How It's Made: Dream Cars (2013) s01e04 Episode Script
Audi R8
Narrator: TODAY,
ON "HOW IT'S MADE: DREAM CARS,"
THE BEST AUDI
SINCE THE ORIGINAL QUATTRO --
THE SUPERSONIC R8 COUPE.
-- Captions by VITAC --
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
AUDI'S QUINTESSENTIAL TWO-SEATER
IS THE ALL-WHEEL DRIVE R8 COUPE,
BUILT IN NECKARSULM, GERMANY.
THE ESSENCE OF THE CAR COMPANY
KNOWN AS AUDI
BEGAN IN 1899,
WHEN ENGINEER AUGUST HORCH
INTRODUCED HIS FIRST AUTO BRAND,
HORCH.
DURING THAT TIME,
THE MAIN COMPETITORS
WERE MERCEDES AND BENZ.
IN 1909, AFTER DISPUTES
WITH HIS BUSINESS PARTNERS,
HORCH LEFT THE COMPANY
HE FOUNDED TO START AUDI.
ONE YEAR LATER,
THE FIRST SET OF NEW CARS
WITH THE AUDI NAMEPLATE
HIT THE MARKE
AND WON PEOPLE'S ATTENTION.
IN THE 1920s,
CAR SALES WERE DOWN IN GERMANY,
AND STRONG COMPETITION
FROM ABROAD
FORCED THE GERMAN CAR INDUSTRY
INTO A FINANCIAL CRISIS.
IN 1932,
IN ORDER TO SURVIVE THE CRISIS,
AUDI GREW BY MERGING
WITH AUTOMAKERS HORCH, DKW,
AND WANDERER
TO FORM THE AUTO UNION.
THIS WOULD BECOME
THE SYMBOLIC MEANING
OF THE OVERLAPPING
FOUR RINGS,
NOW KNOWN AS
THE ICONIC AUDI LOGO.
THE R8 USES A LIGHTWEIGHT,
ALL-ALUMINUM CHASSIS AND BODY.
MATCHED WITH A V-10 ENGINE,
IT DASHES
FROM 0 TO 62 MILES PER HOUR
IN 3.9 SECONDS.
FROM 2000 TO 2005,
THE RACING R8 TEAM VERSION
OF THE R8
WON THE LE MANS
24-HOUR ENDURANCE RACE
FIVE OUT OF SIX TIMES.
THE FOUNDATION OF THIS SUPERCAR
IS BASED
ON A SPACE-FRAME CHASSIS
AND MONOCOQUE DESIGN.
INTERLOCKING STRUTS FORM
THE CHASSIS PATTERN
WITH FEW INTERIOR SUPPORTS
WHILE THE CHASSIS,
ENGINE, AND SUSPENSION
ARE INTEGRATED INTO THE BODY.
WEIGHING ABOUT 460 POUNDS,
THE SPACE FRAME IS COMPRISED
OF 22% ALUMINUM PLATING,
70% OF EXTRUDED
ALUMINUM PROFILES
AND 8% OF AN ALUMINUM-BASED
VACUUM-PRESSURE CASTING.
BUILT IN THE NEWLY RENOVATED
FACTORY
AT THE MANUFACTURER'S
ALUMINUM SITE,
WORKERS ASSEMBLE
THE SPACE-FRAME CHASSIS,
PLACING THE STRUCTURAL STRUTS
INTO HIGH-PRESSURE VICES
CALLED CLAMPING FIXTURES.
THESE JIGS LOCK
THE CHASSIS PIECES INTO PLACE
TO BE WELDED TOGETHER.
WORKERS WELD THE FRAME PARTS
WITH TORCHES THAT HEAT UP TO
ABOUT 1,600 DEGREES FAHRENHEIT.
ALUMINUM BURNS
MORE RAPIDLY THAN STEEL,
FORCING WORKERS TO MOVE QUICKLY,
WITH DELICACY.
ONCE THE WORKER
FINISHES WELDING,
HE USES A HOIS
TO LIFT THE FRAME SECTION
TO ANOTHER WORKSTATION.
THE CAR'S CHASSIS CONSISTS
OF THREE MAJOR SECTIONS --
THE CENTRAL FLOOR, THE REAR END,
AND THE FRONT END.
AN OVERHEAD CONVEYOR CRANE
DELIVERS THE CHASSIS SECTIONS
TO ANOTHER WORKSTATION,
WHERE THE LARGE UNDERBODY PARTS
LOWER FOR MORE WELDING.
THE CHASSIS USES
MULTIPLE SECTIONS
AND INTEGRAL ADDITIONS
FOR COMPLETION.
WORKERS POSITION
THE FRAME PIECES
IN THE CLAMPING FIXTURES,
WHICH LOCK THE CHASSIS PARTS
INTO THEIR FINISHED POSITIONS,
CREATING THE ULTRA-LIGHTWEIGH
ALUMINUM UNDERCARRIAGE.
WORKERS METICULOUSLY WELD
EVERY INTERSECTING CORNER
OF THE CHASSIS.
ONCE THE WELDED JOINTS COOL,
WORKERS RELEASE
THE FINISHED CHASSIS.
AN OVERHEAD TRANSFER BEL
LIFTS THE FRAME
TO ANOTHER WORKSTATION
FOR MORE CONSTRUCTION.
ONE OF THE VERY FEW ROBOTIC
OPERATIONS IN THE BODY SHOP
IS THE INSERTION
OF FLOW-DRILL SCREWS
INTO THE CAR'S FLOOR
AND CABIN SUBSTRUCTURE WALLS.
A FASTENING ROBO
SPINS THE SELF-TAPPING SCREWS
AT A HIGH SPEED,
WHERE THEY FLASH MELD
INTO THE ALUMINUM,
CREATING AN ELONGATED,
THREADED SHANK
ON THE BACKSIDE
OF THE ALUMINUM SHEET.
THIS ADDS TO THE PULL STRENGTH.
SELF-TAPPING SCREWS
DRILL THEIR OWN HOLES
WHEN THEY SCREW INTO MATERIALS
LIKE WOOD, PLASTIC, AND METAL.
THE FLOOR TUNNEL IS REINFORCED
BY CUSTOM LIGHTWEIGHT,
TAILORED ALUMINUM BLANKS
THAT SAVE WEIGHT.
THE THICKNESS OF THE PANELS
VARIES
BASED ON DESIGN AND FUNCTION.
IT TAKES 308 AUTOMATICALLY
PLACED SELF-TAPPING SCREWS
TO JOIN THE COMPONENTS
OF THIS CAR'S SUBSTRUCTURE.
AS CARS ARE PRODUCED TO MEE
CONSUMER CUSTOMIZATION REQUESTS,
THE VEHICLES ARE PRODUCED
IN SEQUENCE.
ONE WEEK BEFORE THE BODY SHOP
BEGINS ASSEMBLING THE CHASSIS,
SISTER FACTORIES AND SUPPLIERS
FROM ACROSS THE COUNTRY
BEGIN THEIR PRODUCTION
OF INDIVIDUALIZED ITEMS.
