Bentley Mulsanne: Testing and sign-off

Bentley continues publishing press releases about the Mulsanne and this time, it's about the testing and sign-off procedures.

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The Mulsanne build story concludes with a range of exhaustive real world tests and checks that underline Bentley�s total commitment to the quality of its new flagship.

Whilst quality checks are fundamental to every stage of the Mulsanne�s build, it is at the penultimate sign-off stage �Checkpoint 7� that the complete car is given the most rigorous examination possible. Every Mulsanne must pass through 503 individual checks conducted by Donna Morrey and her inspectors from the Quality team.

The inspection lasts a full two hours and features all of the functional measures you�d expect of a modern automotive plant but with key two critical differences; Bentley reviews every single Mulsanne, without exception, and the inspection team sets the most exacting standards of quality which are commensurate with a flagship model at the pinnacle of the ultra-luxury segment.

�New colleagues are sometimes surprised by the lengths we go to and have been honest enough to admit that what we consider an issue would not register at another facility.� Donna Morrey explains.

Whilst checking that every function works (first time, every time and on every car) Donna�s team is also tasked with looking beyond the merely operational. In her own words the team will also act as the �hands and eyes of the customer� and a skilled inspector has a natural empathy for the car and how it should look and feel. Morrey adds:

�This element is not an exact science. However, it is a crucial skill that we value greatly and it is particularly relevant for a car like the Mulsanne which features so much craftsmanship and character. For example, we will run a hand across a particular surface in the cabin to ensure it feels right and that it delivers the tactile experience the craftsman wanted to create.�

After testing on the shake rig and rolling road, every Mulsanne completes a rigorous on-road evaluation. Jason Davies and his colleagues have an in-depth knowledge of the roads surrounding Bentley�s headquarters and the 21-mile route has been chosen to assess the Mulsanne�s engine performance, ride quality and cabin refinement. Morrey comments:

�Jason and his team have one of the most enviable jobs at the factory but their work involves something far more important than completing some basic checks and enjoying a drive. Each Mulsanne is driven on a wide range of carefully selected roads offering variations in camber and surface quality. Road types range from narrow English country lanes to fast dual carriageways, allowing the car to be comprehensively evaluated.�

Once the car returns to the Pyms Lane factory it enters a special test facility that simulates monsoon-like weather conditions to ensure that it is completely watertight before heading for the very final sign-off stage � �Checkpoint 8�. Here, the car progresses through a long line of ultra-bright overhead and side lights (nicknamed the �shipping lane�) which enables the Quality team to inspect every surface in the most minute detail.

During the critical pre-production stage senior Bentley managers from right across the business join the vehicle review at �Checkpoint 8� to examine the culmination of their efforts, despite having previously completed hundreds of their own checks.

�The way all the teams come together to view the pre-production models demonstrates just how much genuine pride goes into the building of these very first cars,� Morrey notes.

Source: Bentley Motors

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Bentley Mulsanne: Unrivaled craftsmanship

Here is another press release by Bentley about the craftsmanship of its new flagship, the new Mulsanne.

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When Bentley�s craftsmen and women begin this summer to create the very first production examples of the new Mulsanne�s beautiful cabin, it will represent the culmination of an extraordinary four-year journey for the Crewe-based company. While Bentley is long renowned for its handcrafted interiors, it was decided at the earliest stages of concept planning that even higher standards of quality and luxury would be required for the new Mulsanne, the company�s new flagship Grand Tourer.

Bentley�s Design team, led by Dirk van Braeckel, commissioned an exhaustive research study to identify the classic signature features that have defined Bentleys from the 1920s to the present day, as Dirk explains:

�Hundreds of cars were the subject of a painstaking review to define highly challenging targets for every facet of the new Mulsanne�s interior. This embraced key elements, such as materials, colour harmony and craftsmanship, ensuring the new Mulsanne will become the purest expression of Bentley design yet.�

Similarly stringent targets were set for the operational refinement and robustness of all control mechanisms to provide Crewe�s craftsmen and women with materials and components of the highest quality and authenticity.
Responding to customer demand, the research study even extended to the smell of the leather hides. This resulted in the reintroduction of a complex, traditional tanning process to create a rich, mature leather aroma, evoking that of vintage Bentleys.

When production begins later this year, Mulsanne customers may select from a broad palette of hides, including a range of 24 �standard� colours as well as a wide selection of rich �heritage� colours from previous Bentley models. These colours may be specified in single-tone or duo-tone combinations in four different styles (colour splits) allowing the customer to choose not just the colour scheme but also the mood of the interior � from very elegant to sporty.

These exquisite hides are fashioned by a team of craftsmen and women who apply the same fastidious attention to every detail of the opulent cabin. All stowage compartments, including iPod drawer, glovebox and luggage compartment are leather-lined, while the creation of the hand-sewn leather rim around the Mulsanne�s steering wheel takes two days of intense, expert concentration � even longer if the customer opts for cross-stitching.

Bentley�s unrivalled expertise in the crafting of leather is complemented by the extraordinary skills of the company�s �Wood Shop�, the largest of its kind in the luxury car industry.

