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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,937 --> 00:00:05,162
THE McLAREN 650S,
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00:00:05,164 --> 00:00:08,224
A SUPERCAR FOR THE RACE TRACK
OR THE OPEN ROAD.
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00:00:17,218 --> 00:00:20,153
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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FAMED NEW ZEALAND DRIVER
BRUCE McLAREN
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WON HIS FIRST RACE
IN THE AUSTIN 7 ULSTER.
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00:00:30,841 --> 00:00:34,968
HE FOUNDED BRUCE McLAREN RACING
IN 1963.
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00:00:34,970 --> 00:00:38,865
THE TEAM COMPETED AND WON
IN THE FORMULA ONE, CAN-AM,
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00:00:38,867 --> 00:00:41,859
INDY 500, AND LE MANS RACES.
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00:00:41,861 --> 00:00:43,194
TODAY, McLAREN CARS
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00:00:43,196 --> 00:00:47,991
ARE LEGENDARY FOR
THEIR EXTRAORDINARY PERFORMANCE.
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00:00:47,993 --> 00:00:52,453
IN 1992, THE CAR MAKER
UNVEILED THE McLAREN F1,
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00:00:52,455 --> 00:00:56,883
A ROAD CAR THAT REWROTE
THE SUPERCAR RULE BOOK.
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00:00:56,885 --> 00:00:59,011
WITH THE F1,
McLAREN DISTILLED
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00:00:59,013 --> 00:01:01,605
ITS UNPARALLELED SUCCESS
ON THE TRACK
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00:01:01,607 --> 00:01:04,141
INTO THE FASTEST
NATURALLY-ASPIRATED
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00:01:04,143 --> 00:01:06,269
PRODUCTION CAR IN THE WORLD.
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THE 650S CONTINUES
THE TRADITION.
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00:01:11,768 --> 00:01:14,027
IT IS A SERIES PRODUCTION
SUPERCAR
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00:01:14,029 --> 00:01:16,629
AVAILABLE AS A COUPE
OR CONVERTIBLE.
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00:01:16,631 --> 00:01:18,423
THE CAR'S TWIN-TURBO V8
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00:01:18,425 --> 00:01:22,486
IS THE POWERHOUSE BEHIND
A BLISTERING ACCELERATION PACE.
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00:01:22,488 --> 00:01:25,955
IT HAS A TOP SPEED
OF 207 MILES PER HOUR
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00:01:25,957 --> 00:01:29,685
AND CAN GO FROM 0 TO 60
IN JUST THREE SECONDS.
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00:01:35,643 --> 00:01:38,044
BACK IN 1981,
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McLAREN PIONEERED THE USE
OF CARBON FIBER IN FORMULA ONE.
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00:01:42,041 --> 00:01:45,001
AND IN 1992, THE McLAREN F1
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BECAME THE WORLD'S FIRST
CARBON-FIBER ROAD CAR.
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THE 650S IS NO EXCEPTION.
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IT'S FITTED WITH A LIGHTWEIGHT
CARBON-FIBER MONOCELL CHASSIS
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00:01:54,463 --> 00:01:58,157
WITH ALUMINUM CRASH STRUCTURES
BOLTED TO THE FRONT AND REAR.
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00:02:00,486 --> 00:02:02,219
THE McLAREN PRODUCTION CENTRE
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IS LOCATED NEXT DOOR
TO THE McLAREN TECHNOLOGY CENTRE
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00:02:05,215 --> 00:02:07,208
IN SURREY, ENGLAND.
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00:02:07,210 --> 00:02:08,943
AT THIS STATION,
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00:02:08,945 --> 00:02:11,671
A TECHNICIAN ASSEMBLES THE FRONT
AND REAR CRASH STRUCTURES
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00:02:11,673 --> 00:02:15,567
ONTO THE CARBON-FIBER MONOCELL.
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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.
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00:02:20,232 --> 00:02:23,592
HE USES A WRENCH WITH A PRESET
TORQUE SPECIFICATION
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00:02:23,594 --> 00:02:26,228
TO TIGHTEN THE BOLTS.
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00:02:26,230 --> 00:02:31,024
LIKE MANY SUPERCARS,
THE 650S IS HAND-BUILT.
