Behind the Scenes at Bentley Factory – Supercar Superbuild – S01 EP03 – Car Show

Explore Bentley’s journey from classic luxury to modern innovation. Witness the creation of their iconic W12 engine and step inside the Bentley factory, where craftsmanship and precision meet. Discover the fusion of power and luxury that defines Bentley’s legacy.

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[Music] for Generations Bentley has ruled the  world of luxury saloons by being bigger faster   and louder than the competition it’s beautiful  it’s luxurious it’s fast it’s expensive that’s   rarefied air for over a decade the Continental  GT has been the Brand’s signature machine  

Once it was the fastest 4C production car in the  world hitting a top speed of 318 kilometers an   hour combining competition level performance  with luxury worthy of royalty the proudest   achievement was producing a car for the Queen  of England in the same year as winning them all  

However the platform has aged cars had  an extremely long chocolate It’s featured   competitors are nipping at the company’s heels the  world is catching up quickly if Bentley doesn’t   keep innovating then they’ll have a problem the  Brand’s answer isn’t to reinvent an icon but  

To refine it creating their most powerful and  fuel efficient machine ever Continental GT V8s [Music] thank you foreign [Music] GT V8s is the latest Bentley to wear a red flying  B a subtle Insignia that hides in plain sight but  

The Red Badge means only one thing speed with 521  horsepower on tap the GT V8s is the most powerful   entry-level variant a machine that’s over a  decade old in 2003 the Continental GT emerged   as the Ultimate dual threat supercar exuding  high-end luxury and total performance it was  

A real bold move to decide to go for a luxury  Coupe for the brand to set up the start of the   brand and the reset the Bentley 2.0 phase of  the brand Bentley came into this segment there   was really nothing that competed against  Continental GT it sort of opened up a new  

Segment up there between 150 and 200 000 that  ruled for many many years single-handedly the   GT resuscitates the Grand Touring genre it was  about creating a really special group two plus   two seater which was combining performance  and incredible Driving Experience [Applause]

It was really coming together at Two Worlds the  blending of the luxury world performance world there’s a real breakthrough car for us almost  overnight the machine becomes an automotive icon   when it entered the market in 2003 it changed  the perception of the whole brand completely

Part supercar Super Saloon the machine quickly  increases sales fivefold the change was dramatic   from where it was producing just around 2  000 cars per annums to reducing just over   10 000 cars Continental was a play for volume by  Bentley this was a car that was more affordable  

And also an everyday livable car GT’s success  traces its roots back to a formula that’s nearly   a hundred years old that special combination  of the performance luxury and practicality   that’s what makes that bendy GT to an icon a  mantra where bigger is always better it’s an  

Ideology that Harkens back to w o Bentley the  man who founds the company in 1919 W.O Bentley   created relatively big cars he was of the opinion  that if the car is not fast enough I have to put  

A bigger engine in when the brand reboots in  2003 the team doesn’t start with the engine but rather the shape of the car itself  it started with a blank sheet of paper   Believe It or Not The Styling of the car  certainly dictated quite a small engine  

Bay so we had to come up with an engine  that would package in that tight engine   bay and produce the power and torque  that one would expect from a Bentley kitchen concerns lead the team to create a unique

The W12 is an interesting engine and it’s its  layout is not really shared by anything else the   W12 is two VR6 engines which are staggered when  you combine two of them is four rows of cylinder  

Space that’s the W12 but age has a way of catching  up with beauty no matter how powerful it is it’s not a particularly efficient design it  doesn’t fit into the mold in the way that   some smaller lines do because it doesn’t get  the greatest fuel economy the once emboldened  

Continental is now on borrowed time when we  entered the market with a Continental GT it   was unique today there are probably 10 or  20 competitors younger lighter and nimbler   Challengers have started to steal its Thunder for  years Rolls-Royce was the Brand’s main rival but  

Now a variety of marks have Bentley in their  crosshairs so there’s no time for us to sit   still the high-end Posh society that the original  machine targeted has changed consumers can be very   fickle after a while if something stops being  cool they’re going to move on to the next thing  

Rising fuel costs have also challenged the  very foundation of the brand they’re in a   very difficult position that they’ve been  very successful in this car and there’s   a lot of people who want this car the way it  is but they still also have to keep it modern  

