How It's Made: Dream Cars (2013) s01e05 Episode Script
Rolls-Royce Phantom
Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
THE ICONIC ROLLS-ROYCE PHANTOM,
WITHOUT A DOUB
THE MOST LUXURY SUPERCAR EVER.
-- Captions by VITAC --
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
GOODWOOD, ENGLAND,
IS THE HOME OF ROLLS-ROYCE'S
WORLD HEADQUARTERS.
THE MANUFACTURER IS SYNONYMOUS
WITH EXTRAVAGANT DESIGN,
ENGINEERING, AND CRAFTSMANSHIP.
THE FOUNDERS
OF ROLLS-ROYCE MOTOR CARS
CAME FROM OPPOSITE SIDES
OF THE TRACKS.
CHARLES ROLLS
HAD A PRIVILEGED UPBRINGING
IN THE HIGH SOCIETY
OF BRITISH ARISTOCRACY.
FREDERICK ROYCE
WAS THE SON OF A MILLER
AND HAD TO BECOME
THE BREADWINNER FOR HIS FAMILY
AT THE AGE OF 9.
DESPITE THE DIFFERENCES
IN THEIR CIRCUMSTANCES,
IN 1903, THEY WENT ON TO BUILD
AN INCREDIBLE ALLIANCE.
IT WAS BORN OUT OF
THEIR MUTUAL APPRECIATION
FOR ENGINEERING AND MOTORCARS,
AND ROLLS-ROYCE MOTOR CARS
WAS BORN.
UNFORTUNATELY, THEIR PARTNERSHIP
DISSOLVED AFTER SIX YEARS,
BUT BEFORE THEIR SEVERANCE,
THEY DESIGNED AND ENGINEERED
WHAT MOST OF THE PLANE
CONSIDERED AT THE TIME
TO BE THE BEST CAR
IN THE WORLD --
THE SILVER GHOST.
IN 1925, THE PHANTOM
WOULD BECOME ITS REPLACEMENT,
WITH MODEL VARIATIONS
FOR THE NEXT 65 YEARS.
IN 1998,
LUXURY GERMAN AUTOMAKER BMW
ACQUIRED ROLLS-ROYCE
AND ESTABLISHED A NEW COMPANY
WITH A NEW MANUFACTURING PLAN
AND TEAM OF EMPLOYEES.
DEBUTING IN 2003,
THE NEW PHANTOM SIGNALED
A NEW DIRECTION FOR ROLLS-ROYCE.
THIS CAR HAS ONE OF THE LARGES
ALL-ALUMINUM CHASSIS EVER.
IT'S MADE FROM 200 SECTIONS
OF EXTRUDED ALUMINUM
AND 300 ALLOY PARTS,
REQUIRING 2,000 WELDS,
WHICH ARE ALL DONE BY HAND.
THE SPACEFRAME CHASSIS
IS BUILT IN GERMANY
AND THEN SHIPPED TO
THE GOODWOOD PLANT IN THE U.K.
BECAUSE OF
ITS INCREDIBLE STIFFNESS
AND LIGHTWEIGHT MATERIAL,
IT ALSO ENHANCES
THE DRIVE AND COMFORT OF THE CAR
BY REDUCING
OVERALL VIBRATIONS AND NOISE.
INSIDE THE PAINT SHOP,
IT REQUIRES 22 STEPS,
FIVE LAYERS OF PAINT,
AND SEVEN DAYS BEFORE THE BODY
CAN LOOK PICTURE-PERFECT.
AND IN TOTAL,
NEARLY 100 POUNDS OF PAIN
ARE SPRAYED ON
TO THE BODY SHELL.
TECHNICIANS PAINT BY HAND
IN AND AROUND THE CAR,
REACHING CHALLENGING AREAS
SUCH AS DOOR HINGES AND MORE.
THE NEW ALUMINUM BODY
WAS IMPORTED
FROM A PLAN
IN DINGOLFING, GERMANY,
AND MANUFACTURED
ALMOST ENTIRELY BY HAND.
STANDING ON A TRANSFER BELT,
IT MOVES TOWARD
TWO PROGRAMMABLE PAINT ROBOTS
THAT WILL APPLY
A LAYER OF PRIMER.
THE PRIMER PROVIDES RESISTANCE
AGAINST U.V. LIGHTING
AND METAL CORROSION.
THE ROBOTS ARE TWO OF ONLY
FOUR ROBOTS IN THE FACTORY.
THEY ARE ALSO CAPABLE
OF MOVING PARTS
LIKE THE DOORS,
HOOD, AND TRUNK LID
TO ADMINISTER THE PROTECTIVE
PAINT AND INTERSECTIONS
AND THE INTERNAL SKIN
OF THE BODY PANELS.
THEY CAN FURTHER APPLY
THE PRIMER COATING
TO VARIOUS FILM THICKNESS
IF DESIRED BY THE MANUFACTURER.
THESE TWIN ROBOTS MANAGE
TO PAINT THE CAR'S SHELL
WITH AUTOMATED STYLE
AND ROBOTIC PERFECTION,
ANOTHER COMPLIMENT TO
THE ASSEMBLY OF A FINE SUPERCAR.
AFTER RECEIVING THE PRIMER COAT,
THE BODY SHELL WILL OBTAIN
THREE MORE PAINTING STEPS,
INCLUDING COLOR COATING
AND TWO PHASES OF CLEAR COATING.
THE HIGH-GLOSS
CLEAR COATING LACQUER
WILL CREATE
A FLAWLESS MIRROR-LIKE FINISH,
AND WITH 44,000 PAINT COLORS
TO CHOOSE FROM,
THE OUTCOME
CAN ONLY BE EXCEPTIONAL.
AFTER THE PAINTING PROCESS
IS COMPLETE,
A SMALL TEAM
OF SURFACE FINISHING EXPERTS
SAND THE BODY PERFECTLY
USING HANDHELD POWER SANDERS,
BUFFERS, AND CHAMOIS CLOTHS.
THE ADVANTAGES
OF SURFACE FINISHING
ARE A DECORATIVE APPEARANCE,
A LONG-TERM WEAR,
CORROSION RESISTANCE,
AND MATERIAL HARDNESS.
THIS OPERATION
CANNOT BE DONE BY ROBOTS
AND CAN TAKE UP TO FIVE HOURS
TO EXECUTE.
IT TRULY REQUIRES
A HUMAN TOUCH OF ATTENTION,
CONCENTRATION, AND DETAIL
BEFORE A FINAL INSPECTION.
ANOTHER METICULOUS
AND UNIQUE CONTRIBUTION
TO THE VEHICLE'S
ILLUSTRIOUS IMAGE
IS THE COACH LINE,
A STYLISTIC PINSTRIPE.
IN AUTOMOTIVE BODYWORK,
DECORATIVE PINSTRIPES
ARE A THIN VINYL TAPE OR PAINT.
ON THIS CAR,
THE FEATURE IS PAINTED BY HAND
BY ONE PERSON ONLY AND ALWAYS.
