE, TECHNICIANS 187 00:10:33,920 --> 00:10:38,048 PREPARE THEM TO BE FITTED ONTO A DYNAMOMETER, OR DYNO. 188 00:10:38,050 --> 00:10:40,375 THIS TEST IS KNOWN AS BIPO, 189 00:10:40,377 --> 00:10:43,337 WHICH STANDS FOR "BREAK IN AND PASS OFF." 190 00:10:45,474 --> 00:10:47,266 RICARDO TESTS EVERY ENGINE 191 00:10:47,268 --> 00:10:50,995 TO ENSURE IT MEETS ALL OF ITS PARAMETERS. 192 00:10:50,997 --> 00:10:53,664 OPERATORS REV THE ENGINE RIGHT UP TO THE LIMITER 193 00:10:53,666 --> 00:10:57,126 AND IN SOME CASES BRING IT TO FULL POWER. 194 00:10:57,128 --> 00:10:58,820 DURING THESE TESTS, 195 00:10:58,822 --> 00:11:03,116 THE EXHAUST SYSTEM HEATS UP TO OVER 1,700 DEGREES. 196 00:11:12,688 --> 00:11:16,415 Narrator: ONCE RICARDO TECHNICIANS FULLY ASSEMBLE THE ENGINES, 197 00:11:16,417 --> 00:11:19,043 THEY SEND THEM HERE TO THE McLAREN PRODUCTION CENTRE 198 00:11:19,045 --> 00:11:20,578 IN SURREY, ENGLAND. 199 00:11:20,580 --> 00:11:23,239 THESE PAINTED CAR BODIES ARE READY TO MEET 200 00:11:23,241 --> 00:11:26,042 THEIR BRAND-NEW, STATE-OF-THE-ART POWERTRAINS. 201 00:11:29,440 --> 00:11:32,165 AT THE START OF THE GENERAL ASSEMBLY LINE, 202 00:11:32,167 --> 00:11:35,327 A TECHNICIAN BRINGS THE POWERTRAIN OVER TO A CAR BODY. 203 00:11:38,231 --> 00:11:41,458 HE POSITIONS THE POWERTRAIN DIRECTLY UNDER THE BODY. 204 00:11:41,460 --> 00:11:45,187 THE BODY WILL THEN BE LOWERED ONTO THE POWERTRAIN. 205 00:11:45,189 --> 00:11:47,381 AT A DIFFERENT SUBASSEMBLY STATION, 206 00:11:47,383 --> 00:11:49,651 TECHNICIANS HAVE ALREADY UNITED THE ENGINE 207 00:11:49,653 --> 00:11:52,646 WITH ITS SEVEN-SPEED, DUAL-CLUTCH GEARBOX. 208 00:11:54,316 --> 00:11:55,741 WHEEL-MOUNTED ROCKER PADDLES 209 00:11:55,743 --> 00:11:57,875 ALLOW DRIVERS TO SHIFT THE TRANSMISSION 210 00:11:57,877 --> 00:12:00,604 BETWEEN FULLY AUTOMATIC, SEMIAUTOMATIC, 211 00:12:00,606 --> 00:12:02,940 AND FULLY MANUAL MODES. 212 00:12:07,271 --> 00:12:09,864 A TECHNICIAN FITS A HEAT SHIELD OVER THE ENGINE 213 00:12:09,866 --> 00:12:12,258 BEFORE INSTALLING THE EXHAUST SYSTEM. 214 00:12:15,496 --> 00:12:17,622 HE USES A BATTERY-POWERED WRENCH 215 00:12:17,624 --> 00:12:20,216 TO SECURE THE COMPONENTS TEMPORARILY. 216 00:12:20,218 --> 00:12:24,946 HE COMPLETES THE PROCESS WITH A PRESET MANUAL TORQUE WRENCH. 