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Ferrari
·¨À­Àû

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For decades, one of the most legendary names in automobiles

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Now, a new model is hitting the streets

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One-and-a-quarter tones of high-performance sports car,

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engineered with the precision of a spacecraft

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The fastest, most powerful production car Ferrari has ever designed

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And this is where it is being made

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inside Ferrari's ultimate factory

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High-end sports cars

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They are fast

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luxurious

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and very very expensive

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Each has its own claim to fame

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But one has become an icon

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Ferrari

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To some, it's a car

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To others, it's a work of art

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To many, it's the perfect fusion of both

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The name Ferrari conjures high-performance

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and breath-taking design

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Few cars have carried such an aura of legend and mystique through the decades

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The Ferrari of the Formula-1 track

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The winning of its name in the history of the sport

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The Ferrari of the open road

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an iconic sports car of the ages

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Whether for the racetrack or for the road,

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every Ferrari is handcrafted

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Northern Italy, the town of Maranello

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This is the site of Ferrari's ultimate factory

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The factory is part hi-tech garage
and part art studio.

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It's a place where raw metal is transformed
into raw power,

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and where cars are created like sculptures.

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And the buildings of the factory
are every bit as sleek and modern

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as the cars created within them.

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Because Ferrari makes cars for the street
and the racetrack,

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the factory boasts some unique features.

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It has a wind tunnel
for research and development

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designed by Italy's super-architect,
Renzo Piano.

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There's an engine works flooded by natural
Light,

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with trees to provide exactly the right humidity
for engine construction.

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There's even a three-kilometer-long
private racetrack

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that's used to trial Ferrari's latest race cars
and road test its sports cars.

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These are the buildings through which
every Ferrari makes its first journey.

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And for the 3,000 workers here,
this job is an Italian dream.

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For us Italians,
Ferrari has always been a myth, always.

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I mean,
the boys here grow up with Ferrari in them.

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Security is intense at the factory.

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Few outsiders and even fewer cameras
are ever allowed inside.

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Ferrari's Formula-1 team is based at the factory,

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and there's the ever-present threat
of industrial espionage.

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And Ferrari's Formula-1 secrets
also go straight into its street cars.

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This is the fastest and most powerful production
car Ferrari has ever designed: the Fiorano 599.

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It can top 330kmh
and it costs more than 200,000 Euros.

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The president of Ferrari is Luca di
Montezemelo.

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For me, these kind of cars means freedom.

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Braking, acceleration, handling, engine, music,

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all these ingredients
make Ferrari something unique.

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Five years of research and development
have gone into Ferrari's latest model.

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But so have 60 years of history.

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Ferrari's legendary founder,
Enzo Ferrari, was a racing purist.

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For him, the production of street cars was simply
a way to help fund his Formula-1 team.

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Early Ferrari sports cars
may have been beautiful to look at,

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but they were notoriously difficult to drive,

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because their racing characteristics
weren't suited to the open road.

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But over the decades, Ferrari has moved closer
and closer to designing a sports car

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that incorporates all the company's Formula-1
experience in the ultimate street machine.

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That car is the Fiorano 599.

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Ferrari's designers and workers face
a daunting challenge.

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They have to build a car with the soul,
and speed, of a Formula-1 racer,

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but that handles smooth as silk
on the streets of the real world.

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They have to make it beautiful,
according to the Ferrari legacy of art in motion.

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And they have to make it luxurious enough
to warrant its price tag.

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Race car, street car,

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work of art and luxury item.

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It's a tall order
for the team at the Maranello factory,

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a vast complex comprising 45 buildings,
with enough space to fit 50 football fields.

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In all, eight separate areas of the factory
will be involved in building the 599 from scratch.

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They'll include the fires of the foundry,

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the beauty of the body shop,

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the robotic precision
of the engine works and paint shop,

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the handcrafting of the 599's leather upholstery

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and the final assembly line,
where it all comes together.

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The factory's first challenge
is to give the 599 its signature trait, speed.

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The 599 boasts a V1 2 engine,
putting out 620 horsepower.

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This key component begins its life in the
foundry.

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Here, Ferrari's metalworkers cast
the two core elements of the engine,

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the cylinder head and the engine block.

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Most factories mass-produce these parts,
but Ferrari turns them out one at a time.

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A separate mould is produced
for every single engine,

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made out of compacted sand and resin.

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Other car companies use sand casts,

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but at high-end factories like Ferrari,
workers finish the sand moulds by hand.

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It takes around five hours to hand finish
the moulds for a single V1 2 engine.

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Then they're fitted together
like an intricate three-dimensional jigsaw puzzle

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to minimize the chance of chips, cracks or flaws.

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This will be cast into the cylinder head of a 599.