WITH A VERY MINIATURE
SWORD-SHAPED PAINTBRUSH
MADE OF SQUIRREL HAIR,
THE CRAFTSMAN DIPS THE BRUSH
INTO THE GLOSSY ENAMEL PAINT.
HE DELICATELY PAINTS A 3mm LINE
ONTO THE SURFACE
OF THE BODY SHELL,
STRETCHING
THE COMPLETE 20 FEET OF THE CAR.
THE PERFECT ILLUSTRATION
OF REFINED CRAFTSMANSHIP
THAT GOES INTO BUILDING
A ROLLS-ROYCE PHANTOM,
THIS NAIL-BITING PROCESS
TAKES THREE HOURS AT A TIME.
Narrator: ROLLS-ROYCE'S PHANTOM
USES SELECT VENEERS
FROM AROUND THE GLOBE
TO CREATE
THE DASHBOARD'S WOODEN FINISH.
THE VENEERS ARE STORED
IN A HUMIDIFIED ROOM
TO ABSORB MOISTURE,
MAKING THEM SUPPLE ENOUGH
TO USE WITHOUT CRACKING.
WHAT SETS THIS CAR APAR
IN THE SUPERCAR CATEGORY
ARE PERSONAL TOUCHES,
LIKE
THE LEATHER UPHOLSTERY COLORS
OR THE 20,000 AVAILABLE
WOOD VENEER COMBINATIONS.
42 WOOD PARTS WILL FURNISH
THE INTERIOR OF THE CAR.
A CRAFTSMAN ACCUMULATES
A SERIES OF WOOD SHEETS
AND ADHESIVE SHEETS
IN ORDER
TO FORM THICK GROUPINGS.
THE MULTIPLE PIECES ARE PLACED
INTO A SPECIAL
ONE-TON HEAT PRESS,
WHICH SLOWLY DESCENDS
ON THE WOOD.
THEY'RE THEN COMPRESSED
FOR VERY LITTLE TIME --
JUST ENOUGH
TO MATE THE ITEMS TOGETHER.
THE VENEER SHEETS
ARE NOW THICKER,
YET DELICATE PIECES OF WOOD
TO BE USED
IN THE CAR'S INTERIOR TRIM.
A LARGE PIECE OF WOOD
SITS ON AN AUTOMATED CARRIER
IN A CLOSED CONTAINER,
WHERE IT IS CUT AND RESHAPED
BY A COMPUTERIZED PRECISION SAW.
THE SAW WILL CUT THE WOOD
BASED ON A PATTERN
CONFORMED FOR THE CAR'S CABIN.
EVENTUALLY,
THE BLOCK IS CUT AND MODIFIED
INTO A FINAL FORM
MADE FOR THE INTERIOR CABIN.
WALNUT TEMPLATES FOR THE WOODEN
VENEER DASHBOARD PANELS
ARE CAREFULLY CRAFTED.
A CRAFTSWOMAN LAYS VENEER PIECES
ONTO A WORK TABLE
WITH A GREEN VELVET CLOTH,
WHICH ACTS AS A PROTECTAN
FROM SCRATCHES.
EMPLOYING A TRADITIONAL PRACTICE
CALLED BOOK MATCHING,
SHE ALIGNS THE CORRESPONDING
WOOD-GRAIN PATTERNS
SO THEY MIRROR EACH OTHER
IN APPEARANCE.
SHE TAPES THE PIECES TOGETHER
ON BOTH SIDES.
NEXT,
THE VENEER PIECES ARE COVERED
WITH A PLASTIC BLUE SHEET.
ANY AIR BUBBLES ARE PUSHED OU
WITH A SMALL PRESSING BLOCK.
USING A GRAPHIC PENCIL AND RULER
TO MARK THE CENTER
WITH A DIVIDING LINE,
THE CRAFTSWOMAN CONTINUES
TO SECTION THE SHEET.
WITH A WIDE TRANSPARENT GUIDE,
SHE USES A HOBBY KNIFE
TO SEPARATE THE THIN SHEET,
REMOVING AN UNNECESSARY SECTION.
SHE MOVES THE SHEET OVERTOP A
PANEL TEMPLATE WITH SHARP EDGES
AND SECURES IT WITH TAPE.
AT ANOTHER WORKSTATION,
SHE APPLIES A LARGE, THIN PIECE
OF PLASTIC ON TOP.
SHE THEN LOWERS
A LARGE MECHANICAL PRESS
ONTO THE PIECES,
WHICH RESULTS
IN CUTTING AND SHAPING.
AFTER THE CUTTING PROCESS,
THE THIN WOOD VENEER COVERING
APPEARS TO BE PERFECTLY SHAPED
TO FIT A WOOD DASHBOARD PANEL.
AS THE WOOD PANEL
SITS IN A HOLDING CAST,
THE CRAFTSWOMAN
ROLLS A SMALL PAINT ROLLER
IN A TRAY OF WOOD GLUE
AND THEN EVENLY
OVER THE TIMBER PANEL.
THE PRE-SHAPED VENEER COVER
IS THEN AFFIXED TO THE PANEL
WITH MASKING TAPE
TO KEEP IT IN PLACE.
THE PANEL AND COVER
ARE THEN PLACED INTO
A VACUUM FRAME PRESS,
WHERE A LARGE
POLYURETHANE MEMBRANE
IS COMPRESSED FOR 45 MINUTES
TO VACUUM-SEAL THE WOODEN UNIT.
THIS WILL PERFECT ITS ADHESION
TO THE GLUE AND WOODEN PANEL.
IN THE NEXT STAGE,
AT ANOTHER WORKSTATION,
A CRAFTSMAN REMOVES
THE BLUE PROTECTIVE PLASTIC
TO EXPOSE THE WOOD VENEER
FOR FURTHER TREATMENT.
ANY AREAS THAT ARE DAMAGED
REQUIRE REPAIR
AND ARE FIXED USING BONDING GLUE
ALONG WITH
SOME MATCHING RAW MATERIALS.
AN IRON IS USED
TO SPEED THE GLUE'S DRYING TIME
AND ENSURE THE MATERIALS
ARE AFFIXED FOR LONG-TERM USAGE.
AFTER REMOVING
ANY EXCESS MATERIAL,
THE PANEL PIECE IS FILED
TO LOOK COMPLETELY UNIFORM.
AT ANOTHER WORKSTATION,
A CRAFTSWOMAN
CAREFULLY TOUCHES UP ANY AREAS
THAT DO NOT MATCH
THE COMPONENT'S COLOR.
AFTERWARD, WITH A LARGE BRUSH,
SHE APPLIES
A QUICK-DRYING LACQUER,
WHICH DRIES TO FORM
A HARD PROTECTIVE COATING.
AGAIN, SHE APPLIES
THE SPECIAL POLISHING PASTE
UNTIL ALL IS PERFECT.
IN THE MEANTIME,
THE PANEL DRIES FOR AN HOUR.
A TECHNICIAN GENTLY SANDS THE
SURFACE OF THE VENEER COMPONEN
ON A WIDE BELT SANDER
TO GIVE IT A POLISHED LOOK.
