Original subtitles

Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS,"

THE LOTUS EVORA, A PERFORMANCE SPORTS CAR

INSPIRED BY TRACK RACING BUT FIT FOR THE ROAD.

-- Captions by VITAC -- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

ENGINEERS DESIGN LOTUS CARS AT THEIR HEADQUARTERS

IN HETHEL, U.K.

MODERN LOTUS CARS ARE THE RESULT

OF OVER 60 YEARS OF INNOVATIVE AUTOMOTIVE ENGINEERING.

LOTUS FOUNDER COLIN CHAPMAN MADE HIS MARK IN THE RACING INDUSTRY

IN THE 1960s.

HE SOLIDIFIED HIS REPUTATION AS A LEADING RACECAR BUILDER

WHEN HIS VEHICLES WON

SEVERAL DOUBLE F1 CONSTRUCTORS' AND DRIVERS' CHAMPIONSHIPS.

ONE EXAMPLE IS MARIO ANDRETTI'S 1978 VICTORY

WITH A LOTUS TYPE 79.

CHAPMAN INTRODUCED THE FIRST F1 CAR

WITH A CARBON FIBER MONOCOQUE IN 1981.

THAT VEHICLE ILLUSTRATED HIS DESIGN PHILOSOPHY --

TO ADD SPEED, ADD LIGHTNESS.

THE LOTUS EVORA, LOTUS ELISE, AND LOTUS EXIGE

WERE ALL DESIGNED FOLLOWING CHAPMAN'S MOTTO.

AT THE LOTUS DRIVING ACADEMY,

CAR ENTHUSIASTS CAN EXPERIENCE THE HANDLING,

DYNAMIC PERFORMANCE,

AND TRACK ABILITY OF THESE SUPERCARS.

STYLISTS AND DESIGNERS STUDY EXISTING LOTUS CARS.

THEY DISCUSS THE AESTHETIC, TECHNOLOGICAL,

AND AERODYNAMIC FEATURES OF EACH MODEL.

THEY ALSO CONSIDER IMPROVEMENTS

THAT COULD BE MADE TO THE NEXT GENERATION OF MODELS.

THE TEAM ALWAYS KEEPS IN MIND CHAPMAN'S PHILOSOPHY

OF ENHANCING PERFORMANCE BY MAKING THE CARS LIGHTER,

RATHER THAN SIMPLY MAKING THEM MORE POWERFUL.

IN THE STYLING STUDIO,

AN ARTIST SKETCHES A MODEL IN A 3-D CAD SYSTEM.

LAYER BY LAYER, HE ADDS DETAIL TO THE VIRTUAL SKETCH.

A CLAY-MODELING ROBOT GIVES SHAPE TO THE DESIGN.

THE CNC-CONTROLLED END MILL TOOL CARVES THE CLAY,

FOLLOWING PRECISE INSTRUCTIONS FROM THE DESIGN SYSTEM.

A THICK CLAY LAYER COVERING A MODELING JIG

ALLOWS THE CNC MACHINE TO MAKE A COARSE MODEL.

ONCE THE ROBOT IS DONE, A WORKER FINISHES THE MODELING.

THE MODELER BRUSHES OFF THE CLAY FLAKES

AND HAND-FINISHES THE MODEL.

HE USES PRECISION SCULPTING TOOLS

TO EVEN OUT THE CLAY AS MUCH AS POSSIBLE.

THE GOAL IS TO IMITATE THE SMOOTHNESS

OF A POLISHED CAR BODY.

THE CLAY MODEL HELPS DESIGNERS VISUALIZE THE FULL-SIZED CAR.

IT REPRODUCES EVERY DETAIL OF THE VIRTUAL DESIGN

AND WILL BE USED FOR AERODYNAMIC TESTING.

THE LOTUS LIGHTWEIGHT STRUCTURES ANODIZING PLANT

IS LOCATED IN WELLINGBOROUGH, U.K.

THIS IS WHERE WORKERS PREPARE THE CAR'S ALUMINUM

FOR ANODIZING.

AN ELECTROLYTIC PROCESS

FORMS AN OXIDE LAYER ON THE ALUMINUM SURFACE.

