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Narrator: TODAY,
ON "HOW IT'S MADE: DREAM CARS,"
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00:00:03,070 --> 00:00:04,562
THE ULTIMA EVOLUTION,
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00:00:04,564 --> 00:00:09,024
POSSIBLY THE QUICKEST PRODUCTION
VEHICLE IN THE WORLD.
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00:00:09,026 --> 00:00:12,094
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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♪♪
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ULTIMA FIRST CAME ON THE SCENE
WITH THE MK1 BACK IN 1983.
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INSPIRED BY THE FAMED GROUP "C"
LE MANS CARS OF THE 1980s,
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THE MID-ENGINE MK1
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WAS A NO-NONSENSE SPEED MACHINE
INSIDE AND OUT.
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00:00:39,133 --> 00:00:40,732
THE CAR'S CREATOR,
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00:00:40,734 --> 00:00:42,927
AUTOMOTIVE ENGINEER
AND DESIGNER LEE NOBLE,
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SOLD HIS FIRST CAR,
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THE ULTIMA MK2,
TO CIVIL ENGINEER TED MARLOW,
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WHO WENT ON TO RACE IT
TO MANY VICTORIES
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THROUGHOUT THE '80s.
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00:00:53,882 --> 00:00:57,942
TED MARLOW BOUGHT THE RIGHTS
TO THE BRAND IN 1991.
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00:00:57,944 --> 00:01:00,412
AND TOGETHER
WITH HIS SON, RICHARD,
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TRANSFORMED ULTIMA
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00:01:01,874 --> 00:01:04,741
INTO A MANUFACTURER
OF STREET-LEGAL SUPERCARS
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00:01:04,743 --> 00:01:07,870
AVAILABLE AS KITS
OR AS PRODUCTION VEHICLES.
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00:01:10,232 --> 00:01:14,561
IN 2015, ULTIMA
INTRODUCED THE EVOLUTION.
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00:01:14,563 --> 00:01:17,030
WHILE THE EVOLUTION MAINTAINS
THE ULTIMA ETHOS
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00:01:17,032 --> 00:01:20,625
OF LE MANS GROUP "C"-INSPIRED
DESIGN,
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00:01:20,627 --> 00:01:23,887
OVERALL, THE CAR HAS
A MORE POLISHED LOOK.
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00:01:23,889 --> 00:01:27,316
BUT THE EVOLUTION
IS NO GRAND TOURER.
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00:01:27,318 --> 00:01:30,978
THIS CAR IS BUILT FOR SPEED,
NOT FOR LUXURY MOTORING.
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DESIGN PRIORITY WAS GIVEN
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TO PERFORMANCE
AND OPTIMAL AERODYNAMICS,
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00:01:39,839 --> 00:01:42,498
WITH ULTIMA EXTENSIVELY TESTING
THE EVOLUTION
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00:01:42,500 --> 00:01:43,800
IN THE FAMED WIND TUNNEL
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OF THE MOTOR INDUSTRY RESEARCH
ASSOCIATION.
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A TECHNICIAN CARRIES OUT
A THOROUGH QUALITY-CONTROL CHECK
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00:01:51,393 --> 00:01:55,987
OF THE EVOLUTION'S CHASSIS
PRIOR TO POWDER COATING.
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00:01:55,989 --> 00:01:57,856
THE STEEL SPACE-FRAME CHASSIS
FEATURES
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A HIGHLY TRIANGULATED STRUCTURE,
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00:02:00,619 --> 00:02:02,152
A FULL ROLL CAGE,
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AND LARGE REAR AND SIDE
CRUMPLE ZONES.
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00:02:06,684 --> 00:02:09,610
THESE ELEMENTS, ALONG WITH
THE STURDY MIG-WELDED JOINTS,
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00:02:09,612 --> 00:02:12,839
RESULT IN A REMARKABLE DEGREE
OF TORSIONAL RIGIDITY.
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00:02:15,502 --> 00:02:17,702
ULTIMA BUILDS THE BULK
OF THE SPACE FRAME
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00:02:17,704 --> 00:02:19,963
FROM 38-MILLIMETER STEEL TUBING,
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00:02:19,965 --> 00:02:22,032
EXCEPT FOR THE ROLL CAGE,
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00:02:22,034 --> 00:02:27,096
WHICH IS MADE WITH 45-MILLIMETER
COLD-DRAWN SEAMLESS TUBING.
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00:02:27,098 --> 00:02:29,023
THE CHASSIS IS
THEN SHOT-BLASTED,
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00:02:29,025 --> 00:02:33,152
SPRAY PRIMED, AND POWDER COATED.
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00:02:33,154 --> 00:02:35,154
A TECHNICIAN NOW
BEGINS THE PROCESS
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OF CLADDING THE CHASSIS
IN ALUMINUM SHEETS.
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00:02:38,918 --> 00:02:44,239
HE STARTS BY SQUEEZING A BEAD
OF SEALANT AROUND A PERIMETER.
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00:02:44,241 --> 00:02:45,707
HE THEN PLACES A PRE-CUT
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AND FINISHED SHEET
ON THE SEALANT.
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THE ALUMINUM IS
1.5-MILLIMETER NS4,
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00:02:52,132 --> 00:02:54,333
AN ALLOY KNOWN
FOR ITS FORMABILITY
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00:02:54,335 --> 00:02:57,794
IN SPITE OF
ITS HIGH STRENGTH AND HARDNESS.
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00:02:57,796 --> 00:02:59,263
AS HE PLACES EACH SHEET,
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00:02:59,265 --> 00:03:02,190
HE ANCHORS IT IN POSITION
BY INSERTING A RIVET
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00:03:02,192 --> 00:03:04,452
INTO ONE OF
THE PRE-DRILLED HOLES.
