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These are the user uploaded subtitles that are being translated: 1 00:00:02,003 --> 00:00:03,669 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 -- 3 00:00:06,032 --> 00:00:08,290 THE SUPERSONIC R8 COUPE. 4 00:00:08,292 --> 00:00:11,227 -- Captions by VITAC -- www.vitac.com 5 00:00:11,229 --> 00:00:14,222 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:24,117 --> 00:00:26,443 AUDI'S QUINTESSENTIAL TWO-SEATER 7 00:00:26,445 --> 00:00:30,572 IS THE ALL-WHEEL DRIVE R8 COUPE, BUILT IN NECKARSULM, GERMANY. 8 00:00:30,574 --> 00:00:33,434 THE ESSENCE OF THE CAR COMPANY KNOWN AS AUDI 9 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. 12 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, 17 00:00:52,855 --> 00:00:55,282 THE FIRST SET OF NEW CARS WITH THE AUDI NAMEPLATE 18 00:00:55,284 --> 00:00:58,677 HIT THE MARKET AND WON PEOPLE'S ATTENTION. 19 00:00:58,679 --> 00:01:01,671 IN THE 1920s, CAR SALES WERE DOWN IN GERMANY, 20 00:01:01,673 --> 00:01:04,275 AND STRONG COMPETITION FROM ABROAD 21 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, 23 00:01:10,766 --> 00:01:14,427 AUDI GREW BY MERGING WITH AUTOMAKERS HORCH, DKW, 24 00:01:14,429 --> 00:01:17,363 AND WANDERER TO FORM THE AUTO UNION. 25 00:01:17,365 --> 00:01:19,224 THIS WOULD BECOME THE SYMBOLIC MEANING 26 00:01:19,226 --> 00:01:21,158 OF THE OVERLAPPING FOUR RINGS, 27 00:01:21,160 --> 00:01:24,554 NOW KNOWN AS THE ICONIC AUDI LOGO. 28 00:01:24,556 --> 00:01:28,850 THE R8 USES A LIGHTWEIGHT, ALL-ALUMINUM CHASSIS AND BODY. 29 00:01:28,852 --> 00:01:31,311 MATCHED WITH A V-10 ENGINE, 30 00:01:31,313 --> 00:01:34,306 IT DASHES FROM 0 TO 62 MILES PER HOUR 31 00:01:34,308 --> 00:01:35,841 IN 3.9 SECONDS. 32 00:01:35,843 --> 00:01:38,703 FROM 2000 TO 2005, 33 00:01:38,705 --> 00:01:41,438 THE RACING R8 TEAM VERSION OF THE R8 34 00:01:41,440 --> 00:01:43,999 WON THE LE MANS 24-HOUR ENDURANCE RACE 35 00:01:44,001 --> 00:01:46,928 FIVE OUT OF SIX TIMES. 36 00:01:50,000 --> 00:01:51,858 THE FOUNDATION OF THIS SUPERCAR 37 00:01:51,860 --> 00:01:54,394 IS BASED ON A SPACE-FRAME CHASSIS 38 00:01:54,396 --> 00:01:56,121 AND MONOCOQUE DESIGN. 39 00:01:56,123 --> 00:01:58,949 INTERLOCKING STRUTS FORM THE CHASSIS PATTERN 40 00:01:58,951 --> 00:02:01,151 WITH FEW INTERIOR SUPPORTS 41 00:02:01,153 --> 00:02:03,613 WHILE THE CHASSIS, ENGINE, AND SUSPENSION 42 00:02:03,615 --> 00:02:06,415 ARE INTEGRATED INTO THE BODY. 43 00:02:06,417 --> 00:02:09,543 WEIGHING ABOUT 460 POUNDS, 44 00:02:09,545 --> 00:02:14,808 THE SPACE FRAME IS COMPRISED OF 22% ALUMINUM PLATING, 45 00:02:14,810 --> 00:02:19,263 70% OF EXTRUDED ALUMINUM PROFILES... 46 00:02:19,265 --> 00:02:23,133 AND 8% OF AN ALUMINUM-BASED VACUUM-PRESSURE CASTING. 47 00:02:26,297 --> 00:02:28,088 BUILT IN THE NEWLY RENOVATED FACTORY 48 00:02:28,090 --> 00:02:30,291 AT THE MANUFACTURER'S ALUMINUM SITE, 49 00:02:30,293 --> 00:02:32,485 WORKERS ASSEMBLE THE SPACE-FRAME CHASSIS, 50 00:02:32,487 --> 00:02:36,113 PLACING THE STRUCTURAL STRUTS INTO HIGH-PRESSURE VICES 51 00:02:36,115 --> 00:02:38,182 CALLED CLAMPING FIXTURES. 52 00:02:38,184 --> 00:02:41,177 THESE JIGS LOCK THE CHASSIS PIECES INTO PLACE 53 00:02:41,179 --> 00:02:43,313 TO BE WELDED TOGETHER. 