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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS" --
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00:00:02,803 --> 00:00:05,562
THE FALCON F7,
A MID-ENGINE SUPERCAR
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00:00:05,564 --> 00:00:08,357
WITH THE HEART
OF AN AMERICAN HOT ROD.
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-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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THE FALCON F7 IS MADE
IN HOLLY, MICHIGAN,
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THE HEART
OF AMERICAN CAR COUNTRY.
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JEFF LEMKE,
FOUNDER OF FALCON MOTORSPORTS,
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GREW UP IN THE DETROIT AREA.
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00:00:36,572 --> 00:00:40,266
HE FELL IN LOVE
WITH CORVETTES AS A CHILD.
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00:00:40,268 --> 00:00:44,461
FOR YEARS, LEMKE BUILT SPECIALTY
PARTS FOR EXOTIC SPORTS CARS.
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00:00:44,463 --> 00:00:47,957
EVENTUALLY, HE DECIDED TO MAKE
HIS OWN SUPERCAR.
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00:00:51,655 --> 00:00:54,681
FALCON INTRODUCED THE F7
AS A CONCEPT CAR
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00:00:54,683 --> 00:00:59,878
AT THE NORTH AMERICAN
INTERNATIONAL AUTO SHOW IN 2011.
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00:00:59,880 --> 00:01:02,673
THE RECEPTION
WAS SO ENTHUSIASTIC THAT LEMKE
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00:01:02,675 --> 00:01:05,008
DECIDED TO BUILD CARS TO SELL.
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THE AWARDS HAVE BEEN
ROLLING IN EVER SINCE.
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JEFF LEMKE'S DESIGN
OF THE FALCON F7 PAYS HOMAGE
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TO HIS FAVORITE CARS --
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THE CORVETTE, THE FORD GT40,
AND THE FERRARI GTO.
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IT DRIVES LIKE AN OLD-SCHOOL
SPORTS CAR.
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00:01:24,156 --> 00:01:27,316
THERE ARE NO PADDLE SHIFTERS
AND NO AUTOMATIC OPTIONS.
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THE FALCON F7 IS MANUAL, PERIOD.
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CARS ARE NOT THE ONLY SOURCE OF
INSPIRATION FOR THE FALCON F7.
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00:01:40,306 --> 00:01:43,800
LEMKE INCORPORATED FEATURES
FROM U.S. AIR FORCE FIGHTER JETS
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00:01:43,802 --> 00:01:46,661
INTO THE DESIGN.
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FIGHTER JETS ARE BUILT
AROUND AERODYNAMIC EFFICIENCY,
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00:01:49,666 --> 00:01:51,758
SPEED, AND FUNCTIONALITY.
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00:01:53,929 --> 00:01:55,320
BUT THEIR AGGRESSIVE LINES
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HAVE THE POWER AND ATTITUDE
LEMKE WANTED FOR HIS CAR.
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00:01:59,952 --> 00:02:01,418
THE FALCON'S TAILLIGHTS
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AND CENTRALLY LOCATED EXHAUST
PIPE LOOK LIKE JET THRUSTERS.
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00:02:07,610 --> 00:02:08,942
EVEN THE NAME, F7,
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00:02:08,944 --> 00:02:11,738
IS A TRIBUTE TO PLANES,
LIKE THE F-15.
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00:02:13,942 --> 00:02:17,435
LEMKE STARTED BY SKETCHING OUT
HIS IDEA.
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BUT HE HAD TO BUILD A MODEL
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TO MAKE SURE THE DESIGN
WORKED IN THE REAL WORLD.
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LEMKE TAUGHT HIMSELF
THE TRADITIONAL CRAFT
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OF CLAY CAR SCULPTING
WHILE MAKING CUSTOM BODY PARTS
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00:02:34,088 --> 00:02:36,648
FOR VIPERS
AND OTHER EXOTIC CARS.
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00:02:39,319 --> 00:02:41,978
TYPICALLY, THIS IS SOMETHING
ONLY TRAINED ARTISANS
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00:02:41,980 --> 00:02:43,312
KNOW HOW TO DO.
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00:02:43,314 --> 00:02:46,241
LEMKE'S EXPERIENCE
COMES IN HANDY AS HE WORKS OUT
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00:02:46,243 --> 00:02:49,202
THE FINER DETAILS
OF THE F7's DESIGN.
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00:02:52,800 --> 00:02:55,133
ONCE HE'S SATISFIED
WITH HIS DESIGN,
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00:02:55,135 --> 00:02:57,394
A COMPUTER SCANS THE CLAY MODEL,
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00:02:57,396 --> 00:02:59,863
PROVIDING A DIGITAL IMAGE
THAT CAN BE REFINED
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00:02:59,865 --> 00:03:03,326
AND FINALIZED IN
COMPUTER-AIDED DESIGN SOFTWARE.
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00:03:07,990 --> 00:03:10,083
ONE ADVANTAGE
TO MANUFACTURING A CAR
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IN THE DETROIT AREA IS THAT
EVERYTHING YOU NEED IS NEARBY.
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TO CUT THE PIECES
FOR THE F7's ALUMINUM MONOCOQUE,
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FALCON FOUND A PLACE
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A MILE DOWN THE ROAD
THAT USES WATER-JET TECHNOLOGY.
