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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:
In racecar engines,
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00:00:54,689 --> 00:00:57,137
Excess lubricating oil
Is stored in tanks
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00:00:57,137 --> 00:00:59,000
Rather than oil pans.
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00:00:59,000 --> 00:01:02,275
This prevents the oil from
Sloshing around during the race
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00:01:02,275 --> 00:01:04,931
And causing drag
On the crankshaft.
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00:01:04,931 --> 00:01:07,793
With less drag,
Performance is increased.
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00:01:07,793 --> 00:01:10,896
So these oil tanks
Are part of a winning strategy.
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Racecar oil tanks
Come in various shapes
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00:01:16,448 --> 00:01:19,586
And sizes in order to fit
Into difference vehicles.
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00:01:19,586 --> 00:01:21,551
But their purpose is the same --
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00:01:21,551 --> 00:01:23,793
To keep excess oil
Out of the engine
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00:01:23,793 --> 00:01:26,482
To boost performance.
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00:01:26,482 --> 00:01:29,827
Each tanks starts
With a computer design.
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00:01:29,827 --> 00:01:32,965
The engineer maps out
The precise dimensions.
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00:01:32,965 --> 00:01:34,586
They input the measurements
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00:01:34,586 --> 00:01:37,172
Into computerized
Machining systems.
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00:01:37,172 --> 00:01:39,827
This first one cuts
A long piece of aluminum
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00:01:39,827 --> 00:01:41,620
Into smaller pieces,
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00:01:41,620 --> 00:01:44,793
Creating blanks to make parts
Known as tank rings.
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00:01:47,068 --> 00:01:48,827
A vertical milling tool sculpts
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00:01:48,827 --> 00:01:52,275
A recess in the blank
To seat an o-ring sealer.
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00:01:52,275 --> 00:01:53,827
Then, switching bits,
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00:01:53,827 --> 00:01:56,206
The machine contours
The outside of the blank,
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00:01:56,206 --> 00:01:58,931
Taking it from
Rectangular to round.
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00:02:01,000 --> 00:02:03,793
Other tools carve
A large hole in the center
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00:02:03,793 --> 00:02:05,586
And profile the inner diameter
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00:02:05,586 --> 00:02:08,655
So that the part
Will mate to the tank.
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00:02:08,655 --> 00:02:11,068
This ring is designed
To be removable
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To access the tank
For maintenance.
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00:02:13,655 --> 00:02:16,896
Here's the blank before
And after machining.
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00:02:18,862 --> 00:02:20,758
Like powerful cookie cutters,
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00:02:20,758 --> 00:02:23,310
Computerized punches cut
Out numerous parts
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00:02:23,310 --> 00:02:25,379
From an aluminum sheet.
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00:02:25,379 --> 00:02:27,034
They include the oil tank body,
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00:02:27,034 --> 00:02:29,724
The top,
And other assembly pieces.
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00:02:31,862 --> 00:02:34,344
To make the tank
Body cylindrical,
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00:02:34,344 --> 00:02:37,172
A worker turns a crank
To curl it around a roller.
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00:02:37,172 --> 00:02:40,931
This tank body
Is called the wrapper.
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00:02:40,931 --> 00:02:43,241
He drills a hole
In the bottom cone.
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00:02:43,241 --> 00:02:44,689
The hole is for the line
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00:02:44,689 --> 00:02:48,310
That returns lubricating oil
To the racecar engine.
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00:02:48,310 --> 00:02:49,793
Using a thin band saw,
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00:02:49,793 --> 00:02:52,724
He trims the cone
To fit the tank ring.
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00:02:55,448 --> 00:02:58,241
With a device known
As a hydraulic tube bender,
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00:02:58,241 --> 00:03:02,000
A worker shapes a piece of pipe
To a precise radius.
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00:03:06,068 --> 00:03:08,793
This pipe will be used
To vent air into a chamber
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00:03:08,793 --> 00:03:10,862
At the side of the oil tank.
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00:03:16,000 --> 00:03:20,206
He trims the ends of
The vent tube using a band saw.
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00:03:23,448 --> 00:03:27,000
A worker welds the tank ring
To the bottom cone,
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00:03:27,000 --> 00:03:29,689
Creating a thick seam
All the way around.
