Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS,"
THE BENTLEY MULSANNE,
AN OPULENT PALACE ON WHEELS.
-- Captions by VITAC -- www.vitac.com
CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS
BENTLEY HAS BEEN BUILDING POWERFUL, LUXURIOUS,
HANDMADE CARS SINCE 1919.
AT THE COMPANY'S FACTORY HEADQUARTERS IN CREWE, ENGLAND,
THE LEGENDARY BRAND CONTINUES ITS LONG TRADITION.
THE 41/2-LITER BLOWER OF 1930
IS ONE OF THE RAREST AND MOST VALUABLE BENTLEYS IN THE WORLD.
IT'S A CELEBRATED VETERAN OF LE MANS AND MANY OTHER RACES.
ROLLS-ROYCE BOUGHT BENTLEY IN 1931.
IN 1933, THE COMPANY INTRODUCED THE 31/2-LITER BENTLEY DERBY,
MARKING A SHIFT IN FOCUS FROM SPEED TO ELEGANCE.
THE CAR WAS NAMED FOR THE ROLLS-ROYCE FACTORY
IN DERBY, ENGLAND, WHERE IT WAS BUILT.
THE FABLED 1928 BENTLEY SPEED 6
BEAT THE BLUE TRAIN FROM CANNES TO CALAIS IN 1930.
THE BENTLEY MULSANNE SPEED FUSES THOSE TWO TRADITIONS TOGETHER,
BUT LATER BECAME SYNONYMOUS WITH REFINED ELEGANCE.
IT'S NAMED AFTER THE RENOWNED SECTION
OF THE LE MANS 24-HOUR RACE CALLED THE MULSANNE STRETCH.
THIS SUPER CAR CAN ROCKET UP TO 190 MILES PER HOUR
IN LUXURIOUS STYLE.
A CRANE LOWERS THE REAR SECTION
OF THE GALVANIZED STEEL MONOCOQUE ONTO A JIG.
NEXT THE CRANE BRINGS THE CENTER FLOOR AND FRONT END SECTION
INTO POSITION.
WORKERS CLAMP THEM IN PLACE
TO PREPARE THEM FOR THE NEXT PHASE OF PRODUCTION.
THEY ADD SMALLER COMPONENTS, LIKE THE SILL INSERT.
THEN WORKERS USE PORTABLE RESISTANCE SPOT-WELDERS
TO MELT THE METAL.
THE WELDERS USE AN ELECTRIC CURRENT TO JOIN THE SHEETS
IN A LOCAL SPOT.
THIS TECHNIQUE GENERATES LESS HEAT
THAN OTHER FUSION-WELDING METHODS.
THE MULSANNE HAS ROUGHLY 5,800 SPOT-WELDS.
THE ROOF AND THE CAR SIDES
HAVE BEEN PRE-ASSEMBLED IN ANOTHER PART OF THE FACILITY.
A CRANE JOINS THIS SUB-ASSEMBLY TO THE UNDERFRAME.
THE MULSANNE ROOF HAS A CLAMSHELL STRUCTURE,
MEANING IT EXTENDS DOWN INTO THE DOORFRAMES.
THE WORKERS BEGIN A PROCESS CALLED BRAZING,
WHICH CREATES A SEAMLESS SURFACE
FROM ONE SIDE OF THE CAR TO THE OTHER.
THEY USE A SPECIAL CLAMP
TO KEEP THE STEEL PANELS PROPERLY ALIGNED.
THE CLAMP ALSO CONDUCTS HEAT AWAY FROM THE JOINT
AS IT'S BEING WELDED.
THIS HELPS REDUCE DISTORTION IN THE METAL.
A WORKER BEGINS THE LONG PROCESS OF SMOOTHING OUT THE JOINT.
HE CAREFULLY WORKS THE WELD FROM ONE SIDE TO THE OTHER
USING PROGRESSIVELY FINER GRIT FINISHING SURFACES.
HE COMPLETES THE JOB BY HAND.
WHEN THE BODY GOES TO THE PAINT SHOP,
ANY REMAINING SCRATCHES ARE SO FINE
THAT THE PAINT JOB WILL COVER THEM COMPLETELY.
A WORKER USES A LIFT ASSIST
TO BRING ONE OF THE MULSANNE'S FOUR DOORS
INTO POSITION.
UNLIKE THE STEEL MONOCOQUE AND ROOF,
THE DOORS ARE MADE OF ALUMINUM.
USING SETTING AIDS AND GAUGES, A WORKER INSTALLS THE HOOD.
HE RAISES AND LOWERS IT TO CONFIRM THE FIT.
