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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Firefighter helmets.
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00:00:32,517 --> 00:00:34,068
Nautical compasses.
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Packaging tubes.
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And handsaws.
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00:00:53,206 --> 00:00:54,965
In the early 1800s,
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Luggage maker henry gratacap
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Created one
Of the first firefighter hats.
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The leather helmet
Had a long rear brim
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00:01:01,137 --> 00:01:04,241
And curved sides as a shield
Against falling debris
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And water running down the neck.
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00:01:06,103 --> 00:01:08,275
Except for a few
High-tech additions,
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This basic design
Is still used today.
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Leather is surprisingly
Flame-resistant.
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When reinforced,
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It also becomes
A remarkable hard hat,
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00:01:25,517 --> 00:01:29,931
Protecting from heat, liquids,
And sudden impact.
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00:01:29,931 --> 00:01:31,275
On this newer model,
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The accessories
Shield the eyes and ears, too.
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A helmet starts with four
Die-cut leather sections.
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They sew them together
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To make what's called
The skull of the helmet.
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This piece will become
The brim of the helmet.
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To give the skull structure,
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A worker folds
And sews each section,
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00:01:57,103 --> 00:02:00,137
Then flattens the crease
With a special hammer.
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00:02:01,620 --> 00:02:04,827
He uses a template to score
A sewing line in the leather.
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00:02:04,827 --> 00:02:06,827
Then he uses
A powerful sewing machine
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To join the sections together.
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00:02:11,724 --> 00:02:14,241
He now joins
The two halves together,
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Reinforcing them
With double stitching.
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00:02:16,965 --> 00:02:18,448
The resulting eight ridges
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Give the skull stiffness
And strength.
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He stretches the leather
Over a plastic mold
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And trims excess leather
From the ridges.
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00:02:30,344 --> 00:02:33,931
Then he clamps four vise grips
To the rim.
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00:02:33,931 --> 00:02:36,103
These attach to a hydraulic jack
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That stretches
The skull overnight.
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After applying glue
To the ridges,
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He runs them through compression
Rollers for a tight bond.
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They wet the brim piece
Several times
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To make it more pliable.
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Then they stamp it
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With the design used
By this company since 1846.
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But first,
A worker inserts a wire
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That will give the brim
Some structural support,
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00:03:12,689 --> 00:03:14,862
Then a temporary plastic cover
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And a lid to ensure
An even spread of pressure
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Across the brim.
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00:03:18,931 --> 00:03:21,379
She stuffs the edges
Of the leather inside
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Before the press applies 10 tons
Of force to imprint the design.
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Next, a worker sews the skull
To the brim.
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He removes the excess leather
At the base of the skull...
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...And cuts out
The center of the brim.
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Then he removes
The plastic mold.
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00:04:00,000 --> 00:04:01,827
To seal the leather,
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00:04:01,827 --> 00:04:04,068
They dip the hats in a vat
Of hot rosin,
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00:04:04,068 --> 00:04:06,000
A type of tree sap.
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00:04:07,965 --> 00:04:09,689
After 55 minutes,
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They remove them
And let them dry
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At room temperature
For eight weeks.
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00:04:13,862 --> 00:04:15,413
This slow-drying process
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Makes the leather
About as hard as wood.
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Drying it mechanically
Would make it brittle.
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Now for the inside.
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They insert a plastic cap
To reinforce the structure.
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The fit is intentionally tight,
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00:04:28,379 --> 00:04:31,482
So they use a mallet
To tap it into place.
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Inside that
They add another plastic cap
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With nylon straps to resist
The impact of falling objects.
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Here a worker uses
An acetylene torch
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00:04:48,103 --> 00:04:50,689
To burn off any loose threads
And soften the leather
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In order to bend the brim
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00:04:52,000 --> 00:04:54,000
And straighten
The ridges later on.
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00:05:08,689 --> 00:05:11,931
Turning up the sides
Is basically for aesthetics,
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00:05:11,931 --> 00:05:13,517
But the longer edge in the back
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Is to direct water
Away from the neck.
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After adding a synthetic,
Fire-retardant liner,
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He sands the outer surface
To prep it for painting.