THIS INCLUDES SEATS,
RUNNING GEAR, AND BUMPERS,
ALL DEPENDING
ON EACH CAR'S VARIATION.
AS THE CHASSIS STANDS
AT A WORKSTATION,
WORKERS DELIVER PARTS,
LIKE THE DOORS, TRUNK LID,
AND ENGINE HOOD,
WITH THE ASSISTANCE
OF LIFTING DEVICES.
THE PARTS ARE BOLTED
WITH TORQUE WRENCHES.
WORKERS DELIVER THE BODY'S
TRUNK LID FOR INSTALLATION.
SINCE THE CAR'S ENGINE
IS LOCATED IN THE MIDSECTION,
THE CARGO AREA
IS IN THE FRONT END.
WHILE ATTACHING THE TRUNK LID,
THE WORKERS ALSO INSPEC
THE MOBILITY
OF ITS GAS PRESSURE SPRINGS
AND CERTIFY
THAT THE LID IS A PERFECT FI
AND MOVES PROPERLY.
BEFORE THE BODY PANELS
MEET THE PAINT SHOP,
WORKERS REMOVE
ANY EXCESS RESIDUE
WITH HEAVY-DUTY GRINDERS, FILES,
AND HIGH-POWERED SANDERS
TO CREATE
PERFECTLY UNIFORM SURFACES.
AS THE FINAL STAGE,
A WORKER CAREFULLY SANDS
THE ALUMINUM SKIN PANELS BY HAND
WITH A SANDING BLOCK.
THIS ENSURES PRECISE SMOOTHNESS
TO THE SURFACE
BEFORE ANY FURTHER
CONSTRUCTION OR ALTERATIONS.
FOR THIS CAR,
THE TOTAL PRODUCTION TIME
IN THE PAINT SHOP
IS FOUR DAYS.
11 OPTIONAL COLORS
ARE AVAILABLE,
YET ANY COLOR IS POSSIBLE
TO CREATE
TO MEET A CUSTOMER'S DESIRE.
AFTER 96 HOURS OF CONSTRUCTION
AND A FIVE-STAGE PAINT PROCESS,
THE BODY IS READY TO RECEIVE
ITS RUNNING GEAR AND MORE.
Narrator:
THIS AUDI R8 ROAD CAR'S
HIGH-PERFORMANCE BRAKING SYSTEM
IS DIRECTLY MODELED AFTER
ITS FORMULA ONE EDITION,
ALLOWING IT TO STOP
HARDER AND FASTER
IN SHORTER DISTANCES
OR EVERYDAY TRAFFIC.
A WORKER SETS A ROTOR DISC
ON A WORK TABLE
AND ADDS THE STEERING BUCKLE,
WHICH WILL ATTACH
TO THE SUSPENSION COMPONENTS.
THEN IT'S LOCKED INTO POSITION
WITH A TORQUE WRENCH.
HE ADDS A SMALL CALIPER,
WHICH IS FOR
THE PARKING-BRAKE SYSTEM,
AND ADDS AND FASTENS
THE BOLTING PINS
WITH THE AUTOMATED WRENCH.
HE INSTALLS
THE HYDRAULIC BRAKE HOSE
WITH A SLIGHT TWIST.
INSTALLATION OF THE LOWER AND
UPPER SUSPENSION CONTROL ARMS,
MORE COMMONLY KNOWN
AS WISHBONES, FOLLOWS.
USING AN IMPACT DRIVER,
HE BOLTS
THE NARROW END OF EACH ARM
TO THE STEERING KNUCKLE.
THE CONTROL ARMS PIVO
ON BALL JOINTS
AND HELP ISOLATE THE VEHICLE
FROM ROAD SHOCK.
THEY ALSO CONTROL THE MOTION
OF THE WHEEL THROUGHOUT TRAVEL,
CONTROLLING PARAMETERS SUCH AS
THE CAMBER ANGLE, TOE PATTERN,
ROLL CENTER HEIGHT, AND MORE.
PUT INTO PLACE AFTERWARD
IS A TIE ROD,
A STRUCTURAL UNI
THAT ATTACHES ON BOTH ENDS
OF THE STEERING RACK,
WHICH AIDS IN THE PUSHING AND
PULLING MOVEMENT OF THE WHEELS.
THE TIE ROD ALSO ASSISTS
WITH THE VEHICLE'S STEERING
AND THE CAR'S ULTIMATE SAFETY.
THE WORKER ADDS
THE MONOBLOC ALUMINUM
BRAKE CALIPER AND ITS PINS,
WHICH HOUSES THE BRAKE PADS
AND SIX PISTONS.
FINALLY, HE ATTACHES
A FEW MORE PARTS TO THE TIE ROD,
INCLUDING
THE BOLT AND SOCKET ARRANGEMENT,
WITH A TAPERED STUD
FOR THE MOUNT BRACKET.
THIS WILL COMPLETE THE ASSEMBLY
BEFORE IT JOINS
THE REST OF THE RUNNING GEAR
AND THE NEW CHASSIS.
ONCE THE WORKER FINISHES
THE BRAKE ASSEMBLY,
A HOIST TAKES IT AWAY
TO ANOTHER WORKSTATION.
COMING FROM A SISTER PLAN
IN HUNGARY,
A WORKER SHUTTLES THE 560-POUND,
10-CYLINDER ENGINE
TO A WORKSTATION,
WHERE IT RECEIVES
MORE ASSEMBLY TIME
DUE TO ADDITIONAL PARTS.
THIS 5.2-LITER ENGINE GENERATES
525 HORSEPOWER,
AFFORDING THE CAR A TOP SPEED
OF 195 MILES PER HOUR.
WHILE ADDING
MORE PARTS TO THE ENGINE,
THE WORKER ATTACHES
THE DRIVE PLATE
AND ITS NECESSARY SCREWS
TO THE ENGINE FLYWHEEL,
A DEVICE USED
TO STORE ROTATIONAL ENERGY.
HE INSERTS EACH SCREW BY HAND
AND FASTENS THEM WITH
A POWER DRIVER.
BEFORE CONNECTING THE ENGINE
TO THE TRANSMISSION SHAFT,
THE COMPONENT THAT TRANSMITS
TORQUE AND ROTATION,
HE SCANS THE DRIVE PLATE
USING A SCANNER.
THE SCANNER IS LINKED
TO COMPUTER-PROCESSED
MONITORING SOFTWARE
FOR THE CAR'S ASSEMBLY RECORDS.
USING OTHER COMPUTER SOFTWARE,
HE ALSO VERIFIES
WHETHER THE SCREWS
ARE FITTED CORRECTLY
AND WITH THE RIGHT AMOUN
OF TENSION TO THE DRIVE PLATE,
MEETING ENGINEERING
AND MANUFACTURING STANDARDS.