THE HOOD IS ALSO MADE OF ALUMINUM.
THE TRUNK LID IS MADE OF SHEET-MOLDED COMPOSITE.
THE COMPLETED CAR BODY IS SENT TO THE INSPECTION AREA.
AN EXPERT THOROUGHLY CHECKS THE SURFACES.
HE USES A SPECIAL FINE-GRAINED STONE TO IDENTIFY ANY DEFECTS
WITHOUT COMPROMISING THE OVERALL SURFACE QUALITY.
THE HIGHLIGHT FLUID IS APPLIED IN LOCAL AREAS
TO MIMIC THE LOOK OF PAINT.
WITH THE HELP OF SPECIAL LIGHTING,
THE INSPECTOR CAN SEE ANY FLAWS ON THE SURFACE.
ONCE THE BODY PASSES INSPECTION, IT TRAVELS TO THE PAINT SHOP.
CUSTOMERS CAN CHOOSE FROM MORE THAN 100 COLORS
OR MATCH THE PAINT JOB TO ANYTHING,
FROM A FAVORITE TIE
TO A PARTICULAR SHADE OF LIPSTICK.
Narrator: BENTLEY'S BRAWNY V8 ENGINE
IS A CORNERSTONE OF THE COMPANY'S BRAND.
FOR THE NEW MULSANNE, THEY'VE RE-ENGINEERED
THE FAMED 63/4-LITER POWERHOUSE,
PUSHING THE PEAK TORQUE TO 811 FOOT-POUNDS.
A TECHNICIAN USES A HOIST
TO CAREFULLY LOWER THE CRANKSHAFT INTO THE CRANK CASE.
HE USES THE MAIN BEARING CAPS TO ATTACH THE PARTS.
HE SECURES THE CAPS WITH BOLTS.
THEN CONFIRMS THAT THE CRANKSHAFT
CAN SPIN FREELY IN ITS BEARING.
A TECHNICIAN SLOWLY DROPS THE CAMSHAFT INTO THE ENGINE BLOCK.
HE MAKES SURE THE BLOCK DOESN'T DAMAGE THE CAMSHAFT LOBES
AS THEY GO IN.
HE ADDS SEALING RINGS TO THE END OF THE CAMSHAFT
BEFORE HE INSTALLS THE TOP PLATE.
THE RINGS KEEP THE CAMSHAFT END FLOAT WITHIN PARAMETERS.
USING A PISTON CHECKING GAUGE, AN OPERATOR
ENSURES THE COMPONENTS' CIRCLIPS ARE IN PLACE
BEFORE SEPARATING THE CAP FROM THE ROD.
THIS ALLOWS HIM TO EASILY INSTALL THE CON ROD BEARINGS
AND CAP BEARINGS.
HE ATTACHES TWO NYLON RODS TO THE PISTON
AND COMPRESSES THE PISTON RINGS IN A SPECIALIZED TOOL.
HE BRINGS THE PISTON TO THE ENGINE BLOCK
AND INSERTS IT INTO ITS ASSIGNED BORE.
THE TECHNICIAN REMOVES
THE PROTECTIVE NYLON RODS FROM THE BORE,
THEN HE INSTALLS THE CAPS, AND TORQUES THEM IN PLACE.
HE FINISHES THE INSTALLATION
AND THEN TURNS THE CRANKSHAFT.
HE RUNS THE PISTONS UP AND DOWN THE BORES
TO MAKE SURE THEY CAN MOVE FREELY.
A TECHNICIAN INSTALLS THE CRANKSHAFT FLEX PLATE.
THE FLEX PLATE IS PART OF THE COMPONENT THAT TURNS THE GEARBOX
AND PROVIDES DRIVE.
THEN HE PLACES THE SECOND PLATE ON TOP
BEFORE POSITIONING A PLASTIC TORQUE TIGHTENING GUIDE.
THE TECHNICIAN FOLLOWS THREE PRESCRIBED STEPS
IN TORQUING THE BOLTS.
THE BOLTS MUST BE TIGHTENED TO A TORQUE
SPECIFIED BY THE ENGINEERS WHO DESIGNED THE ENGINE.
A WORKER BRINGS THE LIGHTWEIGHT ALUMINUM HEADS
TO THE ENGINE BLOCK
AND USES A SET OF LOCATOR PINS TO POSITION THEM.
THE TECHNICIAN ADDS A PAIR OF GASKETS.
AND THEN DROPS THE MANIFOLD INTO POSITION.
HE FOLLOWS THE TORQUING SPECIFICATIONS
TO RUN DOWN THE BOLTS.
