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These are the user uploaded subtitles that are being translated: 1 00:00:00,587 --> 00:00:03,254 (rousing music) 2 00:00:06,830 --> 00:00:09,182 (engine roaring) 3 00:00:09,182 --> 00:00:12,300 - [Narrator] It is synonymous with sophisticated elegance, 4 00:00:12,300 --> 00:00:14,964 high performance, and secret agents. 5 00:00:14,964 --> 00:00:17,760 (tires screeching) 6 00:00:17,760 --> 00:00:18,810 For over a hundred years, 7 00:00:18,810 --> 00:00:21,663 Aston Martin has made distinguished sports cars, 8 00:00:22,800 --> 00:00:25,860 but now this tiny British brand stands alone. 9 00:00:25,860 --> 00:00:28,020 - We are a David versus a Goliath. 10 00:00:28,020 --> 00:00:30,030 - [Narrator] Battling multinational conglomerates 11 00:00:30,030 --> 00:00:31,560 in an ever changing world. 12 00:00:31,560 --> 00:00:33,510 - Aston Martin has no margin error. 13 00:00:33,510 --> 00:00:36,270 - [Narrator] To survive, they need a new machine. 14 00:00:36,270 --> 00:00:37,170 - We are it. 15 00:00:37,170 --> 00:00:39,870 There is no helper or big brother. 16 00:00:39,870 --> 00:00:43,590 - [Narrator] A small but dedicated team looks to the past, 17 00:00:43,590 --> 00:00:47,160 only to find salvation in an old American hot rodders trick. 18 00:00:47,160 --> 00:00:48,270 - I was absolutely adamant, 19 00:00:48,270 --> 00:00:50,420 we're gonna make this do 200 miles an hour. 20 00:00:53,983 --> 00:00:55,530 - [Narrator] A uniquely English machine 21 00:00:55,530 --> 00:00:58,416 called the V12 Vantage S. 22 00:00:58,416 --> 00:01:00,279 (engine roaring) 23 00:01:00,279 --> 00:01:02,946 (rousing music) 24 00:01:18,755 --> 00:01:22,200 In 2007, Aston Martin stands as one of the top 25 00:01:22,200 --> 00:01:25,569 European sports car manufacturers in the world, 26 00:01:25,569 --> 00:01:28,402 (engines roaring) 27 00:01:30,030 --> 00:01:31,953 winning both on the race track, 28 00:01:33,420 --> 00:01:35,430 and also on the showroom floor. 29 00:01:35,430 --> 00:01:37,170 - We were really into our stride 30 00:01:37,170 --> 00:01:39,600 and producing over 7,000 cars. 31 00:01:39,600 --> 00:01:43,410 And we had established the DB9 as the the new icon, 32 00:01:43,410 --> 00:01:45,030 a super cool GT, 33 00:01:45,030 --> 00:01:46,950 we got the VA Vantage in production, 34 00:01:46,950 --> 00:01:49,533 and we established what we call the new era. 35 00:01:50,730 --> 00:01:51,840 - [Narrator] Almost without warning, 36 00:01:51,840 --> 00:01:54,385 the world economy collapses. 37 00:01:54,385 --> 00:01:57,135 (tranquil music) 38 00:01:57,990 --> 00:02:01,320 Overnight, Aston Martin loses its empire. 39 00:02:01,320 --> 00:02:03,540 - Some challenges in the market for sure, 40 00:02:03,540 --> 00:02:07,140 from 2008 onwards, a global recession. 41 00:02:07,140 --> 00:02:08,310 - [Narrator] It's a global recession 42 00:02:08,310 --> 00:02:11,730 that sends car makers around the world into a tailspin. 43 00:02:11,730 --> 00:02:14,940 For Aston Martin, it's now do or die. 44 00:02:14,940 --> 00:02:17,610 - Aston Martin is one of the very few independent, 45 00:02:17,610 --> 00:02:19,383 really small car makers. 46 00:02:21,390 --> 00:02:23,040 - Most supercar manufacturers 47 00:02:23,040 --> 00:02:25,980 are owned by worldwide conglomerates, 48 00:02:25,980 --> 00:02:28,983 but Aston Martin has no corporate safety net. 49 00:02:31,050 --> 00:02:33,513 The company's next move could be its last. 50 00:02:36,030 --> 00:02:37,530 - No matter what's going on in the company, 51 00:02:37,530 --> 00:02:39,420 in the economy, in whatever, these guys gotta be thinking, 52 00:02:39,420 --> 00:02:41,220 I wanna build a sports car, I wanna build a sports car. 53 00:02:41,220 --> 00:02:42,170 And well, they did. 54 00:02:43,860 --> 00:02:46,950 - [Narrator] Now, for the first time in over 20 years, 55 00:02:46,950 --> 00:02:51,120 it's success or failure rests solely in British hands. 56 00:02:51,120 --> 00:02:53,453 - They have to fight for their own little niche. 57 00:02:54,330 --> 00:02:55,980 They don't have economies of scale 58 00:02:55,980 --> 00:02:57,420 which other manufacturers have, 59 00:02:57,420 --> 00:02:59,820 so they have to pay more for every single part 60 00:02:59,820 --> 00:03:01,470 that they develop for their cars. 61 00:03:03,360 --> 00:03:06,180 - So what Aston has done is sort of repurpose 62 00:03:06,180 --> 00:03:08,010 the same architecture and their same engine 63 00:03:08,010 --> 00:03:09,633 to make new things. 64 00:03:12,390 --> 00:03:14,040 - [Narrator] Lead designer Marek Reichman 65 00:03:14,040 --> 00:03:16,080 itches to push the brand forward. 66 00:03:16,080 --> 00:03:18,690 - We've always had a policy of of thinking about 67 00:03:18,690 --> 00:03:20,490 what could we do next with the assets 68 00:03:20,490 --> 00:03:21,840 that we have around us. 69 00:03:21,840 --> 00:03:22,937 What would be exciting? 70 00:03:22,937 --> 00:03:26,010 (engine roaring) 71 00:03:26,010 --> 00:03:26,850 - [Narrator] With limited money 72 00:03:26,850 --> 00:03:29,613 to build a new machine from the ground up, 73 00:03:31,290 --> 00:03:34,290 Reichman has to do a lot with a little. 74 00:03:34,290 --> 00:03:35,123 - The idea was, well, 75 00:03:35,123 --> 00:03:37,950 what if we put the V12 engine into the Vantage? 76 00:03:37,950 --> 00:03:39,393 How could we make that work? 77 00:03:41,550 --> 00:03:43,740 - [Narrator] Squeezing the brand's biggest engine 78 00:03:43,740 --> 00:03:46,530 into one of its smallest and oldest chassis 79 00:03:46,530 --> 00:03:48,003 is a daring proposition, 80 00:03:49,860 --> 00:03:54,333 yet the notion ignites a passion for speed. 81 00:03:55,611 --> 00:03:58,260 - And that genesis absolutely, of Ian coming along saying, 82 00:03:58,260 --> 00:04:00,300 hey, we have this idea. 83 00:04:00,300 --> 00:04:03,603 We talked together, said this will be an amazing car to do. 84 00:04:04,860 --> 00:04:06,930 - The engineering team quickly sets its sight 85 00:04:06,930 --> 00:04:08,793 on creating a bold goal. 86 00:04:13,530 --> 00:04:16,680 - When we're laying down the targets for the V12 Vantage S, 87 00:04:16,680 --> 00:04:18,270 I was absolutely adamant to the guys, 88 00:04:18,270 --> 00:04:20,463 we're gonna make this do 200 miles an hour. 89 00:04:22,055 --> 00:04:24,330 (engine roaring) 90 00:04:24,330 --> 00:04:25,560 - [Narrator] An outrageous top speed 91 00:04:25,560 --> 00:04:27,183 isn't the only objective. 92 00:04:29,250 --> 00:04:30,990 - We wanted to get below the magic 93 00:04:30,990 --> 00:04:32,682 four seconds of naught to 60. 94 00:04:32,682 --> 00:04:35,432 (engine roaring) 95 00:04:36,270 --> 00:04:38,370 So it really came out of a small group of guys 96 00:04:38,370 --> 00:04:39,450 free thinking. 97 00:04:39,450 --> 00:04:41,670 But once we got hold of the concept, then we thought, yeah, 98 00:04:41,670 --> 00:04:44,640 this is a serious project and a serious car. 99 00:04:44,640 --> 00:04:46,530 - [Narrator] With the performance target set, 100 00:04:46,530 --> 00:04:49,830 the design team faces a unique challenge, 101 00:04:49,830 --> 00:04:53,700 how to take an existing and universally applauded supercar 102 00:04:53,700 --> 00:04:56,580 and fit a substantially larger engine inside it. 103 00:04:56,580 --> 00:04:59,070 - We had a Vmax target. 104 00:04:59,070 --> 00:05:00,573 All those were defined. 105 00:05:01,980 --> 00:05:03,060 We create the sketch, 106 00:05:03,060 --> 00:05:05,820 and that sketch has to look like an Aston Martin. 