It takes five weeks to turn a rough �root ball� (individually selected by Bentley experts) into a full set of mirror-matched, fine-polished leaves. Each piece of veneer is carefully stored in a special humidity-controlled chamber and then applied onto a solid walnut base, a process that alone takes two weeks to complete. Veneers are then polished to a perfect mirror finish. The quality of every piece is carefully inspected and approved before being delivered to the vehicle assembly hall.

The entire Mulsanne cabin is encased by a �ring of wood� waistrail, as part of which a single, �unbroken� panel of wood graces the Mulsanne�s dashboard. Customers may select from an extensive range of premium quality veneers, unbleached for a natural appearance, including Walnut, Piano Black, Oak, Bird�s Eye Maple, Vavona, Olive Ash and Sapelli Pommele, harvested from sustainable sources across the globe.

Utilising the intricate skills of the Crewe-based experts, two marquetry options are available for the new Mulsanne: picture framing-style inlays to waistrails and contemporary-style crossbanding and inlay to dashboard and waistrails.

One of the most striking examples of Bentley craft skills can be found on the Mulsanne�s upper dashboard where a new 8-inch multimedia screen is housed unobtrusively behind an electrically operated veneered door. When the screen is not required the door blends effortlessly into the veneered dashboard.

The exquisite hides and veneers of Bentley�s new flagship are fashioned by the company�s highly skilled craftsmen and women with over 40 years� experience who will invest over 170 hours into creating the interior of just one Mulsanne, as Robin Page, Head of Interior Design, comments:

�Crafting the Mulsanne�s interior represents a substantial part of the build process. At Crewe, Bentley�s way of working is the exact opposite of mass production � we start where others stop.�

The �starting where others stop� philosophy has been applied to virtually every feature of the Mulsanne�s cabin. The use of wood and leather hides has been significantly increased for an even more refined and sumptuous cabin, while the stainless steel brightware receives an intensive 10-hour finishing process to offer a near-perfect gleam (ensuring that even the smallest part will catch the eye). The carpet has been given increased fibre depth and density to further enhance the quality feel.

An ultra-rigorous approach to quality, applied from the earliest planning stages, means that the Mulsanne�s interior will be enjoyed by current as well as future generations of drivers. Every new leather and wood veneer option was subjected to extreme temperatures as well as an exhaustive array of further durability tests. Sun creams, skin lotions and even a chemical formula for human perspiration were applied to leather hide samples to ensure no staining or fading.

And perhaps most remarkably, the durability of a hide will be is tested over 20,000 times by a team of people of varying height and weight (rather than the robots used by other manufacturers) to provide the most authentic, real-world assessment possible.

�Much of our work takes place behind the scenes,� explains John Minshull, Head of the Bentley Laboratory at Crewe.

�However, this development and scientific testing work is a key part of the Mulsanne story as it provides our craftsmen and women with the best quality materials. And it is the combination of their creativity and our research which makes the Mulsanne interior so special.�

Source: Bentley Motors
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Related posts: Car production: Labour hours required & some fine examples of craftsmanship!

READ MORE - Bentley Mulsanne: Unrivaled craftsmanship

Bentley Mulsanne: The mighty new V8

Bentley continues to publish press releases about special aspects of its new flagship, the new Mulsanne, and this time it's all about the V8 engine.

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Right at the heart of Crewe�s new flagship Mulsanne is the company�s famous V8 engine which is renowned for delivering the Bentley �wave of torque�. The V8 engine, the same configuration of which has powered some of the company�s most iconic cars including the Arnage, Azure, Brooklands, the original Mulsanne, Turbo R and S2 Continental, has been completely re-engineered for the new Mulsanne.

The V8 configuration will strike a chord with aficionados, the 6� litre displacement having been the favoured option for many years. For the Mulsanne, however, the very latest technologies have been employed including two new control systems: cam phasing and variable displacement delivering even greater refinement as well as a 15 per cent improvement in emissions and fuel consumption.

The pioneering application of these new technologies in combination allows the Mulsanne�s engine management system to adjust the V8�s breathing for improved engine idle quality and torque delivery. However, by closing the valves of four of the eight cylinders, fuel economy is maximised when cruising.

All the major building blocks of the Mulsanne�s engine are new including the lightweight componentry such as pistons, connecting rods and forged crankshaft which reduce reciprocating mass and internal friction for improved engine response. These significant changes are complemented by the introduction of a new eight-speed automatic transmission offering virtually imperceptible gearshifts.

In total over 300 new or significantly re-engineered components have been created for the Mulsanne engine and the famed Bentley �wave of torque� (1020Nm/752lb ft) is now delivered in full even earlier, at 1750rpm. This improvement in torque delivery from just above idle � as well as across the rev range � ensures that a mere tap of the throttle pedal will deliver phenomenal acceleration with 0-60mph achievable in just 5.1 seconds (0-100km/h in 5.3 seconds).

For Phil Cooper, Bentley�s senior production manager in the engine build workshop, the new V8 engine has provided an opportunity to introduce a range of new technologies whilst retaining the hand-built skills at which his team has long excelled.  Phil explains:

�Our new V8 takes nearly 30 hours to build and we never release an engine to our colleagues in the main build hall until we are literally prepared to put our name to it.�

In the immaculately tidy V8 engine build area, where every set of craftsman�s tools are stored and labelled with the exact precision of a surgeon�s implements, the team use a combination of the high-tech and applied-by-hand skills to achieve the best results.

