Hi everyone! Dragtimes is going to go to the Pagani factory.
We have Giulia Roncarati with us, the PR manager of Pagani.
- So, let's go. Should we start? - OK. Let's go.
Entrance to the production line is unusual.
It looks like a classing old Modena passage.
But instead of garden in the window we can see Pagani Revolution.
It set the lap record on the Nurburgring.
It used to be Zonda R but was rebuilt to Revolition.
Just look at the production line. It's a real workhouse. You will see what I mean.
welcome to the production department of Pagani Automobili.
As you can see this is... doesn't look like an official workshop.
It look more like a typical Italian square with a...
...street lamps, with the... with the red bricks, medieval tower...
...with the arches. It looks like a typical Italian environment.
Super clean, and with the pavements... the carbon fiber even inside the pavements.
This is... the first production of the very new Pagani Huayra Roadster.
The latest model which we presented in Geneva.
As you can see there is no production line. All our car are built by hand...
...by our savvy artisans which carefully apply every single element with maximum attention.
Huayra Roadster is our... it's the latest car that we produced.
And we presented it in March last year.
And it's a car that is going to be made in just 100 units. And they all sold.
It's basically the Roadster version of Huayra Coupe.
And it's a first roadster that is lighter than the couple version.
Guys, FYI. There are 500 LaFerrari's.
But this car... only 100. 100 assembled by hand.
As you can see each car is built from scratch.
Our artisans, they start from...
...a single monocoque made in carbon fiber and carbo-titanium.
And for this special model here a new composite material which is called carbotriax HP52.
...allowed to achieve extra strength and extra rigidity...
...elasticity for the monocoque for the Roadster version.
Then every single component is hand built and hand installed into the car.
So, we start from the center monocoque...
...with a two steel frames, front and rear frames.
And all mechanical parts which are made by the best suppliers...
...on the international market are installed into the car.
Pagani is famous for it's magic with carbon and composite materials.
Horacio Pagani was a chief of the Lamborghini composite material department.
In Pagani he always using the latest technologies..
All Pagani are made... their monocoques, the central piece, are made of carbo-titanium.
It's a carbon woven with titanium.
The problem with Pagani Roadster is that there is no roof. The chassis has lesser stiffness.
To compensate that Pagani choose the hard way.
He invented the new material called carbon triax HP52.
It is even more durable and stiffer that the carbon titanium.
And it's not much heavier.
We developed the general shape of the car.
And then we care about the design of the every single component.
So, the suspension, for an example, they have...
...a very beautifully structure. They are made by a very special company called Aspa.
But they designed and conceived by Pagani.
So, even if we are just focusing...
...on the design and on a carbon fiber manufacturing, which is our core...
...skill, let's say... we have a good collaboration with these trusted partners...
...who produce the components only for this brand and for this car. So, just for Pagani.
It's hard to see on the video but it looks like a masterpiece.
It was already been said that Horacio developed the design of the parts himself.
What an attention to the details!
So, we have carbon ceramic brakes made by Brembo.
We have the radiator, we have...
...the central tube as I already says which of made out of carbon titanium and carbotriax HP52.
The engine, the engine is made by Mercedes AMG, it's a V12.
It's not a standard V12 made in Germany...
...but it's a special one developed by Pagani and manufactured...
...at AMG in a separate factory, in a separate building...
...where they only focus on Pagani engines.
Then we have the shock absorbers which are made by Ohlins in Sweeden.
All the electronics are supplied by Bosch,...
..one of the best players on the international market.
The weight is just 1280 kg.
What a weight to power ratio! It's crazy.
1280 kg... it's about like Ford Focus. Ford Focus is even heavier. And it has 760 horses.
Every is made to order.
So, you know, the mission of the designed is to understand what thrills most our... the customers.
So, we have to understand what customer want in his car.
And we do our best to achieve the maximum level of personalization.
Every single car which is manufactured inside this...
...assembly area as a different bespoke personalization.
And here we can find for example, of this carriage all the metal elements...
...which are going to be installed on...
...especially on this car over here.
And which have been chosen and personalized as a configuration option by our customer.
Every one of these elements is made from a single block of aluminum or a titanium...
...depending on what the customer choose to get.
