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-- captions by vitac --
Www.Vitac.Com
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>> narrator: a pneumatic impact
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Wrench is a power tool that
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Tightens and untightens nuts,
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Bolts, and other fasteners.
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You hook it up to the air hose
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Coming off a compressor.
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The anvil at the tip turns at
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High speed to tighten until
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Snug, then switches to a
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Hammering action, called
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Impacting, to tighten even more.
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You've probably seen a pneumatic
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Impact wrench in action at your
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Local garage.
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It's standard equipment for
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Removing and installing wheels.
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Air pressure runs through the
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Tool's motor, spinning a rotor
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Within.
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That rotates the tool's anvil,
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Which turns the wheel nut.
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At the manufacturing plant, they
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Machine the rotor from a bar of
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Steel mounted on a lathe.
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It takes about a minute and a
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Half for the computer-guided
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Precision tools to carve out the
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Basic shape.
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The next machine carves teeth on
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One end of the rotor, creating
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What's called a hobbed edge.
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Now a computer-guided mill cuts
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Eight slots.
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This shaping of the steel
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Generates a lot of heat, so
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Coolant flows throughout all
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These machining phases to
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Prevent the equipment from
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Overheating.
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Next, they temper the rotors for
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10 hours in a
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1,700-degree-fahrenheit furnace.
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This hardens and strengthens the
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Steel, but to fortify it
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Further, they pump in carbon
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From a propane burner.
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The carbon impregnates each
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Rotor to a depth of
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.7 millimeters.
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Once the rotor cools, a
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Computer-controlled grinder
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Shapes it to the final
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Specifications.
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Then a machine with nylon
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Bristles smoothes the surface.
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This completes the
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Transformation from steel bar to
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Rotor.
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Meanwhile, the tool's magnesium
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Housing has been getting a
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Bright coat of paint.
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The housing has two parts -- the
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Main section and a back cap.
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Both go into an oven where the
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Paint bakes for a half-hour at
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Almost 400 degrees fahrenheit.
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Now assembly begins with the
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Trigger and the stem of the main
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Section and then, with this
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Tool, what's called the tipper
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Valve.
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When you push the trigger, it
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Tips, letting in air.
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This spring keeps the tipper
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Valve closed when you're not
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Pushing the trigger.
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And this bushing is where you
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Attach the air hose coming from
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The compressor.
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Next, they install the reversing
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Valve.
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It slots into the housing just
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Above the trigger.
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When you press the trigger, the
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Anvil rotates clockwise to
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Tighten the fastener, but when
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You activate the reversing
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Valve, it sends the air into
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Different chambers, turning
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The tool counter-clockwise to
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Remove the fastener.
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They glue a rubber pad to the
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Top of the housing to cushion
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Your grip on the tool.
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A laser engraves manufacturing
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Information on the back cap.
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To assemble the motor, they
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Start with a back cap and press
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In a bearing on which the rotor
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Will spin.
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Next, a plate to enclose one end
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Of the rotor and an alignment
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Pin to position the plate for
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Enclosing the other end.
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And finally, the rotor itself.
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Into each of the rotors' slots
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Goes a vein made of resin-imbued
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Fabric.
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These veins work like the blades
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On a windmill.
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The air entering the tool turns
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Them, which spins the rotor.
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After slipping a steel cylinder
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Over the rotor, they enclose it
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With a second plate, then a
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Larger plate with a ball
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Bearing.
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Now some oil to lubricate what
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They call the impact mechanism.
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This component contains the
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Tool's anvil, as well as the
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Parts that produce the hammering
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Action.
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Finally, a press seals the main
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Section of the housing to the
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Back cap.
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Every pneumatic impact wrench
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This factory produces goes
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Through extensive testing in
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Both free speed -- that's when
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The tool spins like an ordinary
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Drill -- and in impact mode.
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So, if you've got a nut or other
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Fastener to drive, take one of
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These babies for a spin.
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>> narrator: natural marble
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Has a modern alternative -- a
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Composite material known as
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Cultured marble.
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It consists of ground marble or
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Limestone mixed with liquid
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Plastic.
