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Today on "how it's made"...
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Throttle bodies.
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limestone fireplace mantels.
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candied fruit
and fruit jellies.
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00:00:43,978 --> 00:00:46,211
and linen ukuleles.
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the throttle body is a device
that allows the engine
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of a fuel-injected
vehicle to breathe.
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Pressing on
the accelerator pedal
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00:01:01,028 --> 00:01:05,564
opens the throttle body's blades
to allow air into the engine.
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00:01:05,566 --> 00:01:09,168
The greater the airflow,
the higher the rpm.
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All the driver has to do
is step on the gas.
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00:01:14,442 --> 00:01:17,409
designed for race cars,
the throttle body could make
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the difference between
winning and losing.
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00:01:20,448 --> 00:01:22,514
That's due to the way
it delivers the air
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the engine needs for speed.
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00:01:25,453 --> 00:01:29,855
Making a throttle body starts
with this solid aluminum disk.
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00:01:29,857 --> 00:01:32,324
A technician mounts it to
a machining fixture
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and closes the door.
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00:01:35,429 --> 00:01:37,963
Computer controlled
cutters move in.
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00:01:37,965 --> 00:01:42,434
The cutters reduce the thickness
of the disk and contour it.
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00:01:42,436 --> 00:01:46,038
They also rough out the shape
of four air passageways.
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00:01:48,509 --> 00:01:50,375
then they flip the part over,
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00:01:50,377 --> 00:01:55,180
and more cutting tools work
on it from the other side.
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00:01:55,182 --> 00:01:58,183
The cutters open up the air
passageways completely
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00:01:58,185 --> 00:02:02,354
and create a hole
in the center for a bolt.
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00:02:02,356 --> 00:02:04,823
The technician clamps
a square chunk of aluminum
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00:02:04,825 --> 00:02:06,058
in the fixture,
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00:02:06,060 --> 00:02:09,728
and cutters transform it
into the main body part.
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00:02:09,730 --> 00:02:13,532
This is a computer simulation
of the process.
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00:02:13,534 --> 00:02:15,934
The tools carve four holes
to match up
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00:02:15,936 --> 00:02:18,036
to the ones on the top piece.
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00:02:18,038 --> 00:02:22,107
These holes will hold
the throttle mechanisms.
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00:02:22,109 --> 00:02:25,043
The transformation
takes just minutes.
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00:02:27,948 --> 00:02:30,482
with the parts now
electrically charged,
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00:02:30,484 --> 00:02:32,985
workers plunge them
into a pool of chemicals
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00:02:32,987 --> 00:02:34,386
called an etching bath.
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The chemicals gravitate to the
electrically charged parts
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and lightly etch the surface.
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00:02:41,195 --> 00:02:44,429
A dip in soapy water
cleans the parts.
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00:02:44,431 --> 00:02:46,532
They are now ready
for anodizing,
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00:02:46,534 --> 00:02:49,334
a process that will form
an anti-corrosion finish
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00:02:49,336 --> 00:02:52,371
on the surface.
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00:02:52,373 --> 00:02:55,741
In the anodizing bath,
an electrical charge causes
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00:02:55,743 --> 00:02:59,077
a protective oxide layer
to form on the metal,
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00:02:59,079 --> 00:03:03,115
and black dye
seeps into the pores.
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00:03:03,117 --> 00:03:06,885
Here are the parts before
and after anodizing.
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00:03:10,257 --> 00:03:12,357
a laser then engraves
the brand name
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onto the side of
the throttle body part.
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00:03:15,296 --> 00:03:17,563
The etched aluminum wording
stands out
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00:03:17,565 --> 00:03:21,099
against the black
anodized coating.
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00:03:21,101 --> 00:03:24,503
A technician then inserts
two stainless steel shafts
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00:03:24,505 --> 00:03:27,706
into sealed bearings
in holes on the side.
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00:03:27,708 --> 00:03:30,509
When turned, the shafts
will open and close
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00:03:30,511 --> 00:03:34,279
the round throttle blades.
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00:03:34,281 --> 00:03:37,749
He installs retaining clips
on the shafts.
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00:03:37,751 --> 00:03:41,553
This keeps them in place
and centers them perfectly.
