Today, on How It's Made: Dream Cars,
The Wiesmann GT MF5,
tailor made to stick to the road.
资源提供：回家洗澡
时间校对：昆哥 【黄色字体是源文件缺失我依靠想象力自行脑补的，仅供参考】
水电赞助：广外干训楼
In Dulamn Germany's stands Wiesmann's Production facility.
The building's design
even incorporates the brand's Gecko logo.
Brothers Martin and Friedhelm Wiesmann
introduced their first prototype, a roadster,
when the company made its debut.
Since the company's launch, the Wiesmann brand
has added a number of new, conceptual, and race ready cars
to the lineup,
garnering international praise.
First produced in 2003,
the GT MF4 roadster is a shining example
of the small yet eclectic array of vehicles
that exude power, refreshing design, and elegance.
The predecessor to GT MF4 and 5 was the acclaimed mf3,
discontinued after an 18 year run
that started in 1993.
This commemorative model is powered
by a 3.2 liter, 6 cylinder engine
that outputs 338 horsepower.
It can go from zero to 60 in 4.9 seconds
with a top speed of 158 miles per hour.
Anyone who gets behind the wheel of the Wiesmann GT MF5
will immediately notice
that it's a charismatic and powerful car,
boasting wide, sweeping wheel casings
and a low crouching body.
It makes any driver feel connected to the road
with an impression of unlimited engine power
at the tip of your fingers.
The aluminum monocoque chassis
is composed of 111 parts
coated with cathodic dip painting,
which are bonded with stainless steel rivets
and polyurethane adhesive.
A technician installs a reactive adhesive
in and around the chassis.
The adhesive is designed to glue together metallic parts.
The glue requires curing for 24 hours
at about 70 degrees fahrenheit.
Pushing the chassis parts closer together,
the technician inserts stainless steel rivets
to permanently fasten the chassis.
To solidify the expansive bolts,
the technician uses a servo driven tool
for uncompromised repeatability
and quality of water tight joints.
In another section of the factory,
fiberglass parts such as the engine cover are built.
A technician uses a small paint roller
to apply the primary layer of gel coat into a panel mold.
Gel coat is a hard polyester resin coating
that is applied
to provide a smooth, glossy, protective surface.
Using a wet film thickness gauge,
the technician measures the gel coat in microns
for precision.
A technician uses a small foam paint roller
to cover the non woven fiberglass layer
in two to three coats of polyester resin.
Each fiberglass layer is very thin
and spread over the resin layer and mold.
The fiber sheets may look fragile,
but they are stronger than steel
and will not stretch, burn, or rot.
Fiberglass is also extremely lightweight,
making it an ideal choice
for a sports car's body shell and many parts.
He applies another layer of fiberglass fabric with resin
and brushes them into the mold's cavities.
He continues to apply the fiberglass fabric with a roller,
removing any air bubbles.
Once complete,
the fiberglass cover sits to dry.
The fiberglass cover's made up
of flexible, non woven fiberglass,
fiberglass mat,
and two layers of fiberglass fabric.
The technician flips the mold over to inspect both sides,
ensuring accuracy, quality control,
and complete smoothness.
Fabricated in the same method as the engine cover,
the dashboard is made of fiberglass
and is essential to the vehicle's cockpit,
with dedicated clusters for operations indicators,
an audio system, and climate control gauges.
A technician saws away the unnecessary fiberglass pieces
using a handheld vacuum saw.
Using a variety of hole cutting saws,
the technician creates multiple holes
for the installation of indicators and buttons
like the speedometer, odometer, fuel monitor,
and push start button.
Essential to the creation of the rear body shell is its mold.
Made of fiberglass, it weighs about 440 pounds
and took two weeks to construct.
In another area,
two workers put a strip of foam material
wrapped in two layers of fiberglass within the mold
made for the production of a convertible's windscreen.
Next, a technician lays down a bonding glue
between the lime colored foam and the windscreen mold,
as well as on the edges.
The workers load a matching component
onto the bottom fiberglass mold
and add a little pressure to set it in place.
They position f clamps to hold the composite mold in position.
The mold remains stationary
as it cures for 24 hours at room temperature
before a heat curing treatment.
When the windscreen frame is removed from the mold,
it will stand in a curing room for two days.
At a separate paint shop,
workers sand, grind, and condition
the front end body shell,
smoothing and preparing the surface for fresh paint.
In a neighboring room,
a paint technician
cautiously applies a coat of paint to the panel.
The clear coat is a glossy and transparent coating
that forms the final interface with the environment.
It's durable enough to resist abrasion
and chemically stable enough to withstand U.V. light.
Another technician sands and polishes the surface
for further smoothness and beautification.
He also applies a rubbing compound
formulated for the painted panel,
which will give it a near perfect glossy finish.
