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These are the user uploaded subtitles that are being translated: 1 00:00:00,968 --> 00:00:02,301 Narrator: Today on 2 00:00:02,303 --> 00:00:04,336 "HOW IT'S MADE: DREAM CARS, PORSCHE EDITION"... 3 00:00:04,338 --> 00:00:07,339 the 911 and the 918 spyder two supercars 4 00:00:07,341 --> 00:00:10,476 built by one of Germany's most iconic automakers. 5 00:00:12,880 --> 00:00:16,048 Captions by VITAC www.vitac.com 6 00:00:16,050 --> 00:00:19,485 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 7 00:00:25,393 --> 00:00:28,560 The sixth largest city in Germany stuttgart 8 00:00:28,562 --> 00:00:31,130 is known as the cradle of the automobile. 9 00:00:31,132 --> 00:00:33,465 Here, the Porsche family designs and assembles 10 00:00:33,467 --> 00:00:36,135 some of the most famous sports cars on the planet. 11 00:00:36,137 --> 00:00:39,138 3,000 employees work to manufacture 12 00:00:39,140 --> 00:00:43,008 Porsche's most celebrated car the 911 coupe. 13 00:00:43,010 --> 00:00:47,012 In 1963, ferdinand Alexander Porsche 14 00:00:47,014 --> 00:00:50,883 designed the original 911 to be called the 901, 15 00:00:50,885 --> 00:00:52,718 but there was a little competition 16 00:00:52,720 --> 00:00:55,554 an existing model from a competing automaker 17 00:00:55,556 --> 00:00:59,224 forced Porsche to rename the car the 911. 18 00:00:59,226 --> 00:01:02,394 By 1964, the Porsche 911 19 00:01:02,396 --> 00:01:05,764 was the most dynamic sports car of the period. 20 00:01:05,766 --> 00:01:09,268 This car is the result of a long history, 21 00:01:09,270 --> 00:01:13,205 with the creation of the 1939 type 64 22 00:01:13,207 --> 00:01:15,541 a model with an all-aluminum chassis 23 00:01:15,543 --> 00:01:18,477 whose final version never emerged. 24 00:01:18,479 --> 00:01:19,845 Porsche considers it 25 00:01:19,847 --> 00:01:21,780 the grandfather of all their cars. 26 00:01:23,117 --> 00:01:26,819 Since the beginning, the company has created sports cars 27 00:01:26,821 --> 00:01:29,088 and cars specifically for motor sports. 28 00:01:30,758 --> 00:01:34,927 This 911 is the most sophisticated model ever built, 29 00:01:34,929 --> 00:01:37,763 with futuristic design, advanced technologies, 30 00:01:37,765 --> 00:01:41,767 improved engine performance, and a lightweight body. 31 00:01:41,769 --> 00:01:43,769 It's a supercar that epitomizes 32 00:01:43,771 --> 00:01:47,506 tradition, innovation, and a racing pedigree. 33 00:01:47,508 --> 00:01:50,142 The 911 starts with the bodyshell assembly, 34 00:01:50,144 --> 00:01:55,414 where the chassis is made with mild steel and aluminum. 35 00:01:55,416 --> 00:01:58,250 Production islands with weld-and-transfer robots 36 00:01:58,252 --> 00:02:00,419 put together the largest parts 37 00:02:00,421 --> 00:02:03,422 notably, the base of the engine bay. 38 00:02:03,424 --> 00:02:05,424 The three robots are programmed to work on 39 00:02:05,426 --> 00:02:08,260 all variants of the model. 40 00:02:08,262 --> 00:02:11,430 Two workers verify the quality of the spot welding. 41 00:02:11,432 --> 00:02:15,767 Inspecting each weld, they execute necessary changes, 42 00:02:15,769 --> 00:02:18,770 as well as measure the distance between the parts. 43 00:02:22,643 --> 00:02:25,144 When the workers complete their assessment, 44 00:02:25,146 --> 00:02:29,481 robots move the parts to another workstation. 45 00:02:29,483 --> 00:02:31,316 The car's bodyshell side panels 46 00:02:31,318 --> 00:02:34,153 move via a conveyor lift to a welding station. 47 00:02:35,389 --> 00:02:38,824 A worker installs the panels into a secure section 48 00:02:38,826 --> 00:02:41,994 where robots weld the parts with precision. 49 00:02:41,996 --> 00:02:44,830 Since the car's chassis is a monokote structure 50 00:02:44,832 --> 00:02:46,832 rather than a traditional chassis, 51 00:02:46,834 --> 00:02:51,503 the side panels are attached with the base already complete. 52 00:02:51,505 --> 00:02:54,006 Automated guides hold the panels in place 53 00:02:54,008 --> 00:02:56,708 while they are welded to the base. 54 00:02:58,812 --> 00:03:02,114 The bodyshell assembly line delivers the doors, 55 00:03:02,116 --> 00:03:04,783 and weld robots secure them 56 00:03:04,785 --> 00:03:07,786 by precisely welding the hinges to the body. 57 00:03:07,788 --> 00:03:10,122 However, it's only temporary, 58 00:03:10,124 --> 00:03:13,458 since the doors will be taken away after the painting process, 59 00:03:13,460 --> 00:03:16,595 only to be reattached on the vehicle assembly line. 60 00:03:16,597 --> 00:03:20,732 Other frame parts in the car's rooftop 61 00:03:20,734 --> 00:03:22,234 are welded to the vehicle platform 62 00:03:22,236 --> 00:03:24,903 in this automated assembly section. 63 00:03:28,142 --> 00:03:31,143 An automated lift moves the skeletal body of the car 64 00:03:31,145 --> 00:03:34,813 to another station for treatment and inspection. 65 00:03:39,353 --> 00:03:41,019 Workers inspect the body 66 00:03:41,021 --> 00:03:44,323 and verify the strength and quality of the machined welds. 67 00:03:44,325 --> 00:03:46,658 Afterward, the structure is taken 68 00:03:46,660 --> 00:03:48,327 by an overhead conveyor lift 69 00:03:48,329 --> 00:03:52,831 to another assembly line for parts and cleaning. 70 00:03:52,833 --> 00:03:56,268 At this stage, workers install the hood cover 71 00:03:56,270 --> 00:03:58,437 and carry out manual cleaning. 72 00:03:58,439 --> 00:04:01,773 Using soft cloths and special cleaning agents, 73 00:04:01,775 --> 00:04:03,942 workers eliminate any construction dust 74 00:04:03,944 --> 00:04:06,478 along the body's surface. 75 00:04:06,480 --> 00:04:08,313 The frame, weighing 80 pounds less 76 00:04:08,315 --> 00:04:10,649 than the previous generation's chassis, 77 00:04:10,651 --> 00:04:13,819 is moved by a transfer lifter to the paint shop. 78 00:04:15,689 --> 00:04:20,192 The painting process begins by dipping the body 79 00:04:20,194 --> 00:04:23,195 into a bath of cathodic dip primer. 80 00:04:23,197 --> 00:04:24,696 Cathodic paint enhances 81 00:04:24,698 --> 00:04:27,366 the corrosion resistance of the car's structure, 82 00:04:27,368 --> 00:04:30,302 bringing the body closer to an immune state. 83 00:04:33,207 --> 00:04:36,375 Next, a high-pressure shower rinses the frame 84 00:04:36,377 --> 00:04:38,210 to remove any excess paint 85 00:04:38,212 --> 00:04:42,614 before the frame dips into the primer treatment again. 86 00:04:42,616 --> 00:04:45,450 Seven consecutive primer baths are employed 87 00:04:45,452 --> 00:04:47,786 to shield the car's bodyshell from rust 88 00:04:47,788 --> 00:04:50,122 and other environmental damage. 