ONCE THE WORKER ACCURATELY
INSTALLS THE DRIVE PLATE,
HE ATTACHES
THE DOUBLE-CLUTCH TRANSMISSION
TO THE V-10 ENGINE.
USING AN IMPACT DRIVER
TO FASTEN THE SCREWS,
THE TWO LARGE RUNNING PARTS
ARE MATED
TO BECOME THE HEART AND SPIRI
OF THE R8.
Narrator: EACH AUDI R8 IS MADE
OF MORE THAN 5,000 PARTS,
INSTALLED MOSTLY BY HAND.
WITH 14 STATIONS
IN THE ASSEMBLY HALL,
EACH HAS A STRICT CYCLE TIME
OF 30 MINUTES.
THOUGH ONE OF THE FASTEST CARS
IN THE WORLD,
IT'S GRADUALLY MADE
IN EIGHT DAYS.
THE REAR OF THIS SUPERCAR
IS THE MOST COMPLEX PAR
OF THE VEHICLE.
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
WORKERS MANEUVER THE CHASSIS
ONTO A TRANSFER DOLLY.
THEY POSITION
THE SPACE FRAME PROPERLY
TO DROP IN THE V-10 MID-ENGINE,
THE GEAR BOX, THE FUEL TANK,
INTERIOR PANELS,
AND OTHER TRIM ITEMS.
THEY ALSO ATTACH THE SPECIFIED
CABLING AND PIPING,
ALONG WITH
THE NECESSARY SCREWS AND BOLTS.
BECAUSE THIS CAR USES
A FLAT OIL PAN,
IT ALLOWS THE ENGINE
TO BE INSTALLED LOWER,
BRINGING THE CAR'S CENTER
OF GRAVITY CLOSER TO THE GROUND,
RESULTING IN OUTSTANDING
ROAD HANDLING.
NEXT, THE WORKERS ROTATE
THE CHASSIS,
ALONG WITH THE NEW ENGINE
AND INTERIOR COMPONENTS,
TO INSERT MORE ELECTRICAL WIRING
AND PLASTIC PIPING
TO THE RUNNING-GEAR ELEMENTS
AND MORE.
WITH A LOT OF COMPLEXITIES
AND A LARGE AMOUN
OF INTRICATE LABOR,
THE MULTIPLE INSTALLATION STEPS
OF MOST ITEMS
HAVE TO BE FLAWLESS.
AS THEY SITUATE PARTS,
THEY INSTALL THE SCREWS
MANUALLY.
DURING THIS PROCESS,
WORKERS INSTALL 50 TO 60 PARTS
WITHIN 30 MINUTES.
ASSISTED BY A SPECIALIZED
LIFTING DEVICE,
A WORKER INSTALLS
A BRAKING ASSEMBLY UNI
FITTED WITH CARBON-FIBER
REINFORCED CERAMIC BRAKE DISCS.
USING A TORQUE WRENCH,
HE FASTENS THE LOCKING BOLTS,
SECURING THE UNIT INTO POSITION.
THE BODY AND CHASSIS
ARE SHUTTLED BY A TRANSFER HOIS
DOWN THE ASSEMBLY LINE
TO STATION NUMBER NINE,
WHERE MORE WORKERS AWAI
TO ADD KEY AESTHETIC
AND FUNCTIONAL FEATURES.
USING A SPECIALIZED
LIFTING CRANE,
THE WORKERS LOWER
THE CAR'S RETRACTABLE ACOUSTIC
FOLDING ROOF MADE OF CLOTH.
IT WEIGHS LESS THAN A HARD TOP
AND DOESN'T REDUCE
THE CAR'S HANDLING DYNAMICS.
ONCE IT'S FIT INTO POSITION,
THE CRANE RELEASES
THE COMPONENT.
WHILE A WORKER FASTENS THE BOLTS
OF THE CONVERTIBLE ROOF COVER,
ANOTHER ATTACHES
THE CAR'S L.E.D. TAILLIGHTS,
WHICH NOT ONLY ADD FLARE,
BUT ARE EXTREMELY
VIBRATION-RESISTANT.
L.E.D.s HAVE
A VERY LONG SERVICE LIFE
AND ILLUMINATE 250 MILLISECONDS
FASTER THAN CONVENTIONAL
INCANDESCENT-BULB-TYPE
ASSEMBLIES,
INCREASING SAFETY.
WORKERS ALSO INSTALL
THE BATTERY, DASHBOARD,
AND FRONT AND REAR BUMPERS.
THE REAR BUMPER LOOKS SHARP,
BUT ALSO CONCEALS
ULTRASONIC SENSORS
THAT ASSIST THE VISUAL
AND ACOUSTIC PARKING SYSTEM.
FINALLY, WORKERS INSTALL
THE ENGINE COVER,
WHICH IS SET BETWEEN THE FULLY
AUTOMATIC HOOD ROOF COVER
AND THE RETRACTABLE
REAR SPOILER.
USING A TORQUE WRENCH,
A WORKER ATTACHES THE COVER
TO THE HINGES
BEFORE ATTACHING
ITS GAS PRESSURE SPRINGS.
IN ANOTHER WORK AREA,
A ROBOT ADDS
A HIGH-STRENGTH ADHESIVE
TO THE EDGES
OF THE FRONT WINDSCREEN.
WORKERS DELIVER
THE LARGE GLASS PANE,
SUCTIONED TO TWIN-CUP
VACUUM LIFTERS,
AND LAY THE WINDOW
INTO ITS PRE-ALIGNED POSITION.
AFTERWARD, THE BOTTOM
AND BODY SHELL BRACKETS
WILL BE INSTALLED
TO FURTHER CONTAIN THE GLASS.
ANOTHER WORKER INSERTS
THE STEERING WHEEL
AND THE STEERING COLUMN AIRBAG,
INCLUDING ITS ELECTRICAL WIRING.
COVERINGS FOR THE CAR'S INTERIOR
INCLUDE FINE NAPA LEATHER,
COMPOSED OF LAMB OR SHEEPSKIN,
AS WELL AS ALCANTARA,
WHICH RESEMBLES SUEDE.
IN THE CAR'S
CONVERTIBLE VERSION,
A SPECIAL PIGMENTATION
PREVENTS THE SEATS
FROM OVERHEATING IN THE SUN.
A WORKER SITUATES
THE PREMIUM LEATHER BUCKET SEATS
INSIDE THE COCKPIT,
USING A SEAT-INSTALLATION
LIFTER.
THE PNEUMATIC ARM
MAKES IT EASIER FOR WORKERS
TO INSERT ANY ELECTRICAL WIRING
IN AND AROUND THE SEATING.
A WORKER,
USING A LIFTING DEVICE,
DELIVERS A FORGED 19-INCH
ALUMINUM-ALLOY WHEEL AND TIRE
TO THE FRONT PASSENGER SIDE
WHEEL PLATE
AND FASTENS THE LUG BOLTS
WITH AN AIR IMPACT DRIVER.