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A flaming torch blackens the sand model
with a thin layer of carbon.

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The carbon acts as a lubricant,

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allowing the molten metal
to flow smoothly into the spaces of the cast.

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Finally, the moulds are ready.

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Precision is critical in this casting procedure.

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Any flaw could cause the finished engine
to under-perform.

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The moisten metal is prepared
just as carefully as the sand moulds.

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In the melting process,
obviously, there can't be any mistakes.

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It has to be of the highest quality to be able
to sustain a car that goes over 200mph.

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At a temperature of over 700 degrees Celsius,

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the heart of the 599 engine begins its fiery birth.

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In the Ferrari foundry,
the main furnace is fired up.

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This is where the metal

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that will be cast into the core
of the 599's mighty engine will be melted.

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Some of the raw metal being fed into the
furnace

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comes from previously-cast components
that have failed Ferrari's quality checks.

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The metal melts almost instantly, as massive
electrical charges are fired through it.

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Melting the two tones of metal in the furnace
uses enough electricity in one day

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to Light a house for an entire year!

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The raw molten metal pours into a giant crucible
for further purifying.

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At 700 degrees, it Looks Like Liquid silver.

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But, in fact, this is a super-strong,
super-secret aluminum alloy,

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specifically created for Ferrari's engines.

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Nitrogen pumps through the metal
in the crucible,

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combining with any impurities,
which float to the surface.

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The pure alloy is transferred
to smaller holding tanks,

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from which the engine components will be cast.

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This mould of compacted sand
is about to become the cylinder head

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of one of the most powerful
production car engines ever made.

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Metal gushes into the mould.

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A casting takes place here every ten minutes.

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Incredibly, only one in every 50 components
fails its quality test

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and is sent back to the scrap heap

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because of the care that's gone into preparing
both mould and metal.

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While the foundry casts the Ferrari's V1 2 heart,
workers in another building fashion its body.

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Like many high-end sports car makers,
Ferrari's body shop is part art studio.

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But while the 599 may be Ferrari's Latest
artwork,

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it's also a masterpiece
of aerodynamic engineering.

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Thousands of hours have gone into designing
a sports car that's not only beautiful,

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but can cheat the air almost as well
as Ferrari's FormuIa-1 race cars.

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In essence, the 599's body shape
is the opposite of an aircraft wing.

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At high speed,
its streamlined body creates negative Lift,

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using the airflow over and through it
to press the car to the road.

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The down force means more secure road
handing and far better traction out of corners.

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But the Ferrari's streamlined body needs
strong support.

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If you want to put a FormuIa-1 race car
on the street,

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you need a chassis that can take the stresses
of high speed and high performance.

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Made entirely of aluminum alloy,

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the 599's chassis needs to be strong enough
to do three things:

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It has to be able to withstand
high-speed impacts,

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it has to anchor the 230kg V1 2 engine,

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which produces a tremendous amount
of torque and power,

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and the chassis also has to provide a strong
mount for the wheel assembly and suspension.

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At high speeds, the wheels of a sports car
go up and down Like a jackhammer,

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so Ferrari has equipped the 599's chassis
with super-tough suspension mounts.

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High-strength adhesives
and meticulous hand welding

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make the joints in this chassis
as strong as the original metal.

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Regular cars' chassis are put together
by machines,

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but high performance sports cars Like the 599
are hand welded.

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This means
the chassis can be more exactly shaped,

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and the body panels more precisely fitted.

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With the 599's chassis now welded
and the first of its body panels attached,

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it's time for one of the factory's robots
to take over.

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It operates Like a gigantic stapler.

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The robot is programmed to precisely drive
1 80 rivets at specific points on the chassis.

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The rivets give the car the muscle

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to hold itself together
at 330-pIus kilometers an hour.

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Each time these jaws snap,

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they punch a high-strength rivet
through up to three Layers of solid aluminum.

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But the chassis can't move on down the Line
until it's passed a rigorous test.

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For this, another robot comes into play,
one equipped with needle-like probes.

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The probes test the chassis
in 800 different places.

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At each of these points, they touch the metal.

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When they do this, they're measuring the body
against a computer model,

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searching for tiny cracks in the metal
or any flaw in the chassis' overall shape.

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If a flaw is detected, the chassis is sent back,
but that only happens to one in every hundred.

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There's an important reason
for this insistence on perfection:

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any flaw in a component of a high-performance
sports car can create a ''ripple effect'',

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and the flaw can magnify through
all the other components dependent on it.

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At high speeds, the stresses on the chassis
could turn cracks into fissures,

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and compromise
the car's structural integrity.

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After an exhaustive examination,
the robot arms rise for the Last time.