IN MINUTES, A POWER BUFFER
CAN FURTHER ENHANCE
THE SMOOTHNESS AND SHINE
OF THE VENEER'S SURFACE.
A TECHNICIAN
INSERTS ELECTRICAL COMPONENTS
INTO THE WOOD PANEL'S BACK END.
ONCE THE DIALS ARE INSTALLED,
IT IS CLEAR THAT THE PANEL
IS PART OF THE HEA
AND AIR CONDITIONING SYSTEM.
FINALLY, IN THE CAR'S CABIN,
A TECHNICIAN CONNECTS THE WIRING
AND INSTALLS
THE CLIMATE-CONTROL PANEL
INTO THE CENTER CONSOLE STACK
OF A NEW ROLLS-ROYCE PHANTOM.
THE TECHNICIAN ENSURES THA
THE VENEERED PANEL FITS SUPERBLY
INTO THIS FLAWLESS SUPERCAR.
Narrator:
THE PREMIUM LEATHER SEATS
OF A ROLLS-ROYCE PHANTOM
ARE DESIGNED FOR DRIVING,
COMFORT, AND LOUNGING.
NOT ONLY
DO THEY LOOK AND FEEL GREAT,
BUT THEY SOUND GREAT.
ALL SEATING IS TESTED
FOR SQUEAKING OR RATTLING
BEFORE INSTALLATION
INTO THE CABIN.
A TECHNICIAN PLACES
A SHEET OF GRADE-A BULLHIDE
ONTO A WORK TABLE
THAT AUTOMATICALLY
PULLS THE MATERIAL.
THIS ALLOWS HIM TO SCREEN ANY
FLAWS, MOSQUITO BITES, OR SCARS.
IT TAKES 17 DAYS
TO COMPLETE AN INTERIOR,
WHICH INCLUDES 11 BULLHIDES.
450 PIECES OF LEATHER ARE USED
TO PRODUCE THE INTERIOR.
ANY DEFECTS IN THE MATERIAL ARE
CIRCLED WITH A WHITE WAX PENCIL
TO VERIFY THAT THOSE SECTIONS
ARE NOT APPLIED
TO THE UPHOLSTERY,
INCLUDING AREAS
THAT HAVE STRETCH MARKS.
AT A HIGH-END
COMPUTERIZED CUTTING TABLE,
A TECHNICIAN OUTLINES THE AREAS
THAT REQUIRE CUTTING
WITH A HANDHELD PATTERN EMITTER.
AFFORDING CERTAIN SHAPES TO BE
ILLUSTRATED AGAINST THE LEATHER,
THEY CAN APPEAR ANYWHERE ON
THE HIDE WITHIN SPECIAL LIMITS.
WHEN THE AREAS
HAVE BEEN SELECTED,
THE GREEN LASER PATTERNS
FLASH DRAMATICALLY
BEFORE THE NEXT STAGE
OF THE CUTTING PROCESS BEGINS.
THE AUTOMATED CUTTING TABLE
VACUUMS THE MATERIAL AGAINST I
WHILE A LASER-GUIDED,
SELF-SHARPENING BLADE
CUTS THE DESIRED PATTERNS.
THE SYSTEM CAN PRODUCE
UP TO 56,000 INCISIONS A MINUTE.
ONCE THE CUTTING SESSION
IS COMPLETE
AND THE DESIRED PATTERNS
ARE OUTLINED,
THE TECHNICIAN REMOVES
THE REFINED PIECES FOR SEWING
WHILE THE REMAINS AND RESIDUE
ARE DISCARDED.
IT TAKES UP TO TWO WEEKS TO
UPHOLSTER THIS CAR'S INTERIOR.
TOPSTITCHING,
A SEWING TECHNIQUE THAT HELPS
THE LEATHER TO STAY IN PLACE,
IS MOST CRITICAL.
ALL SEWING HAS TO BE CLEAN
AND EVEN TO EXUDE QUALITY.
FURTHERMORE,
EACH LEATHER COMPONEN
IS PERSONALLY SIGNED BY THE
SEAMSTRESS THAT SEWED AND FIT I
INTO THE VEHICLE'S TRIM.
IN A ROOM OF THREAD, MATERIALS,
AND SEWING MACHINERY,
SEAMSTRESSES
ASSEMBLE THE UPHOLSTERY.
THIS INCLUDES THE LOGO-EMBOSSED
HEADREST COVER.
NEXT,
SHE CUTS, BENDS, AND HAMMERS
THE EDGES
OF A PLASTIC LINER COMPONENT,
WHICH IS USED WITHIN
THE STRUCTURE OF THE COVER.
AFTER BENDING THE MATERIAL
ALONG THE EDGES,
SHE HAMMERS THE COMPONENT FIRMLY
ALONG WITH THE COVER.
SHE CONTINUES
TO SEW THE TWO ELEMENTS TOGETHER
FOR SUPERB ATTACHMENT.
WHEN SHE'S DONE,
SHE UNFOLDS THE MATERIAL
FROM THE INSIDE TO THE OUTSIDE,
REVEALING A PREMIUM
EMBOSSED LOGO HEADREST COVER.
A TECHNICIAN MOUNTS THE
OPEN-CELL FOAM OF THE HEADRES
ONTO A VACUUM HEAD
RESTRAINT FIXTURE.
THIS UNIT ABSORBS THE AIR
WITHIN THE CUSHION,
ALLOWING
THE GREEN PLASTIC COVERING
TO MAINTAIN THE CUSHION
IN A DENSE POSITION,
WHERE THE LEATHER COVER
CAN BE FITTED ON TOP.
WHEN THE VACUUM HEAD RESTRAIN
FIXTURE RELEASES THE AIR,
THE FOAM CUSHION
AND LEATHER OVERLAY
RETURN TO THEIR RESPECTIVE
SHAPES AND SIZES.
THE HEADREST COVER IS MOVED
TO A NEIGHBORING WORKSTATION,
WHERE IT RECEIVES
ITS PLASTIC SUPPORT BRACKE
AND SLIDING METAL SHAFTS
THAT INSERT INTO THE SEAT BACK.
FITTING THE COVER
AS MUCH AS POSSIBLE,
THE TECHNICIAN
ROTATES THE RESTRAINT,
FIXING THE CORNERS WITH A SMALL,
SPECIALIZED TAILORING TOOL.
THE LEATHER HEADREST COVER
IS FINALLY FIXED,
FOLDED, AND SMOOTHED OUT,
LOOKING FORMFITTING
AND UPSCALE,
READY TO STAND WITH ITS
COUNTERPART IN A DELUXE CABIN.
SITTING IN THE LAP OF LUXURY
REQUIRES A LITTLE LABOR.
A TECHNICIAN FITS
THE SEAT BACK'S LEATHER COVER
ONTO ITS FRAME
BY SMOOTHING, PUSHING,
AND PULLING
UNTIL THE LEATHER
FITS LIKE A GLOVE.
ONCE THE SEAT BACK COVER
IS FASTENED TO THE FRAMEWORK,
HE ADDS
THE ACCOMPANYING HEADREST.
THE ONLY THING MISSING NOW
IS THE REST OF THIS
RITZY ROLLS-ROYCE PHANTOM.