107 00:05:05,820 --> 00:05:07,320 - [Narrator] Making an Aston Martin 108 00:05:07,320 --> 00:05:10,323 look like an Aston Martin is no easy task. 109 00:05:11,340 --> 00:05:15,423 - Your first reaction has to be, (gasps), it's beautiful. 110 00:05:17,310 --> 00:05:18,570 - [Narrator] It takes time to find 111 00:05:18,570 --> 00:05:20,700 the right balance of beautiful. 112 00:05:20,700 --> 00:05:22,890 - If I was to describe the thing that we had to win, 113 00:05:22,890 --> 00:05:26,010 it was about making sure that proportion 114 00:05:26,010 --> 00:05:28,350 was absolutely perfect. 115 00:05:28,350 --> 00:05:30,003 So the fight was for perfection. 116 00:05:32,370 --> 00:05:35,460 - [Narrator] It's a distinctly British form of perfection 117 00:05:35,460 --> 00:05:37,743 that starts in a very old-world way. 118 00:05:38,850 --> 00:05:40,680 - All Aston Martins start with a sketch. 119 00:05:40,680 --> 00:05:42,450 In my mind, that immediately starts 120 00:05:42,450 --> 00:05:44,160 to give you a proportion. 121 00:05:44,160 --> 00:05:47,220 Within that proportion, you have to fit the person. 122 00:05:47,220 --> 00:05:49,980 So you can then start to realize where the front wheel is, 123 00:05:49,980 --> 00:05:52,260 where the rear wheel is, where the occupant will sit, 124 00:05:52,260 --> 00:05:54,330 and you can start to sketch. 125 00:05:54,330 --> 00:05:56,340 You can start to have an idea of the form, 126 00:05:56,340 --> 00:05:58,350 the language of the car. 127 00:05:58,350 --> 00:06:01,710 - [Narrator] That language is the key to Aston's rebirth, 128 00:06:01,710 --> 00:06:04,500 and it's all due to a time honored process. 129 00:06:04,500 --> 00:06:08,103 - That sketch then becomes a three-dimensional scale model. 130 00:06:12,720 --> 00:06:14,970 - Designers design a lot of stuff on computers, 131 00:06:14,970 --> 00:06:17,070 but you can't touch what's on the computer screen, 132 00:06:17,070 --> 00:06:18,753 but you can touch what's in clay. 133 00:06:21,930 --> 00:06:24,730 - [Narrator] At first, they create an 1/8th scale model. 134 00:06:28,260 --> 00:06:30,780 It's a fast way to bring the language of the car to life. 135 00:06:30,780 --> 00:06:33,000 - At that point, we can then start to scan 136 00:06:33,000 --> 00:06:34,590 that three dimensional form. 137 00:06:34,590 --> 00:06:36,030 The CAD doesn't understand 138 00:06:36,030 --> 00:06:37,680 whether this is a scale model or not, 139 00:06:37,680 --> 00:06:40,860 because we can convert the scale to full size. 140 00:06:40,860 --> 00:06:42,660 So we can turn a 10 millimeter square 141 00:06:42,660 --> 00:06:44,430 into a 100 millimeter square. 142 00:06:44,430 --> 00:06:46,353 So immediately then we have a surface. 143 00:06:48,030 --> 00:06:49,920 - [Narrator] Once the surface becomes digital, 144 00:06:49,920 --> 00:06:52,800 the team can look for the most minute imperfections. 145 00:06:52,800 --> 00:06:54,960 - Our role is to get the scan data 146 00:06:54,960 --> 00:06:56,760 and the nuances that are done physically 147 00:06:56,760 --> 00:06:57,990 by the clay modeler. 148 00:06:57,990 --> 00:07:00,120 Our job is to refine those. 149 00:07:00,120 --> 00:07:01,620 Then we go back to the physical world 150 00:07:01,620 --> 00:07:03,698 to make sure what we've done is correct. 151 00:07:03,698 --> 00:07:06,365 (rousing music) 152 00:07:16,830 --> 00:07:18,300 - [Narrator] Modelers work tirelessly 153 00:07:18,300 --> 00:07:20,493 to perfect the shape in the real world, 154 00:07:27,900 --> 00:07:30,810 handcrafting each sensuous curve in clay 155 00:07:30,810 --> 00:07:31,983 on a life-size model. 156 00:07:39,986 --> 00:07:42,240 (engine roaring) 157 00:07:42,240 --> 00:07:45,900 - I'm not a designer, but it's all about their proportions. 158 00:07:45,900 --> 00:07:49,320 It's all about the way that car sits with a big, long hood, 159 00:07:49,320 --> 00:07:52,170 and just the elegant, simple lines that go across it. 160 00:07:52,170 --> 00:07:53,270 They're just timeless. 161 00:07:57,000 --> 00:07:58,320 - When you build something in clay, 162 00:07:58,320 --> 00:08:00,660 you get this full-size model, 163 00:08:00,660 --> 00:08:02,760 and you get the whole feeling of how the car looks 164 00:08:02,760 --> 00:08:05,220 and what it's gonna express that you just don't get 165 00:08:05,220 --> 00:08:07,720 if you design the car solely on a computer screen. 166 00:08:08,760 --> 00:08:10,230 - We're looking for the most beautiful 167 00:08:10,230 --> 00:08:11,523 proportion all the time. 168 00:08:13,410 --> 00:08:16,290 We use golden section naturally as designers 169 00:08:16,290 --> 00:08:18,813 to create form, to create shape. 170 00:08:19,740 --> 00:08:22,050 - [Narrator] The golden section, or golden ratio 171 00:08:22,050 --> 00:08:25,860 is a mathematical formula used to describe beauty. 172 00:08:25,860 --> 00:08:27,810 It was first discovered by the ancient Greeks 173 00:08:27,810 --> 00:08:29,973 over 2,500 years ago. 174 00:08:31,260 --> 00:08:34,443 It's a theorem that tries to find logic in beauty. 175 00:08:35,730 --> 00:08:38,700 Yet even today, it still affects the most exotic 176 00:08:38,700 --> 00:08:41,193 and modern supercars in the world. 177 00:08:42,120 --> 00:08:43,380 - It's a rule and a principle, 178 00:08:43,380 --> 00:08:45,783 a mathematical rule, comes from nature. 179 00:08:48,120 --> 00:08:49,620 The nautilus shell for instance, 180 00:08:49,620 --> 00:08:51,120 everything within the nautilus shell 181 00:08:51,120 --> 00:08:53,250 fits perfectly within that golden section, 182 00:08:53,250 --> 00:08:55,140 the golden triangle, as it were. 183 00:08:55,140 --> 00:08:58,680 - [Narrator] The golden rule might come from the old world, 184 00:08:58,680 --> 00:09:01,560 but the design teams' use is uniquely contemporary 185 00:09:01,560 --> 00:09:03,210 and uniquely British. 186 00:09:03,210 --> 00:09:06,270 - The Brits are known for understated design. 187 00:09:06,270 --> 00:09:08,430 They bring cues from the 60s and 70s, 188 00:09:08,430 --> 00:09:10,680 and they brought that all the way into today. 189 00:09:12,090 --> 00:09:14,250 It's not an easy thing to define necessarily, 190 00:09:14,250 --> 00:09:17,220 but it's an elegant, classy design. 191 00:09:17,220 --> 00:09:19,020 It's not vulgar in any way. 192 00:09:19,020 --> 00:09:20,730 There's no huge affectations. 193 00:09:20,730 --> 00:09:24,720 - Aston Martin means these sporty grand touring cars, 194 00:09:24,720 --> 00:09:27,060 cars that you wanna drive across continental Europe 195 00:09:27,060 --> 00:09:29,160 in 10 minutes with your foot on the floor. 196 00:09:31,800 --> 00:09:32,970 They're incredibly powerful, 197 00:09:32,970 --> 00:09:35,580 but they're also incredibly comfortable and beautiful. 198 00:09:35,580 --> 00:09:37,113 It's a car to be seen in. 199 00:09:38,700 --> 00:09:40,850 - It's the understated gentleman's Ferrari. 200 00:09:44,250 --> 00:09:45,120 - [Narrator] Marek and his team 201 00:09:45,120 --> 00:09:48,000 blend that open appeal with a modern style. 202 00:09:48,000 --> 00:09:49,020 - That becomes the battle, 203 00:09:49,020 --> 00:09:51,780 to make sure we get the best looking car 204 00:09:51,780 --> 00:09:55,353 that is gonna be timeless design, a future classic. 205 00:09:56,190 --> 00:09:58,860 So it's really about making sure 206 00:09:58,860 --> 00:10:01,683 everyone understands the direction and the goal. 207 00:10:02,700 --> 00:10:05,820 - [Narrator] That goal is a contemporary reinterpretation 208 00:10:05,820 --> 00:10:08,640 of an old American hot rodders trick. 209 00:10:08,640 --> 00:10:12,480 Take the biggest, heaviest, and most powerful engine 210 00:10:12,480 --> 00:10:14,380 and drop it into the lightest chassis, 211 00:10:15,585 --> 00:10:19,277 a 565-horsepower engine called the AM28. 