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Narrator:
Today on "How it's made"...
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Handcuffs...
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...Caulking
And joint compound...
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...Propane tanks...
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00:00:43,724 --> 00:00:47,241
...And forensic
Facial reconstruction.
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When a crime is committed,
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A slap on the wrist
Usually isn't enough.
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It's time to handcuff them.
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The need for some restraint
Goes back centuries,
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But the handcuff's design
Was really improved in 1862
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When adjustable ratchets
Were added.
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They allow the cuffs to snugly
Grip the suspect's wrist.
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When they put the handcuffs
On you,
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You know you may be in trouble.
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Handcuffs start
With a roll of steel.
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A machine pulls it
Through a straightener
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And then through a die
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That punches out
A handcuff frame part.
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A revolving barrel cage
Sifts out the waste
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And kicks the frames into a bin.
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Here, a worker stacks "U"-shaped
Steel parts on a fixture,
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Which he then clamps
Onto a machine.
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A cutter makes ratchet teeth
In the parts.
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Coolant keeps the tool
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From heating up and getting
Too soft to do the job.
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Each set of handcuffs
Will have two of these ratchets.
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00:02:09,896 --> 00:02:14,137
Next, they load steel rods
Into a slowly revolving device.
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It moves the rods
Through a series of cutters.
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This is how they make swivels
For the handcuffs.
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They round the tips of the rods
And then carve necks below.
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This tool slices the swivel
To the proper length.
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And then the partially finished
Swivel falls into a basket.
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Next, a drill
Works on the rounded tip,
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Scooping out the center.
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And now you have
A finished swivel.
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They take two chain links
And two swivels.
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They make a small chain --
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Two links with swivels
On the ends.
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They lock the links
And the swivels together.
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00:03:14,758 --> 00:03:17,896
And now the swivel-link assembly
Is complete.
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The swivels will provide
Some rotational freedom
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Between the cuffs.
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But if they don't weld
The links together,
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The prisoner
Could have total freedom.
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It's time to assemble
The handcuffs.
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They install studs
In the outer framework
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And attach the ratchets to them.
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The swivel link fits into the
Little grooves in the framework.
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They hammer the inner frame on
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And then lift the top and bottom
Assemblies together.
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A tap with a hammer
Holds them loosely together.
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Then a press bears down
To make a tight seal.
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These cuffs look complete,
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But they aren't quite ready
For a life of crime.
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They need to be toughened up.
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So they spend 25 minutes
In a furnace,
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And the searing heat
Hardens the seal.
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This is the pawl,
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A spring-loaded bar that will
Engage the teeth of the ratchet.
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They lock the pawl and spring
In place.
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A press pushes pins
Into the assembly
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To hold everything in position.
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Then they stamp serial numbers
Onto each set of handcuffs
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So that the police
Can keep track of them.
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Now the handcuffs shake in
A vibrating bin full of stones.
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This polishes the rough edges.
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It's time for the ultimate test.
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They activate a 500-pound pull,
And the handcuffs remain strong.
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They also tap each set to make
Sure the ratchets drop freely.
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Handcuffs are
Temporary restraints,
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And most can be opened
With the universal key.
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They pack two with each set,
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Along with the instructions.
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There's no doubt
They'll have a captive market
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Because there's always someone
Who needs to be locked up.
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But then again, there are also
Those who deserve their freedom.
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Narrator: the need to seal
Windows and cracks
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In walls and floors has been
Around since antiquity.
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Lucky for us, we no longer
Have to stuff rags
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Or smelly fish glue
Into these crevices.
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Today's caulking
And drywall compounds
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Form durable synthetic seals
That also blend into the decor.
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This company's caulking comes
In two types, latex and acrylic,
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Both good
For indoor and outdoor use.
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To make acrylic caulking,
They blend water with chemicals
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That prevent mold and help the
Caulking withstand cold weather.
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Everything blends
For about one minute.
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The batch then goes
Into another mixer
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Containing 1,500 pounds
Of synthetic resin.
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They add a plasticizer
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That keeps the caulking flexible
Over time.
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A combination of colorants
Tints the caulking --
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In this case, a shade of brown
Called sandalwood.
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After 15 minutes of blending,
The caulking is ready.