AT ANOTHER WORKSTATION,
USING SELF-TAPPING SCREWS
AND AN IMPACT DRIVER,
A WORKER INSTALLS AND FASTENS
SIX ALUMINUM UNDERLINING
BODY PANELS UNDERNEATH THE CAR.
THESE PANELS APPLY
ADDITIONAL BODYWORK RIGIDITY
AND GENERATE MORE DOWNFORCE
AT HIGH SPEEDS,
AS WELL AS SOME PROTECTION
TO RUNNING-GEAR PARTS
FROM ENVIRONMENTAL EFFECTS.
ONLY 20 R8 CARS ARE MADE DAILY,
AND WHEN THEY REACH
THE END OF THE LINE,
IT'S TIME
FOR SOME EXCITING TEST DRIVES.
Narrator: THE R8's V-10 ENGINE
IS EXCELLENT.
WITH SUPREME POWER, TORQUE,
AND FUEL EFFICIENCY,
IT'S A ROAD CAR
THAT TRULY GOES THE DISTANCE,
THANKS TO THE DIREC
FUEL-INJECTION SYSTEM,
ORIGINALLY DEVELOPED FOR
THE 24 HOURS OF LE MANS RACES.
NAMED AFTER THE AUDI QUATTRO,
THIS FACTORY
WAS PRIMARILY FOUNDED
TO PRODUCE
HIGH-PERFORMANCE SPORTS CARS.
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
A STATION KNOWN AS
THE FINISH LINE,
WORKERS INSPEC
FINAL CONSTRUCTION DETAILS.
THEY EXAMINE
ALL ELECTRICAL SYSTEMS,
ALL LIGHTS,
AND THE POWER STEERING.
WORKERS ALSO ADD
FUNCTIONING FLUIDS
LIKE COOLANT, OIL,
TRANSMISSION FLUID,
AND BRAKE FLUID BEFORE
THE CAR IS SENT TO ENDURE
SOME METICULOUS DRIVING TESTS.
THE CAR NOW STANDS
IN A DYNAMOMETER ROLL BOOTH,
WHICH USES
MULTIPLE DRIVE ROLLERS
FOR ROUGHLY 10 MINUTES.
THE CAR IS OFTEN DRIVEN
AT SPEEDS
OF UP TO 100 MILES PER HOUR
THROUGHOUT THIS EVALUATION.
VEHICLES ARE DRIVEN
WHILE A COMPUTERIZED PROGRAM
CONDUCTS A SERIES OF OPERATIONS,
SIMULATING
REALISTIC DRIVING CONDITIONS.
THEY EXAMINE TRANSMISSION,
SUSPENSION, BRAKING,
AND, NOT TO MENTION,
THE ENGINE'S HORSEPOWER
AND TORQUE.
THE TESTING ALSO INCLUDES
LOAD SIMULATIONS,
SUCH AS UPHILL DRIVING
AND TRAILER TOWING.
BUT THE TESTING
DOES NOT END HERE.
IT'S TIME TO GET OUTSIDE.
TO PUT THE CAR'S FUNCTIONALITY
AND VALIDATION TO THE TEST,
QUALIFIED TESTERS DRIVE THE CAR
ON CLOSED-OFF TRACKS
AS PART OF A PRE-DELIVERY
DURABILITY TEST.
THIS SPECIAL-SURFACE TRACK
IS A LOW-SPEED COURSE
WITH A VARIETY
OF DEMANDING ROAD CONDITIONS.
TESTERS CHECK THE TRANSMISSION,
STEERING,
SUSPENSION, AND BRAKES,
PLUS THE OVERALL RIDE
AND HANDLING OF THE DRIVE.
THE PERFORMANCE DEVELOPMEN
TEST TRACK
EVALUATES
NEW AND PROTOTYPE VEHICLES
IN A HIGH-SPEED BOWL
WITH LANE-CHANGE AREAS,
STRAIGHTAWAYS,
AND BANKED CORNERS.
THE CAR'S TOP SPEED
AND PERFORMANCE IN WARM WEATHER
IS ALSO EVALUATED.
QUALITY IS ALSO
SOMETHING YOU CAN HEAR.
EVERY CAR IS DRIVEN
AT A HIGH STRESS LEVEL,
AND SOUND TESTS ARE APPLIED
TO CHECK FOR INTERIOR NOISE,
NOISE VIBRATION, WIND NOISE,
AND RUNNING-GEAR NOISE.
BEYOND THE FACTORY TEST TRACKS,
THE MANUFACTURER HAS A SET OF
HILL ROUTES AND CITY COURSES
THAT PROGRESSIVELY CHALLENGE
THE VEHICLE'S PERFORMANCE
AND DURABILITY.
FOLLOWING THE STRIC
AND EXTENSIVE TESTING,
THE CAR IS TREATED TO MORE
MANUAL QUALITY ASSURANCE
AND PRECISION CARE.
AFTER A HIGH-PRESSURE WASH,
A WORKER GIVES THE LUXURIOUS
SPORTS CAR SOME FINAL ATTENTION
BY VERIFYING THE BODY PAIN
AND BUFFING THE SKIN PANELS
WITH A NON-ABRASIVE,
LEATHER CLOTH.
THIS CAREFULLY REMOVES ANY DIRT,
DUST, OR LIQUID.
WHETHER IN COUPE
OR CONVERTIBLE FORM,
THIS CAR
IS AN AUTOMOTIVE MASTERPIECE,
DESIGNED AND ENGINEERED TO MAKE
A STATEMENT ON EVERY ROAD.
WORKERS APPLY A PROTECTIVE,
WHITE, NEW-CAR WRAPPING
OVER THE VEHICLE.
AN OUTER FILM LAYER
PROTECTS THE CAR FROM WATER
WHILE AN INNER, FLEECE LAYER
PROTECTS THE PAINTWORK
FROM ANY SCRATCHES.
EVEN WITH THE PROTECTIVE WRAP
OVERTOP,
A WORKER CAN STILL
DRIVE THE VEHICLE
WHERE IT NEEDS TO GO NEXT.
BUILT TO LOOK ELEGAN
YET ROBUST,
THE R8 HAS A UNIQUE
SUPERCAR POISE.
WITH A DESIGN INFLUENCE
THAT COMES FROM CAR RACING,
STYLE AND FUNCTIONALITY
ARE NEVER IN QUESTION,
LIKE TRANSFORMING
A CONVERTIBLE TO A COUPE
AT SPEEDS
OF UP TO 30 MILES PER HOUR
IN AS LITTLE AS 25 SECONDS.
IGNITED BY ONGOING,
SPORTS-MINDED PASSION
AND CONSTRUCTED
FOR DISTINCTIVE PERFORMANCE,
THE AUDI R8
IS THE PERFECT SUPERCAR
FOR ANY LONG-DISTANCE CRUISE,
BUT TO TRULY ENJOY
HOW IT'S MADE,
ONE HAS TO LISTEN
TO HOW IT SOUNDS
AND FEEL HOW IT HANDLES
BOTH IN EVERYDAY TRAFFIC
AND ON THE RACETRACK.