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The 599's metal skeleton is now ready
to receive the rest of its sculpted body panels.

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Back in the foundry,
the engine casts are complete.

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Seven minutes Later, they've cooled enough
for the sand moulds to be removed.

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There's nothing too high-tech about this
process!

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The compressed sand
is simply shaken off the solidified metal.

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The high-performance specs of the 599 require
engine parts that are perfect,

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so powerful X-rays scan the cast components,

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Looking for any microscopic cracks
or flaws in the metal.

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The slightest vibration
from a defect in the finished engine

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would be magnified at high speed.

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In the worst case scenario,
the engine itself could fail.

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Components that pass the X-ray test
are hand finished,

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Then, they're checked again.

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It's no surprise that Ferrari foundry workers feel
they're making more than just an engine.

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We create the soul, and then someone else
adds the organs to make it Live.

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In the body shop, metal becomes art
as the 599's sleek outer shell meets its chassis.

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When anyone thinks of a Ferrari,
you think of two things in particular:

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one, the motor, immense power,

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the sound, the growl of it,

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and second, the external beauty of the Ferrari.

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Like its chassis,
the Ferrari's body panels are aluminum.

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It may be the most powerful production car
the company's ever made,

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but its fully-aluminum construction means
it's also one of the Lightest.

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The 599 has more power propelling Less car.

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Workers fix the doors, bonnet and boot
to their precision hinges

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and align them to a tenth of a millimeter.

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From this point on, it's all about art,

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creating a finished body
that's as close to flawless as possible.

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The body shop's specialists check for trouble
spots, dents or flaws, no matter how small.

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To the people at Ferrari,
this is no Longer a car. It's a sculpture.

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In a sealed Plexiglas room, where no speck
of dust can interfere with its final inspection,

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the 599 is given the thumbs up
to move out of the body shop.

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We have to guarantee the perfect shape,

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the unique finishing,
consequently the perfect paint job.

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The unfinished Fiorano 599 then takes
its next step towards the finish Line.

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This is Ferrari's 21 st century paint shop,

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one of the most advanced of its kind
in any car factory in the world.

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The environment is a high priority
for this paint shop.

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Most materials are water-based,
and nearly all waste is captured and recycled.

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FormuIa-1 racers don't have to worry about rust,
but the 599 is built for the streets.

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Before it can be painted, every 599 car body
receives an anti-corrosion treatment Like this.

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Ferrari claims it's the most advanced
rust-proofing in the world:

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a claim that's hard to test,

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because the chemical process used here
is a trade secret.

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The one-tone bodies are plunged,
tipped, and shaken.

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Every one of these giant baths
chemically alters the metal of the car's body,

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creating a super-thin armour
against the elements.

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These anti-corrosion baths also give
the 599's body a positive electrical charge,

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something that's vital
to the next stage of the painting process.

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00:21:06,887 --> 00:21:11,085
At the end of this tunnel Lies
the heart of the paint shop.

229
00:21:14,127 --> 00:21:17,676
It's a glass-walled, hermetically-sealed place,

230
00:21:17,727 --> 00:21:21,515
populated by graceful robots
and their human controllers.

231
00:21:23,127 --> 00:21:26,597
The chambers are sealed
to avoid any air draughts

232
00:21:26,647 --> 00:21:31,926
that might cause the tiny particles of primer
and paint to drift and create an uneven finish.

233
00:21:36,527 --> 00:21:41,806
This first coat is a primer, a special compound
that binds the actual paint to the body.

234
00:21:46,167 --> 00:21:48,886
The primer is a dust, as fine as talcum powder,

235
00:21:48,927 --> 00:21:53,717
which sticks to the body because of
the electrical charge the metal was given earlier.

236
00:21:57,807 --> 00:22:00,002
The robots are programmed

237
00:22:00,047 --> 00:22:04,518
to spread the particles of primer
into a Layer about as thick as a human hair.

238
00:22:10,647 --> 00:22:13,002
The body then glides into a giant oven,

239
00:22:13,047 --> 00:22:15,242
which bakes the primer, fusing it onto the metal,

240
00:22:15,287 --> 00:22:18,484
and providing the foundation Layer
for the final paint finish.

241
00:22:22,127 --> 00:22:26,678
Every stage of a Ferrari's construction
is about beauty and power.

242
00:22:29,887 --> 00:22:34,597
The 599's power is its V1 2 engine,
created in the engine works.

243
00:22:45,087 --> 00:22:49,478
The engine blocks and cylinder heads
cast in the foundry

244
00:22:49,527 --> 00:22:52,803
are now fine-tuned
to an almost microscopic degree.

245
00:22:57,207 --> 00:23:01,837
Meanwhile, other workers turn out
the rest of the engine's 800 parts.