HE INSTALLS THE FUEL RAILS ON EITHER SIDE
OF THE MANIFOLD BASE.
THE TECHNICIAN CAREFULLY PLACES AN OILED BALL BEARING
ON TOP OF EACH OF THE ENGINE'S 16 PUSH RODS.
THEN HE USES FIVE LOCATOR STUDS TO INSTALL THE ROCKER SHAFT.
HE TORQUES DOWN THE NUTS WITH A THREE-STAGE PROCESS
THAT GENTLY COMPRESSES THE PUSH RODS
WITHOUT BENDING THE ROCKER SHAFT.
AFTER PRE-OILING THE ROCKER SHAFT,
THE TECHNICIAN ADDS THE ROCKER COVER.
THEN A WORKER STAMPS ON THE ENGINE'S NUMBER.
HE HAMMERS A UNIQUE COMBINATION
OF LETTERS AND NUMBERS INTO THE SIDE OF THE BLOCK.
THAT NUMBER INCREASES BY ONE WITH EACH NEW ENGINE.
FINALLY, A WORKER INSTALLS THE TURBO AND EXHAUST MANIFOLD.
HE USES BRASS NUTS TO HOLD IT IN PLACE
BECAUSE BRASS IS RESISTANT TO HEAT EXPANSION.
THE COMPLETELY ASSEMBLED V8 ENGINE
IS NOW READY TO POWER A BENTLEY MULSANNE
FROM ZERO TO 60 MILES PER HOUR IN JUST 4.9 SECONDS.
Narrator: WOOD IS A TRADEMARK ELEMENT OF BENTLEY CARS,
AND THE MULSANNE HAS A LOT OF IT.
THE WOOD PANELING BELOW THE DOOR WINDOW IS CALLED THE WAIST RAIL.
BUILDING IT REQUIRES FINE MATERIALS
AND EVEN FINER CRAFTSMANSHIP.
ARTISANS START THE PROCESS
BY MACHINING A PAIR OF MATCHING TONGUES AND GROOVES
IN TWO PIECES OF WOOD.
IN THIS CASE, THE WOOD IS AMERICAN BLACK WALNUT,
BUT CUSTOMERS CAN CHOOSE FROM A VARIETY OF OPTIONS.
A WOODWORKER APPLIES GLUE TO THE TONGUES
AND AN ACTIVATOR COMPOUND TO THE GROOVES.
THEN HE CAREFULLY FITS THE TWO PIECES OF WOOD TOGETHER.
A HYDRAULIC PRESS PROVIDES JUST ENOUGH PRESSURE
TO FORCE THE GLUE ALONG THE GROOVE LINES,
ENSURING THERE ARE NO GAPS.
AFTER 20 MINUTES,
THE GLUE IS HARD ENOUGH TO START SHAPING THE MATERIAL.
WORKING FREEHAND,
A CRAFTSMAN USES A BAND SAW TO CUT OFF SURPLUS WOOD,
LEAVING THE ROUGH SHAPE OF A WAIST RAIL.
EACH MULSANNE HAS FOUR WAIST RAILS, ONE PER DOOR.
AN OPERATOR LOADS ALL FOUR ONTO A FIXTURE
USING A VACUUM SYSTEM TO HOLD THEM IN PLACE.
THE FIXTURE SLIDES INTO A FIVE-AXIS CNC MACHINE.
THE MACHINE USES A SET OF FORMING TOOLS
TO CUT THE SURFACE DETAILING.
IN THIS CASE, IT'S WORKING ON WHAT'S CALLED THE "B" SIDE
OF THE WAIST RAIL.
THIS SIDE, WHICH WON'T BE VISIBLE,
INCLUDES ALL THE ATTACHMENT POINTS.
OPERATORS FLIP THE WOOD OVER
TO LET THE CNC MACHINE FINISH THE "A" SIDE.
TO ACHIEVE THE SIGNATURE BENTLEY LOOK, THE COMPANY USES
HIGH-QUALITY SOURCES LIKE CALIFORNIA BURL WALNUT.
THE BURL COMES FROM THE ROOT OF THE TREE.
THE VENEER SUPPLIER
SHAVE THE BURL INTO LEAVES JUST A HALF A MILLIMETER THICK
AND PACKAGE THEM IN BUNDLES.
HERE, A CRAFTSMAN CAREFULLY FLICKS A SET OF LEAVES
TO MAKE SURE THE KNOTS LINE UP PERFECTLY.
HE PLACES TWO LEAVES END TO END,
WITH THE KNOT PATTERNS MIRRORING EACH OTHER PRECISELY.