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00:03:08,391 --> 00:03:11,017
HE FILLS ALL THE HOLES
WITH RIVETS,
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00:03:11,019 --> 00:03:14,279
THEN SLIDES THE HEAD OF A GUN
OVER THE RIVETS' GUIDE DOWEL
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00:03:14,281 --> 00:03:16,548
AND SQUEEZES.
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00:03:16,550 --> 00:03:19,142
SQUEEZING DEFORMS
THE TAIL OF THE RIVET
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00:03:19,144 --> 00:03:23,004
TO 1.5 TIMES ITS ORIGINAL SIZE,
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00:03:23,006 --> 00:03:26,233
LOCKING IT IN PLACE
AND SNAPPING OFF THE DOWEL.
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00:03:30,098 --> 00:03:32,764
PANELING THE ENTIRE CHASSIS
WITH ALUMINUM SHEETS
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00:03:32,766 --> 00:03:35,559
SERVES MORE THAN ONE PURPOSE.
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IT CREATES
A PASSENGER COMPARTMENT,
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00:03:37,556 --> 00:03:42,050
WATERPROOFS THE COCKPIT,
SMOOTHES AIRFLOW UNDER THE CAR,
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00:03:42,052 --> 00:03:44,986
PROVIDES MOUNTING POINTS
FOR VARIOUS COMPONENTS,
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00:03:44,988 --> 00:03:46,179
SUCH AS THE BATTERY,
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00:03:46,181 --> 00:03:47,848
AND IMPROVES
THE TORSIONAL RIGIDITY
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OF THE CAR AS A WHOLE.
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00:03:53,347 --> 00:03:55,773
A SPECIALIST APPLIES
A PIGMENTED GEL COAT
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TO THE HIGH-GLOSS MOLD
OF THE HOOD AND FENDERS.
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00:04:01,539 --> 00:04:05,333
ONCE THE FIRST LAYER CURES,
HE WILL APPLY A SECOND LAYER.
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00:04:08,997 --> 00:04:10,588
HE NOW ROLLS A LIQUID RESIN
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00:04:10,590 --> 00:04:14,351
ONTO A PRE-CUT MAT
OF FIBERGLASS.
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00:04:14,353 --> 00:04:18,279
THIS PROCESS
IS CALLED WETTING OUT.
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00:04:18,281 --> 00:04:20,215
AFTER WETTING OUT THE FLIP SIDE,
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00:04:20,217 --> 00:04:21,817
HE CARRIES IT TO THE MOLD
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00:04:21,819 --> 00:04:24,145
AND MANUALLY PRESSES IT
INTO PLACE.
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00:04:26,307 --> 00:04:29,342
AFTER TRIMMING OFF THE EXCESS
MATERIAL WITH SCISSORS,
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00:04:29,344 --> 00:04:31,102
THE SPECIALIST USES A BRUSH
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00:04:31,104 --> 00:04:34,339
TO DAB THE FIBERGLASS
MORE FIRMLY INTO PLACE.
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00:04:37,235 --> 00:04:39,493
NEXT, HE CONSOLIDATES
THE MATERIAL
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00:04:39,495 --> 00:04:40,962
WITH A SMALL ROLLER,
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00:04:40,964 --> 00:04:43,957
SMOOTHING THE MATERIAL
INTO EVERY CORNER OF THE MOLD,
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00:04:43,959 --> 00:04:45,626
ENSURING THERE ARE
NO AIR POCKETS
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00:04:45,628 --> 00:04:49,188
BETWEEN THE LAYERS OF FIBERGLASS
AND THE GEL COAT.
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00:04:52,318 --> 00:04:55,444
HE LEAVES IT TO CURE
IN THE MOLD FOR 24 HOURS.
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00:04:58,449 --> 00:05:00,842
TO CREATE RETURNS
IN THE FIBERGLASS PANEL,
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00:05:00,844 --> 00:05:03,044
FLANGES ARE BOLTED IN PLACE.
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00:05:03,046 --> 00:05:05,438
ONCE THE MATERIAL HAS CURED,
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00:05:05,440 --> 00:05:08,800
THE SPECIALIST REMOVES ALL BOLTS
FROM THE FLANGES
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00:05:08,802 --> 00:05:13,129
AND THEN CAREFULLY REMOVES
EACH FLANGE.
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00:05:13,131 --> 00:05:16,792
HE AND A COLLEAGUE EXTRACT
THE FIBERGLASS BODY SECTIONS,
96
00:05:16,794 --> 00:05:18,727
WHICH COME OUT
WITH A HIGH-GLOSS FINISH
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00:05:18,729 --> 00:05:23,190
REPRESENTATIVE OF
THE EXTREMELY HIGH-QUALITY MOLD.
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00:05:23,192 --> 00:05:25,618
INCREDIBLY,
THIS MANUFACTURING METHOD
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00:05:25,620 --> 00:05:28,479
REMOVES THE NEED
FOR A PAINT JOB.
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00:05:28,481 --> 00:05:31,549
BUT THAT DOESN'T MEAN
THE PANELS ARE FINISHED.
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00:05:31,551 --> 00:05:33,543
IN THE TRIM SHOP, A SPECIALIST
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00:05:33,545 --> 00:05:35,478
USES A DIAMOND-TIPPED
GRINDING WHEEL
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00:05:35,480 --> 00:05:38,640
TO CUT THE NECESSARY OPENINGS.
104
00:05:41,903 --> 00:05:45,230
ALTHOUGH MOST OF THE SURFACES
REQUIRE NO FINISHING,
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00:05:45,232 --> 00:05:47,633
A FEW SPOTS
WHERE FLANGES WERE REMOVED
106
00:05:47,635 --> 00:05:51,428
NEED TO BE SMOOTHED
TO A HIGH GLOSS.
