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These are the user uploaded subtitles that are being translated: 1 00:00:01,469 --> 00:00:03,001 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,003 --> 00:00:04,761 THE ARIEL ATOM 3S, 3 00:00:04,763 --> 00:00:08,290 A SUPERCAR BUILT FOR THE TRACK BUT COMFORTABLE ON THE ROAD. 4 00:00:08,292 --> 00:00:11,227 -- Captions by VITAC -- www.vitac.com 5 00:00:11,229 --> 00:00:14,288 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:14,290 --> 00:00:17,250 ♪♪ 7 00:00:23,317 --> 00:00:25,108 THE 20,000-SQUARE-FOOT FACILITY 8 00:00:25,110 --> 00:00:27,577 LOCATED IN HALIFAX COUNTY, VIRGINIA, 9 00:00:27,579 --> 00:00:31,774 HOUSES THE TMI AUTOTECH HEADQUARTERS. 10 00:00:31,776 --> 00:00:33,567 THIS IS WHERE HIGHLY SKILLED WORKERS 11 00:00:33,569 --> 00:00:37,263 ASSEMBLE THE ARIEL ATOM 3S. 12 00:00:37,265 --> 00:00:38,998 FOR THE FINAL ASSEMBLY STEP, 13 00:00:39,000 --> 00:00:41,592 EACH UNIT IS ASSIGNED TO ONE TECHNICIAN 14 00:00:41,594 --> 00:00:45,254 WHO COMPLETES THE MONTH-LONG MANUFACTURING PROCESS. 15 00:00:45,256 --> 00:00:48,458 TECHNICIANS WORK SIDE BY SIDE ON FIVE UNITS 16 00:00:48,460 --> 00:00:52,320 AT DIFFERENT STAGES OF THE ASSEMBLY PROCESS. 17 00:00:52,322 --> 00:00:53,680 IT TAKES ABOUT 4 WEEKS 18 00:00:53,682 --> 00:00:56,082 TO GET FROM THE BARE, POWDER-COATED CHASSIS 19 00:00:56,084 --> 00:00:59,077 TO THE ASSEMBLED EXOSKELETON OF THE CAR, 20 00:00:59,079 --> 00:01:02,806 WHICH IS FITTED WITH A FIBERGLASS BASE. 21 00:01:02,808 --> 00:01:06,335 THE BASE HOLDS A LAMINATED SAFETY GLASS WINDSHIELD, 22 00:01:06,337 --> 00:01:08,337 A FRONT-MOUNTED ALUMINUM RADIATOR, 23 00:01:08,339 --> 00:01:11,632 AND FIVE-SPOKE RACE MOTOR SPORT WHEELS. 24 00:01:11,634 --> 00:01:14,961 THIS 3S COMES EQUIPPED WITH HIGH-OUTPUT HEADLIGHTS, 25 00:01:14,963 --> 00:01:18,056 A PUSH-ROD AND ROCKER-ARM REAR SUSPENSION SYSTEM, 26 00:01:18,058 --> 00:01:21,293 SPECIAL 12-SPOKE RIMS, 27 00:01:21,295 --> 00:01:25,822 AND LOADED WITH A 365-HORSEPOWER ENGINE. 28 00:01:25,824 --> 00:01:27,649 THE TWO IN-FRONT SUSPENSION DAMPERS 29 00:01:27,651 --> 00:01:29,717 ALLOW THE CAR TO BEND INTO CURVES 30 00:01:29,719 --> 00:01:32,646 RATHER THAN DARTING INTO THEM. 31 00:01:32,648 --> 00:01:35,708 ♪♪ 32 00:01:35,710 --> 00:01:39,770 A MECHANICAL ENGINEER REVIEWS THE ATOM'S EXOSKELETON DESIGN, 33 00:01:39,772 --> 00:01:41,038 USING A CAD SOFTWARE 34 00:01:41,040 --> 00:01:44,800 TO STUDY A 3-D MODEL OF THE CHASSIS. 35 00:01:44,802 --> 00:01:47,128 HE GOES OVER THE WELDING SPECIFICATIONS 36 00:01:47,130 --> 00:01:53,193 FOR ALL 183 INDIVIDUAL PIECES COMPRISING THE CHASSIS. 37 00:01:53,195 --> 00:01:55,987 A FABRICATION TECHNICIAN ASSEMBLES THE CHASSIS 38 00:01:55,989 --> 00:01:58,457 ON A MODULAR FIXTURE TABLE. 39 00:01:58,459 --> 00:02:01,151 HE POSITIONS THE MACHINED ALUMINUM JIG 40 00:02:01,153 --> 00:02:03,412 AND SECURES IT IN PLACE. 41 00:02:03,414 --> 00:02:05,480 THIS KEEPS THE CHASSIS TUBE STABLE 42 00:02:05,482 --> 00:02:08,409 DURING THE WELDING PROCESS. 43 00:02:08,411 --> 00:02:10,677 THE TECHNICIAN BRINGS IN A ROLLED STEEL TUBE, 44 00:02:10,679 --> 00:02:13,740 WHICH WILL FORM THE RIGHT UPPER SIDE RAIL OF THE CHASSIS. 45 00:02:16,970 --> 00:02:20,163 HE PLACES THE TUBE FLUSH AGAINST THE FRONT-END MODULE 46 00:02:20,165 --> 00:02:25,360 BEFORE HE POSITIONS ANOTHER TUBE ACROSS THE FRAME. 47 00:02:25,362 --> 00:02:29,823 THE ENTIRE CHASSIS IS BUILT USING MILD STEEL. 48 00:02:29,825 --> 00:02:32,018 THE ELECTRIC RESISTANCE WELDING PROCESS 49 00:02:32,020 --> 00:02:34,686 INCREASES THE STRENGTH AND HARDNESS OF THE STEEL 50 00:02:34,688 --> 00:02:38,182 WHILE DECREASING ITS DUCTILITY. 