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00:03:41,555 --> 00:03:45,857
But at the same time, they allow
the blades to turn freely.
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00:03:49,997 --> 00:03:55,167
he then screws round blades
to the flat part of each shaft.
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00:03:55,169 --> 00:03:59,037
As the shafts turn, these blades
will move into an open
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00:03:59,039 --> 00:04:01,139
or closed position.
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00:04:01,141 --> 00:04:02,741
They'll act as valves,
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00:04:02,743 --> 00:04:06,378
allowing air into the engine
or shutting it off.
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00:04:09,950 --> 00:04:14,620
he attaches a mechanical linkage
to the end of each shaft.
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00:04:14,622 --> 00:04:17,956
These linkages will ultimately
be connected to a cable
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00:04:17,958 --> 00:04:20,792
that runs to the gas pedal.
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00:04:20,794 --> 00:04:22,928
When the driver steps
on the gas,
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00:04:22,930 --> 00:04:25,197
the linkages
will turn the shafts,
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00:04:25,199 --> 00:04:27,699
and the blades
will open and close.
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00:04:32,273 --> 00:04:36,341
he connects the two linkages
with a part called a tie bar.
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00:04:40,281 --> 00:04:41,647
now that they're connected,
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00:04:41,649 --> 00:04:44,683
the linkages will move
together in one action.
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00:04:49,323 --> 00:04:51,657
the technician tests
the linkages to confirm
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00:04:51,659 --> 00:04:53,759
that they operate smoothly.
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00:04:56,063 --> 00:04:59,931
He now places the top part
onto the throttle body.
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00:04:59,933 --> 00:05:02,734
He applies a thread-lock
solution to a bolt,
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00:05:02,736 --> 00:05:06,938
which he then inserts
in the center of the assembly.
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00:05:06,940 --> 00:05:08,907
This is a crucial connection.
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00:05:08,909 --> 00:05:12,311
It's what holds the two parts
of the throttle body together.
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00:05:16,116 --> 00:05:19,484
He secures the center bolt
with a threaded insert.
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00:05:19,486 --> 00:05:24,990
This insert will also be used to
attach an intake air cleaner.
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00:05:24,992 --> 00:05:29,094
This throttle body
is now complete.
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00:05:29,096 --> 00:05:31,796
Workers measure air flow
through the throttle body
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00:05:31,798 --> 00:05:35,133
using smoke so our camera
can photograph it.
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00:05:35,135 --> 00:05:37,602
With this measurement,
they give the throttle body
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00:05:37,604 --> 00:05:39,504
a performance rating.
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00:05:41,842 --> 00:05:43,742
A crew installs
the throttle body
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00:05:43,744 --> 00:05:47,612
between the race car's
intake manifold and air filter.
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00:05:47,614 --> 00:05:49,715
Then, they check its function.
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00:05:52,052 --> 00:05:56,254
This performance throttle body
is now ready to compete.
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00:06:10,337 --> 00:06:12,671
narrator:
For hundreds of years,
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00:06:12,673 --> 00:06:14,740
stone carvers have
skillfully sculpted
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00:06:14,742 --> 00:06:18,910
blocks of solid stone
into ornate fireplace mantels.
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00:06:18,912 --> 00:06:21,546
A work of art with
an imposing presence,
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00:06:21,548 --> 00:06:24,816
a stone mantel is the decorative
centerpiece of a room.
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00:06:24,818 --> 00:06:26,952
Whether or not there's
a fire burning,
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00:06:26,954 --> 00:06:30,055
it creates a warm ambience.
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00:06:31,859 --> 00:06:35,093
modern-day stone carvers
carry on a trade passed down
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00:06:35,095 --> 00:06:36,628
through the centuries,
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00:06:36,630 --> 00:06:39,297
crafting limestone
fireplace mantels
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00:06:39,299 --> 00:06:42,801
that exude old-world elegance.
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00:06:42,803 --> 00:06:45,804
Artisans sketch out
a creative design,
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00:06:45,806 --> 00:06:50,075
then produce a technical drawing
and 3-d model on a computer.
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00:06:50,077 --> 00:06:53,845
This particular mantel,
carved from beige limestone,
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00:06:53,847 --> 00:06:56,882
will feature a medallion
of red sandstone.
