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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Today, on "How it's made"...
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History suggests slate
May have first been mined
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In the roman era,
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Although the earliest confirmed
Records date back to
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00:00:58,206 --> 00:01:01,413
The early 1700s.
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00:01:01,413 --> 00:01:04,827
Slate tiles were used for
General building construction
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And are still used today
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00:01:06,344 --> 00:01:08,724
For practical and aesthetic
Purposes.
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These pieces of floor slate
Appear to be right
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00:01:15,413 --> 00:01:16,724
From the quarry,
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00:01:16,724 --> 00:01:19,758
But they're part
Of an 18-piece
Puzzle
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That's cut the same way
Every time.
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00:01:22,344 --> 00:01:23,896
These pieces of wall slate
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00:01:23,896 --> 00:01:25,896
Are much thinner
And are used for paneling.
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00:01:29,103 --> 00:01:31,931
Uncut sheets of slate
In a variety of thicknesses
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00:01:31,931 --> 00:01:33,517
Come straight from the quarry.
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00:01:37,137 --> 00:01:40,068
After the slate sheets
Are stacked on a forklift,
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00:01:40,068 --> 00:01:41,793
A worker carefully
Drives them
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00:01:41,793 --> 00:01:43,758
To another part
Of the storage yard.
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00:01:47,000 --> 00:01:48,724
He sets them down gently.
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00:01:52,034 --> 00:01:54,344
Another worker splits the sheets
Of slate
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00:01:54,344 --> 00:01:55,793
Using a pneumatic zip gun.
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00:01:58,965 --> 00:02:01,758
It's a delicate process.
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00:02:01,758 --> 00:02:04,000
Once he splits the slate sheets,
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00:02:04,000 --> 00:02:07,068
The worker inspects the lines
In the pieces of slate
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00:02:07,068 --> 00:02:08,413
And looks for cracks.
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00:02:11,965 --> 00:02:15,275
Then, he carries the sheet
To a gauging machine.
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00:02:15,275 --> 00:02:17,206
He checks the thickness
Of the sheet
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00:02:17,206 --> 00:02:20,034
To make sure it won't cause jams
On the cutting table.
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00:02:24,206 --> 00:02:27,482
This multiblade cutting table
Slices a sheet of slate
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00:02:27,482 --> 00:02:29,137
Into a series of strips.
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00:02:33,241 --> 00:02:35,586
It's covered
With recycled water.
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00:02:35,586 --> 00:02:37,862
This lubricates
The cutting process,
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00:02:37,862 --> 00:02:39,862
Cools the slate
And cutting blades,
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00:02:39,862 --> 00:02:42,793
And removes unwanted dust
And particles.
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00:02:42,793 --> 00:02:45,379
A conveyor slowly moves
The slate sheet forward.
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00:02:49,068 --> 00:02:51,000
A total of 18 diamond blades
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00:02:51,000 --> 00:02:53,724
Slice the sheet of slate
Into strips.
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00:02:57,103 --> 00:02:59,689
These strips of slate
Will be used for wall paneling.
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00:03:03,413 --> 00:03:06,103
This cutting table
Can cut several sheets of slate
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00:03:06,103 --> 00:03:07,551
At the same time.
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00:03:10,793 --> 00:03:13,379
Once the cutting process
Is complete,
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00:03:13,379 --> 00:03:16,241
A worker inspects the strips
Of slate and sorts
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Them according to thickness
And width.
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00:03:20,551 --> 00:03:23,896
Next, he piles some of them
In preparation for splitting.
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00:03:26,000 --> 00:03:29,103
He cracks thicker strips
Of slate using a stone splitter
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00:03:29,103 --> 00:03:30,862
With a hardened steel blade.
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00:03:34,000 --> 00:03:35,413
He makes sure
They're thin enough
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00:03:35,413 --> 00:03:37,689
To be used for wall paneling.
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00:03:37,689 --> 00:03:43,310
Once the pieces of slate
Reach their final thickness,
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00:03:43,310 --> 00:03:47,103
A worker places them in boxes,
Ready for installation.