107
00:05:51,430 --> 00:05:53,089
AFTER SANDING THEM DOWN,
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00:05:53,091 --> 00:05:55,357
A SPECIALIST APPLIES
A CUTTING PASTE
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00:05:55,359 --> 00:05:56,851
AND BUFFS THE SURFACE
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00:05:56,853 --> 00:05:59,520
WITH A LAMBSWOOL ATTACHMENT
ON AN ORBITAL MOP
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00:05:59,522 --> 00:06:01,847
BEFORE ADDING
A PROTECTIVE POLISH.
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00:06:01,849 --> 00:06:04,876
♪♪
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00:06:11,988 --> 00:06:14,147
Narrator: ALTHOUGH
THE EVOLUTION'S SEATS
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00:06:14,149 --> 00:06:15,682
BEAR NO OBVIOUS RESEMBLANCE
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00:06:15,684 --> 00:06:18,343
TO THE CAR'S GLOSSY
EXTERIOR BODY,
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00:06:18,345 --> 00:06:20,679
UNDERNEATH THE LEATHER
AND ALCANTARA UPHOLSTERY,
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00:06:20,681 --> 00:06:22,973
THEY'RE MADE OF EXACTLY
THE SAME MATERIAL
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00:06:22,975 --> 00:06:24,909
IN EXACTLY THE SAME WAY.
119
00:06:28,439 --> 00:06:31,699
BUILT IN A MOLD
WITH LAYERS OF FIBERGLASS,
120
00:06:31,701 --> 00:06:34,226
EACH SEAT HAS
FOUR LOCATION POINTS
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00:06:34,228 --> 00:06:38,990
WHERE IT WILL BE ATTACHED
DIRECTLY TO THE CAR'S CHASSIS.
122
00:06:38,992 --> 00:06:41,459
HERE, A SPECIALIST
ADDS FOUR LUGS
123
00:06:41,461 --> 00:06:45,188
AND LAMINATES THEM IN PLACE
WITH RESIN.
124
00:06:45,190 --> 00:06:48,583
HE THEN COVERS THE DEPRESSIONS
WITH LAYERS OF FIBERGLASS
125
00:06:48,585 --> 00:06:53,046
AND CONSOLIDATES THEM FIRMLY
INTO POSITION WITH A ROLLER.
126
00:06:53,048 --> 00:06:56,275
THE FIBERGLASS USED FOR BOTH
THE CAR BODY AND THE SEATS
127
00:06:56,277 --> 00:06:58,736
IS CALLED
THE CHOPPED STRAND MAT,
128
00:06:58,738 --> 00:07:02,565
WHICH COMES IN
DIFFERENT WEIGHTS.
129
00:07:02,567 --> 00:07:04,734
FOR THE EVOLUTION,
THE MANUFACTURERS
130
00:07:04,736 --> 00:07:06,661
RELY ON TWO LAYERS OF A MAT
131
00:07:06,663 --> 00:07:10,657
THAT WEIGHS 13 OUNCES
PER SQUARE YARD.
132
00:07:10,659 --> 00:07:12,826
THIS MATERIAL IS
A BIG PART OF THE REASON
133
00:07:12,828 --> 00:07:15,954
THAT THE EVOLUTION IS
SO REMARKABLY LIGHTWEIGHT.
134
00:07:21,621 --> 00:07:23,679
AFTER THE LUG WELLS
HAVE BEEN COVERED,
135
00:07:23,681 --> 00:07:25,080
THE EDGES ARE TRIMMED
136
00:07:25,082 --> 00:07:29,710
AND THE OPENINGS
FOR THE SEAT BELTS MADE.
137
00:07:29,712 --> 00:07:31,237
A TECHNICIAN SPRAYS AN ADHESIVE
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00:07:31,239 --> 00:07:33,606
ON THE INTERIOR SURFACE
OF THE SEAT...
139
00:07:36,770 --> 00:07:39,070
...THEN SPRAYS A FOAM CUT-OUT,
AS WELL.
140
00:07:42,568 --> 00:07:45,060
HE CAREFULLY POSITIONS
AND ADHERES THE FOAM
141
00:07:45,062 --> 00:07:47,855
TO THE INTERIOR LEFT SIDE PANEL
OF THE SEAT.
142
00:07:50,926 --> 00:07:53,486
HE WRAPS THE FOAM
TO THE EDGE OF THE SEAT.
143
00:07:57,450 --> 00:07:59,651
SOME CAR MANUFACTURERS
OFFER SEATS
144
00:07:59,653 --> 00:08:02,278
WITH ELECTRONICALLY ADJUSTABLE
LUMBAR SUPPORT
145
00:08:02,280 --> 00:08:04,872
FOR THE BASE OF THE SPINE.
146
00:08:04,874 --> 00:08:06,942
BUT ULTIMA'S UNUSUAL SOLUTION
147
00:08:06,944 --> 00:08:11,538
IS A MANUALLY ADJUSTED
PNEUMATIC SUPPORT.
148
00:08:11,540 --> 00:08:15,133
A TECHNICIAN INSTALLS THE DETAIL
AND TESTS IT OUT.
149
00:08:15,135 --> 00:08:16,560
A FEW SQUEEZES OF A PUMP
150
00:08:16,562 --> 00:08:18,229
ARE ENOUGH
TO CREATE AN AIR PILLOW
151
00:08:18,231 --> 00:08:19,630
THAT COULD MAKE
ALL THE DIFFERENCE
152
00:08:19,632 --> 00:08:21,891
ON A LONG DRIVE.