ON "HOW IT'S MADE: DREAM CARS,"
THE BEST AUDI
SINCE THE ORIGINAL QUATTRO --
THE SUPERSONIC R8 COUPE.
-- Captions by VITAC --
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
AUDI'S QUINTESSENTIAL TWO-SEATER
IS THE ALL-WHEEL DRIVE R8 COUPE,
BUILT IN NECKARSULM, GERMANY.
THE ESSENCE OF THE CAR COMPANY
KNOWN AS AUDI
BEGAN IN 1899,
WHEN ENGINEER AUGUST HORCH
INTRODUCED HIS FIRST AUTO BRAND,
HORCH.
DURING THAT TIME,
THE MAIN COMPETITORS
WERE MERCEDES AND BENZ.
IN 1909, AFTER DISPUTES
WITH HIS BUSINESS PARTNERS,
HORCH LEFT THE COMPANY
HE FOUNDED TO START AUDI.
ONE YEAR LATER,
THE FIRST SET OF NEW CARS
WITH THE AUDI NAMEPLATE
HIT THE MARKE
AND WON PEOPLE'S ATTENTION.
IN THE 1920s,
CAR SALES WERE DOWN IN GERMANY,
AND STRONG COMPETITION
FROM ABROAD
FORCED THE GERMAN CAR INDUSTRY
INTO A FINANCIAL CRISIS.
IN 1932,
IN ORDER TO SURVIVE THE CRISIS,
AUDI GREW BY MERGING
WITH AUTOMAKERS HORCH, DKW,
AND WANDERER
TO FORM THE AUTO UNION.
THIS WOULD BECOME
THE SYMBOLIC MEANING
OF THE OVERLAPPING
FOUR RINGS,
NOW KNOWN AS
THE ICONIC AUDI LOGO.
THE R8 USES A LIGHTWEIGHT,
ALL-ALUMINUM CHASSIS AND BODY.
MATCHED WITH A V-10 ENGINE,
IT DASHES
FROM 0 TO 62 MILES PER HOUR
IN 3.9 SECONDS.
FROM 2000 TO 2005,
THE RACING R8 TEAM VERSION
OF THE R8
WON THE LE MANS
24-HOUR ENDURANCE RACE
FIVE OUT OF SIX TIMES.
THE FOUNDATION OF THIS SUPERCAR
IS BASED
ON A SPACE-FRAME CHASSIS
AND MONOCOQUE DESIGN.
INTERLOCKING STRUTS FORM
THE CHASSIS PATTERN
WITH FEW INTERIOR SUPPORTS
WHILE THE CHASSIS,
ENGINE, AND SUSPENSION
ARE INTEGRATED INTO THE BODY.
WEIGHING ABOUT 460 POUNDS,
THE SPACE FRAME IS COMPRISED
OF 22% ALUMINUM PLATING,
70% OF EXTRUDED
ALUMINUM PROFILES
AND 8% OF AN ALUMINUM-BASED
VACUUM-PRESSURE CASTING.
BUILT IN THE NEWLY RENOVATED
FACTORY
AT THE MANUFACTURER'S
ALUMINUM SITE,
WORKERS ASSEMBLE
THE SPACE-FRAME CHASSIS,
PLACING THE STRUCTURAL STRUTS
INTO HIGH-PRESSURE VICES
CALLED CLAMPING FIXTURES.
THESE JIGS LOCK
THE CHASSIS PIECES INTO PLACE
TO BE WELDED TOGETHER.
WORKERS WELD THE FRAME PARTS
WITH TORCHES THAT HEAT UP TO
ABOUT 1,600 DEGREES FAHRENHEIT.
ALUMINUM BURNS
MORE RAPIDLY THAN STEEL,
FORCING WORKERS TO MOVE QUICKLY,
WITH DELICACY.
ONCE THE WORKER
FINISHES WELDING,
HE USES A HOIS
TO LIFT THE FRAME SECTION
TO ANOTHER WORKSTATION.
THE CAR'S CHASSIS CONSISTS
OF THREE MAJOR SECTIONS --
THE CENTRAL FLOOR, THE REAR END,
AND THE FRONT END.
AN OVERHEAD CONVEYOR CRANE
DELIVERS THE CHASSIS SECTIONS
TO ANOTHER WORKSTATION,
WHERE THE LARGE UNDERBODY PARTS
LOWER FOR MORE WELDING.
THE CHASSIS USES
MULTIPLE SECTIONS
AND INTEGRAL ADDITIONS
FOR COMPLETION.
WORKERS POSITION
THE FRAME PIECES
IN THE CLAMPING FIXTURES,
WHICH LOCK THE CHASSIS PARTS
INTO THEIR FINISHED POSITIONS,
CREATING THE ULTRA-LIGHTWEIGH
ALUMINUM UNDERCARRIAGE.
WORKERS METICULOUSLY WELD
EVERY INTERSECTING CORNER
OF THE CHASSIS.
ONCE THE WELDED JOINTS COOL,
WORKERS RELEASE
THE FINISHED CHASSIS.
AN OVERHEAD TRANSFER BEL
LIFTS THE FRAME
TO ANOTHER WORKSTATION
FOR MORE CONSTRUCTION.
ONE OF THE VERY FEW ROBOTIC
OPERATIONS IN THE BODY SHOP
IS THE INSERTION
OF FLOW-DRILL SCREWS
INTO THE CAR'S FLOOR
AND CABIN SUBSTRUCTURE WALLS.
A FASTENING ROBO
SPINS THE SELF-TAPPING SCREWS
AT A HIGH SPEED,
WHERE THEY FLASH MELD
INTO THE ALUMINUM,
CREATING AN ELONGATED,
THREADED SHANK
ON THE BACKSIDE
OF THE ALUMINUM SHEET.
THIS ADDS TO THE PULL STRENGTH.
SELF-TAPPING SCREWS
DRILL THEIR OWN HOLES
WHEN THEY SCREW INTO MATERIALS
LIKE WOOD, PLASTIC, AND METAL.
THE FLOOR TUNNEL IS REINFORCED
BY CUSTOM LIGHTWEIGHT,
TAILORED ALUMINUM BLANKS
THAT SAVE WEIGHT.
THE THICKNESS OF THE PANELS
VARIES
BASED ON DESIGN AND FUNCTION.
IT TAKES 308 AUTOMATICALLY
PLACED SELF-TAPPING SCREWS
TO JOIN THE COMPONENTS
OF THIS CAR'S SUBSTRUCTURE.
AS CARS ARE PRODUCED TO MEE
CONSUMER CUSTOMIZATION REQUESTS,
THE VEHICLES ARE PRODUCED
IN SEQUENCE.
ONE WEEK BEFORE THE BODY SHOP
BEGINS ASSEMBLING THE CHASSIS,
SISTER FACTORIES AND SUPPLIERS
FROM ACROSS THE COUNTRY
BEGIN THEIR PRODUCTION
OF INDIVIDUALIZED ITEMS.
