A single-piece magnesium alloy instrument carrier is then bolted across the front of the car. This stiffens the shell to prevent squeaks and rattles occurring later in life. It helps to create a shell that's 2.5 times stiffer than a Sauber F1 car and is one of the reasons why the tailored sound system is so crisp.
The front fenders are composite material to further reduce weight. Even with its 6.75 liter motor, the Phantom is one of the most efficient in its class.
The cars move down the main line, where they meet the drivetrain assembly. The V12 motor is hand built in BMW's M plant. It was developed in parallel with BMW's own V12 but has a very flat torque curve that peaks at very low rpm. "The engine is totally unstressed so will last forever," Jon assured us. "After all, we fit the same powerplant in our 2 tonne armored Phantoms."
Hand-built 6.75 liter V12 and drivetrain being readied for installation
What's more, a Rolls Royce is utterly silent. We were constantly stepping in front of slow-moving cars in the finishing area without realizing they were there. Apparently there used to be a sign in the old Crewe factory: "Beware, silent cars being moved!"
The V12 is mated to a six-speed ZF auto transmission but gets nothing as vulgar as paddle shifts.
At the time of our visit, the new Phantom Drophead Coupe was being readied for delivery. "The problem is, every customer wants to be the first to receive their car. So we're trying to build enough that 70 customers will be first," Jon told us.
Everyhid is checked by hand but laser-cut
While the cars are on the assembly line, the famous Rolls Royce interior shop gets to work. Forty people are employed here. They ensure all of the 15-18 leather hides for each car is inspected by hand. Any imperfections are either hidden behind panels in the car or, if it's too bad, the hide goes to the fashion industry.
A laser then cuts the hides, ensuring total accuracy, although most other jobs are done by hand.
Three types of leather are used in each car - soft "natural" for the seats, "tipped" on the door cards and "pre-shrunk" on the dash. Then there's perforated leather that was used for the headliner in the car we sampled.In the wood shop, they hand select the different woods such as burr walnut, elm, oak, birdseye maple, black tulip, rosewood, etc. And all are laminated with aluminum for improved crash safety.
Teak deck for the Drophead taken from top of the hill and dragged by elephants
For the Drophead, they use teak on the rear deck. "We have buyers in southeast Asia who select our woods. For the teak they insisted the wood come from the top of the hills where there was better drainage to improve the grain. And rather than have the wood leave the forest by river, risking water damage, they requested it be dragged out by elephants," Jon said.
"So we're actually helping to bring elephants back to the forests."
The RangeThe current line-up includes the Phantom, Phantom Extended, Drophead Coupe [convertible] and an approved specialist builds an even longer wheelbase and armored cars. The company was also awaiting approval for the new Phantom Coupe and is hoping to build a second, smaller model by the end of the decade.
Once the cars have been assembled, each is submitted to final checks that include a shaker test to detect any squeaks or rattles, in addition to a road test.
Even Rolls has to move with the times, and a new 21" wheel option was fitted to the majority of cars we saw. There's also a 15-speaker sound system that was designed into the car from inception. It includes 45 liter bass boxes to provide incredible sound quality.
Phantom drivers are required to point out the emergency exits
In the rear, you can specify either a bench seat or two individual chairs with 12" screens and picnic tables in front of them. But if you opt for the 400mm extra-extended wheelbase, Rolls can fit a plasma screen to the wall separating you from the driver. And with the Bespoke service, you can basically have whatever you desire.
The Rolls Royce experience is like nothing else. From the umbrella secreted in the doors, to the Spirit of Ecstacy that can be hidden at the touch of a button, it's like nothing we'd come across before. It's best summed up by Jon Stanley who reminded us "A Rolls Royce is not about a single superlative, it's about delivering a superb package." And having witnessed both the Phantom's production and driven the finished product, we can confirm these cars represent a host of superlatives. Certainly the finest car we've ever driven, and also the most unique.