51 00:02:38,184 --> 00:02:40,977 THE ROLLED STEEL IS FORMED INTO A ROUND TUBE 52 00:02:40,979 --> 00:02:44,906 AND CLOSED USING A FLASH BUTT WELDING TECHNIQUE. 53 00:02:44,908 --> 00:02:47,309 THE TUBE IS THEN DRAWN OVER A MANDREL 54 00:02:47,311 --> 00:02:49,970 TO REMOVE THE WELD SEAM. 55 00:02:49,972 --> 00:02:52,197 THIS PROCESS MAKES THE CHASSIS STIFFER 56 00:02:52,199 --> 00:02:53,732 AND MORE RESISTANT, 57 00:02:53,734 --> 00:02:56,293 LEAVING THE TUBING VIRTUALLY SEAMLESS. 58 00:02:58,865 --> 00:03:01,257 THE TECHNICIAN BRINGS IN THE SIDE RAIL, 59 00:03:01,259 --> 00:03:04,192 ALIGNS IT WITH THE LASER-NOTCHED END OF THE MAIN TUBE, 60 00:03:04,194 --> 00:03:06,587 AND PLACES IT ON THE FRONT-END MODULE. 61 00:03:10,418 --> 00:03:13,144 IT TAKES ABOUT A DAY TO TACK THE ENTIRE CHASSIS 62 00:03:13,146 --> 00:03:15,347 BEFORE IT'S READY FOR FINISH WELDING. 63 00:03:18,476 --> 00:03:20,869 A WELDER STARTS ON THE BASE OF A CHASSIS TUBE 64 00:03:20,871 --> 00:03:22,737 USING A TIG WELDING TORCH 65 00:03:22,739 --> 00:03:24,932 AND A SILICON BRONZE ROD. 66 00:03:28,704 --> 00:03:31,297 NEXT, HE TAKES SMALL LASER-CUT STEEL PARTS 67 00:03:31,299 --> 00:03:34,892 THAT HAVE BEEN ENGINEERED TO MAKE CHASSIS BRACKETS. 68 00:03:34,894 --> 00:03:38,154 HE PLACES THE PIECES ON A ROTATING WELDING FIXTURE, 69 00:03:38,156 --> 00:03:39,489 CLAMPS THEM FIRMLY, 70 00:03:39,491 --> 00:03:45,053 AND WELDS THEM USING A SMALL SILICON BRONZE TIG ROD. 71 00:03:45,055 --> 00:03:47,381 THE MELTING POINT OF SILICON BRONZE 72 00:03:47,383 --> 00:03:50,108 IS AROUND 1,800 DEGREES FAHRENHEIT, 73 00:03:50,110 --> 00:03:53,571 ABOUT 700 DEGREES BELOW THE MELTING POINT OF STEEL. 74 00:03:53,573 --> 00:03:56,506 SILICON BRONZE WELDING REQUIRES LESS HEAT. 75 00:03:56,508 --> 00:03:59,001 SO THERE'S LESS OF A CHANCE THAT THE WELDER WILL MELT 76 00:03:59,003 --> 00:04:01,403 THE STEEL BASE METAL INTO THE WELD, 77 00:04:01,405 --> 00:04:04,264 WHICH COULD THEN BRITTLE OR CRACK. 78 00:04:04,266 --> 00:04:07,126 THE WELDER PUTS THE PIECE ON AN ALUMINUM BLOCK 79 00:04:07,128 --> 00:04:09,988 AND SECURES IT WITH CUSTOMIZED FIXTURES. 80 00:04:12,859 --> 00:04:16,186 HE PLACES ANOTHER LASER-CUT STEEL PIECE ON THE BLOCK. 81 00:04:18,883 --> 00:04:22,576 HE USES A FIXTURE TO HOLD IT IN PLACE. 82 00:04:24,880 --> 00:04:28,074 THIS TIME, HE USES A STEEL FILLER ROD 83 00:04:28,076 --> 00:04:30,009 BECAUSE THIS PARTICULAR WELDING SEAM 84 00:04:30,011 --> 00:04:32,337 WILL NOT BE VISIBLE ON THE CHASSIS. 85 00:04:34,374 --> 00:04:37,766 THESE THREE-PIECE BRACKETS FORM ROLL BAR MOUNTS. 86 00:04:37,768 --> 00:04:40,028 USING A LOCATOR FIXTURE AND A SPACER, 87 00:04:40,030 --> 00:04:43,824 THE WELDER POSITIONS THE BRACKET ON THE FRAME. 88 00:04:43,826 --> 00:04:47,285 HE SECURES THE FIXTURE IN PLACE BY DRIVING ITS THREADED HEAD 89 00:04:47,287 --> 00:04:51,649 THROUGH A HOLE MACHINED INTO THE TUBING. 90 00:04:51,651 --> 00:04:52,983 USING A TIG TORCH, 91 00:04:52,985 --> 00:04:55,378 THE WELDER BRAZES THE SILICON BRONZE FILLER, 92 00:04:55,380 --> 00:04:58,046 WHICH BONDS THE BRACKET TO THE MAIN SIDE RAIL 93 00:04:58,048 --> 00:05:00,308 AND TO THE REAR SUB-FRAME ASSEMBLY. 94 00:05:02,912 --> 00:05:04,838 HE REMOVES THE LOCATOR FIXTURE, 95 00:05:04,840 --> 00:05:08,333 LEAVING THE ROLL BAR MOUNTS SAFELY WELDED ONTO THE CHASSIS. 96 00:05:14,600 --> 00:05:19,653 THE CHASSIS RESTS ON A ROTATING FIXTURE CALLED A ROTISSERIE. 97 00:05:19,655 --> 00:05:20,988 ON THIS WELDING JIG, 98 00:05:20,990 --> 00:05:25,217 THE CAR'S EXOSKELETON CAN ROTATE A FULL 360 DEGREES. 