54 00:02:43,315 --> 00:02:44,706 WORKERS WELD THE FRAME PARTS 55 00:02:44,708 --> 00:02:49,169 WITH TORCHES THAT HEAT UP TO ABOUT 1,600 DEGREES FAHRENHEIT. 56 00:02:49,171 --> 00:02:52,197 ALUMINUM BURNS MORE RAPIDLY THAN STEEL, 57 00:02:52,199 --> 00:02:55,134 FORCING WORKERS TO MOVE QUICKLY, WITH DELICACY. 58 00:02:55,136 --> 00:02:57,260 ONCE THE WORKER FINISHES WELDING, 59 00:02:57,262 --> 00:02:58,529 HE USES A HOIST 60 00:02:58,531 --> 00:03:02,525 TO LIFT THE FRAME SECTION TO ANOTHER WORKSTATION. 61 00:03:02,527 --> 00:03:06,253 THE CAR'S CHASSIS CONSISTS OF THREE MAJOR SECTIONS -- 62 00:03:06,255 --> 00:03:10,550 THE CENTRAL FLOOR, THE REAR END, AND THE FRONT END. 63 00:03:10,552 --> 00:03:11,951 AN OVERHEAD CONVEYOR CRANE 64 00:03:11,953 --> 00:03:15,280 DELIVERS THE CHASSIS SECTIONS TO ANOTHER WORKSTATION, 65 00:03:15,282 --> 00:03:18,675 WHERE THE LARGE UNDERBODY PARTS LOWER FOR MORE WELDING. 66 00:03:20,804 --> 00:03:23,071 THE CHASSIS USES MULTIPLE SECTIONS 67 00:03:23,073 --> 00:03:26,033 AND INTEGRAL ADDITIONS FOR COMPLETION. 68 00:03:26,035 --> 00:03:27,300 WORKERS POSITION 69 00:03:27,302 --> 00:03:29,228 THE FRAME PIECES IN THE CLAMPING FIXTURES, 70 00:03:29,230 --> 00:03:33,091 WHICH LOCK THE CHASSIS PARTS INTO THEIR FINISHED POSITIONS, 71 00:03:33,093 --> 00:03:36,527 CREATING THE ULTRA-LIGHTWEIGHT ALUMINUM UNDERCARRIAGE. 72 00:03:41,985 --> 00:03:43,852 WORKERS METICULOUSLY WELD 73 00:03:43,854 --> 00:03:46,079 EVERY INTERSECTING CORNER OF THE CHASSIS. 74 00:03:47,983 --> 00:03:49,908 ONCE THE WELDED JOINTS COOL, 75 00:03:49,910 --> 00:03:52,377 WORKERS RELEASE THE FINISHED CHASSIS. 76 00:03:52,379 --> 00:03:54,772 AN OVERHEAD TRANSFER BELT LIFTS THE FRAME 77 00:03:54,774 --> 00:03:58,634 TO ANOTHER WORKSTATION FOR MORE CONSTRUCTION. 78 00:04:01,071 --> 00:04:04,465 ONE OF THE VERY FEW ROBOTIC OPERATIONS IN THE BODY SHOP 79 00:04:04,467 --> 00:04:05,533 IS THE INSERTION 80 00:04:05,535 --> 00:04:08,194 OF FLOW-DRILL SCREWS INTO THE CAR'S FLOOR 81 00:04:08,196 --> 00:04:10,021 AND CABIN SUBSTRUCTURE WALLS. 82 00:04:10,023 --> 00:04:11,857 A FASTENING ROBOT 83 00:04:11,859 --> 00:04:15,752 SPINS THE SELF-TAPPING SCREWS AT A HIGH SPEED, 84 00:04:15,754 --> 00:04:17,687 WHERE THEY FLASH MELD INTO THE ALUMINUM, 85 00:04:17,689 --> 00:04:20,348 CREATING AN ELONGATED, THREADED SHANK 86 00:04:20,350 --> 00:04:23,010 ON THE BACKSIDE OF THE ALUMINUM SHEET. 87 00:04:23,012 --> 00:04:25,478 THIS ADDS TO THE PULL STRENGTH. 88 00:04:25,480 --> 00:04:28,541 SELF-TAPPING SCREWS DRILL THEIR OWN HOLES 89 00:04:28,543 --> 00:04:32,103 WHEN THEY SCREW INTO MATERIALS LIKE WOOD, PLASTIC, AND METAL. 90 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. 93 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 96 00:04:52,651 --> 00:04:55,711 TO JOIN THE COMPONENTS OF THIS CAR'S SUBSTRUCTURE. 97 00:04:55,713 --> 00:04:59,707 AS CARS ARE PRODUCED TO MEET CONSUMER CUSTOMIZATION REQUESTS, 98 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, 103 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. 109 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, 117 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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