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THE MACHINE
POSITIONS ITS CUTTING
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IN A WAY THAT MINIMIZES
LEFTOVER SCRAP METAL.
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00:03:36,095 --> 00:03:39,689
ONCE CUT, WORKERS REMOVE
THE PIECES FROM THE SHEET.
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EACH MONOCOQUE CHASSIS REQUIRES
2 1/2 SHEETS OF ALUMINUM.
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00:03:45,054 --> 00:03:48,315
BECAUSE THE WATER-JET CUTTING
PROCESS DOESN'T USE HEAT,
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00:03:48,317 --> 00:03:50,241
THE RESULT
IS AN EXTREMELY CLEAN,
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00:03:50,243 --> 00:03:53,471
PRECISE CUT WITH NO WARPING
OR DISTORTION OF THE METAL.
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00:03:57,042 --> 00:04:00,869
NEXT, THE SHEETS GO BACK TO
LEMKE'S MANUFACTURING FACILITY,
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00:04:00,871 --> 00:04:04,198
WHERE TECHNICIANS WELD THEM ONTO
THE TUBULAR ALUMINUM FRAMEWORK
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00:04:04,200 --> 00:04:05,992
OF THE CHASSIS.
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00:04:05,994 --> 00:04:08,461
LEMKE WORKS ALONGSIDE HIS TEAM
OF CRAFTSMEN
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00:04:08,463 --> 00:04:10,789
THROUGHOUT THE ASSEMBLY PROCESS.
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00:04:15,287 --> 00:04:17,887
HE STARTS BY TACK WELDING
THE PARTS IN PLACE
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00:04:17,889 --> 00:04:19,815
BEFORE COMPLETING THE JOINT.
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00:04:25,747 --> 00:04:29,008
ALUMINUM SURFACE COATING,
HIGH THERMAL CONDUCTIVITY
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00:04:29,010 --> 00:04:30,275
AND LOW MELTING TEMPERATURE
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MAKE THE WELDING PROCESS
DIFFERENT FROM WELDING STEEL.
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00:04:37,636 --> 00:04:39,628
ONCE THE MONOCOQUE IS COMPLETE,
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00:04:39,630 --> 00:04:42,823
A TECHNICIAN INSTALLS THE FORGED
ALUMINUM CONTROL ARMS
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00:04:42,825 --> 00:04:45,492
AND UPRIGHTS.
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00:04:45,494 --> 00:04:51,048
THESE ARE CORVETTE ZR1-BASED
PARTS FROM GENERAL MOTORS.
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00:04:51,050 --> 00:04:53,183
FALCON USES OFF-THE-SHELF
COMPONENTS
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00:04:53,185 --> 00:04:56,545
TO MAKE SERVICING THE F7 EASIER
AND CHEAPER.
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00:04:58,582 --> 00:05:00,841
WHILE THE BRAKE
PICTURED HERE IS STANDARD,
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00:05:00,843 --> 00:05:04,303
CARBON CERAMIC BRAKES
ARE OPTIONAL.
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00:05:04,305 --> 00:05:06,639
THE CAR HAS PUSH-ROD SUSPENSION
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00:05:06,641 --> 00:05:09,267
WITH THE SHOCKS
SEPARATED FROM THE CONTROL ARMS
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00:05:09,269 --> 00:05:11,528
TO CUT DOWN ON UNSPRUNG WEIGHT.
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00:05:20,923 --> 00:05:23,390
LEMKE AND ANOTHER TECHNICIAN
LOAD THE PRECUT,
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00:05:23,392 --> 00:05:27,119
PRE-BENT CHROMOLY STEEL
TUBING INTO A WELDING FIXTURE.
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00:05:29,549 --> 00:05:33,710
CHROMOLY STEEL'S HIGH CARBON
CONTENT GIVES IT ADDED STRENGTH.
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00:05:36,139 --> 00:05:39,407
FALCON COULD BUILD THE ROLL CAGE
OUT OF ALUMINUM,
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00:05:39,409 --> 00:05:42,502
BUT THE RESULT WOULD BE
A BULKY STRUCTURE INCONSISTENT
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00:05:42,504 --> 00:05:44,430
WITH THE LOOK OF THE F7.
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00:05:47,635 --> 00:05:50,694
CHROMOLY STEEL TUBING
IS MUCH HEAVIER THAN ALUMINUM.
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00:05:50,696 --> 00:05:52,888
HOWEVER,
IT'S ALSO MUCH STRONGER,
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00:05:52,890 --> 00:05:56,451
ALLOWING FOR A MORE STREAMLINED
FRAMEWORK.
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00:06:05,366 --> 00:06:09,093
Narrator: TO GAIN ACCESS
TO THE F7's V-8 ENGINE,
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00:06:09,095 --> 00:06:10,428
FALCON CREATED ONE
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OF THE LARGEST SINGLE-PIECE
CARBON-FIBER CAR PANELS
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00:06:12,890 --> 00:06:14,624
IN EXISTENCE.
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00:06:14,626 --> 00:06:18,586
THE F7's REAR DECK LID IS A VERY
COMPLEX COMPONENT TO BUILD.
