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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,204 --> 00:00:04,895
THE LOTUS EVORA,
A PERFORMANCE SPORTS CAR
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00:00:04,897 --> 00:00:08,290
INSPIRED BY TRACK RACING
BUT FIT FOR THE ROAD.
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00:00:08,292 --> 00:00:11,227
-- Captions by VITAC --
www.vitac.com
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00:00:11,229 --> 00:00:14,255
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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ENGINEERS DESIGN LOTUS CARS
AT THEIR HEADQUARTERS
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IN HETHEL, U.K.
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00:00:29,774 --> 00:00:31,573
MODERN LOTUS CARS ARE THE RESULT
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00:00:31,575 --> 00:00:35,202
OF OVER 60 YEARS OF INNOVATIVE
AUTOMOTIVE ENGINEERING.
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00:00:38,466 --> 00:00:42,192
LOTUS FOUNDER COLIN CHAPMAN MADE
HIS MARK IN THE RACING INDUSTRY
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00:00:42,194 --> 00:00:44,128
IN THE 1960s.
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00:00:44,130 --> 00:00:47,524
HE SOLIDIFIED HIS REPUTATION
AS A LEADING RACECAR BUILDER
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00:00:47,526 --> 00:00:48,992
WHEN HIS VEHICLES WON
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00:00:48,994 --> 00:00:53,120
SEVERAL DOUBLE F1 CONSTRUCTORS'
AND DRIVERS' CHAMPIONSHIPS.
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00:00:53,122 --> 00:00:56,816
ONE EXAMPLE
IS MARIO ANDRETTI'S 1978 VICTORY
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00:00:56,818 --> 00:00:59,411
WITH A LOTUS TYPE 79.
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00:00:59,413 --> 00:01:01,739
CHAPMAN INTRODUCED
THE FIRST F1 CAR
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00:01:01,741 --> 00:01:04,742
WITH A CARBON FIBER MONOCOQUE
IN 1981.
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00:01:04,744 --> 00:01:07,870
THAT VEHICLE ILLUSTRATED
HIS DESIGN PHILOSOPHY --
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00:01:07,872 --> 00:01:10,798
TO ADD SPEED, ADD LIGHTNESS.
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00:01:15,429 --> 00:01:19,224
THE LOTUS EVORA, LOTUS ELISE,
AND LOTUS EXIGE
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00:01:19,226 --> 00:01:22,085
WERE ALL DESIGNED
FOLLOWING CHAPMAN'S MOTTO.
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00:01:22,087 --> 00:01:23,953
AT THE LOTUS DRIVING ACADEMY,
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00:01:23,955 --> 00:01:26,515
CAR ENTHUSIASTS
CAN EXPERIENCE THE HANDLING,
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00:01:26,517 --> 00:01:28,116
DYNAMIC PERFORMANCE,
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00:01:28,118 --> 00:01:31,112
AND TRACK ABILITY
OF THESE SUPERCARS.
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STYLISTS AND DESIGNERS
STUDY EXISTING LOTUS CARS.
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THEY DISCUSS THE AESTHETIC,
TECHNOLOGICAL,
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00:01:42,308 --> 00:01:44,801
AND AERODYNAMIC FEATURES
OF EACH MODEL.
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THEY ALSO CONSIDER IMPROVEMENTS
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THAT COULD BE MADE TO THE NEXT
GENERATION OF MODELS.
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00:01:51,793 --> 00:01:54,853
THE TEAM ALWAYS KEEPS IN MIND
CHAPMAN'S PHILOSOPHY
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00:01:54,855 --> 00:01:58,123
OF ENHANCING PERFORMANCE
BY MAKING THE CARS LIGHTER,
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00:01:58,125 --> 00:02:01,018
RATHER THAN SIMPLY MAKING
THEM MORE POWERFUL.
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00:02:06,417 --> 00:02:08,076
IN THE STYLING STUDIO,
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00:02:08,078 --> 00:02:11,938
AN ARTIST SKETCHES A MODEL
IN A 3-D CAD SYSTEM.
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00:02:11,940 --> 00:02:15,967
LAYER BY LAYER, HE ADDS DETAIL
TO THE VIRTUAL SKETCH.
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00:02:21,967 --> 00:02:25,360
A CLAY-MODELING ROBOT
GIVES SHAPE TO THE DESIGN.
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00:02:25,362 --> 00:02:28,755
THE CNC-CONTROLLED END MILL TOOL
CARVES THE CLAY,
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00:02:28,757 --> 00:02:32,385
FOLLOWING PRECISE INSTRUCTIONS
FROM THE DESIGN SYSTEM.
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00:02:35,356 --> 00:02:37,982
A THICK CLAY LAYER
COVERING A MODELING JIG
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00:02:37,984 --> 00:02:41,411
ALLOWS THE CNC MACHINE
TO MAKE A COARSE MODEL.
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00:02:45,508 --> 00:02:51,371
ONCE THE ROBOT IS DONE,
A WORKER FINISHES THE MODELING.
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00:02:51,373 --> 00:02:53,932
THE MODELER BRUSHES OFF
THE CLAY FLAKES
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00:02:53,934 --> 00:02:57,261
AND HAND-FINISHES THE MODEL.
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HE USES PRECISION SCULPTING
TOOLS
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00:02:59,599 --> 00:03:02,792
TO EVEN OUT THE CLAY
AS MUCH AS POSSIBLE.