In order to remain at the top of the GT category  Bentley has to do two contradictory things at the   same time increase power and slim its Flagship  down families have never been lightweight they’ve   never been small cars they weigh as much as  a lot of SUVs but they make up for that with  

A lot of power reworking the Bentley archetype  is no small feat for a brand like Bentley very   important to understand how to transfer this Rich  history into today now it’s up to Luke donkevolk   head of design to bring the classic Conti  shape into the Modern Age it’s an industrial  

Process relying on artistic communication  language which is the drawing [Music]   to get modern the team goes back in time they  start the new model’s revision by sketching   lines on paper it’s really important is whether  we call the the power line and the hounds those  

Two lines are the DNA of the brand and they are  really present in different orchestration the   Brand’s strong history is a blessing and a curse  if we don’t want to make a retro car but we want  

To Anchor it in the past in the traditions of the  company designers labor to push the edge this wow   effect you get when you see that car first time  is coming from The Styling tradition takes a   dramatic sidestep towards new tech inside the  Bentley visualization Suite a state-of-the-art  

Facility where a simple sketch on a napkin can  become a life-sized three-dimensional model exterior designer Gareth Thomas is tasked with  tweaking the car’s classic lines once we’ve   developed the the sketch we’ll work with the cad  modelers and that’s where the exciting bit begins  

Really his team sculpts the Next Generation  Bentley using Next Generation technology   you can see the cad one-to-one scale of the  Continental GT within this virtual photorealistic   environment Parts can be tested for both look and  functionality it’s really important that what we  

Are designing isn’t just fantasy the cad data  is is a really important crucial part of of the   design process it’s from this CAD data that the  actual parts are manufactured designers can test   each particular piece for size shape and surface  quality it’s like a video game for creativity

The new headlamps become one of the key  parts to move the machine into the modern   era the challenge is always how to do  this on a modern interpretation and to   to keep the design fresh the development of LED  technology is certainly allowing us to do that  

The LED lights and glass covers are  created with a click of the mouse beyond the face virtually refined  as well [Music] the reflections is   how you read the surfaces of the car itself  Reflections are key to all great supercars

Bentley’s sense of time is based on a classical  philosophy the shape is orchestrated by those   really sharp and precise lines there’s a  riddance like in morecaster where you have   one instrument after the other so you have the  violin stopping and then you have to you know  

The other instrument that is basically  starting picking up in in a room this is   orchestrated by volumes by concave and convex  surfaces which gives this richness of the form by utilizing the latest technology designers  have modified the classic look of a Bentley

Nearly a hundred years ago in the British town of  cricklewood in Northwest London Railway engineer   makes a fateful decision to build engine parts  out of aluminum instead of cast iron his name w   o Bentley a man notorious for building the biggest  engines around and the most efficient wo Bentley  

In 1919 wasn’t all about just big cubic capacity  he was all about technology and efficiency   wo’s early engines offer cutting-edge technology  his power plants feature overhead cams and twin   carburetors it was more about talk rather than big  displacement wo’s genius starts with engineering  

But it crosses the finish line thanks to promotion  he realizes it isn’t the power of His Pistons that   attracts buyers or whether or not they win on the  racetrack in the late 20s a group of Rich breads   called the Bentley boys would take their giant  imposing massive Bentleys to the 24-hour Lamar  

Race in France and race their cars and party and  it was a whole lifestyle thing and they would win five Le Mans victories later Bentley  Motors is world renowned for hand   for handling luxurious  high-performance machines that win in 2003 Bentley introduces the reborn  Continental with a new W12 power plant  

It wins critical Acclaim but time moves  fast even faster than a continental what was once deemed an  exceptional piece of engineering   now a liability the Continental had  always been built on the W12 but   obviously with fuel efficiency and  regulations we needed to downsize

Brian gosh the current director of Motorsport is  one of the key engineering members tasked with   finding a more environmentally friendly  solution we had to produce an engine   that was worthy of being called a Bentley  engine provided that that effortless talk