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First, a fire-retardant
Chemical primer.
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Then they use
A semigloss latex paint
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In firefighter's black or white
For the chief...
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...Or, if you prefer,
A clear varnish
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To show off the natural leather.
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Add a front piece
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With the firefighters'
Signature brass eagle on top
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And some fluorescent stickers
For extra visibility,
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And you've got
The right headgear
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For a hero's job.
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Narrator:
For more than 1,700 years,
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The compass has been helping
People find their way.
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It was first developed in china,
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But when the far east
Met the far west,
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European sailors
Adopted the technology,
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Using it to chart
Their own courses.
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To make a nautical compass,
They use this device
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To magnetize
A special metal alloy.
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A technician slips
A retainer ring onto a jig
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And positions the magnet
On top of it.
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She places an aluminum skirt
Over the magnet.
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This will support the compass
Dial, which goes on next.
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She inserts a pivot needle
In the center,
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Which will allow the dial
To rotate.
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Then she press-fits
All the pieces together.
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She carefully inspects the fit,
And it looks solid.
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She sprays a chemical cleaner
Into the pivot cavity.
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It has to be spotless
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Because any dirt
Would impede its function.
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She also cleans
A little jewel post
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That contains a tiny sapphire.
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Then she fixes the jewel post
In the dial.
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00:07:27,965 --> 00:07:30,517
The jewel post
Will support the dial
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While allowing the pivot needle
To move easily
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As it's pulled
By magnetic forces.
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She places the dial on a machine
That mimics the earth's pull.
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It's a crucial step
Because magnetic force varies
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Depending on where you are
In the world.
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She brushes a weighted paint
Onto the back of the dial
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To counteract the pull.
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This balances the compass dial,
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00:07:58,103 --> 00:08:00,827
Preventing false readings
Due to differences
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00:08:00,827 --> 00:08:02,862
In the planet's magnetic force.
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00:08:08,344 --> 00:08:12,000
These are lubber lines --
Little direction markers.
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00:08:12,000 --> 00:08:14,758
She inserts them
Into holes in a jig.
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Then she lines them up
With holes
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00:08:18,068 --> 00:08:20,000
In an aluminum gimbal pan
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00:08:20,000 --> 00:08:22,965
And press-fits the lubber lines
To the pan.
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00:08:27,689 --> 00:08:30,931
Now she inserts two pins
Into the gimbal ring
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That allow the ring
To flip around the gimbal pan.
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Then she attaches the compass
Dial to the gimbal assembly.
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The technician spray-paints
The metal compass bowl black
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And pops a rubber diaphragm
Into it.
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00:08:55,103 --> 00:08:58,827
A bronze ring
Will hold it in place.
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This flexible rubber liner
Will contain the compass fluid
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And allow it to expand
And contract.
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00:09:08,482 --> 00:09:11,827
She snaps the dial
And gimbal setup to the bowl.
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00:09:13,413 --> 00:09:17,000
She just has to bend
A little tab to level it out.
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00:09:19,620 --> 00:09:23,137
She positions
An acrylic dome on top.
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Using another jig,
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00:09:27,206 --> 00:09:30,931
She puts a rubber o-ring
Over the dome to seal it,
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00:09:30,931 --> 00:09:32,827
Followed by a metal collar.
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With a power screwdriver,
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00:09:37,241 --> 00:09:40,827
She anchors these pieces
To the rest of the compass.
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00:09:43,517 --> 00:09:46,689
Then she pumps fluid
Into the bowl,
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00:09:46,689 --> 00:09:49,068
Filling it right up
To the dome.
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The fluid makes the numbers
On the dial look bigger.
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00:09:58,241 --> 00:10:01,896
Next, they magnetically charge
Two metal rods
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00:10:01,896 --> 00:10:05,827
And install them
In a compass base.
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00:10:05,827 --> 00:10:09,862
They'll compensate
For magnetic fields on the boat.
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00:10:17,103 --> 00:10:20,793
She mounts a big metal
Housing unit on the base.