246
00:23:05,687 --> 00:23:08,804
Ferrari's engine works
is an architectural triumph.

247
00:23:08,847 --> 00:23:11,919
Natural Light floods in through a glass roof.

248
00:23:11,967 --> 00:23:17,041
This is not only environmentally efficient,
but it also provides better Light for the workers.

249
00:23:19,847 --> 00:23:25,843
And in the centre of the engine works
is a small forest of trees growing indoors.

250
00:23:25,887 --> 00:23:31,200
These trees help maintain the ideal humidity
and air quality levels for engine construction.

251
00:23:34,567 --> 00:23:36,956
They're also here to ensure the workers'
comfort.

252
00:23:41,407 --> 00:23:45,366
This factory is rated
as one of the best places to work in Italy.

253
00:23:45,407 --> 00:23:48,843
Ferrari workers don't see themselves
as part of a production Line,

254
00:23:48,887 --> 00:23:52,197
rather as craftspeople,
building a handmade product.

255
00:23:55,567 --> 00:23:57,558
My passion is to make Ferraris.

256
00:23:57,847 --> 00:24:02,125
I think I've made a part of the motor of every
single vehicle that you see on the road,

257
00:24:02,167 --> 00:24:05,045
and every time I see a Ferrari,
I feel pride in my heart.

258
00:24:05,087 --> 00:24:07,078
Inside that motor is a part of my heart.

259
00:24:11,367 --> 00:24:15,155
At every step of a Ferrari's creation,
they sign off on their work.

260
00:24:22,727 --> 00:24:27,323
I am, and we all are,
absolutely responsible for what we build.

261
00:24:28,487 --> 00:24:31,285
We certify what we do
so it can be traced back to us.

262
00:24:39,127 --> 00:24:41,118
Throughout the engine works,

263
00:24:41,167 --> 00:24:45,957
Ferrari's metal workers are machining the most
detailed components of the V1 2 engine.

264
00:24:48,967 --> 00:24:50,958
Italians have a reputation for being

265
00:24:51,007 --> 00:24:53,805
some of the most skilled metal workers
in the world.

266
00:24:57,367 --> 00:25:02,236
This tiny valve is only one
of the 599 engine's 800 components,

267
00:25:02,287 --> 00:25:05,165
but it alone takes nearly an hour to make.

268
00:25:12,327 --> 00:25:15,046
While the emphasis in the engine works
is on hand crafting,

269
00:25:15,087 --> 00:25:17,726
there are two very special robots here.

270
00:25:22,807 --> 00:25:25,879
The first is a robot called Romeo and Juliet.

271
00:25:27,687 --> 00:25:32,158
These two arms are Romeo, giving Juliet a ring,

272
00:25:35,847 --> 00:25:37,838
but this is no ordinary ring.

273
00:25:39,727 --> 00:25:43,163
It's actually the valve seat
in the engine's cylinder.

274
00:25:43,207 --> 00:25:45,721
It forms a seal through which the valve moves,

275
00:25:45,767 --> 00:25:49,965
allowing air into the chamber,
where it mixes with the fuel and explodes.

276
00:25:51,327 --> 00:25:54,763
With the valve moving in and out
thousands of times a second,

277
00:25:54,807 --> 00:25:57,844
the valve seat has to be tight, immovable in fact.

278
00:25:57,887 --> 00:26:01,880
If it came Loose, it could enter the engine
and cause complete failure.

279
00:26:09,967 --> 00:26:14,119
Romeo dips each valve ring
into a bath of Liquid nitrogen,

280
00:26:14,167 --> 00:26:18,843
freezing it to minus 1 80 degrees
and shrinking it by a tiny amount.

281
00:26:21,807 --> 00:26:26,323
Juliet holds the cylinder head
while Romeo sets the valve ring in place.

282
00:26:28,967 --> 00:26:34,041
The first is a practice run, to check the exact
position of the two components.

283
00:26:34,087 --> 00:26:39,286
Laser sensors make minute adjustments,
then Romeo places the valve ring.

284
00:26:46,927 --> 00:26:50,761
In the following few seconds, the frozen ring
warms and expands.

285
00:26:52,327 --> 00:26:54,318
It's now Locked in place.

286
00:27:01,647 --> 00:27:04,081
The second of the engine works' two robots

287
00:27:04,127 --> 00:27:07,961
has to fine-tune another critical component:
the crankshaft.

288
00:27:15,007 --> 00:27:20,001
The power generated by the 599's engine
is transferred through the crankshaft,

289
00:27:20,727 --> 00:27:23,287
to the transmission,

290
00:27:23,327 --> 00:27:25,318
to the driveshaft,

291
00:27:26,407 --> 00:27:28,398
to the wheels,

292
00:27:29,607 --> 00:27:31,598
and then to the open road.

