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5:32

Materials

6:12

Wiring Harness

6:43

Rear Frame

7:19

Volkswagen Engine Plant

9:14

Turbo Charging

10:46

Oil Pan

12:18

The Combustion Engine

20:52

Test Driver

27:08

Exhaust System

34:33

Bugatti Special Tires

35:17

Operating Fluids

38:42

Installing the Windshield

41:31

Aerodynamics

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Bugatti Chiron

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00:00:10

[Music]

00:00:26

[Music]

00:00:38

[Music]

00:00:48

it's the fastest most extreme and most

00:00:52

exclusive production super sports car in

00:00:54

the world the French made vehicle shoots

00:00:56

along the road at a top speed of 420

00:00:59

kilometers an hour this hyper car

00:01:01

scratches at the boundaries of physics a

00:01:03

motorized superlative it is this

00:01:07

ambivalence between beauty and beast to

00:01:11

awaken the beast in this ultra powerful

00:01:13

engineering work of art the developers

00:01:16

have made the best even better I think

00:01:19

you start working where others have

00:01:21

stopped the mission a hyper sports car

00:01:23

with 1500 horsepower and a top speed of

00:01:26

420 kilometers an hour that the whole

00:01:29

world said you'll never manage to cram

00:01:31

so much power in a car the whole world

00:01:35

was wrong but the enormous power

00:01:37

concealed in this rocket poses new

00:01:40

challenges

00:01:43

you have to be sure that you've still

00:01:45

got enough white on the front that it

00:01:46

won't take off to ensure a healthy body

00:01:50

mass index the Alsace engineers have

00:01:52

fitted the all-wheel drive vehicle with

00:01:54

lots of carbon titanium and magnesium

00:01:57

potential lots of things you would

00:01:59

normally only find in Formula one cars

00:02:01

and the elegant top athlete with the 16

00:02:05

cylinder engine is anything but normal

00:02:07

the design engineers all agree about

00:02:09

that but my nature can you compare the

00:02:12

sheer on with another vehicle no God

00:02:15

created heaven and earth and the French

00:02:17

created the bugatti shear on the

00:02:25

spearhead of vehicle construction is

00:02:27

located in multi france the bugatti

00:02:30

hyper sports car manufacturer these

00:02:33

record-holding dream cars have been

00:02:35

built on the site of the former family

00:02:36

estate for the past 110 years built in

00:02:40

2004 in the form of a company logo the

00:02:44

Alsatians lovingly refer to the new

00:02:46

production building as the Dream Factory

00:02:52

inside 20 employees assemble up to 16

00:02:56

vehicles at the same time at 12 stations

00:02:58

with these production figures Bugatti is

00:03:01

part of the ort Keturah

00:03:03

among vehicle manufacturers the bugatti

00:03:05

chiron is the flagship of the current

00:03:08

collection

00:03:11

it's a lot of manual work it's like in a

00:03:14

Formula One racing stable everything's

00:03:16

handmade at various stations yeah I some

00:03:24

300 people work at Bugatti engineers

00:03:27

sales representatives and purchasers I

00:03:29

encode for people who share a passion us

00:03:31

to develop build and sell super sports

00:03:34

cars weekend Subhan

00:03:35

once offical fini it takes two months

00:03:38

until the French have assembled around

00:03:40

2,600 individual parts to form a new

00:03:44

motorsport work of art

00:03:50

the Sheeran's hood conceals pure

00:03:53

performance the world's most powerful

00:03:55

production engine has 16 cylinders and a

00:03:58

displacement of 8 litres this enables

00:04:01

the Bugatti to reach its record-breaking

00:04:02

speed of 420 kilometers an hour for

00:04:06

offset operating turbochargers

00:04:08

accelerate the 1500 horsepower

00:04:11

projectile from zero to a hundred

00:04:13

kilometers an hour in just 2.4 seconds

00:04:18

instead of a classic production line

00:04:20

there are four special stations in

00:04:22

Molsheim they each contain two

00:04:25

independent lifting platforms because

00:04:28

the sports coupe a is made up of two

00:04:31

parts which the employees marry with one

00:04:33

another during production three

00:04:36

mechanics always assemble what is called

00:04:38

the Sheeran's

00:04:40

rolling chassis strictly by hand the

00:04:42

drivable naked vehicle skeleton

00:04:47

[Applause]