Year, they are CNC.
Thank you, I'll break it. We should be careful.
Every part on this carriage will be installed...
...into this Huyara Roadster, the one we are shooting. Every part...
... are made of titanium or aluminum cut out of a piece of material.
The is no joints. Each bolt has Pagani logo engraved on it.
Every part has a label of Pagani. It's engraved.
The exhaust is made by a German company.
And as you can see study and research and development study has been done...
...for achieving this shape of the pipe in order to get extra sound.
Yeah.
And how it looks... Just unbelievable, it's a masterpiece.
Everything are made out of titanium, of course.
Most of the engineering which is going on inside this beautiful project...
...that was the Huayra Roadster has been developed during...
...the work we have done with Huayra BC, which is track focused car.
It's a sporty car and it allowed great work of research...
...and development which allowed to conceive this...
...this masterpiece of engineering such as the new....
...7-speed AMT plus reverse gearbox,...
...a transversal and latitudinal made by Xtrack in England....
...just on Pagani specification, so exclusively for this car.
This is one of the Huayra Roadster...
...which are in production in a moment.
It's a beautiful spec Huayra Roadster.
You can see the perfection in a layering of the carbon fiber...
...which is in this configuration is pretty much naked, visible.
Just underneath the clear coat, top coat.
- Yeah. - And...
... here you can see a different pattern of carbon fiber which is actually...
...in a different formula. You can see the carbotitanium and on...
....on another layer we have carbon fiber HP... triax HP52.
And this has not only an esthetically function.
It, as I said, it also allow to achieve 52% in...
...rigidity, extra rigidity.
To... to achieve....
...great result to have a roadster lighter than the coupe version.
So, with the absence of the roof we achieve this 52% in rigidity.
It's not only an assemble here.
There is other cars as well. This Countach, for an example.
Guilia, please tell us why this Lamborghini Countach is here.
This is our history corner except from the museum. This is...
...one of our special babies. Mr. Pagani when he used to work in Lamborghini, he was the...
...the designer that carried out the restyling of the original Countach...
...made by Bertone. So, he actually designed this model right here.
The Countach 25th anniversary.
- Yeah, very nice car. - Thank you.
And there is something which a...
- Quite special. - Should ask you what's that? It looks like a car but not a real car. What's that?
This is one to one scale model. It's a mock up of the Huayra Coupe.
This one dates back to 2008 probably.
And this is a scale model we used to develop the...
...the project Pagani Huayra, the first car to feature active aerodynamic...
...on it's body, so...
Carrying features directly from the aerospace industry.
And it still carry the notes...
...by Mr.Pagani on the development of the design.
- Really nice, really nice. - Thank you.
Next is... Zonda.
Zonda. This is another great launch legend. This is Pagani Zonda F.
And this is Mr.Pagani favorite model.
This is a car that we presented in 2005.
And Mr.Pagani really loves this car, because it's a car that he...
...dedicated to his great friend Juan Manuel Fangio.
It's a clubsport or... clubsport?
- Clubsport. Zonda F Clubsport.
Juan Manual Fangio, if you never heard of him...
...he is a five times Formula 1 champion.
He helped Pagani to get involved into the auto industry.
As you can see, there is Lamborghini... Pagani is carried.
Huayra, and we are in it's way.
Pagani Zonda Cinque. Which kind of Cinque is it? Why is it here? And why it is special.
This is actually a car that has been stored in the factory right now.
And this is our unicorn, of course. This is a car which we made in 2008.
And it's a very first one which features the carbon fiber...
...and carbon titanium on the central chassis.
...on the central monicoque for the extra strength.
And without any increase on the global weight.
It has this very iconic livery.
And which actually was....
....was dedicated to the Asian market. This is a car that is actually...
...requested by our dealer in Hong Kong.
It's one of five cars. This is the second one.
It was made for Hong Kong, as Giulia said.
It were luck enough to see a very rare Huayra manufactured.
Its a sport version, Huayra BC.
BC is Benny Caiola, the first customer of Pagani.
This particular BC is called Macchina Volante. And it's for a very special customer.
A lot of custom parts. Just look, this car just...
...hot. It is faster and lighter than the original Huayra.
It has different clutch and subframes.