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00:06:26,580 --> 00:06:28,571
DESPITE THE CAR'S RETRO LOOK,
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LEMKE WANTED TO USE CARBON FIBER
FOR ALL OF THE BODY PANELS.
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00:06:33,637 --> 00:06:35,429
A TECHNICIAN CAREFULLY
CUTS A PIECE
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00:06:35,431 --> 00:06:37,965
OF THE SPECIALIZED MATERIAL.
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00:06:37,967 --> 00:06:40,193
THIS MATERIAL PROVIDES
A HIGH-QUALITY,
101
00:06:40,195 --> 00:06:41,794
HIGH-PERFORMANCE RESULT
102
00:06:41,796 --> 00:06:45,189
AND DOESN'T REQUIRE
EXPENSIVE TOOLING TO PRODUCE.
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00:06:45,191 --> 00:06:48,952
THIS IS IDEAL FOR SMALL-SCALE,
HIGH-END MANUFACTURING.
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00:06:51,748 --> 00:06:53,448
TECHNICIANS APPLY A GEL COAT
105
00:06:53,450 --> 00:06:56,076
ON THE INSIDE SURFACE
OF THE GIANT MOLD
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00:06:56,078 --> 00:06:58,478
BEFORE THEY BEGIN
THE PAINSTAKING PROCESS
107
00:06:58,480 --> 00:07:00,406
OF LAYING THE CARBON FIBER.
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00:07:02,944 --> 00:07:06,203
A SPECIALIZED ROLLER TOOL HELPS
THEM PRESS THE FIBER TIGHTLY
109
00:07:06,205 --> 00:07:09,065
INTO EVERY CORNER OF THE MOLD.
110
00:07:09,067 --> 00:07:12,260
AND AEROSOL GLUE
HOLDS THE FIBER IN PLACE.
111
00:07:16,032 --> 00:07:18,357
NEXT, TECHNICIANS
COVER THE CARBON FIBER
112
00:07:18,359 --> 00:07:21,420
WITH A LAYER OF MATERIAL
CALLED PEEL PLY CLOTH.
113
00:07:25,284 --> 00:07:30,846
THIS MESH MATERIAL, CALLED
MEDIA FLOW, FORMS A THIRD LAYER.
114
00:07:30,848 --> 00:07:33,641
WHEN TECHNICIANS
INFUSE THE MOLD WITH RESIN,
115
00:07:33,643 --> 00:07:35,576
THE MESH STRUCTURE
OF THE MEDIA FLOW
116
00:07:35,578 --> 00:07:39,706
ALLOWS THE LIQUID
TO FLOW EVERYWHERE.
117
00:07:39,708 --> 00:07:41,432
THE WORKERS CUT THE MEDIA FLOW
118
00:07:41,434 --> 00:07:44,602
INTO SMALL SECTIONS TO MAKE SURE
IT COVERS EVERYTHING.
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00:07:47,799 --> 00:07:49,925
IT TAKES TWO TECHNICIANS
A FULL DAY
120
00:07:49,927 --> 00:07:53,921
TO BUILD THE OUTER SKIN
OF A SINGLE BODY PANEL.
121
00:07:53,923 --> 00:07:57,416
THAT'S BECAUSE IT REQUIRES THE
CAREFUL AND DETAILED APPLICATION
122
00:07:57,418 --> 00:08:00,252
OF THREE LAYERS
OF SPECIALIZED MATERIAL.
123
00:08:02,681 --> 00:08:06,943
NOW, THE TECHNICIANS
INSTALL AN INJECTION HOSE.
124
00:08:06,945 --> 00:08:09,670
THE HOSE IS ACTUALLY
AN OPEN SPIRAL.
125
00:08:09,672 --> 00:08:13,600
THIS ALLOWS THE RESIN TO BE
EVENLY DISTRIBUTED AS IT FLOWS.
126
00:08:16,538 --> 00:08:20,198
NEXT, THEY TAPE ON A VACUUM BAG
AND REMOVE THE AIR,
127
00:08:20,200 --> 00:08:23,360
PRESSING THE CARBON FIBER
TIGHTLY AGAINST THE MOLD.
128
00:08:26,023 --> 00:08:30,351
THEN, TECHNICIANS INJECT RESIN.
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00:08:30,353 --> 00:08:33,688
A VACUUM PUMP DISTRIBUTES
THE RESIN THROUGHOUT THE MOLD.
130
00:08:36,817 --> 00:08:39,844
THANKS TO CAREFUL PLACEMENT
OF THE MEDIA FLOW CLOTH,
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00:08:39,846 --> 00:08:42,372
THE RESIN SPREADS EASILY.
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00:08:42,374 --> 00:08:46,568
THEY LET THE CARBON FIBER CURE
IN THE MOLD FOR 12 TO 15 HOURS.
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00:08:50,566 --> 00:08:54,033
BECAUSE THE CARBON-FIBER SHELL
OF THE DECK LID IS SO LARGE,
134
00:08:54,035 --> 00:08:57,363
IT NEEDS ADDITIONAL
STRUCTURAL SUPPORT ELEMENTS.
