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Narrator: TODAY,
ON "HOW IT'S MADE: DREAM CARS,"
2
00:00:03,671 --> 00:00:06,030
THE BEST AUDI
SINCE THE ORIGINAL QUATTRO --
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00:00:06,032 --> 00:00:08,290
THE SUPERSONIC R8 COUPE.
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00:00:08,292 --> 00:00:11,227
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:24,117 --> 00:00:26,443
AUDI'S QUINTESSENTIAL TWO-SEATER
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00:00:26,445 --> 00:00:30,572
IS THE ALL-WHEEL DRIVE R8 COUPE,
BUILT IN NECKARSULM, GERMANY.
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00:00:30,574 --> 00:00:33,434
THE ESSENCE OF THE CAR COMPANY
KNOWN AS AUDI
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00:00:33,436 --> 00:00:35,569
BEGAN IN 1899,
10
00:00:35,571 --> 00:00:36,770
WHEN ENGINEER AUGUST HORCH
11
00:00:36,772 --> 00:00:40,465
INTRODUCED HIS FIRST AUTO BRAND,
HORCH.
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00:00:40,467 --> 00:00:42,126
DURING THAT TIME,
13
00:00:42,128 --> 00:00:45,188
THE MAIN COMPETITORS
WERE MERCEDES AND BENZ.
14
00:00:45,190 --> 00:00:48,324
IN 1909, AFTER DISPUTES
WITH HIS BUSINESS PARTNERS,
15
00:00:48,326 --> 00:00:51,452
HORCH LEFT THE COMPANY
HE FOUNDED TO START AUDI.
16
00:00:51,454 --> 00:00:52,853
ONE YEAR LATER,
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00:00:52,855 --> 00:00:55,282
THE FIRST SET OF NEW CARS
WITH THE AUDI NAMEPLATE
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00:00:55,284 --> 00:00:58,677
HIT THE MARKET
AND WON PEOPLE'S ATTENTION.
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00:00:58,679 --> 00:01:01,671
IN THE 1920s,
CAR SALES WERE DOWN IN GERMANY,
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00:01:01,673 --> 00:01:04,275
AND STRONG COMPETITION
FROM ABROAD
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00:01:04,277 --> 00:01:07,069
FORCED THE GERMAN CAR INDUSTRY
INTO A FINANCIAL CRISIS.
22
00:01:07,071 --> 00:01:10,764
IN 1932,
IN ORDER TO SURVIVE THE CRISIS,
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00:01:10,766 --> 00:01:14,427
AUDI GREW BY MERGING
WITH AUTOMAKERS HORCH, DKW,
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00:01:14,429 --> 00:01:17,363
AND WANDERER
TO FORM THE AUTO UNION.
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00:01:17,365 --> 00:01:19,224
THIS WOULD BECOME
THE SYMBOLIC MEANING
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00:01:19,226 --> 00:01:21,158
OF THE OVERLAPPING
FOUR RINGS,
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00:01:21,160 --> 00:01:24,554
NOW KNOWN AS
THE ICONIC AUDI LOGO.
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00:01:24,556 --> 00:01:28,850
THE R8 USES A LIGHTWEIGHT,
ALL-ALUMINUM CHASSIS AND BODY.
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00:01:28,852 --> 00:01:31,311
MATCHED WITH A V-10 ENGINE,
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00:01:31,313 --> 00:01:34,306
IT DASHES
FROM 0 TO 62 MILES PER HOUR
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00:01:34,308 --> 00:01:35,841
IN 3.9 SECONDS.
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00:01:35,843 --> 00:01:38,703
FROM 2000 TO 2005,
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00:01:38,705 --> 00:01:41,438
THE RACING R8 TEAM VERSION
OF THE R8
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00:01:41,440 --> 00:01:43,999
WON THE LE MANS
24-HOUR ENDURANCE RACE
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00:01:44,001 --> 00:01:46,928
FIVE OUT OF SIX TIMES.
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00:01:50,000 --> 00:01:51,858
THE FOUNDATION OF THIS SUPERCAR
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00:01:51,860 --> 00:01:54,394
IS BASED
ON A SPACE-FRAME CHASSIS
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00:01:54,396 --> 00:01:56,121
AND MONOCOQUE DESIGN.
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00:01:56,123 --> 00:01:58,949
INTERLOCKING STRUTS FORM
THE CHASSIS PATTERN
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00:01:58,951 --> 00:02:01,151
WITH FEW INTERIOR SUPPORTS
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00:02:01,153 --> 00:02:03,613
WHILE THE CHASSIS,
ENGINE, AND SUSPENSION
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00:02:03,615 --> 00:02:06,415
ARE INTEGRATED INTO THE BODY.
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00:02:06,417 --> 00:02:09,543
WEIGHING ABOUT 460 POUNDS,
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00:02:09,545 --> 00:02:14,808
THE SPACE FRAME IS COMPRISED
OF 22% ALUMINUM PLATING,
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00:02:14,810 --> 00:02:19,263
70% OF EXTRUDED
ALUMINUM PROFILES...
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00:02:19,265 --> 00:02:23,133
AND 8% OF AN ALUMINUM-BASED
VACUUM-PRESSURE CASTING.
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00:02:26,297 --> 00:02:28,088
BUILT IN THE NEWLY RENOVATED
FACTORY
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AT THE MANUFACTURER'S
ALUMINUM SITE,
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00:02:30,293 --> 00:02:32,485
WORKERS ASSEMBLE
THE SPACE-FRAME CHASSIS,
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00:02:32,487 --> 00:02:36,113
PLACING THE STRUCTURAL STRUTS
INTO HIGH-PRESSURE VICES
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00:02:36,115 --> 00:02:38,182
CALLED CLAMPING FIXTURES.
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00:02:38,184 --> 00:02:41,177
THESE JIGS LOCK
THE CHASSIS PIECES INTO PLACE
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00:02:41,179 --> 00:02:43,313
TO BE WELDED TOGETHER.
