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These are the user uploaded subtitles that are being translated: 1 00:00:01,601 --> 00:00:02,801 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS" -- 2 00:00:02,803 --> 00:00:05,562 THE FALCON F7, A MID-ENGINE SUPERCAR 3 00:00:05,564 --> 00:00:08,357 WITH THE HEART OF AN AMERICAN HOT ROD. 4 00:00:08,359 --> 00:00:11,293 -- Captions by VITAC -- www.vitac.com 5 00:00:11,295 --> 00:00:14,289 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,116 --> 00:00:26,242 THE FALCON F7 IS MADE IN HOLLY, MICHIGAN, 7 00:00:26,244 --> 00:00:28,904 THE HEART OF AMERICAN CAR COUNTRY. 8 00:00:32,109 --> 00:00:34,701 JEFF LEMKE, FOUNDER OF FALCON MOTORSPORTS, 9 00:00:34,703 --> 00:00:36,570 GREW UP IN THE DETROIT AREA. 10 00:00:36,572 --> 00:00:40,266 HE FELL IN LOVE WITH CORVETTES AS A CHILD. 11 00:00:40,268 --> 00:00:44,461 FOR YEARS, LEMKE BUILT SPECIALTY PARTS FOR EXOTIC SPORTS CARS. 12 00:00:44,463 --> 00:00:47,957 EVENTUALLY, HE DECIDED TO MAKE HIS OWN SUPERCAR. 13 00:00:51,655 --> 00:00:54,681 FALCON INTRODUCED THE F7 AS A CONCEPT CAR 14 00:00:54,683 --> 00:00:59,878 AT THE NORTH AMERICAN INTERNATIONAL AUTO SHOW IN 2011. 15 00:00:59,880 --> 00:01:02,673 THE RECEPTION WAS SO ENTHUSIASTIC THAT LEMKE 16 00:01:02,675 --> 00:01:05,008 DECIDED TO BUILD CARS TO SELL. 17 00:01:05,010 --> 00:01:07,937 THE AWARDS HAVE BEEN ROLLING IN EVER SINCE. 18 00:01:10,300 --> 00:01:13,727 JEFF LEMKE'S DESIGN OF THE FALCON F7 PAYS HOMAGE 19 00:01:13,729 --> 00:01:15,361 TO HIS FAVORITE CARS -- 20 00:01:15,363 --> 00:01:21,426 THE CORVETTE, THE FORD GT40, AND THE FERRARI GTO. 21 00:01:21,428 --> 00:01:24,154 IT DRIVES LIKE AN OLD-SCHOOL SPORTS CAR. 22 00:01:24,156 --> 00:01:27,316 THERE ARE NO PADDLE SHIFTERS AND NO AUTOMATIC OPTIONS. 23 00:01:27,318 --> 00:01:30,644 THE FALCON F7 IS MANUAL, PERIOD. 24 00:01:35,577 --> 00:01:40,304 CARS ARE NOT THE ONLY SOURCE OF INSPIRATION FOR THE FALCON F7. 25 00:01:40,306 --> 00:01:43,800 LEMKE INCORPORATED FEATURES FROM U.S. AIR FORCE FIGHTER JETS 26 00:01:43,802 --> 00:01:46,661 INTO THE DESIGN. 27 00:01:46,663 --> 00:01:49,664 FIGHTER JETS ARE BUILT AROUND AERODYNAMIC EFFICIENCY, 28 00:01:49,666 --> 00:01:51,758 SPEED, AND FUNCTIONALITY. 29 00:01:53,929 --> 00:01:55,320 BUT THEIR AGGRESSIVE LINES 30 00:01:55,322 --> 00:01:59,950 HAVE THE POWER AND ATTITUDE LEMKE WANTED FOR HIS CAR. 31 00:01:59,952 --> 00:02:01,418 THE FALCON'S TAILLIGHTS 32 00:02:01,420 --> 00:02:05,581 AND CENTRALLY LOCATED EXHAUST PIPE LOOK LIKE JET THRUSTERS. 33 00:02:07,610 --> 00:02:08,942 EVEN THE NAME, F7, 34 00:02:08,944 --> 00:02:11,738 IS A TRIBUTE TO PLANES, LIKE THE F-15. 35 00:02:13,942 --> 00:02:17,435 LEMKE STARTED BY SKETCHING OUT HIS IDEA. 36 00:02:17,437 --> 00:02:18,703 BUT HE HAD TO BUILD A MODEL 37 00:02:18,705 --> 00:02:21,765 TO MAKE SURE THE DESIGN WORKED IN THE REAL WORLD. 