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00:03:50,172 --> 00:03:51,965
A worker inspects a sheet
Of slate
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00:03:51,965 --> 00:03:54,241
That will be used for flooring.
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00:03:54,241 --> 00:03:56,862
The thickness of slate flooring
Must be constant.
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00:04:01,137 --> 00:04:03,379
He places a sheet on a conveyor.
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00:04:03,379 --> 00:04:05,827
It takes the slate
Through a gauging machine,
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00:04:05,827 --> 00:04:08,000
Where its surface
Will be made perfectly even.
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00:04:12,103 --> 00:04:15,482
Using two diamond grinding
Wheels, the gauging machine
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00:04:15,482 --> 00:04:19,517
Shaves off any pieces of stone
That exceed a preset thickness.
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00:04:22,137 --> 00:04:23,965
After several minutes
Of shaving,
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00:04:23,965 --> 00:04:27,793
The slate sheet emerges
From the gauging machine.
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00:04:27,793 --> 00:04:31,724
An employee checks the sheet
To make sure it's smooth.
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00:04:31,724 --> 00:04:36,896
First, he checks the underside
Of the eventual floor tiles.
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00:04:36,896 --> 00:04:38,896
Then, he checks the top side,
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00:04:38,896 --> 00:04:40,931
The stone face
That will be displayed.
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The worker places the smooth,
Flat piece of slate
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On a cutting frame.
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00:04:48,620 --> 00:04:50,310
The computerized cutting machine
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00:04:50,310 --> 00:04:55,034
Cuts 18 pieces of slate
According to a preset pattern.
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00:04:55,034 --> 00:04:58,206
A high-velocity water jet
Cuts the stone at three times
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The speed of sound.
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00:05:00,620 --> 00:05:04,275
The water is pure,
Filtered several times.
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00:05:04,275 --> 00:05:07,000
The first time the slabs
Move through the machine,
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00:05:07,000 --> 00:05:09,448
It cuts pieces 1 to 9,
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And the second time through,
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It cuts pieces 10 to 18.
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00:05:17,068 --> 00:05:20,172
The worker snaps off excess trim
And stacks
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The cut pieces of slate
According to their numbers.
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All the number ones
Are identical to each other,
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As are each of the other numbers
In the 18-piece pattern.
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Repeated on a floor,
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The 18-piece pattern
Appears natural.
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This nonporous slate comes in
Different textures and colors,
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And can also be used
In bathrooms or roofing.
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Narrator:
The first hot dog carts
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Were rolled out in new york city
In the mid-19th century.
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00:06:06,551 --> 00:06:10,448
They were simple push carts
With small charcoal stoves
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And served sausages on buns.
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Those sandwiches became known
As hot dogs.
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A modern hot dog cart
Is a kitchen on wheels.
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Equipped with a water tank
And sink,
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A steamer and grill,
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And a cooler,
It's made to serve the public.
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And they're sometimes designed
To stand out in a crowd.
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To make this hot dog cart,
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They start with molds
For the hot dog-shaped body.
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A worker brushes a nonstick
Coating into the first mold.
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It will allow the completed part
To be easily removed.
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He places fiberglass one sheet
At time in the mold.
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He brushes a generous amount
Of epoxy resin onto each piece.
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The fiberglass starts
To solidify very quickly,
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00:07:12,482 --> 00:07:15,586
But he leaves it to set
Overnight for a complete cure.
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00:07:21,137 --> 00:07:24,206
They assemble the two halves
Of the hot dog-shaped body
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And apply bonding to the seams.
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A colorful paint job
Completes the look.
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00:07:32,965 --> 00:07:35,068
Next, computerized tools
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Cut holes in a sheet
Of food-grade steel.
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These holes will accommodate
The sink, faucets,
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And other parts.
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Then, the cooler door
Takes shape.
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Using a press,
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The worker bends up the edge
Of a piece of steel
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That's been cut to size.
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He transfers the part
To another break press.
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This one is computerized.