135
00:09:01,193 --> 00:09:02,526
ONCE IT'S CURED,
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00:09:02,528 --> 00:09:05,921
TECHNICIANS APPLY A BEAD
OF STRUCTURAL ADHESIVE TO BOND
137
00:09:05,923 --> 00:09:10,251
THE FRAMEWORK COMPONENTS
IN PLACE.
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00:09:10,253 --> 00:09:13,079
THESE ELEMENTS WILL TRANSFORM
THE FLOPPY SHELL
139
00:09:13,081 --> 00:09:15,107
INTO A RIGID BODY PANEL.
140
00:09:17,744 --> 00:09:19,803
THE ADHESIVE HAS FULLY CURED,
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00:09:19,805 --> 00:09:21,805
SO THE TECHNICIANS
POP THE DECK LID
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00:09:21,807 --> 00:09:23,599
OUT OF ITS MOLD.
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00:09:25,736 --> 00:09:28,829
THE COMPONENT NOW
MOVES TO THE FINISHING AREA.
144
00:09:28,831 --> 00:09:32,558
WORKERS USE BLOCK SANDERS
TO SMOOTH THE SURFACE.
145
00:09:32,560 --> 00:09:36,287
THEY COULD USE MOTORIZED SANDERS
TO BRING DOWN BULKY SPOTS,
146
00:09:36,289 --> 00:09:38,490
BUT IT'S SAFER
TO HAND-SAND CARBON FIBER
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00:09:38,492 --> 00:09:40,884
TO AVOID DAMAGING THE SURFACE.
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00:09:45,715 --> 00:09:46,982
HERE, A SPECIALIST
149
00:09:46,984 --> 00:09:51,711
APPLIES A FINAL GEL COAT
BEFORE THE PRIMER GOES ON.
150
00:09:51,713 --> 00:09:53,038
THE PANEL GETS A COAT
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00:09:53,040 --> 00:09:56,467
OF VINYL GEL BEFORE AND AFTER
THE SANDING PROCESS.
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00:09:58,637 --> 00:10:02,765
THE GEL COAT SEALS THE CARBON
FIBER WITH A PROTECTIVE COATING.
153
00:10:11,599 --> 00:10:15,826
Narrator: THE FALCON F7 COMES
STANDARD WITH AN LS7-BASED V-8
154
00:10:15,828 --> 00:10:17,353
OR A TWIN-TURBO OPTION
155
00:10:17,355 --> 00:10:20,289
THAT CRANKS OUT MORE THAN
1,100 HORSEPOWER,
156
00:10:20,291 --> 00:10:23,185
ENOUGH TO GUN THIS SUPERCAR
FROM ZERO TO 60
157
00:10:23,187 --> 00:10:25,020
IN LESS THAN THREE SECONDS.
158
00:10:27,516 --> 00:10:28,781
FALCON ASKED DETROIT-BASED
159
00:10:28,783 --> 00:10:30,709
LINGENFELTER
PERFORMANCE ENGINEERING
160
00:10:30,711 --> 00:10:33,571
TO BUILD ITS ENGINES.
161
00:10:33,573 --> 00:10:35,305
AT THE LINGENFELTER FACILITY,
162
00:10:35,307 --> 00:10:37,440
THEY START WITH AN ALUMINUM
ENGINE BLOCK
163
00:10:37,442 --> 00:10:39,268
FROM GENERAL MOTORS.
164
00:10:39,270 --> 00:10:42,262
A FOUR-AXIS CNC MACHINE
MEASURES ALL THE HOLES
165
00:10:42,264 --> 00:10:45,959
IN THE BLOCK TO ENSURE
THEY MATCH THE SPECIFICATIONS.
166
00:10:48,529 --> 00:10:51,590
THE MACHINE CHANGES TOOLS
AND DRILLS THE OPENINGS
167
00:10:51,592 --> 00:10:53,984
TO A SLIGHTLY LARGER DIAMETER.
168
00:10:57,088 --> 00:10:58,547
THEN, ANOTHER TOOL PERFORMS
169
00:10:58,549 --> 00:11:01,283
AN ACTION
CALLED DECKING TO THE BLOCK.
170
00:11:01,285 --> 00:11:04,078
A CAST BLOCK CAN HAVE
A SLIGHT TAPER TO IT,
171
00:11:04,080 --> 00:11:07,406
INTERFERING WITH THE ACTION
OF THE PISTONS.
172
00:11:07,408 --> 00:11:11,636
THIS OPERATION ENSURES THE DECK
OF THE BLOCK IS PERFECTLY FLAT.
173
00:11:13,840 --> 00:11:16,366
THE CRANKSHAFT IS MICROPOLISHED,
174
00:11:16,368 --> 00:11:19,494
MEASURED FOR DIMENSION,
AND WEIGHT-BALANCED.
175
00:11:22,032 --> 00:11:27,086
NOW THE TECHNICIAN CAREFULLY
POSITIONS IT IN THE CRANK CASE.
176
00:11:27,088 --> 00:11:28,553
HE SECURES IT IN PLACE
177
00:11:28,555 --> 00:11:32,249
WITH A COMPONENT
CALLED A MAIN BEARING CAP.
178
00:11:32,251 --> 00:11:37,046
THESE CAPS SLIDE DOWN OVER A SET
OF FOUR STUDS.