Using a soft, pliable cloth, he wipes the surface clean
where the front end of this Wiesmann sports car
begins to take shape and shine.
Narrator: Wiesmann uses the image of a Gecko Lizard
to portray a symbol of quality and excellence.
Geckos are vocal reptiles with adhesive pads on their feet.
For Wiesmann, their cars stick to the road
like Geckos to a wall.
No sports car is complete
without a badge or hood ornament,
which adds mystique to its identity.
Here's how this automaker's little Lizard is made.
At a primary station,
a technician removes a Gecko emblem made of a wax composition
from a high density foam mold.
At an adjacent work table,
a technician attaches the Gecko shaped wax figurine
to a casting tree,
grouping it with other statuettes.
After being moved into a small, perforated flask,
the casting tree flask
is placed into a large containment cylinder
of a ceramic mixer machine.
A worker unloads a pail full of ceramic powder
into the upper processing container.
The large container is moved over the flasks
and clamped shut.
The container is covered with a plexiglass cap
while a large stirring arm begins churning the powder
within the large chamber.
In a short amount of time,
the mixer produces a homogeneous substance.
When the mixing is complete,
the technician releases the large container.
This reveals the flask filled with the ceramic powder,
creating a crucible interlaced with the wax casting tree.
Next is the lost wax casting process.
A technician deposits small ingots of brass
into the melting chamber
of a vacuum pressured casting machine.
The technician closes the chamber cover,
where it heats to be filled with a casting metal.
The brass ingots are mixed and melted
at 1,650 degrees fahrenheit.
In the meantime,
the technician uses tongs to place the perforated flask
into the lower vacuum chamber.
He places a filling cone over the flask
and slides the vacuum chamber underneath the melting chamber.
In the casting process,
the ceramic crucible is set under pressure
and the flask under vacuum.
The wax casting tree is melted away,
leaving Gecko shaped molds within the crucible.
The difference of pressure leads the liquid brass metal
into the finest ramifications of the crucible
and into the emblem's form.
Once the casting process is complete,
the metal cools for three minutes.
Afterward, the technician opens the vacuum chamber
and moves the flask to another workbench
for the washing cycle.
After a few minutes in a small, high pressure washing unit,
the ceramic layer is rinsed to reveal the brass casting tree.
Using a stationary power saw,
each emblem is removed from the casting tree
and placed onto a production tray for further processing.
A technician grinds the emblem against a motorized sander
to remove any excess material,
creating a smooth and even finish along the edges.
Using a handheld grinder,
he removes more excess material with meticulous delicacy,
getting at hard to reach places.
Afterward, the brass emblem is polished
on all ends and every edge, offering a strong glow.
But for a more polished look,
the emblem is chrome plated later on.
Manufactured by hand and running throughout the car
are the wire harnesses,
which is an assembly of cables
that relay signals or electrical power
to a variety of components.
A specialist creates the electric work from scratch
using a large assembly board with nails
to measure wiring length and accurate positioning.
His task of selecting the proper wires
will eventually lead to the control of functions
like starting the engine, lighting, meters,
and other vehicle devices.
Creating the wire harness for one vehicle
takes four days of assembly
due to the many different production processes involved.
The wires are composed of copper with plastic coverings
and have a heat resistance of around 210 degrees fahrenheit.
The harness is assembled onto a pin board
according to the design specification.
After fitting any protective sleeves or conduit,
the harness is shipped to another work station
to be fitted into the vehicle.
In total, the Wiesmann GT MF5 wire harness
is composed of 587 wires
with a total length of 3,800 feet.
Narrator: Manufacturer approved cowhides
bought from certified cattle herds
are used for the cockpit of the Wiesmann GT MF5.
Five to six hides are used to create the 100 leather pieces
required to furnish one dashing interior.
In the upholstery section of the factory,
cockpit leather color is chosen according to customer choice,
with 4,000 combinations offered.
On this upholstery work table,
a leather worker checks the material
and identifies any imperfections with a wax marker.
Any damaged areas are circled and eliminated from the process.
He places a thin cardboard cutting template
onto the leather material
and traces around and away from any damaged areas
to maximize the use of the material.
Every step is done carefully by hand,
using a series of traditional
and high quality leather working hand tools.
Using trimmer shears,
the leather worker cuts the stenciled leather
into its proper portion size.
Using trimmer shears
is quite uncommon in automotive manufacturing,
since most car makers
use automated cutting machines over conventional tools.
This step is repeated several times,
creating various handcrafted trim sections.
Once all the leather material is cut,
certain sections are placed
under a fabric stamp punch machine,
which stamps the automaker's stylized Gecko logo
into the leather.
The stamp will soon receive complementing stitching
within the imprint to illustrate the edgy icon.