153
00:08:25,955 --> 00:08:27,889
ALTHOUGH THE INTERIOR
OF THE EVOLUTION
154
00:08:27,891 --> 00:08:29,882
IS RELATIVELY NO-NONSENSE,
155
00:08:29,884 --> 00:08:33,078
IT FEATURES A NUMBER
OF FINELY CRAFTED DETAILS,
156
00:08:33,080 --> 00:08:37,174
INCLUDING THE LEATHER
AND ALCANTARA SEAT COVERS.
157
00:08:37,176 --> 00:08:39,643
HERE, A TAILOR MAKES THEM
ONE BY ONE
158
00:08:39,645 --> 00:08:42,571
WITH THE AID OF
A POWERFUL SEWING MACHINE,
159
00:08:42,573 --> 00:08:47,834
FINISHING THE EDGES
WITH COLOR-MATCHED PIPING.
160
00:08:47,836 --> 00:08:50,696
WHEN FINISHED, SHE TRIMS OFF
THE EXCESS MATERIAL
161
00:08:50,698 --> 00:08:52,565
WITH SCISSORS.
162
00:08:52,567 --> 00:08:56,394
INSIDE AND OUT, THE EVOLUTION
IS TRULY A HANDMADE CAR.
163
00:08:59,991 --> 00:09:02,117
IN KEEPING WITH
THE HIGHLY CUSTOM-MADE NATURE
164
00:09:02,119 --> 00:09:03,384
OF THE VEHICLE,
165
00:09:03,386 --> 00:09:05,445
CUSTOMERS CAN CHOOSE
ANY COLOR THEY WISH
166
00:09:05,447 --> 00:09:07,147
FOR THE PIPING AND STITCHING.
167
00:09:10,611 --> 00:09:12,611
AN UPHOLSTERER
BEGINS THE PROCESS
168
00:09:12,613 --> 00:09:15,206
OF APPLYING THE SEAT COVER
ONTO ITS BASE,
169
00:09:15,208 --> 00:09:19,802
CAREFULLY BRUSHING ADHESIVE
OVER THE LEATHER.
170
00:09:19,804 --> 00:09:22,864
IT REQUIRES CONSIDERABLE
MANUAL SKILL AND STRENGTH
171
00:09:22,866 --> 00:09:25,825
TO WRAP THE UPHOLSTERY
AROUND THE SIDE EDGES.
172
00:09:25,827 --> 00:09:27,827
IT'S NO ACCIDENT
173
00:09:27,829 --> 00:09:31,156
THAT THE EVOLUTION'S SEATS
HAVE HIGH SIDES.
174
00:09:31,158 --> 00:09:34,217
THEY HAVE TO BE HIGH IN ORDER
TO HOLD THE DRIVER AND PASSENGER
175
00:09:34,219 --> 00:09:36,686
FIRMLY IN PLACE
WHEN TAKING CORNERS,
176
00:09:36,688 --> 00:09:38,346
DUE TO THE LATERAL G-FORCES
177
00:09:38,348 --> 00:09:41,817
PRODUCED BY
A CAR THIS POWERFUL.
178
00:09:41,819 --> 00:09:44,111
IN FACT, ULTIMA
SET THE WORLD RECORD
179
00:09:44,113 --> 00:09:46,180
FOR THE ROAD CAR SKIDPAD TEST
180
00:09:46,182 --> 00:09:49,908
BY LOGGING A LATERAL GRIP
OF 1.176 "G"
181
00:09:49,910 --> 00:09:52,704
AROUND A CIRCLE
200 FOOT IN DIAMETER.
182
00:09:54,833 --> 00:09:57,500
THIS ATTESTS TO THE CAR'S
REMARKABLE CAPACITY
183
00:09:57,502 --> 00:10:00,729
FOR HANDLING AND CORNERING
AT HIGH SPEED.
184
00:10:07,054 --> 00:10:08,921
THE UPHOLSTERER
CAREFULLY CUTS OUT
185
00:10:08,923 --> 00:10:10,522
THE SET OF OPENINGS
IN THE COVER,
186
00:10:10,524 --> 00:10:12,983
THROUGH WHICH THE SEAT BELTS
WILL BE INTRODUCED.
187
00:10:16,681 --> 00:10:20,141
HIGH-STRENGTH PLASTIC GROMMETS
FIT SNUGGLY INTO THE OPENINGS.
188
00:10:22,011 --> 00:10:24,137
IT GOES WITHOUT SAYING
THAT IF YOU'RE GOING TO DRIVE
189
00:10:24,139 --> 00:10:27,006
A CAR THAT CAN PERFORM
LIKE THE EVOLUTION,
190
00:10:27,008 --> 00:10:29,601
YOU NEED TO BE
SECURELY BELTED IN PLACE.
191
00:10:33,866 --> 00:10:35,691
HAVING DESIGNED
THE EVOLUTION'S SEATS
192
00:10:35,693 --> 00:10:39,620
TO MAXIMIZE HEAD ROOM, LEG ROOM,
AND ERGONOMIC COMFORT,
193
00:10:39,622 --> 00:10:41,889
ULTIMA BUILDS EACH ONE
FROM SCRATCH.
194
00:10:41,891 --> 00:10:44,317
♪♪
195
00:10:50,288 --> 00:10:53,715
Narrator: WHILE ULTIMA SELLS
THE EVOLUTION FULL ASSEMBLED,
196
00:10:53,717 --> 00:10:56,576
ADVENTUROUS BUYERS
CAN ALSO PURCHASE IT AS A KIT
197
00:10:56,578 --> 00:10:58,712
AND BUILD IT THEMSELVES.
198
00:10:58,714 --> 00:11:00,305
HERE, ULTIMA PREPARES
199
00:11:00,307 --> 00:11:02,174
THE CONVERTIBLE VERSION
OF THE EVOLUTION
200
00:11:02,176 --> 00:11:04,135
FOR SHIPMENT AS A KIT.
