All language subtitles for S10E12 - Steel Shipping Drums; Police Whistles; Miniature Train Wagons; Glass Blocks (1080p AMZN WEB-DL x265 Garshasp)_track3_[eng]

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Narrator: today,
On "How it's made"...

Steel shipping drums...

Police whistles...

♪♪

Miniature-train cars...

♪♪

And glass blocks.

♪♪

The steel shipping drum

Was invented in the late 19th
Century for the oil industry,

Which needed an alternative
To leaky wooden barrels.

But those first steel drums

Also leaked
From their soldered seams.

Welding them proved to be
The solution,

Giving this container
An airtight reputation.

It's a product that really
Delivers the goods.

A punch press first cuts
And forms the drum's bottoms

In one swoop.

A conveyer shuttles the bottoms
Down the line to a turntable.

As a drum bottom
Rotates on the turntable,

A nozzle sprays sealant onto it,
Coating it completely.

♪♪

Then the drum bottoms
Are stacked up.

Meanwhile, another punch press

Shapes steel discs into tops
For the drums.

Rollers turn up the outer edge
To a precise measurement.

Next, steel fittings tumble down
A vibratory conveyer

To a machine
That simultaneously punches

Threaded openings in the tops

And inserts the fittings.

One hole is for opening
And closing the drum.

The other is a vent.

At this station, workers check
The thickness of sheet steel

That will be used
For the body of the drum.

The thickness varies

Depending on what the container
Is to hold.

A machine called a shear

Slices the the coiled steel
Into sheets.

The steel sheets then move on
To a forming machine,

Where rollers curl them
Into the drum's shell.

Automated pushers
Then move each shell

Through an electric-resistance
Welder.

It generates heat
To weld the side seam,

Bonding it from both the inside
And the outside

So it won't leak.

♪♪

The shells roll down
To a machine called a flanger.

The flanger stretches and
Presses on the outer rims

At both ends, creating a lip.

♪♪

Then it's over to the beater.

Its rollers bear down
On the shells

To make grooves
Called rolling hoops.

These rolling hoops
Add rigidity to the shells.

♪♪

The shells now travel down
Another conveyer

And merge with the drum tops.

Automated pushers deliver a top
To the base of a shell.

♪♪

The shell rotates
In a spinning clamp

As rollers curl the edges
Of the top and shell together.

This creates an interlocked seam
Called a chime,

Which is then flattened by
Another roller.

Mechanized arms flip the shells

So the bottoms
Can now be installed.

♪♪

To join the bottoms
To the shells,

Rollers form another chime.

These interlocking seams

Are comprised of seven layers
Of steel,

Making them leakproof.

♪♪

That's critical,
Since the steel drums

May be used to transport
Hazardous goods.

♪♪

The steel drums now move forward
To a testing station.

Here, inspectors inject air
Into each drum

And check the seams for leaks.

The seams have been soaked up,

So if bubbles materialize,
It signifies a problem.

♪♪

The steel drums then go for
A whirl under the paint gun.

It sprays them with enamel paint
For a protective sheen.

Black is the most common color
For these shipping containers.

But custom colors
Can be ordered, too.

The steel drums
Then journey through an oven

That bakes the paint
To a hard finish.

The thickness of the paint
Is gauged with a special tool

That makes sure it's thick
Enough to withstand rusting.

Workers plug both openings

And put a temporary seal on
The vent to prevent tampering.

After that,
These steel shipping drums

Are ready for the long haul.

Next, get the blow-by-blow
At a police-whistle factory.

Narrator:
It was in the late 19th century

That london police started using
A special whistle

To get attention.

It was lightweight
And had a piercing sound --

A real improvement
Over the hand rattles

They had been using before.

That same design
Is still used today.

♪♪

They may be a blast
From the past,

But there's nothing better

For blowing the whistle
On lawbreakers.

The average traffic cop

Blows his whistle
Thousands of times a day,

So the whistles
Have to resist a lot of spit.

The whistle's body is made
Of high-grade brass tubing,

In which two slots are punched.

These are sound holes that
Will allow the noise to escape.

Using hydraulic pressure,

The brand name
Is stamped onto the tube.

♪♪

Next comes the mouthpiece.

Rollers sculpt
A piece of spinning brass

Into a shape
That's a bit like an hourglass.

♪♪

With the mouthpiece complete,

A hydraulic punch is used
To bend a piece of brass

Into a part called the slab.