A state-of-the-art balancing machine ensures all the spinning components are rigorously tested (and if necessary rebalanced using tiny washers) and the level of accuracy achieved by this process ensures that when the engine is at idle there is not a hint of vibration. Alongside the use of the balancing machine, Bentley�s engine builders still fit each of the pistons into the V8 block by hand as well as the 16 individual ball-bearings which are inserted into the valve train.

Once assembled, every Mulsanne V8 is tested over an 80-minute cycle by the team. The �hot testing� process tests the engine from idle through to maximum revs and the load on the engine is varied to simulate real-world driving conditions.

�Every element of the engine�s performance is analysed and recorded before it is sent through to the build hall,�
Cooper explains.

Whilst the V8 engineering and engine-build teams have introduced a host of new technologies and are working with hundreds of new parts, one classic touch remains unchanged � a signed engine maker�s plate is still attached to every Crewe-built V8 to provide a reassuring symbol of quality, performance and reliability.

Source: Bentley Motors
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READ MORE - Bentley Mulsanne: The mighty new V8

Bentley Mulsanne Vs Rolls-Royce Ghost

A nice video explaining all the important facts about the new Bentley Mulsanne and Rolls-Royce Ghost.

READ MORE - Bentley Mulsanne Vs Rolls-Royce Ghost

Bentley Mulsanne visualiser now available

Following all the posts and interesting press releases regarding the new Bentley Mulsanne, a visualiser is at last available showing some of the colour options. So, if configuring cars is your cup of tea, then check it out!

READ MORE - Bentley Mulsanne visualiser now available

Bentley Mulsanne: The art of colour

If you appreciate a Bentley and the craftsmanship involved, then this an interesting press release regarding the new Mulsanne (earlier post).

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Exacting standards of craftsmanship and technology are employed by Bentley�s body assembly team to create the new Mulsanne�s distinctive, hand-crafted �hewn form solid� appearance. But this is just a precursor to the painstaking attention to detail afforded to Bentley�s new 4-door flagship in the paint facility at the company�s headquarters in Crewe, England.

The new Mulsanne will be offered in no fewer than 115 �standard colours� and that is just the start of the story � because, like every grand Bentley � the only real limit on the colour of the car is the customer�s imagination.

Once the bare metal, pre-production Mulsanne bodyshell arrives at the paint shop via the automated overhead gantry, it passes through a series of full-immersion tanks, designed first to de-grease, then in turn to clean, condition, rinse, phosphate and passivate the steel and aluminium structure.

At each tank the shell is immersed before being tipped fore and aft to ensure that every single crevice is reached. Once drained, the bodyshell is lowered into an electro-coating tank, where power is increased to 320 volts, attracting particles-in-solution to deposit on the charged, metal bodywork to form, in conjunction with the phosphate, a hard protective shell of corrosion-proof zinc primer.

From this point, the judgement and skill of Bentley�s craftsmen come to the fore. A two-coat primer is applied by hand, ready for colour-of-choice to be applied. Each primed body is minutely inspected, sanded � or flatted � using a combination of hand and power tools. Only when the primer coat is flawless will the colour basecoat be applied, again by hand, to achieve the optimum finish. Clear lacquer coats are then applied robotically followed by final polishing for a perfectionist finish and detailed inspection in the specialist bays created for the Mulsanne.

But if the lacquer can be applied by robotics, why not the colour? Dave Walton of the Mulsanne bespoke paint shop explains:

�Different colours have markedly different characteristics and your perception of a colour�s shade changes according to how deep the coat is. Then there�s the fact that no two expert sprayers would apply that colour basecoat in exactly the same way. You learn to trust each craftsman�s eyes and skills, not just the process.

It takes many months of in-depth training for a quality control inspector to learn how to identify defects that an owner might never notice, yet each one will be rectified, even if this means sending it around the entire process again. We always operate way above customer expectations of quality,�  

With the introduction of new satin paint finishes and two-tone colour schemes to Bentley�s extensive portfolio, Walton says the skills of the team are always evolving. Satin in particular can�t be locally reworked and polished, so even the most miniscule imperfection means the entire panel is refinished.

However, Bentley�s craftsmen are eagerly awaiting the moment the Mulsanne goes into full production according to Walton:

�We�ve been asked to match a paint finish to a cherished nail polish, a 50-year old classic Bentley and on one occasion a shade of turquoise on a food mixer for our Arnage, Brooklands and Azure customers. But even with over a hundred �standard colours� to choose from we�re still looking forward to that first commission to create a bespoke colour from scratch and execute it perfectly.�

Source: Press Office of Bentley Motors

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READ MORE - Bentley Mulsanne: The art of colour

Bentley announces detailed spec of new Mulsanne

Bentley has published the technical spec of the new Mulsanne and just to get an idea of what we are talking about, in the new Mulsanne, the 6�-litre V8 develops 512 PS (505 bhp/377 kW) while the massive torque (1020 Nm / 752 lb ft) is delivered at 1750 rev/min!

Below you can read all the details about this impressive car.