293
00:27:39,207 --> 00:27:44,076
At top speed, the 599's crankshaft is spinning
over 1 00 times a second.

294
00:27:44,127 --> 00:27:46,163
If it failed,

295
00:27:46,207 --> 00:27:50,280
the pistons attached to it would shoot through
the engine block and destroy the engine.

296
00:27:58,607 --> 00:28:01,041
The crankshaft is the heart of the motor,

297
00:28:01,087 --> 00:28:06,719
therefore every tiny operation needs to be as
precise as possible and as perfect as possible.

298
00:28:10,647 --> 00:28:13,320
When it's spinning at over 8,000rpm,

299
00:28:13,367 --> 00:28:16,962
any imperfections could cause the crankshaft
to become unbalanced

300
00:28:17,007 --> 00:28:21,523
and create potentially destructive vibrations
throughout the entire engine.

301
00:28:24,607 --> 00:28:30,443
The robot drills, shaves and grinds
the crankshaft, until it's perfectly balanced.

302
00:28:41,087 --> 00:28:44,921
Removing excess metal also improves
the engine's performance.

303
00:28:44,967 --> 00:28:48,880
The Less the crankshaft weighs,
the easier it is to make it spin,

304
00:28:48,927 --> 00:28:52,397
and the faster it spins,
the more power the engine generates.

305
00:28:57,287 --> 00:29:00,245
Eight hundred separate components
have been made,

306
00:29:00,287 --> 00:29:02,755
fine-tuned and checked in the engine works.

307
00:29:06,607 --> 00:29:08,996
From its birth from molten metal in the foundry,

308
00:29:09,047 --> 00:29:13,325
the 599's engine is about to be assembled
into its final form.

309
00:29:16,847 --> 00:29:19,122
While the engine works builds the power,

310
00:29:19,167 --> 00:29:22,682
the paint shop adds the beauty
for which Ferrari is famous.

311
00:29:26,527 --> 00:29:28,358
The final coats of paint are applied.

312
00:29:33,687 --> 00:29:37,043
Unlike the primer, the paint is Liquid.

313
00:29:37,087 --> 00:29:40,716
Tiny droplets spin out
from the tips of these robot arms.

314
00:29:40,767 --> 00:29:44,885
Their movements have been precisely
programmed using computer models.

315
00:29:47,487 --> 00:29:52,925
The robots apply exactly the right amount
of paint to achieve a perfectly even surface.

316
00:29:54,887 --> 00:29:57,276
You just have to Look at the Lines of the car,

317
00:29:57,327 --> 00:30:02,447
the effort we put in producing
the best paint job that it's possible to produce.

318
00:30:06,007 --> 00:30:09,841
After the paint
comes an ultra-tough clear ceramic Layer.

319
00:30:12,607 --> 00:30:16,919
The smoothness and the quality
of the clear coat that we put on the car,

320
00:30:16,967 --> 00:30:23,566
it's a ceramic clear coat, very hard,
very shiny and it's very durable.

321
00:30:26,727 --> 00:30:30,720
The clear ceramic coat provides
extreme scratch resistance,

322
00:30:30,767 --> 00:30:34,521
something you want when you're spending
200,000 Euros on your car.

323
00:30:40,287 --> 00:30:42,278
Though 1 2 colors are standard,

324
00:30:42,327 --> 00:30:46,036
599 owners can order the car
in any color they choose.

325
00:30:50,807 --> 00:30:54,641
The bodies are polished
to a surface as smooth as window glass.

326
00:30:59,007 --> 00:31:04,161
But before a Ferrari Leaves the paint shop,
it has to pass a rigorous final quality check.

327
00:31:09,767 --> 00:31:14,283
The slightest surface flaws in the paint work
are polished and rechecked.

328
00:31:14,327 --> 00:31:18,764
The paint depth is measured ultrasonically
to within a thousandth of a millimeter

329
00:31:18,807 --> 00:31:21,037
to achieve an evenness of finish and color.

330
00:31:28,087 --> 00:31:30,965
If an imperfection can't be polished away,

331
00:31:31,007 --> 00:31:33,805
the body is sent back down the Line
to be repainted.

332
00:31:37,087 --> 00:31:41,205
Robots finish the paint job,
but a man will assemble the engine.

333
00:31:46,807 --> 00:31:50,083
Each engine is built by one man, by hand.

334
00:31:53,967 --> 00:31:57,243
Putting together the 800 precision components

335
00:31:57,287 --> 00:32:00,359
is one of the most skilled jobs
in the Ferrari factory.