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Less expensive than natural
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Marble and easier to work with
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Than stone, cultured marble is
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Often used to create unique
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Bathroom and kitchen fixtures.
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This vanity top and pedestal
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Sink are both made of cultured
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Marble, cast in fiberglass
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Molds.
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To make a vanity top, a worker
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Centers a sink-bowl mold on a
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Counter mold...
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Then places a drainpipe
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Attachment over the sink mold's
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Exit drain.
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He marks with a grease pencil
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Where the faucet openings will
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Be.
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Then, he masks off areas to
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Protect and places a bees'-wax
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Seal all along the bowl's edge
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Where it meets the counter.
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He sprays the molds with
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Protective gel that will give
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The vanity top a shiny
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Protective finish.
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Finally, he places cardboard
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Tubes over the faucet-hole
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Marks.
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The molds are now ready for
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Casting.
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A machine equipped with a mixing
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Pot automatically measures out
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The resin workers pour into
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These molds.
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Raw pigments like sterling
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Silver, sandbar, wild rose,
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White titanium, and fawn beige
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Gives the resin its color.
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A worker sifts them in measured
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Amounts into the resin as it's
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Mixing.
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Next, he adds a catalyst to the
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Resin...
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Then some granulated limestone
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To thicken it.
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The catalyst sets off the
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Chemical reaction that causes
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The resin mix, known as matrix,
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To harden.
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From this moment on, he needs to
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Be swift.
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He has only 15 minutes to mix,
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Color, and pour this batch of
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Matrix into the molds before it
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Hardens.
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He adds more white pigment to
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The base color, using a paddle
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To mix it along the surface.
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Then he takes the wild rose
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Pigment, mixes in some resin,
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And again works it into the
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Surface to streak it with color,
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An effect known as veining,
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That mimics the look of marble.
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He scoops out some of the
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Surface mix and pours it onto
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The mold.
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As the matrix pulls, the
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Rose-colored veining in the
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Surface mix is visible.
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Now he pours out the rest of the
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Matrix.
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He casts the sink and counter in
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A single piece so there won't
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Be any grout lines around the
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Bowl.
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A pneumatic tool vibrates the
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Molds, bringing tiny air bubbles
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To the surface -- the vanity's
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Underside.
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Air trapped in the matrix can
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Cause it to break or mar the
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Finish.
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A worker lays down a temporary
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Plastic hat over the bowl.
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He weighs it down to hold it in
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Place as he pours matrix inside
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The hat to cast a bowl that's as
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Thick as the base -- about
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.8 inches.
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He lets the matrix set for
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30 minutes, then removes the hat
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From the bowl.
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Next, he drops down the mold's
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Backsplash and puts a hole in
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The drain.
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He shoots in bursts of
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Compressed air while a co-worker
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Carefully wedges under the
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Backsplash to part the mold,
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Revealing the vanity's marbled
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Surface.
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To make sure the vanity lies
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Level on its cabinet, a worker
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Grinds down the underside, then
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The drain area.
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Next, he sands down the
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Backsplash and the sides,
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Working at an angle with a hand
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Sander to dull any sharp edges.
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He removes the drain mold and
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Buffs the surface to a mirror
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Finish.
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Finally, he knocks out the
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Faucet holes.
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Here's a finished vanity with a
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Variety of integrated sink bowls
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On display.
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Cultured marble truly is a
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Versatile material that offers
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Endless possibilities.
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>> narrator: many of us take
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Time out to enjoy a tasty snack
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Like plantain chips, but we know
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We should put limits when
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Treating ourselves to a good
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Thing.
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The trick is to learn as much as
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We can about the snacks we're
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Eating so we can choose a treat
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That's right for us.
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Seeing how plantain chips are
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Made can help us make an
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Informed choice.
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This looks like a banana, but
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It's actually a plantain --
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A staple food in many parts of
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The world.
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00:11:21,800 --> 00:11:23,633
In tropical countries like
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00:11:23,633 --> 00:11:25,433
Costa rica, it's made into a
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00:11:25,433 --> 00:11:26,900
Popular snack called plantain
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Chips.