89 00:04:55,062 --> 00:04:58,230 By flipping and returning the body into the basin, 90 00:04:58,232 --> 00:05:00,399 the primer paint is guaranteed to reach 91 00:05:00,401 --> 00:05:03,235 every cavity and corner. 92 00:05:03,237 --> 00:05:05,237 It also eliminates any streaks 93 00:05:05,239 --> 00:05:07,539 that might develop at intersections. 94 00:05:09,877 --> 00:05:14,046 After the paint is cured in a 30-minute drying procedure, 95 00:05:14,048 --> 00:05:16,548 the structure moves into another room 96 00:05:16,550 --> 00:05:19,718 where paint robots underseal with seam-sealing paint, 97 00:05:19,720 --> 00:05:22,688 which consists of a pvc coating. 98 00:05:22,690 --> 00:05:26,358 This layer of protection waterproofs all seals 99 00:05:26,360 --> 00:05:30,028 and eliminates additional possibilities of corrosion. 100 00:05:34,301 --> 00:05:38,337 In another paint room, the body receives a filler coating. 101 00:05:38,339 --> 00:05:41,340 Paint robots apply this base coat, 102 00:05:41,342 --> 00:05:46,011 which serves to protect the body from flying stones. 103 00:05:46,013 --> 00:05:49,414 The filler-coating color is selected by the customer. 104 00:05:49,416 --> 00:05:54,686 All paint colors can be reproduced at an added cost. 105 00:06:00,761 --> 00:06:03,261 The structure requires eight layers 106 00:06:03,263 --> 00:06:05,764 of the environment-friendly, water-based filler coating 107 00:06:05,766 --> 00:06:08,233 for full coverage. 108 00:06:08,235 --> 00:06:10,068 Once the paint is cured, 109 00:06:10,070 --> 00:06:12,170 the bodyshell moves to another area 110 00:06:12,172 --> 00:06:15,874 where robots apply two solvent-based clear coats 111 00:06:15,876 --> 00:06:19,778 to provide protection against scrapes and scratches. 112 00:06:19,780 --> 00:06:22,948 A worker wearing protective gloves 113 00:06:22,950 --> 00:06:25,450 to avoid any contact with the new paint 114 00:06:25,452 --> 00:06:28,120 installs the company's crest on the hood 115 00:06:28,122 --> 00:06:31,256 with a specially crafted clamp, 116 00:06:31,258 --> 00:06:37,295 revealing the symbol of stuttgart's pride. 117 00:06:40,367 --> 00:06:41,833 Narrator: The 911 may be 118 00:06:41,835 --> 00:06:44,002 Porsche's most iconic sports car, 119 00:06:44,004 --> 00:06:47,839 but the 918 spyder is Porsche's supercar of the future. 120 00:06:47,841 --> 00:06:52,177 Porsche's 918 spyder hybrid combines the essentials 121 00:06:52,179 --> 00:06:56,515 of motor racing with superb fuel economy. 122 00:06:56,517 --> 00:06:59,718 Originally unveiled as a concept car in 2010, 123 00:06:59,720 --> 00:07:03,889 it's the newest blueprint for future Porsche sports cars. 124 00:07:03,891 --> 00:07:07,559 The automakers' design team started with a clean slate, 125 00:07:07,561 --> 00:07:11,463 no constraints, or compromises. 126 00:07:11,465 --> 00:07:16,635 The goal was to develop a highly fuel-efficient supercar, 127 00:07:16,637 --> 00:07:20,105 smartly built around a powerful hybrid drive system. 128 00:07:20,107 --> 00:07:25,610 The 918 uses the same v-8 engine as the rs spyder racecar. 129 00:07:25,612 --> 00:07:27,779 The engine was developed exclusively 130 00:07:27,781 --> 00:07:31,316 for the annual 24-hour race in le mans, France. 131 00:07:34,321 --> 00:07:38,323 In 2013, the 918 spyder hit the streets 132 00:07:38,325 --> 00:07:40,325 as a limited-production car. 133 00:07:40,327 --> 00:07:44,329 Its appearance is beyond any driver's wildest dream. 134 00:07:44,331 --> 00:07:47,165 This supercar has a rolling chassis, 135 00:07:47,167 --> 00:07:50,502 a vehicle that can be driven without a stylistic shell. 136 00:07:50,504 --> 00:07:54,105 This is one of the automakers' ongoing traditions. 137 00:07:57,211 --> 00:08:00,545 Production starts with the assembly of the chassis. 138 00:08:00,547 --> 00:08:03,215 In the fabric shop, massive sheets 139 00:08:03,217 --> 00:08:06,885 of prepreg composite carbon-fiber-reinforced polymer 140 00:08:06,887 --> 00:08:09,988 are cut into wide pattern pieces with an automatic cutter. 141 00:08:09,990 --> 00:08:13,825 The cutter uses a high-speed oscillating blade, 142 00:08:13,827 --> 00:08:17,662 which alternates at around 18,000 strokes per minute. 143 00:08:17,664 --> 00:08:22,200 The system also vacuums away any dust during cutting. 144 00:08:22,202 --> 00:08:24,703 The sheets are fit into molds 145 00:08:24,705 --> 00:08:27,372 that produce a two-part interlocking chassis, 146 00:08:27,374 --> 00:08:30,375 a monocoque, and a unit carrier. 147 00:08:32,713 --> 00:08:35,714 Carbon-fiber-reinforced polymer is very thin 148 00:08:35,716 --> 00:08:38,884 and affords extreme torsional rigidity. 149 00:08:38,886 --> 00:08:43,722 When the car is complete, it weighs just under 3,700 pounds, 150 00:08:43,724 --> 00:08:47,459 an incredibly low weight for a hybrid sports car. 151 00:08:49,463 --> 00:08:51,129 This aluminum honeycomb layer 152 00:08:51,131 --> 00:08:54,299 keeps the car's chassis at an even lower weight. 153 00:08:56,537 --> 00:09:00,205 With a small offset tool, the specialist installs 154 00:09:00,207 --> 00:09:03,375 the honeycomb sheets into complex areas. 155 00:09:10,751 --> 00:09:14,586 This red fluoropolymer release film has perforations 156 00:09:14,588 --> 00:09:17,756 that allow air and epoxy resin to flow through it. 157 00:09:17,758 --> 00:09:21,259 The film allows the honeycomb cores and carbon-fiber layers 158 00:09:21,261 --> 00:09:24,162 to bind together. 159 00:09:24,164 --> 00:09:27,165 Technicians fit more carbon-fiber sheets 160 00:09:27,167 --> 00:09:28,400 onto the mold, 161 00:09:28,402 --> 00:09:32,571 trimming any excess pieces with utility knives. 162 00:09:32,573 --> 00:09:35,574 In addition to carbon-fiber-reinforced plastic, 163 00:09:35,576 --> 00:09:37,909 magnesium and aluminum are used 164 00:09:37,911 --> 00:09:42,247 to keep the chassis weight down to 3,615 pounds. 165 00:09:46,386 --> 00:09:48,453 Removable white covers are for de-molding. 166 00:09:51,124 --> 00:09:53,458 They use plastic bags and suction hoses 167 00:09:53,460 --> 00:09:55,827 to seal fibrous layers onto the mold. 168 00:09:58,832 --> 00:10:01,666 Permeable lightweight polyester sheets, 169 00:10:01,668 --> 00:10:04,169 known as breather cloths, receive a spray 170 00:10:04,171 --> 00:10:08,340 of adhesive liquid to bond them into position. 171 00:10:08,342 --> 00:10:11,009 The fabric absorbs excess resin and allows air 172 00:10:11,011 --> 00:10:13,845 to flow freely between the bag and the composite 173 00:10:13,847 --> 00:10:16,348 before it enters the autoclave. 