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00:03:02,794 --> 00:03:05,052
THE GOAL IS TO IMITATE
THE SMOOTHNESS
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00:03:05,054 --> 00:03:08,448
OF A POLISHED CAR BODY.
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00:03:08,450 --> 00:03:12,878
THE CLAY MODEL HELPS DESIGNERS
VISUALIZE THE FULL-SIZED CAR.
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00:03:12,880 --> 00:03:16,480
IT REPRODUCES EVERY DETAIL
OF THE VIRTUAL DESIGN
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00:03:16,482 --> 00:03:19,209
AND WILL BE USED
FOR AERODYNAMIC TESTING.
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00:03:26,302 --> 00:03:28,902
THE LOTUS LIGHTWEIGHT STRUCTURES
ANODIZING PLANT
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00:03:28,904 --> 00:03:31,296
IS LOCATED
IN WELLINGBOROUGH, U.K.
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00:03:31,298 --> 00:03:33,957
THIS IS WHERE WORKERS
PREPARE THE CAR'S ALUMINUM
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00:03:33,959 --> 00:03:35,827
FOR ANODIZING.
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00:03:35,829 --> 00:03:37,220
AN ELECTROLYTIC PROCESS
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00:03:37,222 --> 00:03:40,557
FORMS AN OXIDE LAYER
ON THE ALUMINUM SURFACE.
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00:03:40,559 --> 00:03:43,451
WORKERS BEGIN BY PLACING
MACHINED METAL SHEETS
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00:03:43,453 --> 00:03:48,915
ONTO ELECTRICALLY CHARGED RACKS
CALLED FLIGHT BARS.
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00:03:48,917 --> 00:03:51,577
THE FLIGHT BARS RUN ELECTRIC
CURRENT THROUGH THE ALUMINUM
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00:03:51,579 --> 00:03:54,171
DURING THE ANODIZING PROCESS.
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00:03:54,173 --> 00:03:55,773
BUT BEFORE THIS HAPPENS,
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00:03:55,775 --> 00:03:57,800
THE PANELS
NEED TO GO THROUGH A DEGREASING
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00:03:57,802 --> 00:04:00,002
AND DESCALANT BATH.
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00:04:00,004 --> 00:04:03,464
NOW THAT THE ALUMINUM SHEETS
ARE CLEAN, THE FLIGHT BAR
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00:04:03,466 --> 00:04:07,393
DIPS THE PANELS INTO
A SODIUM-HYDROXIDE SOLUTION.
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00:04:07,395 --> 00:04:10,121
THE SOLUTION DISSOLVES
A THIN LAYER OF THE ALUMINUM,
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00:04:10,123 --> 00:04:13,725
OPENING UP NANOPORES
IN THE METAL SHEETS.
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00:04:13,727 --> 00:04:15,085
IN THE NEXT TANK,
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00:04:15,087 --> 00:04:18,279
SULFURIC ACID IS COMBINED
WITH AN ELECTRIC CURRENT,
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00:04:18,281 --> 00:04:19,948
TRIGGERING A CHEMICAL REACTION
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00:04:19,950 --> 00:04:22,084
THAT LEAVES A COAT
OF ALUMINUM OXIDE
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00:04:22,086 --> 00:04:24,145
ON THE SURFACE OF THE METAL.
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00:04:26,674 --> 00:04:30,701
THIS CORROSION-RESISTANT LAYER
BONDS TO THE ALUMINUM ITSELF,
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00:04:30,703 --> 00:04:32,770
PROVIDING PROTECTION
THAT WILL NEVER CHIP
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00:04:32,772 --> 00:04:34,531
OR PEEL OFF.
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00:04:41,698 --> 00:04:43,290
NEXT, THE FLIGHT BAR
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00:04:43,292 --> 00:04:46,526
LOWERS THE ANODIZED ALUMINUM
INTO A RINSING TANK.
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00:04:49,356 --> 00:04:52,249
PLASTIC BALLS FLOATING
ON THE SURFACE OF THE TANK
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00:04:52,251 --> 00:04:54,919
PREVENT THE LIQUID
FROM EVAPORATING.
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00:04:54,921 --> 00:04:59,007
NOW, THE RINSED ALUMINUM SHEETS
ARE LOWERED OVER AN AIR JET.
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00:04:59,009 --> 00:05:00,241
THEY'RE BLOW-DRIED
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00:05:00,243 --> 00:05:03,369
BEFORE HEADING OFF
TO THE ASSEMBLY DEPARTMENT.
85
00:05:07,041 --> 00:05:09,467
AT THE LOTUS
LIGHTWEIGHT STRUCTURES FACILITY
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00:05:09,469 --> 00:05:11,069
IN WORCESTER, U.K.,
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00:05:11,071 --> 00:05:15,198
AN ADHESIVE ROBOT
PREPARES THE PARTS FOR BONDING.
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00:05:15,200 --> 00:05:16,992
THE ROBOT APPLIES EPOXY ADHESIVE
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00:05:16,994 --> 00:05:20,254
ON EACH BONDING POINT
AND FLANGE.
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00:05:21,857 --> 00:05:25,484
THIS PROCESS MAKES THE CHASSIS
VERY STRONG AND STIFF.