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00:11:28,833 --> 00:11:30,833
The cycle from fruit to snack
288
00:11:30,833 --> 00:11:32,433
Begins here.
289
00:11:32,433 --> 00:11:34,067
A worker cleans off the root of
290
00:11:34,067 --> 00:11:35,867
An offspring from a mature
291
00:11:35,867 --> 00:11:42,200
Plantain tree.
292
00:11:42,200 --> 00:11:43,733
He prepares the root for
293
00:11:43,733 --> 00:11:49,633
Planting as if it were a seed.
294
00:11:49,633 --> 00:11:52,067
In time, this seed will grow
295
00:11:52,067 --> 00:12:00,467
Into a mature plantain tree.
296
00:12:00,467 --> 00:12:02,533
After about nine months, the
297
00:12:02,533 --> 00:12:04,933
Plantain is ready to harvest.
298
00:12:11,600 --> 00:12:13,300
When a worker picks the fruit,
299
00:12:13,300 --> 00:12:14,767
They wrap it in plastic to
300
00:12:14,767 --> 00:12:16,467
Protect it against insects and
301
00:12:16,467 --> 00:12:18,067
Disease.
302
00:12:18,067 --> 00:12:20,233
Each mature tree yields only one
303
00:12:20,233 --> 00:12:21,767
Bushel of fruit its entire
304
00:12:21,767 --> 00:12:22,867
Life.
305
00:12:22,867 --> 00:12:24,067
Once he harvests the mature
306
00:12:24,067 --> 00:12:26,333
Tree, it's the tree's offspring
307
00:12:26,333 --> 00:12:27,833
That yield more fruit and
308
00:12:27,833 --> 00:12:31,333
Continue the life cycle.
309
00:12:31,333 --> 00:12:32,933
The worker then rinses the
310
00:12:32,933 --> 00:12:34,767
Plantain in treated water that
311
00:12:34,767 --> 00:12:37,067
Helps wash off sap and kill any
312
00:12:37,067 --> 00:12:38,933
Possible fungus.
313
00:12:44,633 --> 00:12:46,433
Local workers then load the
314
00:12:46,433 --> 00:12:48,167
Cases of plantains onto their
315
00:12:48,167 --> 00:12:50,133
Boat for a full day's trip to
316
00:12:50,133 --> 00:12:52,233
The processing plant.
317
00:12:52,233 --> 00:12:54,200
Their hard work is valued by the
318
00:12:54,200 --> 00:12:55,733
Company which is proud to
319
00:12:55,733 --> 00:12:57,633
Support the local economy.
320
00:13:01,767 --> 00:13:04,233
At the plant, a worker puts the
321
00:13:04,233 --> 00:13:05,933
Plantain into boiling water for
322
00:13:05,933 --> 00:13:07,267
About a minute.
323
00:13:07,267 --> 00:13:08,833
Boiling the fruit changes its
324
00:13:08,833 --> 00:13:10,767
Color, but more importantly, it
325
00:13:10,767 --> 00:13:12,067
Greatly reduces the amount of
326
00:13:12,067 --> 00:13:14,200
Sap the fruit releases, which
327
00:13:14,200 --> 00:13:15,567
Makes handling and peeling the
328
00:13:15,567 --> 00:13:22,067
Otherwise sticky skin possible.
329
00:13:22,067 --> 00:13:23,733
The various lengths and widths
330
00:13:23,733 --> 00:13:25,767
Of plantain prohibit peeling it
331
00:13:25,767 --> 00:13:27,367
By machine.
332
00:13:27,367 --> 00:13:28,733
Workers at this costa rican
333
00:13:28,733 --> 00:13:30,867
Plant cut more than 50,000
334
00:13:30,867 --> 00:13:32,900
Pounds of plantain every day,
335
00:13:32,900 --> 00:13:34,800
All by hand.
336
00:13:38,467 --> 00:13:40,200
Each one is then cut into slices
337
00:13:40,200 --> 00:13:41,967
Of a specific thickness for
338
00:13:41,967 --> 00:13:46,433
Chips.
