All language subtitles for S28E07 - Metal Nail Files; Birch Bark Canoes; Cruiser Boat Hardtops; High Voltage Circuit Breakers (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Today on "How it's made"...
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Metal nail files.
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Birch bark canoes.
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Cruiser boat hardtops.
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And high-voltage
Circuit breakers.
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Throughout history,
People have wanted nice nails.
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And they used whatever
They could get their hands on
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To make them look good.
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Marie antoinette is said to have
Used a pumice stone file
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00:01:03,689 --> 00:01:05,827
To shape her fingernails.
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By the end of the 19th century,
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Metal nail files
Became the norm.
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Metal nail files
Can be used to grind
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And shape fingernails
With a few strokes.
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Their abrasiveness is the secret
To their popularity.
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Making metal nail files starts
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With a thick spool
Of stainless steel.
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The steel unwinds
At a steady pace.
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A punch press wields
88 tons of hydraulic pressure
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To cut out nail file blanks.
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The blanks spill into a bin
And accumulate.
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The blanks bounce around
With ceramic stones
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And a mix of water
And polishing solution.
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00:01:56,827 --> 00:01:59,172
This smoothes the rough bits
On the blanks
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00:01:59,172 --> 00:02:01,620
And also cleans them.
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00:02:01,620 --> 00:02:05,965
The nail file blanks then slide
Down a chute into a dryer.
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00:02:10,068 --> 00:02:13,448
This dryer doesn't use
Hot air to do the job.
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Instead, a pulsating mass
Of hot corn grain
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Soaks up the lingering liquid
On the blanks.
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As the blanks exit,
Some of the corn falls
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00:02:23,206 --> 00:02:25,931
Through a perforated conveyor
To be reused.
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00:02:25,931 --> 00:02:29,793
The blanks continue on
And land in a bin,
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Ready for the next phase
Of production.
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It involves the cutting of
An abrasive grid on both sides.
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It's a three-stage process.
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First, a worker places the blank
Under a sharp tool
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That's angled at 52 degrees.
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The tool pounds the blank
Repeatedly
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To cut angled grooves into it.
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Here is the blank before
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And after the first cut.
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He switches the cutting tool,
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00:03:01,103 --> 00:03:04,241
And it carves over the first
Cuts on the opposite angle.
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The third cut goes straight
Across the other two.
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00:03:13,344 --> 00:03:16,724
The ridges and valleys
Created by the cross cuts
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00:03:16,724 --> 00:03:19,620
Make the surface of the blank
Sharp.
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00:03:19,620 --> 00:03:22,068
The grid cutting has bent
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The still-pliable steel
Out of shape,
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So the worker now bends the nail
Files in the opposite direction,
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Using a round form as a guide.
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This restores
Their linear profile.
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The carving process
Has also caused steel to bulge
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On the edges of the nail files,
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So he grinds them against
A fine abrasive sanding belt
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To make the edges smooth again.
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Next, he places
The metal nail files
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In perfect alignment in a tray.
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He transfers the tray of files
To an oven.
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The files bake for an hour
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At a temperature of
1,832 degrees fahrenheit.
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The intense heat begins to alter
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The physical properties
Of the steel
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And is the first phase of
A hardening process.
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When the hour is up,
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He takes the red-hot tray
Of nail files
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Out of the oven using tongs
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00:04:24,931 --> 00:04:29,517
And then immerses them
In a vat of cold saltwater.
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This is called quenching.
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The shock of the quench
Completes the hardening process.
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Shielded by an enclosure,
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He sandblasts each nail file
To remove stains
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Left by the hardening process
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And to make the steel around
The triple-cut grid shinier.
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He places the handle
Into the nail file
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Beneath a plastic stencil.
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A stamp applies acid to
The open areas of the stencil
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To etch brand information
Onto it.
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Some nail files
Have plastic handles.
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To make the handles,
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This machine melts plastic
And injects it into molds.
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The handles are stuck together
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By hardened flow lines
Or runners.
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A few tumbles in this revolving
Drum knocks off the runners,
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Separating the handles
From them.
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The worker places each handle
Under an automated printing head
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That soaks up ink from a pad
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And then stamps brand
Information onto the plastic.
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Another worker heats the end
Of each metal nail file
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Using copper elements.