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00:05:25,486 --> 00:05:29,147
BONDING WITH ADHESIVE ALSO
MAINTAINS DIMENSIONAL ACCURACY
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00:05:29,149 --> 00:05:32,809
AND INTEGRITY, WHICH CANNOT BE
ACHIEVED BY WELDING.
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00:05:35,413 --> 00:05:36,738
A WORKER TAKES THE PARTS
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00:05:36,740 --> 00:05:40,300
TO THE ASSEMBLY DEPARTMENT
ON A LOW BUILD TROLLEY.
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00:05:40,302 --> 00:05:41,501
THE CHASSIS BUILD
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00:05:41,503 --> 00:05:44,037
BEGINS BY ADDING
MACHINED ALUMINUM EXTRUSIONS
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00:05:44,039 --> 00:05:45,898
TO THE ASSEMBLY FIXTURE.
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00:05:49,428 --> 00:05:52,821
THEY ASSEMBLE THE TRIANGULAR
MAIN CHASSIS FRAME.
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00:05:52,823 --> 00:05:56,718
IT'S DESIGNED TO BEAR MOST OF
THE VEHICLE'S HANDLING FORCES.
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00:05:59,589 --> 00:06:02,248
THE WORKERS THEN
USE BENDING BEAM EXTRUSIONS
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00:06:02,250 --> 00:06:04,842
TO FORM THE SIDE RAILS
OF THE CAR.
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00:06:04,844 --> 00:06:07,779
THEY MUST BE PERFECTLY
ALIGNED WITH THE CHASSIS.
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00:06:09,975 --> 00:06:12,575
MOUNTING BRACKETS ARE INSTALLED
FOR THE TANK PANEL
104
00:06:12,577 --> 00:06:14,503
AND REAR TORSION BOX.
105
00:06:17,466 --> 00:06:20,334
ONCE THE CHASSIS IS FITTED
WITH THE FRONT TORSION BOX
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00:06:20,336 --> 00:06:23,195
AND SIDE MEMBER REINFORCEMENTS
ON BOTH RAILS,
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00:06:23,197 --> 00:06:25,356
IT'S READY FOR ASSEMBLY.
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00:06:36,669 --> 00:06:40,930
Narrator: THE MAIN CHASSIS
ASSEMBLY LINE IN HETHEL, U.K.,
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00:06:40,932 --> 00:06:42,724
IS WHERE SKILLED WORKERS
ASSEMBLE
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00:06:42,726 --> 00:06:44,993
THE MAIN COMPONENTS
OF THE LOTUS EVORA
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00:06:44,995 --> 00:06:47,154
TO ITS BONDED ALUMINUM FRAME.
112
00:06:51,718 --> 00:06:54,478
A TECHNICIAN STARTS
BY POSITIONING THE CHASSIS
113
00:06:54,480 --> 00:06:56,680
ON A ROLLOVER BUILD TROLLEY.
114
00:06:56,682 --> 00:06:58,607
THIS TOOL ALLOWS HIM
TO FIT PARTS
115
00:06:58,609 --> 00:07:00,810
UNDER THE CHASSIS WITH EASE.
116
00:07:00,812 --> 00:07:03,404
NEXT, HE ROUTES
THE MAIN ELECTRICAL HARNESS
117
00:07:03,406 --> 00:07:04,872
ALONG THE FRAME,
118
00:07:04,874 --> 00:07:08,401
WORKING THE CABLES THROUGH HOLES
IN THE ALUMINUM EXTRUSIONS.
119
00:07:08,403 --> 00:07:09,995
THE HARNESS CONTAINS CABLES
120
00:07:09,997 --> 00:07:12,663
FOR THE ELECTRICAL COMPONENTS
OF THE CAR,
121
00:07:12,665 --> 00:07:15,358
INCLUDING THE DOOR LOCKS,
WINDOW CONTROLS,
122
00:07:15,360 --> 00:07:17,628
HEADLIGHT CONTROLS, FUEL SENDER,
123
00:07:17,630 --> 00:07:19,889
INSTRUMENTS, AND NAVIGATION.
124
00:07:23,285 --> 00:07:25,819
THE TECHNICIAN TILTS
THE ROLLOVER BUILD TROLLEY
125
00:07:25,821 --> 00:07:29,615
TO THE SIDE AND MOVES ON
TO THE NEXT ASSEMBLY STEP.
126
00:07:29,617 --> 00:07:31,910
THERE ARE EIGHT ASSEMBLY STAGES.
127
00:07:31,912 --> 00:07:36,239
EACH STEP TAKES
JUST UNDER AN HOUR.
128
00:07:36,241 --> 00:07:37,641
THE CHASSIS ASSEMBLY STEPS
129
00:07:37,643 --> 00:07:40,701
ARE GENERALLY THE SAME
FOR MOST LOTUS MODELS.
130
00:07:40,703 --> 00:07:42,696
BUT THE EVORA
HAS A LARGER CHASSIS
131
00:07:42,698 --> 00:07:44,964
WITH DIFFERENT PART
SPECIFICATIONS,
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00:07:44,966 --> 00:07:48,027
SUCH AS THIS FULLY ADJUSTABLE
STEERING COLUMN.
133
00:07:51,057 --> 00:07:53,190
BEFORE ASSEMBLING
THE STEERING COLUMN,
134
00:07:53,192 --> 00:07:56,318
THE TECHNICIAN MUST USE
AN ELECTRONIC CENTRALIZING JIB
135
00:07:56,320 --> 00:07:58,521
TO CENTER THE STEERING RACK.