And his team turned their attention to the smaller  twin turbo V8 the 4-liter twin turbo V8 gives us a   similar feeling with a lot less capacity but first  the new V8 sucks down fuel at an alarming rate   so Engineers turn to a new technology  using cylinder deactivation dropping  

Onto porcelain has enabled us  to drop the fuel consumption disengaging the cylinders shuts down  half of the engine during moments of   low demand turning a V8 into a V4 it’s part  of modern reality that all car companies need   to consider smaller models smaller  engines more fuel efficient vehicles  

It’s got decent fuel economy for something  this big and this heavy and this powerful eight engine is far more fuel  efficient than its predecessor but that doesn’t help the Continental  save weight and the heavier a machine  

Is the harder it is to stop an equal match for  the Bentley’s engines are its brakes it’s got   huge huge carbon ceramic rotors they’re basically  as big as an economy car’s entire wheel the Conti   needs large brakes because the machine deals with  a tremendous amount of energy during heavy braking  

Automotive brake systems transform the car’s  movement or kinetic energy into heat everything good kilometers an hour a maximum stop for a 1  600 kilogram vehicle generates enough electricity   to keep a 100 watt light bulb lit for an hour  and a half the Continental GT weighs over 2250  

Kilograms from our top speed to standstill the  brakes have to deal with 10 megajoules of energy 10 megajoules is enough power to keep an average  family home going for six hours it’s massive   massive carbon ceramic brakes that you can just  dump a ton of speed into that and they’re unfazed  

By the fact that the car weighs 5 000 plus pounds  the largest disc brakes on the passenger car in   the world well that’s another unique Bentley  development which we’re particularly proud of 420 millimeters each carbon ceramic disc  brake uses eight piston calipers and is  

The size of a deep dish pizza [Music]  if you go fast you’ve got a stop fast While torque fuel performance has been a  bent in trait for nearly a hundred years if it wasn’t for the craftsmanship behind  the badge there’d be just another sports   car for a brand like Bentley with this  Rich history of nearly no 100 views it   is very important to understand what are our DNA

[Music] today that DNA is found here  inside the Bentley Factory in crew England   built for World War II the factory is  entrenched in the history of British   motoring and Engineering nothing would  prepare you for working in Bentley the   processes and the materials we deal with  are completely different to anywhere else

This is where the Brand’s coach building past  combines with modern Technologies to create the   new continental GTO Continental takes about 120  hours to build it feels very high particularly   from the car industry but the difference  here is at Bentley we make everything [Music]  

Unlike most car factories the crew there are  individual shops devoted specifically to Wood leather and the famed Bentley power plant it’s about the art of transforming those  materials and putting them together into a car keeping all those substances in check starts  inside a unique laboratory run by Helen davok  

She and her team use a variety of machines  to test each material to its absolute limit   our job quite simply is to make the best  products even better than they already are   materials which range from  man-made metals and glass compounds  

To the tactile parts of the interior wooden  leather are natural products and maybe many   people don’t realize the technology that goes into  them everything in the vehicle from the steering   wheel to the iPod drawer is built for maximum  durability on the outside it simply looks like  

A piece of wood potentially when you look at the  science of it it’s a multiple layer Construction [Music] thank you there’s only so much real-world  testing that can happen in a lab [Music] so the team consistently tests materials  in the world’s harshest environments  

To take whole bandlas and we leave  them in the desert for literally   years and all they do is sit in  the hottest environments and they   were expecting this wood a natural  product to last that kind of environment yeah high-tech science that begins  in a very old-school wood shop  

Where 167 Artisans craft some of the finest  pieces of wood in the world currently we’re   taking about the top 10 percent between 10 and  20 percent of the top veneers across the world the veneers are made from wood  that is sourced around the globe  

There are 14 types of wood and nine veneer options [Music] each layer must first be bolt cut to  size before it can be perfectly matched [Music]   the parts we use at Bentley  actually require mirror matching  

Will Edge and Joint joints one side of the veneer  to create a mirror image we’ll flip the pieces   over create a nice mirror image into the center  of the part when it’s digressed onto the part next the wood is coated with a strong  adhesive before being pressed onto the parts