212 00:10:21,090 --> 00:10:23,340 - And that's just the ancient hot rodders 213 00:10:23,340 --> 00:10:25,950 recipe for making an awesome sports car. 214 00:10:25,950 --> 00:10:27,270 - Everybody loves a good 215 00:10:27,270 --> 00:10:29,580 stick the biggest motor in the smallest car you got. 216 00:10:29,580 --> 00:10:30,660 And sometimes it can be fun, 217 00:10:30,660 --> 00:10:33,060 sometimes it can be a little bit too much. 218 00:10:33,060 --> 00:10:36,180 In the case of the Aston, it's probably both. 219 00:10:36,180 --> 00:10:37,050 - [Narrator] Engineers predict 220 00:10:37,050 --> 00:10:39,960 that the four extra cylinders will propel the machine 221 00:10:39,960 --> 00:10:44,088 to a 329-kilometer-an-hour top speed. 222 00:10:44,088 --> 00:10:47,610 (engine roaring) 223 00:10:47,610 --> 00:10:52,173 There's only one problem, the engine doesn't actually fit. 224 00:10:53,640 --> 00:10:56,190 In an ever-changing automotive landscape, 225 00:10:56,190 --> 00:10:58,350 Aston Martin looks to turn heads 226 00:10:58,350 --> 00:11:00,930 with a new hot-rod-inspired supercar. 227 00:11:00,930 --> 00:11:02,250 - Since Aston Martin doesn't have 228 00:11:02,250 --> 00:11:04,380 a big car maker to support them, 229 00:11:04,380 --> 00:11:05,850 they have to do everything on their own. 230 00:11:05,850 --> 00:11:08,610 - It takes so much money to develop a new car, 231 00:11:08,610 --> 00:11:11,160 and if you don't sell four trillion of them, 232 00:11:11,160 --> 00:11:12,840 you can't recoup that development cost. 233 00:11:12,840 --> 00:11:14,640 - They can't afford to make any big mistakes, 234 00:11:14,640 --> 00:11:16,940 'cause that could cost the company everything. 235 00:11:18,390 --> 00:11:19,770 - If Aston misses on anything, 236 00:11:19,770 --> 00:11:21,960 I think we're gonna have to say goodbye to them. 237 00:11:21,960 --> 00:11:24,060 - [Narrator] So how does an independent car maker 238 00:11:24,060 --> 00:11:25,410 expect to compete 239 00:11:25,410 --> 00:11:28,010 with some of the largest car companies in the world? 240 00:11:29,130 --> 00:11:32,190 The answer lies in the quiet green hills 241 00:11:32,190 --> 00:11:33,573 of Warwickshire, England. 242 00:11:35,040 --> 00:11:36,660 Welcome to Gaydon, 243 00:11:36,660 --> 00:11:40,053 the beating heart of Aston Martin since 2003. 244 00:11:44,400 --> 00:11:46,260 It is one of the most technologically advanced 245 00:11:46,260 --> 00:11:48,540 automotive factories in the world. 246 00:11:48,540 --> 00:11:50,940 - It's a facility where people are manufacturing 247 00:11:50,940 --> 00:11:54,453 these beautiful sports cars with great passion. 248 00:11:56,970 --> 00:11:59,820 - [Narrator] 54 acres of space age technology 249 00:11:59,820 --> 00:12:02,490 paired with British refinement. 250 00:12:02,490 --> 00:12:05,643 - It's quiet, it's clean, it's very, very high tech. 251 00:12:09,810 --> 00:12:12,150 - [Narrator] Every phase from design to production 252 00:12:12,150 --> 00:12:14,463 takes place on a single campus. 253 00:12:17,400 --> 00:12:20,070 It's here that engineers and designers 254 00:12:20,070 --> 00:12:24,511 struggle to solve the critical problems facing the project. 255 00:12:24,511 --> 00:12:25,645 (engine roaring) 256 00:12:25,645 --> 00:12:28,440 - The front end of the car was designed around a V8 engine. 257 00:12:28,440 --> 00:12:30,780 So the first challenge is actually getting 258 00:12:30,780 --> 00:12:33,161 the large engine to fit in the space. 259 00:12:33,161 --> 00:12:35,490 (engine roaring) 260 00:12:35,490 --> 00:12:37,650 - [Narrator] Engineers digitally comb over 261 00:12:37,650 --> 00:12:40,110 every single millimeter of the engine bay 262 00:12:40,110 --> 00:12:41,190 to find a solution. 263 00:12:41,190 --> 00:12:44,040 - The big challenges were the packaging of an engine 264 00:12:44,040 --> 00:12:47,010 which had four more cylinders than the previous engine. 265 00:12:47,010 --> 00:12:48,660 Just to give you an example of that, 266 00:12:48,660 --> 00:12:53,073 that's about that much longer within the same wheel base. 267 00:12:54,120 --> 00:12:56,040 - [Narrator] When engineers first digitally dropped 268 00:12:56,040 --> 00:12:59,370 the V12 engine into the V8 chassis, 269 00:12:59,370 --> 00:13:00,970 they immediately have a problem. 270 00:13:01,920 --> 00:13:04,440 - And you can start to see some of the pinch points here, 271 00:13:04,440 --> 00:13:08,400 and just here on the front of the engine. 272 00:13:08,400 --> 00:13:12,933 As the bonnet dives over, we're in a tight pinch point here. 273 00:13:14,400 --> 00:13:15,233 - [Narrator] A pinch point 274 00:13:15,233 --> 00:13:18,150 is where two pieces don't fit correctly. 275 00:13:18,150 --> 00:13:19,740 Getting the engine to fit comes down 276 00:13:19,740 --> 00:13:22,503 to just 12.5 millimeters, 277 00:13:23,520 --> 00:13:25,500 a little less than the height of two iPhones 278 00:13:25,500 --> 00:13:27,150 stacked on top of each other. 279 00:13:27,150 --> 00:13:30,720 - Usually we'd look for 25 millimeters, 280 00:13:30,720 --> 00:13:33,025 but in some cases we've halved that. 281 00:13:33,025 --> 00:13:35,775 (engine roaring) 282 00:13:37,710 --> 00:13:40,500 - [Narrator] In the end, 12.5 millimeters are the key 283 00:13:40,500 --> 00:13:42,603 to bringing a new machine to life. 284 00:13:43,686 --> 00:13:45,540 (engine roaring) 285 00:13:45,540 --> 00:13:47,730 - The pressure on Aston must be enormous, 286 00:13:47,730 --> 00:13:49,440 because they have such limited resources 287 00:13:49,440 --> 00:13:51,743 and they have to keep coming out with different things. 288 00:13:52,980 --> 00:13:54,810 - [Narrator] Any failure could mean the end 289 00:13:54,810 --> 00:13:57,843 of the mark's illustrious legacy. 290 00:14:00,780 --> 00:14:02,370 - One of the challenges that we believe 291 00:14:02,370 --> 00:14:05,910 we always take on here is doing the impossible. 292 00:14:05,910 --> 00:14:08,520 - [Narrator] With their reputation hanging in the balance 293 00:14:08,520 --> 00:14:10,530 and perhaps, their solvency, 294 00:14:10,530 --> 00:14:13,530 the Aston Martin design team boldly surges forward. 295 00:14:13,530 --> 00:14:15,720 - As a small independent car company, 296 00:14:15,720 --> 00:14:16,950 they're are a lot more agile. 297 00:14:16,950 --> 00:14:18,360 They can do fun things, 298 00:14:18,360 --> 00:14:20,310 they can do crazy things like that car, 299 00:14:22,140 --> 00:14:23,310 things that wouldn't get through 300 00:14:23,310 --> 00:14:25,119 a regular car company's processes. 301 00:14:25,119 --> 00:14:25,952 (tires screeching) 302 00:14:25,952 --> 00:14:27,090 - That's something that we would say, 303 00:14:27,090 --> 00:14:28,540 well, of course we can do it. 304 00:14:29,610 --> 00:14:30,960 We don't have to follow this rule, 305 00:14:30,960 --> 00:14:33,630 we don't have to think in this way. 306 00:14:33,630 --> 00:14:34,860 We can make it work. 307 00:14:34,860 --> 00:14:36,960 - [Narrator] It's a unique form of bravado 308 00:14:37,980 --> 00:14:39,780 from a company that's no longer willing 309 00:14:39,780 --> 00:14:41,400 to keep a stiff upper lip. 310 00:14:41,400 --> 00:14:42,870 - But if they built like some sort of car 311 00:14:42,870 --> 00:14:45,120 that wasn't really an Aston Martin, 312 00:14:45,120 --> 00:14:48,300 and they spent a lot of money on it and it didn't sell, 313 00:14:48,300 --> 00:14:49,410 that could kill the company. 