Video: An In-Depth Look at Building the Fifth-Gen Camaro


The fifth-generation Camaro has been on our streets for a couple of years now but do you know how they get there? Thanks to a Discovery Channel video recently circulated on Camaro5.com, you now have the chance to see just what goes into creating the Camaro. From the stamping of body panels to driving it off the line, the assembly of the Camaro is an extensive process. Check out the video above to see just how your fifth-gen is created.

Just like any car, the Camaro starts out as thin sheets of metal. At the 8.5 million square-foot Oshawa, Canada assembly plant, robot presses are used to stamp these sheets of metal into everything from the roof to the hood to the doors. In just one shift, the stamping presses can create an average of 25,000 Camaro body pieces.

After the body panels are stamped, they are assembled onto the underbody, which is created in the body shop. The underbody is made up of three pieces that are welded together in over 2,000 places. A total of 734 robots are responsible for these welds. Surprisingly, it takes less than 6 minutes to completely weld the underbody together into a structurally-sound piece. After the skin of the Camaro is added to the underbody, it is sent to the paint shop.

The Camaro travels from the body shop across a bridge to the paint shop where precautions are taken to keep all lint and dirt from the environment. To help keep the paint surface free from debris, employees must wear lint-free suits and walk through an air shower before entering the painting area. Inside, the Camaro is treated to an extensive sealing process before it goes through a white-glove inspection for dirt or other particles on the car’s surface. As an extra precaution, every car is then passed under a giant ostrich feather duster which eliminates any surface contaminants that may have been missed before the Camaro enters the paint booth. In the booth, cars are blasted with primer and then one of 10 paint colors. All the paint is electrically charged so that it sticks to the metal of the vehicle.

After 8 and a half hours at the painting facility and a final inspection of the clear coat, the Camaro heads to the trim shop where everything from the carpet to the dash are installed. Wiring is also done in the trim shop. With two guys working on every car, they can wire about one Camaro per minute, or 440 in an 8 hour shift.

The Oshawa plant is the one most thought of as the Camaro assembly plant, but Oshawa is not where the engine is created. Both the V6 and V8 are made at the 1.5 million square-foot Saint Catharine’s plant. The engines are then transported almost 2 hours to meet the rest of the Camaro at Oshawa, but before they leave, every engine is electronically fired up to make sure everything was assembled correctly.

After being shipped to Oshawa, each engine is mated to a transmission, exhaust and full suspension setup in the chassis shop before being married to the rest of the car. It only takes 5 bolts to attach the full chassis and drivetrain to the rest of the Camaro. Once everything is assembled, the last bolts put on the car are the lug nuts. After 18 hours of assembly time, the Camaro is complete, but that doesn’t mean it’s ready to drive away.

Before any Camaro leaves the factory, it is checked for alignment, proper function of the engine and transmission, and leaks. Yes, every fifth-gen Camaro goes through an 8 minute simulated downpour to check for any type of leaks in the car. Once it passes, the Camaro has ended its journey at the assembly plant.

Obviously, there is a lot more to assembling the Camaro, but you’ll have to watch the video to see it. It may take up almost an hour of your time, but if you’re a Camaro fan, watching this video is well worth it.

About the author

Lindsey Fisher

Lindsey is a freelance writer and lover of anything with a rumble. Hot rods, muscle cars, motorcycles - she's owned and driven it all. When she's not busy writing about them, she's out in her garage wrenching away. Who doesn't love a tech-savy gal that knows her way around a garage?
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