00:04:49

an expensive delivery is waiting at the

00:04:51

Bugatti cargo ramp this body component

00:04:54

heralds the construction of a new

00:04:56

all-wheel-drive behemoth the monocoque

00:05:00

is a hollow driver cockpit and is made

00:05:02

entirely of carbon fiber reinforced

00:05:05

plastic or CFRP for steel journals now

00:05:14

rise up out of the gleaming shop floor

00:05:16

two workers install an assembly platform

00:05:19

on them the production crew then heaves

00:05:22

the 150 kilogram carbon framework onto

00:05:25

the platform each material that the

00:05:28

bugatti design engineers install fulfils

00:05:31

a specific purpose the materials we use

00:05:34

at Bugatti are the finest but also the

00:05:36

lightest available we used lots of

00:05:38

magnesium titanium carbon and aluminum

00:05:40

lots of things that you would normally

00:05:42

only find in Formula one cars don't I

00:05:49

think there are no miracles and

00:05:50

Technology our bugatti chiron is capable

00:05:53

of topping 400 kilometres per hour and

00:05:55

can accelerate from zero to 100 in less

00:05:57

than three seconds we're talking about

00:05:59

numbers and performance that are somehow

00:06:01

unreal means that this simply represents

00:06:03

a lot of work at the development and

00:06:05

also at the production level to ensure

00:06:07

this performance is always achieved the

00:06:12

technicians install the wiring harness

00:06:14

inside the carbon cockpit the harness

00:06:17

consists of 2.5 kilometres of cables and

00:06:20

is the nerve system of the shiron it

00:06:23

connects the vehicles 20 control units

00:06:25

the mechanics fastened the electrical

00:06:27

wires to the monocoque with titanium

00:06:30

screws like all of the other elements in

00:06:33

this racing machine the wiring harness

00:06:35

is also designed as compact and light as

00:06:38

possible

00:06:42

the rear frame of the exclusive kupe is

00:06:46

assembled on the second platform

00:06:48

but first the workers move the assembly

00:06:50

frame to the heart of the bugatti the

00:06:53

640 kilograms 16 cylinder engine due to

00:06:57

the size and the enormous weight of this

00:06:59

unit the assembly platform comes to the

00:07:01

engine in Molsheim the mechanics use a

00:07:04

crane to put the german-built

00:07:06

high-performance powerplant down on the

00:07:08

assembly platform

00:07:17

the engines are manufactured at the

00:07:20

Volkswagen engine plant in SATs katha

00:07:22

covering 2.8 million square meters this

00:07:26

site boasts its own bugatti department

00:07:28

whoever works here belongs to the

00:07:31

absolute elite among engine mechanics as

00:07:34

the 16 cylinder is considered to be the

00:07:37

holy grail of engines two technicians

00:07:40

need one week to build one of the 1500

00:07:44

horsepower quad turbo engines your mock

00:07:48

we built a car that does over 400

00:07:50

kilometres an hour and drives elegantly

00:07:52

to the Opera in the evenings to do this

00:07:53

you need not only a car that can achieve

00:07:55

this but also an engine that's capable

00:07:57

of driving in the summer and winter in

00:07:59

cities traffic jams as well as on

00:08:01

racetracks and that's something of a

00:08:02

challenge for the Formula One teams are

00:08:07

good at building racing engines with

00:08:09

lots of power and Volkswagen is adept at

00:08:11

building good engines for the road for a

00:08:13

golf but this combination of two worlds

00:08:15

is Bugatti specialty

00:08:18

[Music]