Narrator: IT'S EASY TO MISTAKE
THE PHANTOM'S GOOD LOOKS
FOR A SLOW RIDE,
BUT MAKE NO MISTAKE.
IT'S FAST.
THE 453-HORSEPOWER,
6.75-LITER V-12 ENGINE
ACHIEVES ZERO TO 60 MILES
PER HOUR IN 5.9 SECONDS.
USING AN AIR HOIS
TO MOVE EQUIPMENT OVERHEAD,
A WORKMAN LOWERS THE REAR AXLE
OF THE CAR
ONTO A MOTORIZED CARRIER.
RIGHT IN TOW,
HE SLOWLY TRANSPORTS AND ROTATES
THE FRONT AXLE
DIRECTLY ONTO
THE MOTORIZED CARRIER
USING ANOTHER AIR HOIST.
NEXT,
THE ENGINE AND TRANSMISSION
ARE LOWERED FROM ANOTHER STATION
AND PUT INTO
THEIR DESIGNATED POSITIONS.
THE RADIATOR IS CARRIED
TO THE FRONT OF THE ENGINE
AND INSTALLED INTO POSITION.
THE WORKER
ALSO BRINGS THE DRIVESHAFT,
A KEY MECHANICAL COMPONEN
WHICH TRANSMITS TORQUE
IN THE ENGINE SYSTEM.
ONCE THE DRIVESHAF
IS PROPERLY POSITIONED,
HE SECURES I
WITH T-BOLTS AND FASTENERS
TO THE CAR'S EIGHT-SPEED
AUTOMATIC TRANSMISSION SYSTEM.
THIS IS FOLLOWED
BY MORE MANUAL FASTENING
USING A WRENCH ALONGSIDE
A MOTORIZED TORQUE WRENCH.
USING THE MOTORIZED CARRIER,
A WORKMAN MANEUVERS THE RUNNING
GEAR BELOW THE BODY SHELL,
WHICH IS SUSPENDED
IN AN OVERHEAD CONVEYER LIFT.
WHEN BOTH MAJOR ELEMENTS
ARE ASSEMBLED TOGETHER,
THE PROCESS
IS CALLED A MARRIAGE.
THE OVERHEAD CONVEYER LIF
CONTAINS THE BODY'S SHELL UNI
AND IS LOWERED
DIRECTLY OVER THE RUNNING GEAR
TO LINK THE TWO COUNTERPARTS
TOGETHER.
WORKMEN CIRCULATE THE FRON
SUSPENSION AND BRAKING SYSTEMS
TO ENSURE THE BOLTS AND
ATTACHMENT BRACKETS ARE SECURE.
REMOVING A HOLDING CLAMP
FROM THE MOTORIZED CARRIER,
A WORKER RAISES THE CONVEYER
FOR THE RUNNING GEAR
TO BE CLOSER TO THE BODY SHELL
FOR FASTENING.
ENSURING ALL COMPONENTS
ARE SECURELY ATTACHED,
HE USES A TORQUE WRENCH
TO LOCK ALL THREADED FASTENERS.
THE MOTORIZED CARRIER
IS THEN LOWERED
AND REMOVED FROM THE STATION.
AS FINAL VERIFICATION
FOR SAFETY AND QUALITY,
HE USES A RATCHE
TO MANUALLY CHECK.
INSTALLATION OF ANY GLASS
INTO THIS CAR IS DONE MANUALLY.
TECHNICIANS,
USING A LIFTING DEVICE
WITH SUCTION MOUNTS,
CALLED A VACUUM GLASS LIFTER,
TRANSPORT THE WINDSCREEN
TO THE BODY SHELL.
AFTER THEY REINFORCE
THE WINDSCREEN'S POSITION
WITH A DELICATE TAPPING
OF PLASTIC MALLETS,
THEY APPLY
URETHANE WINDSHIELD ADHESIVE
UNDER THE SIDE, CORNER,
AND TOP WINDSHIELD MOLDINGS
AND MAKE SURE THE GLASS IS CLEAN
AFTER INSTALLATION.
USING THE LIFTING DEVICE,
A TECHNICIAN
BRINGS A 21-INCH
ALUMINUM ALLOY WHEEL AND TIRE
TO THE DRIVER'S SIDE
FRONT WHEEL PLATE.
CHECKING FOR PRECISION
AND MECHANICAL FUNCTIONALITY,
A TECHNICIAN
TESTS THE AUTOMATED PLATFORM,
WHICH RETRACTS THE ICONIC HOOD
MASCOT, THE SPIRIT OF ECSTASY,
LOCATED WITHIN THE RADIATOR.
THE SPIRIT OF ECSTASY IS
A SYMBOL OF LUXURY AND MYSTIQUE,
DESIGNED IN 1911
BY SCULPTOR CHARLES SYKES.
THE MOTION OF THE ORNAMEN
IS CONTINUALLY TESTED,
AND ITS MACHINERY PARTS
ARE VERIFIED FOR EXCELLENCE.
ONCE THE INSPECTION IS COMPLETE,
THE GRILLE,
WHICH IS POLISHED FOR FIVE HOURS
AND COVERED
IN PROTECTIVE PLASTIC FILM
BEFORE INSTALLATION,
IS MOUNTED ONTO
THE FRONT END OF THE VEHICLE.
THE VEHICLE THEN MOVES ON
TO THE NEXT PHASE --
DRIVING TESTS.
DURING A 20-MINUTE WATER TEST,
73 MID-PRESSURE SHOWERS SIMULATE
THE EFFECTS OF A MONSOON.
IN THE MEANTIME,
A TECHNICIAN SEARCHES FOR LEAKS
IN THE CABIN USING A FLASHLIGHT.
THE CAR NOW STANDS
IN A DYNAMOMETER ROLL BOOTH,
WHICH USES
COMPUTERIZED TEST ROLLERS
TO SIMULATE
VARIOUS DRIVING CONDITIONS.
THEY'LL EXAMINE
THE TRANSMISSION, SUSPENSION,
AND BRAKING.
IT ALSO CHECKS
THE ENGINE'S POWER AND TORQUE.
THE PHANTOM MAY NO
INSTANTLY COME ACROSS
AS THE TYPICAL
AGGRESSIVE AND SPORTY SUPERCAR
LOOKING FOR APPROVAL
AT THE LOCAL RACETRACK,
BUT ITS UNTOUCHABLE APPEARANCE
AND PEDIGREE
IS APPROPRIATELY
REWARDING ENOUGH.
AND IN ITS MANY VERSIONS,
THE ROLLS-ROYCE PHANTOM HAS
AN ELEGANT, YET BOLD PRESENCE,
WITH ITS LUXURIOUS STYLING,
NOVEL FEATURES,
AND ENGAGING AMENITIES,
NOT TO MENTION
ITS ROBUST V-12 ENGINE.
CONSIDERING
THE TWO MONTHS OF ASSEMBLY
AND THE TRADITIONAL
CRAFTSMANSHIP INVOLVED,
IT'S A DREAM CAR
THAT SHINES LIKE NO OTHER.