314 00:14:49,410 --> 00:14:51,240 - [Narrator] This small independent 315 00:14:51,240 --> 00:14:53,100 is about to go toe to toe 316 00:14:53,100 --> 00:14:56,070 with some of the most powerful companies in the world, 317 00:14:56,070 --> 00:14:58,620 but only if it can learn to control something 318 00:14:58,620 --> 00:15:00,183 that you can't actually see. 319 00:15:04,200 --> 00:15:05,910 In the world of extreme supercars, 320 00:15:05,910 --> 00:15:08,730 powerful engines always get the glory, 321 00:15:08,730 --> 00:15:10,560 but it's the air surrounding them 322 00:15:10,560 --> 00:15:12,180 that provides the greatness. 323 00:15:12,180 --> 00:15:14,220 - Literally as you shoehorn your foot 324 00:15:14,220 --> 00:15:15,990 into a very tight shoe, 325 00:15:15,990 --> 00:15:19,620 that's what we try to do with the V12 Vantage S engine. 326 00:15:19,620 --> 00:15:22,320 - [Narrator] Shoehorning the larger V 12 into the chassis 327 00:15:22,320 --> 00:15:23,733 is just the first step. 328 00:15:24,960 --> 00:15:28,110 The real key is to manage the airflow around 329 00:15:28,110 --> 00:15:30,153 and inside the machine itself. 330 00:15:31,290 --> 00:15:32,700 - And we've got a lot to come through the the engine bay, 331 00:15:32,700 --> 00:15:33,720 what we're gonna do with all the air 332 00:15:33,720 --> 00:15:35,393 that's going into the front of the car. 333 00:15:37,590 --> 00:15:38,550 - [Narrator] Controlling the air 334 00:15:38,550 --> 00:15:40,953 creates three distinct challenges. 335 00:15:42,450 --> 00:15:44,580 First, the machine needs to be tuned 336 00:15:44,580 --> 00:15:46,892 so that it's stable at high speed. 337 00:15:46,892 --> 00:15:48,150 (engine roaring) 338 00:15:48,150 --> 00:15:50,790 - At 200 miles an hour, an airplane can take off. 339 00:15:50,790 --> 00:15:52,950 At 200 miles an hour, a car can take off, too. 340 00:15:52,950 --> 00:15:55,290 So you wanna make sure that the aero package is right 341 00:15:55,290 --> 00:15:56,730 so that the car stays on the road. 342 00:15:56,730 --> 00:15:57,840 - [Narrator] But the car also needs 343 00:15:57,840 --> 00:16:00,120 to cut through the air easily. 344 00:16:00,120 --> 00:16:03,720 That requires creating the least amount of drag possible. 345 00:16:03,720 --> 00:16:05,910 Drag is a type of air resistance. 346 00:16:05,910 --> 00:16:08,670 - Drag effectively is the force you've gotta hammer, 347 00:16:08,670 --> 00:16:11,640 how hard you gotta work to push the air out of the way. 348 00:16:11,640 --> 00:16:13,500 - [Narrator] Tuning the machine to be stable 349 00:16:13,500 --> 00:16:15,840 and reducing the drag proved to be easy 350 00:16:15,840 --> 00:16:17,493 compared to cooling the machine. 351 00:16:23,306 --> 00:16:24,840 - You've got a more powerful engine 352 00:16:24,840 --> 00:16:26,370 and it fills the engine bay a lot more. 353 00:16:26,370 --> 00:16:27,540 - As soon as we found out we're gonna 354 00:16:27,540 --> 00:16:30,330 put up a V 12 in this car, first thing for me was 355 00:16:30,330 --> 00:16:32,280 what we're gonna do with all that heat. 356 00:16:37,368 --> 00:16:39,180 - [Narrator] A team of aerodynamicists 357 00:16:39,180 --> 00:16:41,910 use a sophisticated three-dimensional model 358 00:16:41,910 --> 00:16:44,070 made up of over 60 million cells 359 00:16:44,070 --> 00:16:46,707 to find the best way to move the air. 360 00:16:46,707 --> 00:16:49,890 The first step is to map what you can't see. 361 00:16:49,890 --> 00:16:51,030 - Red is good, 362 00:16:51,030 --> 00:16:53,390 and that means there's lots of energy left in the air. 363 00:16:53,390 --> 00:16:55,380 So this is us before we get to the car. 364 00:16:55,380 --> 00:16:57,510 And as the car passes through the air, 365 00:16:57,510 --> 00:17:01,293 that energy is transformed into heat rejection. 366 00:17:03,600 --> 00:17:05,610 - [Narrator] Air particles pass through the car 367 00:17:05,610 --> 00:17:07,803 in just 50 milliseconds. 368 00:17:09,567 --> 00:17:11,460 (engine roaring) 369 00:17:11,460 --> 00:17:13,680 - In that 50 milliseconds worth of time, 370 00:17:13,680 --> 00:17:15,723 that air has to cool the brakes, 371 00:17:19,170 --> 00:17:21,180 it has to travel around the car 372 00:17:21,180 --> 00:17:23,512 without causing too much drag, 373 00:17:23,512 --> 00:17:26,262 (engine roaring) 374 00:17:27,210 --> 00:17:28,860 and it also has to make sure 375 00:17:28,860 --> 00:17:31,603 that the car is absolutely planted at speed. 376 00:17:31,603 --> 00:17:32,940 (engine roaring) 377 00:17:32,940 --> 00:17:34,800 - [Narrator] The air loses half its energy 378 00:17:34,800 --> 00:17:36,483 before it even hits the engine. 379 00:17:39,240 --> 00:17:42,420 - Within the space of about a 100 millimeters, 380 00:17:42,420 --> 00:17:45,210 or the length of your forearm, 381 00:17:45,210 --> 00:17:47,183 the air is slowed down from 200 miles an hour 382 00:17:47,183 --> 00:17:48,930 down to 100 miles per hour. 383 00:17:48,930 --> 00:17:50,040 - [Narrator] When the machine is moving, 384 00:17:50,040 --> 00:17:51,753 the air slows down quickly. 385 00:17:54,630 --> 00:17:56,370 But when the machine is stopped, 386 00:17:56,370 --> 00:17:58,503 getting the hot air out is even trickier. 387 00:17:59,490 --> 00:18:02,070 To do that, they tune the louvers on the hood. 388 00:18:02,070 --> 00:18:05,163 - The aerodynamics is kind of seen as being high speed, 389 00:18:06,270 --> 00:18:08,153 but actually delivers more at low speed. 390 00:18:13,440 --> 00:18:16,290 What we've got here is, this is a prototype bonnet. 391 00:18:16,290 --> 00:18:17,123 We've got this bonnet here 392 00:18:17,123 --> 00:18:18,150 which have all got these extra louvers in, 393 00:18:18,150 --> 00:18:20,400 which we derived from motorsports experience. 394 00:18:21,960 --> 00:18:23,730 These parts actually in here, they can be changed. 395 00:18:23,730 --> 00:18:24,930 So if I flip it over, you can see 396 00:18:24,930 --> 00:18:26,460 each one of them is tuneable. 397 00:18:26,460 --> 00:18:29,823 So we tuned these to get the maximum airflow through them. 398 00:18:31,563 --> 00:18:33,690 (engine roaring) 399 00:18:33,690 --> 00:18:35,190 Whilst it's running at high speed, 400 00:18:35,190 --> 00:18:36,870 so it draws more air out, 401 00:18:36,870 --> 00:18:38,250 that gives you kind of a better head start. 402 00:18:38,250 --> 00:18:39,600 If you keep the engine cool in the first place, 403 00:18:39,600 --> 00:18:40,770 you haven't got such a mountain climb 404 00:18:40,770 --> 00:18:41,920 when you actually stop. 405 00:18:43,830 --> 00:18:45,810 But also, when the car stops, it allows all that heat 406 00:18:45,810 --> 00:18:48,293 that we've built up inside the engine bay to come out. 407 00:18:49,140 --> 00:18:50,880 - [Narrator] At speed, managing the airflow 408 00:18:50,880 --> 00:18:54,150 is critical and complicated. 409 00:18:54,150 --> 00:18:56,010 Because air travels through components 410 00:18:56,010 --> 00:18:58,800 at pressures a thousand times greater 411 00:18:58,800 --> 00:19:00,663 than the capacity of the human lung, 412 00:19:02,370 --> 00:19:04,350 how the team channels it throughout the vehicle 413 00:19:04,350 --> 00:19:06,180 makes all the difference. 414 00:19:06,180 --> 00:19:07,290 - We've gotta kind of separate that out 415 00:19:07,290 --> 00:19:08,490 between how much goes into the engine 416 00:19:08,490 --> 00:19:10,830 to give us the extra power to reach the top speed, 417 00:19:10,830 --> 00:19:12,630 how much we need to obviously cool the engine. 418 00:19:12,630 --> 00:19:14,490 You're gonna heat the brakes up to 700 degrees. 