How to build a Bugatti Chiron in 15 steps

The Bugatti Chiron production has started in the “Atlier”, at the company’s headquarters in Molsheim. The Atlier takes the shape of an oval configuration, the Bugatti Macaron. The Atlier is made up of steel construction and it made to look like that it’s floating.

At present, 12 chirons are being made and 70 of them are to be produced this year. 20 employees hand-assemble around 1,800 individual parts to produce the 1,500 PS sports car. The Atlier has been modified extensively for the production of the extremely powerful and luxurious Bugatti Chiron. The glossy floors are made from epoxy and it ensures dissipation of any electrostatic charges. There are no signs of robots or any conveyor rails as each and every Bugatti is hand-crafted.

Here in Molsheim, we have a small factory with a small warehouse. Neither our equipment nor our procedures can be compared with those of other car plants. Just-in-time has a very special dimension for Bugatti.

says Christophe Piochon, Member of the Bugatti Board of Management responsible for Production and Logistics.

The mighty W16 engine:

The engine is supplied from the Salzgitter plant of Volkswagen where it has been run for eight hours on test benches. The 7-speed dual-clutch transmission is also tested before arriving at Molsheim.

Powertrain assembly:

The power train weighs 628 kilograms and there are three water pumps to cool the components. A Bugatti production worker must know to assemble the entire chassis.

The only electronic tool in Chassis assembly:

There are around 1,800 bolted joints on a Chiron and a nutrunner system gives a signal when the right torque value is reached.

The Marriage Station:

This is where the chassis monocoque is mated to the engine and suspension assembly. 14 titanium bolts weighing just 34 grams each ensure that the bond is durable and strong.

Vroom Vroom:

The wheels are bolted to the chassis and the engine and transmission oil, brake fluid and coolant are filled. The W16 engine is started for the first time.

The most powerful dyno in the world: 

The Rolling dynamometer used in the Molsheim factory is the most powerful dyno in the world. Bugatti had to replace the older dyno cause it couldn’t handle the 1,500 PS and 1,600 Nm of the Chiron. Excess power generated is supplied to the local grid Molsheim.

The wheels are fastened to the floor using special adapters. A team member monitors the engine settings, clutch, the functioning of ESC, ABS. The Chiron covers 60 kms during the two to three hour dyno test.

Eight layers of coating:

It takes three weeks to complete the painting process. Six layers are required in the case of carbon fibre and eight layers for the top coat. The layers are painted by hand and has to be sanded and polished before applying the next layer.

Pre-assembly stage:

During the pre-assembly stage, the exterior parts made up of carbon fiber are fitted on special frames. They are then inspected under lights to check for defects. This takes three to four days and is done at the new technology center of Bugatti near the Atlier.

Water Test:

Water test is the next stage of the production process. The Chiron is exposed to rain of varying conditions for 30 minutes to check for leaks.

Interior trim fitting:

The fitting of interior trim happens next. Two members fit the interior for three days which can be complete leather or a combination of leather and carbon fiber.

The customization program “La Maison Pur Sang” of Bugatti can meet the desires of each and every customer. There are possibilities of selecting from 23 colors and 8 carbon variants for the exterior and 31 colors of leather for the interior in addition to thousands of other colors. From etching of the initials on the rear spoiler to embroidery on the headset, everything is possible.

The test drive:

Test wheels are used and the exterior is covered with plastic to prevent the paint from damage. The test drive takes place on the route to the Colmar airport where speeds in excess of 250 km/h are completed on the runway. 300 kms are driven during the test drive.

After the completion of the test drive, the original wheels are fitted to the Bugatti Chiron.

Cosmetic finish:

The protective layers are removed and cleaning is done before the final paint finish is carried out. This can take up to two days.

Final inspection:

The Chiron is kept in a light tunnel and an inspection is done for more than six hours.

The approval:

Christophe Piochon, a member of the Bugatti Board of Management responsible for Production and Logistics gives the final approval so that the Chiron can leave the factory.

The “Bugatti Chiron” Masterpiece: 

The most noteworthy aspect of owning a Bugatti are the Bugatti Flying Doctors who provide customer support to the ultimate super sports car!


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