"HOW IT'S MADE: DREAM CARS,"
THE ICONIC ROLLS-ROYCE PHANTOM,
WITHOUT A DOUB
THE MOST LUXURY SUPERCAR EVER.
-- Captions by VITAC --
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
GOODWOOD, ENGLAND,
IS THE HOME OF ROLLS-ROYCE'S
WORLD HEADQUARTERS.
THE MANUFACTURER IS SYNONYMOUS
WITH EXTRAVAGANT DESIGN,
ENGINEERING, AND CRAFTSMANSHIP.
THE FOUNDERS
OF ROLLS-ROYCE MOTOR CARS
CAME FROM OPPOSITE SIDES
OF THE TRACKS.
CHARLES ROLLS
HAD A PRIVILEGED UPBRINGING
IN THE HIGH SOCIETY
OF BRITISH ARISTOCRACY.
FREDERICK ROYCE
WAS THE SON OF A MILLER
AND HAD TO BECOME
THE BREADWINNER FOR HIS FAMILY
AT THE AGE OF 9.
DESPITE THE DIFFERENCES
IN THEIR CIRCUMSTANCES,
IN 1903, THEY WENT ON TO BUILD
AN INCREDIBLE ALLIANCE.
IT WAS BORN OUT OF
THEIR MUTUAL APPRECIATION
FOR ENGINEERING AND MOTORCARS,
AND ROLLS-ROYCE MOTOR CARS
WAS BORN.
UNFORTUNATELY, THEIR PARTNERSHIP
DISSOLVED AFTER SIX YEARS,
BUT BEFORE THEIR SEVERANCE,
THEY DESIGNED AND ENGINEERED
WHAT MOST OF THE PLANE
CONSIDERED AT THE TIME
TO BE THE BEST CAR
IN THE WORLD --
THE SILVER GHOST.
IN 1925, THE PHANTOM
WOULD BECOME ITS REPLACEMENT,
WITH MODEL VARIATIONS
FOR THE NEXT 65 YEARS.
IN 1998,
LUXURY GERMAN AUTOMAKER BMW
ACQUIRED ROLLS-ROYCE
AND ESTABLISHED A NEW COMPANY
WITH A NEW MANUFACTURING PLAN
AND TEAM OF EMPLOYEES.
DEBUTING IN 2003,
THE NEW PHANTOM SIGNALED
A NEW DIRECTION FOR ROLLS-ROYCE.
THIS CAR HAS ONE OF THE LARGES
ALL-ALUMINUM CHASSIS EVER.
IT'S MADE FROM 200 SECTIONS
OF EXTRUDED ALUMINUM
AND 300 ALLOY PARTS,
REQUIRING 2,000 WELDS,
WHICH ARE ALL DONE BY HAND.
THE SPACEFRAME CHASSIS
IS BUILT IN GERMANY
AND THEN SHIPPED TO
THE GOODWOOD PLANT IN THE U.K.
BECAUSE OF
ITS INCREDIBLE STIFFNESS
AND LIGHTWEIGHT MATERIAL,
IT ALSO ENHANCES
THE DRIVE AND COMFORT OF THE CAR
BY REDUCING
OVERALL VIBRATIONS AND NOISE.
INSIDE THE PAINT SHOP,
IT REQUIRES 22 STEPS,
FIVE LAYERS OF PAINT,
AND SEVEN DAYS BEFORE THE BODY
CAN LOOK PICTURE-PERFECT.
AND IN TOTAL,
NEARLY 100 POUNDS OF PAIN
ARE SPRAYED ON
TO THE BODY SHELL.
TECHNICIANS PAINT BY HAND
IN AND AROUND THE CAR,
REACHING CHALLENGING AREAS
SUCH AS DOOR HINGES AND MORE.
THE NEW ALUMINUM BODY
WAS IMPORTED
FROM A PLAN
IN DINGOLFING, GERMANY,
AND MANUFACTURED
ALMOST ENTIRELY BY HAND.
STANDING ON A TRANSFER BELT,
IT MOVES TOWARD
TWO PROGRAMMABLE PAINT ROBOTS
THAT WILL APPLY
A LAYER OF PRIMER.
THE PRIMER PROVIDES RESISTANCE
AGAINST U.V. LIGHTING
AND METAL CORROSION.
THE ROBOTS ARE TWO OF ONLY
FOUR ROBOTS IN THE FACTORY.
THEY ARE ALSO CAPABLE
OF MOVING PARTS
LIKE THE DOORS,
HOOD, AND TRUNK LID
TO ADMINISTER THE PROTECTIVE
PAINT AND INTERSECTIONS
AND THE INTERNAL SKIN
OF THE BODY PANELS.
THEY CAN FURTHER APPLY
THE PRIMER COATING
TO VARIOUS FILM THICKNESS
IF DESIRED BY THE MANUFACTURER.
THESE TWIN ROBOTS MANAGE
TO PAINT THE CAR'S SHELL
WITH AUTOMATED STYLE
AND ROBOTIC PERFECTION,
ANOTHER COMPLIMENT TO
THE ASSEMBLY OF A FINE SUPERCAR.
AFTER RECEIVING THE PRIMER COAT,
THE BODY SHELL WILL OBTAIN
THREE MORE PAINTING STEPS,
INCLUDING COLOR COATING
AND TWO PHASES OF CLEAR COATING.
THE HIGH-GLOSS
CLEAR COATING LACQUER
WILL CREATE
A FLAWLESS MIRROR-LIKE FINISH,
AND WITH 44,000 PAINT COLORS
TO CHOOSE FROM,
THE OUTCOME
CAN ONLY BE EXCEPTIONAL.
AFTER THE PAINTING PROCESS
IS COMPLETE,
A SMALL TEAM
OF SURFACE FINISHING EXPERTS
SAND THE BODY PERFECTLY
USING HANDHELD POWER SANDERS,
BUFFERS, AND CHAMOIS CLOTHS.
THE ADVANTAGES
OF SURFACE FINISHING
ARE A DECORATIVE APPEARANCE,
A LONG-TERM WEAR,
CORROSION RESISTANCE,
AND MATERIAL HARDNESS.
THIS OPERATION
CANNOT BE DONE BY ROBOTS
AND CAN TAKE UP TO FIVE HOURS
TO EXECUTE.
IT TRULY REQUIRES
A HUMAN TOUCH OF ATTENTION,
CONCENTRATION, AND DETAIL
BEFORE A FINAL INSPECTION.
ANOTHER METICULOUS
AND UNIQUE CONTRIBUTION
TO THE VEHICLE'S
ILLUSTRIOUS IMAGE
IS THE COACH LINE,
A STYLISTIC PINSTRIPE.
IN AUTOMOTIVE BODYWORK,
DECORATIVE PINSTRIPES
ARE A THIN VINYL TAPE OR PAINT.
ON THIS CAR,
THE FEATURE IS PAINTED BY HAND
BY ONE PERSON ONLY AND ALWAYS.