174 00:10:18,852 --> 00:10:21,019 Next, a thick plastic bag 175 00:10:21,021 --> 00:10:24,856 creates a secondary airtight cover over the mold. 176 00:10:24,858 --> 00:10:28,960 This allows for easy inspection of the laminate as it cures. 177 00:10:31,164 --> 00:10:34,332 In a pressurized oven known as an autoclave, 178 00:10:34,334 --> 00:10:38,670 the fibrous chassis material cures at 248 degrees, 179 00:10:38,672 --> 00:10:43,341 forcing the mats to release their impregnated resin. 180 00:10:43,343 --> 00:10:48,179 An injector pump uses hoses to vacuum out the air, 181 00:10:48,181 --> 00:10:51,683 then pressurizes the vessel with inert gas. 182 00:10:53,920 --> 00:10:56,254 For a 12-hour soak period, 183 00:10:56,256 --> 00:10:59,924 the autoclave will use heat and high consolidation pressure 184 00:10:59,926 --> 00:11:04,429 to cure the carbon-fiber sheets onto the mold. 185 00:11:04,431 --> 00:11:05,930 After the soak period, 186 00:11:05,932 --> 00:11:08,266 a cooling cycle brings the temperature down, 187 00:11:08,268 --> 00:11:12,270 depressurizes the vessel, and stops the gas. 188 00:11:12,272 --> 00:11:14,773 Once it's complete, the technicians 189 00:11:14,775 --> 00:11:17,609 remove the chassis components from the molds. 190 00:11:19,446 --> 00:11:23,615 The chassis still needs work. 191 00:11:23,617 --> 00:11:25,283 In the finishing chamber, 192 00:11:25,285 --> 00:11:28,453 a robotic drill press pierces holes in the chassis 193 00:11:28,455 --> 00:11:31,289 for the car's various components. 194 00:11:36,797 --> 00:11:38,630 Next, the chassis is subjected 195 00:11:38,632 --> 00:11:43,468 to an age-old nondestructive test using a tap hammer. 196 00:11:43,470 --> 00:11:48,640 This examination verifies near-surface delimitations. 197 00:11:50,510 --> 00:11:54,112 An acoustic transducer checks for lamination quality 198 00:11:54,114 --> 00:11:57,315 that is invisible to the naked eye. 199 00:11:59,319 --> 00:12:02,987 A sterile gel coupling provides an acoustic signal 200 00:12:02,989 --> 00:12:05,223 between the ultrasound transducer 201 00:12:05,225 --> 00:12:08,259 and the inspection area. 202 00:12:08,261 --> 00:12:11,262 The transducer sends and receives reflective wave forms 203 00:12:11,264 --> 00:12:14,099 to detect imperfections. 204 00:12:14,101 --> 00:12:18,436 Their intensity and distance are sent to the diagnostic display. 205 00:12:18,438 --> 00:12:20,572 In a larger section of the factory, 206 00:12:20,574 --> 00:12:23,341 production specialists prepare the chassis units 207 00:12:23,343 --> 00:12:25,844 for engine parts and more. 208 00:12:25,846 --> 00:12:28,880 With the aid of a service console and torque wrench, 209 00:12:28,882 --> 00:12:32,016 a technician installs custom aluminum mounting inserts 210 00:12:32,018 --> 00:12:34,519 in predrilled openings. 211 00:12:36,757 --> 00:12:39,924 The support bracket will link suspension control arms 212 00:12:39,926 --> 00:12:41,760 to the engine frame. 213 00:12:48,401 --> 00:12:50,969 These support units are made from cast aluminum. 214 00:12:50,971 --> 00:12:53,638 They secure the attachment of the drivetrain 215 00:12:53,640 --> 00:12:56,007 and the suspension to the chassis. 216 00:12:56,009 --> 00:12:59,844 The carbon-fiber air boxes that feed the v-8 engine clean air 217 00:12:59,846 --> 00:13:01,379 are part of the chassis. 218 00:13:01,381 --> 00:13:03,081 This design feature is both 219 00:13:03,083 --> 00:13:05,750 energy-efficient and a space saver. 220 00:13:11,024 --> 00:13:14,359 The appeal of the Porsche 911 is its iconic design, 221 00:13:14,361 --> 00:13:17,429 but the excitement is from a 6-cylinder flat engine 222 00:13:17,431 --> 00:13:19,765 producing 350 horsepower 223 00:13:19,767 --> 00:13:22,768 more than enough driving force for any road. 224 00:13:22,770 --> 00:13:26,271 A worker delivers pre-picked engine components 225 00:13:26,273 --> 00:13:29,341 such as the crankcase, the crankshaft, and pistons. 226 00:13:29,343 --> 00:13:33,011 Using a rod-connecting machine, 227 00:13:33,013 --> 00:13:37,349 a worker assembles piston rods to heads for a perfect match. 228 00:13:40,821 --> 00:13:43,488 A leak-proof ring surrounds each piston head. 229 00:13:43,490 --> 00:13:45,991 The worker gently slides the combined unit 230 00:13:45,993 --> 00:13:48,927 into the cylinder block of the crankcase. 231 00:13:48,929 --> 00:13:51,663 Once all the pistons are set, 232 00:13:51,665 --> 00:13:54,332 the cylinder block moves to a new workstation. 233 00:13:57,371 --> 00:14:00,038 With the aid of a lifting device, 234 00:14:00,040 --> 00:14:04,209 a worker lowers the crankshaft onto a worktable. 235 00:14:04,211 --> 00:14:07,379 Using lubricated clamps, he installs and fastens 236 00:14:07,381 --> 00:14:10,215 the connecting rods of each piston to the crankshaft 237 00:14:10,217 --> 00:14:13,585 using an air-impact screwdriver. 238 00:14:20,327 --> 00:14:22,160 After securing the piston rods, 239 00:14:22,162 --> 00:14:24,763 the worker adds metal timing chains to the crankshaft. 240 00:14:27,167 --> 00:14:30,836 Too heavy to handle manually, using a mechanized lifter, 241 00:14:30,838 --> 00:14:32,504 a worker lowers the crankshaft 242 00:14:32,506 --> 00:14:34,673 into the casing of the crankcase, 243 00:14:34,675 --> 00:14:38,009 firmly attaching it into position. 244 00:14:38,011 --> 00:14:41,813 He also checks that all moving parts are functional. 245 00:14:48,789 --> 00:14:52,791 As the two separate cases of the crankcase 246 00:14:52,793 --> 00:14:55,126 roll into a containment room, 247 00:14:55,128 --> 00:14:58,630 transfer robots raise one part onto the other. 248 00:15:00,934 --> 00:15:03,702 The two parts are precisely aligned and linked. 249 00:15:03,704 --> 00:15:07,072 The six pistons are now in 250 00:15:07,074 --> 00:15:10,242 horizontally opposite positions of one another. 251 00:15:23,557 --> 00:15:25,891 A worker shifts the new engine block 252 00:15:25,893 --> 00:15:28,894 into a carrier called a crossmember, 253 00:15:28,896 --> 00:15:31,062 which transports the engine to select stations 254 00:15:31,064 --> 00:15:34,366 for further assembly. 255 00:15:34,368 --> 00:15:38,537 In the next circuit, a worker installs a cylinder head gasket 256 00:15:38,539 --> 00:15:40,539 onto the engine block, 257 00:15:40,541 --> 00:15:44,676 which will exist between the two housing parts. 