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00:10:20,793 --> 00:10:23,724
Then she attaches
Shock absorbers
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00:10:23,724 --> 00:10:27,000
To cushion the compass
Against engine vibrations.
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00:10:29,206 --> 00:10:31,793
She installs the compass
In the housing
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00:10:31,793 --> 00:10:34,793
And taps the dome
To test the shocks.
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00:10:34,793 --> 00:10:38,896
A decorative aluminum cover
Fits around the dome.
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00:10:38,896 --> 00:10:41,310
Then she installs a light
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00:10:41,310 --> 00:10:44,241
To allow the navigator
To see at night.
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00:10:48,482 --> 00:10:50,137
She attaches iron spheres,
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Another tactic to counter
Magnetic interference.
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Our journey through the plan
Is now over,
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00:10:56,275 --> 00:10:59,172
And the compass
Is ready to be used.
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Narrator: artists first used
Flexible metal containers
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For their paints back in 1841.
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00:11:12,931 --> 00:11:15,896
Nowadays, we use them
For a range of things,
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Like toothpaste, glue,
And skin cream.
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The tube's design lets us
Squeeze out most of the product
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00:11:22,379 --> 00:11:24,689
And yet still read
That important fine print
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On the twisted package.
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These packaging tubes
Are made of aluminum
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Because it's affordable,
Lightweight, and malleable.
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00:11:36,965 --> 00:11:38,482
This company makes each tube
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00:11:38,482 --> 00:11:42,551
From an aluminum slug
About the size of a coin.
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00:11:42,551 --> 00:11:45,206
A worker dumps a batch of slugs
In a container,
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00:11:45,206 --> 00:11:48,344
Then adds a lubricating powder
Called zinc stearate.
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00:11:54,379 --> 00:11:55,965
The container spins,
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00:11:55,965 --> 00:11:58,241
Causing the powder
To coat the slugs evenly
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00:11:58,241 --> 00:12:01,965
And prep the metal
For stretching later on.
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00:12:01,965 --> 00:12:04,103
The slugs then spin around
In another container,
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Which orients them horizontally
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So they'll fit through a channel
At the bottom.
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00:12:08,793 --> 00:12:14,034
The channel feeds the slugs
Into a forming press.
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00:12:14,034 --> 00:12:16,655
In a process
Called impact extrusion,
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Each slug moves onto a die,
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00:12:18,620 --> 00:12:20,827
Which gives it the exterior
Shape of a tube,
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Including the neck.
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At the same time,
A mandrel forms the interior.
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00:12:27,517 --> 00:12:29,482
This process hardens the metal,
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00:12:29,482 --> 00:12:33,862
Something they'll correct
Later on by heating it.
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00:12:33,862 --> 00:12:36,241
The machine applies 200 tons
Of pressure
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00:12:36,241 --> 00:12:39,793
To as many as 150 slugs
Per minute.
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00:12:39,793 --> 00:12:42,482
They can be as narrow
As a half-inch
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00:12:42,482 --> 00:12:44,413
And as long as 8 1/2 inches.
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00:12:56,724 --> 00:12:59,517
This machine uses compressed air
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00:12:59,517 --> 00:13:02,068
To align the tubes
For the next step.
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00:13:05,000 --> 00:13:07,724
A trimming machine
Cuts threads into the necks
198
00:13:07,724 --> 00:13:11,620
By passing each one between
Two synchronized rollers.
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00:13:15,034 --> 00:13:18,689
Stationary blades
Trim the top of the neck,
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00:13:18,689 --> 00:13:21,137
Making the surface smooth
And safe to handle.
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00:13:21,137 --> 00:13:24,103
The neck on most models
Remains sealed
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00:13:24,103 --> 00:13:26,137
Until the consumer pierces it.
203
00:13:26,137 --> 00:13:28,413
Another company
Eventually seals the tube
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00:13:28,413 --> 00:13:29,896
By rolling up the other end
205
00:13:29,896 --> 00:13:32,586
After they've inserted
Their product.
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00:13:35,827 --> 00:13:38,241
After heating them
To soften the metal,
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00:13:38,241 --> 00:13:42,000
The tubes move through
Another machine.