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She inserts the hot metal
Into the plastic sleeve,
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And the plastic melts a little
To bond to the metal.
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These metal nail files
Are ready for the grind.
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Narrator: for centuries,
The canoe was indispensable
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To the indigenous people
Of north america.
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Essential for hunting, fishing,
Transportation, and commerce,
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Indigenous people often crafted
Their canoes from birch bark,
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Which is lightweight, strong,
Waterproof, and rot-resistant.
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Historically,
Different indigenous tribes
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Constructed different styles
Of birch bark canoes.
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This one is the type crafted by
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Both the algonquian
And eastern ojibwe.
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Even today, the canoe builder
Crafts every component
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From water- and rot-resistant
Plant materials
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Found in the forest,
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Such as the exceptionally strong
Roots of black spruce trees.
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After scraping off the bark
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With a tool crafted from
A moose rib,
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This craftswoman cuts a slit
In the top and pulls,
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Splitting the long root
Into two strips.
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She coils up each strip
And puts it aside to dry out.
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The canoe builder
Uses spruce root
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To bind structural components
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And lace together
Sections of birch bark.
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00:07:16,931 --> 00:07:19,241
To build the canoe's
Cedar structure,
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The builder connects end frames
At the front and back
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00:07:21,931 --> 00:07:24,655
With long strips of cedar
Called gunwales,
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00:07:24,655 --> 00:07:27,689
Then he lashes crossbars
Called thwarts
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To the gunwales
With spruce root.
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00:07:30,482 --> 00:07:32,206
To make each end frame,
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00:07:32,206 --> 00:07:35,310
He splits a piece of cedar
Many times to let it bend,
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Soaks it in boiling water
To soften the wood fibers,
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00:07:38,689 --> 00:07:41,413
And binds the shape
With spruce root.
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Then the builder checks this
Curved part, called the stem,
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Against the straight part,
Called the headboard.
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If the proportions are right,
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He notches the bottom
Of the headboard
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To fit over the base
Of the stem,
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00:07:54,896 --> 00:07:59,034
Then lashes the parts to
Each other with spruce root.
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He laces together
Several pieces of birch bark
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To make a sheet large enough
For the canoe.
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The builder saturates the
Bark sheet with boiling water
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And bends it up
Around a wooden template.
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Then, on each side of the canoe,
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00:08:13,379 --> 00:08:15,620
He sandwiches the top edge
Of the bark
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00:08:15,620 --> 00:08:20,034
In between the two cedar strips
That form the gunwale.
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The builder shaves
Pieces of cedar
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00:08:22,275 --> 00:08:24,896
To make straight,
Vertically laid planks
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00:08:24,896 --> 00:08:27,724
And u-shaped
Horizontally laid ribs
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00:08:27,724 --> 00:08:30,137
That line the inside
Of the canoe.
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He uses a gauge to make sure
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00:08:32,172 --> 00:08:35,206
Each piece
Is the required thickness.
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00:08:35,206 --> 00:08:39,482
He lays each rib piece
Across the structure
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00:08:39,482 --> 00:08:41,689
And makes a mark on each side
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00:08:41,689 --> 00:08:45,275
In line with the bottom edge
Of the floor.
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That's where
He'll bend the piece.
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Just as he did to bend the stem
Portion of the end frame,
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The builder ladles boiling water
Onto the wood
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To soften the fibers.
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00:09:04,862 --> 00:09:07,827
He positions his knees
On the charcoal marks
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00:09:07,827 --> 00:09:10,379
And pulls up the ends.
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00:09:13,379 --> 00:09:15,344
He bends two ribs at a time,
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00:09:15,344 --> 00:09:18,275
As this reduces the chances
Of them cracking.
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After checking that he cut
And bent all the ribs correctly,
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00:09:27,655 --> 00:09:31,758
The builder begins the process
Of securing the birch bark.
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00:09:33,344 --> 00:09:37,241
He drills holes in the gunwales
At nearly six-inch intervals.
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Then he takes pegs
Carved from hardwood
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00:09:41,655 --> 00:09:43,655
Such as ash or maple
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00:09:43,655 --> 00:09:45,655
And hammers one
Through each hole.