201
00:11:06,706 --> 00:11:08,530
THOSE WHO RELY ON
ULTIMA TEAM MEMBERS
202
00:11:08,532 --> 00:11:09,999
TO ASSEMBLE THEIR EVOLUTIONS
203
00:11:10,001 --> 00:11:12,594
ARE IN GOOD HANDS.
204
00:11:12,596 --> 00:11:15,263
HERE, A TECHNICIAN
FITS THE WISHBONE COMPONENT
205
00:11:15,265 --> 00:11:17,457
OF THE REAR SUSPENSION
ONTO THE CHASSIS,
206
00:11:17,459 --> 00:11:20,452
FIRST INSTALLING THE BEARINGS
ON THE ATTACHMENT POINTS
207
00:11:20,454 --> 00:11:23,055
WITH THE HELP OF
A TEMPORARY FILLER RODS,
208
00:11:23,057 --> 00:11:27,217
WHICH HE REPLACES
WITH HIGH-TENSILE BOLTS.
209
00:11:27,219 --> 00:11:29,545
THE WISHBONES ARE CUSTOM-MADE
FOR THE EVOLUTION,
210
00:11:29,547 --> 00:11:31,514
USING PRECISION TIG WELDING.
211
00:11:34,677 --> 00:11:38,805
NEXT, HE CAREFULLY INSTALLS
THE CAR'S STRUTS.
212
00:11:38,807 --> 00:11:40,272
HE STARTS BY ATTACHING
213
00:11:40,274 --> 00:11:42,566
THE UPPER STRUT MOUNT
TO THE CHASSIS.
214
00:11:42,568 --> 00:11:46,296
HE JOINS THE BOTTOM OF THE STRUT
TO THE WISHBONE.
215
00:11:46,298 --> 00:11:48,431
CUSTOM-DESIGNED,
VALVED, AND SPRUNG,
216
00:11:48,433 --> 00:11:51,994
THE STRUTS ARE HIGHLY ADJUSTABLE
FOR BUMP AND REBOUND.
217
00:11:54,356 --> 00:11:57,616
THE HUB IS MADE OF
LM25 ALUMINUM,
218
00:11:57,618 --> 00:12:00,619
A CORROSION-RESISTANT CASTING.
219
00:12:00,621 --> 00:12:04,381
THE TECHNICIAN ATTACHES IT
TO THE TOE LINK ADJUSTER,
220
00:12:04,383 --> 00:12:06,242
THE COMPONENT THAT ALLOWS
FOR ADJUSTING
221
00:12:06,244 --> 00:12:08,845
THE TOE IN OR TOE OUT
OF THE VEHICLE.
222
00:12:10,439 --> 00:12:12,974
HE NOW BRINGS
THE FOUR-PISTON BRAKE CALIPER
223
00:12:12,976 --> 00:12:16,502
TO THE CURVED-VANE,
CROSS-DRILLED VENTED DISC
224
00:12:16,504 --> 00:12:19,131
AND CAREFULLY INSTALLS IT.
225
00:12:19,133 --> 00:12:21,265
A FINAL TORQUE
WITH A RATCHET AND WRENCH
226
00:12:21,267 --> 00:12:25,262
SECURES THE HUB IN PLACE.
227
00:12:25,264 --> 00:12:27,522
THE EVOLUTION HAS
TWO FUEL TANKS,
228
00:12:27,524 --> 00:12:30,384
ONE IN EACH SIDE OF THE CAR.
229
00:12:30,386 --> 00:12:31,652
ULTIMA HAS THE TANKS MADE
230
00:12:31,654 --> 00:12:36,282
FROM SHEETS OF COMMERCIAL
SOFT-GRADE 1050 ALUMINUM.
231
00:12:36,284 --> 00:12:39,677
HAVING ALREADY CUT OUT AND BENT
ALL THE NECESSARY SHAPES,
232
00:12:39,679 --> 00:12:42,180
A SPECIALIST TACK-WELDS
THEM TOGETHER.
233
00:12:44,409 --> 00:12:46,534
HE SPACES THE TACK WELDS CLOSELY
234
00:12:46,536 --> 00:12:48,469
TO PREVENT THE ALUMINUM
FROM BUCKLING
235
00:12:48,471 --> 00:12:51,198
WHEN HE WELDS A FULL SEAM
AT THE JOINTS.
236
00:12:55,696 --> 00:12:58,630
FOR TACK WELDING,
HE USES SUCH A HIGH AMPERAGE
237
00:12:58,632 --> 00:13:02,226
THAT IT SIMPLY FUSES
THE ALUMINUM TOGETHER.
238
00:13:02,228 --> 00:13:04,286
BUT WHEN WELDING THE SEAMS SHUT,
239
00:13:04,288 --> 00:13:09,984
HE USES A SOFT 4043 WELDING ROD
WITH A 5% SILICA MIX,
240
00:13:09,986 --> 00:13:12,846
WHICH PROVIDES
GOOD FLOW AND PENETRATION.
241
00:13:16,777 --> 00:13:18,377
ULTIMA DESIGNED THE GAS TANKS
242
00:13:18,379 --> 00:13:23,040
TO ENABLE GOOD AIRFLOW
IN COMPONENT PACKAGING.
243
00:13:23,042 --> 00:13:25,134
THE SLOPE ON ONE SIDE
OF EACH TANK
244
00:13:25,136 --> 00:13:27,069
LINES UP WITH VENTS
THAT ALLOW AIR
245
00:13:27,071 --> 00:13:29,397
TO FLOW INTO THE ENGINE BAY
AND COOL IT.