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00:08:01,068 --> 00:08:05,758
It folds back the bend to give
The door a strong, smooth edge.
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00:08:05,758 --> 00:08:10,103
He repeats this process
On two other sides.
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00:08:10,103 --> 00:08:15,586
He then clamps a continuous
Hinge to the only unfolded edge,
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00:08:15,586 --> 00:08:17,793
And he welds
And rivets the hinge to it.
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00:08:25,034 --> 00:08:28,379
Work now begins on the chassis
Of the hot dog cart.
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00:08:28,379 --> 00:08:30,413
A worker welds heavy wall steel
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00:08:30,413 --> 00:08:32,586
Tubing to create
A rugged framework.
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00:08:35,034 --> 00:08:36,275
After painting it,
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00:08:36,275 --> 00:08:39,034
He bolts the wheel axle
To brackets on the sides.
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00:08:46,931 --> 00:08:48,172
He tightens the bolts
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00:08:48,172 --> 00:08:50,827
To an exact torque
Using a pneumatic wrench.
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00:08:53,931 --> 00:08:56,344
He screws taillights
To the bumper.
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00:08:56,344 --> 00:08:59,758
The lights are surrounded by
Metal brackets to protect them
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00:08:59,758 --> 00:09:03,103
From being damaged
By customers waiting in line.
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00:09:03,103 --> 00:09:05,586
The brackets also
Serve as a mounting plate.
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00:09:09,034 --> 00:09:11,896
The team now transfers
The fiberglass cart body
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00:09:11,896 --> 00:09:13,172
To the chassis.
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00:09:16,103 --> 00:09:17,517
They drill large holes
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00:09:17,517 --> 00:09:20,965
To vent gas fumes
And smaller screw holes
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00:09:20,965 --> 00:09:22,827
To secure the body
To the chassis.
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00:09:29,862 --> 00:09:34,068
They line the cart with a molded
Fiberglass and styrofoam unit.
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00:09:34,068 --> 00:09:37,275
It has compartments for
The water tank and food cooler,
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00:09:37,275 --> 00:09:39,689
And it also serves
As an insulating layer.
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00:09:42,103 --> 00:09:44,862
They install the steel food
Preparation surface,
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00:09:44,862 --> 00:09:47,344
Which has been equipped
With a sink and faucets.
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00:09:50,448 --> 00:09:53,965
A member of the team tightens
A crimp ring around the hoses
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00:09:53,965 --> 00:09:57,965
To supply water
To the sink faucets.
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00:09:57,965 --> 00:10:01,137
He runs a gas line
To the steamer's burners
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00:10:01,137 --> 00:10:03,413
And lowers the steamer
Into place on the cart.
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00:10:08,000 --> 00:10:11,068
He assembles a barbecue
To the other side of the cart,
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00:10:11,068 --> 00:10:13,103
And this gives customers
A grilled option
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00:10:13,103 --> 00:10:14,172
For their hot dogs.
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00:10:18,931 --> 00:10:21,413
They hinge the cooler door
To the front of the cart.
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00:10:26,931 --> 00:10:29,965
Once closed, the door
Seals the insulated chamber
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00:10:29,965 --> 00:10:33,206
To keep hot dogs, sausages,
And sodas on ice.
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00:10:39,000 --> 00:10:40,931
The team presses bold graphics
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00:10:40,931 --> 00:10:44,379
To the fiberglass shell
And peels off the paper liner.
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00:10:46,965 --> 00:10:50,689
And with that, this hot dog cart
Is ready to hit the street,
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00:10:52,793 --> 00:10:54,551
Just in time for lunch.
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Narrator: decades ago, people
Had to get out of the car
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When arriving home in order
To open the garage door.
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Today, it's routine to open
And close your garage door
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00:11:18,517 --> 00:11:21,275
At the push of a button,
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00:11:21,275 --> 00:11:25,310
Either on a wall-mounted pad
Or on a remote control.
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00:11:27,758 --> 00:11:31,448
A garage door opener's motor
Drives either a belt, a chain,
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00:11:31,448 --> 00:11:33,896
Or a screw rod,
Like these models.