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00:09:50,896 --> 00:09:53,206
Then he pierces holes
Through the bark
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00:09:53,206 --> 00:09:56,103
With a traditional awl
Made from deer antler.
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He threads spruce root
Through the holes
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00:10:01,827 --> 00:10:03,724
To lash the bark to the gunwale.
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00:10:11,034 --> 00:10:12,689
With an assistant's help,
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00:10:12,689 --> 00:10:16,068
He fully lines the canoe
With straight cedar planks
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00:10:16,068 --> 00:10:19,137
And installs the remaining ribs.
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00:10:19,137 --> 00:10:22,137
The tight fit presses the planks
Against the bark,
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00:10:22,137 --> 00:10:25,241
Stretching it taught,
Which strengthens it.
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00:10:26,862 --> 00:10:30,034
The final step is known as
Pitching the seams.
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He melts down dried resin
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Gathered from scars
On spruce trees
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And mixes in two ingredients --
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00:10:37,379 --> 00:10:38,827
Ground charcoal
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00:10:38,827 --> 00:10:41,137
And oil rendered from bear fat.
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He applies this hot mixture
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To all the lacing holes
In the birch bark,
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00:10:44,965 --> 00:10:48,862
Making the canoe water-tight.
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00:10:48,862 --> 00:10:51,965
The canoeist carries
A small supply of dried pitch
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00:10:51,965 --> 00:10:55,724
And lights a stick to remelt
And apply it.
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The repair dries quickly,
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So in about five minutes,
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The canoeist can be
Back in the paddle.
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00:11:14,586 --> 00:11:18,206
Narrator: a hardtop encloses
The cockpit of a cruiser boat.
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00:11:18,206 --> 00:11:21,724
It provides shelter
From water spray, wind, and sun,
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00:11:21,724 --> 00:11:24,310
And a roof on which to
Mount antenna for marine
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00:11:24,310 --> 00:11:26,896
And satellite radio and gps.
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00:11:26,896 --> 00:11:29,620
On the inside,
It provides walls and a ceiling
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00:11:29,620 --> 00:11:32,034
For recessed lighting
And other features.
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00:11:34,517 --> 00:11:36,413
This cruiser hardtop has windows
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00:11:36,413 --> 00:11:38,931
That wrap around the front
And sides.
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00:11:38,931 --> 00:11:41,379
The tall one in the middle
Is retractable
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00:11:41,379 --> 00:11:44,448
So you can walk through
To the front deck.
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00:11:44,448 --> 00:11:47,551
Workers use two molds to make
The inner and outer parts
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00:11:47,551 --> 00:11:49,620
That form the hardtop.
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00:11:49,620 --> 00:11:51,965
First, they spray white gelcoat
197
00:11:51,965 --> 00:11:55,724
To a thickness of
Just .6 millimeters.
198
00:11:55,724 --> 00:12:00,379
Next, workers shoot shredded
Fiberglass strands into the mold
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00:12:00,379 --> 00:12:04,206
Along with a stream of resin
Which saturates the fibers.
200
00:12:04,206 --> 00:12:07,620
When the fiberglass is about
3/4 of an inch thick,
201
00:12:07,620 --> 00:12:11,620
They let the resin cure
For an hour or so.
202
00:12:11,620 --> 00:12:14,551
Then workers apply bonding putty
To the fiberglass
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00:12:14,551 --> 00:12:16,241
In the outer mold.
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00:12:20,655 --> 00:12:22,862
They mate the inner
And outer molds
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00:12:22,862 --> 00:12:24,137
And let the putty set,
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00:12:24,137 --> 00:12:26,068
Which takes about an hour.
207
00:12:29,379 --> 00:12:33,310
Finally, it's time to extract
The fiberglass from the molds.
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00:12:33,310 --> 00:12:35,620
It comes off relatively easily
209
00:12:35,620 --> 00:12:37,965
Because prior to spraying
The gelcoat layer,
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00:12:37,965 --> 00:12:40,965
Workers have applied a release
Agent on the mold's surface.
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00:12:43,344 --> 00:12:46,793
The inner and outer parts are
Built in the mold upside-down
212
00:12:46,793 --> 00:12:49,931
So the gelcoat gives
The coarse fiberglass
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00:12:49,931 --> 00:12:52,655
A smooth and shiny
Surface finish.