339
00:13:46,433 --> 00:13:48,633
To do this, workers push the
340
00:13:48,633 --> 00:13:50,400
Fruit one at a time into a
341
00:13:50,400 --> 00:13:56,067
Cutting machine.
342
00:13:56,067 --> 00:13:57,800
The slices of plantain fall
343
00:13:57,800 --> 00:13:59,233
Through the machine into a
344
00:13:59,233 --> 00:14:03,433
Deep-fry oven below.
345
00:14:03,433 --> 00:14:05,100
A rotating grill and conveyor
346
00:14:05,100 --> 00:14:07,200
System helps ensure uniform
347
00:14:07,200 --> 00:14:09,067
Cooking of the slices in natural
348
00:14:09,067 --> 00:14:11,100
Palm oil as they travel on an
349
00:14:11,100 --> 00:14:13,333
Uninterrupted 30-foot journey.
350
00:14:19,200 --> 00:14:21,133
After cooling, the worker
351
00:14:21,133 --> 00:14:23,267
Removes any under- or overcooked
352
00:14:23,267 --> 00:14:25,500
Chips.
353
00:14:33,267 --> 00:14:35,067
The chips then travel into a
354
00:14:35,067 --> 00:14:37,167
Tumbler that adds salt or other
355
00:14:37,167 --> 00:14:39,200
Seasonings or flavors, depending
356
00:14:39,200 --> 00:14:45,933
On the product.
357
00:14:45,933 --> 00:14:48,133
The chips then exit the tumbler
358
00:14:48,133 --> 00:14:50,067
And are ready for packaging.
359
00:14:53,833 --> 00:14:55,433
The packaging machine gently
360
00:14:55,433 --> 00:14:56,900
Funnels the chips into separate
361
00:14:56,900 --> 00:14:58,800
Chutes as it calculates the
362
00:14:58,800 --> 00:15:00,500
Exact amount it needs to fill
363
00:15:00,500 --> 00:15:02,600
Each bag.
364
00:15:12,900 --> 00:15:14,800
Once filled, the packaging
365
00:15:14,800 --> 00:15:16,567
Machine then cuts and seals the
366
00:15:16,567 --> 00:15:18,667
Individual bags, then sends them
367
00:15:18,667 --> 00:15:20,167
For distribution across the
368
00:15:20,167 --> 00:15:22,133
World.
369
00:15:30,867 --> 00:15:32,667
Plantain chips also come in
370
00:15:32,667 --> 00:15:33,667
Strips.
371
00:15:33,667 --> 00:15:35,567
They're trans-fat free and come
372
00:15:35,567 --> 00:15:37,333
In a variety of formats that
373
00:15:37,333 --> 00:15:39,233
Make a handy treat.
374
00:15:53,300 --> 00:15:54,733
>> narrator: nascar is one of
375
00:15:54,733 --> 00:15:56,067
The most popular spectator
376
00:15:56,067 --> 00:15:57,267
Sports in north america.
377
00:15:57,267 --> 00:15:58,667
The national association for
378
00:15:58,667 --> 00:16:00,167
Stock car auto racing holds a
379
00:16:00,167 --> 00:16:01,967
Series of 36 races a year,
380
00:16:01,967 --> 00:16:03,733
Mostly at oval or d-shaped
381
00:16:03,733 --> 00:16:05,700
Tracks on which the cars make
382
00:16:05,700 --> 00:16:06,733
Only left turns.
383
00:16:06,733 --> 00:16:08,233
They're built from scratch
384
00:16:08,233 --> 00:16:09,700
Following nascar's strict
385
00:16:09,700 --> 00:16:11,600
Technical rules.
386
00:16:18,533 --> 00:16:20,567
Nascar's stock cars are based on
387
00:16:20,567 --> 00:16:22,067
Certain american-made road
388
00:16:22,067 --> 00:16:23,600
Cars.
389
00:16:23,600 --> 00:16:25,667
The frame is made out of steel
390
00:16:25,667 --> 00:16:27,767
Tubing.