00:08:19

christened production nests by the

00:08:21

technicians the four workplaces in the

00:08:24

engine department are also special each

00:08:27

station is structured so that a complete

00:08:28

unit can be built here the experts

00:08:32

manufacture a total of three of these

00:08:34

powerful heavy weights per week

00:08:41

to make the engine as compact as

00:08:44

possible eight cylinders are distributed

00:08:46

over each of the two v-shaped banks thus

00:08:50

creating an artificial W engine with 16

00:08:53

cylinders the W 16 achieves its maximum

00:08:57

acceleration with for high-performance

00:09:00

turbochargers via turbine the quartet

00:09:04

compresses the air in taken at the front

00:09:06

of the vehicle and presses it into the

00:09:08

combustion chamber in stages thanks to

00:09:12

what Bugatti calls sequential turbo

00:09:14

charging turbo 3 and 4 cut in at 2,800

00:09:19

rpm this prevents turbo lag and

00:09:22

therefore ensures constant power at

00:09:28

production nest to a new crankcase is

00:09:30

ready to be assembled a mechanic has

00:09:34

just installed the Pistons in the 16

00:09:36

cylinders and connected them to the

00:09:38

crankshaft before the engine builders

00:09:41

continue their work they use an

00:09:43

electronic torque wrench to simulate

00:09:45

engine operation for instance this

00:09:48

allows the workers to check that the

00:09:50

piston stroke does not lead to friction

00:09:52

on the cylinder wall otherwise serious

00:09:56

engine damage called piston seizure

00:09:58

could occur later while driving

00:10:04

the Sheeran's engine is made up of

00:10:07

around 3,700 individual parts the

00:10:11

technicians pre-assemble individual

00:10:13

components at workplaces next to the

00:10:15

assembly stand this worker is assembling

00:10:22

various engine elements here he is

00:10:25

fitting a fuel pump later on it will

00:10:28

deliver the required quantity of fuel to

00:10:30

the engine the worker then installs the

00:10:33

alternator its task is to generate

00:10:36

electricity for the starter battery and

00:10:38

other electrical components

00:10:43

at the same time his colleague prepares

00:10:46

the oil pan for assembly it has to be

00:10:49

absolutely leak tight because later on

00:10:53

the pan contains the engine oil needed

00:10:55

to lubricate the 16 cylinder engine this

00:10:59

is why the technician now takes it to an

00:11:01

automatic station two different

00:11:03

processes take place here first a

00:11:06

special oxygen plasma cleans the surface

00:11:09

of the pan

00:11:10

although the engineers pay strict

00:11:12

attention to cleanliness there is still

00:11:15

a fine layer of dirt on the components

00:11:20

the station then applies a black sealant

00:11:24

onto the edge of the magnesium pan once

00:11:27

the sealant has been completely

00:11:28

distributed the technician has 20

00:11:30

minutes to assemble the component to do

00:11:33

this he positions the oil pan over the

00:11:36

crankshaft onto the lower side of the

00:11:38

engine block and seals it

00:11:46

only specially trained technicians are

00:11:48

permitted to build the Sheerin engine

00:11:51

whoever has successfully completed the

00:11:53

additional two-year training can

00:11:55

justifiably feel proud I'm one of a

00:12:01

total of eight technicians worldwide who

00:12:02

are permitted to build this engine in

00:12:04

series of course that makes you very

00:12:10

proud it's like you made your hobby your

00:12:12

vocation you can already get a sense of

00:12:17

the enormous dimensions of the

00:12:18

combustion engine at station 3 the quad

00:12:22

turbo engine draws its power from the

00:12:24

ignition of a fuel air mixture these

00:12:28

camshafts ensure the correct mixing

00:12:31

ratio driven by the engines chain the

00:12:34

cams rotate around their metal shaft and

00:12:36

thereby press alternately on the valves

00:12:39

of the individual cylinder heads

00:12:43

this enables them to open and close in a

00:12:46

specific stroke the mechanics bolt two

00:12:49

of these 1 kilogram engine components

00:12:52

per cylinder Bank

00:12:58

the w16 engine in the Sheeran has a

00:13:01

total of four camshafts so that the

00:13:04

mixture can ignite the engineers now

00:13:07

insert sixteen spark plugs into the

00:13:09

cylinders they supply the final pulse

00:13:12

for starting the engine they also

00:13:16

influence the four-stroke engines

00:13:18

performance consumption and pollutant

00:13:20

emissions the plugs generate a powerful

00:13:24

spark between 500 and 3500 times a

00:13:27

minute the resulting explosions set the

00:13:31

ranks of pistons in the cylinder bank in

00:13:33

motion

00:13:36

the stripped engine meaning all of the

00:13:38

components needed to operate the drive

00:13:40

unit is now complete

00:13:42

however the massive power plant is

00:13:45

considerably bigger when fully assembled

00:13:47

all further attaching parts are true to

00:13:51

the Bugatti philosophy of more power and

00:13:53

maximum performance the final dimensions

00:13:57

of the engine in a Sheeran are four

00:14:00

times those of a standard passenger car

00:14:02

engine

00:14:03

[Music]

00:14:06

since 2005 the engines for the French

00:14:09

luxury brand have been hand-built at the

00:14:11

plant in Zod's katha even when the

00:14:17

company was founded in 1909 the engine

00:14:20

blocks were cast by hand at Bugatti back

00:14:23

then the engines for the first models

00:14:25

were produced at the plant premises in

00:14:27

Molsheim although working conditions 110

00:14:31

years ago were certainly tougher the

00:14:33

basic structure of high-performance

00:14:35

engines has barely changed with his

00:14:38

racing and luxury cars the Milan born

00:14:41

company founder was considered to be a

00:14:43

legend of European automobile history

00:14:46

even back then

00:14:47

[Music]