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00:12:56,896 --> 00:12:59,517
Then they cut openings
For the windows
215
00:12:59,517 --> 00:13:01,103
And for the various components
216
00:13:01,103 --> 00:13:03,827
To be installed
Into the hardtop.
217
00:13:06,310 --> 00:13:09,620
They install
The retractable front window.
218
00:13:11,310 --> 00:13:14,724
Workers then position the window
And mark the screw holes,
219
00:13:14,724 --> 00:13:17,137
Then remove it
In order to apply adhesive,
220
00:13:17,137 --> 00:13:19,034
Which also functions
As a sealant
221
00:13:19,034 --> 00:13:21,413
To prevent water infiltration.
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00:13:21,413 --> 00:13:25,344
They reset the window
And screw it to the hardtop.
223
00:13:27,551 --> 00:13:29,655
Workers install
A non-opening window
224
00:13:29,655 --> 00:13:32,034
On each side
Of the retractable one.
225
00:13:32,034 --> 00:13:36,137
After taping off the area,
A worker applies primer.
226
00:13:38,137 --> 00:13:40,896
Once the primer dries,
They remove the tape
227
00:13:40,896 --> 00:13:44,000
And apply an adhesive-backed
Foam gasket
228
00:13:44,000 --> 00:13:46,275
That's about 1/4-inch high.
229
00:13:53,275 --> 00:13:56,275
A worker applies a 1/4-inch high
Bead of adhesive sealant
230
00:13:56,275 --> 00:14:01,310
Next to the gasket
And sets the window.
231
00:14:06,517 --> 00:14:08,586
The primer gasket
And adhesive sealant
232
00:14:08,586 --> 00:14:11,413
Are all black
To match the window frame.
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00:14:17,206 --> 00:14:18,862
On the roof of the hardtop,
234
00:14:18,862 --> 00:14:22,310
Workers install a thin
Molded fiberglass cover.
235
00:14:27,310 --> 00:14:31,103
The retractable window,
When opened, slides under it.
236
00:14:31,103 --> 00:14:33,586
Workers fill the gap
237
00:14:33,586 --> 00:14:36,206
Between the cover and hardtop
With sealant.
238
00:14:36,206 --> 00:14:41,206
This adheres the cover
And makes it watertight.
239
00:14:41,206 --> 00:14:44,689
At the rear, workers install
The radar arch.
240
00:14:44,689 --> 00:14:47,413
This, too, is made of
Molded fiberglass
241
00:14:47,413 --> 00:14:50,379
But with a black gelcoat finish.
242
00:14:50,379 --> 00:14:52,551
They mount various components
On it,
243
00:14:52,551 --> 00:14:56,620
Such as the horn,
Navigation light, and antenna.
244
00:14:56,620 --> 00:14:58,310
Inside the hardtop,
245
00:14:58,310 --> 00:15:00,517
After passing wires
For lighting,
246
00:15:00,517 --> 00:15:03,793
Workers connect the wiring
To the retractable window.
247
00:15:03,793 --> 00:15:07,103
The window comes
As a self-contained unit
248
00:15:07,103 --> 00:15:10,517
With an incorporated motor
And intricate pulley system.
249
00:15:12,862 --> 00:15:16,137
The hardtop is now ready to be
Mounted to the cruiser's deck.
250
00:15:18,896 --> 00:15:20,724
Workers install
A windshield wiper
251
00:15:20,724 --> 00:15:23,310
On each non-opening
Front window.
252
00:15:26,482 --> 00:15:28,758
The last step is to install
A large window
253
00:15:28,758 --> 00:15:30,965
On both sides of the hardtop.
254
00:15:30,965 --> 00:15:34,379
Its middle section opens.
255
00:15:34,379 --> 00:15:37,034
Like a giant windshield,
256
00:15:37,034 --> 00:15:39,620
The hardtop transforms
The cruiser boat's
257
00:15:39,620 --> 00:15:41,517
Otherwise open cockpit
258
00:15:41,517 --> 00:15:44,206
Into a weather-protected lounge.
259
00:16:02,241 --> 00:16:05,758
Narrator: electrical substations
Play a critical role in the grid
260
00:16:05,758 --> 00:16:09,482
As they distribute electricity
To entire communities.