258 00:15:44,678 --> 00:15:46,678 The accompanying cylinder-head section, 259 00:15:46,680 --> 00:15:48,780 which houses the camshaft, 260 00:15:48,782 --> 00:15:53,752 is precisely fastened into place with an air-impact wrench. 261 00:15:53,754 --> 00:15:57,255 The worker rotates the engine block 262 00:15:57,257 --> 00:15:59,925 and installs a second cylinder head gasket 263 00:15:59,927 --> 00:16:02,193 onto the other end of the engine block. 264 00:16:04,765 --> 00:16:07,098 He lowers another large piece of the engine block 265 00:16:07,100 --> 00:16:09,067 with the help of a lifting device. 266 00:16:09,069 --> 00:16:13,905 The worker also puts large bolts into specific positions 267 00:16:13,907 --> 00:16:16,074 before sending the near-complete engine 268 00:16:16,076 --> 00:16:19,077 to another section involving more automation. 269 00:16:21,915 --> 00:16:23,582 On the crossmember, 270 00:16:23,584 --> 00:16:26,017 the engine block shuttles to a new workstation. 271 00:16:28,855 --> 00:16:32,524 After the double-overhead camshaft is complete, 272 00:16:32,526 --> 00:16:35,527 a robot installs and fastens a cover. 273 00:16:35,529 --> 00:16:38,029 Each screw is carefully put into place 274 00:16:38,031 --> 00:16:40,832 and turned by a measured rotation. 275 00:16:40,834 --> 00:16:43,668 The turning power is extremely precise 276 00:16:43,670 --> 00:16:45,837 for a well-sealed completion, 277 00:16:45,839 --> 00:16:50,008 avoiding any unnecessary tightness or damage. 278 00:16:54,848 --> 00:16:57,849 The entire engine assembly rotates 279 00:16:57,851 --> 00:16:59,684 and is set to a new position 280 00:16:59,686 --> 00:17:02,687 before entering a cabinet for a cold test. 281 00:17:06,727 --> 00:17:10,161 This assessment device checks the new engine with a leak test, 282 00:17:10,163 --> 00:17:13,131 flow test, and pressure test 283 00:17:13,133 --> 00:17:15,600 by simulating its function with the assistance 284 00:17:15,602 --> 00:17:16,668 of an automated air pump. 285 00:17:20,107 --> 00:17:22,273 When the tests are successful, 286 00:17:22,275 --> 00:17:26,778 the central part of the flat engine is complete. 287 00:17:26,780 --> 00:17:29,614 The installation of tubing is next. 288 00:17:29,616 --> 00:17:31,616 Placement of the intake manifold, 289 00:17:31,618 --> 00:17:33,451 followed by exhaust manifold, 290 00:17:33,453 --> 00:17:37,789 complete the 3.4-liter flat 6-cylinder engine assembly. 291 00:17:42,396 --> 00:17:44,729 At the end of the line, 292 00:17:44,731 --> 00:17:48,233 a worker transfers the motor to a robotic cart. 293 00:17:48,235 --> 00:17:50,735 Using guidance signals, the cart travels 294 00:17:50,737 --> 00:17:55,240 to the Porsche 911 vehicle assembly line. 295 00:18:00,446 --> 00:18:03,815 Narrator: The Porsche 918 spyder's v-8 engine 296 00:18:03,817 --> 00:18:06,150 is coupled to dynamic hybrid modules. 297 00:18:06,152 --> 00:18:07,985 The modules not only allow the car 298 00:18:07,987 --> 00:18:10,988 to operate fully electrically, but also convert 299 00:18:10,990 --> 00:18:14,458 kinetic braking energy into reusable electricity. 300 00:18:16,029 --> 00:18:19,530 Assembling a hybrid module starts with a magnet 301 00:18:19,532 --> 00:18:25,536 ac synchronous motor made up of a stator and a rotor. 302 00:18:25,538 --> 00:18:27,038 The stator consists of 303 00:18:27,040 --> 00:18:29,574 wound conductors and armature framework, 304 00:18:29,576 --> 00:18:32,343 select small coils with copper winding wires 305 00:18:32,345 --> 00:18:35,012 attached to the circular armature. 306 00:18:36,516 --> 00:18:39,517 Each coil mounts onto the lamination stack, 307 00:18:39,519 --> 00:18:43,187 which includes the stator and rotor core. 308 00:18:43,189 --> 00:18:47,024 Every coil is made of 50 windings of copper wire, 309 00:18:47,026 --> 00:18:50,127 plastic end caps, and isolation paper. 310 00:18:50,129 --> 00:18:55,233 Each coil automatically becomes part of the rotated stack. 311 00:18:55,235 --> 00:18:57,768 The coils mount precisely to the stack 312 00:18:57,770 --> 00:19:00,037 to generate the necessary charge. 313 00:19:00,039 --> 00:19:02,840 When complete, the lamination stack 314 00:19:02,842 --> 00:19:05,776 consists of over 200 sheets of metal. 315 00:19:10,149 --> 00:19:13,985 The armature moves slowly into a brazing station. 316 00:19:13,987 --> 00:19:16,320 Copper wire ends join the inner connectors 317 00:19:16,322 --> 00:19:19,323 through a high-temperature fusion process. 318 00:19:21,861 --> 00:19:24,195 The electric interconnection of the coils 319 00:19:24,197 --> 00:19:27,865 is established by brazing the two copper wires of each coil 320 00:19:27,867 --> 00:19:30,368 at almost 800 degrees. 321 00:19:32,405 --> 00:19:34,906 Plasma-activated silicone is applied 322 00:19:34,908 --> 00:19:37,708 to securely insulate the inner connection. 323 00:19:37,710 --> 00:19:39,243 To ensure its cohesion, 324 00:19:39,245 --> 00:19:42,546 an automated device delivers low-temperature plasma, 325 00:19:42,548 --> 00:19:45,383 creating a thermoplastic layer. 326 00:19:46,920 --> 00:19:50,588 This is the silicone in its liquid state. 327 00:19:50,590 --> 00:19:55,960 The next part of the process is called trickle impregnation. 328 00:19:55,962 --> 00:20:00,498 The armature revolves on an auto-centering Chuck. 329 00:20:00,500 --> 00:20:03,267 As it rotates, a series of drippers 330 00:20:03,269 --> 00:20:07,138 apply insulating resin to the windings at controlled rates. 331 00:20:13,346 --> 00:20:16,314 In the final stages of the motor's assembly, 332 00:20:16,316 --> 00:20:19,450 the armature, the electric metal sheets, and coils 333 00:20:19,452 --> 00:20:21,752 mount onto a base carrier. 334 00:20:21,754 --> 00:20:24,288 Once they lock into position, 335 00:20:24,290 --> 00:20:28,526 the air-guide frame lowers into the armature. 336 00:20:28,528 --> 00:20:31,028 The outer frame aids in the air ventilation paths 337 00:20:31,030 --> 00:20:35,366 between parts and soundproof enclosure during operation. 338 00:20:40,440 --> 00:20:43,174 The current-connecting slip rings and cover 339 00:20:43,176 --> 00:20:47,278 completes the manufacturing of the stator unit. 340 00:20:50,183 --> 00:20:54,685 A small ceiling robot accurately positions and dispenses resin 341 00:20:54,687 --> 00:20:56,854 onto the rotor's encasement. 342 00:20:56,856 --> 00:21:00,458 It can control all aspects of application parameters 343 00:21:00,460 --> 00:21:04,128 such as fluid flow and speed proportional control. 