391
00:16:27,767 --> 00:16:29,833
The hood, roof, and deck lid --
392
00:16:29,833 --> 00:16:31,800
That's like the regular car's
393
00:16:31,800 --> 00:16:33,800
Trunk cover -- are made out of
394
00:16:33,800 --> 00:16:35,100
Sheet steel.
395
00:16:35,100 --> 00:16:36,567
The workers who assemble the
396
00:16:36,567 --> 00:16:38,300
Body are called body hangers.
397
00:16:38,300 --> 00:16:39,733
They position all the parts
398
00:16:39,733 --> 00:16:41,433
According to a nascar-authorized
399
00:16:41,433 --> 00:16:43,333
Template.
400
00:16:43,333 --> 00:16:45,233
Here they clamp the body panels
401
00:16:45,233 --> 00:16:46,067
Together.
402
00:16:46,067 --> 00:16:47,933
Then, with an aluminum bracket,
403
00:16:47,933 --> 00:16:49,833
To the template for shaping.
404
00:16:53,133 --> 00:16:54,633
To make the wheel openings on
405
00:16:54,633 --> 00:16:56,400
The front fender, they use
406
00:16:56,400 --> 00:16:58,233
Shrinking jaws, a tool that
407
00:16:58,233 --> 00:17:00,200
Curves metal by squeezing it.
408
00:17:05,167 --> 00:17:06,767
Then they switch to a tool
409
00:17:06,767 --> 00:17:08,333
Called an english wheel.
410
00:17:08,333 --> 00:17:10,333
It rolls the curved metal into a
411
00:17:10,333 --> 00:17:12,600
Particular shape.
412
00:17:20,167 --> 00:17:21,800
The car's front suspension is
413
00:17:21,800 --> 00:17:23,533
Essentially the same as that of
414
00:17:23,533 --> 00:17:25,300
A regular car, except for the
415
00:17:25,300 --> 00:17:27,133
Angle of the tires, which they
416
00:17:27,133 --> 00:17:28,800
Manipulate by putting shims on
417
00:17:28,800 --> 00:17:30,533
This upper control arm.
418
00:17:30,533 --> 00:17:32,133
The right front tire tilts
419
00:17:32,133 --> 00:17:33,933
Inward and the left front tire
420
00:17:33,933 --> 00:17:35,067
Tilts outward.
421
00:17:35,067 --> 00:17:36,933
That's because these cars race
422
00:17:36,933 --> 00:17:38,367
On an oval track in one
423
00:17:38,367 --> 00:17:39,967
Direction only, so they're
424
00:17:39,967 --> 00:17:45,233
Making only left turns.
425
00:17:45,233 --> 00:17:46,867
Next, they install a brake
426
00:17:46,867 --> 00:17:47,900
Rotor.
427
00:17:47,900 --> 00:17:49,467
Then, a steel spacing plate
428
00:17:49,467 --> 00:17:51,733
Between the rotor and the wheel.
429
00:17:51,733 --> 00:17:53,133
This sets up the specific
430
00:17:53,133 --> 00:17:54,700
Distance from wheel to wheel
431
00:17:54,700 --> 00:17:59,067
That nascar rules require.
432
00:17:59,067 --> 00:18:01,133
They load a pair of brake pads
433
00:18:01,133 --> 00:18:03,233
Into a brake caliper and slide
434
00:18:03,233 --> 00:18:05,133
The caliper onto the rotor.
435
00:18:09,867 --> 00:18:11,133
The caliper contains
436
00:18:11,133 --> 00:18:12,933
Different-sized pistons so that
437
00:18:12,933 --> 00:18:14,767
It applies the brake pads to the
438
00:18:14,767 --> 00:18:22,733
Rotor evenly.
439
00:18:22,733 --> 00:18:24,433
Now they move onto the car's
440
00:18:24,433 --> 00:18:25,533
Inner workings.
441
00:18:25,533 --> 00:18:27,400
They mount the transmission to
442
00:18:27,400 --> 00:18:29,367
An aluminum housing that covers
443
00:18:29,367 --> 00:18:30,700
The flywheel, clutch, and other
444
00:18:30,700 --> 00:18:32,600
Components.