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00:02:43,315 --> 00:02:44,706
WORKERS WELD THE FRAME PARTS
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00:02:44,708 --> 00:02:49,169
WITH TORCHES THAT HEAT UP TO
ABOUT 1,600 DEGREES FAHRENHEIT.
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00:02:49,171 --> 00:02:52,197
ALUMINUM BURNS
MORE RAPIDLY THAN STEEL,
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00:02:52,199 --> 00:02:55,134
FORCING WORKERS TO MOVE QUICKLY,
WITH DELICACY.
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00:02:55,136 --> 00:02:57,260
ONCE THE WORKER
FINISHES WELDING,
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00:02:57,262 --> 00:02:58,529
HE USES A HOIST
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00:02:58,531 --> 00:03:02,525
TO LIFT THE FRAME SECTION
TO ANOTHER WORKSTATION.
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00:03:02,527 --> 00:03:06,253
THE CAR'S CHASSIS CONSISTS
OF THREE MAJOR SECTIONS --
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00:03:06,255 --> 00:03:10,550
THE CENTRAL FLOOR, THE REAR END,
AND THE FRONT END.
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00:03:10,552 --> 00:03:11,951
AN OVERHEAD CONVEYOR CRANE
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00:03:11,953 --> 00:03:15,280
DELIVERS THE CHASSIS SECTIONS
TO ANOTHER WORKSTATION,
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00:03:15,282 --> 00:03:18,675
WHERE THE LARGE UNDERBODY PARTS
LOWER FOR MORE WELDING.
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00:03:20,804 --> 00:03:23,071
THE CHASSIS USES
MULTIPLE SECTIONS
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00:03:23,073 --> 00:03:26,033
AND INTEGRAL ADDITIONS
FOR COMPLETION.
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00:03:26,035 --> 00:03:27,300
WORKERS POSITION
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00:03:27,302 --> 00:03:29,228
THE FRAME PIECES
IN THE CLAMPING FIXTURES,
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00:03:29,230 --> 00:03:33,091
WHICH LOCK THE CHASSIS PARTS
INTO THEIR FINISHED POSITIONS,
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00:03:33,093 --> 00:03:36,527
CREATING THE ULTRA-LIGHTWEIGHT
ALUMINUM UNDERCARRIAGE.
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00:03:41,985 --> 00:03:43,852
WORKERS METICULOUSLY WELD
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00:03:43,854 --> 00:03:46,079
EVERY INTERSECTING CORNER
OF THE CHASSIS.
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00:03:47,983 --> 00:03:49,908
ONCE THE WELDED JOINTS COOL,
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00:03:49,910 --> 00:03:52,377
WORKERS RELEASE
THE FINISHED CHASSIS.
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00:03:52,379 --> 00:03:54,772
AN OVERHEAD TRANSFER BELT
LIFTS THE FRAME
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00:03:54,774 --> 00:03:58,634
TO ANOTHER WORKSTATION
FOR MORE CONSTRUCTION.
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00:04:01,071 --> 00:04:04,465
ONE OF THE VERY FEW ROBOTIC
OPERATIONS IN THE BODY SHOP
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00:04:04,467 --> 00:04:05,533
IS THE INSERTION
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00:04:05,535 --> 00:04:08,194
OF FLOW-DRILL SCREWS
INTO THE CAR'S FLOOR
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00:04:08,196 --> 00:04:10,021
AND CABIN SUBSTRUCTURE WALLS.
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00:04:10,023 --> 00:04:11,857
A FASTENING ROBOT
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00:04:11,859 --> 00:04:15,752
SPINS THE SELF-TAPPING SCREWS
AT A HIGH SPEED,
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00:04:15,754 --> 00:04:17,687
WHERE THEY FLASH MELD
INTO THE ALUMINUM,
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00:04:17,689 --> 00:04:20,348
CREATING AN ELONGATED,
THREADED SHANK
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00:04:20,350 --> 00:04:23,010
ON THE BACKSIDE
OF THE ALUMINUM SHEET.
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00:04:23,012 --> 00:04:25,478
THIS ADDS TO THE PULL STRENGTH.
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00:04:25,480 --> 00:04:28,541
SELF-TAPPING SCREWS
DRILL THEIR OWN HOLES
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00:04:28,543 --> 00:04:32,103
WHEN THEY SCREW INTO MATERIALS
LIKE WOOD, PLASTIC, AND METAL.
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00:04:36,300 --> 00:04:37,900
THE FLOOR TUNNEL IS REINFORCED
91
00:04:37,902 --> 00:04:40,895
BY CUSTOM LIGHTWEIGHT,
TAILORED ALUMINUM BLANKS
92
00:04:40,897 --> 00:04:42,297
THAT SAVE WEIGHT.
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00:04:42,299 --> 00:04:44,157
THE THICKNESS OF THE PANELS
VARIES
94
00:04:44,159 --> 00:04:48,153
BASED ON DESIGN AND FUNCTION.
95
00:04:48,155 --> 00:04:52,649
IT TAKES 308 AUTOMATICALLY
PLACED SELF-TAPPING SCREWS
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00:04:52,651 --> 00:04:55,711
TO JOIN THE COMPONENTS
OF THIS CAR'S SUBSTRUCTURE.
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00:04:55,713 --> 00:04:59,707
AS CARS ARE PRODUCED TO MEET
CONSUMER CUSTOMIZATION REQUESTS,
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00:04:59,709 --> 00:05:02,176
THE VEHICLES ARE PRODUCED
IN SEQUENCE.
99
00:05:02,178 --> 00:05:05,771
ONE WEEK BEFORE THE BODY SHOP
BEGINS ASSEMBLING THE CHASSIS,
100
00:05:05,773 --> 00:05:09,067
SISTER FACTORIES AND SUPPLIERS
FROM ACROSS THE COUNTRY
101
00:05:09,069 --> 00:05:12,329
BEGIN THEIR PRODUCTION
OF INDIVIDUALIZED ITEMS.
102
00:05:12,331 --> 00:05:15,991
THIS INCLUDES SEATS,
RUNNING GEAR, AND BUMPERS,
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00:05:15,993 --> 00:05:18,393
ALL DEPENDING
ON EACH CAR'S VARIATION.