38 00:02:28,357 --> 00:02:30,758 LEMKE TAUGHT HIMSELF THE TRADITIONAL CRAFT 39 00:02:30,760 --> 00:02:34,086 OF CLAY CAR SCULPTING WHILE MAKING CUSTOM BODY PARTS 40 00:02:34,088 --> 00:02:36,648 FOR VIPERS AND OTHER EXOTIC CARS. 41 00:02:39,319 --> 00:02:41,978 TYPICALLY, THIS IS SOMETHING ONLY TRAINED ARTISANS 42 00:02:41,980 --> 00:02:43,312 KNOW HOW TO DO. 43 00:02:43,314 --> 00:02:46,241 LEMKE'S EXPERIENCE COMES IN HANDY AS HE WORKS OUT 44 00:02:46,243 --> 00:02:49,202 THE FINER DETAILS OF THE F7's DESIGN. 45 00:02:52,800 --> 00:02:55,133 ONCE HE'S SATISFIED WITH HIS DESIGN, 46 00:02:55,135 --> 00:02:57,394 A COMPUTER SCANS THE CLAY MODEL, 47 00:02:57,396 --> 00:02:59,863 PROVIDING A DIGITAL IMAGE THAT CAN BE REFINED 48 00:02:59,865 --> 00:03:03,326 AND FINALIZED IN COMPUTER-AIDED DESIGN SOFTWARE. 49 00:03:07,990 --> 00:03:10,083 ONE ADVANTAGE TO MANUFACTURING A CAR 50 00:03:10,085 --> 00:03:14,179 IN THE DETROIT AREA IS THAT EVERYTHING YOU NEED IS NEARBY. 51 00:03:16,550 --> 00:03:19,743 TO CUT THE PIECES FOR THE F7's ALUMINUM MONOCOQUE, 52 00:03:19,745 --> 00:03:21,069 FALCON FOUND A PLACE 53 00:03:21,071 --> 00:03:24,373 A MILE DOWN THE ROAD THAT USES WATER-JET TECHNOLOGY. 54 00:03:28,104 --> 00:03:29,828 THE MACHINE POSITIONS ITS CUTTING 55 00:03:29,830 --> 00:03:32,798 IN A WAY THAT MINIMIZES LEFTOVER SCRAP METAL. 56 00:03:36,095 --> 00:03:39,689 ONCE CUT, WORKERS REMOVE THE PIECES FROM THE SHEET. 57 00:03:39,691 --> 00:03:45,052 EACH MONOCOQUE CHASSIS REQUIRES 2 1/2 SHEETS OF ALUMINUM. 58 00:03:45,054 --> 00:03:48,315 BECAUSE THE WATER-JET CUTTING PROCESS DOESN'T USE HEAT, 59 00:03:48,317 --> 00:03:50,241 THE RESULT IS AN EXTREMELY CLEAN, 60 00:03:50,243 --> 00:03:53,471 PRECISE CUT WITH NO WARPING OR DISTORTION OF THE METAL. 61 00:03:57,042 --> 00:04:00,869 NEXT, THE SHEETS GO BACK TO LEMKE'S MANUFACTURING FACILITY, 62 00:04:00,871 --> 00:04:04,198 WHERE TECHNICIANS WELD THEM ONTO THE TUBULAR ALUMINUM FRAMEWORK 63 00:04:04,200 --> 00:04:05,992 OF THE CHASSIS. 64 00:04:05,994 --> 00:04:08,461 LEMKE WORKS ALONGSIDE HIS TEAM OF CRAFTSMEN 65 00:04:08,463 --> 00:04:10,789 THROUGHOUT THE ASSEMBLY PROCESS. 66 00:04:15,287 --> 00:04:17,887 HE STARTS BY TACK WELDING THE PARTS IN PLACE 67 00:04:17,889 --> 00:04:19,815 BEFORE COMPLETING THE JOINT. 68 00:04:25,747 --> 00:04:29,008 ALUMINUM SURFACE COATING, HIGH THERMAL CONDUCTIVITY 69 00:04:29,010 --> 00:04:30,275 AND LOW MELTING TEMPERATURE 70 00:04:30,277 --> 00:04:33,638 MAKE THE WELDING PROCESS DIFFERENT FROM WELDING STEEL. 71 00:04:37,636 --> 00:04:39,628 ONCE THE MONOCOQUE IS COMPLETE, 72 00:04:39,630 --> 00:04:42,823 A TECHNICIAN INSTALLS THE FORGED ALUMINUM CONTROL ARMS 73 00:04:42,825 --> 00:04:45,492 AND UPRIGHTS. 74 00:04:45,494 --> 00:04:51,048 THESE ARE CORVETTE ZR1-BASED PARTS FROM GENERAL MOTORS. 75 00:04:51,050 --> 00:04:53,183 FALCON USES OFF-THE-SHELF COMPONENTS 76 00:04:53,185 --> 00:04:56,545 TO MAKE SERVICING THE F7 EASIER AND CHEAPER. 