419 00:19:14,490 --> 00:19:16,470 You've gotta have airflow pumping into those wheel arches 420 00:19:16,470 --> 00:19:17,673 to cool those back down. 421 00:19:18,840 --> 00:19:20,220 So it's a finite balance 422 00:19:20,220 --> 00:19:21,630 of we're trying to achieve all those things 423 00:19:21,630 --> 00:19:23,230 with all the air around the car. 424 00:19:25,735 --> 00:19:28,440 (tires screeching) 425 00:19:28,440 --> 00:19:29,700 - [Narrator] From an engineering standpoint, 426 00:19:29,700 --> 00:19:33,750 the V12 Vantage S is an engine-heavy dragster, 427 00:19:33,750 --> 00:19:36,983 just like the 1950s American hot rods that inspired it. 428 00:19:36,983 --> 00:19:39,720 - The V12 Vantage is a real engineer's car. 429 00:19:39,720 --> 00:19:41,550 There's a bit of hot rod in there, 430 00:19:41,550 --> 00:19:43,722 'cause it's a big engine in a smaller car. 431 00:19:43,722 --> 00:19:46,472 (engine roaring) 432 00:19:47,970 --> 00:19:49,980 - [Narrator] One of the keys to a great hot rod 433 00:19:49,980 --> 00:19:51,273 is how it sounds. 434 00:19:54,268 --> 00:19:57,018 (engine roaring) 435 00:19:58,710 --> 00:20:01,800 Inside a hidden garage off limits to the public, 436 00:20:01,800 --> 00:20:05,940 engineers use a high-tech camera system with 32 microphones 437 00:20:05,940 --> 00:20:09,600 to visually chart the engine's audio signals. 438 00:20:09,600 --> 00:20:11,820 This lets the team precisely tune 439 00:20:11,820 --> 00:20:16,350 which sounds occupants hear, and which they don't. 440 00:20:16,350 --> 00:20:20,133 The camera records data at 96,000 times per second. 441 00:20:21,480 --> 00:20:22,890 They then use a color map 442 00:20:22,890 --> 00:20:25,260 to identify the noise characteristics, 443 00:20:25,260 --> 00:20:27,990 with purple being the loudest sound. 444 00:20:27,990 --> 00:20:32,280 Finally, they combine the camera imagery with the audio data 445 00:20:32,280 --> 00:20:35,040 to pinpoint exactly where the sounds originate, 446 00:20:35,040 --> 00:20:38,910 sounds which help intensify Aston's unique exhaust note. 447 00:20:38,910 --> 00:20:41,660 (engine roaring) 448 00:20:43,200 --> 00:20:44,460 - Absolutely beautiful noise 449 00:20:44,460 --> 00:20:46,470 that you only get from a 12 cylinder engine. 450 00:20:46,470 --> 00:20:48,593 I mean, they don't sound like anything else. 451 00:20:54,690 --> 00:20:55,523 - [Narrator] The problem is, 452 00:20:55,523 --> 00:20:57,783 Aston Martin doesn't make hot rods. 453 00:20:59,190 --> 00:21:02,883 They make exquisite supercars laced with sophistication. 454 00:21:04,560 --> 00:21:08,220 Today's global buyers expect more than just a big engine. 455 00:21:08,220 --> 00:21:10,350 - Anybody can make a fast car these days. 456 00:21:10,350 --> 00:21:11,760 What Aston really needs to do 457 00:21:11,760 --> 00:21:13,360 is appeal to the emotional side. 458 00:21:14,460 --> 00:21:17,400 - There's an understated elegance about an Aston Martin. 459 00:21:17,400 --> 00:21:19,950 It's maybe more about wearing the label on the inside 460 00:21:19,950 --> 00:21:21,480 than a label on the outside. 461 00:21:21,480 --> 00:21:22,650 - It is the gentleman's supercar. 462 00:21:22,650 --> 00:21:24,030 First of all, they look the part, 463 00:21:24,030 --> 00:21:26,910 they sound the part, they're a little bit more restrained, 464 00:21:26,910 --> 00:21:29,810 but they are no less serious when it comes to performance. 465 00:21:33,240 --> 00:21:36,030 - [Narrator] So how do you transform a hot rod 466 00:21:36,030 --> 00:21:37,230 into an Aston Martin? 467 00:21:37,230 --> 00:21:39,300 - There were some really long nights on that, 468 00:21:39,300 --> 00:21:41,670 us saying that, how do we make this work? 469 00:21:41,670 --> 00:21:43,980 How do we get that mix of refinement, 470 00:21:43,980 --> 00:21:46,661 but with a little bit of rawness into there? 471 00:21:46,661 --> 00:21:49,411 (engine roaring) 472 00:21:50,790 --> 00:21:52,980 - [Narrator] A fateful discussion over a cup of coffee 473 00:21:52,980 --> 00:21:56,040 has led Aston Martin to put their largest engine 474 00:21:56,040 --> 00:21:57,453 into their smallest chassis. 475 00:21:59,340 --> 00:22:01,740 The question now, is how do they transform 476 00:22:01,740 --> 00:22:06,199 this modern hot rod into a refined luxury vehicle? 477 00:22:06,199 --> 00:22:08,866 (rousing music) 478 00:22:09,930 --> 00:22:13,410 - It's always about pushing the technology, 479 00:22:13,410 --> 00:22:16,230 pushing the innovation of the material. 480 00:22:16,230 --> 00:22:17,910 - [Narrator] High-tech and handmade 481 00:22:17,910 --> 00:22:20,220 are two staples at the Gaydon factory, 482 00:22:20,220 --> 00:22:23,700 where over 200 man hours go into the assembly 483 00:22:23,700 --> 00:22:25,533 of just one Vantage. 484 00:22:26,524 --> 00:22:27,990 (engine roaring) 485 00:22:27,990 --> 00:22:30,360 The process begins in the trim department. 486 00:22:30,360 --> 00:22:31,803 - This is Gaydon Trim Shop. 487 00:22:32,790 --> 00:22:34,320 This is where all the leather panels 488 00:22:34,320 --> 00:22:36,120 are all stitched together. 489 00:22:36,120 --> 00:22:37,800 - [Narrator] Each Vantage interior 490 00:22:37,800 --> 00:22:41,100 utilizes six full hides of leather. 491 00:22:41,100 --> 00:22:42,870 - These are Alcantara panels. 492 00:22:42,870 --> 00:22:44,910 These have just come from the sewing area. 493 00:22:44,910 --> 00:22:48,060 The parts are now being laid out into the spray booths, 494 00:22:48,060 --> 00:22:50,223 and the adhesive is now being applied. 495 00:22:51,930 --> 00:22:53,130 - [Narrator] Once the glue is sprayed, 496 00:22:53,130 --> 00:22:55,260 the leather workers have just four minutes 497 00:22:55,260 --> 00:22:56,613 to apply it to the plastic. 498 00:22:58,230 --> 00:23:00,870 - Now the adhesive's no longer wet, it's just tacky. 499 00:23:00,870 --> 00:23:02,520 Once you put the two parts together, 500 00:23:02,520 --> 00:23:04,590 it forms a permanent bond. 501 00:23:04,590 --> 00:23:06,586 There are 50 trimmers, 502 00:23:06,586 --> 00:23:09,090 and they'll make over 300 parts a day. 503 00:23:09,090 --> 00:23:11,490 - [Narrator] It takes roughly 50 hours 504 00:23:11,490 --> 00:23:15,423 to make all the interior trim pieces for just one Vantage. 505 00:23:19,080 --> 00:23:21,150 And the most important tool has a name 506 00:23:21,150 --> 00:23:23,400 that hearkens back to Stonehenge. 507 00:23:23,400 --> 00:23:24,780 - There is one major tool. 508 00:23:24,780 --> 00:23:25,980 That tool is called a bone, 509 00:23:25,980 --> 00:23:28,410 and that is the one that pretty much does it all. 510 00:23:28,410 --> 00:23:29,243 - [Narrator] The leather parts 511 00:23:29,243 --> 00:23:31,083 might be made very traditionally, 512 00:23:32,760 --> 00:23:34,980 but if you order a bespoke Vantage, 513 00:23:34,980 --> 00:23:37,380 the stitching is absolutely high tech. 514 00:23:37,380 --> 00:23:39,870 - This is the quilting operations area. 515 00:23:39,870 --> 00:23:42,810 This is where our bespoke quilting is produced. 516 00:23:42,810 --> 00:23:44,910 - [Narrator] The quilting machine looks fast. 517 00:23:44,910 --> 00:23:45,930 It had better be. 518 00:23:45,930 --> 00:23:49,113 There's more than one million stitches in a Vantage. 519 00:23:50,850 --> 00:23:53,790 While old-world artisans spend two days 520 00:23:53,790 --> 00:23:55,083 crafting the interior, 521 00:23:57,120 --> 00:24:00,093 it takes just half as long to build the space frame. 522 00:24:01,380 --> 00:24:04,020 Each panel or casting arrives at the factory 523 00:24:04,020 --> 00:24:05,940 having already been super formed, 524 00:24:05,940 --> 00:24:09,450 a process where metal is heated to extreme temperatures 525 00:24:09,450 --> 00:24:11,793 before being stamped into a final shape. 