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00:13:42,000 --> 00:13:47,379
Here nozzles spray the inside
With two coats of epoxy lacquer.
209
00:13:47,379 --> 00:13:49,482
This creates
A protective barrier
210
00:13:49,482 --> 00:13:52,724
Between the aluminum
And the eventual contents.
211
00:13:59,379 --> 00:14:02,758
Rollers apply a coat
Of polyester enamel paint,
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00:14:02,758 --> 00:14:04,275
Which is flexible when dry
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00:14:04,275 --> 00:14:07,517
And resistant to most solvents
And sun damage.
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00:14:10,965 --> 00:14:13,827
Grippers place the tubes
On long pins,
215
00:14:13,827 --> 00:14:16,206
Which move them through an oven
For seven minutes
216
00:14:16,206 --> 00:14:17,793
So the paint can dry.
217
00:14:20,137 --> 00:14:23,413
From there, it's off
To the printing machine.
218
00:14:23,413 --> 00:14:25,551
Each tube makes one
Complete rotation
219
00:14:25,551 --> 00:14:27,241
Against a printing plate.
220
00:14:27,241 --> 00:14:29,000
The plate applies
A colored image
221
00:14:29,000 --> 00:14:32,965
And information that describes
The tube's contents.
222
00:14:32,965 --> 00:14:36,034
Then they go back in the oven
To dry the ink.
223
00:14:36,034 --> 00:14:38,103
The printing's legible
Even when twisted
224
00:14:38,103 --> 00:14:41,620
Because the polyester ink
Remains flexible.
225
00:14:49,068 --> 00:14:52,137
Another machine
Applies 2.2 pounds of torque
226
00:14:52,137 --> 00:14:54,241
To screw on the plastic caps.
227
00:14:54,241 --> 00:14:56,241
Most of the caps
Have pointy tops,
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00:14:56,241 --> 00:14:58,724
Used to pierce the sealed neck
Of the tube.
229
00:14:58,724 --> 00:14:59,931
They use flat caps
230
00:14:59,931 --> 00:15:02,862
To close off tubes
With open necks.
231
00:15:04,689 --> 00:15:06,517
On the next machine,
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00:15:06,517 --> 00:15:08,896
Nozzles spray on a strip
Of latex sealant
233
00:15:08,896 --> 00:15:10,758
Inside the open end of the tube.
234
00:15:10,758 --> 00:15:13,206
The latex is like a gasket.
235
00:15:13,206 --> 00:15:14,655
After the product is inserted,
236
00:15:14,655 --> 00:15:18,758
It seals the tube
When they fold the end over.
237
00:15:18,758 --> 00:15:21,206
After a machine packs boxes
238
00:15:21,206 --> 00:15:23,448
With an average
Of 300 tubes each,
239
00:15:23,448 --> 00:15:26,655
A worker inspects the inside
Of every tube.
240
00:15:26,655 --> 00:15:29,034
A bright spotlight
Reveals any chip in the paint
241
00:15:29,034 --> 00:15:30,862
That makes
The packaging deficient.
242
00:15:30,862 --> 00:15:34,206
About one in every 500 tubes
Is flawed.
243
00:15:36,344 --> 00:15:40,172
A sheet of sticky paper
Over the open ends of the tubes
244
00:15:40,172 --> 00:15:42,482
Keeps them from twisting
During shipping,
245
00:15:42,482 --> 00:15:45,482
And a label on the box
Provides tracking information
246
00:15:45,482 --> 00:15:48,965
And a way to show if someone
Has tampered with it en route.
247
00:15:52,655 --> 00:15:56,310
Empty, each tube sells
For about 12 cents each,
248
00:15:56,310 --> 00:15:59,758
A great bargain
For such a useful item.
249
00:16:15,068 --> 00:16:17,965
Narrator: even though it was
Invented thousands of years ago,
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00:16:17,965 --> 00:16:20,103
The handsaw is still used today.
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You'll find it
At every building site,
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Always at the ready.
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Power tools are higher-tech,
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But the handsaw
Has a basic appeal.
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It doesn't need
An extension cord
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And almost never breaks down.