The slab will be used to create

Two sound chambers
Inside the whistle.

♪♪

A loop is fitted on to an endcap

To make the whistle
Easier to hang on to.

♪♪

A rotating press
Bends the loop's tab

Against the inside of the cap

To fasten them together
Permanently.

♪♪

♪♪

Next, an endcap
Is attached to the slab,

And then the slab is forced
Into the cavity of the whistle,

Splitting it into two chambers.

♪♪

A police whistle actually
Produces two notes at once,

Giving it
That distinctive timbre.

These two separate
Sound chambers

Will produce
Two different pitches.

Now the ends of the whistle
Are dipped in solder paste

And then the looped cap
And mouthpiece

Are hammered onto
The pasted

The solder paste
Is a special lead-free compound

So the whistle-blower
Won't be exposed to toxins.

♪♪

Solder wires are also inserted
In the whistle chambers

Before capping the ends.

♪♪

These solder wires

Will act in conjunction
With the solder paste

To seal the whistle
In a process that happens next.

The whistles move through an
Electromagnetic conduction coil,

Which heats them
To a smoking 425 degrees.

♪♪

This causes the solder paste
And wires inside to melt

And flow into
The whistle's seams.

♪♪

Each whistle is then dipped
In an acid bath,

Which hardens the solder,
Sealing the whistle's seams.

♪♪

Next, the whistles
Are lowered into a nickel bath,

Where positively charged
Nickel ions

Migrate to the negatively
Charged whistles.

♪♪

Now it's time to make
Some noise.

Each whistle is tested
With compressed air.

♪♪

The tiniest pinhole
Will cause a whistle to fail,

And that happens in 3% of them.

♪♪

Failure
Is a crushing experience.

The rejects get flattened

And sent to a company
That reclaims the metal.

♪♪

On both land and sea, whistles
Are the sound of authority.

Here, workers assemble
A boatswain's pipe,

Used by naval officers to issue
Commands and salute dignitaries.

♪♪

There's a tiny hole in the ball
At the end of this pipe.

The player opens and closes
That hole with his hands

To change the whistle's pitch.

♪♪

And with that,

Production
At this whistle factory

Comes to a screeching halt.

♪♪

Up next, all aboard.

You're about to see
How raw plastic

Is transformed
Into a miniature train car.

Narrator: making miniature train
Cars is all about the details.

Every feature is scaled-down to
A fraction of the real thing,

And nothing is too small
To replicate.

The miniature train car is more
Than just a toy.

It's a work of art
And a collectible.

♪♪

On a miniature train track,
The past comes full circle

With replicas of trains from
Days gone by.

Craftsmen start
With historical photos

And drawings
Of actual train cars

And scale them down
To 1/48th size.

They feed polystyrene pellets
Like these

Into an injection-molding
Machine.

It melts the pellets
Into a thick paste.

The four sections
Of the mold close

And nozzles pump in the plastic.

It oozes into all the grooves

And hardens almost instantly
Into the shape of a train car.

♪♪

Then the excess plastic
Gets clipped off.

Here's a view of how the four
Parts of the mold come together

To shape melted plastic
Into a boxcar.

♪♪

They even create holes in the
Boxcar to attach accessories

And they impress details
Like ridging

That mimics the steel ribs
Of the life-size train car.

♪♪

More molds are used
To replicate door rails,

Brake wheels,
And other accessories.

♪♪

The assembler clips the parts
Off the framework

And files down
The rough sections.

♪♪

That is the brake wheel

She's snapping
Onto the end of the model.

Using a hobby knife,

She trims excess plastic
From the train car's step.

♪♪

She then glues a steel weight
To the bottom of the train car

To make it 1/48th the weight
Of the real thing.

Making something to scale
Is a bit of a balancing act.

Finally,
She attaches air-brake tanks

To the underframe of the car,

And it's time to spray-paint the
Model train car vivid orange.

It's a color that would have
Been used on an actual boxcar,

Combined with white.

♪♪

For that two-toned look, the
Model is held in a paint shield,

Which protects
The orange sections

As they spray on the white.

♪♪

This technique ensures
The paint job has clean lines.

♪♪

The car is left to dry
Overnight.

♪♪

Not all paint jobs
Are so flashy.

This car is basic black,

The perfect canvas
For white lettering.

♪♪

A pad picks up the ink
From letter engravings

On a printed plate and
Transfers the image to the car.

Metal wheels now roll off
A revolving conveyer.