00:14:50

at eight order Bugatti developed and

00:14:52

built vehicles that are still icons of

00:14:54

motoring history today cars like the t35

00:14:58

with the bugatti atlantic ettore bugatti

00:15:01

was a perfectionist and did incredible

00:15:03

things here in this plant back in the

00:15:05

20s and 30s the simple fact that we call

00:15:08

our plant an atelier rather than a

00:15:10

factory is quite a statement in itself

00:15:13

the entire mole time site here in Alsace

00:15:16

France is unique for an automotive

00:15:18

manufacturer because it exudes pure

00:15:20

history and no other manufacturer can

00:15:23

offer that

00:15:27

the name Bugatti stood for revolutionary

00:15:30

ideas from the get-go

00:15:32

in 1933 the Milan born visionary even

00:15:36

built a rail bus with a top speed of 200

00:15:39

kilometers an hour a tour day was often

00:15:46

laughed at for his unconventional ideas

00:15:49

but in the 1920s Bugatti super sports

00:15:52

cars achieved worldwide fame thanks

00:15:55

above all to their record number of 2000

00:15:59

race victories

00:16:02

the name Sheeran also played a role back

00:16:05

then

00:16:11

cheval sharone was a racing driver in

00:16:13

the 1920s a very successful one we won a

00:16:16

lot of races with him buddies today the

00:16:19

bugatti chiron named after him as the

00:16:22

ultimate hyper sports car and the engine

00:16:24

is at the heart of it an eight liter

00:16:26

engine with 16 cylinders and up to 1600

00:16:30

horsepower

00:16:31

however the objective of building the

00:16:34

world's fastest production sports car in

00:16:37

the form of the new Sheeran was viewed

00:16:39

very critically by the industry gun

00:16:42

severity the whole world said you'll

00:16:44

never manage to cram so much power in a

00:16:46

car but a displacement of 8 liters over

00:16:48

a thousand horsepower as a conventional

00:16:50

task you had turbochargers to it at some

00:16:52

point you achieve that power and then

00:16:54

you're faced with a big problem you

00:16:55

can't find a test bench anywhere in the

00:16:57

world that can cope with this power but

00:17:00

the engineers solved precisely this

00:17:02

problem on an internally developed test

00:17:05

and they put the eight liter engine

00:17:07

through its paces until the manifold

00:17:09

glows

00:17:14

once completed the engineers test the

00:17:17

power output and above all the

00:17:19

durability of each power plant behind

00:17:23

the roughly 30 centimeter thick safety

00:17:25

walls of the test booth

00:17:27

the team has strapped the combustion

00:17:29

engine down and coupled it to a

00:17:31

dynamometer it's able to demand the

00:17:34

engines full output of 1500 horsepower

00:17:37

at 6700 revolutions per minute the

00:17:41

stress applied on the test bench is

00:17:43

significantly higher than during vehicle

00:17:45

operation an engine is tortured for up

00:17:52

to 1,000 hours on the test bench the sin

00:17:58

fee that's hundreds of thousands of

00:18:00

kilometers on the road and what if an

00:18:02

engine has survived that can survive

00:18:04

anything

00:18:05

a gigantic blower cools the engine

00:18:08

during the test special sensors measure

00:18:12

a total of five hundred different values

00:18:14

which the testers check on the monitor

00:18:21

the tests were also an important part of

00:18:23

developing the 16 cylinder engine

00:18:26

because the results were incorporated

00:18:28

into its 3d model and helped the design

00:18:31

engineers to detect possible critical

00:18:33

areas it took three years to develop the

00:18:37

Sheeran's power plant often optimization

00:18:44

requirements also arise due to legal

00:18:46

specifications corresponding measures

00:18:49

that the engineers plan on their screens

00:18:51

then have to be verified on the real

00:18:54

component during a special auditory test

00:19:02

an acoustic engineer checks whether the

00:19:05

exhaust system simulation matches

00:19:07

reality to do this the sound expert

00:19:10

applies a pure tone to the exhaust

00:19:12

tailpipes using a loudspeaker the sound

00:19:20

causes the air particles inside the

00:19:22

system to vibrate the engineer records

00:19:25

the resonance using a microphone this

00:19:28

allows the sound and the volume to be

00:19:30

viewed on the monitor by 2026 passenger

00:19:35

car driving noises have to be reduced to

00:19:37

68 decibels that's roughly the same as a

00:19:41

television at low volume at the same

00:19:44

time however the engine sound must not

00:19:47

suffer the acoustic factors are

00:19:49

particularly crucial to the experience

00:19:51

of driving the Sheeran

00:19:56

that's what the drivers hearing is an

00:19:58

entirely unconscious process it's

00:20:00

nevertheless he needs specific

00:20:01

information he wants to know when the

00:20:03

road changes he wants to know whether

00:20:05

the engine rpm is too low or too high he

00:20:08

wants to know what the absolute vehicle

00:20:10

speed is because via the wind noises if

00:20:12

any of this information is missing the

00:20:14

vehicle is perceived as unharmonious

00:20:19

[Music]

00:20:22

does her galoshes cliff the rolling

00:20:24

noise is relevant how the windows are

00:20:26

constructed how well the chassis is

00:20:28

insulated from the cockpit just because

00:20:30

all of this characterizes the overall

00:20:32

noise perceived by the driver this all

00:20:35

has to be composed to form a consistent

00:20:37

concert to achieve a positive experience

00:20:39

in the vehicles interior and who better

00:20:44

to test this experience in new models

00:20:46

than a genuine motor racing expert the

00:20:50

former LeMond

00:20:51

winner Andy Wallace is Bugattis test

00:20:53

driver he has already driven around

00:20:56

100,000 kilometers in the luxury sports

00:20:58

car from multi I'm an absolute dream job

00:21:02

the Briton also provides the developers

00:21:05

with direct feedback about the Sheeran's

00:21:07

performance and handling from the

00:21:09

driver's cockpit if he like cars and you

00:21:16

you can maybe dream about supercars this

00:21:19

one is the top the very top of the pile

00:21:21

[Music]

00:21:25

and for me to be able to drive this car

00:21:27

every day if you told me that when I was

00:21:29

seven years old I never would have

00:21:30

believed you so for me it's fantastic

00:21:33

however Wallace will be thinking about

00:21:36

the following drive for a long time to

00:21:38

come with this sheer on the Britain will

00:21:40

set a new speed record of three hundred

00:21:42

and four point seven seven three miles

00:21:44

an hour or four hundred and ninety point

00:21:47

four eight four kilometers an hour

00:21:48

the Sheeran's Super Sport 300 plus

00:21:51

pre-production model offers an

00:21:53

additional 100 horsepower totaling 1600

00:21:57

horsepower on the test track in ela

00:22:00

lesson Germany its tires will be

00:22:02

rotating no fewer than 4,000 100 times

00:22:05

per minute this would be the first time

00:22:07

in history that a production vehicle

00:22:09

breaks the 300 mile an hour barrier

00:22:13

and off he goes Andy Wallace floors the

00:22:18

accelerator and is already doing 100

00:22:20

kilometres an hour two seconds later

00:22:24

covering around 11 square kilometers the

00:22:27

test site lies at the center of a pine

00:22:29

forest curves and straights follow in

00:22:32

quick succession this makes it difficult

00:22:35

to keep the vehicle on track you're

00:22:39

constantly turning to go straight and

00:22:42

this is at the same time that you're

00:22:43

traveling 136 meters per second

00:22:45

everything's coming at you really really

00:22:47

quick so the sense is coming in - you

00:22:50

are crazy and you have to try and keep

00:22:52

all that under control and then it's not

00:22:54

something you do every day so it's not

00:22:55

something you can practice you just end

00:22:57

up doing it and it's um it's pretty

00:23:00

impressive 3.5 kilometers ahead of the

00:23:03

record the Sheeran is still picking up

00:23:06

speed the down thrust also called

00:23:09

downforce on its rear end increases this

00:23:12

causes the front end to lift the Bugatti

00:23:15

uses a complicated aerodynamics concept

00:23:18

to counteract the principle that helps

00:23:20

airplanes to take off after 70 seconds

00:23:23

at full throttle Wallis breaks the

00:23:26

record

00:23:28

Wow guys what a fantastic car thank you

00:23:32

should fancy a messy I can't thank you

00:23:35

enough

00:23:38

[Music]