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00:03:32,827 --> 00:03:36,206
He then seals the seam
Of the cylindrical wrapper body
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00:03:36,206 --> 00:03:40,344
And welds a top cap
To a deaerating baffle.
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00:03:40,344 --> 00:03:42,724
Air will rise through it
And vent it into
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00:03:42,724 --> 00:03:44,206
And out of a side chamber,
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Leaving only oil in the tank.
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00:03:49,931 --> 00:03:53,896
He slides the baffle
Into the wrapper body.
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00:03:53,896 --> 00:03:55,241
He inserts the vent tube
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00:03:55,241 --> 00:03:57,482
In a hole on the side
Of the tank.
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00:04:00,275 --> 00:04:03,827
He fits an adapter ring
To the upper lip of a tank
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00:04:03,827 --> 00:04:06,068
And taps it down
With a rubber mallet.
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00:04:09,862 --> 00:04:13,655
He welds the baffle and
Filler neck to the tank body,
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00:04:13,655 --> 00:04:15,379
And then assembles
The air vent chamber
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To the side of the oil tank
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00:04:17,000 --> 00:04:19,517
And welds it to it.
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00:04:21,896 --> 00:04:24,551
Moving to another station,
A worker now taps
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00:04:24,551 --> 00:04:26,586
Perforated plastic inserts
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00:04:26,586 --> 00:04:29,586
Into holes in
The air vent chamber.
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00:04:29,586 --> 00:04:31,137
These inserts will both vent
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00:04:31,137 --> 00:04:34,620
And filter the air
From the tank.
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00:04:34,620 --> 00:04:37,482
He fits a rubber sealing
Ring around the fill neck
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00:04:37,482 --> 00:04:40,931
And screws the cap on.
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00:04:40,931 --> 00:04:43,000
He applies
The adhesive-back decals
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00:04:43,000 --> 00:04:45,275
To the tank
For branding purposes.
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00:04:47,896 --> 00:04:49,724
He caps the oil inlet tube
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00:04:49,724 --> 00:04:52,344
To keep contaminants out
During shipping.
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00:04:54,793 --> 00:04:57,103
He turns the tank upside down
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00:04:57,103 --> 00:05:01,275
And installs a valve
On the bottom of the vent tank.
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00:05:03,896 --> 00:05:05,448
He inserts a rubber o-ring
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00:05:05,448 --> 00:05:07,965
Into a groove on the base
Of the tank wall
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00:05:07,965 --> 00:05:11,275
And tucks it into place
All the way around.
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00:05:14,896 --> 00:05:16,931
After equipping
The fittings on the cone
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00:05:16,931 --> 00:05:18,413
With caps for shipping,
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00:05:18,413 --> 00:05:21,068
He installs the cone
On the base of the tank
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00:05:21,068 --> 00:05:23,413
And screws the ring
Tightly to it.
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00:05:26,000 --> 00:05:28,034
Accessing the tank
For maintenance reasons
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00:05:28,034 --> 00:05:30,034
Will mean unscrewing this part.
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00:05:33,655 --> 00:05:38,000
That completes
This racecar oil tank.
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Hooked up to a system of pumps,
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00:05:39,689 --> 00:05:42,517
These tanks will receive
And dispense oil
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00:05:42,517 --> 00:05:46,724
Sparingly to improve
Engine performance.
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They've been well-equipped
For life in the fast lane.
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Narrator:
The ancient greeks first
Began beautifying interiors
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00:06:05,655 --> 00:06:09,655
With ornate columns and moldings
Shaped from plaster.
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00:06:09,655 --> 00:06:12,517
Decorative moldings
Were a popular design feature
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00:06:12,517 --> 00:06:16,241
In much of europe from roughly
The 17th century onward,
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00:06:16,241 --> 00:06:18,275
With italian tradesmen
Becoming famous
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00:06:18,275 --> 00:06:20,827
For their mastery
At plasterwork.
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00:06:23,068 --> 00:06:25,137
Specialists
In traditional plasterwork
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00:06:25,137 --> 00:06:27,068
Are a rare breed these days.