77 00:04:58,582 --> 00:05:00,841 WHILE THE BRAKE PICTURED HERE IS STANDARD, 78 00:05:00,843 --> 00:05:04,303 CARBON CERAMIC BRAKES ARE OPTIONAL. 79 00:05:04,305 --> 00:05:06,639 THE CAR HAS PUSH-ROD SUSPENSION 80 00:05:06,641 --> 00:05:09,267 WITH THE SHOCKS SEPARATED FROM THE CONTROL ARMS 81 00:05:09,269 --> 00:05:11,528 TO CUT DOWN ON UNSPRUNG WEIGHT. 82 00:05:20,923 --> 00:05:23,390 LEMKE AND ANOTHER TECHNICIAN LOAD THE PRECUT, 83 00:05:23,392 --> 00:05:27,119 PRE-BENT CHROMOLY STEEL TUBING INTO A WELDING FIXTURE. 84 00:05:29,549 --> 00:05:33,710 CHROMOLY STEEL'S HIGH CARBON CONTENT GIVES IT ADDED STRENGTH. 85 00:05:36,139 --> 00:05:39,407 FALCON COULD BUILD THE ROLL CAGE OUT OF ALUMINUM, 86 00:05:39,409 --> 00:05:42,502 BUT THE RESULT WOULD BE A BULKY STRUCTURE INCONSISTENT 87 00:05:42,504 --> 00:05:44,430 WITH THE LOOK OF THE F7. 88 00:05:47,635 --> 00:05:50,694 CHROMOLY STEEL TUBING IS MUCH HEAVIER THAN ALUMINUM. 89 00:05:50,696 --> 00:05:52,888 HOWEVER, IT'S ALSO MUCH STRONGER, 90 00:05:52,890 --> 00:05:56,451 ALLOWING FOR A MORE STREAMLINED FRAMEWORK. 91 00:06:05,366 --> 00:06:09,093 Narrator: TO GAIN ACCESS TO THE F7's V-8 ENGINE, 92 00:06:09,095 --> 00:06:10,428 FALCON CREATED ONE 93 00:06:10,430 --> 00:06:12,888 OF THE LARGEST SINGLE-PIECE CARBON-FIBER CAR PANELS 94 00:06:12,890 --> 00:06:14,624 IN EXISTENCE. 95 00:06:14,626 --> 00:06:18,586 THE F7's REAR DECK LID IS A VERY COMPLEX COMPONENT TO BUILD. 96 00:06:26,580 --> 00:06:28,571 DESPITE THE CAR'S RETRO LOOK, 97 00:06:28,573 --> 00:06:33,635 LEMKE WANTED TO USE CARBON FIBER FOR ALL OF THE BODY PANELS. 98 00:06:33,637 --> 00:06:35,429 A TECHNICIAN CAREFULLY CUTS A PIECE 99 00:06:35,431 --> 00:06:37,965 OF THE SPECIALIZED MATERIAL. 100 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. 103 00:06:45,191 --> 00:06:48,952 THIS IS IDEAL FOR SMALL-SCALE, HIGH-END MANUFACTURING. 104 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 106 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. 108 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. 119 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. 129 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, 131 00:08:39,846 --> 00:08:42,372 THE RESIN SPREADS EASILY. 132 00:08:42,374 --> 00:08:46,568 THEY LET THE CARBON FIBER CURE IN THE MOLD FOR 12 TO 15 HOURS. 133 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, 136 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. 138 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, 141 00:09:19,805 --> 00:09:21,805 SO THE TECHNICIANS POP THE DECK LID 142 00:09:21,807 --> 00:09:23,599 OUT OF ITS MOLD. 143 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 147 00:09:38,492 --> 00:09:40,884 TO AVOID DAMAGING THE SURFACE. 148 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 151 00:09:53,040 --> 00:09:56,467 OF VINYL GEL BEFORE AND AFTER THE SANDING PROCESS. 152 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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