THIS INCLUDES SEATS,
RUNNING GEAR, AND BUMPERS,
ALL DEPENDING
ON EACH CAR'S VARIATION.
AS THE CHASSIS STANDS
AT A WORKSTATION,
WORKERS DELIVER PARTS,
LIKE THE DOORS, TRUNK LID,
AND ENGINE HOOD,
WITH THE ASSISTANCE
OF LIFTING DEVICES.
THE PARTS ARE BOLTED
WITH TORQUE WRENCHES.
WORKERS DELIVER THE BODY'S
TRUNK LID FOR INSTALLATION.
SINCE THE CAR'S ENGINE
IS LOCATED IN THE MIDSECTION,
THE CARGO AREA
IS IN THE FRONT END.
WHILE ATTACHING THE TRUNK LID,
THE WORKERS ALSO INSPEC
THE MOBILITY
OF ITS GAS PRESSURE SPRINGS
AND CERTIFY
THAT THE LID IS A PERFECT FI
AND MOVES PROPERLY.
BEFORE THE BODY PANELS
MEET THE PAINT SHOP,
WORKERS REMOVE
ANY EXCESS RESIDUE
WITH HEAVY-DUTY GRINDERS, FILES,
AND HIGH-POWERED SANDERS
TO CREATE
PERFECTLY UNIFORM SURFACES.
AS THE FINAL STAGE,
A WORKER CAREFULLY SANDS
THE ALUMINUM SKIN PANELS BY HAND
WITH A SANDING BLOCK.
THIS ENSURES PRECISE SMOOTHNESS
TO THE SURFACE
BEFORE ANY FURTHER
CONSTRUCTION OR ALTERATIONS.
FOR THIS CAR,
THE TOTAL PRODUCTION TIME
IN THE PAINT SHOP
IS FOUR DAYS.
11 OPTIONAL COLORS
ARE AVAILABLE,
YET ANY COLOR IS POSSIBLE
TO CREATE
TO MEET A CUSTOMER'S DESIRE.
AFTER 96 HOURS OF CONSTRUCTION
AND A FIVE-STAGE PAINT PROCESS,
THE BODY IS READY TO RECEIVE
ITS RUNNING GEAR AND MORE.
Narrator:
THIS AUDI R8 ROAD CAR'S
HIGH-PERFORMANCE BRAKING SYSTEM
IS DIRECTLY MODELED AFTER
ITS FORMULA ONE EDITION,
ALLOWING IT TO STOP
HARDER AND FASTER
IN SHORTER DISTANCES
OR EVERYDAY TRAFFIC.
A WORKER SETS A ROTOR DISC
ON A WORK TABLE
AND ADDS THE STEERING BUCKLE,
WHICH WILL ATTACH
TO THE SUSPENSION COMPONENTS.
THEN IT'S LOCKED INTO POSITION
WITH A TORQUE WRENCH.
HE ADDS A SMALL CALIPER,
WHICH IS FOR
THE PARKING-BRAKE SYSTEM,
AND ADDS AND FASTENS
THE BOLTING PINS
WITH THE AUTOMATED WRENCH.
HE INSTALLS
THE HYDRAULIC BRAKE HOSE
WITH A SLIGHT TWIST.
INSTALLATION OF THE LOWER AND
UPPER SUSPENSION CONTROL ARMS,
MORE COMMONLY KNOWN
AS WISHBONES, FOLLOWS.
USING AN IMPACT DRIVER,
HE BOLTS
THE NARROW END OF EACH ARM
TO THE STEERING KNUCKLE.
THE CONTROL ARMS PIVO
ON BALL JOINTS
AND HELP ISOLATE THE VEHICLE
FROM ROAD SHOCK.
THEY ALSO CONTROL THE MOTION
OF THE WHEEL THROUGHOUT TRAVEL,
CONTROLLING PARAMETERS SUCH AS
THE CAMBER ANGLE, TOE PATTERN,
ROLL CENTER HEIGHT, AND MORE.
PUT INTO PLACE AFTERWARD
IS A TIE ROD,
A STRUCTURAL UNI
THAT ATTACHES ON BOTH ENDS
OF THE STEERING RACK,
WHICH AIDS IN THE PUSHING AND
PULLING MOVEMENT OF THE WHEELS.
THE TIE ROD ALSO ASSISTS
WITH THE VEHICLE'S STEERING
AND THE CAR'S ULTIMATE SAFETY.
THE WORKER ADDS
THE MONOBLOC ALUMINUM
BRAKE CALIPER AND ITS PINS,
WHICH HOUSES THE BRAKE PADS
AND SIX PISTONS.
FINALLY, HE ATTACHES
A FEW MORE PARTS TO THE TIE ROD,
INCLUDING
THE BOLT AND SOCKET ARRANGEMENT,
WITH A TAPERED STUD
FOR THE MOUNT BRACKET.
THIS WILL COMPLETE THE ASSEMBLY
BEFORE IT JOINS
THE REST OF THE RUNNING GEAR
AND THE NEW CHASSIS.
ONCE THE WORKER FINISHES
THE BRAKE ASSEMBLY,
A HOIST TAKES IT AWAY
TO ANOTHER WORKSTATION.
COMING FROM A SISTER PLAN
IN HUNGARY,
A WORKER SHUTTLES THE 560-POUND,
10-CYLINDER ENGINE
TO A WORKSTATION,
WHERE IT RECEIVES
MORE ASSEMBLY TIME
DUE TO ADDITIONAL PARTS.
THIS 5.2-LITER ENGINE GENERATES
525 HORSEPOWER,
AFFORDING THE CAR A TOP SPEED
OF 195 MILES PER HOUR.
WHILE ADDING
MORE PARTS TO THE ENGINE,
THE WORKER ATTACHES
THE DRIVE PLATE
AND ITS NECESSARY SCREWS
TO THE ENGINE FLYWHEEL,
A DEVICE USED
TO STORE ROTATIONAL ENERGY.
HE INSERTS EACH SCREW BY HAND
AND FASTENS THEM WITH
A POWER DRIVER.
BEFORE CONNECTING THE ENGINE
TO THE TRANSMISSION SHAFT,
THE COMPONENT THAT TRANSMITS
TORQUE AND ROTATION,
HE SCANS THE DRIVE PLATE
USING A SCANNER.
THE SCANNER IS LINKED
TO COMPUTER-PROCESSED
MONITORING SOFTWARE
FOR THE CAR'S ASSEMBLY RECORDS.
USING OTHER COMPUTER SOFTWARE,
HE ALSO VERIFIES
WHETHER THE SCREWS
ARE FITTED CORRECTLY
AND WITH THE RIGHT AMOUN
OF TENSION TO THE DRIVE PLATE,
MEETING ENGINEERING
AND MANUFACTURING STANDARDS.
ONCE THE WORKER ACCURATELY
INSTALLS THE DRIVE PLATE,
HE ATTACHES
THE DOUBLE-CLUTCH TRANSMISSION
TO THE V-10 ENGINE.