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To test the batch,
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They cure a sample at 77 degrees
Fahrenheit for one week...
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Then check its flexibility.
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If the batch gets the okay,
It goes into this machine,
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Which lines up
Plastic caulking tubes.
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Piston pumps
Lift four tubes at a time,
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And the nozzles fill each tube
With 10 ounces of caulking.
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The machine can fill up
To 1,000 tubes per hour.
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The machine then seals
The bottom end of the tubes
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With plastic covers.
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The top ends have closed nozzles
With replaceable caps.
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00:08:05,000 --> 00:08:07,551
Thanks to the resins
And plasticizers,
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This company's products
Last up to 30 years.
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That's the tough side
Of caulking,
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00:08:14,241 --> 00:08:18,206
But there's also
A gentler, craftier side.
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Start by drawing a pattern
On a piece of paper.
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Then lay glass on top and
Run caulking along the pattern.
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After 48 hours,
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The caulking hardens
Into a delicate lattice.
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Then fill in the spaces
With clear silicone
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00:08:36,793 --> 00:08:38,482
For a frosted look.
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Use a small steel brush
And rubber gloves
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To spread it and create texture.
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Perfect for a door
Or a bathroom window.
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00:08:51,827 --> 00:08:55,137
This factory
Also makes joint compound.
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00:08:55,137 --> 00:08:57,965
Use this product to cover
Cracks, holes, and seams
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00:08:57,965 --> 00:08:59,103
In drywall.
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00:08:59,103 --> 00:09:01,862
To make it, they mix
185 gallons of water
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00:09:01,862 --> 00:09:03,827
With chemicals that prevent mold
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00:09:03,827 --> 00:09:07,551
And a type of clay that makes
The compound more spreadable.
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00:09:10,275 --> 00:09:14,862
Now for the main ingredient --
440 pounds of chalk.
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00:09:14,862 --> 00:09:19,448
It's what remains on the wall
When the compound dries.
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00:09:19,448 --> 00:09:21,172
Next, they add mica,
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00:09:21,172 --> 00:09:24,137
A mineral whose tiny plates
Slide over each other
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00:09:24,137 --> 00:09:27,448
To make the compound flexible
And help prevent cracking.
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00:09:29,827 --> 00:09:32,034
They test the thickness
With a device
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That gauges how much pressure
It takes to stir the compound.
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00:09:40,448 --> 00:09:43,724
Next, they take a sample
From every batch
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00:09:43,724 --> 00:09:45,827
And measure the ph level.
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00:09:45,827 --> 00:09:49,689
It should have a reading of 8.8,
Quite high because of the chalk.
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00:09:51,758 --> 00:09:55,344
This is what's called
A sandability test.
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Technicians first let a precise
Amount of compound harden
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00:09:58,310 --> 00:10:00,275
On a piece of drywall.
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00:10:00,275 --> 00:10:02,000
This machine then sands it down,
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00:10:02,000 --> 00:10:04,931
Applying 100 strokes
In 2 minutes.
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00:10:10,206 --> 00:10:12,758
Technicians then remeasure
The combined weight
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Of the compound and drywall,
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00:10:14,310 --> 00:10:16,689
Registering how much
Has been lost.
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00:10:16,689 --> 00:10:20,068
Maximum weight loss
Should be 4%.
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00:10:20,068 --> 00:10:23,793
If the batch passes the test,
They feed it into this machine.
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00:10:23,793 --> 00:10:27,413
It pumps compound into either
Small-size, 6.6-pound
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00:10:27,413 --> 00:10:32,068
Or large-size, 15.5-pound
Plastic buckets.
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00:10:32,068 --> 00:10:35,137
Then using a hydraulic press,
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00:10:35,137 --> 00:10:38,068
A worker seals the containers
With plastic covers.
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00:10:38,068 --> 00:10:40,689
To open the bucket,
You break a small plastic tab
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00:10:40,689 --> 00:10:42,413
And lift off the cover.
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00:10:44,551 --> 00:10:47,689
Joint compound
Also has its crafty uses.
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00:10:47,689 --> 00:10:49,034
With a stencil,
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00:10:49,034 --> 00:10:51,482
You can apply small amounts
In intricate patterns
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00:10:51,482 --> 00:10:53,379
To decorate a picture frame
Or a mirror.