WITH A VERY MINIATURE
SWORD-SHAPED PAINTBRUSH
MADE OF SQUIRREL HAIR,
THE CRAFTSMAN DIPS THE BRUSH
INTO THE GLOSSY ENAMEL PAINT.
HE DELICATELY PAINTS A 3mm LINE
ONTO THE SURFACE
OF THE BODY SHELL,
STRETCHING
THE COMPLETE 20 FEET OF THE CAR.
THE PERFECT ILLUSTRATION
OF REFINED CRAFTSMANSHIP
THAT GOES INTO BUILDING
A ROLLS-ROYCE PHANTOM,
THIS NAIL-BITING PROCESS
TAKES THREE HOURS AT A TIME.
Narrator: ROLLS-ROYCE'S PHANTOM
USES SELECT VENEERS
FROM AROUND THE GLOBE
TO CREATE
THE DASHBOARD'S WOODEN FINISH.
THE VENEERS ARE STORED
IN A HUMIDIFIED ROOM
TO ABSORB MOISTURE,
MAKING THEM SUPPLE ENOUGH
TO USE WITHOUT CRACKING.
WHAT SETS THIS CAR APAR
IN THE SUPERCAR CATEGORY
ARE PERSONAL TOUCHES,
LIKE
THE LEATHER UPHOLSTERY COLORS
OR THE 20,000 AVAILABLE
WOOD VENEER COMBINATIONS.
42 WOOD PARTS WILL FURNISH
THE INTERIOR OF THE CAR.
A CRAFTSMAN ACCUMULATES
A SERIES OF WOOD SHEETS
AND ADHESIVE SHEETS
IN ORDER
TO FORM THICK GROUPINGS.
THE MULTIPLE PIECES ARE PLACED
INTO A SPECIAL
ONE-TON HEAT PRESS,
WHICH SLOWLY DESCENDS
ON THE WOOD.
THEY'RE THEN COMPRESSED
FOR VERY LITTLE TIME --
JUST ENOUGH
TO MATE THE ITEMS TOGETHER.
THE VENEER SHEETS
ARE NOW THICKER,
YET DELICATE PIECES OF WOOD
TO BE USED
IN THE CAR'S INTERIOR TRIM.
A LARGE PIECE OF WOOD
SITS ON AN AUTOMATED CARRIER
IN A CLOSED CONTAINER,
WHERE IT IS CUT AND RESHAPED
BY A COMPUTERIZED PRECISION SAW.
THE SAW WILL CUT THE WOOD
BASED ON A PATTERN
CONFORMED FOR THE CAR'S CABIN.
EVENTUALLY,
THE BLOCK IS CUT AND MODIFIED
INTO A FINAL FORM
MADE FOR THE INTERIOR CABIN.
WALNUT TEMPLATES FOR THE WOODEN
VENEER DASHBOARD PANELS
ARE CAREFULLY CRAFTED.
A CRAFTSWOMAN LAYS VENEER PIECES
ONTO A WORK TABLE
WITH A GREEN VELVET CLOTH,
WHICH ACTS AS A PROTECTAN
FROM SCRATCHES.
EMPLOYING A TRADITIONAL PRACTICE
CALLED BOOK MATCHING,
SHE ALIGNS THE CORRESPONDING
WOOD-GRAIN PATTERNS
SO THEY MIRROR EACH OTHER
IN APPEARANCE.
SHE TAPES THE PIECES TOGETHER
ON BOTH SIDES.
NEXT,
THE VENEER PIECES ARE COVERED
WITH A PLASTIC BLUE SHEET.
ANY AIR BUBBLES ARE PUSHED OU
WITH A SMALL PRESSING BLOCK.
USING A GRAPHIC PENCIL AND RULER
TO MARK THE CENTER
WITH A DIVIDING LINE,
THE CRAFTSWOMAN CONTINUES
TO SECTION THE SHEET.
WITH A WIDE TRANSPARENT GUIDE,
SHE USES A HOBBY KNIFE
TO SEPARATE THE THIN SHEET,
REMOVING AN UNNECESSARY SECTION.
SHE MOVES THE SHEET OVERTOP A
PANEL TEMPLATE WITH SHARP EDGES
AND SECURES IT WITH TAPE.
AT ANOTHER WORKSTATION,
SHE APPLIES A LARGE, THIN PIECE
OF PLASTIC ON TOP.
SHE THEN LOWERS
A LARGE MECHANICAL PRESS
ONTO THE PIECES,
WHICH RESULTS
IN CUTTING AND SHAPING.
AFTER THE CUTTING PROCESS,
THE THIN WOOD VENEER COVERING
APPEARS TO BE PERFECTLY SHAPED
TO FIT A WOOD DASHBOARD PANEL.
AS THE WOOD PANEL
SITS IN A HOLDING CAST,
THE CRAFTSWOMAN
ROLLS A SMALL PAINT ROLLER
IN A TRAY OF WOOD GLUE
AND THEN EVENLY
OVER THE TIMBER PANEL.
THE PRE-SHAPED VENEER COVER
IS THEN AFFIXED TO THE PANEL
WITH MASKING TAPE
TO KEEP IT IN PLACE.
THE PANEL AND COVER
ARE THEN PLACED INTO
A VACUUM FRAME PRESS,
WHERE A LARGE
POLYURETHANE MEMBRANE
IS COMPRESSED FOR 45 MINUTES
TO VACUUM-SEAL THE WOODEN UNIT.
THIS WILL PERFECT ITS ADHESION
TO THE GLUE AND WOODEN PANEL.
IN THE NEXT STAGE,
AT ANOTHER WORKSTATION,
A CRAFTSMAN REMOVES
THE BLUE PROTECTIVE PLASTIC
TO EXPOSE THE WOOD VENEER
FOR FURTHER TREATMENT.
ANY AREAS THAT ARE DAMAGED
REQUIRE REPAIR
AND ARE FIXED USING BONDING GLUE
ALONG WITH
SOME MATCHING RAW MATERIALS.
AN IRON IS USED
TO SPEED THE GLUE'S DRYING TIME
AND ENSURE THE MATERIALS
ARE AFFIXED FOR LONG-TERM USAGE.
AFTER REMOVING
ANY EXCESS MATERIAL,
THE PANEL PIECE IS FILED
TO LOOK COMPLETELY UNIFORM.
AT ANOTHER WORKSTATION,
A CRAFTSWOMAN
CAREFULLY TOUCHES UP ANY AREAS
THAT DO NOT MATCH
THE COMPONENT'S COLOR.
AFTERWARD, WITH A LARGE BRUSH,
SHE APPLIES
A QUICK-DRYING LACQUER,
WHICH DRIES TO FORM
A HARD PROTECTIVE COATING.
AGAIN, SHE APPLIES
THE SPECIAL POLISHING PASTE
UNTIL ALL IS PERFECT.
IN THE MEANTIME,
THE PANEL DRIES FOR AN HOUR.
A TECHNICIAN GENTLY SANDS THE
SURFACE OF THE VENEER COMPONEN
ON A WIDE BELT SANDER
TO GIVE IT A POLISHED LOOK.
IN MINUTES, A POWER BUFFER
CAN FURTHER ENHANCE
THE SMOOTHNESS AND SHINE
OF THE VENEER'S SURFACE.