99 00:05:25,219 --> 00:05:27,486 THIS ENSURES ACCURATE WELDING 100 00:05:27,488 --> 00:05:29,814 AND SAFE ACCESS TO ALL WELDING POINTS. 101 00:05:29,816 --> 00:05:31,548 THE ASSEMBLED SPACE FRAME 102 00:05:31,550 --> 00:05:33,943 COMES WITH A DISTINCTIVE AIR INTAKE HOOP 103 00:05:33,945 --> 00:05:37,205 AND AN EMBEDDED STEERING COLUMN WELDED INTO THE CHASSIS. 104 00:05:37,207 --> 00:05:39,174 ♪♪ 105 00:05:41,092 --> 00:05:42,925 ♪♪ 106 00:05:44,094 --> 00:05:46,053 Narrator: THE COLD-ROLLED STEEL FENDER STAY 107 00:05:46,055 --> 00:05:48,982 IS A DISTINCTIVE PART OF THE ARIEL ATOM. 108 00:05:48,984 --> 00:05:50,916 IT FEATURES A STOP WASHER 109 00:05:50,918 --> 00:05:53,211 SPOT WELDED WITH A TIG STEEL FILLER 110 00:05:53,213 --> 00:05:57,074 AND MIG-WELDED MOUNTING TABS FOR BETTER RESISTANCE. 111 00:05:57,076 --> 00:05:58,608 ♪♪ 112 00:05:58,610 --> 00:06:03,204 A WORKER FEEDS ROLLED STEEL INTO A TUBE-BENDING MACHINE. 113 00:06:03,206 --> 00:06:05,332 THE WIPER DIE SYSTEM BOTH BENDS 114 00:06:05,334 --> 00:06:07,467 AND PUTS PRESSURE ALL AROUND THE TUBE 115 00:06:07,469 --> 00:06:10,696 TO PREVENT IT FROM COLLAPSING OR DEFORMING. 116 00:06:10,698 --> 00:06:12,991 AS THE NEXT TUBE SECTION COMES OUT, 117 00:06:12,993 --> 00:06:15,827 THE BEND DIE RETURNS TO ITS AXIS. 118 00:06:15,829 --> 00:06:17,420 THE CLAMP DIE AND PRESSURE DIE 119 00:06:17,422 --> 00:06:20,890 MOVE INTO POSITION FOR THE SECOND BEND. 120 00:06:20,892 --> 00:06:22,284 IN LESS THAN ONE MINUTE, 121 00:06:22,286 --> 00:06:25,512 THE MULTI-RADIUS CNC TUBE BENDING MACHINE 122 00:06:25,514 --> 00:06:28,047 AUTOMATICALLY MAKES A SERIES OF FOUR BENDS 123 00:06:28,049 --> 00:06:30,442 TO FORM THE FENDER STAY. 124 00:06:30,444 --> 00:06:33,537 THIS CNC BENDER ALLOWS FOR ACCURATE BENDS 125 00:06:33,539 --> 00:06:36,640 AS WELL AS REPEATABILITY FOR FUTURE BUILDS. 126 00:06:38,969 --> 00:06:40,903 A WELDER NOW BRINGS THE FENDER STAY 127 00:06:40,905 --> 00:06:44,865 FROM THE TUBE BENDING MACHINE TO THE WELDING TABLE. 128 00:06:44,867 --> 00:06:47,727 HE MOUNTS TABS ON A MACHINED ALUMINUM FIXTURE 129 00:06:47,729 --> 00:06:51,522 DESIGNED TO ENSURE THE MOST ACCURATE WELDING. 130 00:06:51,524 --> 00:06:54,250 HE THEN INSERTS AND ROUGHLY LOCATES WASHERS 131 00:06:54,252 --> 00:06:56,787 ON THE FENDER STAY TUBE. 132 00:06:56,789 --> 00:06:58,747 ONCE THE WASHERS ARE IN PLACE, 133 00:06:58,749 --> 00:07:02,209 THE WELDER POSITIONS THE FENDER STAY ON THE FIXTURE. 134 00:07:02,211 --> 00:07:07,139 HE COMPLETES THE ASSEMBLY WITH AN ADDITIONAL MOUNTING TAB. 135 00:07:07,141 --> 00:07:08,874 HE STARTS WELDING THE MOUNTING TABS 136 00:07:08,876 --> 00:07:11,802 USING A MIG WELDING TORCH. 137 00:07:11,804 --> 00:07:13,738 WHILE CURRENT FLOWING BETWEEN THE ELECTRODE 138 00:07:13,740 --> 00:07:15,965 AND THE METAL CREATES AN ELECTRIC ARC, 139 00:07:15,967 --> 00:07:18,501 SHIELDING GASES BLOW THROUGH THE TORCH. 140 00:07:18,503 --> 00:07:20,962 THIS PREVENTS AMBIENT ATMOSPHERIC GASES 141 00:07:20,964 --> 00:07:24,024 FROM FLOWING INTO THE WELD. 142 00:07:24,026 --> 00:07:26,159 THE WELDER THEN SWITCHES BACK TO TIG WELDING 143 00:07:26,161 --> 00:07:29,087 TO TACK-WELD THE FENDER STOP WASHER. 144 00:07:29,089 --> 00:07:30,755 ONCE THE WELDING IS COMPLETE, 145 00:07:30,757 --> 00:07:34,051 THE WELDER UNFASTENS THE WORK PIECE FROM THE FIXTURE 146 00:07:34,053 --> 00:07:36,112 AND TAKES IT TO THE ASSEMBLY LINE. 147 00:07:38,983 --> 00:07:43,435 MEANWHILE, AN ENGINEER WORKS ON THE UPRIGHT ASSEMBLY HOUSING. 148 00:07:43,437 --> 00:07:44,971 IN HIS 3-D CAD SYSTEM, 149 00:07:44,973 --> 00:07:47,398 HE STUDIES THE INTERACTION OF THE PIECES, 150 00:07:47,400 --> 00:07:51,068 SUCH AS THE DRIVE FLANGES AND THE WHEEL BEARING. 