When the cut pieces of the leather material
have been transferred from the cutting table,
they are brought to a seamstress station.
Here is where the precut pieces
are sewn together with double stitching
to conform to the design of the trim frames
and their fiberglass components.
Every piece of leather is meticulously stitched,
padded, and quilted to match any consumer's desire.
When it comes to the leather work for the car's cockpit,
there is an impressive choice of more than 400 types of leather
in every possible color and finish,
along with the incorporation of color coordinated stitching.
At a work table in the upholstery shop,
a technician sprays a high strength adhesive
onto upholstery foam
and the lower section of the center stacks frame.
He places a piece of upholstery foam onto the frame
and removes any unnecessary extra pieces
with a cutting blade.
He then traces an outline
using a black marker and cardboard template.
In this step, the leather is matched
to the corresponding sections of the interior.
Using a high temperature resistant glue,
he brushes the glue onto the foam
and underneath the leather material.
After the leather is applied to the foam and frame,
he uses a setting tool
to further affix the stitched components.
More glue is applied underneath the leather pieces
for adhesion to the frame.
The technician works meticulously
to fit the leather pattern against the frame
before the glue dries.
He continuously smoothes the leather by hand
to fit the pieces into place.
Using a setting tool,
he presses the leather into grooves of the panel.
He adds more glue onto the foam.
Once the glue is applied to all pertinent areas,
the technician lowers the remaining pieces of leather
onto the frame
while matching the components for a perfect fit.
He also checks the edges for perfect alignment.
Once the Wiesmann GT MF5's leather
is fitted onto the frame,
it is polished and readied for more.
Narrator: What makes the Wiesmann GT MF5
a great supercar?
How about the usage of a lightweight aluminum chassis?
Maybe state of the art internal parts
and handmade construction?
Perhaps the running gear
made by suppliers like BMW, for starters?
Workers constantly forge ahead,
assembling everything from the monocoque aluminum chassis
to the installation of the high performance running gear.
Another BMW contribution to this amazing supercar
is the suspension system.
It's equipped with aluminum double wishbone suspension,
along with performance coil Springs
and anti roll bars.
Two workers lift in position the transmission unit
onto the engine block.
The transmission system is manually bolted
onto the engine block using a large Ratchet.
Provided by BMW,
this V 8 twin scroll, twin turbo engine
delivers 555 horsepower
and rushes from zero to 60 miles an hour
in just 3.9 seconds.
As a perk, customers can witness any stage of assembly,
like the installation of the turbo charged engine.
With the assistance of an air hoist,
a worker lowers the engine and transmission assembly
into the frontal section of the vehicle's frame,
while another worker below the vehicle
aids in installing the major component.
The major component also happens to be
the same motor used in BMW's high performance executive cars,
the M5 and the M6 coupé.
Bit by bit, running gear parts are attached,
like the air intake chamber and air filters.
A technician applies a structural adhesive
onto the back end of the chassis cockpit section
before the additional body shell component is delivered.
It takes four workers
to lift and maneuver the car's rear body shell
and slide it onto the back of the vehicle's chassis.
A technician secures and fastens the body parts to the chassis.
Next, he carries the driver's side door
and manually fastens the upper and lower hinges
to the main body using a screwdriver.
Afterward, he installs the door's electrical wiring
for multiple door functions into its proper portals.
A technician manually installs the steering wheel
and its accompanying wiring,
using a Ratchet to connect the wheel to the steering column.
Almost ready for installation to the chassis,
the front body shell requires a few final elements,
including the chrome plated Gecko emblem.
A technician installs the hood ornament in a snap.
Another item that completes the identity of the car
is the chrome grille.
One worker holds it in place,
while another attaches it to the body shell.
The workers move the frontal body panel to the chassis
to add to the vehicle's assembly.
Everything is transported manually,
as the factory doesn't use transfer belts
or specialized robots.
The leather workers perfect every roadster
by contributing to the handmade convertible roof.
This factory produces four cars a week
and roughly 180 per year,
with 60 workers
spending up to 350 hours on one vehicle at a time.
The Wiesmann GT MF5 has a futuristic yet classic design.
The engineers developed
a lightweight, high performance vehicle
that is gripping in both the looks department
and in the fast Lane.
The vehicles of the Wiesmann lineup
are strikingly robust, extremely extravagant,
and unforgettable.
With a winning formula of supreme BMW engines
with lightweight fiberglass bodies,
these unique looking supercars
are made to stick to the road every step of the way.
Less than 30 years young,
this German automaker continues to manufacture handmade vehicles
that cater to drivers
looking for the best and rarest of modern supercars.
It's fine art on wheels,
establishing Wiesmann and their cars
as one of the greatest of all time.