344 00:21:06,165 --> 00:21:08,833 One at a time, a specialist places magnets 345 00:21:08,835 --> 00:21:13,337 into the main clutch of a positioning jig. 346 00:21:13,339 --> 00:21:17,208 The jig's compression vice aligns and firmly attaches 347 00:21:17,210 --> 00:21:21,212 the magnet to the heavy-duty resin on the rotor case. 348 00:21:29,355 --> 00:21:32,189 Within ac synchronous motors, 349 00:21:32,191 --> 00:21:35,192 magnetic fields form in both the rotor and the stator, 350 00:21:35,194 --> 00:21:37,862 producing a torque on the motor shaft. 351 00:21:40,266 --> 00:21:43,434 This is the union of the rotor and the stator. 352 00:21:45,304 --> 00:21:47,471 This bearing bracket creates a clearance gap 353 00:21:47,473 --> 00:21:49,306 between the two elements. 354 00:21:49,308 --> 00:21:51,475 The bracket maintains even spacing 355 00:21:51,477 --> 00:21:55,646 between the parts through the 360 degrees of rotation. 356 00:21:59,685 --> 00:22:04,522 The specialist adds the housing, power terminal, and cables. 357 00:22:04,524 --> 00:22:06,690 The terminal manages the power field 358 00:22:06,692 --> 00:22:10,528 as electricity flows from the battery to the electric motor. 359 00:22:10,530 --> 00:22:12,430 Like most electric and hybrid cars 360 00:22:12,432 --> 00:22:14,899 with a high-voltage electrical system, 361 00:22:14,901 --> 00:22:17,134 cables and connectors are colored bright orange 362 00:22:17,136 --> 00:22:19,203 for safety. 363 00:22:24,350 --> 00:22:28,853 Narrator: The interior of the Porsche 911 is impressively sophisticated, 364 00:22:28,855 --> 00:22:33,357 it's fitted with the finest leather in a variety of colors. 365 00:22:33,359 --> 00:22:36,861 The car's interior is designed to suit any customer's taste. 366 00:22:38,598 --> 00:22:40,665 In the upholstery shop, 367 00:22:40,667 --> 00:22:44,168 leather color is chosen according to customer choice. 368 00:22:44,170 --> 00:22:46,337 Manufacturer-approved cowhide, 369 00:22:46,339 --> 00:22:48,506 bought from certified cattle herds, 370 00:22:48,508 --> 00:22:50,842 sits on an optical scanning table 371 00:22:50,844 --> 00:22:52,677 which removes any wrinkles. 372 00:22:52,679 --> 00:22:57,014 Within seconds, recognition by a high-definition camera 373 00:22:57,016 --> 00:23:00,952 assesses the leather's size, holes, and marks in detail. 374 00:23:00,954 --> 00:23:06,124 Using a special mouse, the worker marks defects 375 00:23:06,126 --> 00:23:09,460 and traces those areas for further recognition. 376 00:23:09,462 --> 00:23:11,896 This eliminates any imperfections 377 00:23:11,898 --> 00:23:14,899 and is essential to cutting the leather into pieces. 378 00:23:14,901 --> 00:23:18,736 The car interior requires the leather of five cows. 379 00:23:18,738 --> 00:23:23,775 And in this process, 40% of the leather is discarded. 380 00:23:30,150 --> 00:23:33,818 Once complete, the worker places a code on the skin 381 00:23:33,820 --> 00:23:37,588 for identification in the next process. 382 00:23:37,590 --> 00:23:42,260 A worker spreads the leather on an automated cutting table. 383 00:23:42,262 --> 00:23:43,928 With the identification code, 384 00:23:43,930 --> 00:23:48,099 the leather will be cut into patterned pieces. 385 00:23:48,101 --> 00:23:51,769 The computerized system confirms the cutting of all pieces 386 00:23:51,771 --> 00:23:55,439 with precise customization. 387 00:23:55,441 --> 00:23:58,442 On the cutting table, a very small ecojet 388 00:23:58,444 --> 00:24:00,478 sprays water at a high pressure, 389 00:24:00,480 --> 00:24:03,648 repeatedly creating contours and outlines 390 00:24:03,650 --> 00:24:06,784 without tearing or damaging the leather. 391 00:24:16,796 --> 00:24:20,264 The worker removes any residue or remains, 392 00:24:20,266 --> 00:24:21,766 keeping the patterned pieces 393 00:24:21,768 --> 00:24:25,336 sliced by the ecojet leather cutter. 394 00:24:25,338 --> 00:24:27,104 Wearing white gloves and using a spatula 395 00:24:27,106 --> 00:24:30,274 to avoid any wear on the material, 396 00:24:30,276 --> 00:24:32,610 he stacks each new piece with others 397 00:24:32,612 --> 00:24:34,779 to send to the sewing room. 398 00:24:39,586 --> 00:24:42,920 Using industrial sewing machines, 399 00:24:42,922 --> 00:24:46,257 skilled garment workers stitch the pieces of leather together 400 00:24:46,259 --> 00:24:49,126 with high-strength needles and thread. 401 00:24:49,128 --> 00:24:51,596 The thread colors often match or contrast 402 00:24:51,598 --> 00:24:54,498 the pigment of the leather cutouts. 403 00:24:55,635 --> 00:24:59,303 A worker places the upper unit of the dashboard 404 00:24:59,305 --> 00:25:01,138 and its leather counterparts, 405 00:25:01,140 --> 00:25:03,307 infused with high-strength bonding glue, 406 00:25:03,309 --> 00:25:05,643 onto a casting unit. 407 00:25:05,645 --> 00:25:07,545 Lowering a pressing device, 408 00:25:07,547 --> 00:25:10,882 it establishes a marriage of the materials. 409 00:25:10,884 --> 00:25:13,951 Ensuring that each section of the leather is properly fitted, 410 00:25:13,953 --> 00:25:17,855 the worker pulls the material to smooth it on all sides, 411 00:25:17,857 --> 00:25:22,026 matching the seams to the frame. 412 00:25:22,028 --> 00:25:25,529 Precision finishing tools, like a directional heater, 413 00:25:25,531 --> 00:25:28,366 certify that the leather is perfectly joined 414 00:25:28,368 --> 00:25:30,868 into every cavity of the dashboard frame 415 00:25:30,870 --> 00:25:33,371 without overlooking any imperfections. 416 00:25:35,875 --> 00:25:38,376 The worker places the dashboard part 417 00:25:38,378 --> 00:25:41,712 into a special kiln to fully dry the adhesive 418 00:25:41,714 --> 00:25:44,148 and perfectly join the materials. 419 00:25:46,719 --> 00:25:51,088 When dried, the unit travels to a new workstation. 420 00:25:51,090 --> 00:25:54,592 A worker places a rear plastic panel 421 00:25:54,594 --> 00:25:57,929 onto the inside of the leather-bound dashboard. 422 00:25:57,931 --> 00:26:00,765 An automated cover contains the area 423 00:26:00,767 --> 00:26:05,102 while a bonding device braces the parts with fastening ties. 424 00:26:05,104 --> 00:26:07,772 The shape and construction of the upper dashboard 425 00:26:07,774 --> 00:26:11,275 make installing the car's dials and switches easy. 426 00:26:15,181 --> 00:26:19,016 Once the fully upholstered dashboard is partially equipped, 427 00:26:19,018 --> 00:26:21,686 workers securely install it into the cockpit 428 00:26:21,688 --> 00:26:25,856 using a mechanical lifter and air-impact screwdrivers. 429 00:26:27,427 --> 00:26:31,228 The car's body moves along the vehicle assembly line, 430 00:26:31,230 --> 00:26:33,564 protected by vinyl coverings. 