246
00:13:33,328 --> 00:13:36,788
TO MAKE THE HUBS, ULTIMA
STARTS WITH AN ALUMINUM CASTING
247
00:13:36,790 --> 00:13:40,283
WHICH IS FINISHED ON A LATHE
AND A CNC MILLING MACHINE.
248
00:13:42,153 --> 00:13:44,079
AFTER THE LATHE DOES ITS WORK,
249
00:13:44,081 --> 00:13:47,808
A TOOL CALLED AN END MILL RIPPER
REMOVES EXCESS MATERIAL.
250
00:13:50,545 --> 00:13:52,805
THE CNC MACHINE
DRILLS THROUGH HOLES
251
00:13:52,807 --> 00:13:55,608
WHERE THE BRAKE CALIPERS
WILL ATTACH.
252
00:13:55,610 --> 00:13:57,034
TO COOL THE WORK AREA,
253
00:13:57,036 --> 00:13:58,902
THE MACHINE SPRAYS
A SPECIAL COOLANT
254
00:13:58,904 --> 00:14:01,497
OF SYNTHETIC OIL
DILUTED WITH WATER.
255
00:14:04,827 --> 00:14:07,228
AFTER ONE HOUR AND
FOUR DIFFERENT OPERATIONS,
256
00:14:07,230 --> 00:14:11,024
THE CNC IS DONE.
257
00:14:11,026 --> 00:14:14,285
A SPECIALIST REMOVES THE BURRS
LEFT BY THE MILLING PROCESS
258
00:14:14,287 --> 00:14:17,848
WITH A HANDHELD
HIGH-SPEED GRINDER.
259
00:14:17,850 --> 00:14:20,976
HE MANUALLY DEBURRS THE OPENINGS
FOR THE ATTACHMENT POINTS
260
00:14:20,978 --> 00:14:22,444
WITH A DIFFERENT TOOL.
261
00:14:24,248 --> 00:14:27,174
TURNING THE ALUMINUM CASTING
INTO A FINISHED HUB
262
00:14:27,176 --> 00:14:30,069
TAKES BETWEEN 1 1/2
AND 2 HOURS IN TOTAL.
263
00:14:32,866 --> 00:14:35,266
A TECHNICIAN BRINGS
THE FULLY MACHINED FRONT HUB
264
00:14:35,268 --> 00:14:36,993
TO THE CHASSIS.
265
00:14:36,995 --> 00:14:41,456
THE FRONT HUB IS CONSIDERABLY
SMALLER THAN THE REAR HUB
266
00:14:41,458 --> 00:14:43,992
AND BOLTS TO THE WISHBONES
AND BALL JOINTS VERTICALLY,
267
00:14:43,994 --> 00:14:46,720
RATHER THAN LATERALLY.
268
00:14:46,722 --> 00:14:50,015
BUT THE DISC AND BRAKE
ARE EXACTLY THE SAME SIZE HERE
269
00:14:50,017 --> 00:14:52,384
AS THEY ARE IN THE BACK.
270
00:14:57,149 --> 00:14:59,342
AT THIS POINT,
IT COMES AS NO SURPRISE
271
00:14:59,344 --> 00:15:01,736
THAT THE ALL-ALUMINUM
GEARSHIFT MECHANISM
272
00:15:01,738 --> 00:15:04,605
IS CUSTOM-MADE
FOR THE EVOLUTION.
273
00:15:04,607 --> 00:15:06,432
ONCE THE MECHANISM IS IN PLACE,
274
00:15:06,434 --> 00:15:08,901
THE TECHNICIAN ATTACHES
THE GEAR-CHANGE CABLES
275
00:15:08,903 --> 00:15:11,329
TO THE SHIFTER
VIA A BALL JOINT.
276
00:15:14,026 --> 00:15:16,960
THE HEAVY-DUTY CABLES
ARE CAPABLE OF HIGH LOADS,
277
00:15:16,962 --> 00:15:18,687
AND THESE, TOO,
HAVE BEEN CUSTOM-MADE
278
00:15:18,689 --> 00:15:21,390
FOR THE EVOLUTION'S
PRECISE SHIFTING REQUIREMENTS.
279
00:15:26,114 --> 00:15:28,047
ULTIMA BUILDS THE CENTER CONSOLE
280
00:15:28,049 --> 00:15:31,909
FROM ULTRA-LIGHTWEIGHT
CARBON FIBER.
281
00:15:31,911 --> 00:15:35,037
WHERE A RACECAR WOULD LEAVE
THE SHIFTER AND CABLE EXPOSED,
282
00:15:35,039 --> 00:15:39,200
THIS SLEEK FEATURE IS REQUIRED
FOR THE CAR TO BE STREET-LEGAL.
283
00:15:39,202 --> 00:15:42,137
♪♪
284
00:15:46,330 --> 00:15:48,555
Narrator: A TECHNICIAN BRINGS
THE LEFT-SIDE FUEL TANK
285
00:15:48,557 --> 00:15:50,624
TO THE CHASSIS.
286
00:15:50,626 --> 00:15:52,084
HAVING TWO INDEPENDENT TANKS
287
00:15:52,086 --> 00:15:55,554
PREVENTS THE CAR
FROM EXPERIENCING FUEL SURGES.
288
00:15:55,556 --> 00:15:57,715
WITH THIS STEP,
THE CAR IS NOW READY
289
00:15:57,717 --> 00:15:59,909
FOR ITS GEL-COAT-FINISHED BODY.
290
00:16:02,380 --> 00:16:05,640
THE TECHNICIAN INSTALLS
THE RIGHT-HAND SIDE POD.
291
00:16:05,642 --> 00:16:10,037
THIS INCLUDES A VENT
THAT WILL HELP COOL THE BRAKES.