Bentley Mulsanne � Technical Specification Summary

Engine

Type: Twin-turbocharged V8
Installation: Front, longitudinal, rear-wheel drive
Construction: Alloy heads and block
Capacity: 6750cc
Power: 512PS / 505bhp / 377kW at 4200 rev/min
Torque: 1020Nm / 752 lb ft at 1750 rev/min

Performance & Economy

0-60 mph in 5.1 secs (0-100 km/h in 5.3s)
0-100 mph in 11.6 secs (0-160 km/h in 11.5s)
Max Speed: 184 mph (296 km/h)
Economy: 16.7 mpg (16.9 l/100km) Combined EU Cycle (figures are provisional and subject to Type Approval)
US EPA Cycle (fuel consumption figures will be advised following Certification)
CO₂ emission: 393 g/km (figure is provisional and subject to Type Approval)

Transmission

Type: Rear-wheel-drive
Gearbox: ZF 8-Speed automatic

Body & Chassis

Length: 5575mm (219.49in)
Width (mirrors folded): 1926mm (75.80in)
Height: 1521mm (59.88in)
Wheelbase: 3266mm (128.60in)
Front Track: 1615mm (63.58in)
Rear Track: 1652mm (65.03in)
Wheels / tyres (standard): 9J x 20in. with 265/45 ZR 20 tyres
(option):   9J x 21in. with 265/40 ZR 21 tyres
Kerb weight: 2585 kg (5700 lb)

Bentley Mulsanne - Standard Feature Specification   Drivetrain

• 6.75 litre twin-turbocharged V8
  
  
  • 512PS / 505bhp / 377kW at 4200 rev/min
  • 1020 Nm/752lbs ft  at 1750 rev/min
  • Cam phasing and variable displacement � a first for the ultra-luxury sector
  • EU5 and LEVII emissions compliant
• 8-speed automatic transmission with electronic shift interface, sport mode and steering-wheel mounted paddleshift
• Rear-wheel drive

  Chassis

• Mulsanne 20" light-alloy wheels with 265 x 45 x ZR20 tyres
• Double wishbone front suspension
• Multilink rear suspension with toe and brake reaction control.  Uniquely developed for Mulsanne to handle extreme torque
• Electronically-controlled air springs with Continuous Damping Control (CDC) to continuously monitor and adjust the vehicle�s damping, ensuring optimum control
  
  
  • Automatic ride height control sensitive to speed and load
• Servotronic speed-sensitive power steering with two settings selectable by Drive Dynamics Control
• Drive Dynamics Control - four driver-selectable settings for CDC and power steerin
  
  
  • Three standard modes: Bentley, Sport and Comfort
  • A fourth mode, Custom allows driver to �tune� system to a preferred driving style
• Electronic Stability Control (ESC) with ABS, traction control, hydraulic brake assist, electronic brake prefill and automatic hill-hold control
• Twin-booster braking system with ventilated discs and Electronic Brake force Distribution (EBD)
  
  
  • "Bentley" branded front brake calipers
  • Front brake discs: Two-piece assembly with 400mm diameter x 38mm thick iron disc and lightweight aluminium hub
  • Rear brake discs: 370mm diameter x 30mm thick iron disc with lightweight aluminium hub
  • Electronic Parking Brake with drive-away assist and hill hold feature.
• Choice of tyre repair/inflation kit or spacesaver spare wheel & toolkit

  Body & Exterior

• Steel monocoque body structure with front and rear energy-absorbing crumple zones
• Aluminium closures
  
  
  • Superformed aluminium front wings
  • Aluminium bonnet
  • Aluminium doors with superformed structure and extruded aluminium side impact beams
• Composite polymer bootlid housing fully concealed antennae systems
• Painted radiator shell with bright stainless steel matrix grille and 2-D Bentley winged "B" badge
• Paintwork applied and polished by hand to a mirror-finish
  
  
  • Choice of 28 paint colours especially selected for Mulsanne. 
• Black matrix grille to lower bumper apertures
• Front wing vents with black matrix grille
• Polished stainless steel brightware to glass surrounds
• Polished stainless steel embellishers to doors and bumpers
• Door pillar finishers in steel with gloss black painted finish
• Polished stainless steel "Mulsanne" treadplates and commissioning plates
• Wide oval polished stainless steel exhaust tailpipes
• Twin bi-xenon projector headlamps with LED halo for supplementary main beam, light-sensing auto operation, daytime running light signature and integrated washer jets
• Floating-ellipse style, LED rear light clusters and discreet high-level stop lamp to rear screen
• Colour-keyed, electronically adjustable door mirrors with heating, power folding, reverse-dip, two memory positions, electrochromatic dimming and integrated puddle lamps
• Keyless entry system with chromed metal door handles and engine start button
• Soft close power latching to all doors for easy entry / exit
• Power boot lid operation with emergency releases inside boot and under rear seat
• Park distance control to front and rear with audible signal and graphics displayed via infotainment screen

  Interior

• Hand-selected leather to all trimmed surfaces including seating, fascia, console, door panels, door pillars, parcel shelf, cantrails, headlining, sunvisors, all stowage compartments and glovebox
  
  
  • 24 �standard� colours in single tone or duo-tone combinations in four different styles (colour splits) allowing the customer to choose not just the colour scheme but the mood of the interior � from very elegant to sporty
• Specially developed, flat-cut and leather-bound carpet.  Choice of 21 colours to match interior hide
  