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It's a time-tested
Building tool.
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Handsaws come in many sizes.
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To make them,
A machine uncoils steel
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And draws it
Into a mechanized punch.
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The punch works
At a blurring speed
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To cut teeth in the steel --
140 notches per minute.
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Here it is in slow motion.
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It makes two cuts
For each sawtooth.
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A reel takes up
The newly serrated steel
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And then will feed it back
To cut teeth on the other side.
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Next, a fingerlike device
Unrolls the steel
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And pushes it to automated jaws.
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The jaws bend the teeth,
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Alternating the direction
Of each one.
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Here's a slow-motion look.
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This is called
Setting the teeth,
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And it will allow the handsaw
To operate smoothly.
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00:17:42,172 --> 00:17:44,655
Now a die punch
Cuts the steel coil
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Into pieces
Called double blanks --
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Double because two saw blades
Will be made from them.
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The die also makes holes
In one end of the double blank
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For attaching handles.
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They feed the double blanks
To a sheer machine.
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A long blade descends
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And cuts it in half
On the diagonal,
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Making two saw blades.
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00:18:15,137 --> 00:18:18,275
Finally, they press the saw
Blades up against a sand belt
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To smooth out the edges.
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00:18:19,931 --> 00:18:23,517
This is called deburring.
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00:18:23,517 --> 00:18:26,241
Here they're making
A higher-end saw blade.
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They flush a piece of steel
With coolant
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As a machine plunge-grinds it
To make teeth.
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00:18:31,241 --> 00:18:33,172
This method
Is more time-consuming
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But results in a superior tool.
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00:18:39,551 --> 00:18:41,517
Again, they set the teeth,
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But this time, mechanical jaws
Do the job a blade at a time,
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Rather than working
On one long coil of steel.
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The sawteeth will need
To be strengthened
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In order to perform,
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So rollers move the blades
To an electrical coil.
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00:19:02,241 --> 00:19:04,827
Within milliseconds,
The temperature of the blade
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Shoots up
To 1,600 degrees fahrenheit.
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This tempers the steel.
300
00:19:16,206 --> 00:19:19,793
The blades drop off
The conveyer into a bin.
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00:19:27,310 --> 00:19:30,103
Here's a look at a blade
Before heat-treating.
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And this is after.
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The black burn line is a sign
This saw can take the pressure.
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A conveyer wheel dunks them
In a pool of clear protectant.
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This will keep them
Looking shiny.
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When they're dry,
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The blades undergo
A trademark technique.
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They place one on a table.
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00:19:51,586 --> 00:19:54,793
It rises and a squeegee
Silk-screens the company name
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Onto it.
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00:20:02,241 --> 00:20:06,068
At this point,
The ink is still wet.
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00:20:06,068 --> 00:20:08,655
They spend 30 seconds
In an infrared oven --
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Enough time
To bake on the brand name.
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00:20:18,758 --> 00:20:23,551
They slide cardboard sleeves
Over the blades,
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00:20:23,551 --> 00:20:26,310
And now it's time
To attach the handle.
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00:20:26,310 --> 00:20:29,034
A worker fits two
Plastic parts together
317
00:20:29,034 --> 00:20:31,448
And places them on a carousel.
318
00:20:36,172 --> 00:20:38,655
An ultrasonic sealer moves in.
319
00:20:38,655 --> 00:20:40,965
It emits a high-frequency sound,
320
00:20:40,965 --> 00:20:44,137
And the vibrations melt
The two plastic pieces together,
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00:20:44,137 --> 00:20:45,931
Forming a handle.
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00:20:48,103 --> 00:20:50,689
A worker fits the handle
Onto a blade,
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And a machine rivets it
In place.
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Some saws have wooden handles.
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Because riveting
Could split the wood,
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They bolt it on
With screws and rivnuts.
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00:21:06,655 --> 00:21:09,862
And now you have
The finished product.
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If you have any comments
About the show,
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00:21:20,206 --> 00:21:22,793
Or if you'd like to suggest
Topics for future shows,
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00:21:22,793 --> 00:21:24,620
Drop us a line at...
25970
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