It takes seven hours to make one piece and there  can be up to 33 wooden pieces in each Continental   extreme heat and extreme pressure for about  five to ten minutes and she allows the veneer   to permanently bond to the substrate this is  a sanded lightly to remove any impurities then  

They’re ready for lacquering what it actually  gets is five layers of polyester lacquer   as you take the surface similar to the  sanding stages we use grades of paper gives it this very kind of dull matted finish   after the lacquer is applied  the pieces are polished

We’ll take it onto our high-powered speed  polishing mops shine up using a series   of wax movement techniques to actually  gets any little scratches or ripples up   the final piece is more mirror than wood  however the treatment isn’t only for appearances   coat creates a microscopic protective barrier  against heat and corrosion while some pieces  

Are pushed to their limits outside others are  heated to their core right inside the laboratory   so what we’ve got here is a thermal cycling  chamber this machine goes perhaps twice as   hot as the hottest day you would get in the  desert to as cold as the coldest parts of Russia

Leather elements are verified for wear resistance   what we’re interested in obviously  with this machine is wear resistance we’d expect more than 20 000 in an ounce of a car   would be something nowadays say  that this would ensure [Music] metals are tested to remain durable  and aesthetically pleasing this is  

A salt spray cabinet which we use to  accelerate corrosion environments each   wheel is drenched in a copper accelerated salt  spray with an acidic pH of 3.2 for several hours   that’s 80 of the acidity in a single can of soda what’s really important for us is

This extremely harsh environment that we  expect all of our Wheels to perform to if they don’t meet that requirements  they won’t be used ornamently   thank you once materials have been tested and  approved it’s time to put them into production   inside a factory that not only  creates cutting-edge machines

Eight years before Bentleys were manufactured  in crew these brick walls were constructed to   Harbor the Ferocious Thunder of 27 liter  fighter plane engines previous booked in   1938 as a factory to build a 12 cylinder Merlin  engines to power the Spitfire and Lancaster planes  

Fire was one of the fastest and most Victorious  British airplanes in World War II it’s a Heritage   valued by the craftsmen who today build more  W12 engines than any Factory in the world   since 1946 the brand has built  over 66 000 12 cylinder engines

Kept the building the same and just  renewed the technology that’s inside them Merlin 12-cylinder aircraft engines produced  over a thousand horsepower not a far cry from   today’s Bentley 12-cylinder engine which  musters up an air-worthy 616 horsepower   we build more 12 cylinder engines than  all other manufacturers put together  

The engine block begins its Journey to the  line on a tall slightly more sophisticated   than the ones used in the 1930s so the first  job we do is we take the engine out of tillage lift it across onto one of these machines here  

The machine is an agv or automated guided  vehicle and it allows engine builders to   move the massive blocks with ease we then  separate the bed plate from the main crankcase how it fit the crankshaft this is the first  stage which we give an engine its main identity   step is done by hand

For the next part of building  a Bentley engine we rotate the   engine around and we apply oil this is  the first time oil touches the engine now the engine’s ready for its Pistons   we then automatically build up the Pistons  so each engine has 12 Pistons 12 con rods

And also 24 different bearings so all those  are built automatically as you can see in   the machine there the machine connects the  Piston head to the conrod far more precisely   than a human when they finish the process  this will have a complete set of Pistons  

One of the main difference as you can see if you  look on the top of one of the Pistons it’s not   flat what it means is that we can get the best  compression ratio on the engine itself [Music] the higher the compression ratio  the better the fuel economy

Once the Pistons are done being fit by hand the  engine goes through an automated sealant process let me do that for a variety of  reasons one’s volume and also   for Quality it also gives us a very  consistent product every single time foreign

So what we have all the  camshafts on the top of the heads   and we have these devices on the  end that allow us to change the   characteristics and the amount of torque  that the engine producing at any one time Laughs timing is important for  the engines and the line itself there are 21 stations installing nearly  700 parts inside of each W12 power plant depending on demand nearly 250 engines  can come off the line in a single week   every 16 minutes we have a brand new  engine coming to the start of the  

Line and a completely finished engine  comes off the end of the line as well that engine is the most powerful  W12 in the automotive world   but before the engine is completed it must be engraved this stage here this robot will give  the engine its unique engine number so  

