Dodge-Challenger

George Washington drove the Dodge Challenger to conquer the British Army !!
If you want to get freedom, buy the Challenger. Just kidding !! Dodge Challenger Commercial !!


Canada: Assembly Plant.
Mexico: Engine.

Stamping, Body Shop, Paint Shop, Trim Line, Engine Line, Chassis Line, Final Line, Pre-Delivery. The Dodge Charger, Chrysler 300C, and Dodge Challenger assembly in the
same line.

Stamping Process begins.











Fender.





Stamping.
Refer to : Camaro



Hood, Door, and other parts die.

How gargantuan it is !!



Small stain on the car panel.

Safety First.

Using the pillar to uphold the die.



The worker came into the mold and clean it up.



Complete fender.





Automated Guided Vehicle.
Refer to "Porsche GT3"

No supervision and few collisions.

Body Shop



The door consists of many parts needed to be welded together.



Now, let the robot finished the left process.

Side panel joined the car body.

It looks like the robot raping this car body. A little bit spooky !!



The outline of Dodge Challenger.

Ready for paint.
The Surface Coating of Car Bodies. The following is the process. 
1.Pre-clean 2.Phosphating 3.Electro-coating 4.Rinsing 5.Baking 6.Primer 7.Color-coat 8.Clear
   Lacquer

1.Pre-clean
Water washed that removed any residue in early process.

2.Phoshating
Change the chemistry of the metal surface by bonding rust resistant zinc molecule to the steel.
Zinc Phosphate Zn3(PO4)2).

Avoid the corrosion creeping across  the whole car.
Even you got the small rock to go down the bare metal, it wouldn't move across the whole car.

3. Electro-Coating. E-Coating.

4. Primer



6. Color-coat

Classic Orange.

Dodge Challenge Soul

Like the baby in the womb.

Using the ultrasonic instrument which magnifies each coat of paint thousand times
to make sure it is applied to the correct thickness.

This sheet is like the order in the restaurant.

Print the sheet.

Put it on the car.

Sunroof installation.

Mexico Engine Plant

Listen to her howling Roar !!

Engine Block. Not machine yet.



Grinding...



























Crankshaft

Gasket







Multiple Displacement System. Hemi-Engine





MDS allows to shut down to 4-cylinders, instead of 8 cylinders.

Install Valve Cover.

Dyno Test



Ship out.





Starter Motor



Front Suspension





The chassis and car body joined together automatically.

Bolt it up. How efficient !! No technician.
Compare to other vehicles, in the marriage process, the technicians do this job
instead of the robot.

Assembly Line.

Instrument Panel









Road Test





Ship out.


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The following is Dodge Challenger modified with the Supercharger.
All pictures captured form Horsepower TV. Just for Fun !!!!!! Automobile Enthusiast !!!!!!

Supercharger !!!!!!
Edelbrock E-Force Supercharger Systems.

Here is how it work.







Maximum flow and minimum temperature.







Integratd Bypass Valve.





Ready to strip down



Remove the Front Bumper

Collect the coolant and then can be reused.

Remove the radiator hoses.



Remove the Radiator.

This pulley was pressed. The extra stress could make it slip.
Harmonic Balancer. Crankshaft Damper. Crank Pulley Damper

Need to make the Keyway.







Keyway

Bolt it up.

Now, the Supercharger pulley can be tighten it up.

Unplug the Air Intake Sensor. Mass Flow Sensor.

Remove Air Inlet Tube.



Remove the Idler Pulley.



Disconnect the fuel line.

Remove the Intake Manifold





Tape it. Keep any debris out.

See the Edelbrock company

It looks like assembling the Sand Mold of Ferrari engine.
Refer to: Ferrari















Coordinate Measure Machine (CMM)















Two new Idler Pulley

Belt Tensioner



WD-40

Put the gasket on.

Install the Supercharger

Fuel Injector

Lubricate it for installing easily.



Put it on the engine.

Tighten Fuel Injector on the supercharger.

Connect the Fuel Supply Line (Driver Side)

Connect the Fuel Supply Line (Passenger Side)

PVC Valve
 
Install Supercharger Drive  Belt.



Water Pump for the Intercooler goes behind the bumper.
The function of the intercooler is cool the temperature of the air compressed in the supercharger.

Radiator

Heat-Exchanger mounted on front A/C Condenser.

The bottom right of the Heat-Exchanger.

The right side of the intercoller.

Top-left of the Heat-Exchanger.

Connect to Water Pump

The Reservoir

This hose connects to the reservoir and the pump.

Connect to the reservoir and the intercooler.

Remove the Throttle Body from the stock intake manifold.

And then tighten the Throttle Body on the Supercharger.

High Flow Cold Air Intake
The cooler air has higher density which allows the more efficiency of the engine.

Mission Complete

Dyno !!  Fantastic moment is coming...

From the chart, they made 102 pound torque than the previous.
But it's just more than horsepower. Look at the following picture.

It carries on all the range of R.P.M !!!!!!



[Highlight]
Stamping
Engine Block machine process

[Questions]

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National Geographic "Ultimate factories" had filmed almost automobile manufacturers in the world. Including the most extravagant (Rolls-Royce, Bentley)  and the fastest (Bugatti, Koenigsegg)

Hand-built (Most of European car manufacturers )
Rolls-Royce, Bentley
Ferrari, Lamborghini, Mclaren-MP4 12C (The most fascinating assembly plant)

Henry-Ford Assembly Line (Mass Production). Assembly Line is also prevalent in other industries. Chevrolet-Camaro, Dodge Challenger... 

We also can understand the "Vertical Integration"  in the automobile industries.
From raw material, manufacturing, assembly plant, car test, to dealership.


Think about the (MLB) Baseball Industry :
Raw Material : Baseball Player. All over the world
                        North America: U.S.A & Canada
                        South America: Mexico,Cuba,Dominican Republic, Venezuela...
                        Asia: Japan, Korea, Taiwan, China...            
Manufacturing: Training in Minor League Baseball
Assembly Plant: MLB 30 Stadiums around in U.S.A
Dealership:Product License. Such as: Jersey, other products...


So, I think I can utilize the same way facilitating to perceive other industries in the world.
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All pictures were captured from NGC.