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00:06:56,884 --> 00:06:59,851
The red medallion will be set
into the keystone,
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00:06:59,853 --> 00:07:02,754
which is the central block
of what's called the lintel,
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00:07:02,756 --> 00:07:04,890
the horizontal part
of the mantel.
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00:07:04,892 --> 00:07:06,992
After finalizing
the measurements,
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00:07:06,994 --> 00:07:09,961
the artisans lay down a sheet
of thick white plastic
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00:07:09,963 --> 00:07:12,130
and draw the mantel's
overall shape,
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00:07:12,132 --> 00:07:15,434
as seen from the front,
in its actual dimensions.
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00:07:15,436 --> 00:07:18,303
The mantel will be composed
of several parts
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so they will also mark the
joints where those parts meet.
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00:07:23,877 --> 00:07:26,945
Using this pattern, they cut
a clear plastic template
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00:07:26,947 --> 00:07:30,682
for each part.
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00:07:30,684 --> 00:07:33,518
The artisans use a combination
of traditional
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00:07:33,520 --> 00:07:36,054
and modern stone-carving tools.
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00:07:38,559 --> 00:07:42,994
First, for each part, they use
an automated diamond-blade saw
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00:07:42,996 --> 00:07:44,830
to cut a block to size.
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00:07:48,635 --> 00:07:51,970
they then measure and mark
where they need to remove stone
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00:07:51,972 --> 00:07:55,040
to shape the block
to the basic profile.
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00:08:02,850 --> 00:08:05,917
the artisan gradually removes
that portion of stone
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00:08:05,919 --> 00:08:09,254
with a hammer
and different types of chisels.
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00:08:09,256 --> 00:08:13,425
Limestone can be hard like
marble, or soft like chalk.
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00:08:13,427 --> 00:08:14,960
There's less margin for error
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00:08:14,962 --> 00:08:17,729
when carving softer
limestone, like this,
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00:08:17,731 --> 00:08:21,032
because every strike of the
hammer removes more stone
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00:08:21,034 --> 00:08:24,936
than the same strike
on a hard limestone would.
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00:08:24,938 --> 00:08:27,906
This tool,
designed for soft limestone,
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00:08:27,908 --> 00:08:32,811
wears away the surface like
a plane does to a piece of wood.
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00:08:32,813 --> 00:08:36,047
Once the artisan has removed
all the excess stone,
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00:08:36,049 --> 00:08:39,551
he checks that
the surface is level.
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00:08:39,553 --> 00:08:42,420
Then, in the side of the block,
he traces a template
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00:08:42,422 --> 00:08:44,289
for the profile.
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00:08:44,291 --> 00:08:46,224
This block will become
the keystone
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00:08:46,226 --> 00:08:50,562
for the horizontal
part of the mantel.
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00:08:50,564 --> 00:08:54,566
He measures out and marks
the center of the keystone...
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00:08:59,740 --> 00:09:03,408
...Then centers the medallion
and traces it.
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00:09:03,410 --> 00:09:07,112
He'll draw the remainder of
the keystone's design freehand.
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00:09:09,383 --> 00:09:11,216
The design is symmetrical,
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00:09:11,218 --> 00:09:14,452
so the artisan draws
on one side of the center line,
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00:09:14,454 --> 00:09:16,955
traces his drawing
onto the clear plastic
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00:09:16,957 --> 00:09:18,590
to make a template,
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00:09:18,592 --> 00:09:21,059
then flips the template onto the
other side of the center line
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00:09:21,061 --> 00:09:24,429
to trace the same design
in mirror image.
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00:09:29,937 --> 00:09:34,339
he begins removing stone with
a hammer and roughing tools.
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00:09:34,341 --> 00:09:38,076
First, he breaks off big chunks
with a chipper.
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00:09:38,078 --> 00:09:42,814
He works his way down to just
above the pencil line.
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00:09:42,816 --> 00:09:47,919
Then, with a finer tooth chisel,
he removes the last bit.
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00:09:47,921 --> 00:09:50,589
Then he switches
to finishing tools.
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00:09:50,591 --> 00:09:53,692
He mounts chisels of varying
widths on an air hammer
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00:09:53,694 --> 00:09:56,628
to remove a precise,
even layer of stone.