That will go with a vehicle identification  number and make up the history for the car most challenging in the station on the line  is this process here so this is fitting   the loom the Looms are always particularly  difficult to fit it requires the operators  

To know exactly where each and every single  connector is going to go to on the engine the   loom looks like one piece but it’s actually  comprised of dozens of wires that allow the   high-tech engine to communicate with  the cutting-edge electronic system  

Installing it is a time-tested process created  by workers who are sometimes Generations in the   making we’ve been Building engines here now  for 75 years so it’s really not that uncommon   to see fathers sons and multi-generations  coming through and learning how to build them

Every single engine we produce we bring it into  one of these test cells and then we run it for   21 minutes to check the power check there’s no  leaks make sure the engine is perfect every time   hot testing an engine like this is the  equivalent of a 16 kilometer Drive [Applause]

Which we build is a Supercar engine high  performance is only part of the Supercar   equation [Music] what you’ll see here  at our facility is craftsmanship on a   mass scale and we’ve got a staggering  choice of options and colors [Music]   there are 13 standard leather  options to choose from and each one  

Is matched by a nearly endless number  of exterior colors in the Bentley paint   shop we’ve got a massive color palette we can  offer a range of around 150 colors here [Music]   each Bentley will be decorated  with nearly 45 kilos of paint [Music]  

When the body is finished being  colored clear coated and then baked   only then can Craftsmen begin to  apply the classic Conti shine [Music] the lunar finish is what sentimentary  apart from the rest of the manufacturers Craftsmen use a variety of different levels of  sandpaper to remove microns of paint [Music] the Finish

Great finishes are only half  of the Bentley story [Music] to stay competitive Bentley must put greater  emphasis on sub-assembly than anyone else in the   business and the rest of the industry about 90 of  the people work on the body of the car work on the  

Car itself here at Bentley we’ve got a complete  shift 80 of our people work on the parts that go   into the car rather than working on the car itself  [Music] it takes over 700 outside contractors   producing 18 000 parts from 32 countries on  six continents to supply the Bentley Factory

It’s very challenging because actually  your your own supplier if things aren’t   right we’ve got to put it right and this  is the area we’d start an area like this   thankfully the quality levels coming out of  these areas is just what we expect for a Bentley [Music]   and the steering wheel

This is Noel Thompson knows one  of our Master Craftsmen one of   the special tools that Knoll uses  is actually a fork and it’s a fork   that gives us this very unique pitch  between stitches on a steering wheel each handcrafted wheel can take up  to four and a half hours to finish

Thank you and to contrast Stitch the  entire cabin can take over five hours part of that cabin includes handcrafted seats   at the moment we’re in the seats Technologies for  leather construction is a four-step process cut so build [Music] and cover [Music]  

Oh you’ll see that they inspector  hide this will be selection to the   different rays of hide that we will be  using for different areas of the scene   selecting the correct pieces for just a  single set of seats can take almost two hours

Six inspection tables on average per  week would go through four thousand hides it takes five hours to complete  a full set of seats for each GT every phase is meticulously done by hand [Music]   except for one very special station where a robot  sows 5 000 stitches to craft a single Beam for  

The headrest if I was going to stitch that by  hand I would say that would take you a good week it’s essentially what the Bentley Heritage is  built on very traditional materials assembled   in a very traditional way it’s more akin to  Furniture Megan than it is to make in cars  

Much easier to use the fake stuff it’s a  real challenge particularly when it’s a   lot more competitive than it was say 30 years ago while the interior sub-assemblies are finished a  brand new engine is being prepped for installation the question is whether or  not it’s too late for the mark

Foreign [Music] GT has been in production for over  a decade in the Supercar realm that is an eternity   especially in a changing world where fossil  fuels are on the Run Bentley’s solution offer   customers two engine choices their famed  W12 and a new V8 that’s more fuel efficient [Music]  

Both engines and production on  the very same powertrain line   we’re in the engine preparation area  we’ve made these engines that you can   see behind us we’ve got the vat engine  and the big powerful 6-liter W12 engine Technicians fit exhaust pipes shocks [Music] foreign [Music] [Applause] [Applause] once prepared the powertrain  is ready to be bolted to the body this   is where we wed the powertrain  with a car and this is really   where everything starts to happen in  a car plant because this is critical just 25 volts secure the V8 into the  engine bay when you’re dealing with a  

