How They Make The World's ld's Most Prestigeous Cars

Waimarino Bulletin, Volume 4, Issue 48, 19 May 1987, Page 4 (Supplement)

How They Make The World's

ld's Most Prestigeous Cars

IT takes at least three months to build a RollsRoyce motor car. And as this construction diary shows, ensuring that it will always be an incomparable pleasure to drive demands extraordinary levels of care and skill. Week One The customer's individual specification is passed to production by Rolls-Royce Motors' saies department. An unpainted steel monocoque bodyshell is taken out of storageand steam-cleaned to remove its coat of oilbased rust preventative. For the next fourdays, it is closely examined for blemishes and tiny deviations from the proper dimensions and rectified as necessary. All areas directly exposed to corrosive agents are zinc coated. The doors, made of aluminium for lightness and because it does not rust, are fitted onto outriggers to ensure access to all concealed faces. All sub-frames are protected inside as well as out by spraying inhibiting oil through access holes which are then carefully sealed. At the end of the week, the bodyshell undergoes another rigprous inspection. If it passes this, it is passed on to the paint shop. Week Two I he bodyshell is cleaned thoroughly using an emulsion soakcleaner. I hisisfollowed by two cold rinses, a phosphate application and three more cold rinses, the last of these with demineralised water. Ihe body is oven-dried at 1 1 5°C. All external surfaces, except under-floor areas, are sprayed with an acidetch primer. Ihe body is then completely immersed in grey phenolic waterborne dip primer. This lorins a barrier almost impervious to water. All internal joints are sealed with a plasticised compound. I wo coats of red epoxy primer surfacer are applied to all exterior surfaces, door shuts and the interior of the luggage and engine compartments. A black guide coat is finally applied over the primer surfacer. Week Three Sealing compound is injected into all under-floor joints. The underside of the body is sprayed with two

coats of black thixotropic bituminous material, which protects it and also helps to deaden sound. I he body is rubbed down by hand and a further coat of primer sealer is applied. It is rubbed down by hand again, after which it undergoes a thorough inspection. lf it meets Rolls-Royce Motors1 high standards, three colour coats of paint are applied. Elsewhere in the factory, the engine is being built. Most of the components are produced in the company's own machine shop to ensure complete control over engineering quality. The machined crankcase is fitted with all studs and cylinder liners and pressure tested, after which the crankshaft, connecting rods and pistons are installed. After an oil test has been carried out, the crankshaft connecting rods and piston assembly is balanced to fine limits. The induction system and accessories are fitted to the engine. It is then tested to ensure that it is running smoothly and near-silently. If all is exactly as it should be, the engine is passed on to production. Week three also sees the production of all components for the car's two independent braking systems. These are made with the same precision as the engine components and are even assembled in a 'clean room'. Many of them are ultrasonically cleaned and assembled in a paraffin bath to avoid any contamination by dust. Week Four The painted bodyshell is passed to the pre-mount section of the car assembly area, where the fuel tank and sound-deadening material is fitted. The hydraulic pipes for the height control and braking systems, fuel pump, brake actuator assembly and pedals are fitted with the body on a turnover jig. The beautiful walnut veneer fascia, complete with instruments, air conditioning equipment and control unit, is installed. Every inch of the mile of wiring has

already been checked on a special jig. I he engine and gearbox assembly, rack and pinion steering, brake discs and suspension are fitted to the lront subframe. All moving parts in the transmission and suspension - and even the brakes discs - are balanced with the same care and precision as the engine. The steering column and gear range selector are assembled. The rear subframe, comprising the final drive unit, crossmembers, brake discs and calipers, is constructed. All crossmembers are fitted with special harmonic dampers and filled with soundabsorbing material to blot out any stray noises. Work is begun on the leather upholstery of the car, using only the finest Connolly hide. Week Five The front and rear subframes are accurately aligned

on a mounting jig. The body mounts are inspected and the shell is mounted on the subframes. The six-element exhaust system is fitted and the hydraulic connections are made. The handbrake lever and cables are installed and adjusted. The steering column, rear suspension springs and dampers, height control rams and front road springs are fitted. All underside equipment is then scrupulously inspected. Week Six The car is passed to the aftermount area. The window lift mechanism, glass and central door locking system are fitted into the doors. The doors are fitted to the body, and it is checked that they are positioncd absolutely correctly in their apertures. The front seat adjustment

mechanism is assembled and fitted into the seat base. Each piece of impactresistant padding in the front seats is individually tested. The back-rest and rake mechanism are fitted. The seats are fitted in the body, and the car interior continues to be trimmed by hand. The deep-pile wool carpets are edged with leather, even in the boot. Carpeted foot rests are provided for the benefit of rear seat passengers. After a final inspection, the car is passed to an annexe for oil and coolant levels to be checked, the engine to be started and the braking and height control systems to be bled free of air. Week Seven The car moves to the test department to undergo a full 1 50 miles road test programme. The air-conditioning unit

is charged with refrigerant. A mechanical road test is carried out to check that all instruments and controls function correctly. Anything less than perfect is rectified and the car is re-tested. The coachwork is tested to identify any creaks or rattles. A check to ensure that the electric windows, door locks and fuel filler flap operate smoothly is carried out. Any faults, however tiny, are eliminated and the car is re-tested. The Spirit of Ecstacy mascot is individually crafted and cast, and one day is spent making the radiator by hand. Week Eight A static water test is carried out and the car is carefully checked for leakage. It is rectified as necessary and re-tested. Once the test programme has been completed, the

underseal is improved still further. The entire underside is again sprayed with black thixotropic bituminous material. The car is passed to the final paint shop, where the sill areas are sprayed with a coating which will prevent them from being chipped by stones. Week Nine The paintwork is inspected and any areas requiring attention before more coats are applied are marked and rectified. The body is flatted by hand and colour coats are applied by hand-spraying. The paint finish is inspected and any slight flaws are made good. Further colour coats are applied as necessary. The paintwork is inspected again, and when it is to the company's satisfaction, fine lines are painted on the body.

Week Ten The car is passed to the finishing shop, where the bumpers and the hand-built radiator, complete with the Spirit of Ecstasy, are given a final inspection. The car is returned to the test department for all electrical equipment to be finally checked, including the alignment of the headlamps. The radio/tape player is checked. The car is given its final test on the roads of Cheshire. If the test driver notices the slightest sound, vibration or feeling that should not be there, he stops and makes adjustments on the spot. Week Eleven On completion of the final road test, the car is returned to the finishing shop for a final paint inspection and rectification as necessary to ensure satisfactory finish. The exterior paintwork is polished, the interior valeted and protective covering is placed on the seats. Week Twelve The car is kitted out with items to be fitted at the time of delivery, such as lambswool rugs, tool kit, cigar lighters, owner's handbook and instruction stereo tape. The car is passed to the saies department and the dealer is informed of its completion. It is collected by the dealer, who carries out an 87-point pre-delivery inspection and valets the car before handing it over to the customer.