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00:10:53,379 --> 00:10:56,172
Now, that is some fancy filler.
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00:11:07,896 --> 00:11:09,310
Narrator: compressing propane
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00:11:09,310 --> 00:11:11,172
Allows you to sell it
By the bottle.
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00:11:11,172 --> 00:11:14,413
When you compress it,
Propane gas turns into a liquid,
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00:11:14,413 --> 00:11:16,689
And as a liquid,
It's much more compact,
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00:11:16,689 --> 00:11:18,931
Which means you can pack
A lot of energy
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00:11:18,931 --> 00:11:20,482
Into a small container.
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00:11:20,482 --> 00:11:23,310
Opening the valve
Converts it back to gas,
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00:11:23,310 --> 00:11:26,413
Giving you energy
That you can put to good use.
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00:11:31,413 --> 00:11:35,448
Bottling energy means you can
Always have fuel on hand.
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00:11:35,448 --> 00:11:40,034
To make these tanks, they start
With this big coil of steel.
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00:11:40,034 --> 00:11:44,965
A press punches out 3 disks
19 inches in diameter
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00:11:44,965 --> 00:11:46,793
With each swoop.
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00:11:55,172 --> 00:11:57,862
A second press clamps the disk
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00:11:57,862 --> 00:12:00,068
As a cylinder-shaped die
Thrusts upward,
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00:12:00,068 --> 00:12:02,379
Transforming it into a shell.
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00:12:16,586 --> 00:12:20,448
Each shell is 1/2
Of a barbecue tank.
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00:12:26,551 --> 00:12:28,586
Next, suctioning devices
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Carry the tank shells
Over to a trimmer,
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00:12:30,896 --> 00:12:32,965
Where a blade gives it
A neat edge.
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Workers then insert flanges
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Into prepunched holes
In the top shells.
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00:12:45,172 --> 00:12:48,206
The top and bottom halves
Of the barbecue tanks
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00:12:48,206 --> 00:12:50,689
Now move in separate directions.
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The tops head into
An automated welding station
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Where the flanges
Are fused to them.
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00:13:00,931 --> 00:13:02,689
The weld has to be perfect
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00:13:02,689 --> 00:13:04,896
So it can take the pressure
Of compressed fuel
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00:13:04,896 --> 00:13:07,068
Without exploding.
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00:13:11,586 --> 00:13:15,758
This die simultaneously bends
Steel strips into rings
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00:13:15,758 --> 00:13:18,068
And punches holes in them.
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00:13:20,517 --> 00:13:22,793
These rings
Will be used as pedestals,
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00:13:22,793 --> 00:13:26,000
And the holes can be used to
Mount the tank to a barbecue.
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00:13:33,793 --> 00:13:36,000
Next, a machine welds the rings
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To the bottoms
Of the tank shells.
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00:13:49,655 --> 00:13:52,379
The top and bottom tank shells
Converge.
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00:13:55,275 --> 00:13:58,724
And a pusher device nudges
The tops onto the bottoms.
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00:14:07,103 --> 00:14:10,862
They load each freshly assembled
Tank onto a welding lathe.
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00:14:10,862 --> 00:14:13,551
The lathe turns
As an automated welding gun
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00:14:13,551 --> 00:14:15,206
Follows the seam precisely,
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00:14:15,206 --> 00:14:18,689
Melting and bonding
The two pieces together.
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00:14:18,689 --> 00:14:21,103
But this processing
Has hardened the steel...
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00:14:21,103 --> 00:14:22,448
Not a good thing
198
00:14:22,448 --> 00:14:25,103
Because these tanks will need
To expand and contract
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00:14:25,103 --> 00:14:27,448
To accommodate pressurized fuel.
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00:14:29,689 --> 00:14:32,310
So they temper the tanks
In a furnace.
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00:14:36,379 --> 00:14:39,241
They do random tests
Of the welded seam.
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00:14:39,241 --> 00:14:42,793
They cut out a piece of the tank
And grind it on both sides
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00:14:42,793 --> 00:14:46,862
To expose the weld.
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00:14:46,862 --> 00:14:48,344
Then they use a jack
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00:14:48,344 --> 00:14:52,482
To bend the sample
Right at the seam.