136
00:07:58,523 --> 00:08:00,181
IT IS CRITICAL
THAT THE STEERING RACK
137
00:08:00,183 --> 00:08:04,544
IS CORRECTLY POSITIONED PRIOR TO
SETTING THE STEERING GEOMETRY.
138
00:08:11,144 --> 00:08:13,604
AN OPERATOR PREPARES
THE FUEL-TANK ASSEMBLY
139
00:08:13,606 --> 00:08:15,998
AT THE NEXT STATION.
140
00:08:16,000 --> 00:08:18,334
HE TIGHTENS BOLTS
ON THE FUEL SENDING UNIT
141
00:08:18,336 --> 00:08:20,494
WITH A MANUAL TORQUE WRENCH.
142
00:08:20,496 --> 00:08:22,029
THEN, HE PERFORMS A TEST
143
00:08:22,031 --> 00:08:25,291
TO ENSURE THAT THE FUEL PUMP
IS FUNCTIONING CORRECTLY.
144
00:08:30,757 --> 00:08:33,950
HE INSERTS THE FUEL TANK
IN THE CHASSIS AND POSITIONS
145
00:08:33,952 --> 00:08:35,552
MOUNTING BRACKETS.
146
00:08:45,239 --> 00:08:49,567
HE USES AN AUTOMATIC TORQUE GUN
TO SECURE THE BRACKETS IN PLACE.
147
00:08:54,999 --> 00:08:58,659
HE INSTALLS THE TANK BAY
SHEER PANEL UNDER THE FUEL TANK.
148
00:08:58,661 --> 00:09:00,853
IT PLAYS A KEY STRUCTURAL ROLE
149
00:09:00,855 --> 00:09:03,623
AND COMPLETES
THE REAR TORSION BOX.
150
00:09:07,187 --> 00:09:09,078
THE PANEL IS SECURED IN PLACE
151
00:09:09,080 --> 00:09:11,347
BY FIRST
LIGHTLY TIGHTENING THE BOLTS,
152
00:09:11,349 --> 00:09:14,076
THEN FINISHING THE JOB
WITH THE TORQUE GUN.
153
00:09:21,068 --> 00:09:24,929
EACH ASSEMBLY STEP OF THE MAIN
CHASSIS IS TIMED TO THE MINUTE.
154
00:09:24,931 --> 00:09:27,965
THIS ALLOWS THE WORKERS
TO MOVE EACH TROLLEY UP THE LINE
155
00:09:27,967 --> 00:09:30,293
IN ALMOST PERFECT
SYNCHRONIZATION.
156
00:09:40,823 --> 00:09:44,349
BEFORE MOUNTING THE SUSPENSION
ON THE MAIN CHASSIS, THEY FIRST
157
00:09:44,351 --> 00:09:48,446
APPLY POLYURETHANE ADHESIVE TO
THE SEAT-BELT ANCHORAGE FRAME.
158
00:09:49,841 --> 00:09:52,575
THE SEAT-BELT ANCHORAGE
INCLUDES ROLLOVER PROTECTION
159
00:09:52,577 --> 00:09:54,635
TO PREVENT THE ROOF
FROM COLLAPSING
160
00:09:54,637 --> 00:09:58,364
IF THE CAR FLIPS OVER
IN AN ACCIDENT.
161
00:09:58,366 --> 00:10:01,701
THE WORKER BOLTS THE SEAT-BELT
ANCHORAGE TO THE MAIN CHASSIS
162
00:10:01,703 --> 00:10:04,529
USING AN AUTOMATIC
CALIBRATED TORQUE GUN.
163
00:10:07,259 --> 00:10:11,587
ANOTHER WORKER INSTALLS
THE FRONT ANTI-ROLL BAR.
164
00:10:11,589 --> 00:10:13,789
THIS IMPORTANT PART
OF THE SUSPENSION ASSEMBLY
165
00:10:13,791 --> 00:10:16,183
GIVES THE CAR
ADDITIONAL WHEEL-SPRING RATE
166
00:10:16,185 --> 00:10:18,644
AND LIMITS
THE VEHICLE'S BODY ROLL.
167
00:10:22,275 --> 00:10:25,476
WORKERS ASSEMBLE THE GALVANIZED
STEEL REAR SUBFRAME
168
00:10:25,478 --> 00:10:27,937
TO THE MAIN CHASSIS.
169
00:10:27,939 --> 00:10:29,672
THE ENGINE AND EXHAUST ASSEMBLY
170
00:10:29,674 --> 00:10:32,834
WILL BE INSTALLED
TO THE REAR SUBFRAME NEXT.
171
00:10:43,904 --> 00:10:45,996
Narrator:
AT THE LOTUS ASSEMBLY PLANT,
172
00:10:45,998 --> 00:10:49,124
TECHNICIANS CUSTOMIZE THE DOUBLE
OVERHEAD CAMSHAFT ENGINE
173
00:10:49,126 --> 00:10:52,519
AND GEARBOX BEFORE ATTACHING
THEM TO THE REAR SUBFRAME
174
00:10:52,521 --> 00:10:54,222
OF THE CARS.
175
00:10:58,486 --> 00:11:00,545
A TECHNICIAN INSERTS
THE DIFFERENTIAL
176
00:11:00,547 --> 00:11:05,074
INSIDE THE SIX-SPEED GEARBOX
OF THE EVORA.