179
00:11:37,048 --> 00:11:41,108
THE BOTTOM END OF EACH STUD
THREADS DIRECTLY INTO THE BLOCK.
180
00:11:41,110 --> 00:11:43,836
WHEN THE TECHNICIAN
TIGHTENS THE BOLT, THE LOAD
181
00:11:43,838 --> 00:11:47,666
TRANSFERS DIRECTLY TO THE BLOCK,
RATHER THAN TWISTING THE STUD.
182
00:11:50,470 --> 00:11:52,996
LINGENFELTER
CUSTOMIZES ITS CAMSHAFTS
183
00:11:52,998 --> 00:11:54,997
FOR EACH APPLICATION.
184
00:11:54,999 --> 00:11:57,525
THIS CAMSHAFT IS MADE
OF BILLET STEEL
185
00:11:57,527 --> 00:12:00,354
SPECIALLY CRAFTED
FOR A SUPERCAR ENGINE.
186
00:12:08,548 --> 00:12:12,675
IT'S TIME TO INSTALL THE PISTONS
AND THEIR CONNECTING RODS.
187
00:12:12,677 --> 00:12:15,011
BECAUSE THIS ENGINE
WILL BE TURBOCHARGED,
188
00:12:15,013 --> 00:12:17,739
THE PISTON HEADS HAVE A COATING
DESIGNED TO WITHSTAND
189
00:12:17,741 --> 00:12:19,967
EXTREMELY HIGH TEMPERATURES.
190
00:12:22,638 --> 00:12:25,029
ONCE THE RODS
ARE SECURED TO THE CRANKSHAFT
191
00:12:25,031 --> 00:12:26,832
WITH THE CONNECTING ROD CAPS,
192
00:12:26,834 --> 00:12:28,192
A TECHNICIAN CAREFULLY
193
00:12:28,194 --> 00:12:31,595
FITS THE MULTILAYER STEEL
HEAD GASKET OVER THE PISTONS.
194
00:12:34,359 --> 00:12:38,119
HE INSERTS THE PUSH RODS,
THEN THE ROCKER ARMS.
195
00:12:38,121 --> 00:12:39,987
WHILE THE HEAD
ITSELF IS ALUMINUM,
196
00:12:39,989 --> 00:12:42,949
THE INTAKES VALVES
ARE LIGHTWEIGHT TITANIUM.
197
00:12:45,379 --> 00:12:51,040
THE EXHAUST VALVES ARE MADE
OF A SUPERALLOY CALLED INCONEL.
198
00:12:51,042 --> 00:12:53,001
THE TECHNICIAN INSTALLS
THE COVER,
199
00:12:53,003 --> 00:12:55,571
WHICH FEATURES THE LINGENFELTER
LOGO.
200
00:12:58,134 --> 00:12:59,466
THE INTAKE MANIFOLD
201
00:12:59,468 --> 00:13:03,195
FOR THE FALCON F7 IS BUILT
BY PERFORMANCE DESIGN,
202
00:13:03,197 --> 00:13:06,290
A COMPANY THAT SPECIALIZES
IN THESE COMPONENTS.
203
00:13:08,461 --> 00:13:11,154
TO CREATE THE MANIFOLD'S
RUNNERS, A TECHNICIAN
204
00:13:11,156 --> 00:13:15,884
STARTS WITH A SEAMLESS LENGTH
OF BRAIDED CARBON-FIBER TUBING.
205
00:13:15,886 --> 00:13:18,010
HE CAREFULLY FITS IT
OVER A FORM,
206
00:13:18,012 --> 00:13:22,207
WHICH IS ACTUALLY
AN INFLATABLE LATEX BLADDER.
207
00:13:22,209 --> 00:13:25,636
SEVEN LAYERS OF CARBON FIBER
WILL FORM EACH RUNNER.
208
00:13:25,638 --> 00:13:29,306
THIS PROCESS TAKES ROUGHLY
45 MINUTES TO COMPLETE.
209
00:13:34,631 --> 00:13:37,890
THE TECHNICIAN PLACES THE
CARBON-FIBER-WRAPPED BLADDERS
210
00:13:37,892 --> 00:13:41,060
INSIDE A CUSTOM-BUILT
BILLET ALUMINUM MOLD.
211
00:13:43,090 --> 00:13:48,118
PERFORMANCE DESIGN SPENT 2 1/2
YEARS DEVELOPING THEIR MANIFOLD.
212
00:13:48,120 --> 00:13:52,847
FALCON PURCHASED ONE OF THE VERY
FIRST ITEMS THEY MADE.
213
00:13:52,849 --> 00:13:56,710
PERFORMANCE DESIGN
USES A HYBRID MOLDING PROCESS.
214
00:13:56,712 --> 00:13:59,972
RESIN INFUSES INTO THE MOLD
WHILE, AT THE SAME TIME,
215
00:13:59,974 --> 00:14:03,667
THE BLADDERS PRESSURIZE.
216
00:14:03,669 --> 00:14:04,802
THE TECHNICIAN MIXES UP
217
00:14:04,804 --> 00:14:07,330
A TWO-PART,
HIGH-TEMPERATURE EPOXY RESIN
218
00:14:07,332 --> 00:14:10,992
THAT WILL BE INJECTED
INTO THE MOLD.