  
  • Set of four carpet overmats to match cabin carpet, leather bound and with polished stainless steel fixings 
• Choice of 23 seatbelt colours with buckles colour-matched to interior hides
• Veneer to fascia, continuous "Ring of wood" waistrails, centre console, rear centre armrest, and front & rear roof consoles in burr walnut, dark-stained burr walnut or piano black.  Six further veneer species are available
• Bright finish interior fittings in polished stainless steel
• Unique, glass-effect switchgear
• Driver's instrument panel featuring inverted, aviation-style dials for vehicle and engine speed; Supplementary colour screen displaying a driver-configurable choice of navigation prompts, compass, infotainment, vehicle or trip information  
• Minor gauges panel in centre fascia with fuel gauge, analogue clock with "Bentley Motors" inscription and coolant temperature gauge
• Concealed passenger-side map lamp
• Boot trimmed in leather and carpeted to match interior cabin with polished stainless steel sill plate

  Comfort & Convenience

• Front seats with 12-way electrical adjustment, including lumbar support, two memory positions, easy entry/exit function and adjustable heating
  
  
  • Front passenger seat - full adjustment from rear cabin.  Controls housed in rear centre armrest
  • Two-plus-one rear seat configuration with 8-way electrical adjustment to outboard seats, including lumbar support, two memory positions and adjustable heating
• Four-zone air conditioning including additional rear cabin A/C unit with front and rear controls for fan speed and temperature
• Traditional, polished stainless steel bullseye air vents & organ stop controls
• Four-spoke, hide trimmed, multi-function steering wheel with electric adjustment for tilt and reach with two memory positions, easy-entry function and paddle shift
• Twin front centre armrests with hide-lined storage and cordless telephone handset.  (Telephone handset not available in North America and Japan)
• Electrical height adjustment for front seatbelts with two memory positions
• Cruise control
• Electrochromatic auto dimming interior rear view mirror with on/off button
• Remote-controlled three-button garage door opener integrated in roof console (Standard in North America, cost option in rest of world)
• Rain sensing windscreen wipers
• Sentinel headlamp functions
• Folding rear centre armrest console with controls for seating and air conditioning and leather-lined stowage compartment with 12V socket 
• Remote control with dedicated stowage in centre console for rear-seat control of main infotainment system including Navigation
• Power windows with one-touch operation and anti-trap protection
• Acoustic glazing with infra red reflective interlayer (except front screen to allow use of mobile communications and toll readers)
• Electrically operated privacy blinds for rear windows and rear screen, controlled from front or rear cabin with one-shot operation and anti-trap
• Twin adjustable front cupholders
• Twin hand-crafted rear cupholders with dedicated stowage
• Front and rear cabin cigar lighters and solid metal ashcans in rear doors
• Hide-lined glovebox with illumination and 12V power socket
• Leather-bound owner's handbook housed in dedicated stowage shelf within glovebox
• Document stowage compartments to front seatbacks

  Infotainment

• 8" high-resolution colour screen to display infotainment and vehicle systems information. Automatically concealed behind veneered panel when not in use
• Central Multi Media Interface (MMI) rotary controller with convenience keys for instant access to main system menus of: Navigation, Telephone, Radio, Media (Including TV when fitted), Tone, Information and Car systems
• 60GB hard disc drive unit fitted in glovebox with 20GB of personal storage space, single slot DVD drive and 2 x SD card readers.  Includes inbuilt Gracenote database that displays artist/album/song names from CD�s 
• 6 x CD changer fitted in glovebox
• Voice control for all major systems and operations
• Satellite navigation system integrated in vehicle's hard disc, ensuring fast route calculation
  
  
  • Six-digit post code destination entry, active traffic information (market dependent)
  • Four map configurations including 3-D topographical maps and city views and day/night display modes
• Mulsanne audio system with 14 speakers
  
  
  • Two subwoofers, powered through six channels with digital sound processing
  • Full iPod� and MP3 player compatibility including full-colour album art display
• Digital radio (DAB) or satellite radio (SDARS) depending on market
• Unique, hide-lined iPod� drawer, with integrated connector, designed for storage and connection of multimedia devices.  Supplied with four different fly-leads as standard with connectors for
  
  
  • iPod� / iPhone�
  • USB for portable hard drives
  • Mini USB for Blackberrys, digital cameras and video cameras
  • 3.5mm auxiliary for other MP3 player
• Telephone system with Bluetooth wireless connectivity
• Cordless telephone and cradle mounted in front armrest with SIM card reader in hard drive unit (rSAP). (Except North America or Japan)

  Safety, Security & Charging

• Intelligent driver's and front passenger air bag with front passenger air bag deactivation facility
• Head and thorax airbags fitted to front and rear seats
  
  
  • Fitting to seats rather than car body ensures optimum positioning relative to occupants at all times as the airbag moves with you as you adjust the seat position 
• 3-point seat belts to front seats with electric height adjustment and memory function, pyrotechnic pre-tensioners and force limiters
• 3-point seat belts to outer and centre rear seats with pyrotechnic pre-tensioners and force limiters to outer seats
• Rear seat ISOFIX child seat fixings with top tether points
• Direct tyre pressure monitoring system with provision for speed related warning
• Vehicle Immobiliser
• Interior volumetric alarm system
• Battery conditioner with magnetic trickle charging point concealed in rear registration plate recess
• 12V power sockets located in glovebox, rear centre armrest and boot in addition to cigar lighter sockets in front and rear cabin