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00:09:58,665 --> 00:10:01,399
Working on the more
complex details,
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00:10:01,401 --> 00:10:03,668
he uses a combination square
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00:10:03,670 --> 00:10:07,205
to mark a consistent height
across the keystone.
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00:10:07,207 --> 00:10:09,507
Every detail of
the keystone profile
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must align with
the same profile detail
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00:10:12,045 --> 00:10:14,613
of the lentil pieces
on either side of it.
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00:10:16,950 --> 00:10:19,884
Once he has finished
the entire profile of the piece,
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00:10:19,886 --> 00:10:24,689
he sands the surface smooth
and brushes away the dust.
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00:10:27,794 --> 00:10:29,694
Now the artisan turns
his attention
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00:10:29,696 --> 00:10:33,098
to the keystone's ornate
sculpt design.
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00:10:33,100 --> 00:10:36,267
With fine, flat,
and pointed chisels,
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00:10:36,269 --> 00:10:39,070
he removes the stone
around his pencil lines
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00:10:39,072 --> 00:10:42,073
until the design
he drew emerges.
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00:10:46,546 --> 00:10:48,980
by switching to
a sculptor's rasp,
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00:10:48,982 --> 00:10:51,650
he smoothes all the rough edges.
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00:10:53,687 --> 00:10:56,621
He checks the fit of the red
sandstone medallion
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00:10:56,623 --> 00:10:57,856
and glues it in.
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00:11:01,461 --> 00:11:04,362
once the artisan finishes
sculpting all the parts,
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00:11:04,364 --> 00:11:05,897
he lays them on the pattern
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00:11:05,899 --> 00:11:09,067
to make sure all
the dimensions are perfect.
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00:11:09,069 --> 00:11:13,271
On installation day, he mounts
the mantel, piece by piece,
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00:11:13,273 --> 00:11:16,174
around the fireplace.
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narrator: Candied fruit
and fruit jellies
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are middle eastern in origin
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00:11:31,958 --> 00:11:34,859
and spread to europe
around the 12th century.
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00:11:34,861 --> 00:11:37,095
This region of France
has been producing them
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00:11:37,097 --> 00:11:39,097
since the 15th century.
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00:11:39,099 --> 00:11:41,633
When wars blocked access
to cane sugar,
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00:11:41,635 --> 00:11:44,402
fruit farmers began
planting sugar beets
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00:11:44,404 --> 00:11:47,906
to preserve this
confectionery tradition.
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00:11:50,243 --> 00:11:53,611
this company in France has been
catering to people's sweet tooth
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00:11:53,613 --> 00:11:56,381
since 1880 with its gift boxes
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00:11:56,383 --> 00:12:01,886
containing traditional candied
fruit and fruit jellies.
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00:12:01,888 --> 00:12:05,824
To make candied fruit, a master
confectioner boils fresh fruit
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00:12:05,826 --> 00:12:08,793
for many hours
to soften the fibers.
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00:12:08,795 --> 00:12:12,764
This process will later help
sugar to penetrate the fruit.
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00:12:12,766 --> 00:12:16,501
He pokes the fruit to see
if it's ready.
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00:12:16,503 --> 00:12:19,938
Boiling time varies
from 1 hour for apricots
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00:12:19,940 --> 00:12:22,340
to 8 hours for chestnuts.
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00:12:22,342 --> 00:12:26,444
Citrus fruits are sliced
before boiling.
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00:12:26,446 --> 00:12:29,447
After boiling, the more
fragile types of fruit,
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00:12:29,449 --> 00:12:32,617
such as apricots,
pears and clementines,
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00:12:32,619 --> 00:12:36,855
go into large hot-air
dehydrators for up to 3 weeks.
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00:12:36,857 --> 00:12:39,390
Every day, the master
confectioner replaces
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00:12:39,392 --> 00:12:42,060
the evaporated water
with sugar syrup,
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00:12:42,062 --> 00:12:45,997
which concentrates over time.
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00:12:45,999 --> 00:12:49,100
For less fragile fruits,
the technique is different.
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00:12:49,102 --> 00:12:53,371
Workers heat them in vats of
sugar syrup for about 10 days.