177
00:11:05,076 --> 00:11:06,543
HE TAKES THE INPUT SHAFT
178
00:11:06,545 --> 00:11:10,105
AND MOUNTS CLOSE-RATIO
HELICAL GEARS ONTO IT.
179
00:11:12,968 --> 00:11:17,096
HE INSTALLS BOTH THE INPUT AND
OUTPUT SHAFTS IN THE GEARBOX.
180
00:11:17,098 --> 00:11:20,032
THE OUTPUT SHAFT
CONNECTS TO THE DIFFERENTIAL.
181
00:11:20,034 --> 00:11:23,494
THIS TRANSFERS POWER
TO THE WHEELS.
182
00:11:23,496 --> 00:11:26,823
THE TECHNICIAN THEN
INSERTS A SECOND OUTPUT SHAFT.
183
00:11:30,787 --> 00:11:34,514
HE INSTALLS THE REVERSE IDLER
SHAFT INSIDE THE GEARBOX,
184
00:11:34,516 --> 00:11:35,782
CONNECTING IT TO THE INPUT
185
00:11:35,784 --> 00:11:37,543
SHAFT.
186
00:11:39,780 --> 00:11:41,638
THE CUSTOMIZATION OF THE GEARBOX
187
00:11:41,640 --> 00:11:45,442
IS A VERY SENSITIVE,
HIGH-PRECISION TASK.
188
00:11:45,444 --> 00:11:47,803
THE TECHNICIAN
NOW INSTALLS SHIFT FORKS
189
00:11:47,805 --> 00:11:51,199
OVER THE SELECTOR COLLAR
ON THE SHAFTS.
190
00:11:51,201 --> 00:11:52,533
THESE FORKS ALLOW FOR SHIFTING
191
00:11:52,535 --> 00:11:56,062
BETWEEN THE SIX FORWARD GEARS
AND REVERSE.
192
00:12:02,421 --> 00:12:06,023
THE TECHNICIAN INSERTS
SLIDER SHAFTS INTO THE FORKS.
193
00:12:06,025 --> 00:12:08,349
THIS ENABLES THE FORKS
TO MOVE UP OR DOWN
194
00:12:08,351 --> 00:12:10,544
WHEN THE DRIVER SHIFTS GEARS.
195
00:12:15,743 --> 00:12:18,336
ONCE THE GEARBOX ASSEMBLY
IS COMPLETE,
196
00:12:18,338 --> 00:12:21,839
THE TECHNICIAN APPLIES A STRIP
OF NONHARDENING ADHESIVE SEALANT
197
00:12:21,841 --> 00:12:23,767
AROUND THE GEARBOX CASING.
198
00:12:27,698 --> 00:12:30,724
THEN, HE PUTS THE GEARBOX COVER
IN PLACE.
199
00:12:40,986 --> 00:12:42,319
NEXT, A TECHNICIAN
200
00:12:42,321 --> 00:12:45,915
ASSEMBLES A SUPERCHARGER
TO THE V-6 ENGINE AND BOLTS
201
00:12:45,917 --> 00:12:48,609
IT IN PLACE
WITH A PNEUMATIC TORQUE WRENCH.
202
00:12:51,907 --> 00:12:54,574
ANOTHER WORKER JOINS THE GEARBOX
TO THE ENGINE
203
00:12:54,576 --> 00:12:56,701
AND INSERTS FIXING BOLTS.
204
00:12:58,805 --> 00:13:02,265
THEN, A TECHNICIAN LOWERS
THE ENGINE AND GEARBOX ASSEMBLY
205
00:13:02,267 --> 00:13:03,959
ONTO THE SUBFRAME.
206
00:13:10,927 --> 00:13:13,686
HE ASSEMBLES THE GEARBOX MOUNT
TO THE SUBFRAME
207
00:13:13,688 --> 00:13:15,913
USING A MANUAL TORQUE WRENCH.
208
00:13:21,279 --> 00:13:23,938
WITH THE HELP
OF AN OVERHEAD LIFTING DEVICE,
209
00:13:23,940 --> 00:13:26,007
HE ALIGNS THE GEARBOX
WITH THE MOUNT
210
00:13:26,009 --> 00:13:27,809
AND SECURES IT IN PLACE.
211
00:13:27,811 --> 00:13:30,337
THIS FINALIZES
THE ENGINE ASSEMBLY.
212
00:13:34,435 --> 00:13:38,962
WORKERS CONNECT THE EXHAUST
SYSTEM TO THE ENGINE.
213
00:13:38,964 --> 00:13:41,757
IT'S MADE OF AVIATION-GRADE
STAINLESS STEEL
214
00:13:41,759 --> 00:13:46,120
AND MAKES A DISTINCTIVE
RACECAR-LIKE GROWL.
215
00:13:46,122 --> 00:13:50,150
A WORKER HOLDS THE ENGINE AS
THE OTHER BOLTS ON THE EXHAUST.
216
00:13:54,181 --> 00:13:58,342
THE EXHAUST FOR THE EVORA
COMES WITH A SIGNATURE OVAL TIP.
217
00:14:00,804 --> 00:14:03,338
NEXT, TECHNICIANS
USE AN OVERHEAD HOIST
218
00:14:03,340 --> 00:14:06,400
TO POSITION THE ENGINE MODULE
AND SUBFRAME ASSEMBLY
219
00:14:06,402 --> 00:14:08,102
ONTO THE MAIN CHASSIS.