High power performance car like a continental this   is critical every one of those screws  has got to be to the right tightness monitors record the torque and angle of  each screw to ensure quality we won’t   allow any car to pass forward with a screw  that isn’t tightened to the correct hold

The engine marriage is one of  the key stations inside the 150   000 square meter final assembly area [Music] the  build Hall at any car plan is really the heartbeat   this is where it started build process so this is  his journey from being a body shell to a full car

It takes 104 hours to build just one Continental  GT the production line essentially is very similar   to other car plants the difficulty we’ve got at  Bentley is we mix three different models together assembling multiple models on one line  exponentially increases the need for  

Efficiency and organization you can imagine  the material that goes into a two-door coupe   is very different to a convertible  which is different again to afford or [Music]   install the radiator [Music]   headlights body panels bumpers and wheels [Music] [Music]   then all the natural materials that have been  painstakingly sourced and tested converged [Music]  

Thank you one of the last stops is the  handcrafted steering wheel we’re on checkpoint a checkpoint  Aid is important in this assembly   process this is the last process  before a car leaves the factory foreign the latest incarnation of Bentley’s  signature Continental is complete [Music]  

But does shaving weight and adding fuel economy  make for a better Bentley [Applause] [Music]   the r-type Continental many regard it as  one of the most elegant cars ever made   the r-type propels the brand to the  Forefront of the Luxury Auto Realm  

More than half a century later Bentley  finds itself at a similar Crossroads Foreign [Music] foreign Car industry has moved on Leaps and Bounds so  what we don’t do is sit back on our laurels   Bentley solution is the brand new Continental  GT V8s a lighter smarter and hopefully quicker   machine for the modern world V8s still have  their own Mythos people still associate them  

With big Power and fast cars but they’re not  quite as prestigious as a 12-cylinder engine enduring wo of day being  answered in a very different way the V8 is a little less special in some people’s   eyes but when you look at  the power this thing makes and what is capable of

You’re not missing out on anything V8s Roars  to the tune of 521 horsepower and the Machine   offers 502 foot-pounds of torque figures  which provide the classic Bentley ground the new twin turbo V8 takes the GT from zero  to 100 kilometers in just over 4.5 seconds

The funny thing about Bentley’s  is you get in them and you say   okay it’s 4.6 seconds to 60 that’s  quick and then you realize it’s like   sitting in your living room and having  your living room go from 0 to 60 to 4.6

Continue to keep the pedal down and you’ll  reach 160 kilometers an hour in just 9.2 seconds   they just keep going and going and going it’s  not the 0-60 it’s the 60 to 120 and the 120 to  

180 they just never stop The Machine’s top speed  Taps out just a shade under 309 kilometers per   hour so you have a little V8 with turbos on it  pushing something the size of a small house at  

200 miles an hour or near there at 100 kilometers  an hour a massive 420 millimeter brakes bring the   GT to a complete stop in 32 meters you can make a  5 000 pound car do anything you want it to do as  

Long as you upsize all the components tires  suspension and of course brakes Something’s   Gotta scrub all that speed off the beauty of the  Bentley brakes is that they just kind of feel   normal there’s nothing really special about  the way they feel except that they stop a 5  

000 pound car the way most brakes can stop  at 3 000 pound car from inside the V8s is   all classic Bentley from top to bottom there’s  a reason why Bentleys are very expensive and   part of that comes from the craftsmanship  that goes into building those Interiors

At 157 000 Euros the GT V8s  isn’t for the conservative crowd   however the price tag is justified by  its rare combination of speed and luxury [Music]   it may not be the Bentley way  to do something smaller [Music]   change in size is something W.O  Bentley would have agreed with  

If you create good car a fast car and at least  in terms of the GT I think the best in its class   you stick to these basic statements of wo  Bentley and do it in the more modern way now  

Like wo’s first engine the new GT is a  clever step towards a smarter future one   of the world’s most renowned British icons  as long as the downsizing happens in a way   that’s not offensive to Bentley’s brand hey  bring it on especially if the cars are faster