00:23:50

in the Atelier in Molsheim France a

00:23:53

worker transports an important component

00:23:55

to a newly arrived engine block two

00:23:59

mechanics now coupled this seven-speed

00:24:01

direct-shift transmission to the

00:24:03

powerplant

00:24:04

the automatic shift unit ensures

00:24:07

constant power output when shifting

00:24:09

gears because one clutch closes at the

00:24:13

same time as the other is opening the

00:24:15

automatic transmission ensures

00:24:17

consistent tractive force the workers

00:24:21

then take the new drive unit to an

00:24:23

assembly station covering 1,000 square

00:24:26

meters the shop is more akin to a

00:24:28

sterile operating room than a vehicle

00:24:30

workshop there are no oil stains or

00:24:33

rubber abrasion from car tires on the

00:24:36

highly polished synthetic resin floor

00:24:38

the two-seaters engine alone costs

00:24:41

around 300 thousand euros

00:24:48

over the next few hours the rear section

00:24:50

of the vehicle will be built around the

00:24:52

high performance unit to do this the

00:24:54

Bugatti surgeons first attached the

00:24:56

chassis to the side sections of the body

00:24:58

alongside the lifting platform they are

00:25:01

also made entirely of carbon a

00:25:03

technician first bolts the independent

00:25:05

wheel suspension elements to the carbon

00:25:07

fiber framework the hypercar has no

00:25:12

rigid axle this means that each wheel

00:25:15

can be actuated individually and

00:25:18

therefore has maximum grip or contact

00:25:20

surface on the asphalt as a result the

00:25:23

two-ton Bugatti remains stable even when

00:25:26

taking tight corners on a wet road

00:25:28

surface depending on the driving

00:25:31

situation the on-board computer

00:25:33

regulates the four wheels tow and camber

00:25:36

to ensure this

00:25:43

the entire substructure of the extreme

00:25:45

sports car is adaptive these suspension

00:25:49

struts that the technician is installing

00:25:51

can also be optionally set to a family

00:25:53

car or racing car profile the hardness

00:25:57

of the damper called its characteristic

00:25:59

and technician jargon is adjusted by

00:26:01

allowing more or less oil to flow from

00:26:04

one shock absorber tube to the other

00:26:07

[Music]