A TECHNICIAN
INSERTS ELECTRICAL COMPONENTS
INTO THE WOOD PANEL'S BACK END.
ONCE THE DIALS ARE INSTALLED,
IT IS CLEAR THAT THE PANEL
IS PART OF THE HEA
AND AIR CONDITIONING SYSTEM.
FINALLY, IN THE CAR'S CABIN,
A TECHNICIAN CONNECTS THE WIRING
AND INSTALLS
THE CLIMATE-CONTROL PANEL
INTO THE CENTER CONSOLE STACK
OF A NEW ROLLS-ROYCE PHANTOM.
THE TECHNICIAN ENSURES THA
THE VENEERED PANEL FITS SUPERBLY
INTO THIS FLAWLESS SUPERCAR.
Narrator:
THE PREMIUM LEATHER SEATS
OF A ROLLS-ROYCE PHANTOM
ARE DESIGNED FOR DRIVING,
COMFORT, AND LOUNGING.
NOT ONLY
DO THEY LOOK AND FEEL GREAT,
BUT THEY SOUND GREAT.
ALL SEATING IS TESTED
FOR SQUEAKING OR RATTLING
BEFORE INSTALLATION
INTO THE CABIN.
A TECHNICIAN PLACES
A SHEET OF GRADE-A BULLHIDE
ONTO A WORK TABLE
THAT AUTOMATICALLY
PULLS THE MATERIAL.
THIS ALLOWS HIM TO SCREEN ANY
FLAWS, MOSQUITO BITES, OR SCARS.
IT TAKES 17 DAYS
TO COMPLETE AN INTERIOR,
WHICH INCLUDES 11 BULLHIDES.
450 PIECES OF LEATHER ARE USED
TO PRODUCE THE INTERIOR.
ANY DEFECTS IN THE MATERIAL ARE
CIRCLED WITH A WHITE WAX PENCIL
TO VERIFY THAT THOSE SECTIONS
ARE NOT APPLIED
TO THE UPHOLSTERY,
INCLUDING AREAS
THAT HAVE STRETCH MARKS.
AT A HIGH-END
COMPUTERIZED CUTTING TABLE,
A TECHNICIAN OUTLINES THE AREAS
THAT REQUIRE CUTTING
WITH A HANDHELD PATTERN EMITTER.
AFFORDING CERTAIN SHAPES TO BE
ILLUSTRATED AGAINST THE LEATHER,
THEY CAN APPEAR ANYWHERE ON
THE HIDE WITHIN SPECIAL LIMITS.
WHEN THE AREAS
HAVE BEEN SELECTED,
THE GREEN LASER PATTERNS
FLASH DRAMATICALLY
BEFORE THE NEXT STAGE
OF THE CUTTING PROCESS BEGINS.
THE AUTOMATED CUTTING TABLE
VACUUMS THE MATERIAL AGAINST I
WHILE A LASER-GUIDED,
SELF-SHARPENING BLADE
CUTS THE DESIRED PATTERNS.
THE SYSTEM CAN PRODUCE
UP TO 56,000 INCISIONS A MINUTE.
ONCE THE CUTTING SESSION
IS COMPLETE
AND THE DESIRED PATTERNS
ARE OUTLINED,
THE TECHNICIAN REMOVES
THE REFINED PIECES FOR SEWING
WHILE THE REMAINS AND RESIDUE
ARE DISCARDED.
IT TAKES UP TO TWO WEEKS TO
UPHOLSTER THIS CAR'S INTERIOR.
TOPSTITCHING,
A SEWING TECHNIQUE THAT HELPS
THE LEATHER TO STAY IN PLACE,
IS MOST CRITICAL.
ALL SEWING HAS TO BE CLEAN
AND EVEN TO EXUDE QUALITY.
FURTHERMORE,
EACH LEATHER COMPONEN
IS PERSONALLY SIGNED BY THE
SEAMSTRESS THAT SEWED AND FIT I
INTO THE VEHICLE'S TRIM.
IN A ROOM OF THREAD, MATERIALS,
AND SEWING MACHINERY,
SEAMSTRESSES
ASSEMBLE THE UPHOLSTERY.
THIS INCLUDES THE LOGO-EMBOSSED
HEADREST COVER.
NEXT,
SHE CUTS, BENDS, AND HAMMERS
THE EDGES
OF A PLASTIC LINER COMPONENT,
WHICH IS USED WITHIN
THE STRUCTURE OF THE COVER.
AFTER BENDING THE MATERIAL
ALONG THE EDGES,
SHE HAMMERS THE COMPONENT FIRMLY
ALONG WITH THE COVER.
SHE CONTINUES
TO SEW THE TWO ELEMENTS TOGETHER
FOR SUPERB ATTACHMENT.
WHEN SHE'S DONE,
SHE UNFOLDS THE MATERIAL
FROM THE INSIDE TO THE OUTSIDE,
REVEALING A PREMIUM
EMBOSSED LOGO HEADREST COVER.
A TECHNICIAN MOUNTS THE
OPEN-CELL FOAM OF THE HEADRES
ONTO A VACUUM HEAD
RESTRAINT FIXTURE.
THIS UNIT ABSORBS THE AIR
WITHIN THE CUSHION,
ALLOWING
THE GREEN PLASTIC COVERING
TO MAINTAIN THE CUSHION
IN A DENSE POSITION,
WHERE THE LEATHER COVER
CAN BE FITTED ON TOP.
WHEN THE VACUUM HEAD RESTRAIN
FIXTURE RELEASES THE AIR,
THE FOAM CUSHION
AND LEATHER OVERLAY
RETURN TO THEIR RESPECTIVE
SHAPES AND SIZES.
THE HEADREST COVER IS MOVED
TO A NEIGHBORING WORKSTATION,
WHERE IT RECEIVES
ITS PLASTIC SUPPORT BRACKE
AND SLIDING METAL SHAFTS
THAT INSERT INTO THE SEAT BACK.
FITTING THE COVER
AS MUCH AS POSSIBLE,
THE TECHNICIAN
ROTATES THE RESTRAINT,
FIXING THE CORNERS WITH A SMALL,
SPECIALIZED TAILORING TOOL.
THE LEATHER HEADREST COVER
IS FINALLY FIXED,
FOLDED, AND SMOOTHED OUT,
LOOKING FORMFITTING
AND UPSCALE,
READY TO STAND WITH ITS
COUNTERPART IN A DELUXE CABIN.
SITTING IN THE LAP OF LUXURY
REQUIRES A LITTLE LABOR.
A TECHNICIAN FITS
THE SEAT BACK'S LEATHER COVER
ONTO ITS FRAME
BY SMOOTHING, PUSHING,
AND PULLING
UNTIL THE LEATHER
FITS LIKE A GLOVE.
ONCE THE SEAT BACK COVER
IS FASTENED TO THE FRAMEWORK,
HE ADDS
THE ACCOMPANYING HEADREST.
THE ONLY THING MISSING NOW
IS THE REST OF THIS
RITZY ROLLS-ROYCE PHANTOM.