104
00:05:18,395 --> 00:05:20,921
AS THE CHASSIS STANDS
AT A WORKSTATION,
105
00:05:20,923 --> 00:05:22,122
WORKERS DELIVER PARTS,
106
00:05:22,124 --> 00:05:25,283
LIKE THE DOORS, TRUNK LID,
AND ENGINE HOOD,
107
00:05:25,285 --> 00:05:28,212
WITH THE ASSISTANCE
OF LIFTING DEVICES.
108
00:05:28,214 --> 00:05:30,214
THE PARTS ARE BOLTED
WITH TORQUE WRENCHES.
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00:05:30,216 --> 00:05:34,110
WORKERS DELIVER THE BODY'S
TRUNK LID FOR INSTALLATION.
110
00:05:35,546 --> 00:05:39,074
SINCE THE CAR'S ENGINE
IS LOCATED IN THE MIDSECTION,
111
00:05:39,076 --> 00:05:41,435
THE CARGO AREA
IS IN THE FRONT END.
112
00:05:41,437 --> 00:05:45,230
WHILE ATTACHING THE TRUNK LID,
THE WORKERS ALSO INSPECT
113
00:05:45,232 --> 00:05:48,192
THE MOBILITY
OF ITS GAS PRESSURE SPRINGS
114
00:05:48,194 --> 00:05:51,027
AND CERTIFY
THAT THE LID IS A PERFECT FIT
115
00:05:51,029 --> 00:05:53,122
AND MOVES PROPERLY.
116
00:05:59,522 --> 00:06:01,848
BEFORE THE BODY PANELS
MEET THE PAINT SHOP,
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00:06:01,850 --> 00:06:04,317
WORKERS REMOVE
ANY EXCESS RESIDUE
118
00:06:04,319 --> 00:06:08,580
WITH HEAVY-DUTY GRINDERS, FILES,
AND HIGH-POWERED SANDERS
119
00:06:08,582 --> 00:06:11,942
TO CREATE
PERFECTLY UNIFORM SURFACES.
120
00:06:14,805 --> 00:06:16,538
AS THE FINAL STAGE,
121
00:06:16,540 --> 00:06:19,934
A WORKER CAREFULLY SANDS
THE ALUMINUM SKIN PANELS BY HAND
122
00:06:19,936 --> 00:06:21,660
WITH A SANDING BLOCK.
123
00:06:21,662 --> 00:06:24,396
THIS ENSURES PRECISE SMOOTHNESS
TO THE SURFACE
124
00:06:24,398 --> 00:06:27,591
BEFORE ANY FURTHER
CONSTRUCTION OR ALTERATIONS.
125
00:06:27,593 --> 00:06:28,926
FOR THIS CAR,
126
00:06:28,928 --> 00:06:30,887
THE TOTAL PRODUCTION TIME
IN THE PAINT SHOP
127
00:06:30,889 --> 00:06:32,088
IS FOUR DAYS.
128
00:06:32,090 --> 00:06:34,215
11 OPTIONAL COLORS
ARE AVAILABLE,
129
00:06:34,217 --> 00:06:37,219
YET ANY COLOR IS POSSIBLE
TO CREATE
130
00:06:37,221 --> 00:06:38,878
TO MEET A CUSTOMER'S DESIRE.
131
00:06:38,880 --> 00:06:44,276
AFTER 96 HOURS OF CONSTRUCTION
AND A FIVE-STAGE PAINT PROCESS,
132
00:06:44,278 --> 00:06:48,205
THE BODY IS READY TO RECEIVE
ITS RUNNING GEAR AND MORE.
133
00:06:54,579 --> 00:06:58,606
Narrator:
THIS AUDI R8 ROAD CAR'S
HIGH-PERFORMANCE BRAKING SYSTEM
134
00:06:58,608 --> 00:07:01,935
IS DIRECTLY MODELED AFTER
ITS FORMULA ONE EDITION,
135
00:07:01,937 --> 00:07:04,004
ALLOWING IT TO STOP
HARDER AND FASTER
136
00:07:04,006 --> 00:07:08,692
IN SHORTER DISTANCES
OR EVERYDAY TRAFFIC.
137
00:07:11,230 --> 00:07:14,090
A WORKER SETS A ROTOR DISC
ON A WORK TABLE
138
00:07:14,092 --> 00:07:15,891
AND ADDS THE STEERING BUCKLE,
139
00:07:15,893 --> 00:07:18,552
WHICH WILL ATTACH
TO THE SUSPENSION COMPONENTS.
140
00:07:18,554 --> 00:07:22,414
THEN IT'S LOCKED INTO POSITION
WITH A TORQUE WRENCH.
141
00:07:22,416 --> 00:07:24,284
HE ADDS A SMALL CALIPER,
142
00:07:24,286 --> 00:07:27,511
WHICH IS FOR
THE PARKING-BRAKE SYSTEM,
143
00:07:27,513 --> 00:07:29,840
AND ADDS AND FASTENS
THE BOLTING PINS
144
00:07:29,842 --> 00:07:31,141
WITH THE AUTOMATED WRENCH.
145
00:07:36,866 --> 00:07:39,166
HE INSTALLS
THE HYDRAULIC BRAKE HOSE
146
00:07:39,168 --> 00:07:41,027
WITH A SLIGHT TWIST.
147
00:07:43,965 --> 00:07:47,592
INSTALLATION OF THE LOWER AND
UPPER SUSPENSION CONTROL ARMS,
148
00:07:47,594 --> 00:07:51,254
MORE COMMONLY KNOWN
AS WISHBONES, FOLLOWS.
149
00:07:51,256 --> 00:07:52,789
USING AN IMPACT DRIVER,
150
00:07:52,791 --> 00:07:54,649
HE BOLTS
THE NARROW END OF EACH ARM
151
00:07:54,651 --> 00:07:56,184
TO THE STEERING KNUCKLE.