It was setup more aggressively.
And an aerodynamic package, of course.
- We are heading to composite material department. Let's go? - Yeah.
Composite materials department. So, basically, is here where....
...our cars take life in terms of body.
So, here is where all our tailors are layering down...
...meters and meters of carbon fiber fabric...
...in order to customize the Pagani cars.
...in order to build the carbon fiber structure of our cars.
So, they start from a mold which is made of carbon fiber as well.
- Of course. - So, on top of the mold the have to...
...layer down different layers of new carbon fiber skin...
....layer after layer.
So....
So, basically, they have book where they need...
...to read all the story of that precise car.
So, they have to follow a configuration. So, each car has been...
...personalized, so, at this stage they need to know whether the is going to be in a...
...carbon look and whether if this component is going to be in a carbon look or not.
- OK, I see. - And then with very precise skills and hands....
...they need to follow the weave of the carbon fiber, they have to...
...tailor it to perfection. - OK. - And, so...
...they apply different layers in opposite direction in order to achieve strength.
So, we use up to several different...
...composite materials, components, some fabrics...
...depending on function and on aesthetic requirements.
As I know the line of carbon fiber it follows on the next part of the car.
- So, it's one part of the car and lines goes continuously. - Yeah. - Very nice.
This requires great rise skills, great ability and...
...on a carbon fiber working.
And all this technology that you can see right here....
...we developed them almost 20 years ago.
So, we use technology now which has a Pagani patent actually....
...which we developed inside Pagani.
Just for one piece... well, it's actually takes I would say a few hours...
...at least or one day.
Maximum one day. Then we need...
...one month to build just the body for one car.
And you can see all these guys are working on the same car.
So, all these are parts of the same car.
So, here they made one car at a time.
The component once... the carbon fiber as being layered down...
...they need to put it inside the plastic bag.
So, it's prepared for the autoclave.
For the bakery process.
The plastic... they are working...
...has the specific function of reducing the...
...the void inside. So, here is the result, the vacuum bag.
- OK, yeah, OK. - So, for pressure.
- Yeah, of course. - No bubbles inside. This is ready...
...to be baked inside the autoclave.
Yeah. If you didn't knew, carbon is baked.
The special autoclave pressed down to a state which we see on the finished car.
Basically, this is the material. This is...
...a raw carbon fiber which is carbon fiber as company used to work it like...
...more that 20 years ago. So, with no resin.
What we use today is called preprag carbon fiber which means that the fabric...
...the carbon fiber is already preimpregnated with a sort of resin.
King of glue, so, it's sticky. It's ready...
It's ready to be applied one layer to the other one.
And this, for an example, is carbon titanium.
It's basically a carbon fiver woven together with titanium wires.
So, it's gets extra strength.
When you look closely you can see the titanium strings in the carbon.
It is one of inventions of Pagani. OK, sorry.
And this is normal carbon fiber but with...
an aesthetic purpose.
It's very beautiful too look at. It's a first layer that we put down...
...the one that you can see of a finished car.
- So, it's a top layer? - Top layer. - OK.
This is how procedure works. Basically, with a mold you start from...
... a mold, in this case the mold for the mirror.
You layer down the carbon fiber fabric...
- Yeah. - And then you put it inside the plastic bag, the vacuum bag.
You bake it in the autoclave at pretty much 140 degree...
...on an average at 6 bars of pressure.
- Sure. - And then once you removed the new part from the mold this is what you get.
- OK. - So, a component that is not finished, of course.
It needs to be polished and trimmed of course.
But you can see that the surface is just beautiful.
- Yes, of course. - It's just you want to see on the finished car.
- Yeah, well... - So, the way the guys in the carbon fiber department work...
...is very important of the final result.
Yes, very nice, very beautiful.
And this is how it looks after painting.
This is just pure naked carbon fiber with a hint of...
...clear top coat, transparent top coat.
All the procedures, all processes regarding the production of the car are all registered....
...inside a book. So, every car has at least one book...
...that tells the complete history of that car.
Wow, OK, that's interesting.
Every person that works in the production of this car...
...has to sign.... - Each checkpoint.
Each step of production, for example who layered this...
...component, at what temperature it has been baked, for how many... for how much time, for example.