151 00:07:51,070 --> 00:07:53,130 HE CHECKS THE FIT BETWEEN THE PIECES 152 00:07:53,132 --> 00:07:56,925 BEFORE THE UPRIGHT FABRICATION BEGINS. 153 00:07:56,927 --> 00:08:00,253 A FABRICATION TECHNICIAN NOW TAKES A WHEEL BEARING HOUSING 154 00:08:00,255 --> 00:08:03,782 AND MOUNTS IT ON AN ALUMINUM JIG. 155 00:08:03,784 --> 00:08:06,719 HE INSERTS A LOCATING FIXTURE THROUGH THE HOUSING 156 00:08:06,721 --> 00:08:11,549 TO ENSURE CORRECT PLACEMENT OF THE PIECE IN THE ASSEMBLY. 157 00:08:11,551 --> 00:08:14,477 NEXT, HE PICKS UP A CAREFULLY MACHINED PART 158 00:08:14,479 --> 00:08:16,404 AND FITS IT TO THE WHEEL BEARING HOUSING 159 00:08:16,406 --> 00:08:19,040 USING ANOTHER SCREW-ON LOCATING FIXTURE. 160 00:08:21,269 --> 00:08:23,537 HE REPEATS THE OPERATION ON THE OTHER SIDE 161 00:08:23,539 --> 00:08:25,064 TO FORM THE UPRIGHT. 162 00:08:28,327 --> 00:08:31,361 THE TECHNICIAN CLOSES THE ASSEMBLY WITH METAL PLATES 163 00:08:31,363 --> 00:08:33,422 LASER-CUT FOR A HIGH-PRECISION FIT 164 00:08:33,424 --> 00:08:37,217 AGAINST THE WHEEL BEARING HOUSING. 165 00:08:37,219 --> 00:08:40,846 THE TECHNICIAN HAMMERS ANOTHER LOCATING FIXTURE IN PLACE 166 00:08:40,848 --> 00:08:43,382 BEFORE HE POSITIONS THE LASER-CUT STEEL PIECE 167 00:08:43,384 --> 00:08:47,312 TO COMPLETE THE UPRIGHT ASSEMBLY. 168 00:08:47,314 --> 00:08:48,971 USING A MIG WELDING TORCH, 169 00:08:48,973 --> 00:08:51,308 HE STARTS WELDING THE PARTS TOGETHER, 170 00:08:51,310 --> 00:08:52,735 FOLLOWING A CONSISTENT PATTERN 171 00:08:52,737 --> 00:08:55,971 TO ENSURE THAT ALL JOINTS ARE WELDED PROPERLY. 172 00:08:55,973 --> 00:08:59,166 THE PROCESS TAKES ABOUT 20 MINUTES TO COMPLETE. 173 00:09:01,996 --> 00:09:05,189 AFTER WELDING, THE UPRIGHT GOES FOR MACHINING 174 00:09:05,191 --> 00:09:08,059 TO ENSURE THE CORRECT BORE SIZE FOR THE BEARING. 175 00:09:10,255 --> 00:09:12,188 MOUNTED ON A CNC LATHE, 176 00:09:12,190 --> 00:09:15,483 THE PIECE STARTS TURNING COUNTERCLOCKWISE. 177 00:09:15,485 --> 00:09:17,285 A COOLING SPRAY PREVENTS THE PIECE 178 00:09:17,287 --> 00:09:19,680 FROM OVERHEATING WHILE THE HIGH-SPEED LATHE 179 00:09:19,682 --> 00:09:23,742 BORES A SOCKET FOR THE BEARING INSIDE THE HOUSING. 180 00:09:23,744 --> 00:09:26,871 THE MACHINED UPRIGHT IS READY FOR POWDER COATING. 181 00:09:29,007 --> 00:09:32,568 A TECHNICIAN ASSEMBLES THE POWDER-COATED UPRIGHT. 182 00:09:32,570 --> 00:09:34,495 HE PLACES THE BEARING IN THE HOUSING 183 00:09:34,497 --> 00:09:37,165 AND ACTIVATES THE HYDRAULIC PRESS. 184 00:09:37,167 --> 00:09:38,558 THE POWER HEAD OF THE PRESS 185 00:09:38,560 --> 00:09:41,953 SLOWLY PUSHES THE BEARING INTO THE HOUSING. 186 00:09:41,955 --> 00:09:45,089 THE PRESS IS EQUIPPED WITH A CUSTOM ALUMINUM TOOLING, 187 00:09:45,091 --> 00:09:48,051 PRESSING ONLY ON THE OUTER PORTION OF THE BEARING. 188 00:09:48,053 --> 00:09:50,779 IT USES LOW PRESSURE TO AVOID DEFORMATION 189 00:09:50,781 --> 00:09:52,548 OF THE BEARING OR HOUSING. 190 00:09:55,110 --> 00:09:57,178 THE TECHNICIAN TAKES A RETAINING RING 191 00:09:57,180 --> 00:09:59,104 DESIGNED TO SECURE THE BEARING 192 00:09:59,106 --> 00:10:02,466 AND INSERTS IT MANUALLY INTO THE HOUSING. 193 00:10:02,468 --> 00:10:05,869 USING AN L-KEY TOOL, HE PUSHES THE SPIRAL LOCK RING 194 00:10:05,871 --> 00:10:08,665 INTO THE HOUSING. 195 00:10:08,667 --> 00:10:11,526 CONTRARY TO SELF-LOCKING RETAINING RINGS, 196 00:10:11,528 --> 00:10:13,327 THE SPIRAL RING SIMPLY POPS 197 00:10:13,329 --> 00:10:16,390 INTO A MACHINED GROOVE IN THE HOUSING. 