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00:02:31,026 --> 00:02:33,085
EVEN THOUGH THERE ARE
NO CONVEYER BELTS
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00:02:33,087 --> 00:02:34,887
OR ROBOTS IN THIS FACILITY,
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00:02:34,889 --> 00:02:38,983
McLAREN STILL MANAGES
TO CONSTRUCT EIGHT CARS A DAY.
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THE TECHNICIAN MARKS EACH BOLT
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TO NOTE THAT IT'S BEEN TIGHTENED
TO THE CORRECT TORQUE.
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00:02:50,171 --> 00:02:52,997
A TWO-PART, HIGH-STRENGTH
STRUCTURAL ADHESIVE
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00:02:52,999 --> 00:02:55,667
IS APPLIED TO LARGE PARTS
OF THE BODY STRUCTURE,
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00:02:55,669 --> 00:02:57,795
LIKE THIS WINDSHIELD FRAME.
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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.
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00:03:10,819 --> 00:03:13,745
THESE POSITIONING TOOLS
MUST BE INCREDIBLY ACCURATE
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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.
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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
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00:03:25,300 --> 00:03:27,802
AND WHEELS IT
TO THE NEXT STATION.
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00:03:29,497 --> 00:03:31,897
HERE AT BODY ASSEMBLY
STATION 90,
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00:03:31,899 --> 00:03:34,491
TECHNICIANS BRING
THE FINAL BODY PANELS
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00:03:34,493 --> 00:03:37,153
TO A FIXTURE EQUIPPED
WITH AN AIR VAC SYSTEM
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00:03:37,155 --> 00:03:41,449
WHICH SUCTIONS THE PARTS
IN PLACE.
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00:03:41,451 --> 00:03:44,852
ONCE A TECHNICIAN SLIDES
THE MONOCELL INTO THE STATION,
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00:03:44,854 --> 00:03:47,714
IT'S CLAMPED SECURELY IN PLACE.
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TECHNICIANS THEN MANUALLY ROTATE
THE PRELOADED PARTS ONTO IT.
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00:03:52,380 --> 00:03:55,773
AN AUTOMATED CERAMIC HEATER
SYSTEM WILL CURE THE ADHESIVE
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00:03:55,775 --> 00:03:58,667
IN JUST 35 MINUTES.
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00:03:58,669 --> 00:04:01,729
A MOTOR-POWERED MECHANICAL GATE
ROTATES THE ROOF PANEL
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00:04:01,731 --> 00:04:06,125
180 DEGREES
ONTO THE TOP OF THE CAR BODY.
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00:04:06,127 --> 00:04:08,461
THANKS TO THAT CERAMIC HEATER,
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00:04:08,463 --> 00:04:11,456
TECHNICIANS CAN UNCLAMP
THE FULLY CURED BODY PANELS
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00:04:11,458 --> 00:04:13,951
AFTER JUST 35 MINUTES.
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00:04:15,554 --> 00:04:16,820
IN THE CONTROLLED ENVIRONMENT
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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,
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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
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00:04:26,149 --> 00:04:28,140
THAT TRAVEL THE LENGTH
OF THE BODY,
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00:04:28,142 --> 00:04:31,836
MEASURING EVERY ELEMENT
OF THE ASSEMBLY.
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00:04:31,838 --> 00:04:34,830
EXTENDING FROM THE END
OF EACH ARM IS A SMALLER ARM
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00:04:34,832 --> 00:04:37,567
THAT CAN ROTATE 360 DEGREES.
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00:04:37,569 --> 00:04:39,360
THIS ROTATION ALLOWS THE ARM
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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
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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
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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.
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00:05:21,390 --> 00:05:22,923
A CLEVER BUSINESSMAN,
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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.
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00:05:44,364 --> 00:05:47,966
ONCE COATED, A CAR BODY
MOVES THROUGH AN OVEN.
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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.
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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,
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00:06:15,939 --> 00:06:18,465
ASSEMBLES
THIS EIGHT-CYLINDER POWERHOUSE,
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00:06:18,467 --> 00:06:20,726
WHICH FEATURES
TWIN TURBOCHARGERS.
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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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