USING AN IMPACT DRIVER
TO FASTEN THE SCREWS,
THE TWO LARGE RUNNING PARTS
ARE MATED
TO BECOME THE HEART AND SPIRI
OF THE R8.
Narrator: EACH AUDI R8 IS MADE
OF MORE THAN 5,000 PARTS,
INSTALLED MOSTLY BY HAND.
WITH 14 STATIONS
IN THE ASSEMBLY HALL,
EACH HAS A STRICT CYCLE TIME
OF 30 MINUTES.
THOUGH ONE OF THE FASTEST CARS
IN THE WORLD,
IT'S GRADUALLY MADE
IN EIGHT DAYS.
THE REAR OF THIS SUPERCAR
IS THE MOST COMPLEX PAR
OF THE VEHICLE.
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
WORKERS MANEUVER THE CHASSIS
ONTO A TRANSFER DOLLY.
THEY POSITION
THE SPACE FRAME PROPERLY
TO DROP IN THE V-10 MID-ENGINE,
THE GEAR BOX, THE FUEL TANK,
INTERIOR PANELS,
AND OTHER TRIM ITEMS.
THEY ALSO ATTACH THE SPECIFIED
CABLING AND PIPING,
ALONG WITH
THE NECESSARY SCREWS AND BOLTS.
BECAUSE THIS CAR USES
A FLAT OIL PAN,
IT ALLOWS THE ENGINE
TO BE INSTALLED LOWER,
BRINGING THE CAR'S CENTER
OF GRAVITY CLOSER TO THE GROUND,
RESULTING IN OUTSTANDING
ROAD HANDLING.
NEXT, THE WORKERS ROTATE
THE CHASSIS,
ALONG WITH THE NEW ENGINE
AND INTERIOR COMPONENTS,
TO INSERT MORE ELECTRICAL WIRING
AND PLASTIC PIPING
TO THE RUNNING-GEAR ELEMENTS
AND MORE.
WITH A LOT OF COMPLEXITIES
AND A LARGE AMOUN
OF INTRICATE LABOR,
THE MULTIPLE INSTALLATION STEPS
OF MOST ITEMS
HAVE TO BE FLAWLESS.
AS THEY SITUATE PARTS,
THEY INSTALL THE SCREWS
MANUALLY.
DURING THIS PROCESS,
WORKERS INSTALL 50 TO 60 PARTS
WITHIN 30 MINUTES.
ASSISTED BY A SPECIALIZED
LIFTING DEVICE,
A WORKER INSTALLS
A BRAKING ASSEMBLY UNI
FITTED WITH CARBON-FIBER
REINFORCED CERAMIC BRAKE DISCS.
USING A TORQUE WRENCH,
HE FASTENS THE LOCKING BOLTS,
SECURING THE UNIT INTO POSITION.
THE BODY AND CHASSIS
ARE SHUTTLED BY A TRANSFER HOIS
DOWN THE ASSEMBLY LINE
TO STATION NUMBER NINE,
WHERE MORE WORKERS AWAI
TO ADD KEY AESTHETIC
AND FUNCTIONAL FEATURES.
USING A SPECIALIZED
LIFTING CRANE,
THE WORKERS LOWER
THE CAR'S RETRACTABLE ACOUSTIC
FOLDING ROOF MADE OF CLOTH.
IT WEIGHS LESS THAN A HARD TOP
AND DOESN'T REDUCE
THE CAR'S HANDLING DYNAMICS.
ONCE IT'S FIT INTO POSITION,
THE CRANE RELEASES
THE COMPONENT.
WHILE A WORKER FASTENS THE BOLTS
OF THE CONVERTIBLE ROOF COVER,
ANOTHER ATTACHES
THE CAR'S L.E.D. TAILLIGHTS,
WHICH NOT ONLY ADD FLARE,
BUT ARE EXTREMELY
VIBRATION-RESISTANT.
L.E.D.s HAVE
A VERY LONG SERVICE LIFE
AND ILLUMINATE 250 MILLISECONDS
FASTER THAN CONVENTIONAL
INCANDESCENT-BULB-TYPE
ASSEMBLIES,
INCREASING SAFETY.
WORKERS ALSO INSTALL
THE BATTERY, DASHBOARD,
AND FRONT AND REAR BUMPERS.
THE REAR BUMPER LOOKS SHARP,
BUT ALSO CONCEALS
ULTRASONIC SENSORS
THAT ASSIST THE VISUAL
AND ACOUSTIC PARKING SYSTEM.
FINALLY, WORKERS INSTALL
THE ENGINE COVER,
WHICH IS SET BETWEEN THE FULLY
AUTOMATIC HOOD ROOF COVER
AND THE RETRACTABLE
REAR SPOILER.
USING A TORQUE WRENCH,
A WORKER ATTACHES THE COVER
TO THE HINGES
BEFORE ATTACHING
ITS GAS PRESSURE SPRINGS.
IN ANOTHER WORK AREA,
A ROBOT ADDS
A HIGH-STRENGTH ADHESIVE
TO THE EDGES
OF THE FRONT WINDSCREEN.
WORKERS DELIVER
THE LARGE GLASS PANE,
SUCTIONED TO TWIN-CUP
VACUUM LIFTERS,
AND LAY THE WINDOW
INTO ITS PRE-ALIGNED POSITION.
AFTERWARD, THE BOTTOM
AND BODY SHELL BRACKETS
WILL BE INSTALLED
TO FURTHER CONTAIN THE GLASS.
ANOTHER WORKER INSERTS
THE STEERING WHEEL
AND THE STEERING COLUMN AIRBAG,
INCLUDING ITS ELECTRICAL WIRING.
COVERINGS FOR THE CAR'S INTERIOR
INCLUDE FINE NAPA LEATHER,
COMPOSED OF LAMB OR SHEEPSKIN,
AS WELL AS ALCANTARA,
WHICH RESEMBLES SUEDE.
IN THE CAR'S
CONVERTIBLE VERSION,
A SPECIAL PIGMENTATION
PREVENTS THE SEATS
FROM OVERHEATING IN THE SUN.
A WORKER SITUATES
THE PREMIUM LEATHER BUCKET SEATS
INSIDE THE COCKPIT,
USING A SEAT-INSTALLATION
LIFTER.
THE PNEUMATIC ARM
MAKES IT EASIER FOR WORKERS
TO INSERT ANY ELECTRICAL WIRING
IN AND AROUND THE SEATING.
A WORKER,
USING A LIFTING DEVICE,
DELIVERS A FORGED 19-INCH
ALUMINUM-ALLOY WHEEL AND TIRE
TO THE FRONT PASSENGER SIDE
WHEEL PLATE
AND FASTENS THE LUG BOLTS
WITH AN AIR IMPACT DRIVER.
AT ANOTHER WORKSTATION,
USING SELF-TAPPING SCREWS
AND AN IMPACT DRIVER,
A WORKER INSTALLS AND FASTENS
SIX ALUMINUM UNDERLINING
BODY PANELS UNDERNEATH THE CAR.