They funnel into mechanisms

That press-fit them
Onto each end of metal axles.

♪♪

The wheel-and-axle assemblies
Drop into a bin below.

♪♪

Two sets of wheels

Are now installed
On a plastic framework.

The framework
Is then attached to a coupler,

The device
That links train cars.

♪♪

The wheels-and-coupler assembly

Are screwed on
To one end of the car.

Then the process is repeated
On the other end.

♪♪

The couplers
Are snapped together

To connect two train cars.

♪♪

In the world of train models,
A little grime is just fine.

A misting of paint

Makes the cars look dusty
And aged on purpose.

♪♪

The painter layers colors
To get just the right effect.

This technique adds
The element of realism

To the model train car.

It's all a matter of preference.

Some hobbyists prefer
This weathered look,

While others like their
Model trains shiny and new.

♪♪

The model train cars have now
Rolled off the assembly line,

And they're ready
To hit the tracks

For a whistle-stop tour
Of another era.

♪♪

Coming up, the hot scoop

On one of the world's
Favorite building blocks.

Narrator: when it comes
To building materials,

Glass blocks
Are clearly a classic.

In the 1920s and '30s,

They were a cornerstone of the
Art-deco style of architecture.

Today, glass blocks are still
Popular for creating walls,

Windows,
And stunning design features,

A stylish way to build
A privacy barrier

That still lets in light.

♪♪

Glass blocks
Aren't just decorative.

They insulate
From heat, cold, and noise.

♪♪

Production begins
With just four ingredients --

Recycled glass pieces
Called cullet, sand,

Soda ash, and limestone.

A computerized system
Portions out each one

And feeds them into a melter.

This giant furnace
Heats the batch of ingredients

To a fiery 2,700 degrees,

Transforming them
Into molten glass.

♪♪

The melter pumps out
Enough molten glass

To make one half block
At a time.

Automated shears
Slice just the right amount.

♪♪

The gob of glass
Then slides into a waiting mold.

♪♪

A plunger pushes the gob down,

Spreading glass
Throughout the mold cavity.

Its waffled surface imprints
That pattern into the glass.

♪♪

A blast of ambient air

Cools down the molten glass
Drastically,

From 1,800 degrees to 1,100
In just a few seconds.

♪♪

This way they don't lose
Their shape

When a retractable arm
Extracts them from the mold

And lays them
On a conveyer belt,

Leading into a sealing machine.

♪♪

This is where
Two half blocks

Join together
To form a full block.

♪♪

Entering the machine,

Each piece passes over
A series of burners

That keep the glass temperature
Constant.

Sudden cooling could crack
Or shatter the glass.

The machine then slowly reheats
The half blocks

Until their edges start melting.

♪♪

Next, they enter the part
Of the machine

Called the squeeze station.

Here, an automated press

Forces a top half
And bottom half together.

Their melted edges fuse,
Forming a single block.

♪♪

The blocks now travel
Into a leer,

An oven that cools the glass

At regulated temperatures
Over several hours.

This annealing process
Prevents cracking

And allows the glass
Time to set properly.

The glass goes in
At about 1,800 degrees.

Coming out, it's down to 175.

♪♪

The blocks are now ready
For inspection.

Workers use
Digital-alignment gauges

To make sure both halves
Are flush.

Then they run
A straight piece of steel

Along the block's surface
To check for any distortion.

Every block must meet
Precise standards

For both size and shape --

A 71/2-inch square
That's 4 inches thick.

♪♪

Building with glass blocks

Is similar to building
With bricks --

You use mortar
To stick them together.

To prep the blocks
For mortaring,

Workers now place each one
Onto a separate station.

♪♪

As it spins, nozzles spray
The edges with liquid vinyl.

This coating
Will help the mortar

Stick to the glass surface.

♪♪

Just one last step.

An ink-jet printer
Applies the product code

Along with
The manufacturing date and time.

♪♪

The quality-control department

Runs samples
Through an impact test.

A worker drops a weight

Through a tube
Onto the side of the block.

This verifies the strength
Of the sidewall and the seal

Between the two halves.

Finally, the glass blocks
Are ready for shipping.

Workers pack them
Into cardboard boxes

That have block-sized sections

To keep them safe
During transport.

Glass blocks come in so many
Shapes, sizes, and patterns

That the design possibilities
Are endless.

Both practical and beautiful,

It's no wonder
They're so popular

With builders and decorators
Alike.

♪♪

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