198 00:10:16,392 --> 00:10:18,425 ♪♪ 199 00:10:24,149 --> 00:10:26,350 ONCE THE BEARING IS LOCKED IN FROM THE BACK 200 00:10:26,352 --> 00:10:27,676 WITH THE RETAINING RING, 201 00:10:27,678 --> 00:10:29,945 THE TECHNICIAN PLACES THE BEARING SEAL 202 00:10:29,947 --> 00:10:32,539 ON THE FRONT SIDE OF THE ASSEMBLY. 203 00:10:32,541 --> 00:10:35,668 HE POSITIONS AN ALUMINUM TOOLING ON THE BEARING SEAL 204 00:10:35,670 --> 00:10:38,004 AND USES AN ARBOR PRESS TO FIT IT TIGHTLY 205 00:10:38,006 --> 00:10:40,131 INTO THE UPRIGHT ASSEMBLY HOUSING. 206 00:10:42,436 --> 00:10:44,894 THE SEAL KEEPS CONTAMINANTS OUT OF THE BEARING 207 00:10:44,896 --> 00:10:47,823 TO ENSURE MAXIMAL ROTATION SPEED. 208 00:10:50,094 --> 00:10:53,087 THE TECHNICIAN PLACES THE DRIVE FLANGE ON THE JIG 209 00:10:53,089 --> 00:10:55,981 AND INSTALLS THE UPRIGHT ON TOP. 210 00:10:55,983 --> 00:10:58,651 HE LOWERS THE POWER HEAD AGAINST THE BEARING 211 00:10:58,653 --> 00:10:59,911 AND USES THE ARBOR PRESS 212 00:10:59,913 --> 00:11:03,514 TO PUSH THE DRIVE FLANGE INTO THE WHEEL BEARING. 213 00:11:03,516 --> 00:11:05,842 THE TECHNICIAN THEN REMOVES THE UPRIGHT ASSEMBLY 214 00:11:05,844 --> 00:11:07,544 FROM THE JIG. 215 00:11:09,639 --> 00:11:11,840 HERE, YOU CAN SEE THE AXLE SPLINES 216 00:11:11,842 --> 00:11:13,199 DRIVEN THROUGH THE WHEEL BEARING 217 00:11:13,201 --> 00:11:17,128 BEFORE THE BEARING SEAL IS INSTALLED. 218 00:11:17,130 --> 00:11:19,064 ♪♪ 219 00:11:20,921 --> 00:11:22,854 ♪♪ 220 00:11:22,856 --> 00:11:26,483 Narrator: ASSEMBLING AN ARIEL ATOM 3S STARTS 221 00:11:26,485 --> 00:11:29,010 WITH THE DOUBLE WISHBONE FRONT SUSPENSION. 222 00:11:29,012 --> 00:11:30,880 THE AIR INTAKE HOOP IS INTEGRATED 223 00:11:30,882 --> 00:11:33,074 INTO THE EXOSKELETON CHASSIS 224 00:11:33,076 --> 00:11:37,002 AS IS THE REAR SUBFRAME HOUSING MODULE FOR THE ENGINE. 225 00:11:37,004 --> 00:11:39,739 ♪♪ 226 00:11:39,741 --> 00:11:42,366 AT THE TMI AUTOTECH HEADQUARTERS, 227 00:11:42,368 --> 00:11:43,835 TWO ASSEMBLY TECHNICIANS 228 00:11:43,837 --> 00:11:46,663 SLIDE THE FIBERGLASS TUB UNDERNEATH THE CHASSIS. 229 00:11:50,160 --> 00:11:52,427 THEY LIFT IT UP AGAINST THE SIDE RAILS 230 00:11:52,429 --> 00:11:54,020 AND USE PRE-WELDED TABS 231 00:11:54,022 --> 00:11:57,349 TO MOUNT IT ON THE CHASSIS WITH ASSEMBLY NUTS AND BOLTS. 232 00:12:02,048 --> 00:12:04,315 THE TECHNICIANS FIT THE ALUMINUM FUEL TANK 233 00:12:04,317 --> 00:12:05,742 RIGHT BEHIND THE SEAT. 234 00:12:08,446 --> 00:12:10,705 THEY MAKE SURE THE FUEL TANK IS LEVELED 235 00:12:10,707 --> 00:12:14,334 AND TAKE MEASUREMENTS TO ENSURE THAT THE ENGINE FITS PROPERLY. 236 00:12:17,798 --> 00:12:18,930 USING MASKING TAPE 237 00:12:18,932 --> 00:12:21,600 TO AVOID SCRATCHING THE POWDER-COATED CHASSIS, 238 00:12:21,602 --> 00:12:26,388 THEY FINE-TUNE THE FUEL TANK'S POSITION. 239 00:12:26,390 --> 00:12:29,325 THEY THEN DRIVE ASSEMBLY BOLTS THROUGH THE MOUNTING TABS 240 00:12:29,327 --> 00:12:31,118 TO HOLD THE TANK IN PLACE 241 00:12:31,120 --> 00:12:34,280 BEFORE USING A RATCHET AND WRENCH TO TORQUE THE NUTS. 242 00:12:42,149 --> 00:12:45,275 NEXT, TECHNICIANS INSTALL THE CHASSIS LOOM. 243 00:12:45,277 --> 00:12:47,001 IT'S AN ELECTRICAL HARNESS THAT CONNECTS 244 00:12:47,003 --> 00:12:51,765 ALL THE ELECTRONIC COMPONENTS TO A FUSE BOX. 245 00:12:51,767 --> 00:12:56,428 A TECHNICIAN INSTALLS THE CHASSIS LOOM ON THE CAR. 246 00:12:56,430 --> 00:12:57,763 HE PLACES THE FUSE BOX 247 00:12:57,765 --> 00:13:01,558 IN THE FIBERGLASS BATTERY BOX AT THE FRONT. 248 00:13:01,560 --> 00:13:04,353 HE THEN ROUTES THE HARNESS ALONG THE CHASSIS 249 00:13:04,355 --> 00:13:08,016 USING PRE-WELDED LOCATIONAL TABS AND TIE WRAPS. 