A NICK ENSURES THEY CAN BE EASILY REALIGNED.
THEN HE FLIPS THE LEAVES OVER
AND CAREFULLY TAPES THEM TOGETHER.
THE NICK HELPS HIM LINE THEM BACK UP QUICKLY.
HE APPLIES LIGHT, SMOOTH PRESSURE TO THE LEAVES
TO MAKE SURE THE TAPE ADHERES COMPLETELY.
THE LEAVES OF THE WALNUT VENEER ARE EXTREMELY FRAGILE.
TO PROTECT THEM FROM CRACKING AND SPLITTING,
THE WORKER COVERS ONE SIDE WITH SPECIALIZED TAPE.
THEN HE CUTS THE VENEER TO THE SHAPE REQUIRED.
NOW HE'S READY TO ATTACH THE VENEER TO THE WALNUT WAIST RAIL.
FIRST THE CRAFTSMAN APPLIES A HEAT-ACTIVATED LIQUID GLUE
TO THE SURFACE.
HE PLACES THE WAIST RAIL ON A FIXTURE THAT WILL PROTECT IT
DURING THE NEXT PHASE OF PRODUCTION.
HE POSITIONS THE VENEER ON TOP
AND, WITH THE HELP OF A SECOND WORKER, SECURES IT IN PLACE.
THEY COVER EVERYTHING WITH A SHEET OF PLASTIC
AND SEND IT INTO A MACHINE CALLED A MEMBRANE PRESS.
PRESSURE FROM THE PRESS BONDS THE VENEER TO THE WAIST RAIL.
AFTER 20 MINUTES IN THE PRESS,
THE TWO WOOD COMPONENTS ARE FIRMLY ADHERED TO EACH OTHER.
NOW A MEMBER OF THE SANDING TEAM GOES TO WORK ON THE WAIST RAIL.
HE STARTS WITH A RELATIVELY COURSE GRIT OF SAND PAPER
TO REMOVE ANY GLUE RESIDUE OR SCRATCHES.
HE FINISHES WITH 120-GRIT PAPER.
THIS WAIST RAIL HAS ALREADY RECEIVED
FIVE COATS OF POLYESTER LACQUER,
AND IT'S READY FOR POLISHING.
A WORKER APPLIES A POLISHING COMPOUND
TO A DEVICE CALLED THE MOP.
THEN HE POLISHES THE WAIST RAIL'S COATING
TO A SMOOTH, HIGH GLOSS.
THE FINISHED WAIST RAIL
WILL FORM PART OF THE FINELY CRAFTED WOOD PANELING
THAT CIRCLES THE INTERIOR OF THE MULSANNE.
Narrator: THE MULSANNE BODY IS READY FOR FINAL ASSEMBLY.
THE CAR IS BARE BONES NOW,
BUT BENTLEY IS RIGHTLY FAMOUS
FOR ITS CARS' LUXURIOUS INTERIORS,
SO THERE'S A LOT OF WORK TO BE DONE.
TWO WORKERS LOAD A BAG FULL OF WIRING INTO THE CAR.
THIS PREASSEMBLED WIRING IS CALLED THE MAIN HARNESS OR LOOM.
IT'S BEEN HEATED TO 136 DEGREES FAHRENHEIT
TO MAKE IT FLEXIBLE AND EASY TO MANIPULATE.
THE INSTALLERS FEED A SECTION OF THE WIRING
THROUGH A OPENING INTO THE TRUNK.
THE HARNESS INCLUDES FIBER OPTIC CABLES
TO RUN THE ENTERTAINMENT SYSTEM
AND AIR LINES FOR THE SUSPENSION.
IT'S EXTREMELY IMPORTANT
NONE OF THESE ARE KINKED DURING INSTALLATION.
A WORKER POSITIONS THE INDICATOR SIDE LIGHTS
AND THEN ADDS THE HEADLIGHTS.
OPERATORS USE SPECIALIZED MACHINERY
TO ADJUST THE DIRECTION OF THE HEADLIGHT BEAMS.
INSTALLERS LOAD THE DASHBOARD,
WHICH BENTLEY WORKERS ASSEMBLED
AT AN ADJACENT STATION ON THE PRODUCTION LINE.
WITH THE CAR ELEVATED ON A LIFT,
WORKERS INSTALL THE EXHAUST SYSTEM.
IT WAS ALSO ASSEMBLED PARALLEL TO THE PRODUCTION LINE.