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In turn, they move a carriage
Connected to the garage door.
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00:11:38,310 --> 00:11:39,689
At this factory,
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00:11:39,689 --> 00:11:42,896
The production line starts
And ends at the same place.
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00:11:42,896 --> 00:11:46,241
They take one completed garage
Door opener off the line,
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00:11:46,241 --> 00:11:47,586
Then start a new one
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00:11:47,586 --> 00:11:52,724
By attaching a power cord
To the unit's steel chassis.
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00:11:52,724 --> 00:11:54,206
Then, they place the chassis
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00:11:54,206 --> 00:11:56,206
Onto a traveling assembly
Fixture
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00:11:56,206 --> 00:11:57,724
And plug in the power cord
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00:11:57,724 --> 00:11:59,827
To prep the unit
For testing later.
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00:12:01,931 --> 00:12:06,827
They place the unit's plastic
Housing next to the chassis,
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00:12:06,827 --> 00:12:09,517
Then snap
In the plastic safety cover.
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00:12:09,517 --> 00:12:11,896
This goes over the direct
Current motor,
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00:12:11,896 --> 00:12:15,862
The equivalent
Of 1 1/4 horsepower.
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00:12:15,862 --> 00:12:18,965
They attach an optical encoder
To the motor.
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00:12:18,965 --> 00:12:22,517
The encoder is a sensor
Which reads the door's position
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00:12:22,517 --> 00:12:25,413
So that the motor knows when
To stop moving the carriage.
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00:12:27,758 --> 00:12:30,137
They place the motor
Against the safety cover,
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00:12:30,137 --> 00:12:31,620
Then screw it in place.
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00:12:34,827 --> 00:12:37,965
In the housing,
They install the motion sensor.
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00:12:37,965 --> 00:12:39,724
It turns on the opener's light
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00:12:39,724 --> 00:12:41,862
As soon
As you walk into the garage
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00:12:41,862 --> 00:12:43,620
Or when the garage door opens.
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00:12:46,758 --> 00:12:50,103
Next are the switches for
Programming the remote control
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00:12:50,103 --> 00:12:52,379
And for setting
The travel limits.
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00:12:52,379 --> 00:12:53,827
These are the points to which
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00:12:53,827 --> 00:12:58,724
The opener must move the door
To fully open and close it.
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00:12:58,724 --> 00:13:01,896
They then install the circuit
Board, routing the antenna
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00:13:01,896 --> 00:13:05,724
For the remote control receiver
To the outside.
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00:13:05,724 --> 00:13:08,482
They plug in the motion
Sensor cable,
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00:13:08,482 --> 00:13:12,310
Then wire and plug in the
Connector for the light bulbs
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00:13:12,310 --> 00:13:15,724
And fasten the board in place
With screws.
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00:13:15,724 --> 00:13:19,689
They attach the electrical
Ground wire to the chassis,
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00:13:19,689 --> 00:13:21,206
Connect the power cable,
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00:13:21,206 --> 00:13:24,206
And then, the optical encoder
To the circuit board.
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00:13:26,724 --> 00:13:29,413
With all the internal components
Installed now,
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00:13:29,413 --> 00:13:32,103
They affix the housing
To the chassis.
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00:13:32,103 --> 00:13:34,655
This completes the brain
Of the garage door opener,
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00:13:34,655 --> 00:13:36,103
Called the operator unit.
203
00:13:39,034 --> 00:13:42,620
An automated testing machine
Now checks all the functions,
204
00:13:42,620 --> 00:13:45,413
Simulating the load
Of the garage door.
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00:13:45,413 --> 00:13:48,896
It also checks the light bulb
Sockets and the connection ports
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00:13:48,896 --> 00:13:53,000
On the circuit board
For the safety beams.
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00:13:53,000 --> 00:13:55,655
The beams stop
And reverse the closing door
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00:13:55,655 --> 00:13:59,241
If they detect any object
In its path.