152
00:07:56,186 --> 00:07:58,712
THE CONTROL ARMS PIVOT
ON BALL JOINTS
153
00:07:58,714 --> 00:08:02,341
AND HELP ISOLATE THE VEHICLE
FROM ROAD SHOCK.
154
00:08:02,343 --> 00:08:06,069
THEY ALSO CONTROL THE MOTION
OF THE WHEEL THROUGHOUT TRAVEL,
155
00:08:06,071 --> 00:08:09,732
CONTROLLING PARAMETERS SUCH AS
THE CAMBER ANGLE, TOE PATTERN,
156
00:08:09,734 --> 00:08:13,068
ROLL CENTER HEIGHT, AND MORE.
157
00:08:13,070 --> 00:08:15,463
PUT INTO PLACE AFTERWARD
IS A TIE ROD,
158
00:08:15,465 --> 00:08:17,064
A STRUCTURAL UNIT
159
00:08:17,066 --> 00:08:19,759
THAT ATTACHES ON BOTH ENDS
OF THE STEERING RACK,
160
00:08:19,761 --> 00:08:24,155
WHICH AIDS IN THE PUSHING AND
PULLING MOVEMENT OF THE WHEELS.
161
00:08:24,157 --> 00:08:26,749
THE TIE ROD ALSO ASSISTS
WITH THE VEHICLE'S STEERING
162
00:08:26,751 --> 00:08:29,386
AND THE CAR'S ULTIMATE SAFETY.
163
00:08:31,815 --> 00:08:33,348
THE WORKER ADDS
164
00:08:33,350 --> 00:08:36,310
THE MONOBLOC ALUMINUM
BRAKE CALIPER AND ITS PINS,
165
00:08:36,312 --> 00:08:40,639
WHICH HOUSES THE BRAKE PADS
AND SIX PISTONS.
166
00:08:40,641 --> 00:08:44,502
FINALLY, HE ATTACHES
A FEW MORE PARTS TO THE TIE ROD,
167
00:08:44,504 --> 00:08:46,763
INCLUDING
THE BOLT AND SOCKET ARRANGEMENT,
168
00:08:46,765 --> 00:08:49,032
WITH A TAPERED STUD
FOR THE MOUNT BRACKET.
169
00:08:49,034 --> 00:08:51,259
THIS WILL COMPLETE THE ASSEMBLY
170
00:08:51,261 --> 00:08:53,995
BEFORE IT JOINS
THE REST OF THE RUNNING GEAR
171
00:08:53,997 --> 00:08:55,822
AND THE NEW CHASSIS.
172
00:09:03,582 --> 00:09:05,916
ONCE THE WORKER FINISHES
THE BRAKE ASSEMBLY,
173
00:09:05,918 --> 00:09:09,412
A HOIST TAKES IT AWAY
TO ANOTHER WORKSTATION.
174
00:09:12,609 --> 00:09:14,808
COMING FROM A SISTER PLANT
IN HUNGARY,
175
00:09:14,810 --> 00:09:17,336
A WORKER SHUTTLES THE 560-POUND,
176
00:09:17,338 --> 00:09:19,864
10-CYLINDER ENGINE
TO A WORKSTATION,
177
00:09:19,866 --> 00:09:21,732
WHERE IT RECEIVES
MORE ASSEMBLY TIME
178
00:09:21,734 --> 00:09:24,895
DUE TO ADDITIONAL PARTS.
179
00:09:24,897 --> 00:09:29,291
THIS 5.2-LITER ENGINE GENERATES
525 HORSEPOWER,
180
00:09:29,293 --> 00:09:33,921
AFFORDING THE CAR A TOP SPEED
OF 195 MILES PER HOUR.
181
00:09:36,017 --> 00:09:38,350
WHILE ADDING
MORE PARTS TO THE ENGINE,
182
00:09:38,352 --> 00:09:40,445
THE WORKER ATTACHES
THE DRIVE PLATE
183
00:09:40,447 --> 00:09:43,381
AND ITS NECESSARY SCREWS
TO THE ENGINE FLYWHEEL,
184
00:09:43,383 --> 00:09:47,577
A DEVICE USED
TO STORE ROTATIONAL ENERGY.
185
00:09:47,579 --> 00:09:50,372
HE INSERTS EACH SCREW BY HAND
186
00:09:50,374 --> 00:09:52,866
AND FASTENS THEM WITH
A POWER DRIVER.
187
00:09:55,571 --> 00:09:58,897
BEFORE CONNECTING THE ENGINE
TO THE TRANSMISSION SHAFT,
188
00:09:58,899 --> 00:10:01,992
THE COMPONENT THAT TRANSMITS
TORQUE AND ROTATION,
189
00:10:01,994 --> 00:10:04,987
HE SCANS THE DRIVE PLATE
USING A SCANNER.
190
00:10:04,989 --> 00:10:06,255
THE SCANNER IS LINKED
191
00:10:06,257 --> 00:10:08,982
TO COMPUTER-PROCESSED
MONITORING SOFTWARE
192
00:10:08,984 --> 00:10:10,852
FOR THE CAR'S ASSEMBLY RECORDS.
193
00:10:12,121 --> 00:10:15,047
USING OTHER COMPUTER SOFTWARE,
HE ALSO VERIFIES
194
00:10:15,049 --> 00:10:17,475
WHETHER THE SCREWS
ARE FITTED CORRECTLY
195
00:10:17,477 --> 00:10:20,545
AND WITH THE RIGHT AMOUNT
OF TENSION TO THE DRIVE PLATE,
196
00:10:20,547 --> 00:10:23,807
MEETING ENGINEERING
AND MANUFACTURING STANDARDS.
197
00:10:32,401 --> 00:10:36,428
ONCE THE WORKER ACCURATELY
INSTALLS THE DRIVE PLATE,
198
00:10:36,430 --> 00:10:38,823
HE ATTACHES
THE DOUBLE-CLUTCH TRANSMISSION
199
00:10:38,825 --> 00:10:40,725
TO THE V-10 ENGINE.