WORKERS BEGIN BY PLACING MACHINED METAL SHEETS

ONTO ELECTRICALLY CHARGED RACKS CALLED FLIGHT BARS.

THE FLIGHT BARS RUN ELECTRIC CURRENT THROUGH THE ALUMINUM

DURING THE ANODIZING PROCESS.

BUT BEFORE THIS HAPPENS,

THE PANELS NEED TO GO THROUGH A DEGREASING

AND DESCALANT BATH.

NOW THAT THE ALUMINUM SHEETS ARE CLEAN, THE FLIGHT BAR

DIPS THE PANELS INTO A SODIUM-HYDROXIDE SOLUTION.

THE SOLUTION DISSOLVES A THIN LAYER OF THE ALUMINUM,

OPENING UP NANOPORES IN THE METAL SHEETS.

IN THE NEXT TANK,

SULFURIC ACID IS COMBINED WITH AN ELECTRIC CURRENT,

TRIGGERING A CHEMICAL REACTION

THAT LEAVES A COAT OF ALUMINUM OXIDE

ON THE SURFACE OF THE METAL.

THIS CORROSION-RESISTANT LAYER BONDS TO THE ALUMINUM ITSELF,

PROVIDING PROTECTION THAT WILL NEVER CHIP

OR PEEL OFF.

NEXT, THE FLIGHT BAR

LOWERS THE ANODIZED ALUMINUM INTO A RINSING TANK.

PLASTIC BALLS FLOATING ON THE SURFACE OF THE TANK

PREVENT THE LIQUID FROM EVAPORATING.

NOW, THE RINSED ALUMINUM SHEETS ARE LOWERED OVER AN AIR JET.

THEY'RE BLOW-DRIED

BEFORE HEADING OFF TO THE ASSEMBLY DEPARTMENT.

AT THE LOTUS LIGHTWEIGHT STRUCTURES FACILITY

IN WORCESTER, U.K.,

AN ADHESIVE ROBOT PREPARES THE PARTS FOR BONDING.

THE ROBOT APPLIES EPOXY ADHESIVE

ON EACH BONDING POINT AND FLANGE.

THIS PROCESS MAKES THE CHASSIS VERY STRONG AND STIFF.

BONDING WITH ADHESIVE ALSO MAINTAINS DIMENSIONAL ACCURACY

AND INTEGRITY, WHICH CANNOT BE ACHIEVED BY WELDING.

A WORKER TAKES THE PARTS

TO THE ASSEMBLY DEPARTMENT ON A LOW BUILD TROLLEY.

THE CHASSIS BUILD

BEGINS BY ADDING MACHINED ALUMINUM EXTRUSIONS

TO THE ASSEMBLY FIXTURE.

THEY ASSEMBLE THE TRIANGULAR MAIN CHASSIS FRAME.

IT'S DESIGNED TO BEAR MOST OF THE VEHICLE'S HANDLING FORCES.

THE WORKERS THEN USE BENDING BEAM EXTRUSIONS

TO FORM THE SIDE RAILS OF THE CAR.

THEY MUST BE PERFECTLY ALIGNED WITH THE CHASSIS.

MOUNTING BRACKETS ARE INSTALLED FOR THE TANK PANEL

AND REAR TORSION BOX.

ONCE THE CHASSIS IS FITTED WITH THE FRONT TORSION BOX

AND SIDE MEMBER REINFORCEMENTS ON BOTH RAILS,

IT'S READY FOR ASSEMBLY.

Narrator: THE MAIN CHASSIS ASSEMBLY LINE IN HETHEL, U.K.,

IS WHERE SKILLED WORKERS ASSEMBLE

THE MAIN COMPONENTS OF THE LOTUS EVORA

TO ITS BONDED ALUMINUM FRAME.

A TECHNICIAN STARTS BY POSITIONING THE CHASSIS

ON A ROLLOVER BUILD TROLLEY.

THIS TOOL ALLOWS HIM TO FIT PARTS

UNDER THE CHASSIS WITH EASE.

NEXT, HE ROUTES THE MAIN ELECTRICAL HARNESS

ALONG THE FRAME,

WORKING THE CABLES THROUGH HOLES IN THE ALUMINUM EXTRUSIONS.