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00:12:53,373 --> 00:12:57,075
The moisture evaporates,
and the syrup concentrates.
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00:12:59,312 --> 00:13:02,313
The factory sells
whole candied fruits
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00:13:02,315 --> 00:13:04,415
like this collection
of clementines,
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00:13:04,417 --> 00:13:07,185
apricots, pears, figs,
and plums,
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00:13:07,187 --> 00:13:09,053
to gourmet food shops,
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00:13:09,055 --> 00:13:11,790
which sell them by the piece
or in elegant,
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00:13:11,792 --> 00:13:14,058
private-label gift boxes.
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00:13:19,499 --> 00:13:21,566
whole candied fruit
are also popular
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00:13:21,568 --> 00:13:25,270
for designing
edible arrangements.
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00:13:25,272 --> 00:13:28,573
Making fruit jellies
is a different process.
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00:13:28,575 --> 00:13:30,942
The recipe combines fruit pulp,
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00:13:30,944 --> 00:13:33,278
making up more than
50 percent of the mixture,
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00:13:33,280 --> 00:13:36,214
with powdered sugar,
liquid glucose,
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00:13:36,216 --> 00:13:38,016
a form of plant sugar,
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00:13:38,018 --> 00:13:40,518
pectin to make
the mixture gelatinous,
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00:13:40,520 --> 00:13:43,154
and natural fruit flavoring.
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00:13:43,156 --> 00:13:45,757
A worker boils down the mix
for a half hour
218
00:13:45,759 --> 00:13:47,492
to concentrate the sugar,
219
00:13:47,494 --> 00:13:49,961
then adds more fruit flavoring.
220
00:13:49,963 --> 00:13:52,163
As the mix continues to cook,
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00:13:52,165 --> 00:13:55,433
she draws samples to measure
the sugar content.
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00:13:55,435 --> 00:13:57,135
She does this until the mix
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00:13:57,137 --> 00:14:01,739
hits its target
concentration of 78 percent.
224
00:14:05,445 --> 00:14:07,812
another worker pours
the batch from the pot
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00:14:07,814 --> 00:14:09,380
into a large pitcher,
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00:14:09,382 --> 00:14:12,283
then into a square
stainless steel mold.
227
00:14:14,454 --> 00:14:17,422
It takes the jelly a day to set.
228
00:14:17,424 --> 00:14:20,592
Once set, a worker removes it
from the mold --
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00:14:20,594 --> 00:14:22,427
this one's
a different flavor --
230
00:14:22,429 --> 00:14:27,432
and coats it with crystallized
sugar to preserve it.
231
00:14:27,434 --> 00:14:30,201
The worker then lays
the jelly square on cutter
232
00:14:30,203 --> 00:14:32,136
the company calls a guitar
233
00:14:32,138 --> 00:14:35,840
because its steel wires
look like guitar strings.
234
00:14:35,842 --> 00:14:39,744
The wires cut once in each
direction to make cubes.
235
00:14:39,746 --> 00:14:43,815
Then, another worker applies
a second coating of sugar.
236
00:14:43,817 --> 00:14:46,451
In addition to this
small-batch production,
237
00:14:46,453 --> 00:14:48,920
the factory
has one automated machine,
238
00:14:48,922 --> 00:14:50,121
which makes fruit jellies
239
00:14:50,123 --> 00:14:53,124
in a variety of geometric
or fruit shapes
240
00:14:53,126 --> 00:14:55,360
created by templates
made of plaster.
241
00:14:58,298 --> 00:15:02,634
this process is much faster
than the handmade approach.
242
00:15:02,636 --> 00:15:07,305
First, the machine
makes a bed of starch.
243
00:15:07,307 --> 00:15:09,974
Then it presses
the plaster form into the bed
244
00:15:09,976 --> 00:15:12,477
to create mold cavities.
245
00:15:17,017 --> 00:15:18,917
the next station fills
the cavities
246
00:15:18,919 --> 00:15:21,486
with hot liquid fruit jelly.
247
00:15:21,488 --> 00:15:25,356
Then, the molds
are set aside for a day.
248
00:15:25,358 --> 00:15:30,428
The starch absorbs the residual
moisture as the jelly sets.