261
00:16:09,482 --> 00:16:11,310
The circuit breakers
At these stations
262
00:16:11,310 --> 00:16:13,206
Routinely interrupt
Short circuits
263
00:16:13,206 --> 00:16:15,172
To prevent damage to the system.
264
00:16:15,172 --> 00:16:16,620
They perform the same function
265
00:16:16,620 --> 00:16:18,689
As the ones in
A home electrical panel,
266
00:16:18,689 --> 00:16:20,413
But on a much larger scale.
267
00:16:21,965 --> 00:16:25,034
The size of a car
Or even a large truck,
268
00:16:25,034 --> 00:16:26,862
These circuit breakers
Troubleshoot
269
00:16:26,862 --> 00:16:30,344
High-current situations
At electrical substations.
270
00:16:30,344 --> 00:16:34,413
This protects the grid
And prevents power outages.
271
00:16:34,413 --> 00:16:37,965
Making one starts with
A cast-aluminum tank
272
00:16:37,965 --> 00:16:41,068
That has receptacles
For bushings.
273
00:16:41,068 --> 00:16:44,172
A worker inspects the tank
For dirt or flaws
274
00:16:44,172 --> 00:16:46,137
And then places
Protective covers
275
00:16:46,137 --> 00:16:48,137
On the bushing receptacles.
276
00:16:48,137 --> 00:16:51,448
He installs bases
For current transformers
277
00:16:51,448 --> 00:16:53,931
On these receptacles.
278
00:16:53,931 --> 00:16:56,551
The worker applies adhesive
279
00:16:56,551 --> 00:17:00,068
To the outside
Of these metal bases.
280
00:17:00,068 --> 00:17:04,103
He presses squares of plastic
Insulation to the glued areas.
281
00:17:06,241 --> 00:17:08,586
With the help
Of an overhead lift,
282
00:17:08,586 --> 00:17:11,034
The worker installs
The two current transformers
283
00:17:11,034 --> 00:17:14,310
On the insulated bases.
284
00:17:14,310 --> 00:17:17,137
These current transformers
Will act as sensors,
285
00:17:17,137 --> 00:17:19,793
Enabling the circuit breaker
To detect short circuits
286
00:17:19,793 --> 00:17:23,000
In an electrical system
In mere milliseconds.
287
00:17:25,965 --> 00:17:28,172
Another worker brushes lubricant
288
00:17:28,172 --> 00:17:30,103
On the moving part
Of the interrupter
289
00:17:30,103 --> 00:17:32,379
That will break the electrical
Current when needed.
290
00:17:33,758 --> 00:17:35,655
He inserts the exhaust tube
291
00:17:35,655 --> 00:17:40,344
That helps direct the flow of
Gas used to break the current.
292
00:17:40,344 --> 00:17:41,827
He sets the interrupter module
293
00:17:41,827 --> 00:17:44,172
In an upright position
On the floor
294
00:17:44,172 --> 00:17:47,103
And returns to the workbench.
295
00:17:47,103 --> 00:17:50,000
The worker dabs thread lock
Liquid in the mounting holes
296
00:17:50,000 --> 00:17:52,655
Of the stationary
Contact assembly
297
00:17:52,655 --> 00:17:56,517
And installs a resin ring
In the base.
298
00:17:56,517 --> 00:17:59,482
He inserts the stationary part
Into the moving one,
299
00:17:59,482 --> 00:18:02,655
Leaving the end protruding.
300
00:18:02,655 --> 00:18:04,931
The worker applies thread lock
301
00:18:04,931 --> 00:18:07,206
To the assembly holes
Of a large tube
302
00:18:07,206 --> 00:18:09,034
That will shield
The entire interrupter
303
00:18:09,034 --> 00:18:11,206
Once it's installed in the tank.
304
00:18:11,206 --> 00:18:15,482
It will also direct the flow
Of interrupting gas.
305
00:18:15,482 --> 00:18:17,862
After assembling it
To the interrupter,
306
00:18:17,862 --> 00:18:20,655
He inserts a synthetic
Insulating tube.