431 00:26:35,735 --> 00:26:37,735 And without the doors, 432 00:26:37,737 --> 00:26:41,072 interior installation work is much easier to execute, 433 00:26:41,074 --> 00:26:43,741 like placing a glass sunroof. 434 00:26:45,311 --> 00:26:47,812 Two window-assembly robots are responsible 435 00:26:47,814 --> 00:26:51,649 for the installation of the front and rear windshields. 436 00:26:51,651 --> 00:26:53,818 The first robot applies an adhesive paste 437 00:26:53,820 --> 00:26:55,820 around the glass edges 438 00:26:55,822 --> 00:26:59,824 as the second robot gently aligns the window into position 439 00:26:59,826 --> 00:27:03,995 using infrared sensors for accuracy. 440 00:27:03,997 --> 00:27:07,331 As a next-level sports car, the construction 441 00:27:07,333 --> 00:27:11,002 of the Porsche 911 continues on multiple stories 442 00:27:11,004 --> 00:27:14,472 all within the same building. 443 00:27:19,745 --> 00:27:22,246 Narrator: The Porsche 918 spyder's 444 00:27:22,248 --> 00:27:26,917 4.6-liter, 8-cylinder engine produces 608 horsepower, 445 00:27:26,919 --> 00:27:29,753 achieving the highest power output per liter 446 00:27:29,755 --> 00:27:33,424 of any Porsche naturally aspirated engine. 447 00:27:36,262 --> 00:27:38,762 On the combustion engine's assembly line, 448 00:27:38,764 --> 00:27:41,765 the engine block shifts to a lightweight trolley. 449 00:27:41,767 --> 00:27:43,834 It uses a vertically-mounted slew ring, 450 00:27:43,836 --> 00:27:48,672 which connects to a bracket on the block's crankshaft housing. 451 00:27:48,674 --> 00:27:51,342 When the engine block locks into place, 452 00:27:51,344 --> 00:27:56,347 it can rotate 360 degrees, allowing for complete access. 453 00:27:58,885 --> 00:28:01,552 The crankshaft and its containment clamps 454 00:28:01,554 --> 00:28:02,887 are locked in place 455 00:28:02,889 --> 00:28:05,556 to keep the revolving engine part in position. 456 00:28:05,558 --> 00:28:07,558 Then a technician uses 457 00:28:07,560 --> 00:28:09,727 a microchip-controlled torque wrench 458 00:28:09,729 --> 00:28:12,229 to test the joints, adjust the torque, 459 00:28:12,231 --> 00:28:14,732 and examine the engine limits. 460 00:28:24,544 --> 00:28:26,710 They use a dial bore Gage 461 00:28:26,712 --> 00:28:30,548 to assess the inside diameter of connecting-rod bolts. 462 00:28:34,120 --> 00:28:37,121 Cylinder head bolts are the connecting elements 463 00:28:37,123 --> 00:28:39,790 between the engine block, cylinder head gasket, 464 00:28:39,792 --> 00:28:41,825 and cylinder head. 465 00:28:41,827 --> 00:28:44,895 The bolt-tightening force is an important factor 466 00:28:44,897 --> 00:28:48,032 for the mutual sealing of the combustion chamber, 467 00:28:48,034 --> 00:28:51,702 oil and coolant channels, as well as the ambient air. 468 00:28:56,042 --> 00:29:00,211 Next, already-installed camshaft brackets lock into position 469 00:29:00,213 --> 00:29:03,881 with their proper fastening bolts by a power driver. 470 00:29:11,057 --> 00:29:13,490 Piping known as fuel injection rail 471 00:29:13,492 --> 00:29:15,859 is installed with a torque wrench. 472 00:29:15,861 --> 00:29:18,562 The rail supplies pressurized fuel 473 00:29:18,564 --> 00:29:21,765 to individual injectors within the engine. 474 00:29:26,205 --> 00:29:29,873 The engine's handmade wiring harness is crucial. 475 00:29:31,677 --> 00:29:34,645 The wires are bound together by cable ties 476 00:29:34,647 --> 00:29:37,381 to save space and minimize the effects 477 00:29:37,383 --> 00:29:40,718 of vibrations, abrasions, and moisture. 478 00:29:44,457 --> 00:29:46,290 The aluminum engine block, 479 00:29:46,292 --> 00:29:48,626 finalized with the rear electric motor, 480 00:29:48,628 --> 00:29:52,296 is ready to join the 7-speed transmission block. 481 00:29:58,504 --> 00:30:02,506 Next, a specialist places the 7-speed gearbox 482 00:30:02,508 --> 00:30:05,476 into position where it will join the driveshaft. 483 00:30:05,478 --> 00:30:10,147 The gearbox provides the controlled application of power 484 00:30:10,149 --> 00:30:12,883 to the wheels. 485 00:30:12,885 --> 00:30:16,387 Then the driveshaft and linkage arms are connected 486 00:30:16,389 --> 00:30:20,057 to the gearbox of the front electric drive system. 487 00:30:20,059 --> 00:30:23,394 The suspension control arms are installed. 488 00:30:23,396 --> 00:30:25,396 They manage the motion of the wheels 489 00:30:25,398 --> 00:30:28,732 as the car rebounds or droops on the road. 490 00:30:30,169 --> 00:30:33,003 Next is the air-conditioning compressor, 491 00:30:33,005 --> 00:30:36,006 the heart of the a.C. System. 492 00:30:36,008 --> 00:30:40,344 It takes the refrigerant gas and pressurizes it to cool air. 493 00:30:40,346 --> 00:30:44,181 It's run by an engine belt and electrically-operated clutch. 494 00:30:47,453 --> 00:30:51,121 A worker adds the suspension shocks. 495 00:30:51,123 --> 00:30:53,457 They are part of an adaptive shock absorber 496 00:30:53,459 --> 00:30:55,626 and rear-axle steering system, 497 00:30:55,628 --> 00:30:59,063 which provides electromechanical wheel adjustment. 498 00:30:59,065 --> 00:31:03,233 With a torque wrench, a specialist installs 499 00:31:03,235 --> 00:31:07,571 and fastens the final bolts to complete the running gear. 500 00:31:12,745 --> 00:31:15,112 In purely electric mode, 501 00:31:15,114 --> 00:31:19,483 the 918 spyder attains zero to 60 in six seconds 502 00:31:19,485 --> 00:31:22,986 and a top speed of 93 miles per hour. 503 00:31:22,988 --> 00:31:26,490 Definitely electrifying. 504 00:31:31,177 --> 00:31:34,512 Narrator: The Porsche 911 engine, transmission, and axles 505 00:31:34,514 --> 00:31:37,348 are mounted by a synchronous elevating platform, 506 00:31:37,350 --> 00:31:40,351 workers also use the platform to install options 507 00:31:40,353 --> 00:31:43,187 like all-wheel drive, ceramic brakes, 508 00:31:43,189 --> 00:31:45,022 or a sports chassis. 509 00:31:46,259 --> 00:31:50,561 Adding to the car's assembly, a worker affixes the gearbox 510 00:31:50,563 --> 00:31:55,266 to the 3.4-liter flat 6-cylinder engine block. 511 00:31:57,136 --> 00:32:00,137 Both parts are lowered with a hoist onto a workstation 512 00:32:00,139 --> 00:32:03,140 where systems, including the drivetrain and suspension, 513 00:32:03,142 --> 00:32:05,042 will join the machinery. 514 00:32:05,044 --> 00:32:10,080 Workers attach and align the exhaust system. 