219
00:14:10,994 --> 00:14:14,195
FALCON SPECIFICALLY DESIGNED
THE F7 BODYWORK
220
00:14:14,197 --> 00:14:16,723
TO SHOWCASE
PERFORMANCE DESIGN'S
221
00:14:16,725 --> 00:14:19,251
REMARKABLE
CARBON-FIBER MANIFOLD.
222
00:14:24,483 --> 00:14:28,411
THE SUCTION FROM THE VACUUM PUMP
PULLS THE RESIN INSIDE THE MOLD,
223
00:14:28,413 --> 00:14:34,542
WHERE THERE'S A NET PRESSURE
OF 125 POUNDS PER SQUARE INCH.
224
00:14:34,544 --> 00:14:36,235
ROUGHLY FOUR HOURS LATER,
225
00:14:36,237 --> 00:14:39,897
THE TECHNICIAN OPENS THE MOLD
AND EXAMINES THE RESULTS --
226
00:14:39,899 --> 00:14:41,032
PERFECTLY FORMED
227
00:14:41,034 --> 00:14:43,894
HIGH-PERFORMANCE
CARBON-FIBER RUNNERS.
228
00:14:47,299 --> 00:14:49,891
THE RED FLANGES ARE MADE
229
00:14:49,893 --> 00:14:54,722
FROM AEROSPACE-QUALITY
6061 BILLET ALUMINUM.
230
00:14:54,724 --> 00:14:57,516
THE TECHNICIAN ASSEMBLES
THESE PARTS TO CREATE ONE BANK
231
00:14:57,518 --> 00:14:59,184
OF THE MANIFOLD.
232
00:14:59,186 --> 00:15:03,648
A SET OF IDENTICAL PARTS
WILL FORM THE OPPOSING BANK.
233
00:15:03,650 --> 00:15:05,975
HE USES AEROSPACE
STRUCTURAL ADHESIVE
234
00:15:05,977 --> 00:15:11,539
TO BOND THE CARBON-FIBER RUNNERS
TO THE ALUMINUM FLANGES.
235
00:15:11,541 --> 00:15:14,735
THE CARBON-FIBER PLENUM
IS THE FINAL ELEMENT.
236
00:15:16,930 --> 00:15:19,198
THE TECHNICIAN
USES A CUSTOM-BUILT FIXTURE
237
00:15:19,200 --> 00:15:21,191
TO HOLD THE PARTS IN PLACE
238
00:15:21,193 --> 00:15:24,161
AS HE PUTS THE TWO BANKS
OF THE MANIFOLD TOGETHER.
239
00:15:27,759 --> 00:15:30,150
THIS REMARKABLE,
HIGH-TECH MANIFOLD
240
00:15:30,152 --> 00:15:34,614
ADDS ALMOST 50 HORSEPOWER
TO THE ENGINE'S OVERALL OUTPUT.
241
00:15:34,616 --> 00:15:39,377
THE FINISHED PRODUCT BOLTS
ONTO THE LINGENFELTER ENGINE.
242
00:15:48,362 --> 00:15:50,120
Narrator:
COMBINING A MANUAL TRANSMISSION
243
00:15:50,122 --> 00:15:52,856
WITH CARBON-FIBER TECHNOLOGY,
RETRO LOOKS,
244
00:15:52,858 --> 00:15:55,083
AND 21st-CENTURY PERFORMANCE,
245
00:15:55,085 --> 00:15:59,080
THE FALCON F7 BELONGS
TO AN EXTREMELY RARE BREED --
246
00:15:59,082 --> 00:16:01,782
THE MID-ENGINED AMERICAN
SUPERCAR.
247
00:16:04,411 --> 00:16:06,212
YOU CAN'T USE
A REGULAR TRANSMISSION
248
00:16:06,214 --> 00:16:08,472
IN A MID-ENGINE CAR.
249
00:16:08,474 --> 00:16:11,100
YOU NEED A
TRANSMISSION-DIFFERENTIAL COMBO,
250
00:16:11,102 --> 00:16:14,370
ALSO KNOWN AS A TRANSAXLE.
251
00:16:14,372 --> 00:16:17,565
HERE, TECHNICIANS
INSTALL THE RADIATOR.
252
00:16:17,567 --> 00:16:20,693
FALCON TYPICALLY USES
A GENERAL MOTORS RADIATOR,
253
00:16:20,695 --> 00:16:24,757
BUT THIS ONE IS SPECIALLY MADE
PER THE CUSTOMER'S REQUEST.
254
00:16:24,759 --> 00:16:26,817
FALCON WORKS CLOSELY
WITH THEIR CLIENTS
255
00:16:26,819 --> 00:16:31,847
TO CREATE ENTIRELY UNIQUE
VERSIONS OF THE F7.
256
00:16:31,849 --> 00:16:35,109
NEXT, THEY ATTACH
THE CARBON-FIBER SILL PANEL,
257
00:16:35,111 --> 00:16:37,511
A COMPONENT
THAT CREATES A DOORJAMB,
258
00:16:37,513 --> 00:16:39,072
COVERS COOLING LINES,
259
00:16:39,074 --> 00:16:44,236
AND FORMS AN ATTACHMENT POINT
FOR OTHER PANELS.
