Car to use as a radio taxi

Ethanol blended fuels are fast emerging as an alternative to pure petrol. ARAI is conducting tests with some Maruti Suzuki cars including the Swift.

A WagonR, part of Maruti's six CNG models, gets a dose of gas at a fuel station in Mumbai. The hatchback delivers fuel efficiency of 26.6km/kg.

The original car is stripped down to its shell.

Armour is then welded on from the bottom up, starting with the quarter panels and the floor.

An exit hatch is put into the rear before the upholstery and glass is replaced.

Spot the difference: the finished fully-armoured Fortuner (L) looks identical to the regular SUV (R).

At highest level of protection, the glass can withstand fire from a sniper rifle.

Run flats can carry the car 60km away if the wheel deflates.

Exhaust pipe cover a small but vital security detail.

Stock hinges are replaced to deal with the added weight of armoured doors.

900kg of additional weightcalls for beefed-up suspension.

Protective shell around fuel tank is defense against IED and grenade attacks.

Armour is tested to withstand 350 rounds from an AK47.

Standard tyres are swapped for run flats. The rims also get a composite ring to keep you moving, should the tyres completely deflate.

“To race is to live; all the rest is just waiting.” We take Silver Arrow racer Rudolf Caracciola’s advice seriously and run an impromptu drag.

AMG says it is an engine maker first, and we seem to have some of the best on sale here. Three individual engines and one variant power the cars sold in India. The range starts off with the record-breaking 2000cc turbo four, known as the M133. It powers the CLA 45 (red) and GLA 45. The M157 5.5-litr

Mercedes-AMG C63S.

Small car, big engine, always a recipe for success.

Aero plays a big role in adding stability today.

Mercedes-AMG CLA45.

CLA’s chin is too low for our conditions.

2.0-litre turbo engine makes 355bhp.

Mercedes-AMG E63.

Seats can be set for a tight embrace; a nice touch.

Essential config buttons are always on hand here.

Mercedes-AMG G63.

Stub side exhausts help deepen the growl further.

The LED strip is the only new bit here.

Mercedes-AMG GL63.

The AMG experience, uniquely enjoyed seven up.

Adjustable dampers essential for sport mode.

Mercedes-AMG GLA45.

One-piece race car-inspired seats look cool.

Splitter helps give SUV look.

Mercedes-AMG GT S.

Launch control allows you to rocket to 100 in just 3.82sec.

The GT S bends the laws of physics for sure.

Mercedes-AMG S63.

AMG pipes hint at what’s under the hood.

An AMG you don’t mind being chauffeured in.

Mercedes-AMG S63 Coupe.

The seats are well put together and very comfy too.

Dynamic Curve helps the car lean into a corner.

Mercedes-AMG SLK55.

5.5 litres of V8 muscle help raise SLK game.

This is where it all begins, from cold rolled steel. From here it goes to a blanking machine where it’s chopped to size.

This plant operates one 800-tonne blanker and three stampers that range from 2,800 to 5,400 tonne.

The first stage I get involved in. Welding the body isn’t for the faint hearted, what with all the sparks flying at you.

The robotic welders take over when it comes to making larger welds that require more accuracy and speed.

Robots give the car a coat of primer and two shiny coats of red paint, deposited using a negative charge on the body.

Our Micra joins a long line of Renault-Nissan cars on the way from the paint shop to the assembly area.

Real assembly work begins; I bolt on the engine mount that has to take all the load of the engine.

The doors now come off for better access; they are put on a trolley and sent away on a separate line.

Fixing the Nissan emblem after attaching a guide, but I still get it wrong the first time. Luckily, the gum isn’t dry.

Snap-fixing the central console isn’t easy if you are on the other side, and sometimes, the holes don’t align.

This car is an export model so it gets curtain airbags which need special care when they are being installed.

Bolting on the frame for the steering column; lots of precision needed here, but the right tools are always at hand.

Some power tools are cordless and this is a massive help, especially when trying to get at something this tricky.

Torquing the starter motor onto the engine is essential, and then you have to check it off the digital list with the barcode reader.

Many operations are manual, but all the heavy lifting is done using powered machines like this electric hoist.

The engine and suspension come together with the part-assembled body; everything is controlled by software.

Fixing the front bumper needs a bit of push and pull, but you have to be careful you don’t crack it.

Manoeuvring the pre-assembled dashboard into a freshly painted shell isn’t all that easy, even with the crane.

Fitting the spoiler needs a bit of help, you have to careful with the rear windscreen so close.

Our Micra goes across from one side of the line to the other, which gives us a much needed break.

Finally, with the completed car, seats, doors and all. Earlier this morning, this was just a sheet of metal: simply amazing!