THE HARNESS CONTAINS CABLES

FOR THE ELECTRICAL COMPONENTS OF THE CAR,

INCLUDING THE DOOR LOCKS, WINDOW CONTROLS,

HEADLIGHT CONTROLS, FUEL SENDER,

INSTRUMENTS, AND NAVIGATION.

THE TECHNICIAN TILTS THE ROLLOVER BUILD TROLLEY

TO THE SIDE AND MOVES ON TO THE NEXT ASSEMBLY STEP.

THERE ARE EIGHT ASSEMBLY STAGES.

EACH STEP TAKES JUST UNDER AN HOUR.

THE CHASSIS ASSEMBLY STEPS

ARE GENERALLY THE SAME FOR MOST LOTUS MODELS.

BUT THE EVORA HAS A LARGER CHASSIS

WITH DIFFERENT PART SPECIFICATIONS,

SUCH AS THIS FULLY ADJUSTABLE STEERING COLUMN.

BEFORE ASSEMBLING THE STEERING COLUMN,

THE TECHNICIAN MUST USE AN ELECTRONIC CENTRALIZING JIB

TO CENTER THE STEERING RACK.

IT IS CRITICAL THAT THE STEERING RACK

IS CORRECTLY POSITIONED PRIOR TO SETTING THE STEERING GEOMETRY.

AN OPERATOR PREPARES THE FUEL-TANK ASSEMBLY

AT THE NEXT STATION.

HE TIGHTENS BOLTS ON THE FUEL SENDING UNIT

WITH A MANUAL TORQUE WRENCH.

THEN, HE PERFORMS A TEST

TO ENSURE THAT THE FUEL PUMP IS FUNCTIONING CORRECTLY.

HE INSERTS THE FUEL TANK IN THE CHASSIS AND POSITIONS

MOUNTING BRACKETS.

HE USES AN AUTOMATIC TORQUE GUN TO SECURE THE BRACKETS IN PLACE.

HE INSTALLS THE TANK BAY SHEER PANEL UNDER THE FUEL TANK.

IT PLAYS A KEY STRUCTURAL ROLE

AND COMPLETES THE REAR TORSION BOX.

THE PANEL IS SECURED IN PLACE

BY FIRST LIGHTLY TIGHTENING THE BOLTS,

THEN FINISHING THE JOB WITH THE TORQUE GUN.

EACH ASSEMBLY STEP OF THE MAIN CHASSIS IS TIMED TO THE MINUTE.

THIS ALLOWS THE WORKERS TO MOVE EACH TROLLEY UP THE LINE

IN ALMOST PERFECT SYNCHRONIZATION.

BEFORE MOUNTING THE SUSPENSION ON THE MAIN CHASSIS, THEY FIRST

APPLY POLYURETHANE ADHESIVE TO THE SEAT-BELT ANCHORAGE FRAME.

THE SEAT-BELT ANCHORAGE INCLUDES ROLLOVER PROTECTION

TO PREVENT THE ROOF FROM COLLAPSING

IF THE CAR FLIPS OVER IN AN ACCIDENT.

THE WORKER BOLTS THE SEAT-BELT ANCHORAGE TO THE MAIN CHASSIS

USING AN AUTOMATIC CALIBRATED TORQUE GUN.

ANOTHER WORKER INSTALLS THE FRONT ANTI-ROLL BAR.

THIS IMPORTANT PART OF THE SUSPENSION ASSEMBLY

GIVES THE CAR ADDITIONAL WHEEL-SPRING RATE

AND LIMITS THE VEHICLE'S BODY ROLL.

WORKERS ASSEMBLE THE GALVANIZED STEEL REAR SUBFRAME

TO THE MAIN CHASSIS.

THE ENGINE AND EXHAUST ASSEMBLY

WILL BE INSTALLED TO THE REAR SUBFRAME NEXT.

Narrator: AT THE LOTUS ASSEMBLY PLANT,

TECHNICIANS CUSTOMIZE THE DOUBLE OVERHEAD CAMSHAFT ENGINE

AND GEARBOX BEFORE ATTACHING THEM TO THE REAR SUBFRAME

OF THE CARS.