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00:14:52,482 --> 00:14:55,379
It doesn't split
And passes the test.
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00:14:58,965 --> 00:15:03,172
In another test, they lower
A tank into a water-filled drum.
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00:15:03,172 --> 00:15:04,931
They pump water into the tank,
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00:15:04,931 --> 00:15:07,551
Causing pressure inside the drum
To rise,
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00:15:07,551 --> 00:15:12,275
Proving the tank will indeed
Expand with pressure changes.
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00:15:12,275 --> 00:15:15,241
The tanks then travel down a row
Of paint guns,
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00:15:15,241 --> 00:15:16,448
Which spray them
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00:15:16,448 --> 00:15:19,172
With electrostatically charged
Powder paint.
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00:15:20,862 --> 00:15:24,931
The tanks journey about a half
Mile to an inspection station.
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00:15:27,482 --> 00:15:30,344
Here, workers
Check for contaminants.
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00:15:33,172 --> 00:15:36,034
Then they drop valves
Into the flanged openings
217
00:15:36,034 --> 00:15:39,103
And place the barbecue cylinder
In a special machine
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00:15:39,103 --> 00:15:41,517
That screws the valve on
Very tightly.
219
00:15:49,344 --> 00:15:53,586
In one final test, they submerge
Air-filled tanks in water.
220
00:15:53,586 --> 00:15:55,172
If the water doesn't bubble up,
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00:15:55,172 --> 00:15:58,206
It means the valve
Isn't leaking.
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00:15:58,206 --> 00:15:59,793
And after all that,
223
00:15:59,793 --> 00:16:03,413
These barbecue tanks should be
Able to take plenty of grilling.
224
00:16:15,034 --> 00:16:18,689
Narrator: when the usual ways of
Identifying human remains fail
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00:16:18,689 --> 00:16:20,413
And the investigation stalls,
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00:16:20,413 --> 00:16:22,862
Police sometimes need
A little image building,
227
00:16:22,862 --> 00:16:25,000
As in facial reconstruction.
228
00:16:25,000 --> 00:16:28,689
Using the skull, they re-create
The face of the deceased
229
00:16:28,689 --> 00:16:31,206
In hopes that it will jog
Someone's memory.
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00:16:31,206 --> 00:16:34,172
It's a high-tech way
To solve a mystery.
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00:16:40,000 --> 00:16:41,793
To reconstruct a face,
232
00:16:41,793 --> 00:16:44,862
The specialist uses resin
To make an exact replica
233
00:16:44,862 --> 00:16:47,344
Of the unidentified man's
Cranium.
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00:16:51,724 --> 00:16:55,000
He attaches it to the rest
Of the skull cast.
235
00:16:57,068 --> 00:17:00,827
And now he has an exact copy
Of the man's skull.
236
00:17:03,655 --> 00:17:06,241
Next he measures rubber pegs
To different lengths
237
00:17:06,241 --> 00:17:08,655
That are equivalent
To the various thicknesses
238
00:17:08,655 --> 00:17:10,586
Of facial skin.
239
00:17:10,586 --> 00:17:14,379
The short one is placed on the
Forehead where the skin is thin.
240
00:17:22,275 --> 00:17:27,344
Then he installs actual
Prosthetic eyes made of plastic.
241
00:17:27,344 --> 00:17:30,758
Those are suction cups
Protruding from them now.
242
00:17:30,758 --> 00:17:33,241
They help him to align the eyes.
243
00:17:33,241 --> 00:17:34,827
He shines a light into them
244
00:17:34,827 --> 00:17:38,896
To confirm that they're looking
Straight ahead.
245
00:17:38,896 --> 00:17:43,000
Next he cuts out muscle shapes
From rolled clay.
246
00:17:43,000 --> 00:17:46,758
This piece simulates the area
Around the mouth.
247
00:17:49,310 --> 00:17:52,965
The man's muscles have left
Tension marks on his skull.
248
00:17:52,965 --> 00:17:56,275
Those marks combined with
The knowledge of facial anatomy
249
00:17:56,275 --> 00:17:59,689
Help him decide
Where to build up muscle.