292
00:16:10,039 --> 00:16:14,332
HE ALIGNS AND HOLDS THE POD
IN PLACE WITH A SCREW.
293
00:16:14,334 --> 00:16:17,595
SEALING AND RIVETING THE PANEL
TO THE CHASSIS HAPPENS LATER.
294
00:16:20,858 --> 00:16:23,726
ULTIMA CALLS THE BODYWORK
THAT SURROUNDS THE COCKPIT
295
00:16:23,728 --> 00:16:25,253
THE CENTER TUB.
296
00:16:25,255 --> 00:16:27,054
TEAM MEMBERS CARRY IT
TO THE CHASSIS
297
00:16:27,056 --> 00:16:29,549
AND LOWER IT OVER THE ROLL CAGE,
298
00:16:29,551 --> 00:16:32,085
READY TO BE SEALED
AND RIVETED IN PLACE.
299
00:16:36,149 --> 00:16:39,476
NEXT, THEY INSTALL
THE FRONT SECTION,
300
00:16:39,478 --> 00:16:43,272
A SINGLE-PIECE UNIT THAT
INCLUDES THE FENDERS AND BUMPER.
301
00:16:43,274 --> 00:16:46,367
SINCE THIS IS A MID-ENGINE CAR,
302
00:16:46,369 --> 00:16:50,363
THE REAR PORTION HINGES OPEN
FOR ACCESS TO THE POWER PLANT.
303
00:16:54,427 --> 00:16:58,555
THE EVOLUTION'S DOOR HINGES
UPWARD AT A 45-DEGREE ANGLE.
304
00:17:01,584 --> 00:17:03,718
THIS DOOR STILL REQUIRES
FINAL TRIMMING,
305
00:17:03,720 --> 00:17:05,679
ALIGNING, AND FINISHING.
306
00:17:11,579 --> 00:17:14,037
TO ADD TO THE CAR'S
TORSIONAL RIGIDITY,
307
00:17:14,039 --> 00:17:17,441
ULTIMA BONDS THE DASHBOARD
DIRECTLY INTO THE CENTER TUB.
308
00:17:19,870 --> 00:17:23,597
A TECHNICIAN INSTALLS
THE CAR'S GAUGES.
309
00:17:23,599 --> 00:17:26,659
IN KEEPING WITH THE OLD-SCHOOL
APPEAL OF THE EVOLUTION,
310
00:17:26,661 --> 00:17:29,128
ULTIMA HAS STUCK
WITH ANALOG DIALS,
311
00:17:29,130 --> 00:17:31,056
WHICH HAVE PROVEN
TO BE SIMPLE, RELIABLE,
312
00:17:31,058 --> 00:17:33,158
AND EASY TO READ AT A GLANCE.
313
00:17:38,282 --> 00:17:42,676
THE RED BUTTON IS ALSO TO READ.
314
00:17:42,678 --> 00:17:45,546
ULTIMA USES A FULLY DRESSED
CHEVY LS V-8
315
00:17:45,548 --> 00:17:48,541
FOR THE EVOLUTION.
316
00:17:48,543 --> 00:17:52,203
THE LS IS THE SAME ENGINE
CHEVY USES IN THE CORVETTE,
317
00:17:52,205 --> 00:17:55,565
BUT FULLY CUSTOMIZED
TO THE EVOLUTION.
318
00:17:55,567 --> 00:17:58,234
CUSTOMERS CAN CHOOSE
15 DIFFERENT POWER OPTIONS,
319
00:17:58,236 --> 00:18:02,956
FROM 345 TO 1,020 HORSEPOWER.
320
00:18:02,958 --> 00:18:06,026
80% OF BUYERS
OPT FOR 500 HORSEPOWER --
321
00:18:06,028 --> 00:18:08,220
MORE THAN ENOUGH
FOR A CAR THIS LIGHT.
322
00:18:11,384 --> 00:18:14,050
NEXT, THEY INSTALL
THE EVOLUTION'S GEARBOX,
323
00:18:14,052 --> 00:18:18,047
A PORSCHE SIX-SPEED TRANSAXLE
KNOWN FOR ITS PERFORMANCE,
324
00:18:18,049 --> 00:18:21,109
DURABILITY, AND
BULLETPROOF RELIABILITY.
325
00:18:23,338 --> 00:18:27,666
A PAIR OF DRIVESHAFTS CONNECTS
THE TRANSAXLE TO THE HUBS.
326
00:18:27,668 --> 00:18:29,667
HALF THE WEIGHT
OF CONVENTIONAL DRIVESHAFTS,
327
00:18:29,669 --> 00:18:34,597
THEY'RE MANUFACTURED
FROM THE S155 STEEL --
328
00:18:34,599 --> 00:18:39,920
THE BRITISH AEROSPACE EQUIVALENT
OF U.S. STEEL GRADE 300M.
329
00:18:39,922 --> 00:18:41,655
THIS HIGH-STRENGTH ALLOY
IS PART
330
00:18:41,657 --> 00:18:46,084
OF WHAT HELPS THEM HANDLE
UP TO 1,020 HORSEPOWER.
331
00:18:46,086 --> 00:18:48,279
THE SEATS MAXIMIZE HEAD ROOM.
332
00:18:48,281 --> 00:18:49,813
ULTIMA CALCULATES
333
00:18:49,815 --> 00:18:54,076
THE EVOLUTION FITS DRIVERS
UP TO 6'8" TALL.
334
00:18:54,078 --> 00:18:58,406
A HAND PUMP SITS
WITHIN EASY REACH.
335
00:18:58,408 --> 00:18:59,807
A FEW SQUEEZES INFLATES
336
00:18:59,809 --> 00:19:02,569
THE LUMBAR SUPPORT CUSHION
SEEN EARLIER.