220
00:14:11,332 --> 00:14:13,257
THEY BOLT THE REAR SUBFRAME
IN PLACE
221
00:14:13,259 --> 00:14:17,061
WITH A PNEUMATIC TORQUE GUN.
222
00:14:17,063 --> 00:14:19,222
ONCE THE ENGINE
IS FIRMLY SECURED,
223
00:14:19,224 --> 00:14:21,024
THE OPERATORS RELEASE THE HOIST
224
00:14:21,026 --> 00:14:23,585
TO PREPARE THE TROLLEY
FOR THE NEXT STATION.
225
00:14:27,749 --> 00:14:29,474
JOINING THE ENGINE
TO THE CHASSIS
226
00:14:29,476 --> 00:14:32,811
IS SLIGHTLY DIFFERENT
FOR THE LOTUS ELISE.
227
00:14:32,813 --> 00:14:35,171
OPERATORS INSTALL
THE FOUR-CYLINDER ENGINE
228
00:14:35,173 --> 00:14:37,307
DIRECTLY INTO THE REAR SUBFRAME.
229
00:14:37,309 --> 00:14:41,637
IT'S ALREADY ATTACHED
TO THE MAIN CHASSIS.
230
00:14:41,639 --> 00:14:44,432
THEY PLUG THE ENGINE HARNESS
INTO THE MAIN HARNESS
231
00:14:44,434 --> 00:14:46,092
AND MAKE
THE AUXILIARY CONNECTIONS
232
00:14:46,094 --> 00:14:48,094
TO FINISH THE PROCESS.
233
00:14:51,825 --> 00:14:55,718
NEXT COMES
THE SUSPENSION ARMS ASSEMBLY.
234
00:14:55,720 --> 00:14:58,980
THE INDEPENDENT-FORGED ALUMINUM
DOUBLE WISHBONE SUSPENSION
235
00:14:58,982 --> 00:15:02,442
IS FITTED WITH SERVO-ASSISTED
VENTILATED BRAKE DISCS,
236
00:15:02,444 --> 00:15:03,978
PROVIDING MAXIMUM CONTROL
237
00:15:03,980 --> 00:15:07,173
OVER THE WHEEL'S CAMBER ANGLE
AND SCRUB RADIUS.
238
00:15:09,711 --> 00:15:11,402
IT TAKES ABOUT A DAY'S WORK
239
00:15:11,404 --> 00:15:13,871
TO GET THE CHASSIS FRAME
FULLY ASSEMBLED
240
00:15:13,873 --> 00:15:16,966
AND READY TO SEND OFF
TO THE BODY ASSEMBLY LINE.
241
00:15:21,264 --> 00:15:22,923
THE BODY PANELS
NEED TO BE PAINTED
242
00:15:22,925 --> 00:15:26,326
BEFORE THEY CAN BE ASSEMBLED.
243
00:15:26,328 --> 00:15:27,752
PAINTERS SPRAY THE PANELS
244
00:15:27,754 --> 00:15:32,216
WITH AN ECOLOGICAL
WATER-BASED PRIMER.
245
00:15:32,218 --> 00:15:36,178
WORKERS PAINT THEM IN SETS
TO ENSURE COLOR CONSISTENCY.
246
00:15:40,477 --> 00:15:42,610
IT'S IMPOSSIBLE
TO USE ELECTROSTATIC PAINT
247
00:15:42,612 --> 00:15:44,170
FOR THE BODY PANELS
248
00:15:44,172 --> 00:15:47,899
BECAUSE THE HIGH-TECH COMPOSITE
MATERIAL IS NOT CONDUCTIVE.
249
00:15:47,901 --> 00:15:50,368
PAINTERS NEED TO APPLY
A WATER-BASED LACQUER
250
00:15:50,370 --> 00:15:53,063
TO PROTECT THE PAINT COATING.
251
00:16:00,043 --> 00:16:02,368
Narrator:
AT THE LOTUS HEADQUARTERS,
252
00:16:02,370 --> 00:16:05,631
WORKERS GET THE CARS READY
TO HIT THE ROAD.
253
00:16:05,633 --> 00:16:07,699
TECHNICIANS PUSH
THIS ASSEMBLED EVORA
254
00:16:07,701 --> 00:16:10,927
TO THE FLUID FILL DEPARTMENT
FOR AN INITIAL FUEL FILLING
255
00:16:10,929 --> 00:16:13,989
BEFORE THE ENGINE
GETS STARTED FOR THE FIRST TIME.
256
00:16:17,127 --> 00:16:20,321
AT ANOTHER STATION, WORKERS
TRANSFER THE CHASSIS OF AN EVORA
257
00:16:20,323 --> 00:16:24,983
FROM A HIGH BUILD TROLLEY
TO A LOW BUILD TROLLEY.
258
00:16:24,985 --> 00:16:27,412
THEY GET READY TO BOND
THE PAINTED BODY PANELS
259
00:16:27,414 --> 00:16:30,540
TO THE EXTRUDED-ALUMINUM
CHASSIS.
260
00:16:30,542 --> 00:16:33,009
A TECHNICIAN
APPLIES A POLYURETHANE ADHESIVE
261
00:16:33,011 --> 00:16:36,604
ON THE UPPER RAIL BEFORE
THE CORE-BODY ASSEMBLY MACHINE
262
00:16:36,606 --> 00:16:40,801
ATTACHES THE SIDE PANEL
TO THE CHASSIS.
