Original subtitles

There we go.

Oh, hey, it's me, Handyman Hal.

Hope you're doing awesome today.

Check out this bike.

You know, have you ever wondered how a bike is made?

We're at the perfect spot. We're here at BCA, Bicycle Corporation of America in

Manning, South Carolina, and they make some really cool bikes here.

Just finishing putting on that pedal with this.

This is a pedal wrench.

It's a really awesome tool.

Yep. So today we're going to find out just how these bikes are manufactured.

Today's visit is brought to you by SME Education Foundation.

So come on.

Let's go see how these are made.

We're at the first step.

in the process of manufacturing a bike.

This is the delivery station.

Here, trucks bring in all kinds of shipments of parts.

They have workers separating the parts out on pallets, and then they have

forklifts that move the parts all throughout this warehouse.

It's awesome. Look, check out the forklift now.

That looks like maybe a set of rims. Or maybe wheels.

Look how big this warehouse is.

It's 55 ,000 square feet.

And all the parts in this warehouse is enough to make 40 ,000 bikes.

That is a lot of bikes.

Oh, well, come on. Let's go see how these things are manufactured. Let's go.

Next up, wheels.

You can't have a bike without wheels.

Here at VCA, they actually make their own rims for their wheels.

And this is what you call an aluminum profile.

Yep. Long piece of aluminum gets put into this machine, and they roll this

It'll be a rim.

Oh, wow, look.

Kind of looks like a slinky.

Like a gigantic spring.

Now, we're going to take this piece.

We're going to put it in this machine, and it cuts it.

And this is going to make three bike rims. Oh, that's awesome.

It's where it actually gets pinned together.

Of course, it's going to have cut marks.

And this connects it together.

Oh, look.

This is Wallace.

And Wallace is working on a really important machine called a lacer.

This machine attaches the spoke to the rim. Right in the center is what you

the hub.

And then the spokes spread out, and that's what strengthens the wheel.

And then after he finishes, he sends it all the way down the line to the

tightener, where every single spoke is tightened evenly.

Pretty awesome.

There goes the tightener.

It's tightening all the spokes to the rim.

Oh, hey, look, it's Erica.

And Erica is putting on a rim band onto the rim.

Rim bands actually help protect the inner tube from any of the metal on the

This is really cool. Can you show me how to do it? Yeah, so you're going to find

the little hole right here. Then you're going to keep this in here. Okay.

And then you're going to come around.

And it stretches.

Just like a band.

Right. Okay.

And it sends it down the line.

Can I try one?

This is going to be great.

All right. So there goes the rim.

Oh, sweet.

Now we've got the thong, the little hole.

Okay. Oh, it's right there?

Oh, yeah, there it is. All right, now let's get a band, right? Right.

There's a lot of bands down there.

So there you go. So the shining side is right here. The shining side is on the

outside.

Oh, there it is.

So we put that in there just like that.

And we stretch the band around, right? Right.

Oh, perfect.

Oh, that's great. So pull this out.

And then always make sure that this one is on the right side. And then we send

it down the line.

Wow. That's great.

Look, these machines are really important to the process of assembling

wheel. They're called truers.

And what they do is they bring a wheel inside and they test how balanced the

wheel is, how true the wheel is. If you put on a regular wheel on the other side

of this machine, your bike's going to wobble all over the place.

But this machine actually makes it to where your wheel is true and centered.

It gives you a nice, smooth ride.

It spins it to find out where all the defects are.

And then they have arms that go in and tighten up each spoke to make it true

valid.

There it goes.

And now on to the next step. Come on, let's go.

Now this is a bike tire.

Check it out.

Got the tread on there.

And on the inside, it's the inner tube.

And here behind me, these guys are working on a really awesome machine

tire mount.

And they're mounting the tire onto the rim.

Yep. After they mount the tire onto the rim, pass it off to the next guy, and he

is filling it up with air.

He's using the valve to fill it up with air, and then he tests it out. He spins

it around and makes sure everything looks just right for the tire.

All right, this is the last part of the wheel assembly.

Check it out.

There's a hole in the table.

So the tire is right there in the hole to make it easy to work.

So what we're doing is installing the disc brake.

What happens is right on the top of that tire there, on top of the hub,

of course, you can use a drill.

And you get these really awesome screws here.

And it takes six screws to attach this brake onto this wheel.

All right, so one at a time.

We'll start on this side here.

And we go opposite on each screw.

All right, there we go.

Come there.

There we go.

There we go. Now we get to tighten them.

Oh, yeah.

And now we're all set.

It's a perfect wheel.

There we go.

Working here at VCA is so much fun.

We're learning all about how bikes are manufactured.

And we're getting to use some really awesome equipment like this.

This is a pallet jack.

And it helps to move pallets with wheels all across the warehouse.

It's great.

You know, here at BCA, they make 1 ,000 bikes a day.

So I guess that means they make 2 ,000 wheels.

That's a lot of wheels.

Well, I guess we might need to get this pallet over to the assembly line so we

can start putting that bike together.

All right, let's see here.

Check this out.

We're in a really awesome area.