445
00:18:36,667 --> 00:18:38,400
Then they install the motor.
446
00:18:38,400 --> 00:18:40,867
It's an eight-cylinder, 750-plus
447
00:18:40,867 --> 00:18:42,767
Horsepower engine.
448
00:18:52,733 --> 00:18:54,800
They attach the car's plastic
449
00:18:54,800 --> 00:18:56,800
Windshield with bolted clips.
450
00:18:56,800 --> 00:18:58,933
If air gets into the car, these
451
00:18:58,933 --> 00:19:00,300
Strong clips will keep the
452
00:19:00,300 --> 00:19:02,200
Windshield from blowing out.
453
00:19:07,300 --> 00:19:09,067
The car's seat core is made of
454
00:19:09,067 --> 00:19:11,133
Aluminum, padded for comfort.
455
00:19:11,133 --> 00:19:13,367
Every nascar driver has his car
456
00:19:13,367 --> 00:19:15,467
Seat custom-built to his body
457
00:19:15,467 --> 00:19:17,367
Shape.
458
00:19:21,133 --> 00:19:23,067
After bolting in the seat, they
459
00:19:23,067 --> 00:19:24,633
Install the steering wheel.
460
00:19:24,633 --> 00:19:26,367
It has a safety release that
461
00:19:26,367 --> 00:19:28,267
Lets the driver remove the wheel
462
00:19:28,267 --> 00:19:29,567
With a single pull.
463
00:19:29,567 --> 00:19:31,433
This enables him to get in and
464
00:19:31,433 --> 00:19:33,200
Out of the car easily and to
465
00:19:33,200 --> 00:19:34,833
Remove the wheel quickly if he's
466
00:19:34,833 --> 00:19:38,667
Injured in a crash.
467
00:19:38,667 --> 00:19:41,100
Now, for the finishing touches.
468
00:19:41,100 --> 00:19:43,067
First, a large decal of the
469
00:19:43,067 --> 00:19:44,600
Car's number centered on each
470
00:19:44,600 --> 00:19:47,267
Door.
471
00:19:53,833 --> 00:19:56,333
Every nascar racecar is also
472
00:19:56,333 --> 00:19:57,500
Plastered with decals
473
00:19:57,500 --> 00:19:58,833
Advertising its driver's
474
00:19:58,833 --> 00:20:00,733
Sponsors.
475
00:20:05,667 --> 00:20:07,667
Nascar's stock cars have a few
476
00:20:07,667 --> 00:20:09,367
Key safety features.
477
00:20:09,367 --> 00:20:11,100
Fenders allow side-to-side
478
00:20:11,100 --> 00:20:13,067
Contact between cars without
479
00:20:13,067 --> 00:20:14,967
Their wheels hooking together.
480
00:20:17,800 --> 00:20:20,233
Roof flaps direct air downward,
481
00:20:20,233 --> 00:20:21,867
Keeping the cars close to the
482
00:20:21,867 --> 00:20:22,533
Ground.
483
00:20:22,533 --> 00:20:24,533
This stops a spinning car from
484
00:20:24,533 --> 00:20:29,967
Flipping over.
485
00:20:29,967 --> 00:20:32,300
A nascar stock car weighs in at
486
00:20:32,300 --> 00:20:34,467
More than 3,300 pounds.
487
00:20:34,467 --> 00:20:36,200
It travels to the track in the
488
00:20:36,200 --> 00:20:37,967
Top deck of a trailer.
489
00:20:37,967 --> 00:20:39,500
This keeps the bottom level
490
00:20:39,500 --> 00:20:41,300
Clear as a work space for the
491
00:20:41,300 --> 00:20:44,167
Driver's mechanical crew.
492
00:20:54,067 --> 00:20:55,833
If you have any comments about
493
00:20:55,833 --> 00:20:57,500
The show or if you'd like to
494
00:20:57,500 --> 00:20:58,667
Suggest topics for
495
00:20:58,667 --> 00:21:00,567
Future shows, drop us a line at
496
00:21:00,567 --> 00:21:04,367
Sciencechannel.Com/howitsmade.
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