Would you like to inspect the original subtitles? 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
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.