250 00:13:25,469 --> 00:13:27,662 THE HARNESS ENDS AT THE DASHBOARD, 251 00:13:27,664 --> 00:13:28,996 WHERE THE LOOM WILL CONNECT 252 00:13:28,998 --> 00:13:34,059 WITH THE DIGITAL DISPLAY UNIT CONTROLLERS AND MONITORS. 253 00:13:34,061 --> 00:13:36,587 THE TECHNICIAN FASTENS THE HARNESS TO THE CHASSIS 254 00:13:36,589 --> 00:13:38,289 WITH A TIE WRAP. 255 00:13:44,080 --> 00:13:45,881 USING AN OVERHEAD HOIST, 256 00:13:45,883 --> 00:13:48,275 TWO TECHNICIANS CAREFULLY LOWER THE DRIVE TRAIN 257 00:13:48,277 --> 00:13:51,871 INTO THE ENGINE COMPARTMENT OF THE REAR SUB-FRAME. 258 00:13:55,142 --> 00:13:56,834 WITH A HANDHELD TOOL, 259 00:13:56,836 --> 00:13:58,702 A TECHNICIAN DRIVES AN ENDLESS SCREW 260 00:13:58,704 --> 00:14:02,031 TO ACTIVATE THE SPECIAL TILTING MECHANISM OF THE HOIST. 261 00:14:02,033 --> 00:14:03,966 THIS SYSTEM ALLOWS THE TECHNICIANS 262 00:14:03,968 --> 00:14:06,528 TO POSITION THE ENGINE IN THE FRAME. 263 00:14:11,025 --> 00:14:12,884 ONCE THE DRIVE TRAIN IS IN POSITION, 264 00:14:12,886 --> 00:14:14,820 THEY REMOVE THE HOIST. 265 00:14:17,249 --> 00:14:18,982 A TECHNICIAN CONNECTS THE EXHAUST 266 00:14:18,984 --> 00:14:20,776 AND FORCED-INDUCTION TURBOCHARGER 267 00:14:20,778 --> 00:14:24,972 TO THE SINGLE PORT MANIFOLD OF THE ENGINE. 268 00:14:24,974 --> 00:14:27,107 HE BOLTS IT ONTO THE BACK OF THE ENGINE 269 00:14:27,109 --> 00:14:31,103 USING A TORQUE WRENCH TO TIGHTEN THE NUTS. 270 00:14:31,105 --> 00:14:36,000 HE NOW ASSEMBLES THE UPRIGHT TO THE SUSPENSION. 271 00:14:36,002 --> 00:14:37,861 HE INSERTS BOLTS THROUGH THE ROD ENDS 272 00:14:37,863 --> 00:14:39,929 OF THE LOWER SUSPENSION ARM. 273 00:14:39,931 --> 00:14:42,857 THE BOLTS ACT AS FIRM AND PRECISE ATTACHMENT POINTS 274 00:14:42,859 --> 00:14:45,185 FOR THE UPRIGHT ASSEMBLY. 275 00:14:45,187 --> 00:14:47,787 THESE LOWER ROD ENDS WILL ALSO AID IN THE ALIGNMENT 276 00:14:47,789 --> 00:14:49,515 OF THE VEHICLE SUSPENSION. 277 00:14:53,613 --> 00:14:55,946 THE TECHNICIAN NOW TAKES THE DRIVE AXLE 278 00:14:55,948 --> 00:14:58,040 AND CONNECTS IT TO THE TRANSMISSION. 279 00:15:01,671 --> 00:15:03,738 HE LOCKS THE AXLE IN WITH A SNAP RING 280 00:15:03,740 --> 00:15:06,666 BEFORE CONNECTING THE UPRIGHT TO THE DRIVE AXLE. 281 00:15:11,231 --> 00:15:13,791 THE TECHNICIAN THEN SCREWS ON THE AXLE NUT 282 00:15:13,793 --> 00:15:15,425 AND COMPLETES THE ASSEMBLY 283 00:15:15,427 --> 00:15:18,320 BY BOLTING THE UPRIGHT TO THE UPPER WISHBONE. 284 00:15:24,387 --> 00:15:26,913 NEXT, THE TECHNICIAN POSITIONS THE FENDER STAY 285 00:15:26,915 --> 00:15:28,981 IN THE SUSPENSION ASSEMBLY, 286 00:15:28,983 --> 00:15:30,908 ALIGNING THE PRE-WELDED MOUNTING TABS 287 00:15:30,910 --> 00:15:33,011 OF THE FENDER STAY WITH THE UPRIGHT. 288 00:15:35,774 --> 00:15:37,773 HE THEN INSERTS ASSEMBLY BOLTS 289 00:15:37,775 --> 00:15:40,602 AND USES AN ELECTRIC TORQUE WRENCH TO TIGHTEN THEM. 290 00:15:47,794 --> 00:15:49,395 THE TECHNICIAN NOW INSERTS 291 00:15:49,397 --> 00:15:51,255 THE VENTILATED AND FLOATING BRAKE DISK 292 00:15:51,257 --> 00:15:52,523 ON THE WHEEL HUB. 293 00:15:54,660 --> 00:15:56,285 HE BOLTS A WHEEL NUT IN PLACE 294 00:15:56,287 --> 00:15:59,380 TO FACILITATE THE INSTALLATION OF THE BRAKE CALIPER. 295 00:16:02,018 --> 00:16:03,275 NEXT, HE MOUNTS 296 00:16:03,277 --> 00:16:05,945 THE FOUR-PISTON BRAKE CALIPER ON THE BRAKE DISK 297 00:16:05,947 --> 00:16:08,340 AND ATTACHES IT TO THE UPRIGHT ASSEMBLY. 298 00:16:10,544 --> 00:16:12,769 THE TECHNICIAN INSERTS A PAIR OF BRAKE PADS 299 00:16:12,771 --> 00:16:14,972 BETWEEN THE CALIPER AND THE DISK. 300 00:16:18,502 --> 00:16:20,294 HE POSITIONS A BRACKET 301 00:16:20,296 --> 00:16:22,563 AND INSERTS A LOCK PIN THROUGH THE CALIPER, 302 00:16:22,565 --> 00:16:25,057 SECURING THE BRAKE PADS IN PLACE. 