Bentley Mulsanne Optional Feature Specification 

• Wheels & Tyres
  
  
  • 20" Mulsanne Alloy Wheel - Chromed
  • 21" Classic Alloy Wheel - Painted
  • 21" Classic Alloy Wheel - Polished
  • 21" Two Piece  5 Spoke Alloy Wheel - Painted
  • 21" Two Piece 5 Spoke Alloy Wheel - Polished
  • Space Saving Spare Wheel  - NCO
  • (standard in Turkey, Bahrain, India, Kuwait, Oman, Qatar, Saudi Arabia & UAE)

• Exterior Fittings
  
  
  • Flying 'B' Radiator Mascot
  • Chromed Radiator Shell with Bright Stainless Steel Matrix Grille
  • Bright Stainless Steel Matrix to Lower Bumper Apertures & Front Wing Vents
  • Jewel Fuel Filler Cap
  • Bright Stainless Steel Door Pillar Finisher

• Exterior Colours
  
  
  • Extended Range including heritage, special satin and pearlescent finishes
  • Duo Tone Range
  • Single Thin Fine Lines
  • Twin Thin Fine Lines
  • Thin Over Thick Fine Lines
  • Thick Over Thin Fine Lines
  • Personal Commission - Solid & Metallic Paint Technologies
  • Personal Commission - Pearlescent/3 Coat Technologies
  • Personal Commission - Satin Paint
  • Personal Commission - Fine Line Colour

• Glass
  
  
  • Shade Band to Tinted Windscreen
  • Privacy Glass to Rear Passenger Compartment

• Seating
  
  
  • Contrast Stitching
  • Cross Stitching
  • Embroidered Bentley Emblems to All Seats
  • Seat Piping
  • Seat Ventilation & Massage Function to Front & Rear Seats

• Steering Wheels & Driver Controls
  
  
  • Veneered Rim Steering Wheel (4 Spoke)
    (available with Burr Oak, Burr Walnut, Piano Black, Birds Eye Maple &
    Dark Stained Burr Walnut veneers)
  • Heated Single Tone Hide Trimmed Steering Wheel (4 Spoke)
  • Duo-Tone Hide Trimmed Steering Wheel (4 Spoke) - NCO
  • Veneered Gear Lever
  • Drilled Alloy Sports Foot Pedals

• Veneers
  
  
  • Dark Stained Burr Walnut
  • Piano Black
  • Burr Oak
  • Bird's Eye Maple
  • Vavona
  • Dark Stained Vavona
  • Olive Ash
  • Sapelli Pommele

• Woodwork & Inlays
  
  
  • Contemporary Style Cross-Banding & Inlay to Fascia & Waistrails
  • (available on Burr Oak & Burr Walnut)
  • Picture Frame Style Inlay to Waistrails (not available with Piano Black)
  • Bentley Wing Badge to Waistrails and Fascia
  • Bentley Wing Badge & Chrome Inlay Strips to Waistrails & Badge to Fascia
  • Veneered Picnic Tables
  • Veneered Picnic Tables with Contemporary Style Cross-Branding & Inlay
  • Veneer  iPod Drawer & Minor Gauges Panel
  • Veneer Door Panels
  • Rear Quarter Companion Mirrors with Veneer Surround

• Mats & Rugs
  
  
  • Lambswool Rugs for Front & Rear (in addition to standard overmats)
  • Deep Pile Wilton Carpet Mats to Front & Rear

• Audio / Video
  
  
  • 'Naim for Bentley' Premium Audio System
  • Six Disc DVD Player
  • Rear Seat Entertainment Package with twin 8� screens to headrests
  • TV Tuner (in addition to DAB radio)
  • (applicable to UK, EU, Australia NZ, Singapore, India,South Africa)
  • TV Tuner
  • (applicable to Japan, China, Indonesia, Malaysia, Philippines, Thailand)
  • DAB Radio
  • (applicable to India & South Africa)

• Convenience
  
  
  • Twin Fold-Down Vanity Mirrors to Rear Cabin Headlining
  • Remote-Controlled Garage Door Opener (Eurolink/Homelink)
  • Valet Key
  • Rear View Camera
  • Side View Camera
  • Adaptive Cruise Control System (P09 - matrix to bumper & vents must also be ordered)
  • Vehicle Tracking System - Preparation Only
  • Vehicle Tracking System - Full Fitment
  • Ambient Interior Mood Lighting
  • Additional Cradle to Rear for Telephone Privacy Handset
  • First Aid Kit in Addition to Warning Triangle (market specific availability)

• Mulliner Catalogue
  
  
  • Personalised Embroidery to all Four Headrests
  • Personalised Embroidery to Rear Headrests
  • Personalised Plaques to all Four Treadplates - Level 1 (Text Only)
  • Personalised Plaques to all Four Treadplates - Level 2 (Text & Graphics)

Related posts: Car production: Labour hours required & some fine examples of craftsmanship!

Source: Press Office of Bentley Motors

READ MORE - Bentley announces detailed spec of new Mulsanne

An early preview of the processes and technology involved in the production of the Bentley Mulsanne

If you have enjoyed the "Car production: Labour hours required & some fine examples of craftsmanship!" post, then I am sure that you will find this press release also interesting!