217 00:12:24,948 --> 00:12:27,549 THE EXHAUST SYSTEM HAS BEEN DESIGNED TO OPTIMIZE 218 00:12:27,551 --> 00:12:30,544 BOTH EFFICIENCY AND SOUND QUALITY. 219 00:12:34,241 --> 00:12:39,370 A CARBON CERAMIC BRAKING SYSTEM COMES STANDARD ON THE 650S. 220 00:12:39,372 --> 00:12:40,830 IN THE 1970s, 221 00:12:40,832 --> 00:12:43,833 THE AEROSPACE INDUSTRY PIONEERED THE MANUFACTURING 222 00:12:43,835 --> 00:12:47,929 OF THIS COMPLEX, HIGH-PERFORMANCE MATERIAL. 223 00:12:47,931 --> 00:12:49,322 BY THE 1980s, 224 00:12:49,324 --> 00:12:51,958 IT BEGAN APPEARING ON RACE CARS. 225 00:12:54,254 --> 00:12:56,121 NOT ONLY IS IT LIGHTER THAN METAL, 226 00:12:56,123 --> 00:12:58,715 IT'S MORE DURABLE, RESISTS CORROSION BETTER, 227 00:12:58,717 --> 00:13:01,143 AND CAN OUTPERFORM TRADITIONAL BRAKE DISCS 228 00:13:01,145 --> 00:13:03,479 IN BOTH WET AND DRY CONDITIONS. 229 00:13:09,204 --> 00:13:10,136 AT THIS STATION, 230 00:13:10,138 --> 00:13:11,871 A TECHNICIAN PREPARES THE CAR 231 00:13:11,873 --> 00:13:14,999 FOR AN OPERATION CALLED THE ENGINE RUN-UP. 232 00:13:15,001 --> 00:13:17,360 HE PLUGS AN EXHAUST EXTRACTION SYSTEM 233 00:13:17,362 --> 00:13:19,896 INTO A VENT HIDDEN IN THE FLOOR. 234 00:13:19,898 --> 00:13:23,157 THIS WAY, WHEN THE VEHICLE IS STARTED FOR THE FIRST TIME, 235 00:13:23,159 --> 00:13:25,953 EXHAUST GASSES ARE VENTED OUT OF THE BUILDING. 236 00:13:34,046 --> 00:13:37,114 THE VEHICLE HAS PASSED THE ENGINE RUN-UP PHASE. 237 00:13:37,116 --> 00:13:39,775 IT'S TIME TO INSTALL THE ENGINE COVER. 238 00:13:39,777 --> 00:13:41,310 THIS INCLUDES ANOTHER HEAT SHIELD, 239 00:13:41,312 --> 00:13:43,437 CREATING A SANDWICH LAYER. 240 00:13:43,439 --> 00:13:46,432 THE ADDED LAYER QUICKLY REDUCES EXHAUST GAS TEMPERATURES 241 00:13:46,434 --> 00:13:50,562 FROM OVER 1,600 DEGREES TO JUST UNDER 600. 242 00:13:50,564 --> 00:13:52,297 A PREFITTED PROTECTIVE COVERING 243 00:13:52,299 --> 00:13:54,524 PREVENTS DAMAGE TO THE PAINTWORK 244 00:13:54,526 --> 00:13:55,826 DURING INSTALLATION. 245 00:13:59,590 --> 00:14:01,589 THE TECHNICIAN CAN NOW FIT THE AIR BRAKE 246 00:14:01,591 --> 00:14:03,851 ONTO ITS MECHANISM. 247 00:14:03,853 --> 00:14:06,779 THE AIR BRAKE INCREASES BRAKING PERFORMANCE. 248 00:14:06,781 --> 00:14:09,982 IT ALSO ADDS DRAG AND REAR DOWNFORCE. 249 00:14:13,680 --> 00:14:16,406 TWO TECHNICIANS MOVE THE CAR'S LIGHTWEIGHT WINDSHIELD 250 00:14:16,408 --> 00:14:17,606 ONTO ITS FRAME, 251 00:14:17,608 --> 00:14:20,335 WHERE ADHESIVE BONDS IT IN PLACE. 