This is the paint booth.

Here at BCA, they use a really special paint to paint their frames.

They use a powder paint.

Yep.

Bikes hang right here on these racks.

And they move along the conveyor belt into this booth.

And this is where they actually get painted. See the little nozzle?

Oh, I can't wait to see this process.

This is going to be awesome.

Here comes the frames of the bikes on the conveyor belt.

They enter the paint booth and they get sprayed with the paint.

This paint, it has a glitter finish to it.

Then the frames go into an oven where the paint dries really quick.

The final step is a clear coat for extra protection and shine.

Here they are.

All of the finished frames, they've been painted, they've been clear -coated,

and these are nice, shiny black.

Yep.

Next, they're ready for their decal, their design, sticker.

I wonder what these might look like.

Then, they head off to the assembly line where all the other parts are attached.

The manufacturer of the bicycle.

Come on, let's go.

Check it out.

It's the kill for today.

We've got to get to 1 ,000.

We've only done 596.

We've got to get to work.

Welcome to the sub -assembly line.

This is where things like seats and reflectors, check those out, are

and put together before it's attached to the bike frame. Right. So when seats

come in, they get their manual attached to them for the bikes.

And then we're going to put this on the pipe here.

Just like that.

And then we're going to attach it.

This awesome air gun. Here you go. Watch.

And it's ready to go. Slide it back into its plastic.

And on to the next one.

This is the start of the assembly line.

We take the finished frame.

We've got some frame wrap on it to protect it.

And this is where they actually attach it to the conveyor belt.

It starts to go around the line.

All the parts get attached to the frame.

This is amazing.

After the cranks are installed, they come here.

This is the fork to frame section.

They're taking the frame, attaching it to the front wheel fork, putting some

bearings, some screws on it, and attaching the handlebars.

And then it gets put onto the assembly line.

That's neat.

Check that out.

The bike, it slips upside down.

So as it goes through the assembly line, it gets assembled.

Upside down.

And this section, they're attaching the rear derailleur and the rear brake.

Oh, and also, they get one of these tags that tells you the frame size.

So these frames are large. Yep. So it fits riders 5 feet

9 inches to riders 6 feet 2 inches.

Oh, that's great.

There goes the kickstand.

And now the bike chain.

This looks like a fun part.

They're attaching the rear wheel to the frame.

They're connecting the chain.

And also they're testing out the derailleur.

You see that?

See how the derailleur moves?

She's making sure it works properly.

If you notice.

There's a lot of bikes on this assembly line.

There's up to 50 bikes at one time on this line.

And from start to finish, it takes about 20 minutes to assemble the

bike. But what's great about an assembly line and all these awesome workers is a

bike can get put together in 25 seconds.

That's amazing.

The bike is completely assembled and tested for safety.

The handlebars and the front tire are removed to save space on shipping.

Off to the stores for display and for us to buy.

Here it is.

This is the final step.

The bike actually is getting packed inside of a box.

Check that out.

That's what they call... an air hoist that helps them lift the bike up and

platter right into the box.

Makes it so easy, right?

And now these boxes are going to be shipped off to stores so they can put

on display.

That's amazing.

Check out this machine.

This is called a stretch wrapper.

What it does is it wraps the boxes, 5, 10, 15,

15 boxes.

So it wraps them and gets them ready to ship out.

That's amazing.

Now, off to shipping.

Yes.

What better way to get around a bike factory than on a bike?

We've had such an awesome day here at the Bicycle Corporation of America in

Manning, South Carolina, where we've learned all about how these bikes are

manufactured.

And, yeah, we've got to give a big thanks to SME Education Foundation for

this day happen. I'll see you later.

No one can.

The sun is up and it is getting hot.

Want to eat something sweet and cool? What have we got?

Do you hear what I hear? We're in luck.

A super duper awesome ice cream truck.

Well, we really cool. Trucks are awesome and they rule.

When I grow up big and strong, I hope to drive one too.

Vroom, vroom, beep, beep. I hope you weren't fastest.

The trucks are waiting just like we do.

There's a truck that you have got to see.

So many wheels on it, I counted 18.

On the highway, they are driving down the road.

Semi -trucks carry a heavy load.

Well, they're really cool. Trucks are awesome and they rule.

When I grow up big and strong, I hope to drive one too.

Vroom, vroom, beep, beep, I hope you're worried. That's a big truck, no waiting,

just back to you.

Bye.

Bye. Bye.

Bye.

Wow, look at my tools.

They're awesome.

They help us do all kinds of things. They're so cool.

Tools, tools are cool.

They can help us do anything.

Tools, tools are cool.

They can help us do anything that we want to do.

I want to hang this picture on the wall.

I need to make sure that it does not fall.

I got my nail. I got my ladder.

I need one more thing. It's called a hammer.

Tools, tools are cool.

That we want to do.

I want to make a table out of wood.

And I need to make sure that it's gonna be good.

This one little tool is my favorite treasure.

What do we need? Of course, the tape measure.

Tools. Tools are cool.

Yeah!

Awesome!

I'm talking about it.

Thank you.

Thank you.

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