337
00:19:02,571 --> 00:19:05,631
SIMPLE, HARD TO BREAK,
AND EASY TO FIX,
338
00:19:05,633 --> 00:19:08,225
THE LUMBAR SUPPORT
CAN BE MINUTELY ADJUSTED
339
00:19:08,227 --> 00:19:10,194
TO THE DRIVER'S NEEDS.
340
00:19:12,257 --> 00:19:14,623
LOCAL HARDWARE STORES
DON'T STOCK THE MATERIAL
341
00:19:14,625 --> 00:19:19,120
USED TO MAKE THE EVOLUTION'S
BODY GRILLWORK.
342
00:19:19,122 --> 00:19:22,715
ULTIMA HAS THIS HEXAGONAL
ALUMINUM GRID CUSTOM-MADE.
343
00:19:24,978 --> 00:19:26,978
THEY THEN FORM
THE PIECES INDIVIDUALLY
344
00:19:26,980 --> 00:19:31,108
WITH THE HELP
OF A PRESS AND A FORM.
345
00:19:31,110 --> 00:19:32,801
PINS LOCATE THE MATERIAL.
346
00:19:32,803 --> 00:19:35,938
THEN, A SERIES OF SPACERS
BRING IT WITHIN REACH.
347
00:19:35,940 --> 00:19:38,566
THE RESULT IS
A PERFECTLY FORMED GRILLE.
348
00:19:40,535 --> 00:19:42,260
BUT IT'S NOT FINISHED.
349
00:19:42,262 --> 00:19:43,863
FIRST, IT NEEDS TO BE TRIMMED,
350
00:19:43,865 --> 00:19:46,457
LEAVING NOTHING MORE
THAN A SLIM FLANGE.
351
00:19:46,459 --> 00:19:48,459
THEN, IT'S ANODIZED BLACK.
352
00:19:52,624 --> 00:19:55,950
THE FINISHED PRODUCT
CAN BE SEEN ALL OVER THE CAR,
353
00:19:55,952 --> 00:19:57,944
FROM THE FRONT BUMPER
ENTRY GRILLE
354
00:19:57,946 --> 00:20:00,547
TO THE VENTILATION
ON TOP OF THE REAR HOOD.
355
00:20:04,412 --> 00:20:07,037
WHILE THE ANALOG DIALS
AND MANUAL STICK SHIFT
356
00:20:07,039 --> 00:20:10,766
HELP GIVE THE EVOLUTION'S
COCKPIT A CLASSIC LOOK,
357
00:20:10,768 --> 00:20:13,635
CUSTOMERS CAN OPT FOR
THE FUTURISTIC RACECAR-INSPIRED
358
00:20:13,637 --> 00:20:16,531
STEERING WHEEL
WITH BUILT-IN DIGITAL DISPLAY.
359
00:20:19,227 --> 00:20:22,086
TEAM MEMBERS CONDUCT ONE
OF THE MANY PRE-DELIVERY CHECKS
360
00:20:22,088 --> 00:20:23,755
THEY SUBJECT THE EVOLUTION TO
361
00:20:23,757 --> 00:20:26,183
THROUGHOUT
THE MANUFACTURING PROCESS.
362
00:20:29,788 --> 00:20:32,047
ULTIMA'S QUALITY-CONTROL
PROTOCOL REQUIRES
363
00:20:32,049 --> 00:20:34,182
CHECKING ALL PARAMETERS OF A CAR
364
00:20:34,184 --> 00:20:38,178
BEFORE DELIVERING IT
TO ITS NEW OWNER.
365
00:20:38,180 --> 00:20:41,373
THE LE MANS GROUP "C"-DERIVED
BODY OPENS UP COMPLETELY,
366
00:20:41,375 --> 00:20:44,868
WITH DOORS, FRONT SECTION,
AND REAR HOOD ALL IN THE AIR,
367
00:20:44,870 --> 00:20:49,131
FOR EASY ACCESS
TO EVERY PART OF THE CAR.
368
00:20:49,133 --> 00:20:51,459
A CERAMIC COATING
ON THE EXHAUST SYSTEM
369
00:20:51,461 --> 00:20:53,662
HELPS REDUCE HEAT
IN THE ENGINE BAY,
370
00:20:53,664 --> 00:20:56,989
WHICH IS ALSO
WELL-VENTILATED FROM BELOW.
371
00:20:56,991 --> 00:20:59,284
FROM THE COMFORTABLE,
SECURE SEATS
372
00:20:59,286 --> 00:21:02,220
TO THE THE MINIMALIST
BUT FINELY CRAFTED COCKPIT,
373
00:21:02,222 --> 00:21:04,548
THE EVOLUTION EMBODIES
ULTIMA'S GOAL
374
00:21:04,550 --> 00:21:09,812
OF CREATING A TIMELESS-LOOKING
ROAD-GOING SUPERCAR.
375
00:21:09,814 --> 00:21:12,874
THE EVOLUTION'S
SUPERCHARGED 6.8-LITER V-8
376
00:21:12,876 --> 00:21:15,635
CRANKS OUT 1,020 HORSEPOWER,
377
00:21:15,637 --> 00:21:19,965
WHILE THE CAR ONLY WEIGHS
A LITTLE OVER A TON.
378
00:21:19,967 --> 00:21:22,233
THAT'S WHY IT CAN HIT
60 MILES PER HOUR
379
00:21:22,235 --> 00:21:23,960
IN LESS THAN 2 1/2 SECONDS,
380
00:21:23,962 --> 00:21:25,495
MAKING IT ARGUABLY
381
00:21:25,497 --> 00:21:27,656
THE QUICKEST PRODUCTION CAR
IN THE WORLD.
382
00:21:27,658 --> 00:21:30,592
♪♪
30253
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