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The shining bare metal shells that will eventually become Bentley�s new flagship are created using a combination of high-strength steels and aluminium. These components are assembled into a complete shell using techniques that range from industry-leading adhesives through to hand-crafted brazing skills.

It requires 125 man-hours to create the body of a pre-production Mulsanne at the new 7,500m2 Assembly Centre. And inside the multi-million pound facility, robotic arms carrying massive self-piercing riveters work in harmony with coachbuilders renowned for their metalworking skills at the company�s Crewe factory.

For example, the Mulsanne�s hewn from solid appearance without visible panel seams is impossible in volume car manufacture. The seamless sweep of the Mulsanne�s roof, rear wing and boot can only be achieved by crafting a hand-brazed seam midway down the D-pillar, a task still best performed with �hand and eye� by Bentley�s award-winning craftsmen. The quality of this type of work has earned Crewe�s craftsmen the rare distinction of a medal from the British Institute of Sheet Metal Engineering.

In complete contrast to the craftsman�s time-honoured skills, is the use of superforming which is essential to create the highly-complex three dimensional curves of the Mulsanne�s front wings. This advanced technique, primarily used by the aerospace industry, heats a single sheet of aluminium to 500 degrees centigrade and then forces it onto a single surface tool using air pressure.

As Bentley prepares to produce the very first customer cars later this year, the body assembly team are undertaking a range of exhaustive tests on the first bodies being developed in pre-production.

This includes tearing apart completed bodies with specialist cutting gear to analyse the breaking point of a seam or weld as well as minutely measuring the accuracy of finished components and bodyshells � a remarkable 588 functions and relationships are measured to ensure complete precision. In addition to cutting apart bodyshells, Bentley uses ultrasonic measuring equipment to analyse the strength and consistency of individual welds.

Gary Picken, Senior Production Manager, explains:

�During these early, pre-production stages we are exhaustively testing the build process to achieve the absolute precision and quality we are seeking for our customers.�

Prospective Mulsanne customers will be able to see their cars take shape, from individual panels to finished body, in a specially designed viewing gallery. It has been created to offer a perfect view of every stage of the build process and watch the 100-strong team at work. Gary Picken adds:

�The Mulsanne has a beautiful and very complex body made from an intelligent mix of high-strength steels, aluminium and composites. Within one assembly area we�re utilising traditional skills for which Bentley is renowned right alongside state-of-the-art manufacturing technology. We combine these two different approaches because it is the best possible route to create a car that will be enjoyed by generations of drivers.�

Source: Bentley Motors UK Press

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READ MORE - An early preview of the processes and technology involved in the production of the Bentley Mulsanne

Car production: Labour hours required & some fine examples of craftsmanship!

Reading the press releases of the new Bentley Mulsanne and the Rolls-Royce Ghost, it's easy to understand why they cost so much money. But let's go back to the basics. How many hours per vehicle are required for a �normal� car to be built? As I was curious to find out the answer, I did a bit of research but before coming to the actual answer, it's wise to determine what we mean by �labour hours�.

�Hours per vehicle reflect the time worked by all direct and indirect labour involved in manufacturing a vehicle. This includes both hourly and salaried workers who are assigned to each company�s stamping, engine, transmission, and assembly plants. The total hours worked are divided by the number of vehicles produced in the calendar year to yield the labour hours per vehicle. It is not a measure of how long it takes for the vehicle to be assembled, rather it measures the quantity of labour required to produce a vehicle.� *

The average time required for a car to be built is around 30 - 35 hours and the graph below provides a global productivity comparison. Note that those labour hours don't take into account the hours required for components supplied by external suppliers. Also, you should bear in mind that more labour hours don't necessarily mean better quality, as too often, large numbers of people and labour hours are devoted to inspecting and repairing vehicles that have not been built right in the first place.

In 2009 issue of Oliver Wyman's automotivemanager, there some interesting facts regarding the gap between automakers, which you can read below.

�Of the six largest automakers in North America (General Motors, Toyota, Honda, Ford, Chrysler, and Nissan), the gap between the most and least productive is now just 3.5 labour hours per vehicle, or about USD 260, down from 10.51 labour hours, or USD 709 per vehicle in 2003. Chrysler showed the biggest improvement, cutting its total manufacturing labour hours per vehicle by 8 percent to 30.37, approximately the same number recorded by Toyota. Performances of the other four companies were all similar: Honda, 31.33 hours; General Motors, 32.29 hours; Nissan, 32.96 hours; and Ford, 33.88 hours.� *

�In Europe, the gap between the most and least productive remains wide (from less than 20 hours per vehicle at the best plants to more than 60 at the worst). Some automakers have made substantial progress toward the types of sustainable manufacturing processes that characterize the world�s best competitors. Others have only just started or are just starting to implement the most basic tools of lean production.� *

So now, you can understand the price difference between a BMW 760Li and a Rolls-Royce Ghost. Achieving the highest level of quality and craftsmanship requires a lot of time and this is what you pay. A BMW 7 Series requires an average of 51 hours in order to be built, while a Ghost... 20 days! A BMW 760Li costs in Germany (base price) �121,260.50 + VAT, while the base price for a Rolls-Royce Ghost is �213,000.00 + VAT (the Ghost borrows 20% of its parts from BMW F01 platform underpinning the 7 Series, while it has a wheelbase, roof height, bonnet height and track widths all of its own).