THESE PANELS APPLY
ADDITIONAL BODYWORK RIGIDITY
AND GENERATE MORE DOWNFORCE
AT HIGH SPEEDS,
AS WELL AS SOME PROTECTION
TO RUNNING-GEAR PARTS
FROM ENVIRONMENTAL EFFECTS.
ONLY 20 R8 CARS ARE MADE DAILY,
AND WHEN THEY REACH
THE END OF THE LINE,
IT'S TIME
FOR SOME EXCITING TEST DRIVES.
Narrator: THE R8's V-10 ENGINE
IS EXCELLENT.
WITH SUPREME POWER, TORQUE,
AND FUEL EFFICIENCY,
IT'S A ROAD CAR
THAT TRULY GOES THE DISTANCE,
THANKS TO THE DIREC
FUEL-INJECTION SYSTEM,
ORIGINALLY DEVELOPED FOR
THE 24 HOURS OF LE MANS RACES.
NAMED AFTER THE AUDI QUATTRO,
THIS FACTORY
WAS PRIMARILY FOUNDED
TO PRODUCE
HIGH-PERFORMANCE SPORTS CARS.
IN ANOTHER SECTION
OF THE ASSEMBLY HALL,
A STATION KNOWN AS
THE FINISH LINE,
WORKERS INSPEC
FINAL CONSTRUCTION DETAILS.
THEY EXAMINE
ALL ELECTRICAL SYSTEMS,
ALL LIGHTS,
AND THE POWER STEERING.
WORKERS ALSO ADD
FUNCTIONING FLUIDS
LIKE COOLANT, OIL,
TRANSMISSION FLUID,
AND BRAKE FLUID BEFORE
THE CAR IS SENT TO ENDURE
SOME METICULOUS DRIVING TESTS.
THE CAR NOW STANDS
IN A DYNAMOMETER ROLL BOOTH,
WHICH USES
MULTIPLE DRIVE ROLLERS
FOR ROUGHLY 10 MINUTES.
THE CAR IS OFTEN DRIVEN
AT SPEEDS
OF UP TO 100 MILES PER HOUR
THROUGHOUT THIS EVALUATION.
VEHICLES ARE DRIVEN
WHILE A COMPUTERIZED PROGRAM
CONDUCTS A SERIES OF OPERATIONS,
SIMULATING
REALISTIC DRIVING CONDITIONS.
THEY EXAMINE TRANSMISSION,
SUSPENSION, BRAKING,
AND, NOT TO MENTION,
THE ENGINE'S HORSEPOWER
AND TORQUE.
THE TESTING ALSO INCLUDES
LOAD SIMULATIONS,
SUCH AS UPHILL DRIVING
AND TRAILER TOWING.
BUT THE TESTING
DOES NOT END HERE.
IT'S TIME TO GET OUTSIDE.
TO PUT THE CAR'S FUNCTIONALITY
AND VALIDATION TO THE TEST,
QUALIFIED TESTERS DRIVE THE CAR
ON CLOSED-OFF TRACKS
AS PART OF A PRE-DELIVERY
DURABILITY TEST.
THIS SPECIAL-SURFACE TRACK
IS A LOW-SPEED COURSE
WITH A VARIETY
OF DEMANDING ROAD CONDITIONS.
TESTERS CHECK THE TRANSMISSION,
STEERING,
SUSPENSION, AND BRAKES,
PLUS THE OVERALL RIDE
AND HANDLING OF THE DRIVE.
THE PERFORMANCE DEVELOPMEN
TEST TRACK
EVALUATES
NEW AND PROTOTYPE VEHICLES
IN A HIGH-SPEED BOWL
WITH LANE-CHANGE AREAS,
STRAIGHTAWAYS,
AND BANKED CORNERS.
THE CAR'S TOP SPEED
AND PERFORMANCE IN WARM WEATHER
IS ALSO EVALUATED.
QUALITY IS ALSO
SOMETHING YOU CAN HEAR.
EVERY CAR IS DRIVEN
AT A HIGH STRESS LEVEL,
AND SOUND TESTS ARE APPLIED
TO CHECK FOR INTERIOR NOISE,
NOISE VIBRATION, WIND NOISE,
AND RUNNING-GEAR NOISE.
BEYOND THE FACTORY TEST TRACKS,
THE MANUFACTURER HAS A SET OF
HILL ROUTES AND CITY COURSES
THAT PROGRESSIVELY CHALLENGE
THE VEHICLE'S PERFORMANCE
AND DURABILITY.
FOLLOWING THE STRIC
AND EXTENSIVE TESTING,
THE CAR IS TREATED TO MORE
MANUAL QUALITY ASSURANCE
AND PRECISION CARE.
AFTER A HIGH-PRESSURE WASH,
A WORKER GIVES THE LUXURIOUS
SPORTS CAR SOME FINAL ATTENTION
BY VERIFYING THE BODY PAIN
AND BUFFING THE SKIN PANELS
WITH A NON-ABRASIVE,
LEATHER CLOTH.
THIS CAREFULLY REMOVES ANY DIRT,
DUST, OR LIQUID.
WHETHER IN COUPE
OR CONVERTIBLE FORM,
THIS CAR
IS AN AUTOMOTIVE MASTERPIECE,
DESIGNED AND ENGINEERED TO MAKE
A STATEMENT ON EVERY ROAD.
WORKERS APPLY A PROTECTIVE,
WHITE, NEW-CAR WRAPPING
OVER THE VEHICLE.
AN OUTER FILM LAYER
PROTECTS THE CAR FROM WATER
WHILE AN INNER, FLEECE LAYER
PROTECTS THE PAINTWORK
FROM ANY SCRATCHES.
EVEN WITH THE PROTECTIVE WRAP
OVERTOP,
A WORKER CAN STILL
DRIVE THE VEHICLE
WHERE IT NEEDS TO GO NEXT.
BUILT TO LOOK ELEGAN
YET ROBUST,
THE R8 HAS A UNIQUE
SUPERCAR POISE.
WITH A DESIGN INFLUENCE
THAT COMES FROM CAR RACING,
STYLE AND FUNCTIONALITY
ARE NEVER IN QUESTION,
LIKE TRANSFORMING
A CONVERTIBLE TO A COUPE
AT SPEEDS
OF UP TO 30 MILES PER HOUR
IN AS LITTLE AS 25 SECONDS.
IGNITED BY ONGOING,
SPORTS-MINDED PASSION
AND CONSTRUCTED
FOR DISTINCTIVE PERFORMANCE,
THE AUDI R8
IS THE PERFECT SUPERCAR
FOR ANY LONG-DISTANCE CRUISE,
BUT TO TRULY ENJOY
HOW IT'S MADE,
ONE HAS TO LISTEN
TO HOW IT SOUNDS
AND FEEL HOW IT HANDLES
BOTH IN EVERYDAY TRAFFIC
AND ON THE RACETRACK.