252 00:14:20,337 --> 00:14:23,397 McLAREN HAS MAXIMIZED THE DEPTH OF THE WINDSHIELD 253 00:14:23,399 --> 00:14:26,033 TO ENHANCE VISIBILITY FOR THE DRIVER. 254 00:14:30,031 --> 00:14:32,222 McLAREN'S SIGNATURE DIHEDRAL DOORS 255 00:14:32,224 --> 00:14:35,684 FIRST APPEARED ON THE LEGENDARY F1. 256 00:14:35,686 --> 00:14:38,354 WITH JUST A SINGLE HINGE FOR AN ATTACHMENT POINT, 257 00:14:38,356 --> 00:14:40,615 THE DOOR SYSTEM IS EYE-CATCHING. 258 00:14:40,617 --> 00:14:42,750 AT THE SAME TIME, IT'S PRACTICAL, 259 00:14:42,752 --> 00:14:47,305 STRAIGHTFORWARD, AND LIGHTER THAN CONVENTIONAL DOORS. 260 00:14:47,307 --> 00:14:49,307 AFTER CAREFULLY FITTING THE DOOR 261 00:14:49,309 --> 00:14:52,435 AND ENSURING ALL MEASUREMENTS MEET THE EXACTING PARAMETERS 262 00:14:52,437 --> 00:14:55,172 SPECIFIED BY THE DESIGNERS AND ENGINEERS, 263 00:14:55,174 --> 00:14:59,034 THE TECHNICIAN WIPES DOWN THE SURFACE. 264 00:14:59,036 --> 00:15:04,257 THE GENERAL ASSEMBLY LINE FOR THE 650S FEATURES 34 STATIONS. 265 00:15:05,193 --> 00:15:08,920 VEHICLES MOVE FROM STATION TO STATION EVERY 48 MINUTES, 266 00:15:08,922 --> 00:15:12,515 COMPLETING THE LINE IN ROUGHLY 27 HOURS. 267 00:15:12,517 --> 00:15:16,344 McLAREN BUILDS BOTH THE 650S COUPE AND CONVERTIBLE 268 00:15:16,346 --> 00:15:18,346 ON THIS LINE SIMULTANEOUSLY. 269 00:15:26,356 --> 00:15:29,216 Narrator: THIS McLAREN 650S IS ASSEMBLED. 270 00:15:29,218 --> 00:15:32,077 NOW, IT'S TIME FOR TUNING AND TESTING. 271 00:15:32,079 --> 00:15:34,279 IN THE WHEEL ALIGNMENT AND GEOMETRY AREA, 272 00:15:34,281 --> 00:15:37,074 TECHNICIANS CHECK ALL KEY CAMBERS AND ALIGNMENTS 273 00:15:37,076 --> 00:15:40,303 BEFORE PREPARING THE CAR FOR DYNAMIC TESTING. 274 00:15:42,240 --> 00:15:46,367 WHEEL ALIGNMENT IS CRUCIAL FOR SAFE AND EFFICIENT PERFORMANCE. 275 00:15:46,369 --> 00:15:50,096 McLAREN USES A HUB-MOUNTED WIRELESS WHEEL ALIGNMENT SYSTEM 276 00:15:50,098 --> 00:15:52,098 THAT DEPLOYS MULTIPLE CAMERAS 277 00:15:52,100 --> 00:15:53,825 TO ACCURATELY DETERMINE 278 00:15:53,827 --> 00:15:56,386 THE EXACT POSITION OF THE WHEELS. 279 00:15:56,388 --> 00:15:58,789 TECHNICIANS MANUALLY ADJUST THE ALIGNMENT 280 00:15:58,791 --> 00:16:03,119 TO ENSURE IT MEETS THE EXACT DESIGN REQUIREMENTS. 