200
00:10:45,749 --> 00:10:49,509
USING AN IMPACT DRIVER
TO FASTEN THE SCREWS,
201
00:10:49,511 --> 00:10:51,978
THE TWO LARGE RUNNING PARTS
ARE MATED
202
00:10:51,980 --> 00:10:54,306
TO BECOME THE HEART AND SPIRIT
OF THE R8.
203
00:11:04,725 --> 00:11:07,818
Narrator: EACH AUDI R8 IS MADE
OF MORE THAN 5,000 PARTS,
204
00:11:07,820 --> 00:11:09,686
INSTALLED MOSTLY BY HAND.
205
00:11:09,688 --> 00:11:12,280
WITH 14 STATIONS
IN THE ASSEMBLY HALL,
206
00:11:12,282 --> 00:11:14,808
EACH HAS A STRICT CYCLE TIME
OF 30 MINUTES.
207
00:11:14,810 --> 00:11:16,743
THOUGH ONE OF THE FASTEST CARS
IN THE WORLD,
208
00:11:16,745 --> 00:11:18,638
IT'S GRADUALLY MADE
IN EIGHT DAYS.
209
00:11:19,974 --> 00:11:21,707
THE REAR OF THIS SUPERCAR
210
00:11:21,709 --> 00:11:24,701
IS THE MOST COMPLEX PART
OF THE VEHICLE.
211
00:11:24,703 --> 00:11:26,763
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
212
00:11:26,765 --> 00:11:30,299
WORKERS MANEUVER THE CHASSIS
ONTO A TRANSFER DOLLY.
213
00:11:30,301 --> 00:11:32,560
THEY POSITION
THE SPACE FRAME PROPERLY
214
00:11:32,562 --> 00:11:35,254
TO DROP IN THE V-10 MID-ENGINE,
215
00:11:35,256 --> 00:11:38,525
THE GEAR BOX, THE FUEL TANK,
INTERIOR PANELS,
216
00:11:38,527 --> 00:11:40,252
AND OTHER TRIM ITEMS.
217
00:11:40,254 --> 00:11:43,781
THEY ALSO ATTACH THE SPECIFIED
CABLING AND PIPING,
218
00:11:43,783 --> 00:11:46,516
ALONG WITH
THE NECESSARY SCREWS AND BOLTS.
219
00:11:46,518 --> 00:11:49,979
BECAUSE THIS CAR USES
A FLAT OIL PAN,
220
00:11:49,981 --> 00:11:52,739
IT ALLOWS THE ENGINE
TO BE INSTALLED LOWER,
221
00:11:52,741 --> 00:11:55,868
BRINGING THE CAR'S CENTER
OF GRAVITY CLOSER TO THE GROUND,
222
00:11:55,870 --> 00:11:59,071
RESULTING IN OUTSTANDING
ROAD HANDLING.
223
00:11:59,073 --> 00:12:01,733
NEXT, THE WORKERS ROTATE
THE CHASSIS,
224
00:12:01,735 --> 00:12:04,327
ALONG WITH THE NEW ENGINE
AND INTERIOR COMPONENTS,
225
00:12:04,329 --> 00:12:07,822
TO INSERT MORE ELECTRICAL WIRING
AND PLASTIC PIPING
226
00:12:07,824 --> 00:12:10,392
TO THE RUNNING-GEAR ELEMENTS
AND MORE.
227
00:12:11,954 --> 00:12:13,353
WITH A LOT OF COMPLEXITIES
228
00:12:13,355 --> 00:12:15,556
AND A LARGE AMOUNT
OF INTRICATE LABOR,
229
00:12:15,558 --> 00:12:18,283
THE MULTIPLE INSTALLATION STEPS
OF MOST ITEMS
230
00:12:18,285 --> 00:12:20,211
HAVE TO BE FLAWLESS.
231
00:12:20,213 --> 00:12:21,946
AS THEY SITUATE PARTS,
232
00:12:21,948 --> 00:12:24,506
THEY INSTALL THE SCREWS
MANUALLY.
233
00:12:24,508 --> 00:12:25,909
DURING THIS PROCESS,
234
00:12:25,911 --> 00:12:29,537
WORKERS INSTALL 50 TO 60 PARTS
WITHIN 30 MINUTES.
235
00:12:32,100 --> 00:12:35,168
ASSISTED BY A SPECIALIZED
LIFTING DEVICE,
236
00:12:35,170 --> 00:12:37,963
A WORKER INSTALLS
A BRAKING ASSEMBLY UNIT
237
00:12:37,965 --> 00:12:42,326
FITTED WITH CARBON-FIBER
REINFORCED CERAMIC BRAKE DISCS.
238
00:12:43,929 --> 00:12:47,256
USING A TORQUE WRENCH,
HE FASTENS THE LOCKING BOLTS,
239
00:12:47,258 --> 00:12:49,250
SECURING THE UNIT INTO POSITION.
240
00:12:57,911 --> 00:13:00,578
THE BODY AND CHASSIS
ARE SHUTTLED BY A TRANSFER HOIST
241
00:13:00,580 --> 00:13:03,940
DOWN THE ASSEMBLY LINE
TO STATION NUMBER NINE,
242
00:13:03,942 --> 00:13:05,600
WHERE MORE WORKERS AWAIT
243
00:13:05,602 --> 00:13:08,537
TO ADD KEY AESTHETIC
AND FUNCTIONAL FEATURES.
244
00:13:10,132 --> 00:13:12,466
USING A SPECIALIZED
LIFTING CRANE,
245
00:13:12,468 --> 00:13:13,859
THE WORKERS LOWER
246
00:13:13,861 --> 00:13:17,822
THE CAR'S RETRACTABLE ACOUSTIC
FOLDING ROOF MADE OF CLOTH.
247
00:13:19,492 --> 00:13:21,217
IT WEIGHS LESS THAN A HARD TOP
248
00:13:21,219 --> 00:13:24,053
AND DOESN'T REDUCE
THE CAR'S HANDLING DYNAMICS.
249
00:13:26,015 --> 00:13:27,949
ONCE IT'S FIT INTO POSITION,
250
00:13:27,951 --> 00:13:30,077
THE CRANE RELEASES
THE COMPONENT.