307
00:18:20,655 --> 00:18:23,103
Then with the help of a lift,
308
00:18:23,103 --> 00:18:24,517
He flips the module over
309
00:18:24,517 --> 00:18:27,793
In order to
Work on the other end.
310
00:18:31,344 --> 00:18:34,586
He installs another
Insulating tube in this end.
311
00:18:34,586 --> 00:18:38,965
He then sets the module
To a stand to steady it
312
00:18:38,965 --> 00:18:41,310
As he inserts
The contact assembly
313
00:18:41,310 --> 00:18:43,862
That opens to interrupt
The electrical current.
314
00:18:48,000 --> 00:18:50,206
He caps one end
Of the interrupter
315
00:18:50,206 --> 00:18:52,586
With the unit that houses
The bell crank.
316
00:18:56,068 --> 00:18:59,724
He slides the bell crank
Into the housing.
317
00:18:59,724 --> 00:19:02,413
This crank will convert
The rotary motion
318
00:19:02,413 --> 00:19:05,413
From the operating mechanism
To a linear motion.
319
00:19:07,137 --> 00:19:10,448
He turns the crank to confirm
That it rotates freely.
320
00:19:14,517 --> 00:19:16,758
He now clamps leads
To test probes
321
00:19:16,758 --> 00:19:18,413
Inserted in the interrupter
322
00:19:18,413 --> 00:19:22,000
And applies 100 amps of current.
323
00:19:22,000 --> 00:19:24,620
The testing device measures
The interrupter's resistance
324
00:19:24,620 --> 00:19:26,103
To the current to confirm that
325
00:19:26,103 --> 00:19:28,241
It's within
An acceptable range.
326
00:19:30,482 --> 00:19:32,379
With a lift bearing the load,
327
00:19:32,379 --> 00:19:35,172
The other member of the team
Guides the interrupter module
328
00:19:35,172 --> 00:19:38,827
Into the cast-aluminum tank.
329
00:19:38,827 --> 00:19:42,310
He bolts the bell crank's
Housing to the tank opening
330
00:19:42,310 --> 00:19:45,034
And places cylindrical
Electrical shields
331
00:19:45,034 --> 00:19:47,517
In each of
The bushing receptacles.
332
00:19:50,379 --> 00:19:52,827
He then encases the transformers
At the base
333
00:19:52,827 --> 00:19:55,827
With aluminum covers.
334
00:19:55,827 --> 00:19:57,620
They'll protect
The transformer wiring
335
00:19:57,620 --> 00:19:59,827
From rain, snow, or dirt.
336
00:19:59,827 --> 00:20:03,206
Lifts now hoist the
Silicone-rubber-wrapped bushings
337
00:20:03,206 --> 00:20:05,448
Into the receptacles.
338
00:20:08,275 --> 00:20:10,275
The worker bolts them
In place...
339
00:20:13,965 --> 00:20:16,724
...And caps the rear
Of the tank.
340
00:20:19,344 --> 00:20:20,827
This interrupter is now ready
341
00:20:20,827 --> 00:20:23,482
To be mounted
To the steel support structure.
342
00:20:23,482 --> 00:20:26,000
Each high-voltage
Circuit breaker
343
00:20:26,000 --> 00:20:29,965
Will be equipped
With three interrupters.
344
00:20:29,965 --> 00:20:32,034
The team connects
The bell cranks
345
00:20:32,034 --> 00:20:34,827
To the operating system
In the control cabinet.
346
00:20:37,206 --> 00:20:41,827
And workers equip each bell
Crank with a pressure gauge.
347
00:20:41,827 --> 00:20:45,172
A worker grounds
The circuit breaker
348
00:20:45,172 --> 00:20:47,689
To the support structure
With copper cables.
349
00:20:47,689 --> 00:20:51,000
This will prevent shocks
To anyone who touches it.
350
00:20:52,275 --> 00:20:54,000
In one last test,
351
00:20:54,000 --> 00:20:56,620
Towering transformers
Apply high voltages
352
00:20:56,620 --> 00:20:58,931
To the circuit breakers.
353
00:20:58,931 --> 00:21:00,689
These high-voltage
Circuit breakers
354
00:21:00,689 --> 00:21:02,655
Are ready to
Interrupt situations
355
00:21:02,655 --> 00:21:04,655
Before they become problems.
28276
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