Bentley has a long-standing reputation for building some of the world’s most luxurious cars and that reputation has been carefully preserved by the company. After all, with the atmospheric prices of their cars, you would hope that they are doing all they can to justify the price tag.

Well if you’re curious to know the production process going on in Bentley, the company was kind enough to give us a glimpse of one of the stages behind the production of their latest flagship sedan, the Mulsanne.
This video takes us on an unprecedented look at how a Bentley Mulsanne is transformed from a plain-looking white body to a glittering and fully-painted vehicle. Fascinating stuff.

The Mulsanne gets six different layers of paint - three for the top coat, and two coats of lacquer – and will be available in both Satin and two-tone versions will be possible.

Bentley also announced that prospective customers can choose from over 115 different colors, 28 of which were created just for the Mulsanne. We didn’t know that you could create new colors, but apparently you can.

Check out the video to see part of the process of how the Mulsanne is what it is – a luxury car of the highest order.

Press Release after the jump

Insight into the 86-hour process used to create the ‘unlimited palette’ available for Bentley’s new flagship

(Crewe, England. 8 March 2010) 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: Bentley

Kirby Garlitos
Automotive Aftermarket Expert -
Kirby’s first exposure into the world of automobiles happened when he caught Knight Rider on television as a five-year old boy. David Hasselhoff didn’t leave much of an impression on him (that happened later on in Baywatch), but KITT certainly did. To this day, Kirby remains convinced that he will one day own a car with the same ‘spirit’ as the original KITT (not the 2008 monstrosity). He doesn't know when that will be, but until then, he’s committed to expressing his love for KITT, and all cars for that matter, here at TopSpeed.  Read More
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  (544) posted on 03.11.2010

Cool. I wonder on how many weeks or months the workers of the factory trained for before they got the job and if they can recognize (through a mark or a signature maybe) the cars that they have worked on or something. I guess it would really be a great feeling to see a car out in the street that you can say, I have been a part of creating this car. Even if the individual just stitched on the seats, it is still a very important part of getting the job done.

  (1022) posted on 03.10.2010

i was surprised when i saw how they made a mulsanne, they really building it by hand and not machine, also i learned that Bently really doesn’t need a big factory because they are building on Orders. quite impressive for a luxury car ain’t it?

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