A TECHNICIAN INSERTS THE DIFFERENTIAL

INSIDE THE SIX-SPEED GEARBOX OF THE EVORA.

HE TAKES THE INPUT SHAFT

AND MOUNTS CLOSE-RATIO HELICAL GEARS ONTO IT.

HE INSTALLS BOTH THE INPUT AND OUTPUT SHAFTS IN THE GEARBOX.

THE OUTPUT SHAFT CONNECTS TO THE DIFFERENTIAL.

THIS TRANSFERS POWER TO THE WHEELS.

THE TECHNICIAN THEN INSERTS A SECOND OUTPUT SHAFT.

HE INSTALLS THE REVERSE IDLER SHAFT INSIDE THE GEARBOX,

CONNECTING IT TO THE INPUT

SHAFT.

THE CUSTOMIZATION OF THE GEARBOX

IS A VERY SENSITIVE, HIGH-PRECISION TASK.

THE TECHNICIAN NOW INSTALLS SHIFT FORKS

OVER THE SELECTOR COLLAR ON THE SHAFTS.

THESE FORKS ALLOW FOR SHIFTING

BETWEEN THE SIX FORWARD GEARS AND REVERSE.

THE TECHNICIAN INSERTS SLIDER SHAFTS INTO THE FORKS.

THIS ENABLES THE FORKS TO MOVE UP OR DOWN

WHEN THE DRIVER SHIFTS GEARS.

ONCE THE GEARBOX ASSEMBLY IS COMPLETE,

THE TECHNICIAN APPLIES A STRIP OF NONHARDENING ADHESIVE SEALANT

AROUND THE GEARBOX CASING.

THEN, HE PUTS THE GEARBOX COVER IN PLACE.

NEXT, A TECHNICIAN

ASSEMBLES A SUPERCHARGER TO THE V-6 ENGINE AND BOLTS

IT IN PLACE WITH A PNEUMATIC TORQUE WRENCH.

ANOTHER WORKER JOINS THE GEARBOX TO THE ENGINE

AND INSERTS FIXING BOLTS.

THEN, A TECHNICIAN LOWERS THE ENGINE AND GEARBOX ASSEMBLY

ONTO THE SUBFRAME.

HE ASSEMBLES THE GEARBOX MOUNT TO THE SUBFRAME

USING A MANUAL TORQUE WRENCH.

WITH THE HELP OF AN OVERHEAD LIFTING DEVICE,

HE ALIGNS THE GEARBOX WITH THE MOUNT

AND SECURES IT IN PLACE.

THIS FINALIZES THE ENGINE ASSEMBLY.

WORKERS CONNECT THE EXHAUST SYSTEM TO THE ENGINE.

IT'S MADE OF AVIATION-GRADE STAINLESS STEEL

AND MAKES A DISTINCTIVE RACECAR-LIKE GROWL.

A WORKER HOLDS THE ENGINE AS THE OTHER BOLTS ON THE EXHAUST.

THE EXHAUST FOR THE EVORA COMES WITH A SIGNATURE OVAL TIP.

NEXT, TECHNICIANS USE AN OVERHEAD HOIST

TO POSITION THE ENGINE MODULE AND SUBFRAME ASSEMBLY

ONTO THE MAIN CHASSIS.

THEY BOLT THE REAR SUBFRAME IN PLACE

WITH A PNEUMATIC TORQUE GUN.

ONCE THE ENGINE IS FIRMLY SECURED,

THE OPERATORS RELEASE THE HOIST

TO PREPARE THE TROLLEY FOR THE NEXT STATION.

JOINING THE ENGINE TO THE CHASSIS

IS SLIGHTLY DIFFERENT FOR THE LOTUS ELISE.

OPERATORS INSTALL THE FOUR-CYLINDER ENGINE

DIRECTLY INTO THE REAR SUBFRAME.

IT'S ALREADY ATTACHED TO THE MAIN CHASSIS.

THEY PLUG THE ENGINE HARNESS INTO THE MAIN HARNESS

AND MAKE THE AUXILIARY CONNECTIONS

TO FINISH THE PROCESS.