260
00:16:44,238 --> 00:16:47,397
THEY BOLT THE CHROMOLY-STEEL
ROLL CAGE IN PLACE.
261
00:16:47,399 --> 00:16:49,532
IT WILL DOUBLE
AS A SAFETY STRUCTURE
262
00:16:49,534 --> 00:16:52,828
AND AS A FRAMEWORK
TO SUPPORT THE BODY PANELS.
263
00:16:56,992 --> 00:17:00,319
FALCON CREATES DISTINCTIVE GAUGE
PODS FROM SOLID PIECES
264
00:17:00,321 --> 00:17:03,523
OF BILLET ALUMINUM.
265
00:17:03,525 --> 00:17:05,083
THE CNC MACHINE
266
00:17:05,085 --> 00:17:08,344
CARVES THROUGH THE ALUMINUM LIKE
A KNIFE SLICING THROUGH BUTTER.
267
00:17:16,338 --> 00:17:19,339
ONCE THE GAUGE-POD PARTS
HAVE BEEN MANUFACTURED,
268
00:17:19,341 --> 00:17:22,167
A TECHNICIAN ASSEMBLES
THEM USING BRASS SCREWS
269
00:17:22,169 --> 00:17:26,097
AND CARBON-FIBER TRIM ELEMENTS.
270
00:17:26,099 --> 00:17:27,431
BUILDING PARTS BY HAND
271
00:17:27,433 --> 00:17:30,493
IS ANOTHER NOD
TO THE CAR'S MICHIGAN ROOTS.
272
00:17:33,356 --> 00:17:36,023
JEFF LEMKE BEGAN
DEVELOPING THE F7
273
00:17:36,025 --> 00:17:39,385
WHEN THE U.S. WAS IN THE MIDDLE
OF THE GREAT RECESSION.
274
00:17:39,387 --> 00:17:41,913
THIS TURNED OUT
TO BE AN ADVANTAGE FOR LEMKE
275
00:17:41,915 --> 00:17:44,975
BECAUSE SPECIALISTS WITH TIME
ON THEIR HANDS WERE EXCITED
276
00:17:44,977 --> 00:17:49,037
TO CONTRIBUTE THEIR EXPERTISE
TO THE FALCON PROJECT.
277
00:17:49,039 --> 00:17:50,305
AT THE SAME TIME,
278
00:17:50,307 --> 00:17:53,868
CUTBACKS CAUSED LOCAL BUSINESSES
TO SLASH PRICES,
279
00:17:53,870 --> 00:17:57,730
MAKING FALCON'S PRODUCTION
PROCESS RELATIVELY AFFORDABLE.
280
00:18:00,067 --> 00:18:02,860
AND IF THERE WERE THINGS
LEMKE DIDN'T KNOW HOW TO DO,
281
00:18:02,862 --> 00:18:04,862
HE JUST ASKED AROUND.
282
00:18:04,864 --> 00:18:08,124
THERE'S NO SHORTAGE
OF CAR EXPERTS IN MOTOR CITY.
283
00:18:08,126 --> 00:18:11,619
DETROIT HAS BEEN A CAPITAL OF
AMERICAN AUTOMOBILE PRODUCTION
284
00:18:11,621 --> 00:18:13,947
SINCE HENRY FORD
FOUNDED FORD MOTOR COMPANY
285
00:18:13,949 --> 00:18:15,983
IN THE EARLY 20th CENTURY.
286
00:18:18,546 --> 00:18:20,012
WHAT SURPRISED LEMKE
287
00:18:20,014 --> 00:18:23,073
WAS HOW WILLING PEOPLE WERE
TO DONATE THEIR TIME AND ENERGY
288
00:18:23,075 --> 00:18:26,902
TO HELP HIM REALIZE HIS VISION.
289
00:18:26,904 --> 00:18:31,699
THESE GAUGE PODS ARE SYMBOLIC
FEATURES OF THAT VISION.
290
00:18:31,701 --> 00:18:34,761
THE GAUGES ARE ONE
OF SEVERAL ELEMENTS ON THE F7
291
00:18:34,763 --> 00:18:38,757
THAT MIMIC THE LOOK
OF U.S. FIGHTER JETS.
292
00:18:38,759 --> 00:18:41,292
THEIR SHAPES
HAVE THE AERODYNAMIC CONTOURS
293
00:18:41,294 --> 00:18:44,854
OF JET TURBINES OR NOSE CONES.
294
00:18:44,856 --> 00:18:46,181
THE ANALOG DIALS
295
00:18:46,183 --> 00:18:49,585
CONTRIBUTE TO THE OLD-SCHOOL
MANUAL DRIVING EXPERIENCE.
296
00:18:54,708 --> 00:18:58,703
THE GAUGES FORM THE CENTERPIECE
OF THE GLOSSY BLACK DASHBOARD
297
00:18:58,705 --> 00:19:01,639
AND CONTRIBUTE TO THE COCKPIT'S
RETRO-FUTURISTIC,
298
00:19:01,641 --> 00:19:03,533
JET-FUELED AESTHETIC.
