Pagani Factory: Inside the Huayra

it's 14 years since i first visited the pagani factory and i'd come to see the very first zonda being built so it seems only fitting that as you walk into the factory today you're met by the mightiest zonda of them all the wild zondara but it's what's behind this mirror door that we've really come to see today because we've got exclusive access to pagani's inner sanctum so we can take under the skin of pagani's latest supercar the incredible why era this is where every year starts its life this is an inner sanctum of pagani and what they do once they've made all the body panels it comes onto this styling buck all the pieces are brought together ready for this man to give its signature they'll actually go off for painting it's harassing signatures one little bit he wants fixing on this piece but i find it exquisite that even though this is going to be a painted car at the end of it yet again we find all the carbon weave matching how the clam shell and the door are absolutely perfectly aligned when you look around the front everything has to have this herringbone every single weave has to be perfect right across the car so this is as naked bare carbon as you can get horatio ticks it and then it's off to the spray shop excuse the noise in here is an autoclave humming away cooking a wire body ready for the morning but i just want to show you this bit this has just come back from the paint shop it's going to be an interesting green but mainly in bare carbon fiber but if we look inside there's one detail i think is fantastic on the wire and that's how they've done the heating if you look here this is where the ducts come out for the ventilation but rather than having separate pipes or anything like that he's actually done it so it's structural and this is hollow it blows it around the windscreen for de-misting or up these vents for the drop again it's all to save weight because there's no additional pipes or anything needed for the ventilation system so these are the rear flaps on this car they're all ready attached this is again come back from the paint shop bare carbon underneath looks absolutely beautiful we really ought to have a look at what car this is going to be attached in which is in the room next door so the rear clam shell is going to go under this car and it's got this beautiful titanium exhaust on it it's actually part of the club sport pack was having this exhaust um carbon ceramic brakes you'll see and a lift at the front so you can get over uh curb stances they announced the price of the worry when it first came out at 825 000 but every single customer now has ticked the club sport so they made it standard and put the price up to 849 000 to include the club sport package 8 730 horsepower but i'll take you around the car there's just details everywhere on this car you've got to see this is the rear suspension all done in gold anodised aluminium is they've all been machined from solid there's no sort of cast in here each individual piece is done individually by hand it's exquisite when you see it open like this some of the details on this card they what they've tried to keep the weight as close to the center as they could and so that's meant it's got a unique transverse gearbox in the back normally it'll stick out the back but this one as you can see it's size on in the chassis the reese's rear exhaust made out of titanium beautiful beautiful things it's like the cans you might find on a ducati or something like that but it's most spectacular features it only weighs 10 kilos and because that weight sort of hangs out the back of the wire that's really critical for handling because it it's a flywheel it normally should weigh about 25 kilos something like that these bits are just exquisite this is actually what carries the rear clam shell absolutely beautiful before it actually gets the spring on it to support the whole frame of the back which is just the beautiful movement you don't see on normally on these sort of cars you'll see this tie rod that's how they do the final adjustment of the clam shell come a bit further around it's a dry sumpt engine v12 twin turbo dry sump there's your oil tankers here all set inside you can't see but hidden away is a petrol tank right behind the bulkhead in the safest possible place you can find one because horacio is obsessed with safety and one of the things mid-engine cars are quite famous for is catching fire so you can minimize it as much as you can by pushing the fuel pumps within the fuel tank and just having the one pipe go into the engine he was telling me actually earlier if there's a sensor on the front we'll find out if the airbags sense they're in an accident it actually cuts the fuel but dumps the fuel what's in the fuel lines into the engine so it's locked inside the engine so it just cannot catch fire we get to the interior the tub carbo titanium is what it's made of all sorts of little cubby holes when you look inside you've got one here if i open the glove box i've never seen it's got a little shelf on it and blow me it's got another little envelope there to keep things and then behind your head there's some more there's a little one block to keep it here there's another little cubby hole in here this is a little secret one in the door when it's when it's open you normally put your sunglasses in there but a few people