NEXT COMES THE SUSPENSION ARMS ASSEMBLY.

THE INDEPENDENT-FORGED ALUMINUM DOUBLE WISHBONE SUSPENSION

IS FITTED WITH SERVO-ASSISTED VENTILATED BRAKE DISCS,

PROVIDING MAXIMUM CONTROL

OVER THE WHEEL'S CAMBER ANGLE AND SCRUB RADIUS.

IT TAKES ABOUT A DAY'S WORK

TO GET THE CHASSIS FRAME FULLY ASSEMBLED

AND READY TO SEND OFF TO THE BODY ASSEMBLY LINE.

THE BODY PANELS NEED TO BE PAINTED

BEFORE THEY CAN BE ASSEMBLED.

PAINTERS SPRAY THE PANELS

WITH AN ECOLOGICAL WATER-BASED PRIMER.

WORKERS PAINT THEM IN SETS TO ENSURE COLOR CONSISTENCY.

IT'S IMPOSSIBLE TO USE ELECTROSTATIC PAINT

FOR THE BODY PANELS

BECAUSE THE HIGH-TECH COMPOSITE MATERIAL IS NOT CONDUCTIVE.

PAINTERS NEED TO APPLY A WATER-BASED LACQUER

TO PROTECT THE PAINT COATING.

Narrator: AT THE LOTUS HEADQUARTERS,

WORKERS GET THE CARS READY TO HIT THE ROAD.

TECHNICIANS PUSH THIS ASSEMBLED EVORA

TO THE FLUID FILL DEPARTMENT FOR AN INITIAL FUEL FILLING

BEFORE THE ENGINE GETS STARTED FOR THE FIRST TIME.

AT ANOTHER STATION, WORKERS TRANSFER THE CHASSIS OF AN EVORA

FROM A HIGH BUILD TROLLEY TO A LOW BUILD TROLLEY.

THEY GET READY TO BOND THE PAINTED BODY PANELS

TO THE EXTRUDED-ALUMINUM CHASSIS.

A TECHNICIAN APPLIES A POLYURETHANE ADHESIVE

ON THE UPPER RAIL BEFORE THE CORE-BODY ASSEMBLY MACHINE

ATTACHES THE SIDE PANEL TO THE CHASSIS.

THE TECHNICIAN PREPARES THE FRONT CRASH STRUCTURE

FOR BONDING.

THIS PART COVERS THE FRONT CHASSIS SUBFRAME

AND IS DESIGNED TO ABSORB THE IMPACT OF AN ACCIDENT.

TECHNICIANS CLAMP IT TIGHT UNTIL THE ADHESIVE CURES.

THEN, THEY BRING IN THE COMPOSITE WINDSCREEN APERTURE.

LOCATOR ARMS ARE USED TO POSITION IT CORRECTLY.

NEXT, THEY FIT THE DOOR TO THE BODY SIDE PANEL.

A TECHNICIAN USES MEASURE GAUGES TO MAKE SURE THE FIT IS PERFECT.

TECHNICIANS ASSEMBLE THE DOOR-CLOSING MECHANISM

CALLED THE DOOR STRIKER.

THEY SCREW IN A STEEL BOLT OVER A WASHER

TO PREVENT DAMAGING THE COMPOSITE.

THE STRIKER IS SET TO ALLOW FOR A NICE AND SMOOTH DOOR CLOSURE.

TECHNICIANS NOW BRING IN THE REAR CLAMSHELL.

IT ONLY WEIGHS ABOUT 40 POUNDS.

THE PANEL FITS OVER THE REAL MODULE

TO COVER BOTH THE ENGINE AND FUEL TANK.

THE TECHNICIAN

SETS THE REAR CLAMSHELL FLUSH TO THE BODY SIDE PANELS.

THEN, THEY INSTALL THE FRONT CLAMSHELL.

THE PANEL FITS OVER THE CRASH STRUCTURE

AND HAS OPENINGS FOR THE RADIATOR VENTS,

HEADLIGHTS, AND FLASHERS.

WITH THE CAR SITTING ON A TWO-POST RAMP LIFT,

A TECHNICIAN INSTALLS THE REAR DIFFUSER.