251
00:13:32,347 --> 00:13:35,907
WHILE A WORKER FASTENS THE BOLTS
OF THE CONVERTIBLE ROOF COVER,
252
00:13:35,909 --> 00:13:39,169
ANOTHER ATTACHES
THE CAR'S L.E.D. TAILLIGHTS,
253
00:13:39,171 --> 00:13:41,038
WHICH NOT ONLY ADD FLARE,
254
00:13:41,040 --> 00:13:44,100
BUT ARE EXTREMELY
VIBRATION-RESISTANT.
255
00:13:44,102 --> 00:13:47,027
L.E.D.s HAVE
A VERY LONG SERVICE LIFE
256
00:13:47,029 --> 00:13:51,190
AND ILLUMINATE 250 MILLISECONDS
FASTER THAN CONVENTIONAL
257
00:13:51,192 --> 00:13:53,192
INCANDESCENT-BULB-TYPE
ASSEMBLIES,
258
00:13:53,194 --> 00:13:55,586
INCREASING SAFETY.
259
00:13:55,588 --> 00:13:58,581
WORKERS ALSO INSTALL
THE BATTERY, DASHBOARD,
260
00:13:58,583 --> 00:14:00,917
AND FRONT AND REAR BUMPERS.
261
00:14:00,919 --> 00:14:03,712
THE REAR BUMPER LOOKS SHARP,
262
00:14:03,714 --> 00:14:06,740
BUT ALSO CONCEALS
ULTRASONIC SENSORS
263
00:14:06,742 --> 00:14:10,010
THAT ASSIST THE VISUAL
AND ACOUSTIC PARKING SYSTEM.
264
00:14:11,472 --> 00:14:14,866
FINALLY, WORKERS INSTALL
THE ENGINE COVER,
265
00:14:14,868 --> 00:14:17,801
WHICH IS SET BETWEEN THE FULLY
AUTOMATIC HOOD ROOF COVER
266
00:14:17,803 --> 00:14:19,996
AND THE RETRACTABLE
REAR SPOILER.
267
00:14:19,998 --> 00:14:21,330
USING A TORQUE WRENCH,
268
00:14:21,332 --> 00:14:24,358
A WORKER ATTACHES THE COVER
TO THE HINGES
269
00:14:24,360 --> 00:14:27,354
BEFORE ATTACHING
ITS GAS PRESSURE SPRINGS.
270
00:14:30,692 --> 00:14:33,351
IN ANOTHER WORK AREA,
271
00:14:33,353 --> 00:14:35,813
A ROBOT ADDS
A HIGH-STRENGTH ADHESIVE
272
00:14:35,815 --> 00:14:38,682
TO THE EDGES
OF THE FRONT WINDSCREEN.
273
00:14:38,684 --> 00:14:41,576
WORKERS DELIVER
THE LARGE GLASS PANE,
274
00:14:41,578 --> 00:14:44,105
SUCTIONED TO TWIN-CUP
VACUUM LIFTERS,
275
00:14:44,107 --> 00:14:47,400
AND LAY THE WINDOW
INTO ITS PRE-ALIGNED POSITION.
276
00:14:49,570 --> 00:14:52,497
AFTERWARD, THE BOTTOM
AND BODY SHELL BRACKETS
277
00:14:52,499 --> 00:14:55,267
WILL BE INSTALLED
TO FURTHER CONTAIN THE GLASS.
278
00:15:00,891 --> 00:15:02,924
ANOTHER WORKER INSERTS
THE STEERING WHEEL
279
00:15:02,926 --> 00:15:07,780
AND THE STEERING COLUMN AIRBAG,
INCLUDING ITS ELECTRICAL WIRING.
280
00:15:07,782 --> 00:15:11,317
COVERINGS FOR THE CAR'S INTERIOR
INCLUDE FINE NAPA LEATHER,
281
00:15:11,319 --> 00:15:13,076
COMPOSED OF LAMB OR SHEEPSKIN,
282
00:15:13,078 --> 00:15:18,074
AS WELL AS ALCANTARA,
WHICH RESEMBLES SUEDE.
283
00:15:18,076 --> 00:15:19,608
IN THE CAR'S
CONVERTIBLE VERSION,
284
00:15:19,610 --> 00:15:21,202
A SPECIAL PIGMENTATION
285
00:15:21,204 --> 00:15:23,738
PREVENTS THE SEATS
FROM OVERHEATING IN THE SUN.
286
00:15:25,801 --> 00:15:28,927
A WORKER SITUATES
THE PREMIUM LEATHER BUCKET SEATS
287
00:15:28,929 --> 00:15:30,596
INSIDE THE COCKPIT,
288
00:15:30,598 --> 00:15:32,356
USING A SEAT-INSTALLATION
LIFTER.
289
00:15:32,358 --> 00:15:36,093
THE PNEUMATIC ARM
MAKES IT EASIER FOR WORKERS
290
00:15:36,095 --> 00:15:39,789
TO INSERT ANY ELECTRICAL WIRING
IN AND AROUND THE SEATING.
291
00:15:43,953 --> 00:15:46,011
A WORKER,
USING A LIFTING DEVICE,
292
00:15:46,013 --> 00:15:49,574
DELIVERS A FORGED 19-INCH
ALUMINUM-ALLOY WHEEL AND TIRE
293
00:15:49,576 --> 00:15:52,110
TO THE FRONT PASSENGER SIDE
WHEEL PLATE
294
00:15:52,112 --> 00:15:56,006
AND FASTENS THE LUG BOLTS
WITH AN AIR IMPACT DRIVER.
295
00:15:59,369 --> 00:16:01,362
AT ANOTHER WORKSTATION,
296
00:16:01,364 --> 00:16:04,498
USING SELF-TAPPING SCREWS
AND AN IMPACT DRIVER,
297
00:16:04,500 --> 00:16:06,392
A WORKER INSTALLS AND FASTENS
298
00:16:06,394 --> 00:16:10,021
SIX ALUMINUM UNDERLINING
BODY PANELS UNDERNEATH THE CAR.