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00:06:27,068 --> 00:06:28,586
But that's who you need to hire
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00:06:28,586 --> 00:06:31,000
To properly repair
Plaster moldings
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00:06:31,000 --> 00:06:32,689
In a historic home
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00:06:32,689 --> 00:06:35,344
Or to craft plaster
Moldings from scratch.
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00:06:38,620 --> 00:06:41,103
To repair this damaged
Ceiling medallion,
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00:06:41,103 --> 00:06:42,689
The plasterman first saws
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00:06:42,689 --> 00:06:45,034
And chisels off
The problem portion,
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Clearing a flat work surface.
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00:06:48,586 --> 00:06:50,896
Then, he drives
And screws part way
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To anchor the new portion
Of molding.
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00:06:53,517 --> 00:06:55,000
The heavier the plaster molding,
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The more screws you need
To hold the load.
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00:06:59,206 --> 00:07:02,793
Another plasterman, meanwhile,
Prepares the plaster.
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00:07:02,793 --> 00:07:05,413
The first ingredient
Is lime compound --
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00:07:05,413 --> 00:07:07,068
A simple mixture of lime,
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00:07:07,068 --> 00:07:12,034
Also known as calcium hydroxide,
And water.
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00:07:12,034 --> 00:07:14,413
He forms a well
With his scraper...
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00:07:18,965 --> 00:07:20,689
Then fills the well
With a mixture
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00:07:20,689 --> 00:07:22,482
Of roughly three-quarters water
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00:07:22,482 --> 00:07:25,379
To one-quarter
Construction-grade bonding glue.
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00:07:32,655 --> 00:07:35,068
He adds just the right amount
Of plaster of paris,
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00:07:35,068 --> 00:07:36,896
Which is powdered gypsum,
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00:07:36,896 --> 00:07:40,344
The same stuff they use
To make casts for broken bones.
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00:07:45,620 --> 00:07:47,068
He takes his trowel
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00:07:47,068 --> 00:07:49,241
And thoroughly blends
The lime compound,
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00:07:49,241 --> 00:07:52,137
Glue mixture
And plaster of paris.
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00:07:52,137 --> 00:07:54,241
When it has the consistency
Of pudding,
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00:07:54,241 --> 00:07:56,172
The plaster is ready.
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00:07:56,172 --> 00:07:58,896
The plasterman does this
All by eye,
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00:07:58,896 --> 00:08:03,793
Without ever actually measuring
A single ingredient.
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00:08:03,793 --> 00:08:06,620
After applying bonding glue
To the repair area,
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00:08:06,620 --> 00:08:11,241
The other plasterman trowels
On lots of plaster.
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00:08:11,241 --> 00:08:14,655
Then, he takes what's called
A circular running mold.
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00:08:14,655 --> 00:08:18,758
Its profile is out
Of the existing molding.
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00:08:18,758 --> 00:08:21,379
He runs it back and forth
Over the wet plaster,
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00:08:21,379 --> 00:08:23,517
Hence the term "Running mold."
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00:08:25,620 --> 00:08:28,241
Then, he carefully scrapes
Away the excess
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00:08:28,241 --> 00:08:30,448
And runs a wet paintbrush
Over the new
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00:08:30,448 --> 00:08:32,724
And old portions of the molding.
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00:08:32,724 --> 00:08:36,586
This makes the transition
Between the two appear seamless
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00:08:36,586 --> 00:08:40,448
And smoothes out
Any imperfections.
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00:08:40,448 --> 00:08:42,103
To make the running molds,
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00:08:42,103 --> 00:08:44,827
He cuts out a cross section
Of the existing molding
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00:08:44,827 --> 00:08:47,448
And traces it to produce
A sheet metal template
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00:08:47,448 --> 00:08:50,758
With the same profile.
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00:08:50,758 --> 00:08:53,413
Then with that, he cuts
The shape in wood,
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00:08:53,413 --> 00:08:56,206
Producing what
They call a stock.
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00:08:56,206 --> 00:08:58,551
After sanding
The stock smooth,
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00:08:58,551 --> 00:09:00,931
He screws on the metal template.
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00:09:00,931 --> 00:09:02,793
The wood backing
Prevents the metal
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00:09:02,793 --> 00:09:06,655
From bending as he runs
It over thick plaster.