249
00:15:30,430 --> 00:15:32,964
The next day,
workers load the molds
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00:15:32,966 --> 00:15:34,732
on top of the same machine,
251
00:15:34,734 --> 00:15:37,769
which flips them to dump out
the jellies.
252
00:15:37,771 --> 00:15:41,172
The jellies tumble down
a vibrating conveyor belt.
253
00:15:41,174 --> 00:15:44,709
The starch shakes off
with each bounce.
254
00:15:44,711 --> 00:15:46,611
Then they pass
under a spinning brush,
255
00:15:46,613 --> 00:15:50,415
which removes
any remaining starch.
256
00:15:50,417 --> 00:15:53,284
The conveyor moves them
into a rotating drum,
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00:15:53,286 --> 00:15:55,286
which showers them with sugar.
258
00:15:57,223 --> 00:16:00,358
On the packaging line,
a slow conveyor belt moves
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00:16:00,360 --> 00:16:03,995
retail boxes
in front of a row of workers.
260
00:16:03,997 --> 00:16:07,498
Each worker is responsible
for a single flavor.
261
00:16:07,500 --> 00:16:09,734
While placing the required
number of fruit jellies
262
00:16:09,736 --> 00:16:10,835
in the box,
263
00:16:10,837 --> 00:16:13,838
she also performs
a quality control check,
264
00:16:13,840 --> 00:16:17,175
removing and replacing
any that are misshapen.
265
00:16:17,177 --> 00:16:19,978
This ensures that these
traditional fruit jellies
266
00:16:19,980 --> 00:16:22,480
look as good as they taste.
267
00:16:34,194 --> 00:16:36,427
narrator:
Linen is believed to be
268
00:16:36,429 --> 00:16:39,430
the oldest of woven textiles.
269
00:16:39,432 --> 00:16:43,701
But for the making of ukuleles,
it's definitely a new material.
270
00:16:43,703 --> 00:16:45,470
Infused with resin,
271
00:16:45,472 --> 00:16:49,474
linen can actually be molded
into a solid ukulele
272
00:16:49,476 --> 00:16:52,577
that has a look and sound
that's similar to wood.
273
00:16:55,782 --> 00:17:00,051
linen may seem to be an unlikely
material for making ukuleles,
274
00:17:00,053 --> 00:17:03,121
but these instruments are proof
that the fabric can be used
275
00:17:03,123 --> 00:17:07,325
for more than just
drapes and tablecloths.
276
00:17:07,327 --> 00:17:09,694
Following
a computer-aided design,
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00:17:09,696 --> 00:17:12,897
workers cut pattern pieces
from linen fabric,
278
00:17:12,899 --> 00:17:17,702
infused with plant resin
and with protective liners.
279
00:17:17,704 --> 00:17:19,670
After peeling off the liners,
280
00:17:19,672 --> 00:17:24,308
a technician layers the linen
pieces in a ukulele mold.
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00:17:24,310 --> 00:17:27,912
The resin has given the fabric
a clay-like consistency,
282
00:17:27,914 --> 00:17:31,883
so it can be easily shaped
to the mold's curves.
283
00:17:31,885 --> 00:17:34,886
He layers 65 linen
pieces in total.
284
00:17:36,856 --> 00:17:39,624
He drapes a nylon fabric
over the linen
285
00:17:39,626 --> 00:17:41,492
and tucks it into the crevices.
286
00:17:41,494 --> 00:17:43,961
The fabric will ultimately
contain the resin
287
00:17:43,963 --> 00:17:46,664
when it's heated and liquefied.
288
00:17:46,666 --> 00:17:50,268
Polyester batting in the center
will soak up excess resin
289
00:17:50,270 --> 00:17:52,670
during baking.
290
00:17:52,672 --> 00:17:55,907
He cooks the linen layers
for several hours.
291
00:17:55,909 --> 00:17:59,143
The resin in the fabric
subsequently liquifies
292
00:17:59,145 --> 00:18:02,580
and finally hardens,
fusing the layers together,
293
00:18:02,582 --> 00:18:06,818
to create a solid ukulele
body, next and head.
294
00:18:06,820 --> 00:18:08,786
After reinforcing the neck,
295
00:18:08,788 --> 00:18:13,624
a computerized router trims
the entire ukulele body.