281 00:16:03,121 --> 00:16:06,314 THE WHEELS ARE CUSTOM-MADE FROM A LIGHTWEIGHT FORGED ALLOY 282 00:16:06,316 --> 00:16:08,908 SPECIFICALLY FOR THE 650S. 283 00:16:13,240 --> 00:16:15,906 PIRELLI, A McLAREN TECHNOLOGY PARTNER, 284 00:16:15,908 --> 00:16:20,470 CUSTOM-DEVELOPED THE P ZERO CORSA TIRES FOR THE 650S. 285 00:16:20,472 --> 00:16:22,931 ONCE THE WHEELS HAVE BEEN ACCURATELY ALIGNED, 286 00:16:22,933 --> 00:16:25,626 TECHNICIANS REMOVE THE WIRELESS SYSTEM. 287 00:16:28,464 --> 00:16:32,525 THEN, EACH CAR IS SUBJECTED TO A FINAL DIAGNOSTIC TEST. 288 00:16:32,527 --> 00:16:34,351 THIS INCLUDES CYCLING THE AIR BRAKE 289 00:16:34,353 --> 00:16:36,120 THROUGH ITS RANGE OF MOTION. 290 00:16:39,684 --> 00:16:42,476 TO DISPLACE WEIGHT AND CHECK THE SUSPENSION SYSTEM, 291 00:16:42,478 --> 00:16:46,440 EVERY VEHICLE MUST TRAVEL OVER THE DYNAMIC DISPLACEMENT ZONE. 292 00:16:49,010 --> 00:16:53,639 THIS GLASS CUBE HOUSES THE DYNAMIC TESTING EQUIPMENT. 293 00:16:53,641 --> 00:16:56,233 HERE, THE CARS RUN ON A ROLLING ROAD. 294 00:16:56,235 --> 00:17:00,763 A DRIVER PUTS IT THROUGH A RIGOROUS TESTING PROGRAM. 295 00:17:00,765 --> 00:17:03,423 A COMPUTER MONITOR IN FRONT OF THE CAR 296 00:17:03,425 --> 00:17:07,653 DETAILS THE TESTING STEPS AND REGISTERS THE RESULTS. 297 00:17:07,655 --> 00:17:09,856 MOST OF THE MAJOR COMPONENTS OF THE CAR 298 00:17:09,858 --> 00:17:13,317 HAVE ALREADY UNDERGONE EXTENSIVE TESTING. 299 00:17:13,319 --> 00:17:17,180 THE ENGINE ALONE GOES THROUGH 5,000 HOURS OF BASIC TESTING 300 00:17:17,182 --> 00:17:20,409 FOLLOWED BY 3,000 HOURS OF TRACK SIMULATION. 301 00:17:27,735 --> 00:17:29,601 ONCE THE TEST IS COMPLETE, 302 00:17:29,603 --> 00:17:31,862 THE DRIVER EXITS THE DYNAMIC TEST 303 00:17:31,864 --> 00:17:33,764 AND HEADS FOR THE NEXT STATION. 304 00:17:37,329 --> 00:17:41,622 NEXT, THE CAR ENTERS AN EXTREME WET-WEATHER TESTING CHAMBER. 305 00:17:41,624 --> 00:17:45,084 McLAREN CALLS THIS "THE MONSOON TEST." 306 00:17:45,086 --> 00:17:46,419 TRUE TO ITS NAME, 307 00:17:46,421 --> 00:17:49,948 THE FACILITY RELEASES A TORRENT OF RAIN ON THE CAR. 308 00:17:49,950 --> 00:17:52,476 OVER 4,000 GALLONS OF WATER HAMMERS 309 00:17:52,478 --> 00:17:56,372 THE SURFACE OF THE 650S FROM EVERY DIRECTION. 310 00:17:56,374 --> 00:17:58,039 TRUE TO McLAREN'S EFFICIENCY GOALS, 311 00:17:58,041 --> 00:18:01,502 EVERY GALLON IS RECYCLED AND DEIONIZED. 