00:26:09

the worker now mounts the finished side

00:26:12

section on the engine block with his

00:26:14

colleague building a new hyper car in

00:26:17

the exclusive French manufactory is

00:26:19

complicated and involves 2590 individual

00:26:23

steps good timing in the production

00:26:26

sequence is absolutely crucial

00:26:33

I'm apologizing we always assemble

00:26:35

sixteen vehicles at the same time using

00:26:38

twenty employees these includes seven

00:26:40

mechanics for coachbuilders three

00:26:43

technicians you assemble the vehicle

00:26:44

interior two painters and for

00:26:47

electricians don't gloss on without this

00:26:55

team of twenty persons assembles the

00:26:56

vehicle in eight weeks visa man this

00:26:59

needs to be well organized to avoid

00:27:01

delays and ensure that the customers are

00:27:03

satisfied yeah next the supercar is

00:27:08

fitted with its exhaust system when the

00:27:11

engine is running temperatures as high

00:27:13

as 500 degrees can be reached at the

00:27:15

rear muffler that's why this employee

00:27:19

first installs a galvanized heat shield

00:27:22

on the exhaust pipes his colleague

00:27:26

carries the gigantic exhaust to the

00:27:29

chassis

00:27:30

later on six tailpipes rid the Sheerin

00:27:33

of everything the eight liter powerplant

00:27:35

spits out of its 16 cylinders

00:27:40

the team now fastens the enormous

00:27:42

titanium muffler to the rear end of the

00:27:44

emerging Bugatti titanium is light

00:27:47

ductile and particularly heat resistant

00:27:51

this is important so that the material

00:27:54

does not crack under the extreme heat

00:27:57

the crew then clads the mid engine with

00:28:00

further elements to protect it on all

00:28:02

sides

00:28:06

tons of them too we've now fitted all

00:28:09

the parts around the engine and once

00:28:11

we've assembled bolted and connected

00:28:13

everything we can connect it to the

00:28:15

front section to the monocoque this is

00:28:18

what distinguishes us from classic

00:28:19

mechanics and garage

00:28:21

this really is assembly we start with

00:28:24

nothing and build the vehicle and that

00:28:26

is the difference between this and other

00:28:28

vehicles because this is an exclusive

00:28:30

card extremely powerful vehicles you

00:28:33

have to work very precisely you can't

00:28:34

afford to make mistakes it's now

00:28:38

becoming cramped in the monocoque - such

00:28:42

a cockpit framework contains a total of

00:28:44

320 square meters of carbon placed end

00:28:48

to end all of the individual carbon

00:28:50

fibers are 9 times the distance from the

00:28:53

earth to the moon a mechanic is now

00:28:57

fitting one of the Sheeran's two

00:28:58

differentials on the underbody of the

00:29:00

chassis element a computer tells him

00:29:03

whether he has tightened all of the

00:29:05

bolts to the correct torque and stores

00:29:08

his production data in the system

00:29:16

the differential compensates the

00:29:19

differences in wheel speeds when

00:29:20

cornering the wheels on the inner side

00:29:23

of a corner cover a shorter distance

00:29:25

than the outer wheels and therefore

00:29:28

turned more slowly conversely this means

00:29:31

that the outer wheels require more power

00:29:34

to cover the greater distance in the

00:29:36

same time a transmission inside the

00:29:38

differential distributes the engines

00:29:40

power to the hypercars individual wheels

00:29:43

to varying degrees

00:29:46

bringing the vehicle to a stop from its

00:29:49

top speed of 420 kilometers an hour

00:29:51

poses a major challenge for the brake

00:29:54

system the temperature can soar to 1,100

00:29:58

degrees when the supercar is braked

00:30:00

that's as hot as glowing lava the men in

00:30:05

the Atelier therefore also fit a heat

00:30:08

shield on the wheel suspension before

00:30:10

installing the carbon ceramic brake

00:30:12

discs one of the sport brake discs

00:30:15

weighs around eight point five kilograms

00:30:17

its caliper is the world's largest 3d

00:30:21

printed titanium part

00:30:26

the Sheerin currently has the most

00:30:28

powerful brakes of any production

00:30:30

vehicle worldwide but this is not enough

00:30:33

for the French 1/2 here a design model

00:30:43

of a brake saddle that we don't have in

00:30:44

production yet but we're testing it

00:30:53

where you see material on this part

00:30:56

that's where the the load path is

00:30:59

happening and that's where the the

00:31:01

strength needs to be on this building

00:31:03

part and where there is no material at

00:31:05

all there's also no load on the part

00:31:08

that means you can save that weight

00:31:09

it doesn't need any styling lines but

00:31:11

just the pure genius of the technical

00:31:14

development is aesthetically so

00:31:16

interesting and so intriguing that you

00:31:19

leave well enough alone and apply it to

00:31:21

the car and this is really fascinating

00:31:22

in itself the bugatti crew assembles the

00:31:27

front of the monocoque this worker is

00:31:30

fitting a guard for the Sheeran's

00:31:32

sensitive electronics and mounting a

00:31:34

control unit for controlling the vehicle

00:31:37

dynamics later on this so-called ESC

00:31:41

helps the driver to keep the hypercar

00:31:43

under control

00:31:44

by specifically breaking individual

00:31:47

wheels for instance the system prevents

00:31:49

the vehicle from skidding when cornering

00:31:51

at high speed over a period of four days

00:32:00

the team has installed 2600 components

00:32:03

at the special stations an important

00:32:06

ceremony is now on the agenda for the

00:32:08

front and rear frames like everything at

00:32:12

Bugatti the marriage of the monocoque

00:32:14

and the rear section in the mall team

00:32:16

luxury Atelier is something special the

00:32:20

crew first moves the platform's to the

00:32:22

same height the frame sections have to

00:32:25

fit precisely in one another in the

00:32:27

worst case the construction would have

00:32:30

to be taken apart again to adjust

00:32:32

individual elements

00:32:35

the three men now maneuver the 750

00:32:38

kilogram rear section to the monocoque

00:32:46

the iron wave accompanies the rear

00:32:49

section to its better half the team

00:32:52

gathers its strength again for the last

00:32:54

few centimetres the fact that the

00:33:00

Sheeran's chassis consists of two parts

00:33:02

offers several advantages so that the

00:33:05

driver's cockpit is subsequently stable

00:33:08

and therefore as safe as possible the

00:33:10

front section is made completely of

00:33:12

carbon however the entire body is too

00:33:15

big to be built entirely of this

00:33:17

lightweight material the vehicle is also

00:33:20

designed so that the rear end can tear

00:33:22

off in the event of an accident because

00:33:25

if the engine catches fire things

00:33:27

quickly become dangerous a total of

00:33:30

fourteen titanium bolts that the

00:33:32

technicians are now fastening ensure

00:33:34

that the front and rear sections are

00:33:36

joined firmly together

00:33:42

on the underbody to Bugatti mechanics

00:33:45

now fasten the lines for the luxury cars

00:33:48

operating fluids later on engine and

00:33:51

transmission oil as well as brake fluid

00:33:54

will flow through them the Sheeran's

00:33:56

fuel hoses are made of tough polyamide

00:33:59

plastic the air stream at the front end

00:34:05

of the vehicle ends up in these two

00:34:07

carbon chambers via special filters it

00:34:10

flows into the four turbochargers

00:34:12

compressors where it is then forced into

00:34:15

the cylinders and increased pressure

00:34:17

this means that there is more air and

00:34:20

therefore more oxygen for combusting the

00:34:23

fuel the result is a more powerful

00:34:26

explosion higher pressure and thus

00:34:28

linear engine power output the Bugatti

00:34:34

special tires are custom products from

00:34:36

Michelin with a width of around 36

00:34:39

centimeters the tires have to withstand

00:34:41

enormous forces during vehicle operation

00:34:44

at maximum speed the wheels rotate

00:34:47

around 50 times per second this means

00:34:50

that 7 metric tonnes are pulling on

00:34:53

their tread that tortures the tough

00:34:55

rubber the Sheerin is fitted with semi

00:34:58

slicks they have a lower tread depth and

00:35:01

therefore less weight as a result the

00:35:04

tires offer plenty of grip despite the

00:35:07

enormous centrifugal forces a set of the

00:35:11

semi slicks costs nine thousand two

00:35:13

hundred and fifty euros the hyper car is

00:35:17

now filled with its operating fluids an

00:35:19

employee feeds the vehicle with engine

00:35:22

oil brake fluid and 40 litres of water

00:35:25

when the car is driving this is

00:35:28

circulated 20 times per minute by the

00:35:30

pump to prevent the engine and

00:35:32

powertrain from overheating the mechanic

00:35:35

then fills the hypercars tank the fuel

00:35:39

tank can hold 100 litres of gasoline the

00:35:43

shiron consumes an average of 20 2.5

00:35:46

litres every 100 kilometers

00:35:53

the Bugattis rolling chassis now

00:35:56

proceeds to its first test station in

00:35:58

the Antilles annex the French had to

00:36:02

develop a new dynamometer for the

00:36:03

sheeran which is capable of withstanding

00:36:06

the hypercars 1,500 horsepower this

00:36:10

means that the bugatti dynamometer is

00:36:12

also the most powerful of its kind in

00:36:15

the world

00:36:20

the technician first attaches the

00:36:22

two-ton vehicle to these wheel clamps

00:36:25

the safety flap of the acceleration

00:36:27

roller then drops down and the

00:36:29

ventilation system shafts rise up then

00:36:33

he fastens a fresh air hose to the front

00:36:36

of the chassis so that he doesn't

00:36:37

suffocate in the cockpit his colleagues

00:36:41

have provisionally fitted a windshield

00:36:43

in the luxury car the technician now

00:36:46

also fits two doors to establish the

00:36:49

most realistic conditions possible in

00:36:51

the vehicle interior now the high

00:36:54

performance car can show what it's made

00:36:56

of for the first time

00:37:05

the employee accelerates up to 200

00:37:09

kilometres an hour the sports car has to

00:37:12

complete a total of 342 tests he tests

00:37:16

the engine the transmission and all

00:37:18

vehicle dynamics programs for 3 hours

00:37:21

the bugatti covers around 60 kilometers

00:37:24

on the dynamometer this Sheeran has

00:37:33

passed all of the tests the employee

00:37:36

releases the vehicle from the wheel

00:37:38

clamps and removes the doors his

00:37:44

colleague now takes this superlative on

00:37:47

wheels to the next station

00:37:48

here the Sheeran is dressed in its

00:37:51

Sunday best to do this the exterior crew

00:37:54

pre assembles the body parts next to the

00:37:57

lifting columns and cleans and polishes

00:37:59

them the individual elements are large

00:38:03

and fragile that makes this work step

00:38:06

extremely demanding we get parts that

00:38:10

are perfectly painted and absolutely

00:38:12

flawless

00:38:15

[Music]