526 00:24:15,630 --> 00:24:18,360 Robots supply oxy adhesive. 527 00:24:18,360 --> 00:24:20,490 The adhesive is both more accurate 528 00:24:20,490 --> 00:24:22,623 and stronger than a traditional weld. 529 00:24:44,580 --> 00:24:46,860 The entire space frame is cured in an oven 530 00:24:46,860 --> 00:24:50,853 at 185 degrees centigrade for over 30 minutes. 531 00:24:54,840 --> 00:24:57,033 A slow burn for a fast machine. 532 00:24:57,870 --> 00:25:00,873 Now the chassis is ready to receive its body work. 533 00:25:02,700 --> 00:25:04,383 Then they fit the doors, 534 00:25:07,200 --> 00:25:08,493 front quarter panels, 535 00:25:12,870 --> 00:25:13,713 and bonnet. 536 00:25:20,640 --> 00:25:23,460 Each body is inspected by hand, 537 00:25:23,460 --> 00:25:26,343 then it's time for a splash of English color. 538 00:25:33,720 --> 00:25:35,850 - We're know at the start of the Aston Martin paint process. 539 00:25:35,850 --> 00:25:39,180 As you can see, we've got the car delivered in to paint. 540 00:25:39,180 --> 00:25:40,920 Quite a different car as to what you're gonna see 541 00:25:40,920 --> 00:25:42,720 at the end of the process. 542 00:25:42,720 --> 00:25:45,330 - [Narrator] Only, at Aston Martin, that colorful demeanor 543 00:25:45,330 --> 00:25:47,700 is just as special as the machine itself. 544 00:25:47,700 --> 00:25:51,510 - The full paint process takes on average 50 hours per car. 545 00:25:51,510 --> 00:25:53,010 - [Narrator] Unlike high volume factories 546 00:25:53,010 --> 00:25:55,893 where cars are painted in batches of the same colors, 547 00:25:57,030 --> 00:26:00,870 at Gaydon, each vehicle is painted individually. 548 00:26:00,870 --> 00:26:03,390 It's not efficient, but it is effective, 549 00:26:03,390 --> 00:26:06,570 even though they actually use very little paint. 550 00:26:06,570 --> 00:26:09,290 - 120 Microns of paint will be added to the car, 551 00:26:09,290 --> 00:26:13,140 of which we'll remove 30 microns in our polish process 552 00:26:13,140 --> 00:26:14,850 to make it a mirror glass finish. 553 00:26:14,850 --> 00:26:18,420 So in theory, you have got something the thickness of that 554 00:26:18,420 --> 00:26:20,583 on the car, finished, gloss level. 555 00:26:21,660 --> 00:26:24,753 - [Narrator] That shine starts with a single coat of primer. 556 00:26:27,570 --> 00:26:29,223 Now it's ready for the prep line. 557 00:26:32,647 --> 00:26:33,960 - The idea of the prep line is, 558 00:26:33,960 --> 00:26:36,810 we look for any imperfection before base coat is applied. 559 00:26:39,697 --> 00:26:41,790 We have a very big ethos with prep work. 560 00:26:44,733 --> 00:26:47,010 - [Narrator] Once the car is primed and prepped, 561 00:26:47,010 --> 00:26:48,153 it's ready for paint. 562 00:26:55,272 --> 00:26:57,930 - This car will have base coat applied in the booth there. 563 00:26:57,930 --> 00:27:00,240 It will then be dried for 20 minutes, 564 00:27:00,240 --> 00:27:01,980 moved into a flash off oven, 565 00:27:01,980 --> 00:27:04,413 and then we apply the clear coat by hand. 566 00:27:07,140 --> 00:27:09,990 - [Narrator] Each Vantage then receives two layers of paint 567 00:27:09,990 --> 00:27:12,330 and two layers of clear coat, 568 00:27:12,330 --> 00:27:15,240 some done by robots, some done by hand. 569 00:27:15,240 --> 00:27:17,490 - The paint shop has a degree of automation, 570 00:27:17,490 --> 00:27:19,740 we've got some robots in there for spraying, 571 00:27:19,740 --> 00:27:21,180 and lots of hand finishing 572 00:27:21,180 --> 00:27:24,213 to get the depth of paint finish onto the car. 573 00:27:26,940 --> 00:27:29,700 - [Narrator] The machine is ready to be polished. 574 00:27:29,700 --> 00:27:31,530 - Very different to high volume. 575 00:27:31,530 --> 00:27:34,593 Run-of-the-mill factories, you will not get this process. 576 00:27:42,120 --> 00:27:42,953 - [Narrator] Once painted, 577 00:27:42,953 --> 00:27:44,980 it's time to put the machine together 578 00:27:50,160 --> 00:27:51,693 in the final assembly hall, 579 00:27:52,710 --> 00:27:56,460 where it takes 42 stations to build a Vantage. 580 00:27:56,460 --> 00:27:58,440 - We're currently on the first part of the assembly line, 581 00:27:58,440 --> 00:27:59,273 trim one. 582 00:28:04,110 --> 00:28:05,550 Throughout the rest of this line, 583 00:28:05,550 --> 00:28:07,170 we're fitting some of the key parts 584 00:28:07,170 --> 00:28:09,450 that your average driver doesn't really think about 585 00:28:09,450 --> 00:28:10,593 on a day-to-day basis. 586 00:28:18,450 --> 00:28:21,300 - [Narrator] It's a very classic way to build a supercar, 587 00:28:24,000 --> 00:28:27,180 and the only way to build an Aston Martin. 588 00:28:27,180 --> 00:28:29,550 - Superficially, it can look very similar 589 00:28:29,550 --> 00:28:32,133 to a conventional car production process. 590 00:28:34,020 --> 00:28:36,670 It's still very much a craft-based production system. 591 00:28:38,370 --> 00:28:40,350 - [Narrator] Rear deck lids are preassembled 592 00:28:40,350 --> 00:28:41,343 and then installed. 593 00:28:44,340 --> 00:28:46,170 Finally, the car is ready 594 00:28:46,170 --> 00:28:48,903 for its massive handcrafted instrument panel. 595 00:28:52,410 --> 00:28:54,570 The technicians will use this big device here, 596 00:28:54,570 --> 00:28:55,987 this assistor, 597 00:28:55,987 --> 00:28:58,050 it's a very heavy part, is the IP, 598 00:28:58,050 --> 00:29:00,423 then pick it up and mount it to the vehicle. 599 00:29:05,820 --> 00:29:07,530 - [Narrator] While the majority of the work on the line 600 00:29:07,530 --> 00:29:08,823 is done by hand, 601 00:29:11,100 --> 00:29:14,640 the newest addition to Gaydon is completely automated. 602 00:29:14,640 --> 00:29:17,850 The robot places adhesive on the edge of the windscreen 603 00:29:17,850 --> 00:29:20,070 and is far more precise than a human. 604 00:29:20,070 --> 00:29:22,260 - Well, it's the first part of automated equipment 605 00:29:22,260 --> 00:29:23,220 that we have on this line, 606 00:29:23,220 --> 00:29:25,820 and we've done it solely to help us improve quality. 607 00:29:27,510 --> 00:29:29,280 - [Narrator] Quality that meets performance 608 00:29:29,280 --> 00:29:31,800 on an adjoining sub-assembly line, 609 00:29:31,800 --> 00:29:33,810 where the powertrain begins to come to life 610 00:29:33,810 --> 00:29:36,675 with a naturally-aspirated V12 engine. 611 00:29:36,675 --> 00:29:38,790 (engine roaring) 612 00:29:38,790 --> 00:29:41,140 - We're now in the powertrain subassembly area. 613 00:29:46,440 --> 00:29:48,483 Here you can see one of the V12 engines. 614 00:29:52,710 --> 00:29:55,223 And what we do is we take the engine in the pallet, 615 00:29:58,710 --> 00:30:01,050 we load it up like this, and then we carry it over 616 00:30:01,050 --> 00:30:03,160 to the first part of the assembly process 617 00:30:09,630 --> 00:30:13,080 where we assemble the engine to the torque tube, 618 00:30:13,080 --> 00:30:15,880 and we then have the gearbox at the back of the vehicle. 619 00:30:22,890 --> 00:30:24,630 - [Narrator] They continue to build up the drivetrain 620 00:30:24,630 --> 00:30:26,343 by bolting on the transmission, 621 00:30:40,260 --> 00:30:42,303 followed by the catalytic converters, 622 00:30:45,180 --> 00:30:46,353 then the heat shield, 623 00:30:54,570 --> 00:30:56,583 rear disc brakes, and suspension. 624 00:31:02,850 --> 00:31:05,340 - So we fix what we call the front corner units. 