Narrator: IT'S EASY TO MISTAKE
THE PHANTOM'S GOOD LOOKS
FOR A SLOW RIDE,
BUT MAKE NO MISTAKE.
IT'S FAST.
THE 453-HORSEPOWER,
6.75-LITER V-12 ENGINE
ACHIEVES ZERO TO 60 MILES
PER HOUR IN 5.9 SECONDS.
USING AN AIR HOIS
TO MOVE EQUIPMENT OVERHEAD,
A WORKMAN LOWERS THE REAR AXLE
OF THE CAR
ONTO A MOTORIZED CARRIER.
RIGHT IN TOW,
HE SLOWLY TRANSPORTS AND ROTATES
THE FRONT AXLE
DIRECTLY ONTO
THE MOTORIZED CARRIER
USING ANOTHER AIR HOIST.
NEXT,
THE ENGINE AND TRANSMISSION
ARE LOWERED FROM ANOTHER STATION
AND PUT INTO
THEIR DESIGNATED POSITIONS.
THE RADIATOR IS CARRIED
TO THE FRONT OF THE ENGINE
AND INSTALLED INTO POSITION.
THE WORKER
ALSO BRINGS THE DRIVESHAFT,
A KEY MECHANICAL COMPONEN
WHICH TRANSMITS TORQUE
IN THE ENGINE SYSTEM.
ONCE THE DRIVESHAF
IS PROPERLY POSITIONED,
HE SECURES I
WITH T-BOLTS AND FASTENERS
TO THE CAR'S EIGHT-SPEED
AUTOMATIC TRANSMISSION SYSTEM.
THIS IS FOLLOWED
BY MORE MANUAL FASTENING
USING A WRENCH ALONGSIDE
A MOTORIZED TORQUE WRENCH.
USING THE MOTORIZED CARRIER,
A WORKMAN MANEUVERS THE RUNNING
GEAR BELOW THE BODY SHELL,
WHICH IS SUSPENDED
IN AN OVERHEAD CONVEYER LIFT.
WHEN BOTH MAJOR ELEMENTS
ARE ASSEMBLED TOGETHER,
THE PROCESS
IS CALLED A MARRIAGE.
THE OVERHEAD CONVEYER LIF
CONTAINS THE BODY'S SHELL UNI
AND IS LOWERED
DIRECTLY OVER THE RUNNING GEAR
TO LINK THE TWO COUNTERPARTS
TOGETHER.
WORKMEN CIRCULATE THE FRON
SUSPENSION AND BRAKING SYSTEMS
TO ENSURE THE BOLTS AND
ATTACHMENT BRACKETS ARE SECURE.
REMOVING A HOLDING CLAMP
FROM THE MOTORIZED CARRIER,
A WORKER RAISES THE CONVEYER
FOR THE RUNNING GEAR
TO BE CLOSER TO THE BODY SHELL
FOR FASTENING.
ENSURING ALL COMPONENTS
ARE SECURELY ATTACHED,
HE USES A TORQUE WRENCH
TO LOCK ALL THREADED FASTENERS.
THE MOTORIZED CARRIER
IS THEN LOWERED
AND REMOVED FROM THE STATION.
AS FINAL VERIFICATION
FOR SAFETY AND QUALITY,
HE USES A RATCHE
TO MANUALLY CHECK.
INSTALLATION OF ANY GLASS
INTO THIS CAR IS DONE MANUALLY.
TECHNICIANS,
USING A LIFTING DEVICE
WITH SUCTION MOUNTS,
CALLED A VACUUM GLASS LIFTER,
TRANSPORT THE WINDSCREEN
TO THE BODY SHELL.
AFTER THEY REINFORCE
THE WINDSCREEN'S POSITION
WITH A DELICATE TAPPING
OF PLASTIC MALLETS,
THEY APPLY
URETHANE WINDSHIELD ADHESIVE
UNDER THE SIDE, CORNER,
AND TOP WINDSHIELD MOLDINGS
AND MAKE SURE THE GLASS IS CLEAN
AFTER INSTALLATION.
USING THE LIFTING DEVICE,
A TECHNICIAN
BRINGS A 21-INCH
ALUMINUM ALLOY WHEEL AND TIRE
TO THE DRIVER'S SIDE
FRONT WHEEL PLATE.
CHECKING FOR PRECISION
AND MECHANICAL FUNCTIONALITY,
A TECHNICIAN
TESTS THE AUTOMATED PLATFORM,
WHICH RETRACTS THE ICONIC HOOD
MASCOT, THE SPIRIT OF ECSTASY,
LOCATED WITHIN THE RADIATOR.
THE SPIRIT OF ECSTASY IS
A SYMBOL OF LUXURY AND MYSTIQUE,
DESIGNED IN 1911
BY SCULPTOR CHARLES SYKES.
THE MOTION OF THE ORNAMEN
IS CONTINUALLY TESTED,
AND ITS MACHINERY PARTS
ARE VERIFIED FOR EXCELLENCE.
ONCE THE INSPECTION IS COMPLETE,
THE GRILLE,
WHICH IS POLISHED FOR FIVE HOURS
AND COVERED
IN PROTECTIVE PLASTIC FILM
BEFORE INSTALLATION,
IS MOUNTED ONTO
THE FRONT END OF THE VEHICLE.
THE VEHICLE THEN MOVES ON
TO THE NEXT PHASE --
DRIVING TESTS.
DURING A 20-MINUTE WATER TEST,
73 MID-PRESSURE SHOWERS SIMULATE
THE EFFECTS OF A MONSOON.
IN THE MEANTIME,
A TECHNICIAN SEARCHES FOR LEAKS
IN THE CABIN USING A FLASHLIGHT.
THE CAR NOW STANDS
IN A DYNAMOMETER ROLL BOOTH,
WHICH USES
COMPUTERIZED TEST ROLLERS
TO SIMULATE
VARIOUS DRIVING CONDITIONS.
THEY'LL EXAMINE
THE TRANSMISSION, SUSPENSION,
AND BRAKING.
IT ALSO CHECKS
THE ENGINE'S POWER AND TORQUE.
THE PHANTOM MAY NO
INSTANTLY COME ACROSS
AS THE TYPICAL
AGGRESSIVE AND SPORTY SUPERCAR
LOOKING FOR APPROVAL
AT THE LOCAL RACETRACK,
BUT ITS UNTOUCHABLE APPEARANCE
AND PEDIGREE
IS APPROPRIATELY
REWARDING ENOUGH.
AND IN ITS MANY VERSIONS,
THE ROLLS-ROYCE PHANTOM HAS
AN ELEGANT, YET BOLD PRESENCE,
WITH ITS LUXURIOUS STYLING,
NOVEL FEATURES,
AND ENGAGING AMENITIES,
NOT TO MENTION
ITS ROBUST V-12 ENGINE.
CONSIDERING
THE TWO MONTHS OF ASSEMBLY
AND THE TRADITIONAL
CRAFTSMANSHIP INVOLVED,
IT'S A DREAM CAR
THAT SHINES LIKE NO OTHER.