00:38:19

a pesky can be what is then complicated

00:38:22

for us is to install these parts without

00:38:24

damaging them that's not easy we have to

00:38:28

take great care work very precisely and

00:38:30

attach the part so that everything is

00:38:32

perfect for the final quality check and

00:38:35

the customers ultimately satisfied it

00:38:40

takes up to four days to clothe the

00:38:42

vehicle installing the windshield is

00:38:44

particularly complicated it has to be

00:38:47

positioned exactly and be absolutely

00:38:50

watertight to install the windshield the

00:38:53

technicians first coat the body with a

00:38:55

primer they apply a special adhesive

00:38:58

onto the safety glass

00:39:02

the workers then place the windshield

00:39:04

onto the vehicle frame using a vacuum

00:39:06

lifter the two component mixture reacts

00:39:11

to form a particularly elastic resin and

00:39:13

ensures that the glass can withstand

00:39:15

even strong vibrations each Sheerin is a

00:39:23

unique work of art and can be completely

00:39:26

individualized the choice of material

00:39:29

and color combinations for styling the

00:39:31

vehicle is virtually unlimited

00:39:33

Ettore Bugatti himself once said

00:39:36

perfection is never achieved but to this

00:39:40

very day designers have been attempting

00:39:42

to create the most perfect models with a

00:39:44

mixture of unbridled power technical

00:39:47

beauty and flawless elegance to

00:39:49

accomplish this they work closely with

00:39:51

the developers because the paramount

00:39:54

objective of motorsport artists is form

00:39:57

follows performance the striking see of

00:40:00

the Bugatti DNA on both of the Sheeran's

00:40:03

flanks therefore also serves a specific

00:40:05

purpose to a lot of people that line

00:40:09

looks like a stylistic idea of a

00:40:11

designer or because it looks so nice and

00:40:13

romantic let's just do it like that it's

00:40:17

exactly the opposite the performance

00:40:20

need from the engineer was as much air

00:40:23

intake along the whole body side of the

00:40:25

car was needed to feed all that

00:40:27

pressured air into the engine

00:40:29

compartment for cooling purposes and for

00:40:32

me that is always the most authentic way

00:40:34

as a car designer that I can answer the

00:40:36

need of a technical problem with a

00:40:38

stylistic combination Bugattis vehicle

00:40:42

DNA has constantly evolved according to

00:40:44

this principle due to its shape the

00:40:47

exclusive Koopas extraordinary radiator

00:40:49

grille has been nicknamed the horseshoe

00:40:53

in 1910 however the first Bugatti model

00:40:57

the type 13 had an egg-shaped front end

00:41:01

to improve the vehicles aerodynamics and

00:41:04

cool the increasingly larger engine the

00:41:07

designers adapted the look of the grille

00:41:09

to the technical requirements probably

00:41:13

the only part of a bugatti whose shape

00:41:15

or weight has not been optimized is the

00:41:18

brand logo this sheer on in the Atelier

00:41:24

in mall time is now almost fully dressed

00:41:28

each paneling element also plays a role

00:41:31

in the complex aerodynamics this

00:41:34

consists of active and passive systems

00:41:37

all of the components integrated into

00:41:40

the paneling are passive the active

00:41:43

modules can be actuated and adjusted to

00:41:46

the position and speed of the vehicle

00:41:50

the super sports car is a master of

00:41:53

aerodynamics the air curtains at the

00:41:56

front specifically guide the impacting

00:41:58

air pressure through and past the

00:42:00

vehicle this presses the Sheerin onto

00:42:04

the asphalt and cools the brakes

00:42:07

[Music]