303 00:16:32,184 --> 00:16:35,251 THE TECHNICIAN FINALLY INSTALLS THE PARKING BRAKE CALIPER 304 00:16:35,253 --> 00:16:37,746 ON THE REARWARD SIDE OF THE BRAKE DISK. 305 00:16:42,177 --> 00:16:43,777 HE COMPLETES THE BRAKE ASSEMBLY 306 00:16:43,779 --> 00:16:46,171 BY BOLTING THE PARKING BRAKE ON THE UPRIGHT 307 00:16:46,173 --> 00:16:49,467 USING AN ELECTRIC IMPACT WRENCH TO TORQUE THE BOLTS. 308 00:16:53,932 --> 00:16:55,931 THE TECHNICIAN NOW PREPARES TO INSTALL 309 00:16:55,933 --> 00:16:58,192 THE REAR SUSPENSION DAMPER. 310 00:16:58,194 --> 00:17:00,194 HE INSTALLS A FASTENER TO ATTACH 311 00:17:00,196 --> 00:17:03,256 THE UPPER PORTION OF THE DAMPER TO THE CHASSIS 312 00:17:03,258 --> 00:17:06,485 AND INSERTS SPACERS ON THE LOWER PORTION OF THE DAMPER. 313 00:17:09,347 --> 00:17:11,815 HE ATTACHES THE DAMPER TO THE BELL CRANK, 314 00:17:11,817 --> 00:17:13,608 WHICH CONNECTS THE SUSPENSION DAMPER 315 00:17:13,610 --> 00:17:15,744 TO THE LOWER WISHBONE ARM. 316 00:17:15,746 --> 00:17:19,139 FINALLY, HE INSTALLS THE FIBERGLASS FENDER 317 00:17:19,141 --> 00:17:21,267 OVER THE UPRIGHT ASSEMBLY. 318 00:17:23,437 --> 00:17:25,396 ♪♪ 319 00:17:27,296 --> 00:17:29,228 ♪♪ 320 00:17:29,230 --> 00:17:32,724 Narrator: THE ATOM 3S FEATURES A DISTINCTIVE AIR INTAKE SNORKEL 321 00:17:32,726 --> 00:17:33,859 EMBEDDED IN THE CHASSIS, 322 00:17:33,861 --> 00:17:35,419 TWO SIDE RADIATORS 323 00:17:35,421 --> 00:17:38,489 INTEGRATED WITH A TURBOCHARGER INTERCOOLING SYSTEM 324 00:17:38,491 --> 00:17:39,681 AND A STAINLESS STEEL, 325 00:17:39,683 --> 00:17:43,477 CUSTOM-FABRICATED, REPACKABLE EXHAUST. 326 00:17:43,479 --> 00:17:44,745 ♪♪ 327 00:17:44,747 --> 00:17:46,547 THE FABRICATION TECHNICIAN 328 00:17:46,549 --> 00:17:49,675 MOUNTS A FIVE-SPOKE MOTOR SPORT WHEEL ON THE DRIVE FLANGE. 329 00:17:49,677 --> 00:17:50,877 HE TIGHTENS THE NUTS 330 00:17:50,879 --> 00:17:54,405 WITH AN ELECTRIC IMPACT TORQUE WRENCH. 331 00:17:54,407 --> 00:17:57,834 A FIBERGLASS ENGINE COVER PROTECTS THE ENGINE BLOCK. 332 00:17:57,836 --> 00:18:01,096 IT ALSO SERVES AS A BASE FOR THE ENGINE COOLANT RESERVOIR 333 00:18:01,098 --> 00:18:02,764 AND THE WASHABLE AIR FILTER, 334 00:18:02,766 --> 00:18:07,227 WHICH IS SEALED WITH THE INTAKE SNORKEL. 335 00:18:07,229 --> 00:18:09,488 THE TECHNICIAN INSTALLS THE FRONT RADIATOR 336 00:18:09,490 --> 00:18:12,717 AND FAN ASSEMBLY ON THE FRONT SUB-FRAME MODULE. 337 00:18:15,055 --> 00:18:16,312 HE MOUNTS THE RADIATOR 338 00:18:16,314 --> 00:18:18,514 ON BONDED RUBBER INSULATION MOUNTS 339 00:18:18,516 --> 00:18:21,877 DESIGNED TO ABSORB VIBRATIONS FROM THE ROAD. 340 00:18:26,775 --> 00:18:30,169 HE THEN CONNECTS THE RADIATOR TO THE MAIN ELECTRICAL HARNESS. 341 00:18:32,731 --> 00:18:33,998 TWO TECHNICIANS INSTALL 342 00:18:34,000 --> 00:18:36,391 THE CUSTOM-MOLDED, UPHOLSTERED SEAT COVER 343 00:18:36,393 --> 00:18:39,295 ON TOP OF THE FIBERGLASS BUCKET. 344 00:18:40,990 --> 00:18:43,992 THE COVER HAS BUILT-IN SLOTS FOR THE GEAR SHIFT LEVER 345 00:18:43,994 --> 00:18:46,453 AND FOR THE HARNESS ANCHOR POINTS. 346 00:18:48,815 --> 00:18:50,749 AT LAST, A TECHNICIAN BRINGS IN 347 00:18:50,751 --> 00:18:53,476 THE AERODYNAMIC FIBERGLASS SIDE POD 348 00:18:53,478 --> 00:18:57,205 AND POSITIONS IT ON TOP OF THE SIDE RADIATOR. 349 00:18:57,207 --> 00:18:59,608 THE TECHNICIANS FINALIZE THE ASSEMBLY 350 00:18:59,610 --> 00:19:01,235 WITH THE WIND SCREEN, 351 00:19:01,237 --> 00:19:03,170 THE FIBERGLASS NOSE AND HOOD, 352 00:19:03,172 --> 00:19:06,165 ALONG WITH THE FRONT WHEELS AND FENDERS. 