THE DIFFUSER IS DESIGNED FOR OPTIMAL AERODYNAMICS,

REDUCING BOTH DRAG AND LIFT.

IT PREVENTS AIR TURBULENCE FROM REDUCING THE CAR'S PERFORMANCE.

NOW, A TECHNICIAN MOUNTS THE WHEELS

ON CROSS-DRILLED BRAKE DISCS.

HE ROUGHLY TIGHTENS THE NUTS THROUGH THE 12-SPOKE RIM

BEFORE LOWERING THE VEHICLE ON ITS WHEELS

FOR THE VERY FIRST TIME.

THE TECHNICIAN FINISHES TORQUEING THE WHEEL NUTS

WITH A MANUAL WRENCH.

HE MARKS EACH ONE THAT'S BEEN TIGHTENED TO THE CORRECT TORQUE.

NEXT, THE FINISHED CAR GOES TO THE CHASSIS DYNAMOMETER

OR ROLLING ROAD.

THIS IS WHERE THE VEHICLE

GOES THROUGH A COMPLETE FUNCTIONAL TESTING PROCESS.

DRIVE ROLLERS ACTIVATE THE FRONT WHEELS

TO CALIBRATE THE DYNAMOMETER.

A COMPUTER PROMPTS THE DRIVER

WITH INSTRUCTIONS THROUGHOUT THE TESTING CYCLE.

INTEGRATED CALIBRATION TOOLS

MONITOR AND ANALYZE THE CAR'S RESPONSE.

THE DRIVER MOVES THE REAR WHEELS ONTO THE ROLLERS

TO TEST VARIOUS DRIVETRAIN COMPONENTS LIKE THE REAR BRAKES.

THE COMPUTER PROCESSES THE DATA

AND USES IT FOR ENGINE CALIBRATION.

THE DYNAMOMETER MEASURES THE ENGINE RPM,

HORSEPOWER, AND TORQUE OUTPUT AT VARIOUS SPEEDS

AND ALSO MONITORS THE ENGINE'S RESPONSE

TO ACCELERATION AND GEAR SHIFTING.

THIS SYSTEM ALLOWS FOR THE DYNAMIC TESTING

OF ALL THE VEHICLE'S FEATURES,

INCLUDING EMISSION SAMPLING AND FUEL-CONSUMPTION ANALYSIS.

THE ENGINE MANAGEMENT SOFTWARE MUST HAVE THIS TEST DATA

BEFORE THE CAR CAN LEAVE THE PRODUCTION LINE.

FINALLY, THE CARS GO TO SURFACE FINISHING.

WORKERS POLISH AND CLEAN THE CAR BODY

USING PNEUMATIC ORBITAL POLISHERS.

LOW-SPEED DRY POLISHING LEAVES A GLOSSY FINISH,

ENHANCING THE SMOOTHNESS AND SHINE

OF THE LACQUER-PROTECTED COLOR COATING.

THESE SUPERCARS ARE READY TO BE TRIED OUT --

THE EVORA, WITH ITS INTEGRATED AERODYNAMIC REAR BOOT SPOILER;

THE SLICK CONVERTIBLE ELISE SPORTS CAR;

AND THE EXIGE COUPE.

THE INTERIOR OF THE CARS ARE UPHOLSTERED IN LEATHER

AND FEATURE AN ERGONOMICALLY SHAPED STEERING WHEEL

WITH LIGHTWEIGHT RIM.

COMBINING AERODYNAMIC DRAG-REDUCTION ENGINEERING

WITH AESTHETIC DESIGN, LOTUS CARS

ARE AMONG THE BEST-HANDLING SPORTS CARS IN THE WORLD.

THEY CAN TAKE ON A CURVE AT HIGH SPEEDS

WITHOUT LOSING TRACTION.

A LOTUS DRIVING ACADEMY INSTRUCTOR NOW TAKES THE EVORA

FOR A TEST DRIVE.

THE LOTUS EVORA

IS LARGER AND MORE SOPHISTICATED THAN THE ELISE AND EXIGE

BUT HAS THE SAME EASY HANDLING AND SMOOTH RIDE.