00:42:09

the 1.5 meter wide rear spoiler adapts

00:42:13

fully automatically to the respective

00:42:15

driving situation 0.8 seconds after

00:42:19

applying the brakes the adaptive wing

00:42:21

tilts to an angle of 49 degrees thus

00:42:24

acting as an extremely effective air

00:42:27

brake to decelerate the Bugatti the

00:42:33

hydraulic spoiler is the last of a total

00:42:35

of 55 panel parts that the mechanics fit

00:42:38

onto the luxury car we regulate the

00:42:42

angular position of the rear wing the

00:42:44

diffuser flaps in the underbody via the

00:42:46

speed range

00:42:51

this is how we ensure that the vehicle

00:42:54

is safe in every driving situation and

00:42:56

that the focus is on straight-line

00:42:57

stability or agility

00:43:05

in 2017 the airbrake played an important

00:43:09

role in another world record formula one

00:43:12

winner

00:43:13

juan pablo montoya accelerated the

00:43:15

Sheerin to four hundred kilometers an

00:43:17

hour from a standing start after 700

00:43:21

meters he was already doing over 300

00:43:24

kilometres an hour in the 33rd second

00:43:28

the Colombian racing driver reached the

00:43:30

400 kilometer an hour mark

00:43:32

he brought the two-ton vehicle to a

00:43:35

standstill again after 491 meters in

00:43:39

just nine point three seconds by fully

00:43:42

applying the brakes Montoya

00:43:44

took exactly 41.96 seconds and covered a

00:43:48

distance of 3.1 kilometers to accelerate

00:43:51

the Sheerin up to its top speed and

00:43:53

break it that was a new world record so

00:43:57

far no other vehicle has managed to

00:43:59

achieve this outstanding performance

00:44:07

a force of 850 kilograms presses on the

00:44:10

rear wing during maximum braking from

00:44:13

top speed

00:44:14

this brings the hypercars rear axle to

00:44:17

its knees

00:44:18

during this sharp breaking maneuver

00:44:20

forces of around 2g act on the vehicle

00:44:23

and the driver

00:44:36

a further shiron has now been fully

00:44:39

assembled at the Bugatti premises in

00:44:41

multi France so that it's not scratched

00:44:46

during its first test-drive the employee

00:44:48

is covering each millimeter of the hyper

00:44:50

sports car with a protective film

00:44:54

covering the paneling takes around four

00:44:56

hours

00:45:02

this supercar has been fully covered

00:45:05

later on it will demonstrate what it's

00:45:08

capable of

00:45:09

each Sheeran has to complete a

00:45:11

test-drive of around 350 kilometers

00:45:14

before being delivered we do the test

00:45:17

drives with a protective film in the car

00:45:19

on the windshield it takes half a day to

00:45:21

cover the sharone with film but it's up

00:45:23

to us not to damage the car under any

00:45:24

circumstances we want to deliver a

00:45:27

perfect vehicle over these 350

00:45:34

kilometers we simulate all the driving

00:45:36

situations that the customer might

00:45:38

encounter villages country roads

00:45:40

mountains freeways and of course we have

00:45:42

rented the airfield in Colmar to test

00:45:44

everything that's not allowed on public

00:45:46

roads only then can the customers safely

00:45:49

drive the vehicle at its top speed of

00:45:51

400 km/h so that he can do that the

00:45:55

quality tester now climbs into the

00:45:57

driver's seat for around 5 hours the

00:46:00

cockpit is also fitted with protective

00:46:03

covers the tester additionally wears

00:46:06

gloves so that no marks are left on the

00:46:08

sports steering wheel

00:46:12

the tester tests different factors such

00:46:15

as performance the individual drive

00:46:18

programs and the background noise in the

00:46:20

interior of the Sheeran before leather

00:46:23

seats so much as squeaks when cornering

00:46:25

the test driver notes this defect in his

00:46:29

log the tester then turns onto an

00:46:31

airfield here he immediately takes the

00:46:35

Sheerin up to its limits he communicates

00:46:41

with the tower crew by radio because air

00:46:44

traffic is still operating and that can

00:46:47

quickly become hazardous the stormy

00:46:51

weather also makes conditions more

00:46:53

difficult the test driver quickly drives

00:46:56

up to the start of the 1.6 kilometer

00:46:59

long takeoff runway then he's given the

00:47:02

green light from the tower the expert

00:47:07

hits the accelerator

00:47:11

he accelerates the hypercar up to 300

00:47:15

kilometres an hour in around 13 seconds

00:47:18

however the primary objective is not to

00:47:21

test the top speed but to get the shear

00:47:23

on to develop its full output of 1500

00:47:26

horsepower due to safety reasons the

00:47:29

sports car is governed to 380 kilometres

00:47:32

an hour

00:47:33

this special key can be used to

00:47:36

accelerate it a further 40 kilometres an

00:47:38

hour as soon as the high speed key is

00:47:41

engaged on the left of the driver's seat

00:47:43

the vehicle checks all of its systems

00:47:46

fully automatically because at over 400

00:47:49

kilometres an hour

00:47:50

any defect can immediately prove to be

00:47:53

fatal the shear on is wonderful to drive

00:47:58

it is incredibly stable when you switch

00:48:00

from left to right its chassis is also

00:48:03

fantastic in response to any road

00:48:05

conditions like a dream as if you were

00:48:07

skiing after the stress tests the shear

00:48:11

on is taken to the company's own washing

00:48:13

facility the hypercar can only be

00:48:16

delivered to its new owner when it's

00:48:18

absolutely spotless

00:48:24

bugatti the french sports car

00:48:27

menufactory is an absolute superlative

00:48:30

at 12 high-end production stations in

00:48:34

mul time 20 elite mechanics produce the

00:48:38

fastest most exquisite and most extreme

00:48:42

hyper cars in the world with multiple

00:48:45

world records the french extremists have

00:48:47

proved and if it's comparable if it's no

00:48:51

longer bugatti after even more than 110

00:48:55

years of vehicle production nothing

00:48:57

about this philosophy has changed

Description:

Bugatti - A legendary name in the automotive industry, amongst car connoisseurs and pretty much everyone else. The French luxury brand (founded in France by an Italian industrialist named Bugatti) has made the impossible possible: To produce a car of this magnitude in series: voilà the Bugatti Chiron, hypercar with 1500 HP. Produced and assembled in Molsheim, Alsace, the Hypercars are (naturally) 100% handmade. The production site of the Bugatti Chiron is a studio - not a factory. The designers insisted. A specially developed W16 engine gives the bolide its power, coupled with exceptional luxury and safety systems, a piece of automotive art is created here. At Bugatti the motto is "If it is comparable - it is not a Bugatti". 🏎 Dream Cars Inside The Factory Documentaries https://www.youtube.com/playlist?list=PL-5sURDcN_ZnEEe5LWRD6Ou55EcF5qnXs 📺 Watch more documentaries https://www.youtube.com/playlist?list=PL-5sURDcN_Zl8hBqkvZ6uXFpP3t55HU9s 🔔 Subscribe our full documentary channel https://www.youtube.com/channel/UCBAeFXaLV1ZqKqc-Uf3pKaA?sub_confirmation=1

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