296
00:18:13,626 --> 00:18:16,160
Another router trims
the sound board,
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00:18:16,162 --> 00:18:17,762
which is the resonant part
298
00:18:17,764 --> 00:18:20,798
that serves as the front
of the instrument.
299
00:18:20,800 --> 00:18:23,468
It, too, has been molded
from linen material.
300
00:18:26,806 --> 00:18:30,675
a technician pipes epoxy glue
along the rim of the body
301
00:18:30,677 --> 00:18:32,376
to attach the soundboard,
302
00:18:32,378 --> 00:18:35,513
which is being reinforced
with carbon fiber
303
00:18:35,515 --> 00:18:38,983
and a plastic liner applied
for the front to protect it
304
00:18:38,985 --> 00:18:40,985
during this stage
of fabrication.
305
00:18:44,023 --> 00:18:48,893
he glues a front plate
to the headstock of the ukulele.
306
00:18:48,895 --> 00:18:52,163
He then places the ukulele
in a fixture.
307
00:18:52,165 --> 00:18:55,833
He clamps the fixture together
to keep the parts in position
308
00:18:55,835 --> 00:19:00,705
as the glue hardens
for 24 hours.
309
00:19:00,707 --> 00:19:03,841
He props up the headstock
with a block of wood
310
00:19:03,843 --> 00:19:08,946
and uses a separate clamp
to keep the assembly tight.
311
00:19:08,948 --> 00:19:12,283
A router carves an opening
in the soundboard.
312
00:19:12,285 --> 00:19:14,852
This sound hole with
allow the instrument
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00:19:14,854 --> 00:19:18,956
to project music
more efficiently.
314
00:19:18,958 --> 00:19:23,961
The router also drills
tuning holes in the head plate.
315
00:19:23,963 --> 00:19:27,231
Another member of the team
now applies a wood stain
316
00:19:27,233 --> 00:19:30,968
to the linen composite surface.
317
00:19:30,970 --> 00:19:33,638
This gives it
a more uniform finish.
318
00:19:37,177 --> 00:19:39,410
The next part
is the finger board,
319
00:19:39,412 --> 00:19:42,613
made of a wood fiber
and plastic composite.
320
00:19:42,615 --> 00:19:45,583
Another technician hammers
nickel silver frets
321
00:19:45,585 --> 00:19:47,818
into the fingerboard's slots.
322
00:19:50,123 --> 00:19:55,593
He then clips the ends to make
them flush to the fingerboard.
323
00:19:55,595 --> 00:20:00,164
He files the ends to make them
smooth to the touch.
324
00:20:00,166 --> 00:20:04,735
He then glues the fingerboard
to the ukulele neck.
325
00:20:04,737 --> 00:20:07,805
The technician installs
the bridge on the soundboard.
326
00:20:07,807 --> 00:20:09,473
Using a special fixture,
327
00:20:09,475 --> 00:20:11,442
he clamps the fingerboard
and bridge
328
00:20:11,444 --> 00:20:15,446
to the instrument to apply
pressure while the glue dries.
329
00:20:17,517 --> 00:20:20,885
It takes another 24 hours
for the glue to set.
330
00:20:25,425 --> 00:20:29,293
the next day, a technician
applies an adhesive-backed label
331
00:20:29,295 --> 00:20:31,162
with the serial number
printed on it
332
00:20:31,164 --> 00:20:33,531
to the inside of the ukulele.
333
00:20:38,705 --> 00:20:41,138
he inserts tuning pegs
into holes drilled
334
00:20:41,140 --> 00:20:44,609
into the headstock.
335
00:20:44,611 --> 00:20:48,045
He secures the pegs with bolts
at the back of the headstock
336
00:20:48,047 --> 00:20:50,615
and tightens the bolts
with a nut driver.
337
00:20:53,019 --> 00:20:56,787
Then he runs strings from
the bridge to the tuning pegs
338
00:20:56,789 --> 00:20:59,123
and knots them to
hold them in place.
339
00:21:02,762 --> 00:21:04,962
he turns the tuners
to pull the strings
340
00:21:04,964 --> 00:21:06,897
to a specific tension,
341
00:21:06,899 --> 00:21:10,835
and this linen-composite ukulele
is ready for a show.
27874
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