625 00:31:05,340 --> 00:31:07,710 So that's the assembly of the brake disc, 626 00:31:07,710 --> 00:31:10,500 the brake parts, and the suspension parts, 627 00:31:10,500 --> 00:31:12,663 before we then marry it up to the car. 628 00:31:16,140 --> 00:31:17,580 - [Narrator] The front suspension is built 629 00:31:17,580 --> 00:31:18,880 as a separate subassembly, 630 00:31:20,130 --> 00:31:23,160 where they bolt on the 398-millimeter 631 00:31:23,160 --> 00:31:25,203 carbon-ceramic disc brakes. 632 00:31:35,970 --> 00:31:36,960 Once it's completed, 633 00:31:36,960 --> 00:31:39,060 it's joined to the rest of the drivetrain. 634 00:31:49,830 --> 00:31:51,450 - We need to fit the radiator 635 00:31:51,450 --> 00:31:52,710 on the front of the engine unit. 636 00:31:52,710 --> 00:31:55,650 By having the engine, torque tube and gearbox arrangement, 637 00:31:55,650 --> 00:31:58,140 we can get the optimum weight distribution in the car, 638 00:31:58,140 --> 00:32:00,840 which is so important for the handling of the vehicle. 639 00:32:01,715 --> 00:32:04,500 (engine roaring) 640 00:32:04,500 --> 00:32:06,540 - [Narrator] 85% of the weight distribution 641 00:32:06,540 --> 00:32:08,403 sits between the wheels, 642 00:32:11,430 --> 00:32:14,098 helping agility on a track. 643 00:32:14,098 --> 00:32:17,670 (engine roaring) 644 00:32:17,670 --> 00:32:20,010 The seven-speed transmission launches the machine 645 00:32:20,010 --> 00:32:24,247 from zero to a 100 kilometers an hour in under four seconds. 646 00:32:30,600 --> 00:32:33,210 Now it'll take the team at Gaydon 40 minutes 647 00:32:33,210 --> 00:32:36,903 to install the single most important piece of the Vantage. 648 00:32:38,561 --> 00:32:41,311 (engine roaring) 649 00:32:43,500 --> 00:32:46,990 It's taken over a 100 man hours for the fastest 650 00:32:48,180 --> 00:32:51,930 production-based Aston Martin ever 651 00:32:51,930 --> 00:32:54,960 to get to the single most important station on the line. 652 00:32:54,960 --> 00:32:56,340 - The bit that I like the best 653 00:32:56,340 --> 00:32:58,470 is what we call the marriage station, 654 00:32:58,470 --> 00:33:01,070 where we take the whole of the drive line of the car 655 00:33:03,030 --> 00:33:05,977 and we marry that up into the body structure of the car. 656 00:33:19,484 --> 00:33:22,530 (engine roaring) 657 00:33:22,530 --> 00:33:24,420 - [Narrator] Even though the machine is now married, 658 00:33:24,420 --> 00:33:26,270 it's not quite ready for a honeymoon. 659 00:33:28,260 --> 00:33:31,053 The Vantage still needs some key bits of kit, 660 00:33:35,340 --> 00:33:36,623 like exhaust pipes, 661 00:33:40,821 --> 00:33:43,571 (engine roaring) 662 00:33:44,784 --> 00:33:45,753 the front bumper. 663 00:33:52,197 --> 00:33:55,608 (tires screeching) 664 00:33:55,608 --> 00:33:57,330 - There is no line that intersects 665 00:33:57,330 --> 00:33:58,590 between the lamp and the fender. 666 00:33:58,590 --> 00:34:01,203 It's embedded like a jewel set in a ring. 667 00:34:03,060 --> 00:34:05,340 - [Narrator] Jewelry that takes a surprisingly long time 668 00:34:05,340 --> 00:34:06,213 to install. 669 00:34:08,250 --> 00:34:11,403 It takes 15 minutes to set just one headlight. 670 00:34:16,972 --> 00:34:19,639 Then they place the tail lights. 671 00:34:22,350 --> 00:34:24,653 - Clearly, these cars are gonna need some wheels. 672 00:34:27,210 --> 00:34:28,043 And after that, 673 00:34:28,043 --> 00:34:30,523 we build up the interior trim of the vehicle. 674 00:34:43,874 --> 00:34:45,420 - [Narrator] The Vantage is ready to move 675 00:34:45,420 --> 00:34:46,917 to the very last line. 676 00:34:46,917 --> 00:34:49,470 - And trim tree is around fitting all the parts of the car 677 00:34:49,470 --> 00:34:52,220 that you touch and you feel when you're inside the car. 678 00:35:12,810 --> 00:35:14,130 - [Narrator] Front seats come to the line 679 00:35:14,130 --> 00:35:15,903 fully assembled from the trim shop. 680 00:35:23,790 --> 00:35:25,593 Then the hand-sewn steering wheel. 681 00:35:42,270 --> 00:35:43,720 Doors are brought to the line 682 00:35:46,320 --> 00:35:47,613 and carefully installed. 683 00:35:51,690 --> 00:35:54,060 - Once we fitted the doors, the car will complete 684 00:35:54,060 --> 00:35:56,660 the last couple of stations on the assembly process. 685 00:36:04,650 --> 00:36:06,810 - [Narrator] As the car nears the end of the line, 686 00:36:06,810 --> 00:36:08,613 there's one more key step, 687 00:36:10,170 --> 00:36:12,183 the famed Aston Martin Wing, 688 00:36:13,140 --> 00:36:15,450 so precious that they keep it locked up 689 00:36:15,450 --> 00:36:17,280 until it's ready to be installed. 690 00:36:17,280 --> 00:36:19,260 - This is the only badge, or wing 691 00:36:19,260 --> 00:36:23,130 left in the automotive industry made by a jeweler. 692 00:36:23,130 --> 00:36:25,353 So we know this is very special. 693 00:36:47,700 --> 00:36:49,170 - [Narrator] Before a completed Aston Martin 694 00:36:49,170 --> 00:36:50,520 can leave the factory, 695 00:36:50,520 --> 00:36:53,343 it must first take a few laps around the test track. 696 00:36:54,858 --> 00:36:57,691 (engine rumbling) 697 00:37:09,990 --> 00:37:12,300 - This is part of the off-tracks facility. 698 00:37:12,300 --> 00:37:14,580 This is our new rolling road. 699 00:37:14,580 --> 00:37:17,230 It's gonna get it up to about 70 or 80 miles an hour. 700 00:37:18,180 --> 00:37:21,120 - [Narrator] Off-tracks is where each vehicle is tested 701 00:37:21,120 --> 00:37:22,830 to meet quality control standards 702 00:37:22,830 --> 00:37:24,753 like wind noise and waterproofing. 703 00:37:25,599 --> 00:37:28,349 (engine roaring) 704 00:37:39,333 --> 00:37:42,000 - By doing these test processes in a controlled environment, 705 00:37:42,000 --> 00:37:44,300 we can make sure we do it the same every time. 706 00:37:45,960 --> 00:37:47,430 - [Narrator] Then building a Vantage 707 00:37:47,430 --> 00:37:49,263 literally hits a bump in the road. 708 00:37:51,600 --> 00:37:52,770 In the hydro pulse area, 709 00:37:52,770 --> 00:37:56,010 they simulate road inputs using hydraulic actuators 710 00:37:56,010 --> 00:37:57,843 to find squeaks and rattles. 711 00:38:04,890 --> 00:38:07,503 The very last test is a final inspection. 712 00:38:08,400 --> 00:38:10,221 - Where we spend about 20 hours 713 00:38:10,221 --> 00:38:13,980 specifically checking over the car as it's produced, 714 00:38:13,980 --> 00:38:15,030 and at the very end of line 715 00:38:15,030 --> 00:38:16,770 to make sure it's absolutely perfect 716 00:38:16,770 --> 00:38:18,520 before we ship it on to a customer. 717 00:38:21,600 --> 00:38:24,420 - [Narrator] It's taken almost 10 days of assembly 718 00:38:24,420 --> 00:38:27,093 to complete the V12 Vantage S, 719 00:38:28,920 --> 00:38:32,373 the fastest production-based Aston Martin ever built, 720 00:38:33,990 --> 00:38:36,540 and a bold gambit by one of the only remaining 721 00:38:36,540 --> 00:38:38,995 independent car makers in the world. 722 00:38:38,995 --> 00:38:42,420 (engine roaring) 723 00:38:42,420 --> 00:38:44,730 In a hyper-competitive automotive world, 724 00:38:44,730 --> 00:38:47,670 Aston Martin must do a lot with a little 725 00:38:47,670 --> 00:38:49,113 in order to stay relevant. 726 00:38:53,160 --> 00:38:54,720 - Building a car on your own is expensive. 727 00:38:54,720 --> 00:38:56,430 If they build the wrong car that doesn't sell, 728 00:38:56,430 --> 00:38:58,973 they're a company that's gonna be in a lot of trouble. 729 00:39:02,370 --> 00:39:04,290 - [Narrator] Now, after months of sketches, 730 00:39:04,290 --> 00:39:07,230 sculpting, and intricate assembly, 731 00:39:07,230 --> 00:39:10,786 the risky idea is finally ready to enter the real world. 