209
00:13:59,241 --> 00:14:04,103
Once the operator unit
Passes inspect,
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00:14:04,103 --> 00:14:08,275
It comes full circle to the end,
Which is also the start,
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00:14:08,275 --> 00:14:09,379
Of the production line.
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00:14:11,655 --> 00:14:14,413
A plastic lens
To enclose the light bulbs,
213
00:14:14,413 --> 00:14:16,793
And the unit comes off the line.
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00:14:21,034 --> 00:14:25,931
The carriage rail
Is milled from galvanized steel.
215
00:14:25,931 --> 00:14:28,758
It has slots
For locking in plastic liners
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00:14:28,758 --> 00:14:31,206
Which hold the screw rod.
217
00:14:38,413 --> 00:14:40,103
To produce the screw rod,
218
00:14:40,103 --> 00:14:42,931
The factory machines
A solid bar of steel
219
00:14:42,931 --> 00:14:45,517
To the required dimensions
And profile.
220
00:14:45,517 --> 00:14:49,517
Then, with high-pressure
Rollers, it forms threads in it.
221
00:14:49,517 --> 00:14:53,310
Workers insert the screw rod
Into the liners in the rail.
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00:14:53,310 --> 00:14:54,655
For the retail market,
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00:14:54,655 --> 00:14:57,586
Rather than produce
One long rail and screw rod,
224
00:14:57,586 --> 00:14:59,862
The factory
Makes three shorter connecting
225
00:14:59,862 --> 00:15:03,551
Sections that fit
Into a smaller package.
226
00:15:03,551 --> 00:15:06,862
This machine lubricates
The screw rod with grease.
227
00:15:06,862 --> 00:15:09,620
It helps it rotate smoothly
In the rail liner
228
00:15:09,620 --> 00:15:12,689
When the opener's motor
Is running.
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00:15:12,689 --> 00:15:14,655
When the screw rod turns,
230
00:15:14,655 --> 00:15:16,862
Teeth on the base
Of the carriage interlock
231
00:15:16,862 --> 00:15:18,034
With the threads,
232
00:15:18,034 --> 00:15:20,379
Moving the carriage
Along the rail.
233
00:15:20,379 --> 00:15:24,620
Workers first install the
Carriage base at the factory.
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00:15:24,620 --> 00:15:25,896
Then, they pack
235
00:15:25,896 --> 00:15:28,344
All the garage door opener
Components for shipping,
236
00:15:28,344 --> 00:15:30,793
Starting with the rail sections
And the operator unit.
237
00:15:35,551 --> 00:15:39,620
Last to go in are
The wall-mounted control pad,
238
00:15:39,620 --> 00:15:42,724
The remote controls,
And the safety beams,
239
00:15:42,724 --> 00:15:46,827
Which you install on each side
Of the garage door opening.
240
00:15:46,827 --> 00:15:49,034
When you install
The garage door opener,
241
00:15:49,034 --> 00:15:52,448
You insert the screw rod
Into the motor's drive shaft.
242
00:15:52,448 --> 00:15:54,793
Then, you assemble the rest
Of the carriage,
243
00:15:54,793 --> 00:15:56,068
Connecting it to an arm
244
00:15:56,068 --> 00:15:58,413
Which attaches
To the garage door.
245
00:15:58,413 --> 00:16:02,793
Motor runs,
Screw rod turns, carriage moves,
246
00:16:02,793 --> 00:16:05,241
And your garage door
Opens or closes.
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00:16:15,586 --> 00:16:17,275
Narrator: the bicycle
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Is the most efficient mode
Of transport ever invented.
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Ninety-nine percent
Of the effort
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Put into turning a pedal
Is transferred to movement,
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So the lighter the bike,
The better.
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Using cutting-edge materials,
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A high-performance seat can
Weigh as little as five ounces.
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This company made a special seat
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For a past tour de france
Winner.
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In fact, half the cyclists on
The prestigious pro tour racing
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Circuit use their seats.
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The design process begins with
The simplest tools --
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Pencils and paper.