263
00:16:40,803 --> 00:16:43,695
THE TECHNICIAN PREPARES
THE FRONT CRASH STRUCTURE
264
00:16:43,697 --> 00:16:45,497
FOR BONDING.
265
00:16:45,499 --> 00:16:48,225
THIS PART COVERS
THE FRONT CHASSIS SUBFRAME
266
00:16:48,227 --> 00:16:51,887
AND IS DESIGNED TO ABSORB
THE IMPACT OF AN ACCIDENT.
267
00:16:51,889 --> 00:16:55,416
TECHNICIANS CLAMP IT TIGHT
UNTIL THE ADHESIVE CURES.
268
00:16:55,418 --> 00:16:58,753
THEN, THEY BRING IN THE
COMPOSITE WINDSCREEN APERTURE.
269
00:16:58,755 --> 00:17:03,441
LOCATOR ARMS ARE USED
TO POSITION IT CORRECTLY.
270
00:17:03,443 --> 00:17:07,837
NEXT, THEY FIT THE DOOR
TO THE BODY SIDE PANEL.
271
00:17:07,839 --> 00:17:12,001
A TECHNICIAN USES MEASURE GAUGES
TO MAKE SURE THE FIT IS PERFECT.
272
00:17:22,931 --> 00:17:25,456
TECHNICIANS ASSEMBLE
THE DOOR-CLOSING MECHANISM
273
00:17:25,458 --> 00:17:27,324
CALLED THE DOOR STRIKER.
274
00:17:27,326 --> 00:17:29,919
THEY SCREW IN A STEEL BOLT
OVER A WASHER
275
00:17:29,921 --> 00:17:32,347
TO PREVENT
DAMAGING THE COMPOSITE.
276
00:17:32,349 --> 00:17:36,310
THE STRIKER IS SET TO ALLOW FOR
A NICE AND SMOOTH DOOR CLOSURE.
277
00:17:39,548 --> 00:17:42,540
TECHNICIANS NOW BRING
IN THE REAR CLAMSHELL.
278
00:17:42,542 --> 00:17:45,068
IT ONLY WEIGHS ABOUT 40 POUNDS.
279
00:17:45,070 --> 00:17:47,071
THE PANEL FITS
OVER THE REAL MODULE
280
00:17:47,073 --> 00:17:49,832
TO COVER
BOTH THE ENGINE AND FUEL TANK.
281
00:17:49,834 --> 00:17:51,834
THE TECHNICIAN
282
00:17:51,836 --> 00:17:55,797
SETS THE REAR CLAMSHELL FLUSH
TO THE BODY SIDE PANELS.
283
00:17:59,294 --> 00:18:01,920
THEN, THEY INSTALL
THE FRONT CLAMSHELL.
284
00:18:04,783 --> 00:18:06,783
THE PANEL FITS
OVER THE CRASH STRUCTURE
285
00:18:06,785 --> 00:18:08,911
AND HAS OPENINGS
FOR THE RADIATOR VENTS,
286
00:18:08,913 --> 00:18:10,980
HEADLIGHTS, AND FLASHERS.
287
00:18:13,776 --> 00:18:16,969
WITH THE CAR
SITTING ON A TWO-POST RAMP LIFT,
288
00:18:16,971 --> 00:18:19,972
A TECHNICIAN
INSTALLS THE REAR DIFFUSER.
289
00:18:19,974 --> 00:18:23,368
THE DIFFUSER IS DESIGNED
FOR OPTIMAL AERODYNAMICS,
290
00:18:23,370 --> 00:18:25,795
REDUCING BOTH DRAG AND LIFT.
291
00:18:25,797 --> 00:18:30,392
IT PREVENTS AIR TURBULENCE FROM
REDUCING THE CAR'S PERFORMANCE.
292
00:18:31,595 --> 00:18:33,720
NOW, A TECHNICIAN
MOUNTS THE WHEELS
293
00:18:33,722 --> 00:18:36,656
ON CROSS-DRILLED BRAKE DISCS.
294
00:18:36,658 --> 00:18:40,252
HE ROUGHLY TIGHTENS THE NUTS
THROUGH THE 12-SPOKE RIM
295
00:18:40,254 --> 00:18:42,413
BEFORE LOWERING THE VEHICLE
ON ITS WHEELS
296
00:18:42,415 --> 00:18:44,682
FOR THE VERY FIRST TIME.
297
00:18:44,684 --> 00:18:47,009
THE TECHNICIAN FINISHES
TORQUEING THE WHEEL NUTS
298
00:18:47,011 --> 00:18:48,811
WITH A MANUAL WRENCH.
299
00:18:48,813 --> 00:18:52,173
HE MARKS EACH ONE THAT'S BEEN
TIGHTENED TO THE CORRECT TORQUE.
300
00:18:54,536 --> 00:18:58,029
NEXT, THE FINISHED CAR
GOES TO THE CHASSIS DYNAMOMETER
301
00:18:58,031 --> 00:18:59,564
OR ROLLING ROAD.
302
00:18:59,566 --> 00:19:00,899
THIS IS WHERE THE VEHICLE
303
00:19:00,901 --> 00:19:05,362
GOES THROUGH A COMPLETE
FUNCTIONAL TESTING PROCESS.