312 00:18:04,031 --> 00:18:06,833 EVERY MODEL BUILT AT THE McLAREN PRODUCTION CENTRE 313 00:18:06,835 --> 00:18:09,026 MUST ENDURE AN EXTENSIVE ROAD TEST. 314 00:18:09,028 --> 00:18:13,456 McLAREN CALLS THIS "A SHAKEDOWN." 315 00:18:13,458 --> 00:18:15,984 TO PREPARE THIS 650S FOR ITS SHAKEDOWN, 316 00:18:15,986 --> 00:18:18,053 THE TECHNICIAN APPLIES PROTECTION 317 00:18:18,055 --> 00:18:19,880 OVER THE CAR'S LOWER BODY WORK. 318 00:18:24,645 --> 00:18:28,206 THIS OPERATION MUST BE DONE BOTH QUICKLY AND ACCURATELY 319 00:18:28,208 --> 00:18:30,408 TO PREVENT THE CAREFULLY PREPARED CAR 320 00:18:30,410 --> 00:18:33,036 FROM BEING DAMAGED DURING THE ROAD TEST. 321 00:18:40,863 --> 00:18:44,722 EACH 650S GOES THROUGH THE DYNAMIC TESTING PHASE 322 00:18:44,724 --> 00:18:46,991 WITH THE FINAL ALLOY WHEELS AND TIRES 323 00:18:46,993 --> 00:18:48,385 THAT IT WILL BE WEARING 324 00:18:48,387 --> 00:18:50,487 WHEN THE CUSTOMER FIRST DRIVES IT. 325 00:18:52,516 --> 00:18:54,483 BUT FOR THE SHAKEDOWN, THE TECHNICIAN 326 00:18:54,485 --> 00:18:57,478 TEMPORARILY REPLACES THEM WITH AN IDENTICAL SET 327 00:18:57,480 --> 00:19:00,114 THAT HAS BEEN PUT ASIDE FOR THIS PURPOSE. 328 00:19:05,905 --> 00:19:07,638 NOW, A McLAREN TECHNICIAN 329 00:19:07,640 --> 00:19:12,994 TAKES THE 650S OUTDOORS FOR THE FIRST TIME. 330 00:19:12,996 --> 00:19:16,231 HE TESTS EVERY ELEMENT OF THE CAR'S PERFORMANCE. 331 00:19:16,233 --> 00:19:19,292 AN EXTENSIVE TEST ON ROAD AND TRACK IS REQUIRED, 332 00:19:19,294 --> 00:19:21,027 WORKING THROUGH THE VARIOUS SYSTEMS 333 00:19:21,029 --> 00:19:23,589 BOTH INTERNALLY AND EXTERNALLY. 334 00:19:23,591 --> 00:19:25,849 THIS IS A STANDARD PROCEDURE 335 00:19:25,851 --> 00:19:28,385 IN HIGH-PERFORMANCE CAR MANUFACTURING. 336 00:19:28,387 --> 00:19:30,379 IT FOLLOWS AN ENGINEERING CONCEPT 337 00:19:30,381 --> 00:19:32,782 KNOWN AS THE BATHTUB CURVE. 338 00:19:32,784 --> 00:19:35,243 ACCORDING TO THIS CONCEPT, 339 00:19:35,245 --> 00:19:38,738 ANY COMPONENTS THAT MIGHT FAIL WILL FAIL EARLY, 340 00:19:38,740 --> 00:19:43,001 SO WHAT SURVIVES THE SHAKEDOWN WILL LAST A LONG TIME. 341 00:19:43,003 --> 00:19:45,069 ON A GRAPH, 342 00:19:45,071 --> 00:19:48,399 THIS CONCEPT SHOWS UP AS A CURVE THAT LOOKS LIKE A BATHTUB, 343 00:19:48,401 --> 00:19:50,159 HENCE THE NAME. 344 00:19:55,225 --> 00:19:57,558 THIS CAR HAS PASSED THE SHAKEDOWN TEST 345 00:19:57,560 --> 00:20:00,953 AND HAS FINALLY EARNED ITS McLAREN BADGE. 