There is a signature, so a personal control and then, computer control with bar code.
OK, very nice. So, everyone is responsible of what he is doing.
Yeah, supposed in 30 years from now...
...the car needs restoration. We can go back and see...
- What have been done, yeah. - See everything, what have been done and...
We keep old molds, of course, so we can always...
...repair and do any sort of maintenance on the car.
- OK. So, 30 years later you can still own Zonda or Huyara. - Yes. - Nice.
These are the components that have been manufactured in the carbon fiber department.
They have been put inside this plastic bag.
And now they are ready to be baked inside an oven.
The oven in this case is a huge massive autoclave.
This is an autoclave. The parts...
...packed in the bags. These parts are placed in a giant autoclave where they are baked.
The autoclave bakes at pretty much 140 degree.
...at 6 bars of pressure.
Up to... from 2 up to 10 hours, depending on their dimensions an thickness.
- Of the piece? - Yeah, of the piece.
Then once the baking process is over...
...the new part is separated from the mold underneath.
- And it just perfect. Let me show you something. - Yes, of course.
This is a front bonnet of Huayra.
And then, you see that this is just been...
...taken off from the mold. You see that just off the baking the pattern...
...is one you want to see on the finished car.
- Really nice. - That, the fishbone pattern here is just perfect.
So, now it just needs to be polished and trimmed cut.
And that's it. These guys are not astronauts. They are...
...they are hand trimming the carbon fiber components.
They are in a controlled atmosphere, so...
...they don't breath the carbon finer powder.
- Of course. - And then the manual part continues this way.
On this way they need to...
... prepare all body parts in order to be assembled together.
As a hand made suit...
This is the first test before installing the components.
OK.
- So, it's a bespoke car. - It's a bespoke suit, so...
This is an assembly of the all body parts...
...which have no mechanic parts, no engine, no nothing.
In order to check that everything is really fits together.
- Yeah. - Everything matches together.
If there anything to be fixed...
...they do it by hand.
Does it happen a lot or not, in general?
This is the process, the normal process.
Every car is finished by hand.
After it, the body checking when all parts are ready...
...they sent to painting outside to another company.
- OK, oh. - And then they are shipped back to the factory.
Like this. And they are ready to be installed into the car....
...for the real assembly.
Now all parts are shipped here.
Shipped back here, and this is where...
...the assembly, the real assembly of the car starts. So, we have...
...the first step which is the powertrain.
So we have the engine installed...
...together with a gearbox. - Yeah. - OK.
And then the front and rear frames in chromoly steel.
-OK. - And...
...an installing of all the parts which is this way here...
This is the customized bespoke parts that...
...have been chosen for this car. So...
- We have only aluminum details anodized in black. - Yeah.
So, the logo matching the rest...
...of the components. Look at this. - This is cool.
- Isn't it light? - Yeah. Really cool.
- I'm afraid to break it. - Yeah, sort of a piece of jewelry. - Yes.
That's really nice.
Suspension arms.
Very light, of course.
This is titanium. You can feel how light they are.
And it's made from single brick, right?
- This one? - Yes.
This part, as I understand, is a frame of a speaker.
Sound, audio, and it's made out of...
...the single piece. An arm? OK.
So, 6, 7 grams, not more than that.
This is the assembly of the interior.
As well we can see here other different personalizations.
It stated that it is number 95 out of 100. Every car...
...has a serial number. Not one out of 100 without the specified number, but with a serial number.
Parts getting prepared for final assembly.
- Can I pick it up? - Yeah.
It a start.
It's a button.
Feels like true mechanics.
Steampunk.
Instrument cluster made out of a single piece as well.
Reset. Just look.
Here we got final other details.
Which are ready for the final installation.
And this is basically the last part.
- The main part. - The main part. - Key. Look at the keys.
Open and close. Just the buttons but in a shape of Huyara.
How? Like this?
- Pull it. - Pull it harder?
Looks familiar, isn't it?
So, this is the end of our journey to the Pagani factory...
Or Pagani workshop.
- Giulia, thanks so much. It's a great honor. - Thank you.
- It was nice to meet you and thanks for this amazing excursion. - Thank you.
-Thank you. - It was a pleasure.
Goodbye everyone.
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