336
00:32:06,927 --> 00:32:09,600
The engine mechanic fits
the massive engine block

337
00:32:09,647 --> 00:32:13,765
with the pistons that will turn explosive energy
into propulsive force.

338
00:32:24,247 --> 00:32:28,763
Then he puts the most critical piece of all
into the engine block, the crankshaft.

339
00:32:42,967 --> 00:32:46,676
The remainder of the engine takes shape
as the hours spin by.

340
00:33:00,167 --> 00:33:03,477
A full day after work began,
the engine is finished.

341
00:33:05,607 --> 00:33:09,236
From fire and raw metal, this has been made.

342
00:33:15,487 --> 00:33:19,560
The workers in Ferrari's paint shop
and engine works have done their jobs.

343
00:33:20,887 --> 00:33:24,596
Now, the beauty and the brute strength
are about to come together.

344
00:33:33,207 --> 00:33:37,246
Ferrari's Maranello factory has met
two of its challenges.

345
00:33:37,287 --> 00:33:42,202
The newly designed 599 has its powerful heart
and its beautiful body,

346
00:33:42,247 --> 00:33:46,684
but that power will have to be harnessed,
and that body kept on the road,

347
00:33:46,727 --> 00:33:50,515
if this heir to a FormuIa-1 racer
is to perform on the street.

348
00:33:55,807 --> 00:33:59,846
Meeting that challenge
is the job of the final assembly Line.

349
00:34:02,927 --> 00:34:07,239
On regular assembly Lines,
the car being made never stops moving,

350
00:34:09,687 --> 00:34:14,078
but a Ferrari stops 32 separate times
during its final assembly.

351
00:34:17,167 --> 00:34:21,922
At the top of the Line, the 599's biggest,
heaviest, and most crucial component

352
00:34:21,967 --> 00:34:26,358
finally meets the body
it will propel at speeds of over 300kmh.

353
00:34:34,727 --> 00:34:39,562
The V1 2 engine alone
accounts for a fifth of the 599's total weight.

354
00:34:42,247 --> 00:34:45,637
The engine has to be bolted to the chassis
and wired up.

355
00:34:49,287 --> 00:34:52,199
Fierce Italian pride drives the mechanics' work.

356
00:34:58,967 --> 00:35:03,324
Of course we all feel proud of our work,
because we have to give the best we have,

357
00:35:03,367 --> 00:35:06,882
so that every vehicle is the same as the next,
exactly the same.

358
00:35:15,167 --> 00:35:18,682
The engine is in, but that's only half the job.

359
00:35:19,647 --> 00:35:23,276
They've still got to fit
the 599's transmission system,

360
00:35:23,327 --> 00:35:27,445
made up of its gearbox and massive driveshaft,
already bolted together.

361
00:35:33,247 --> 00:35:37,445
The engine creates the power, 620 horsepower,

362
00:35:37,487 --> 00:35:40,797
but all that power is transferred by the driveshaft

363
00:35:40,847 --> 00:35:44,237
through the gearbox
to the 599's axles and wheels.

364
00:35:48,847 --> 00:35:52,965
The driveshaft is one of the only components
encased in steel.

365
00:35:53,007 --> 00:35:57,398
It has to be if it's to handle
the power surging through it from the engine.

366
00:36:06,927 --> 00:36:11,318
That power is controlled
by the 599's racing-bred gear system.

367
00:36:15,247 --> 00:36:19,035
Changing gears in the 599 is virtually instant.

368
00:36:19,087 --> 00:36:21,681
In the space of a tenth of a second,

369
00:36:21,727 --> 00:36:25,037
the power pumping from the engine can be
shifted up or down a gear.

370
00:36:30,487 --> 00:36:33,604
That's ten times faster
than the gears in an average car.

371
00:36:36,087 --> 00:36:39,557
And only a fraction more time
than it takes in a FormuIa-1 car.

372
00:36:44,567 --> 00:36:47,684
This extraordinary power management
allows a Ferrari

373
00:36:47,727 --> 00:36:54,599
to accelerate through all its gears and be
moving at over 200kmh in just 1 1 seconds.

374
00:36:57,767 --> 00:37:00,600
But only if the factory workers get it right.

375
00:37:04,887 --> 00:37:09,722
On the assembly Line, they finish mounting
the 599's engine and transmission system.

376
00:37:19,127 --> 00:37:23,598
It's not enough for a sports car to go fast.
It also has to stay on the road!

377
00:37:24,567 --> 00:37:28,321
The suspension system
in high-performance vehicles Like the 599

378
00:37:28,367 --> 00:37:30,961
is far more important than it is in a normal car.

379
00:37:35,687 --> 00:37:40,886
The 599's suspension uses revolutionary shock
absorbers developed in the United States.