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Designers sketch
Out a few basic ideas.
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Specialists then transform
The sketched ideas
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Into 3-d digital images.
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The manufacturers machine-model
Those images into a prototype.
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After testing, they
Begin the manufacturing process.
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A worker places a base,
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Or shell,
On the upper segment of a mold.
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This company makes their shells
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From a variety
Of carbon fiber materials.
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Polyurethane pours into
The other section of the mold.
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This is the part of the mold
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That will give the seat
Its shape.
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When the mold closes,
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It cooks at a mere 104 degrees
Fahrenheit.
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A chemical reaction takes place
Inside the mold,
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Which causes the polyurethane
To expand.
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Five minutes later,
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An operator removes the seats
From the molds.
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Here, we see what the shells
Look like before and after.
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A worker removes excess
Polyurethane from the edges
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With a knife.
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While the polyurethane cures,
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Workers
Prepare the cover material.
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The material is
A proprietary microfiber
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Specially made for this company.
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Not only does this material need
To be flexible, waterproof,
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And comfortable,
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It has to be incredibly durable.
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Once they've cut the material
Into strips,
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The workers
Stack them on a stamping press.
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A die has been custom made
To match the design of the seat.
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The stamping press
Descends with enough force
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To cut through multiple layers.
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It's now time to join
The three panels of material
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That make up the seat cover.
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This facility
Has two different methods
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For attaching the pieces
To each other.
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00:18:36,172 --> 00:18:37,620
In this case,
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A skilled worker carefully
Stitches the material together.
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A different method
Of joining the panels
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Involves a process
Called thermal welding.
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An operator skives, or thins,
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The edges by shaving them
So that there won't be a bump
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Where they overlap.
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Double-sided tape
Will hold the material together.
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00:19:00,896 --> 00:19:06,000
A special tape dispenser applies
The tape to the skived edges.
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A worker positions the panels,
Carefully overlapping the edges.
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A vacuum system removes air
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From between the top and bottom
Sections of the press,
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Holding the panels in position
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And ensuring there will be
No bubbles at the seams.
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The press then
Heats the material
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Up to 280 degrees fahrenheit,
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Ensuring that the adhesive bonds
The panels together.
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The design
Of the shell for this seat
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Has several slots in it
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To help create
The right combination
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Of flexibility and rigidity.
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A laser machine
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Cuts stripes in the cover fabric
To create a graphic element
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That reflects this design
Feature.
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Workers glue silver material
Under the stripes
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To highlight them,
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00:19:52,448 --> 00:19:56,551
Then brush glue all over
The underside of the cover.
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Mounting the cover on the seat
Requires two operators.
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They place the cover glue side
Down on the seat,
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Ensuring
That it's positioned perfectly
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And that there are no
Air pockets.
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They work the cover
Into a small recess
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That runs around the perimeter
Of the base.
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They will then trim off
The excess material
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With a utility knife.
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The amount
Of skilled manual craftsmanship
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Required to build these seats
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Is a key feature
Of their quality,
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But the company also relies
On state-of-the-art technology.
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Bicycle seats sit on a framework
Called a rail.
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This facility makes rails
From both carbon fiber
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And metal alloys,
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And it tests each one
With a dynamometer.
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Workers put glue
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In the attachment points
On the bottom of the seat
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To ensure that it
Passes a stringent safety test.
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00:20:51,413 --> 00:20:55,724
A customized machine bends
The seat to fit into the rail.
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00:20:55,724 --> 00:20:58,896
The seat will then be bent back
In the other direction
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To return it
To its original shape.
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The seat is now finished.
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00:21:04,724 --> 00:21:06,896
Fusing
State-of-the-art technology
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With skilled craftsmanship,
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This company
Makes 520,000 bicycle seats
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Every year.
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If you have any comments
About the show,
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00:21:22,965 --> 00:21:25,551
Or if you'd like to suggest
Topics for future shows,
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00:21:25,551 --> 00:21:30,965
Drop us a line at
Sciencechannel.Com/howitsmade.
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