Ep 6. Audi S8

How It's Made: Dream Cars season 4 episode 6 takes viewers on an exhilarating journey behind the scenes of the Audi S8 manufacturing process. The episode provides an in-depth look at how the car is designed, assembled and tested to make it one of the most high-performance luxury cars in the market today.

The episode begins with an exploration of the design process of the S8, which begins with the creation of the car's 3D model. The team responsible for the design must pay close attention to the car's aerodynamics, as well as the placement of its various components, including the engine and the transmission. Once the design has been completed, the team moves onto the manufacturing process.

The Audi S8 is assembled at the company's Neckarsulm plant in Germany. The factory is populated with highly skilled workers who have spent years honing their craft. The factory is also equipped with the latest manufacturing technology, including robotic arms and computer-controlled machinery. These tools help ensure that every S8 vehicle built is manufactured to the same high standards of quality and precision.

The assembly line for the Audi S8 consists of several distinct stages. The first stage is the body assembly. Here, the car's steel frame is welded together, and various body panels are added, including the doors, bonnet, and boot lid. Meanwhile, the car's engine and transmission are being assembled in another part of the factory.

Once the body assembly is complete, the car is moved to the painting station. Here, the car is painted with several layers of primer and paint, and then coated with a clear coat to protect the finish. The paint station is a highly controlled environment, with strict procedures in place to ensure that the paint finish is of the highest quality.

After the painting stage, the car moves onto the assembly stage. At this point, the car's engine and transmission are installed. The car's wiring and electrics are also fitted, and the car's suspension and braking systems are installed. The interior fitting is also an important aspect, as the team has to ensure that the leather seats and various other components are fitted perfectly.

The final stage of the manufacturing process is the testing stage. Here, the car is put through its paces on a testing track. The car's engineers carry out a series of tests to ensure that the car is performing to the desired standards, including tests of the car's acceleration, top speed, handling, and braking. They also carry out a noise and vibration test to ensure that the car is comfortable to drive.

Once the car has been tested and approved, it is ready for delivery to the customer. Each S8 is tested again by the customer before being officially handed over to them.

The Audi S8 is a complex and highly sophisticated car that requires a lot of skill, precision, and attention to detail to manufacture. This episode of How It's Made: Dream Cars season 4 episode 6 showcases the many processes and techniques that go into making this exceptional vehicle. Viewers will be rewarded with a unique insight into the world of car manufacturing and the incredible technology and innovation that makes vehicles like the S8 possible.