299
00:16:11,324 --> 00:16:14,384
THESE PANELS APPLY
ADDITIONAL BODYWORK RIGIDITY
300
00:16:14,386 --> 00:16:17,279
AND GENERATE MORE DOWNFORCE
AT HIGH SPEEDS,
301
00:16:17,281 --> 00:16:19,914
AS WELL AS SOME PROTECTION
TO RUNNING-GEAR PARTS
302
00:16:19,916 --> 00:16:22,609
FROM ENVIRONMENTAL EFFECTS.
303
00:16:24,813 --> 00:16:28,540
ONLY 20 R8 CARS ARE MADE DAILY,
304
00:16:28,542 --> 00:16:30,467
AND WHEN THEY REACH
THE END OF THE LINE,
305
00:16:30,469 --> 00:16:33,996
IT'S TIME
FOR SOME EXCITING TEST DRIVES.
306
00:16:42,956 --> 00:16:45,382
Narrator: THE R8's V-10 ENGINE
IS EXCELLENT.
307
00:16:45,384 --> 00:16:48,677
WITH SUPREME POWER, TORQUE,
AND FUEL EFFICIENCY,
308
00:16:48,679 --> 00:16:51,713
IT'S A ROAD CAR
THAT TRULY GOES THE DISTANCE,
309
00:16:51,715 --> 00:16:53,407
THANKS TO THE DIRECT
FUEL-INJECTION SYSTEM,
310
00:16:53,409 --> 00:16:57,136
ORIGINALLY DEVELOPED FOR
THE 24 HOURS OF LE MANS RACES.
311
00:16:58,473 --> 00:17:00,539
NAMED AFTER THE AUDI QUATTRO,
312
00:17:00,541 --> 00:17:03,001
THIS FACTORY
WAS PRIMARILY FOUNDED
313
00:17:03,003 --> 00:17:05,995
TO PRODUCE
HIGH-PERFORMANCE SPORTS CARS.
314
00:17:05,997 --> 00:17:08,198
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
315
00:17:08,200 --> 00:17:10,425
A STATION KNOWN AS
THE FINISH LINE,
316
00:17:10,427 --> 00:17:13,553
WORKERS INSPECT
FINAL CONSTRUCTION DETAILS.
317
00:17:13,555 --> 00:17:15,288
THEY EXAMINE
ALL ELECTRICAL SYSTEMS,
318
00:17:15,290 --> 00:17:19,685
ALL LIGHTS,
AND THE POWER STEERING.
319
00:17:19,687 --> 00:17:22,613
WORKERS ALSO ADD
FUNCTIONING FLUIDS
320
00:17:22,615 --> 00:17:25,574
LIKE COOLANT, OIL,
TRANSMISSION FLUID,
321
00:17:25,576 --> 00:17:28,511
AND BRAKE FLUID BEFORE
THE CAR IS SENT TO ENDURE
322
00:17:28,513 --> 00:17:30,705
SOME METICULOUS DRIVING TESTS.
323
00:17:37,505 --> 00:17:41,099
THE CAR NOW STANDS
IN A DYNAMOMETER ROLL BOOTH,
324
00:17:41,101 --> 00:17:42,859
WHICH USES
MULTIPLE DRIVE ROLLERS
325
00:17:42,861 --> 00:17:44,194
FOR ROUGHLY 10 MINUTES.
326
00:17:44,196 --> 00:17:46,188
THE CAR IS OFTEN DRIVEN
327
00:17:46,190 --> 00:17:48,723
AT SPEEDS
OF UP TO 100 MILES PER HOUR
328
00:17:48,725 --> 00:17:51,118
THROUGHOUT THIS EVALUATION.
329
00:17:51,120 --> 00:17:52,519
VEHICLES ARE DRIVEN
330
00:17:52,521 --> 00:17:55,982
WHILE A COMPUTERIZED PROGRAM
CONDUCTS A SERIES OF OPERATIONS,
331
00:17:55,984 --> 00:17:59,043
SIMULATING
REALISTIC DRIVING CONDITIONS.
332
00:17:59,045 --> 00:18:03,006
THEY EXAMINE TRANSMISSION,
SUSPENSION, BRAKING,
333
00:18:03,008 --> 00:18:04,140
AND, NOT TO MENTION,
334
00:18:04,142 --> 00:18:06,076
THE ENGINE'S HORSEPOWER
AND TORQUE.
335
00:18:08,138 --> 00:18:10,664
THE TESTING ALSO INCLUDES
LOAD SIMULATIONS,
336
00:18:10,666 --> 00:18:13,801
SUCH AS UPHILL DRIVING
AND TRAILER TOWING.
337
00:18:15,062 --> 00:18:17,129
BUT THE TESTING
DOES NOT END HERE.
338
00:18:17,131 --> 00:18:19,490
IT'S TIME TO GET OUTSIDE.
339
00:18:22,821 --> 00:18:26,288
TO PUT THE CAR'S FUNCTIONALITY
AND VALIDATION TO THE TEST,
340
00:18:26,290 --> 00:18:29,684
QUALIFIED TESTERS DRIVE THE CAR
ON CLOSED-OFF TRACKS
341
00:18:29,686 --> 00:18:33,546
AS PART OF A PRE-DELIVERY
DURABILITY TEST.
342
00:18:33,548 --> 00:18:36,508
THIS SPECIAL-SURFACE TRACK
IS A LOW-SPEED COURSE
343
00:18:36,510 --> 00:18:39,636
WITH A VARIETY
OF DEMANDING ROAD CONDITIONS.
344
00:18:39,638 --> 00:18:42,572
TESTERS CHECK THE TRANSMISSION,
STEERING,
345
00:18:42,574 --> 00:18:44,166
SUSPENSION, AND BRAKES,
346
00:18:44,168 --> 00:18:47,036
PLUS THE OVERALL RIDE
AND HANDLING OF THE DRIVE.