732 00:39:10,786 --> 00:39:13,536 (engine roaring) 733 00:39:18,938 --> 00:39:21,688 (tranquil music) 734 00:39:33,180 --> 00:39:35,100 - The first thing you do when you get into any Aston Martin 735 00:39:35,100 --> 00:39:36,693 is go, how do I start it? 736 00:39:38,520 --> 00:39:41,043 You have this key that is made out of crystal, 737 00:39:44,010 --> 00:39:46,050 and you put it in a slot in the dash and you press it in, 738 00:39:46,050 --> 00:39:47,977 hold it, and then the engine starts. 739 00:39:47,977 --> 00:39:50,810 (engine rumbling) 740 00:39:51,720 --> 00:39:53,970 Aston calls it the Emotional Control Unit. 741 00:39:53,970 --> 00:39:55,320 You could look at it as gimmicky, 742 00:39:55,320 --> 00:39:57,450 but when it's that beautiful, it doesn't matter. 743 00:39:57,450 --> 00:39:59,400 It's a little bit of theater, but my God, 744 00:39:59,400 --> 00:40:00,390 if you're gonna do theater, 745 00:40:00,390 --> 00:40:01,920 you might as well do it on a car that looks like that. 746 00:40:01,920 --> 00:40:04,410 - You fire the car up and it just goes (engine roaring), 747 00:40:04,410 --> 00:40:06,630 and it just wakes up like it's been in some deep slumber 748 00:40:06,630 --> 00:40:09,360 and it's really pissed off that you just woke it up. 749 00:40:09,360 --> 00:40:12,810 And then you go out driving it and more of that happens. 750 00:40:12,810 --> 00:40:14,430 - [Narrator] It's a decidedly angry form 751 00:40:14,430 --> 00:40:16,260 of British sophistication. 752 00:40:16,260 --> 00:40:17,710 - Astons are British Camaros. 753 00:40:18,990 --> 00:40:21,140 They're loud, they're brash, they're rough. 754 00:40:22,830 --> 00:40:24,930 What Aston's done brilliantly over the years 755 00:40:24,930 --> 00:40:27,390 is taking a small number of ingredients 756 00:40:27,390 --> 00:40:29,043 and making a lot of different dishes with them. 757 00:40:29,043 --> 00:40:30,330 This V12, for example, 758 00:40:30,330 --> 00:40:31,770 dates back to the year of the flood. 759 00:40:31,770 --> 00:40:32,955 It's really old. 760 00:40:32,955 --> 00:40:35,370 (engine roaring) 761 00:40:35,370 --> 00:40:37,770 - [Narrator] What makes the AM28 so unique 762 00:40:37,770 --> 00:40:39,450 isn't new technology, 763 00:40:39,450 --> 00:40:41,973 but rather, old technology at its best. 764 00:40:44,550 --> 00:40:45,900 - Thank God it's not a turbo. 765 00:40:45,900 --> 00:40:47,730 Downsizing an engine and putting turbos on it 766 00:40:47,730 --> 00:40:49,890 makes easy power, but I call it cheating. 767 00:40:49,890 --> 00:40:51,273 It's just too easy. 768 00:40:52,909 --> 00:40:54,390 (engine roaring) 769 00:40:54,390 --> 00:40:56,850 There is a charm and a personality 770 00:40:56,850 --> 00:40:59,223 that normally aspirated engines have, 771 00:41:01,170 --> 00:41:03,660 and that's something we're missing out on. 772 00:41:03,660 --> 00:41:05,370 - To have a naturally-aspirated engine these days 773 00:41:05,370 --> 00:41:07,320 is actually becoming kind of rare. 774 00:41:07,320 --> 00:41:08,730 It's old technology. 775 00:41:08,730 --> 00:41:11,080 But there's something kind of special about it. 776 00:41:12,480 --> 00:41:13,800 - It's an angry, angry car, 777 00:41:13,800 --> 00:41:16,187 and it's really visceral and really powerful. 778 00:41:16,187 --> 00:41:17,020 (engine roaring) 779 00:41:17,020 --> 00:41:19,320 (tires screeching) 780 00:41:19,320 --> 00:41:20,550 It really speaks to you in that way. 781 00:41:20,550 --> 00:41:22,230 - And every time Aston comes out 782 00:41:22,230 --> 00:41:23,670 with a new version of this engine, you think, 783 00:41:23,670 --> 00:41:25,080 oh, they're beating this dead horse, 784 00:41:25,080 --> 00:41:26,613 except the horse ain't dead. 785 00:41:27,960 --> 00:41:30,750 This horse is faster than the previous one. 786 00:41:30,750 --> 00:41:31,741 It sounds better. 787 00:41:31,741 --> 00:41:32,760 (engine roaring) 788 00:41:32,760 --> 00:41:33,602 It's more powerful. 789 00:41:33,602 --> 00:41:35,040 (engine roaring) 790 00:41:35,040 --> 00:41:35,970 It responds better. 791 00:41:35,970 --> 00:41:39,180 - [Narrator] The V12 Vantage S is the most mainstream Aston 792 00:41:39,180 --> 00:41:42,990 to ever crack the 330-kilometer-an-hour barrier. 793 00:41:42,990 --> 00:41:44,730 - We've sort of dialed a few things up, 794 00:41:44,730 --> 00:41:47,250 maybe from 10 to 11 in some cases, 795 00:41:47,250 --> 00:41:50,220 and we put more power and performance into the car. 796 00:41:50,220 --> 00:41:52,260 - 205 miles an hour is incredible. 797 00:41:52,260 --> 00:41:54,540 It's a completely different world. 798 00:41:54,540 --> 00:41:56,400 This is the highest performance version 799 00:41:56,400 --> 00:41:58,500 of a high performance version of a high performance version 800 00:41:58,500 --> 00:42:00,420 of the Vantage. 801 00:42:00,420 --> 00:42:01,710 Every time you step up the ladder, 802 00:42:01,710 --> 00:42:03,450 you get a little bit more jewelry 803 00:42:03,450 --> 00:42:04,680 and spoilers and stuff like that. 804 00:42:04,680 --> 00:42:06,330 - It's an extreme way of building a car, 805 00:42:06,330 --> 00:42:07,950 and that's not for everybody. 806 00:42:07,950 --> 00:42:09,330 You throw fuel economy out the window. 807 00:42:09,330 --> 00:42:11,220 You throw everything that most people 808 00:42:11,220 --> 00:42:12,840 really care about on a daily basis, 809 00:42:12,840 --> 00:42:15,420 you throw that out the window and you build an extreme car 810 00:42:15,420 --> 00:42:18,704 that's loud, and powerful, and raucous, and fast. 811 00:42:18,704 --> 00:42:21,510 (engine roaring) 812 00:42:21,510 --> 00:42:25,264 - [Narrator] An extreme car with extreme performance. 813 00:42:25,264 --> 00:42:28,014 (tranquil music) 814 00:42:29,337 --> 00:42:30,720 (engine roaring) 815 00:42:30,720 --> 00:42:32,400 - If you take one drive in one of these cars, 816 00:42:32,400 --> 00:42:34,110 you realize that the people who are working 817 00:42:34,110 --> 00:42:36,780 behind the scenes at Aston are clearly sports car guys. 818 00:42:36,780 --> 00:42:39,030 - [Narrator] Sports car guys who continue to battle 819 00:42:39,030 --> 00:42:40,530 for their very survival 820 00:42:40,530 --> 00:42:42,690 by doing the only thing they know how to do, 821 00:42:42,690 --> 00:42:45,423 build beautifully exotic supercars. 822 00:42:46,830 --> 00:42:48,330 - At the end of the day, no matter what I drive 823 00:42:48,330 --> 00:42:50,700 at what whatever speed and whatever track, 824 00:42:50,700 --> 00:42:53,370 I always come away from the Aston thinking, 825 00:42:53,370 --> 00:42:55,370 God, that's more fun than anything else. 826 00:42:57,060 --> 00:42:59,130 - I pinch myself every single day still, 827 00:42:59,130 --> 00:43:02,536 after almost nine years, that this is not a job, 828 00:43:02,536 --> 00:43:03,900 it's a vocation, 829 00:43:03,900 --> 00:43:06,800 it's something which is very hard to describe the feeling. 830 00:43:09,710 --> 00:43:12,750 (rousing music) 831 00:43:12,750 --> 00:43:16,260 Just the sensation of what you're actually achieving 832 00:43:16,260 --> 00:43:19,290 in terms of the heritage, the future 833 00:43:19,290 --> 00:43:20,835 of the brand of Aston Martin. 834 00:43:20,835 --> 00:43:23,502 (rousing music) 835 00:43:26,520 --> 00:43:28,980 - They are the most communicative sports cars 836 00:43:28,980 --> 00:43:30,180 on the market now, 837 00:43:30,180 --> 00:43:33,120 and they show no signs of moving anywhere away from that. 838 00:43:33,120 --> 00:43:34,740 If that means there's no Aston in 20 years, 839 00:43:34,740 --> 00:43:37,090 hey, at least we had some of the best cars now. 65752

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