THE POWER TRAIN, WHICH INCLUDES THE ENGINE, GEARBOX,
PROP SHAFT, REAR DIFFERENTIAL, AND BRAKES,
SITS ON A FIXTURE CALLED THE MARRIAGE BED.
IT'S READY TO JOIN THE CAR'S BODY.
THE MARRIAGE, AS IT'S CALLED,
IS AN EXTREMELY INTENSIVE PROCESS.
THE MARRIAGE BED FLOATS ON A BEARING,
ALLOWING OPERATORS
TO MANUALLY ALIGN THE TWO SUB-ASSEMBLIES
AS THEY COME TOGETHER.
THE RADIATOR SHELL CAN BE PAINTED OR FULLY CHROMED
ACCORDING TO CUSTOMER PREFERENCE.
CUSTOMERS CAN OPT FOR THE BENTLEY TWO-DIMENSIONAL BADGE
OR FOR ITS FAMOUS FLYING "B" HOOD ORNAMENT.
THE "B" HAS BEEN DESIGNED TO RETRACT AT THE SLIGHTEST TOUCH.
BENTLEY ARTISANS MAKE THEIR CAR SEATS ON SITE,
CUSTOMIZING ALL UPHOLSTERY, TRIM,
AND OTHER SPECIAL FEATURES TO THE CUSTOMER'S SPECIFICATIONS.
THIS PARTICULAR MODEL
FEATURES A SCREEN EMBEDDED IN THE BACK OF THE HEADREST.
OTHERS COME WITH INTEGRATED TABLETS AND KEYBOARDS.
THE MULSANNE STEERING WHEELS ARE ALSO CUSTOM-MADE ON SITE.
WHEELS CAN COME HEATED,
MADE OF WOOD, FULLY UPHOLSTERED IN LEATHER,
OR A COMBINATION OF ALL THREE.
A WORKER BUILDS A DOOR PARALLEL TO THE ASSEMBLY LINE.
WITH THE WOODEN WAIST RAIL ALREADY CLAMPED IN PLACE,
HE ADDS THE CASING AROUND THE SPEAKER SYSTEM.
BUILDING COMPONENTS NEXT TO THE ASSEMBLY LINE
REDUCES THE RISK OF DAMAGE DURING TRANSIT.
LIKE EVERY OTHER ELEMENT OF THE MULSANNE,
THE DOORS' INTERIOR MATERIALS, COLOR SCHEME,
AND EVEN UPHOLSTERY STITCHING PATTERN ARE CUSTOM-MADE.
AN INSTALLER USES A LIFT ASSIST
TO TRANSFER THE DOOR TO ITS MATCHING CAR
AND ALIGN THE HINGES FOR ATTACHMENT.
A SYSTEM OF BAR CODES AND SCANNERS ENSURES WORKERS
ASSEMBLE THE RIGHT PARTS TO THE RIGHT CAR.
THE TREAD PLATE BADGE
CAN FEATURE THE NAME OF AN INDIVIDUAL, A COMPANY,
OR ANYTHING ELSE A CUSTOMER REQUESTS.
AN INSPECTOR STARTS AT ONE CORNER
AND WORKS HER WAY AROUND THE MULSANNE
IN A PRESCRIBED PATTERN.
SHE EXAMINES THE CAR FOR FLAWS
AND ENSURES THAT IT'S BUILT TO THE CUSTOMER'S REQUIREMENTS.
WITH ITS LONG, GRACEFUL LINES AND SMOOTH, POLISHED SURFACES,
THE EXTERIOR OF THE MULSANNE SPEED
RECALLS THE OLD-SCHOOL ELEGANCE OF CARS LIKE THE 1933 DERBY.
EVEN THE WHEELS LOOK GRACEFUL.
INSIDE, BENTLEY'S FLAIR FOR LUXURY IS ON FULL DISPLAY.
THE REFINED STYLE BARELY CONCEALS THE POWERHOUSE
THAT GENERATES BENTLEY'S FAMOUS WAVE OF TORQUE,
MAKING IT MORE POWERFUL THAN ANY MUSCLE CAR.
THE BENTLEY MULSANNE IS 13% MORE EFFICIENT
THAN PREVIOUS MODELS,
GIVING IT A SMALLER CARBON FOOTPRINT
AND EXTENDING ITS RANGE BY 50 MILES.
HANDMADE FROM TOP TO BOTTOM,
THE MULSANNE SPEED CALLS ON BOTH STRANDS
OF ITS BRAND'S HISTORICAL TRADITIONS,
FUSING SPEED AND STRENGTH
WITH THE OPULENCE OF THE MOST LUXURIOUS LIMOUSINE.