347
00:18:47,038 --> 00:18:49,563
THE PERFORMANCE DEVELOPMENT
TEST TRACK
348
00:18:49,565 --> 00:18:52,191
EVALUATES
NEW AND PROTOTYPE VEHICLES
349
00:18:52,193 --> 00:18:54,193
IN A HIGH-SPEED BOWL
350
00:18:54,195 --> 00:18:56,387
WITH LANE-CHANGE AREAS,
STRAIGHTAWAYS,
351
00:18:56,389 --> 00:18:58,122
AND BANKED CORNERS.
352
00:18:58,124 --> 00:19:01,451
THE CAR'S TOP SPEED
AND PERFORMANCE IN WARM WEATHER
353
00:19:01,453 --> 00:19:04,045
IS ALSO EVALUATED.
354
00:19:04,047 --> 00:19:06,514
QUALITY IS ALSO
SOMETHING YOU CAN HEAR.
355
00:19:06,516 --> 00:19:09,543
EVERY CAR IS DRIVEN
AT A HIGH STRESS LEVEL,
356
00:19:09,545 --> 00:19:13,138
AND SOUND TESTS ARE APPLIED
TO CHECK FOR INTERIOR NOISE,
357
00:19:13,140 --> 00:19:17,802
NOISE VIBRATION, WIND NOISE,
AND RUNNING-GEAR NOISE.
358
00:19:17,804 --> 00:19:20,463
BEYOND THE FACTORY TEST TRACKS,
359
00:19:20,465 --> 00:19:23,866
THE MANUFACTURER HAS A SET OF
HILL ROUTES AND CITY COURSES
360
00:19:23,868 --> 00:19:25,293
THAT PROGRESSIVELY CHALLENGE
361
00:19:25,295 --> 00:19:28,321
THE VEHICLE'S PERFORMANCE
AND DURABILITY.
362
00:19:31,693 --> 00:19:34,486
FOLLOWING THE STRICT
AND EXTENSIVE TESTING,
363
00:19:34,488 --> 00:19:37,681
THE CAR IS TREATED TO MORE
MANUAL QUALITY ASSURANCE
364
00:19:37,683 --> 00:19:39,616
AND PRECISION CARE.
365
00:19:39,618 --> 00:19:41,977
AFTER A HIGH-PRESSURE WASH,
366
00:19:41,979 --> 00:19:45,973
A WORKER GIVES THE LUXURIOUS
SPORTS CAR SOME FINAL ATTENTION
367
00:19:45,975 --> 00:19:48,041
BY VERIFYING THE BODY PAINT
368
00:19:48,043 --> 00:19:49,435
AND BUFFING THE SKIN PANELS
369
00:19:49,437 --> 00:19:52,037
WITH A NON-ABRASIVE,
LEATHER CLOTH.
370
00:19:52,039 --> 00:19:56,234
THIS CAREFULLY REMOVES ANY DIRT,
DUST, OR LIQUID.
371
00:19:58,463 --> 00:20:00,597
WHETHER IN COUPE
OR CONVERTIBLE FORM,
372
00:20:00,599 --> 00:20:03,592
THIS CAR
IS AN AUTOMOTIVE MASTERPIECE,
373
00:20:03,594 --> 00:20:07,654
DESIGNED AND ENGINEERED TO MAKE
A STATEMENT ON EVERY ROAD.
374
00:20:16,549 --> 00:20:19,875
WORKERS APPLY A PROTECTIVE,
WHITE, NEW-CAR WRAPPING
375
00:20:19,877 --> 00:20:21,144
OVER THE VEHICLE.
376
00:20:21,146 --> 00:20:24,071
AN OUTER FILM LAYER
PROTECTS THE CAR FROM WATER
377
00:20:24,073 --> 00:20:25,607
WHILE AN INNER, FLEECE LAYER
378
00:20:25,609 --> 00:20:29,695
PROTECTS THE PAINTWORK
FROM ANY SCRATCHES.
379
00:20:29,697 --> 00:20:32,998
EVEN WITH THE PROTECTIVE WRAP
OVERTOP,
380
00:20:33,000 --> 00:20:35,159
A WORKER CAN STILL
DRIVE THE VEHICLE
381
00:20:35,161 --> 00:20:37,920
WHERE IT NEEDS TO GO NEXT.
382
00:20:39,557 --> 00:20:42,024
BUILT TO LOOK ELEGANT
YET ROBUST,
383
00:20:42,026 --> 00:20:46,412
THE R8 HAS A UNIQUE
SUPERCAR POISE.
384
00:20:46,414 --> 00:20:49,682
WITH A DESIGN INFLUENCE
THAT COMES FROM CAR RACING,
385
00:20:49,684 --> 00:20:52,776
STYLE AND FUNCTIONALITY
ARE NEVER IN QUESTION,
386
00:20:52,778 --> 00:20:55,638
LIKE TRANSFORMING
A CONVERTIBLE TO A COUPE
387
00:20:55,640 --> 00:20:58,108
AT SPEEDS
OF UP TO 30 MILES PER HOUR
388
00:20:58,110 --> 00:21:00,702
IN AS LITTLE AS 25 SECONDS.
389
00:21:07,461 --> 00:21:11,388
IGNITED BY ONGOING,
SPORTS-MINDED PASSION
390
00:21:11,390 --> 00:21:13,724
AND CONSTRUCTED
FOR DISTINCTIVE PERFORMANCE,
391
00:21:13,726 --> 00:21:16,786
THE AUDI R8
IS THE PERFECT SUPERCAR
392
00:21:16,788 --> 00:21:19,113
FOR ANY LONG-DISTANCE CRUISE,
393
00:21:19,115 --> 00:21:21,715
BUT TO TRULY ENJOY
HOW IT'S MADE,
394
00:21:21,717 --> 00:21:23,476
ONE HAS TO LISTEN
TO HOW IT SOUNDS
395
00:21:23,478 --> 00:21:25,478
AND FEEL HOW IT HANDLES
396
00:21:25,480 --> 00:21:29,608
BOTH IN EVERYDAY TRAFFIC
AND ON THE RACETRACK.
31501
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