will actually know there's another little one in there the only trouble with that one is your doors have to be open to use it continue around to the front again we've got this beautiful gold anodized suspension just like at the rear but all this bit all this is in beautiful gloss carbon fiber you won't see this but he can't help itself at pagani they have to do it in gloss this one's quite an interesting one if we see here these are the intercoolers for the engine and out to the back of them is a duct and that duct actually feeds the air around to the brake so there's going to be a flexible pipe going on here in final assembly and he said well why they duct in hot air to the brake disc well it's not hot air because it only gets about 80 degrees and that primes the disc to the most perfect working temperature around 80 85 degrees never seen that on a car before continue around carbon fiber on top of the radiator no one's going to see it it's the best finish you can imagine and yet it's locked away forever the other thing about the wire everyone is bespoke to the customer who's ordered it and this this customer is actually one obviously he doesn't like a lot of carbon fiber because this is painted here that's the only one i've seen and they've actually painted the whole tub so there's no bare carbon that i can see visible on the outside of this car of course when you open everything up then there's bare carbon everywhere the other thing that's unique on all paganis he uses a metal crash structure at the front i asked him why he doesn't use carbon for this piece and it's all to do with insurance costs it's much cheaper to replace a metal frame like this and it absorbs energy really well what's really strong in a carbon car is the strength of the tub but you want the crumple zone still around you and by using metal to take the main force it makes it very easy to repair this car which i hope you never have to do there we have the one fuel line going to the engine from the fuel tanks with the fuel pumps within the fuel tank and what's really neat about this this is actually kevlar like no other fuel pipe i've ever seen and it has a really neat trick because i've got the fuel pipe here but if i do this it's flame proof so i can carry on like that and that will never catch light just amazing so three cars under construction here chassis six seven and eight and this is some of the carbon parts here russia was telling me there's four thousand seven hundred parts go into making hawaii era compared to three thousand on the zonda endless beautiful carbon fibre parts here they've done my favorite of all has to be the mirror so i think it's just the most exquisite shape and i just love the way they actually put the italian flag within it it's meant to look like a woman's eye i think it's just exquisite it's like jewellery this cupboard um these are the really precious pieces the titanium um take you around them but there's amazing pieces in here here we are titanium wheel nuts individual they're actually exactly the same as the zonda are i asked if they're left and right hand thread but they're all right hand thread the interior mirror again of course carbon and really small i can't get over how narrow that is but um it's aesthetics up here is the famous gear change and the engineers are saying they thought they were all sorted on this um but actually decided it wasn't quite the right click so they spent the last month redoing the click paddles go on the steering wheel so the gear change paddles go on the gear change again they've these are in smoke titanium look you have an aluminium i mean they're behind the steering wheel if we're going to say but no you can choose what finish you want on them it's just endless in this car you can see that this is the chassis plate so this is chassis number six this is all this car's going on naturally the wire badges we've all seen is actually cut out of one piece block of uh aluminium just lovely one of the things i can't get over on this car is how many times it says pagani on it it just shows you how bespoke this car is but here's the hydraulic gearbox activator pagani you see it on here on the brakes you can see it on the suspension you can see it on every single nut and bolt on every cooling hose on here on the tank but my favorite of all has to be on the buckle that actually holds the rear clamshell on pagani it says it's on there as well it's one final detail i've got to show you and there's this battery for the way era lithium-ion battery and below me that's made of carbon fiber as well i've never seen this on a car before it's incredibly light i mean it's it's still it weighs about four or five kilos but for a battery of this size it normally weighs about 12 13 kilos that's amazing and the other thing about it is the price he won't tell me the exact price but all you'll tell me it was 13 times more expensive than a conventional battery so that's a lot so there we have it the pagani y era just stuff for the most exquisite details everywhere you look it's no wonder it costs 849 000 pounds because there is no other car i know that's built this level of attention it's exquisite

Channel: EVO

Views: 555,088

Keywords: Factory, Build, birth, documentary, Harry Metcalfe Zonda Huayra, Italy, Lamborghini, Aventador

Id: g6L-j6s9OPU

Length: 11min 3sec (663 seconds)

Published: Fri Jun 29 2012