380
00:37:43,007 --> 00:37:45,760
While conventional shock absorbers
are oil-filled,

381
00:37:45,807 --> 00:37:50,085
the shock absorbers used on the 599 contain
a magnetically-charged fluid.

382
00:37:55,367 --> 00:37:59,326
Like two opposing magnets,
they read and react to every bump in the road

383
00:37:59,367 --> 00:38:03,246
far more precisely and instantly
than oil-filled shock absorbers.

384
00:38:08,527 --> 00:38:13,920
Installing the shock absorbers is a critical
and painstaking step in the 599's final assembly.

385
00:38:17,487 --> 00:38:21,275
But Ferrari's mechanics mount this key
component in under an hour.

386
00:38:26,127 --> 00:38:32,885
The Maranello factory has now given the 599
speed, beauty and handing for the street,

387
00:38:32,927 --> 00:38:36,840
but there's still one challenge Left to meet:
Luxury.

388
00:38:39,527 --> 00:38:41,677
That's the job of the coachworks,

389
00:38:41,727 --> 00:38:47,996
where the 599 gets its Luxurious Leather interior,
each piece individually handcrafted.

390
00:39:00,167 --> 00:39:03,045
A highly-trained team of seamstresses

391
00:39:03,087 --> 00:39:06,796
draws on a centuries-old Italian tradition
of fine Leatherwork.

392
00:39:10,447 --> 00:39:12,358
Specially-selected cow hides

393
00:39:12,407 --> 00:39:16,116
are transformed into the Ferrari's upholstery,
dashboard and trim.

394
00:39:21,807 --> 00:39:25,516
This is the coachworks' concession
to the 21 st century:

395
00:39:25,567 --> 00:39:30,277
a computer-controlled marking system
to avoid even minute defects in the Leather.

396
00:39:30,327 --> 00:39:33,558
Ferrari's customers pay handsomely
for perfection.

397
00:39:39,887 --> 00:39:44,756
A Laser beam directed by the computer
precisely cuts the sections of Leather.

398
00:39:46,887 --> 00:39:50,482
But beyond this stage,
it's all human skill with needle and thread,

399
00:39:50,527 --> 00:39:53,997
that creates the unique interiors
in all the colors of the rainbow.

400
00:39:54,687 --> 00:39:59,636
If money's no object, Ferrari will dye the Leather
of your 599 any color you want,

401
00:39:59,687 --> 00:40:01,723
and the same with the stitching.

402
00:40:03,527 --> 00:40:08,078
The Leather is the same as that used
to make some of Europe's finest furniture.

403
00:40:08,127 --> 00:40:11,722
Ferrari will even create matching Luggage
in the same Leather.

404
00:40:17,007 --> 00:40:21,205
Everything is sewn, stretched
and applied with the same meticulous care,

405
00:40:21,247 --> 00:40:24,637
from this roll bar to these dashboards.

406
00:40:25,287 --> 00:40:31,203
It takes an average of 30 hours to cut, sew
and assemble a single Ferrari's Leather interior.

407
00:40:36,287 --> 00:40:39,085
It's pride, because I go out and I see a Ferrari,

408
00:40:39,127 --> 00:40:43,917
and I always stop and Look and I say,
''Hey! Maybe I sewed the Leather in that one.''

409
00:40:47,127 --> 00:40:50,164
Each time we finish a piece,
the satisfaction is huge,

410
00:40:50,207 --> 00:40:54,723
because it's a totally manual job
that creates something from nothing,

411
00:40:54,767 --> 00:40:58,840
and seeing as something is one of the most
prestigious cars in the world,

412
00:40:58,887 --> 00:41:01,162
it is a great satisfaction for everyone.

413
00:41:05,287 --> 00:41:07,403
Back on the assembly Line,

414
00:41:07,447 --> 00:41:11,963
the final pieces of this 200,000-Euro
jigsaw puzzle are being put in place.

415
00:41:16,607 --> 00:41:19,804
The computer-controlled instrumentation
inside a 599

416
00:41:19,847 --> 00:41:24,284
is almost identical to that in the cockpit
of Ferrari's FormuIa-1 racing cars.

417
00:41:28,847 --> 00:41:32,442
The car's computer monitors
all its electronic systems,

418
00:41:32,487 --> 00:41:37,277
everything from the heaters in the seats,
to the all-important traction control system.

419
00:41:39,767 --> 00:41:44,966
The traction control system processes data
coming from sensors on the 599's wheels,

420
00:41:45,007 --> 00:41:49,956
then modifies the car's handing
to give the driver more control in any situation.

421
00:41:53,887 --> 00:41:58,881
In wet conditions, for example, the system
makes minute adjustments to avoid skidding.