346 00:20:00,955 --> 00:20:03,281 THIS ICONIC SYMBOL WAS INSPIRED 347 00:20:03,283 --> 00:20:06,610 BY THE ONE ON THE HOOD OF THE LEGENDARY F1. 348 00:20:06,612 --> 00:20:10,405 THE 650S LOGO COMPLETES THE EXTERIOR STYLING. 349 00:20:13,043 --> 00:20:15,369 IT'S TIME FOR THE LAST PHASE OF PRODUCTION 350 00:20:15,371 --> 00:20:18,764 AND ONE FINAL QUALITY CHECK. 351 00:20:18,766 --> 00:20:20,032 INSPECTION LIGHTING 352 00:20:20,034 --> 00:20:22,627 REVEALS ANY POTENTIAL DAMAGE DONE 353 00:20:22,629 --> 00:20:24,094 DURING THE SHAKEDOWN. 354 00:20:24,096 --> 00:20:27,056 IT'S HERE THAT EACH CAR RECEIVES A FINAL POLISH 355 00:20:27,058 --> 00:20:29,258 BEFORE IT'S HANDED OVER TO THE DISPATCH TEAM 356 00:20:29,260 --> 00:20:30,952 FOR DELIVERY. 357 00:20:38,720 --> 00:20:40,845 THE SHAPE OF THE L.E.D. HEADLAMPS, 358 00:20:40,847 --> 00:20:42,447 THE DISTINCTIVE DOOR BLADES, 359 00:20:42,449 --> 00:20:44,340 AND FRONT AND REAR BUMPER DESIGN 360 00:20:44,342 --> 00:20:48,304 ALL CONTRIBUTE TO THE DRAMATIC LOOK OF THE 650S. 361 00:20:50,407 --> 00:20:54,268 AS STANDARD, McLAREN TRIMS THE 650S INTERIOR 362 00:20:54,270 --> 00:20:57,529 WITH LIGHTWEIGHT ALCANTARA UPHOLSTERY. 363 00:20:57,531 --> 00:20:59,991 THE ELECTRICALLY RETRACTABLE HARDTOP ROOF 364 00:20:59,993 --> 00:21:02,927 AUTOMATICALLY LOWERS IN JUST 17 SECONDS. 365 00:21:02,929 --> 00:21:04,420 THIS CAN BE DONE AT REST 366 00:21:04,422 --> 00:21:07,749 OR AT ANY SPEED UP TO 20 MILES PER HOUR. 367 00:21:07,751 --> 00:21:10,285 BRUCE McLAREN DREAMED OF LAUNCHING 368 00:21:10,287 --> 00:21:12,078 A ROAD-LEGAL SPORTS CAR, 369 00:21:12,080 --> 00:21:13,947 BUT SADLY, HE DIED IN 1970 370 00:21:13,949 --> 00:21:16,742 WHILE TESTING HIS LATEST CAN-AM RACER. 371 00:21:16,744 --> 00:21:19,937 THE RELEASE OF THE CELEBRATED F1 IN 1992 372 00:21:19,939 --> 00:21:21,572 FULFILLED HIS DREAM. 373 00:21:21,574 --> 00:21:24,366 THE 650S IS THE MOST RECENT ADDITION 374 00:21:24,368 --> 00:21:26,702 TO A RANGE OF McLAREN SUPERCARS 375 00:21:26,704 --> 00:21:28,963 THAT SPEED BRUCE McLAREN'S LEGACY 376 00:21:28,965 --> 00:21:31,666 INTO THE 21st CENTURY. 29905

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