515 00:32:11,817 --> 00:32:14,985 Raised and transported by a suspended conveyor lift, 516 00:32:14,987 --> 00:32:17,087 workers slowly lower the body 517 00:32:17,089 --> 00:32:20,257 to ensure the engine block, dampers, and suspension 518 00:32:20,259 --> 00:32:23,093 slide directly into their designated locations 519 00:32:23,095 --> 00:32:26,030 without any complications. 520 00:32:26,032 --> 00:32:29,066 Commonly known as the marriage of elements, 521 00:32:29,068 --> 00:32:31,235 workers bolt the drivetrain and chassis 522 00:32:31,237 --> 00:32:33,404 to the body of the car. 523 00:32:41,380 --> 00:32:44,215 Adding to the car's flair and safety, 524 00:32:44,217 --> 00:32:47,051 two workers mount the bumpers. 525 00:32:47,053 --> 00:32:49,220 Another worker, using a preset mold, 526 00:32:49,222 --> 00:32:53,390 attaches the legendary nameplate with care and precision. 527 00:32:55,261 --> 00:32:57,595 A simple adhesive and finishing roller 528 00:32:57,597 --> 00:32:58,996 keep it together. 529 00:33:01,167 --> 00:33:05,669 And a quick wipe-down adds to the shine of the car's identity. 530 00:33:07,206 --> 00:33:10,040 The car now enters the final stations 531 00:33:10,042 --> 00:33:12,276 of the vehicle assembly line. 532 00:33:12,278 --> 00:33:13,777 Using a lifting device, 533 00:33:13,779 --> 00:33:17,448 a worker mounts the tires and rims onto each wheel plate. 534 00:33:17,450 --> 00:33:20,251 The company's assembly planning 535 00:33:20,253 --> 00:33:23,988 uses the cost-effective "just in time" strategy, 536 00:33:23,990 --> 00:33:28,659 which avoids keeping any inventory of parts in overstock. 537 00:33:28,661 --> 00:33:32,663 At this station, the car regains its doors. 538 00:33:32,665 --> 00:33:37,167 Manufactured offsite by recaro, a name synonymous with racing, 539 00:33:37,169 --> 00:33:40,838 the sporty, leather bucket seats are fit into the cabin. 540 00:33:44,744 --> 00:33:46,744 After body and electrical adjustments 541 00:33:46,746 --> 00:33:48,746 on the vehicle's assembly line, 542 00:33:48,748 --> 00:33:51,749 the car will undergo driving tests. 543 00:33:54,620 --> 00:33:57,688 A worker drives the car onto test rollers. 544 00:33:57,690 --> 00:34:01,191 Computerized laser sensors scan labels on each wheel 545 00:34:01,193 --> 00:34:02,693 and monitor their movement 546 00:34:02,695 --> 00:34:06,697 for alignment, tire balance, and handling qualities. 547 00:34:13,873 --> 00:34:17,541 At another workstation, a worker shakes the wheels laterally 548 00:34:17,543 --> 00:34:20,044 to manually check the axle alignment. 549 00:34:20,046 --> 00:34:24,014 Sensors and computer software help perfect the adjustments. 550 00:34:24,016 --> 00:34:27,518 Next, a worker assesses the orientation 551 00:34:27,520 --> 00:34:30,354 of the car's optical blocks and light units. 552 00:34:30,356 --> 00:34:34,925 A worker drives the car onto another set of test rollers. 553 00:34:34,927 --> 00:34:38,962 In this exercise, while the accelerator is pressed, 554 00:34:38,964 --> 00:34:42,466 a device called a dynamometer records motor performance. 555 00:34:42,468 --> 00:34:44,368 It measures the power and torque output 556 00:34:44,370 --> 00:34:49,473 delivered by the 3.4-liter flat 6-cylinder engine. 557 00:34:49,475 --> 00:34:53,243 A water-leakage test uses mid-pressure showers 558 00:34:53,245 --> 00:34:57,214 as a worker searches for leaks in the cabin using a flashlight. 559 00:34:59,218 --> 00:35:02,553 When the extensive drive tests are successful, 560 00:35:02,555 --> 00:35:05,556 the car is ready to exit the plant. 561 00:35:05,558 --> 00:35:08,659 The factory in the zuffenhausen district of stuttgart, Germany, 562 00:35:08,661 --> 00:35:12,162 produces more than 40,000 cars per year 563 00:35:12,164 --> 00:35:15,666 twice the amount since the early '90s. 564 00:35:15,668 --> 00:35:18,102 Only variants of this model and another model 565 00:35:18,104 --> 00:35:19,937 are assembled here. 566 00:35:19,939 --> 00:35:21,605 Instantly recognizable 567 00:35:21,607 --> 00:35:24,608 and originally engineered for the racetrack, 568 00:35:24,610 --> 00:35:28,278 this car continues to stir emotion and garner attention, 569 00:35:28,280 --> 00:35:32,282 just as it did in its original year. 570 00:35:32,284 --> 00:35:36,820 With a perfect leather interior, advanced technology, 571 00:35:36,822 --> 00:35:41,158 and powerful 3.4-liter flat 6-cylinder engine, 572 00:35:41,160 --> 00:35:43,660 this car is one of the most captivating sports cars 573 00:35:43,662 --> 00:35:46,130 in the entire world. 574 00:35:46,132 --> 00:35:51,268 Although a grand departure from the first 911, 575 00:35:51,270 --> 00:35:55,339 this car still retains a lot of the original styling 576 00:35:55,341 --> 00:35:57,474 with a modern edge 577 00:35:57,476 --> 00:36:01,445 and the gift of new aerodynamics. 578 00:36:01,447 --> 00:36:05,616 For this automaker, form always follows function. 579 00:36:05,618 --> 00:36:07,451 This car is no exception to the rule, 580 00:36:07,453 --> 00:36:09,787 which has made it classically appealing 581 00:36:09,789 --> 00:36:11,622 for more than 40 years. 582 00:36:11,624 --> 00:36:14,958 As one of Germany's hallmark dream cars 583 00:36:14,960 --> 00:36:18,629 the compact Porsche 911 is powerfully agile 584 00:36:18,631 --> 00:36:22,966 and visually legendary without compromise. 585 00:36:27,273 --> 00:36:31,108 The Porsche 918 spyder's combination of innovative design 586 00:36:31,110 --> 00:36:34,178 and hybrid technology rivals any racecar. 587 00:36:34,180 --> 00:36:36,013 With revolutionary components 588 00:36:36,015 --> 00:36:38,015 and high-recuperation performance, 589 00:36:38,017 --> 00:36:41,084 it is the supercar of the future. 590 00:36:42,521 --> 00:36:45,355 On an engine cradle Dolly, technicians bring 591 00:36:45,357 --> 00:36:48,358 the carrier unit to the drive-system elements. 592 00:36:48,360 --> 00:36:52,696 This includes the v-8 engine, an electric drive, and gearbox. 593 00:36:52,698 --> 00:36:55,866 Tubing to the air filter and the engine's exhaust 594 00:36:55,868 --> 00:36:57,868 are subsequently fit. 595 00:36:59,538 --> 00:37:02,706 The carrier unit has three specific mounting points 596 00:37:02,708 --> 00:37:04,208 for the drive system 597 00:37:04,210 --> 00:37:06,877 two points in the front of the carbon-fiber unit 598 00:37:06,879 --> 00:37:10,214 and another in the rear section. 599 00:37:10,216 --> 00:37:13,884 In the front, two lightweight gray cast-iron mounting brackets 600 00:37:13,886 --> 00:37:17,888 are attached with a power driver to hold the motor in position. 601 00:37:23,162 --> 00:37:24,661 The oval-shaped air filters 602 00:37:24,663 --> 00:37:27,164 protect the fuel-injection and air-intake systems 603 00:37:27,166 --> 00:37:30,934 from dust and debris that can be sucked in during operation. 