422
00:42:02,647 --> 00:42:05,161
The 599's wheels are made of aluminum alloy,

423
00:42:05,207 --> 00:42:08,756
which means they're both incredibly Light
and incredibly strong.

424
00:42:09,607 --> 00:42:15,682
Thanks to its racing heritage, the 599's tyres
have a footprint twice as wide as a regular car's,

425
00:42:15,727 --> 00:42:20,437
and more rubber on the road means
there's more grip for acceleration and cornering.

426
00:42:25,847 --> 00:42:31,205
The 599's windshield is precision curved
to maintain the car's aerodynamic profile.

427
00:42:37,087 --> 00:42:39,806
Final checks are done on every part of the car.

428
00:42:42,007 --> 00:42:45,966
And only when it's passed this inspection
is the 599 declared ready

429
00:42:46,527 --> 00:42:49,485
to receive its badge of honour:
Ferrari's prancing horse.

430
00:42:56,167 --> 00:43:00,046
But despite all the care and all the pride
that have gone into its construction,

431
00:43:00,087 --> 00:43:03,557
the finished 599 must still prove itself
road-ready.

432
00:43:05,447 --> 00:43:10,123
And in Ferrari terms, road-ready
is as close as you can get to race-ready.

433
00:43:13,927 --> 00:43:16,680
Ferrari's workers have done everything they
can,

434
00:43:16,727 --> 00:43:20,686
and taken the 599
from raw metal to finished sports car,

435
00:43:20,727 --> 00:43:23,764
but it now has to pass a final test.

436
00:43:29,127 --> 00:43:34,645
This is the racetrack at Maranello, where
Ferrari tests its Legendary FormuIa-1 cars.

437
00:43:41,767 --> 00:43:44,122
And it's also where new 599's are tested

438
00:43:44,167 --> 00:43:48,046
to ensure
their performance matches Ferrari's promise.

439
00:43:53,487 --> 00:43:57,560
High on the List of critical checks
is the traction control system.

440
00:43:57,607 --> 00:44:02,044
The tiny sensors mounted behind the wheels
feed data to the car's computer,

441
00:44:02,087 --> 00:44:05,841
adjusting its handing
from one split-second to the next.

442
00:44:15,127 --> 00:44:20,326
On the racetrack, the test driver first checks
the 599 with its traction control turned off.

443
00:44:27,007 --> 00:44:31,523
Then he performs the same manoeuvres
with the traction control system engaged.

444
00:44:35,807 --> 00:44:37,763
For a normal driver,

445
00:44:37,807 --> 00:44:43,677
this enhanced handing could be the difference
between maintaining control and Losing the car.

446
00:44:47,087 --> 00:44:52,525
But despite its FormuIa-1 pedigree,
the 599 is not bred for the racetrack,

447
00:44:52,567 --> 00:44:57,357
so, in the hills above the Ferrari factory,
each one is put through a second road test.

448
00:45:02,847 --> 00:45:07,637
The 599's suspension and handing
are also tested in a real world environment.

449
00:45:09,607 --> 00:45:12,485
So is its tenth-of-a-second gear shift system.

450
00:45:15,927 --> 00:45:20,603
Each gear change means a virtually instant shift
in the power reaching the wheels.

451
00:45:24,127 --> 00:45:27,358
If the gear system
is even a fraction of a second out,

452
00:45:27,407 --> 00:45:29,716
the car could be sent into a high-speed slide,

453
00:45:29,767 --> 00:45:32,235
something that could be deadly
on the open road.

454
00:45:37,127 --> 00:45:40,676
The test driver pushes the 599 to its Limits,

455
00:45:40,727 --> 00:45:43,764
continually checking
the computer instrumentation

456
00:45:43,807 --> 00:45:48,437
and constantly matching the cars promised
performance against its actual performance.

457
00:45:53,607 --> 00:45:57,441
With its V1 2 heart pumping
as it never has before,

458
00:45:57,487 --> 00:46:00,877
and its aerodynamic body cutting the Italian air,

459
00:46:00,927 --> 00:46:03,885
the new Ferrari is now free of the factory,

460
00:46:03,927 --> 00:46:07,761
and on its way to an owner
who's waited two years for their prize.

461
00:46:15,727 --> 00:46:20,926
AII told, it's taken nearly two months
to create this fusion of power and art.

462
00:46:24,647 --> 00:46:27,320
Each section, and each worker,

463
00:46:27,367 --> 00:46:32,077
has been part of the team
that's brought the Fiorano 599 into existence.

464
00:46:35,727 --> 00:46:38,924
Day by day, part by part,

465
00:46:39,767 --> 00:46:45,205
and process by process, the Ferrari
mega-factory has delivered perfection!