Some fine examples of British craftsmanship!

Below you can read some impressive facts related to the craftsmanship of Bentley and Rolls-Royce cars, which offer unrivalled choice of veneers, leather hides and paint colours ensuring that the needs of all customers can be matched perfectly.

The Rolls-Royce Phantom Coup� uses an all-aluminium spaceframe, first seen in the Phantom. Manufactured to within a tolerance of just 0.1 mm / 0.004 in, each spaceframe is constructed by hand and then checked by computer to ensure total accuracy. The body�s structure, comprised of box sections of aluminium, is painstakingly hand-welded by a team of experts. Every morning, each member of the team performs a 300 mm test weld to ascertain atmospheric effects on the metal with which they are working so that these can be taken into account. In all, more than 130 metres of weld are used to create the Coup�s spaceframe.

Five layers of paint and clear lacquer are applied to each Rolls-Royce � seven if it�s a two-tone car � and between each application, technicians sand the body by hand. After the final layer has been applied, the body is hand-polished for five hours. Which is why when you look closely at the car's paint work, you�ll see a perfect reflection of yourself staring back at you. The painting process takes in total seven days to achieve. In that time, they spend longer sanding the bodyshell between coats by hand than they do painting it. Customers can choose from 15 standard exterior paint colours, or 45,000 Bespoke colours, for their Phantom.

Each set of veneers comes from a single tree to create a simple, seamless, flow of high-gloss wood from the fascia through the whole car. Depending on specification, up to 43 wood parts are used in each Rolls-Royce Phantom (this translates to more than 10m2 of wood). Each of these is constructed from up to 28 layers of wood, interspersed with thin sheets of aluminium to ensure strength and to prevent splintering in the event of an impact.

It takes between 15 and 18 hides to upholster one Phantom � more for the Phantom Extended Wheelbase. Each one comes from specially selected herds of cattle, and only the most supple mature bull hides are used. Each hide is checked meticulously by hand to identify any imperfections. The 450 individual leather parts are then cut out using a precision laser before being carefully stitched by hand.

Three different types of leather are used: natural grain for the seats and trims, pre-shrunk in sun-lit areas and tipped (embossed) on the centre console and door trims to provide an attractive variation.

It takes, on average, 460 hours to hand-build each Phantom, not including engine or body-building time.

The Rolls-Royce Ghost passes through 60 pairs of hands before it�s handed over to the customer. Modern manufacturing processes combine with traditional craft skills to turn the bodyshell into the finished car. In all, it involves over 2,000 individual operations and takes 20 days to complete. The body is constructed from steel sections and then wrapped in steel panels, which are brazed by hand. This allows a near-seamless join, which is then sanded by hand until it is perfect. In total, Ghost�s frame contains 4.9 m of seam weld and braze and 6,988 spot-welds. The bonnet and windscreen surround are then honed from aluminium.

A Bentley Mulsanne takes 9 weeks to complete and over 170 hours, almost half the entire build process, go into crafting the interior! Each steering wheel, for example, can take 15 hours to hand-stitch (and three times longer if the customer opts for cross-stitching). Stainless steel brightware gleams so perfectly thanks to an intensive 10-hour finishing process. A wood veneer takes two weeks to turn from a rough root ball into a full set of mirror-matched, fine-polished leaves.

The old-school Bentley models, Azure / Arnage / Brookland, are by far my favourite ones and the first chance I got to seat behind the steering wheel of such a car was at the British International Motor Show back in 1999 (it was a beautiful red Arnage!!!). Every veneer leaf is just 0.6mm thick and in the two weeks that it takes to prepare the wood for one car's interior, the veneers are given five coats of lacquer and three days of curing time before being wax polished by hand. The wood shop uses no bleaching or staining techniques; the rich colour of the veneers is entirely natural. It can take as many as 24 leaves of veneer to make the main veneered components of a Bentley cabin.

Each leaf of veneer can be traced back to the tree from which it came. The most popular choice is Burr Walnut, the distinctive pattern coming from a fungus in the root ball. These root balls, generally around 1 metre in diameter, would typically be over eighty years old. Each tree used for veneer is past its fruit-bearing age and is replaced with three more. Up to 6.2m2 of veneer is used in every standard Azure / Arnage / Brookland, each wood-set taking approximately sixty hours to complete.

It takes 17 separate hides to create the leather surrounds of the Azure / Arnage / Brookland interior cabin. To avoid any variation in texture between the different hides, they are selected and cut at the same time after being minutely inspected for imperfections. Even something as slight as a scratch or an insect bite will cause a hide to be rejected, which is why our hides are selected from herds in Northern Europe, renowned for their remarkable lack of imperfections (e.g. no mosquito bites).

Sources: 2009 issue of Oliver Wyman's automotivemanager (*), Bentley Motors, Rolls-Royce Motor Cars

READ MORE - Car production: Labour hours required & some fine examples of craftsmanship!

Live photos of Bentley Mulsanne from Detroit - Part 3

Source: egmCarTech

READ MORE - Live photos of Bentley Mulsanne from Detroit - Part 3