604 00:37:35,341 --> 00:37:37,674 Technicians connect the power terminal 605 00:37:37,676 --> 00:37:42,179 and high-voltage cables to the lithium-ion battery. 606 00:37:44,350 --> 00:37:48,185 The battery then shuttles to a finished monocoque. 607 00:37:48,187 --> 00:37:50,854 With the assistance of an electric drive stacker, 608 00:37:50,856 --> 00:37:54,191 the monocoque shell hovers above the battery. 609 00:37:58,597 --> 00:38:01,431 The power source raises to its new home 610 00:38:01,433 --> 00:38:04,768 below the fuel tank and behind the cockpit. 611 00:38:06,171 --> 00:38:07,337 The liquid-cooled 612 00:38:07,339 --> 00:38:10,007 6.8-kilowatt-an-hour battery pack 613 00:38:10,009 --> 00:38:12,676 has 312 individual cells 614 00:38:12,678 --> 00:38:16,513 and discharges 220 kilowatts of peak power. 615 00:38:16,515 --> 00:38:18,682 Two technicians install 616 00:38:18,684 --> 00:38:22,185 the 18-gallon aluminum hybrid-pressure fuel tank. 617 00:38:22,187 --> 00:38:26,023 The tank sits inside the monocoque behind the seats. 618 00:38:31,797 --> 00:38:34,631 After the fuel cell, they add a low-mass 619 00:38:34,633 --> 00:38:39,970 aluminum heat-resistant panel along with protected cabling. 620 00:38:39,972 --> 00:38:42,639 This aluminum shell reduces the transmission of heat 621 00:38:42,641 --> 00:38:45,142 and vibrations to the cockpit. 622 00:38:46,979 --> 00:38:49,446 Next, technicians add the carrier unit 623 00:38:49,448 --> 00:38:51,715 mounted with the engine components 624 00:38:51,717 --> 00:38:53,984 to the monocoque cockpit section. 625 00:38:53,986 --> 00:38:57,721 Technicians use torque wrenches to adjust the bolts that join 626 00:38:57,723 --> 00:39:01,124 the interlocking carbon-fiber resin polymer structures 627 00:39:01,126 --> 00:39:02,459 together. 628 00:39:06,699 --> 00:39:09,866 This is the exhaust system with top pipes. 629 00:39:09,868 --> 00:39:13,937 It is made of extreme heat and pressure-resistant steel. 630 00:39:13,939 --> 00:39:15,872 The system is also wrapped 631 00:39:15,874 --> 00:39:19,876 in thin-walled heat- and noise-barrier shields. 632 00:39:19,878 --> 00:39:23,213 Below the exhaust is a temporary tarpaulin sheet 633 00:39:23,215 --> 00:39:26,550 to protect the engine cradle and other parts. 634 00:39:29,388 --> 00:39:31,521 A technician attaches the running gear 635 00:39:31,523 --> 00:39:33,490 to the rear section of the chassis. 636 00:39:33,492 --> 00:39:37,694 A lift elevates the drivetrain, the suspension system, 637 00:39:37,696 --> 00:39:40,163 and braking units into position. 638 00:39:44,136 --> 00:39:46,970 The running gear is bolted to the carrier unit 639 00:39:46,972 --> 00:39:48,972 using a power driver. 640 00:39:55,981 --> 00:39:59,282 Here, the car's stylish sills meet the chassis, 641 00:39:59,284 --> 00:40:02,386 including the right panel with the fuel cap. 642 00:40:04,690 --> 00:40:06,356 Using a feeler Gage, 643 00:40:06,358 --> 00:40:08,692 the measurement of the clearance in gap width 644 00:40:08,694 --> 00:40:13,063 between the two parts is taken for accuracy. 645 00:40:13,065 --> 00:40:16,366 Next, more ultralight carbon-fiber panels 646 00:40:16,368 --> 00:40:19,169 are added to the body of the car. 647 00:40:19,171 --> 00:40:21,672 For those who want to keep the car as lightweight as possible, 648 00:40:21,674 --> 00:40:24,841 a pricy weight-reducing coating is available 649 00:40:24,843 --> 00:40:27,811 instead of metallic paint. 650 00:40:27,813 --> 00:40:30,047 During the final stages of assembly, 651 00:40:30,049 --> 00:40:32,449 each car's various aesthetic components, 652 00:40:32,451 --> 00:40:34,951 including the exterior accessories, 653 00:40:34,953 --> 00:40:38,789 lights, and interior trim are painstakingly fit. 654 00:40:38,791 --> 00:40:41,291 This is one of very few supercars 655 00:40:41,293 --> 00:40:46,463 that employs a modern yet handcrafted production line. 656 00:40:46,465 --> 00:40:48,465 A specialist attaches 657 00:40:48,467 --> 00:40:52,636 the adjustable, aerodynamic, three-setting retractable wing 658 00:40:52,638 --> 00:40:56,406 and measures it with a feeler Gage for a precision fit. 659 00:40:56,408 --> 00:40:58,942 He also checks the hydraulic operation of the wing 660 00:40:58,944 --> 00:41:00,944 to ensure that the mechanical linkage, 661 00:41:00,946 --> 00:41:03,547 adjusting cylinders, and guidance 662 00:41:03,549 --> 00:41:06,316 all operate within desirable limits. 663 00:41:06,318 --> 00:41:11,154 He calculates the gap width to ensure the fit of the spoiler. 664 00:41:11,156 --> 00:41:13,156 Technicians install 665 00:41:13,158 --> 00:41:17,127 the stainless-steel exhaust system cover plate. 666 00:41:17,129 --> 00:41:21,631 This cockpit is clearly imagined with the driver in mind. 667 00:41:21,633 --> 00:41:25,135 The controls are grouped around a multifunction steering wheel, 668 00:41:25,137 --> 00:41:28,805 merging with three large, round instrument panels. 669 00:41:28,807 --> 00:41:31,141 It is polished off with an infotainment block 670 00:41:31,143 --> 00:41:33,643 in an elevated center console. 671 00:41:36,281 --> 00:41:39,282 As a plug-in hybrid, this automobile combines 672 00:41:39,284 --> 00:41:42,119 the driving dynamics of a performance racecar 673 00:41:42,121 --> 00:41:46,790 with a low thirst for fuel, making the drive fun and long. 674 00:41:46,792 --> 00:41:48,992 If things are kept purely electric, 675 00:41:48,994 --> 00:41:52,763 a drive range of 18 miles is achievable. 676 00:41:52,765 --> 00:41:56,867 Two removable roof panels offer a premium view. 677 00:41:56,869 --> 00:41:58,835 Control panels for climate control, 678 00:41:58,837 --> 00:42:00,804 wing adjustment, and communications 679 00:42:00,806 --> 00:42:04,174 connect the driver to the car. 680 00:42:04,176 --> 00:42:08,078 No longer just a concept car made for showrooms, 681 00:42:08,080 --> 00:42:11,481 the Porsche 918 spyder is a living dream. 682 00:42:11,483 --> 00:42:14,151 It contributes to a long-standing tradition 683 00:42:14,153 --> 00:42:16,820 of exceptional supercars. 684 00:42:16,822 --> 00:42:19,489 A sports car unlike any other, it breaks the boundaries 685 00:42:19,491 --> 00:42:22,826 of style, performance, and technology, 686 00:42:22,828 --> 00:42:25,495 defiant in design to inspire generations 687 00:42:25,497 --> 00:42:29,633 of engineers, enthusiasts, and hybrid supercars to come. 53378

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