353 00:19:08,702 --> 00:19:10,695 BEFORE LEAVING THE ASSEMBLY AREA, 354 00:19:10,697 --> 00:19:12,963 EACH CAR UNDERGOES A SERIES OF TESTS 355 00:19:12,965 --> 00:19:15,825 ON A CHASSIS DYNAMOMETER, OR DYNO. 356 00:19:15,827 --> 00:19:17,119 [ ENGINE REVS ] 357 00:19:17,121 --> 00:19:20,454 THE DYNO USES WHAT IS CALLED THE SALVISBERG ROLLER 358 00:19:20,456 --> 00:19:23,317 TO MONITOR VARIOUS ASPECTS OF THE CAR'S PERFORMANCE, 359 00:19:23,319 --> 00:19:26,645 SUCH AS ENGINE SPEED AND LOAD CONTROL. 360 00:19:27,647 --> 00:19:28,981 IN A CONTROLLED ENVIRONMENT, 361 00:19:28,983 --> 00:19:31,975 THE ROLLERS ALLOW THE TECHNICIAN TO FIRE UP THE ENGINE, 362 00:19:31,977 --> 00:19:35,538 BRINGING IT FROM IDLE TO ALMOST 8,000 RPM. 363 00:19:40,670 --> 00:19:44,063 A DRIVER NOW TAKES THE FINISHED CAR TO A TEST TRACK. 364 00:19:44,065 --> 00:19:46,024 THE DRIVER PAYS SPECIAL ATTENTION 365 00:19:46,026 --> 00:19:49,594 TO THE CAR'S ACCELERATION, BRAKING, AND CORNERING. 366 00:19:49,596 --> 00:19:51,688 HE ALSO LISTENS FOR UNUSUAL SOUNDS 367 00:19:51,690 --> 00:19:54,616 OR ABNORMAL VIBRATIONS. 368 00:19:54,618 --> 00:19:58,020 THE TEST TRACK IS DESIGNED TO PUT THE CAR TO THE TEST, 369 00:19:58,022 --> 00:20:01,415 WITH SHARP TURNS EXERTING VERY HIGH CORNERING FORCES 370 00:20:01,417 --> 00:20:04,744 AND LONG, STRAIGHT STRETCHES TO ASSESS THE ACCELERATION. 371 00:20:07,607 --> 00:20:09,207 AFTER A SERIES OF LAPS, 372 00:20:09,209 --> 00:20:12,969 THE CAR PULLS OFF THE ROAD FOR A PIT STOP. 373 00:20:12,971 --> 00:20:14,896 TECHNICIANS VISUALLY INSPECT THE CAR 374 00:20:14,898 --> 00:20:20,227 FOR LEAKS, LOOSE PARTS, OR ANY AREAS OF CONCERN. 375 00:20:20,229 --> 00:20:22,887 THE TECHNICIANS ALSO MANUALLY INSPECT THE CAR 376 00:20:22,889 --> 00:20:26,191 TO MAKE SURE NOTHING HAS COME LOOSE DURING THE TEST LAPS. 377 00:20:28,454 --> 00:20:30,054 WITH THE TECHNICIANS' APPROVAL, 378 00:20:30,056 --> 00:20:31,780 THE DRIVER HEADS BACK TO THE TRACK 379 00:20:31,782 --> 00:20:33,816 FOR A LAST TEST DRIVE. 380 00:20:37,047 --> 00:20:40,573 THIS ROAD-READY ATOM 3S FEATURES A FRONT AIR FOIL 381 00:20:40,575 --> 00:20:41,841 FOR LIFT REDUCTION, 382 00:20:41,843 --> 00:20:44,269 SPECIAL 12-SPOKE WHEELS, 383 00:20:44,271 --> 00:20:46,538 AND A HONDA 2.4-LITER ENGINE 384 00:20:46,540 --> 00:20:50,467 TIGHTLY PACKED UNDER A FIBERGLASS COVER. 385 00:20:50,469 --> 00:20:52,527 EQUIPPED WITH A SIX-POINT HARNESS, 386 00:20:52,529 --> 00:20:54,129 A REMOVABLE STEERING WHEEL, 387 00:20:54,131 --> 00:20:55,856 AND TWO-PIECE SPRING DAMPERS, 388 00:20:55,858 --> 00:20:58,259 THIS HIGH-PERFORMANCE, ROAD-LEGAL CAR 389 00:20:58,261 --> 00:21:00,620 HAS SEVERAL RACE-INSPIRED FEATURES, 390 00:21:00,622 --> 00:21:03,089 SUCH AS THE AERODYNAMIC SIDE PODS 391 00:21:03,091 --> 00:21:07,685 AND THE REAR AIR FOIL FOR DRAG REDUCTION. 392 00:21:07,687 --> 00:21:09,279 A DRIVER NOW TAKES THE CAR 393 00:21:09,281 --> 00:21:12,473 FOR A TOUR ON SMALL COUNTRY ROADS. 394 00:21:12,475 --> 00:21:13,808 ON A FLAT ROAD SURFACE, 395 00:21:13,810 --> 00:21:15,476 THE CAR IS WELL-BALANCED 396 00:21:15,478 --> 00:21:18,438 AND BITES SMOOTHLY INTO THE CURVES. 397 00:21:18,440 --> 00:21:19,839 THIS CAR IS NOT DESIGNED 398 00:21:19,841 --> 00:21:22,367 FOR REGULAR, INNER-CITY COMMUTERS. 399 00:21:22,369 --> 00:21:24,628 THE ARIEL ATOM 3S IS A CAR 400 00:21:24,630 --> 00:21:27,898 FOR DRIVING ENTHUSIASTS TO ENJOY ON AN OPEN ROAD, 401 00:21:27,900 --> 00:21:29,892 WHERE THE FULL POTENTIAL OF THIS SUPERCAR 402 00:21:29,894 --> 00:21:32,094 CAN BE PUT TO GOOD USE. 31380

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