299
00:19:03,535 --> 00:19:05,201
THEY ARE INSTALLED
IN THE DASHBOARD
300
00:19:05,203 --> 00:19:07,429
BEHIND THE TWO-TONE
STEERING WHEEL.
301
00:19:13,662 --> 00:19:17,523
THE VENTS IN THE F7's HOOD
REFERENCE THE LEGENDARY GT40,
302
00:19:17,525 --> 00:19:20,417
BUT THEY DO MORE THAN JUST VENT.
303
00:19:20,419 --> 00:19:23,479
THEY'RE AERODYNAMICALLY DESIGNED
TO KEEP THE FRONT END OF THE CAR
304
00:19:23,481 --> 00:19:25,748
ON THE GROUND AT HIGH SPEEDS.
305
00:19:29,412 --> 00:19:31,937
THE CUSTOM-MADE EXHAUST
IS INSTALLED ABOVE,
306
00:19:31,939 --> 00:19:33,739
RATHER THAN BELOW, THE BUMPER,
307
00:19:33,741 --> 00:19:37,702
ADDING TO THAT FIGHTER JET LOOK.
308
00:19:37,704 --> 00:19:40,697
NEXT, TECHNICIANS
INSTALL THE REAR BUMPER.
309
00:19:40,699 --> 00:19:43,425
IT'S MADE ENTIRELY
WITH CARBON FIBER.
310
00:19:50,560 --> 00:19:52,585
THEY NOW MOUNT THE REAR
DECK LID,
311
00:19:52,587 --> 00:19:55,454
THE CAR'S SHOWPIECE
CARBON-FIBER PANEL.
312
00:19:55,456 --> 00:19:57,949
IT'S ATTACHED
WITH FLOATING PINS.
313
00:20:00,044 --> 00:20:04,639
THEY LOWER IT INTO POSITION,
WHERE IT LATCHES FIRMLY SHUT.
314
00:20:04,641 --> 00:20:06,107
INSTALLING THE REAR DECK LID
315
00:20:06,109 --> 00:20:09,436
IS THE FINAL STEP
OF THE BODY ASSEMBLY PHASE.
316
00:20:12,265 --> 00:20:15,267
THE FALCON F7
IS NEARLY 7 FEET WIDE,
317
00:20:15,269 --> 00:20:17,595
SO IT NEEDS CUSTOMIZED WHEELS.
318
00:20:17,597 --> 00:20:21,390
THESE MADE-TO-ORDER COMPONENTS
COME FROM FORGELINE MOTORSPORTS.
319
00:20:21,392 --> 00:20:24,327
THEY WON'T FIT
ANY OTHER VEHICLE.
320
00:20:24,329 --> 00:20:28,748
SPC INTERIORS, ANOTHER DETROIT
ENTERPRISE, TRIMS THE F7
321
00:20:28,750 --> 00:20:32,485
IN WHATEVER MATERIAL
THE CUSTOMER REQUESTS,
322
00:20:32,487 --> 00:20:35,280
FROM ALCANTARA
TO POLISHED LEATHER.
323
00:20:38,143 --> 00:20:43,172
THE F7 IS A MASH-UP
OF JEFF LEMKE'S FAVORITE CARS.
324
00:20:43,174 --> 00:20:46,367
THE WEDGE-SHAPED HEADLIGHTS
PAY TRIBUTE TO THE SUPERCARS
325
00:20:46,369 --> 00:20:48,369
OF THE 1980s.
326
00:20:48,371 --> 00:20:51,964
THE NOSE IS REMINISCENT
OF A LAMBORGHINI.
327
00:20:51,966 --> 00:20:55,960
AND THE TAIL RECALLS
THE FERRARI 512 BERLINETTA.
328
00:20:55,962 --> 00:20:58,188
IT'S ONE THING
TO GATHER THE BEST ELEMENTS
329
00:20:58,190 --> 00:20:59,722
OF YOUR FAVORITE CARS.
330
00:20:59,724 --> 00:21:02,784
IT'S ANOTHER TO BLEND
THEM TOGETHER INTO A COHERENT
331
00:21:02,786 --> 00:21:04,252
AND DISTINCTIVE VEHICLE
332
00:21:04,254 --> 00:21:09,708
THAT LOOKS LIKE A 21st-CENTURY
SUPERCAR FROM TOP TO BOTTOM.
333
00:21:09,710 --> 00:21:12,444
THEY SAY IT TAKES A VILLAGE
TO RAISE A CHILD.
334
00:21:12,446 --> 00:21:15,472
MAYBE THE SAME
IS TRUE OF SUPERCARS.
335
00:21:15,474 --> 00:21:17,207
IT TOOK A MAN WITH A VISION
336
00:21:17,209 --> 00:21:19,268
AND THE BEST AND BRIGHTEST
OF DETROIT
337
00:21:19,270 --> 00:21:22,463
TO BRING THE FALCON F7
INTO EXISTENCE.
338
00:21:22,465 --> 00:21:24,465
CAR ENTHUSIASTS
HAVE BEEN DEMANDING
339
00:21:24,467 --> 00:21:27,060
AN AMERICAN MID-ENGINE
SUPERCAR FOR DECADES.
340
00:21:27,062 --> 00:21:31,122
NOW THEY'VE FINALLY GOT IT.
27789
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