304
00:19:05,364 --> 00:19:08,090
DRIVE ROLLERS ACTIVATE
THE FRONT WHEELS
305
00:19:08,092 --> 00:19:11,818
TO CALIBRATE THE DYNAMOMETER.
306
00:19:11,820 --> 00:19:13,354
A COMPUTER PROMPTS THE DRIVER
307
00:19:13,356 --> 00:19:16,916
WITH INSTRUCTIONS
THROUGHOUT THE TESTING CYCLE.
308
00:19:16,918 --> 00:19:18,642
INTEGRATED CALIBRATION TOOLS
309
00:19:18,644 --> 00:19:21,546
MONITOR AND ANALYZE
THE CAR'S RESPONSE.
310
00:19:24,376 --> 00:19:27,436
THE DRIVER MOVES THE REAR WHEELS
ONTO THE ROLLERS
311
00:19:27,438 --> 00:19:31,865
TO TEST VARIOUS DRIVETRAIN
COMPONENTS LIKE THE REAR BRAKES.
312
00:19:31,867 --> 00:19:33,867
THE COMPUTER PROCESSES THE DATA
313
00:19:33,869 --> 00:19:38,129
AND USES IT
FOR ENGINE CALIBRATION.
314
00:19:38,131 --> 00:19:40,791
THE DYNAMOMETER MEASURES
THE ENGINE RPM,
315
00:19:40,793 --> 00:19:44,119
HORSEPOWER, AND TORQUE OUTPUT
AT VARIOUS SPEEDS
316
00:19:44,121 --> 00:19:46,389
AND ALSO MONITORS
THE ENGINE'S RESPONSE
317
00:19:46,391 --> 00:19:50,751
TO ACCELERATION
AND GEAR SHIFTING.
318
00:19:50,753 --> 00:19:53,146
THIS SYSTEM ALLOWS
FOR THE DYNAMIC TESTING
319
00:19:53,148 --> 00:19:54,881
OF ALL THE VEHICLE'S FEATURES,
320
00:19:54,883 --> 00:19:59,103
INCLUDING EMISSION SAMPLING
AND FUEL-CONSUMPTION ANALYSIS.
321
00:19:59,105 --> 00:20:02,339
THE ENGINE MANAGEMENT SOFTWARE
MUST HAVE THIS TEST DATA
322
00:20:02,341 --> 00:20:05,201
BEFORE THE CAR
CAN LEAVE THE PRODUCTION LINE.
323
00:20:09,766 --> 00:20:12,825
FINALLY, THE CARS
GO TO SURFACE FINISHING.
324
00:20:15,888 --> 00:20:18,022
WORKERS POLISH AND CLEAN
THE CAR BODY
325
00:20:18,024 --> 00:20:21,584
USING
PNEUMATIC ORBITAL POLISHERS.
326
00:20:21,586 --> 00:20:24,579
LOW-SPEED DRY POLISHING
LEAVES A GLOSSY FINISH,
327
00:20:24,581 --> 00:20:26,848
ENHANCING THE SMOOTHNESS
AND SHINE
328
00:20:26,850 --> 00:20:29,443
OF THE LACQUER-PROTECTED
COLOR COATING.
329
00:20:39,405 --> 00:20:42,331
THESE SUPERCARS
ARE READY TO BE TRIED OUT --
330
00:20:42,333 --> 00:20:48,062
THE EVORA, WITH ITS INTEGRATED
AERODYNAMIC REAR BOOT SPOILER;
331
00:20:48,064 --> 00:20:50,523
THE SLICK CONVERTIBLE
ELISE SPORTS CAR;
332
00:20:50,525 --> 00:20:53,318
AND THE EXIGE COUPE.
333
00:20:53,320 --> 00:20:56,613
THE INTERIOR OF THE CARS
ARE UPHOLSTERED IN LEATHER
334
00:20:56,615 --> 00:20:59,216
AND FEATURE AN ERGONOMICALLY
SHAPED STEERING WHEEL
335
00:20:59,218 --> 00:21:00,976
WITH LIGHTWEIGHT RIM.
336
00:21:03,281 --> 00:21:06,540
COMBINING AERODYNAMIC
DRAG-REDUCTION ENGINEERING
337
00:21:06,542 --> 00:21:08,901
WITH AESTHETIC DESIGN,
LOTUS CARS
338
00:21:08,903 --> 00:21:12,205
ARE AMONG THE BEST-HANDLING
SPORTS CARS IN THE WORLD.
339
00:21:12,207 --> 00:21:14,498
THEY CAN TAKE ON A CURVE
AT HIGH SPEEDS
340
00:21:14,500 --> 00:21:17,294
WITHOUT LOSING TRACTION.
341
00:21:17,296 --> 00:21:20,563
A LOTUS DRIVING ACADEMY
INSTRUCTOR NOW TAKES THE EVORA
342
00:21:20,565 --> 00:21:21,957
FOR A TEST DRIVE.
343
00:21:21,959 --> 00:21:23,291
THE LOTUS EVORA
344
00:21:23,293 --> 00:21:26,953
IS LARGER AND MORE SOPHISTICATED
THAN THE ELISE AND EXIGE
345
00:21:26,955 --> 00:21:31,951
BUT HAS THE SAME EASY HANDLING
AND SMOOTH RIDE.
27866
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