250
00:17:59,689 --> 00:18:02,379
He makes the face expressionless
251
00:18:02,379 --> 00:18:04,172
Because expressions are unique
252
00:18:04,172 --> 00:18:07,482
And impossible to extrapolate
From a skull.
253
00:18:09,551 --> 00:18:13,275
Next he sculpts muscle
Around the prosthetic eyes.
254
00:18:15,310 --> 00:18:19,137
There are no clues about the
Actual shape of this man's eyes,
255
00:18:19,137 --> 00:18:21,413
So he gives them a generic look.
256
00:18:27,310 --> 00:18:31,103
The skull does divulge
The length and width of the nose
257
00:18:31,103 --> 00:18:34,931
As well as the location
Of the nostrils.
258
00:18:34,931 --> 00:18:38,137
Now he builds up smiling muscles
259
00:18:38,137 --> 00:18:41,620
Followed by fat
And a salivary gland.
260
00:18:41,620 --> 00:18:46,034
He uses different-colored clay
So he can see them more clearly.
261
00:18:46,034 --> 00:18:49,137
He maps out a location
For the ears
262
00:18:49,137 --> 00:18:52,689
But doesn't yet attach them.
263
00:18:52,689 --> 00:18:54,896
He shapes muscles in the neck,
264
00:18:54,896 --> 00:18:59,655
Working from measurements
And photos from the crime scene.
265
00:18:59,655 --> 00:19:02,068
Next he gives the model skin.
266
00:19:11,482 --> 00:19:13,965
As he applies
This layer of clay,
267
00:19:13,965 --> 00:19:17,551
He uses the protruding pegs
As thickness guides.
268
00:19:23,931 --> 00:19:27,689
And after much sculpting,
The model has come to life.
269
00:19:30,103 --> 00:19:32,448
But he needs one more clay ear.
270
00:19:32,448 --> 00:19:35,551
The skull offers some hints
About the ears' size
271
00:19:35,551 --> 00:19:38,551
But not their shape,
So he keeps that generic.
272
00:19:46,379 --> 00:19:49,344
Now he sponges the clay
To give it some texture
273
00:19:49,344 --> 00:19:51,103
So it looks more like real skin.
274
00:19:55,172 --> 00:19:59,310
The artist snaps his picture
With a digital camera
275
00:19:59,310 --> 00:20:02,137
And then downloads the image
Onto a computer.
276
00:20:02,137 --> 00:20:04,517
Using photo-editing software,
277
00:20:04,517 --> 00:20:07,620
He transfers some hair
To the shot of the clay model.
278
00:20:07,620 --> 00:20:09,896
He knows from evidence
On the scene
279
00:20:09,896 --> 00:20:12,172
That the man's hair
Was styled in dreadlocks
280
00:20:12,172 --> 00:20:14,206
And that he had a beard.
281
00:20:19,931 --> 00:20:23,379
He borrows brows
From another photo.
282
00:20:33,103 --> 00:20:35,655
He paints in the brows
With a stylus,
283
00:20:35,655 --> 00:20:38,758
Which is a kind
Of computer mouse.
284
00:20:38,758 --> 00:20:41,931
Using the same technique,
285
00:20:41,931 --> 00:20:44,068
He gives the image facial hair.
286
00:20:50,896 --> 00:20:54,275
This digital artistry
Takes a couple of days,
287
00:20:54,275 --> 00:20:56,206
And the skull mold
And clay model
288
00:20:56,206 --> 00:20:58,862
Take 12 days to complete...
289
00:20:58,862 --> 00:21:00,862
Time well spent
290
00:21:00,862 --> 00:21:03,000
Because once the pictures
And information
291
00:21:03,000 --> 00:21:05,068
Are posted on police sites
Like this one,
292
00:21:05,068 --> 00:21:08,068
It may finally help them
Put a name to this face.
293
00:21:08,068 --> 00:21:10,620
--captions by vitac--
Www.Vitac.Com
294
00:21:10,620 --> 00:21:13,517
Captions paid for by
Discovery communications, inc.
295
00:21:18,172 --> 00:21:20,241
If you have any comments
About the show
296
00:21:20,241 --> 00:21:22,862
Or if you'd like to suggest
Topics for future shows,
297
00:21:22,862 --> 00:21:24,551
Drop us a line at...
24066
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