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00:09:06,655 --> 00:09:10,758
He screws more wood
To the stock to form a handle.
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00:09:10,758 --> 00:09:13,344
To make crown moldings,
The plasterman mounts
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00:09:13,344 --> 00:09:16,724
A track to guide
His running mold.
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00:09:16,724 --> 00:09:20,034
He checks for anchor screws
Obstructing the path.
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00:09:20,034 --> 00:09:24,931
If he finds any, he drives them
A bit further into the ceiling.
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00:09:24,931 --> 00:09:26,793
He brushes on bonding glue
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00:09:26,793 --> 00:09:28,793
And lets it sit
For five minutes.
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00:09:32,655 --> 00:09:36,310
Then, he begins applying
The plaster in sizable globs.
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00:09:39,724 --> 00:09:42,793
He passes the running
Mold over the plaster.
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He repeats several times
With additional plaster,
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Waiting 20 minutes
Or so between coats
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00:09:48,206 --> 00:09:52,793
To let the plaster harden
Just enough to hold the shape.
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00:09:52,793 --> 00:09:55,137
He applies the final coat
By hand,
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00:09:55,137 --> 00:09:57,793
Filling in crevices
And imperfections.
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00:09:57,793 --> 00:10:02,000
Then, he passes the running
Mold one last time.
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00:10:02,000 --> 00:10:04,241
The wet plaster
Molding takes anywhere
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00:10:04,241 --> 00:10:07,551
From 48 to 72 hours to dry,
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00:10:07,551 --> 00:10:13,344
Depending on its size
And on the humidity in the room.
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00:10:13,344 --> 00:10:15,896
Only when the molding is
Completely dry can
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00:10:15,896 --> 00:10:18,586
The plasterman begin
The next step,
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00:10:18,586 --> 00:10:23,000
Crafting the corner pieces,
Called miters.
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00:10:23,000 --> 00:10:25,689
Starting with larger knives
And scrapers,
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00:10:25,689 --> 00:10:29,551
He uses the edge of the adjacent
Moldings as a guide,
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00:10:29,551 --> 00:10:31,689
Adding some plaster,
Sculpting it,
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00:10:31,689 --> 00:10:34,793
Then removing the excess.
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00:10:34,793 --> 00:10:36,344
He keeps repeating these steps
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00:10:36,344 --> 00:10:38,689
Until each side
Of the miter matches
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00:10:38,689 --> 00:10:41,379
The molding it joins perfectly.
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00:10:41,379 --> 00:10:43,413
It's a slow
And meticulous process
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00:10:43,413 --> 00:10:47,862
That takes patience
And an expert eye.
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00:10:47,862 --> 00:10:49,758
Once he has perfected
The profile,
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He refines the edges
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00:10:51,103 --> 00:10:54,827
With smaller
Knives and scrapers.
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00:10:54,827 --> 00:10:57,862
Finally, he blends the surface
With a wet brush,
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00:10:57,862 --> 00:10:59,793
Rendering the transition
From miter
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00:10:59,793 --> 00:11:03,448
To molding visually seamless.
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00:11:03,448 --> 00:11:06,827
Brand-new yet
Distinctively old-world.
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00:11:17,344 --> 00:11:20,241
Narrator: lemongrass isn't just
A culinary herb.
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00:11:20,241 --> 00:11:21,482
Oil distilled from the plant
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00:11:21,482 --> 00:11:25,448
Is a popular ingredient
In soap and spa products.
193
00:11:25,448 --> 00:11:28,965
Used in aromatherapy
For numerous therapeutic reasons
194
00:11:28,965 --> 00:11:31,551
With a fragrance
That's citrusy yet sweet,
195
00:11:31,551 --> 00:11:35,000
Lemongrass oil definitely
Passes the smell test.
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00:11:38,344 --> 00:11:40,068
Follow the scent
Of lemongrass,
197
00:11:40,068 --> 00:11:42,862
And the trail leads
To thailand.
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00:11:42,862 --> 00:11:45,310
It's here that the plant
Is grown and processed
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00:11:45,310 --> 00:11:47,896
Into an essential oil.
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00:11:47,896 --> 00:11:50,103
Lemongrass oil is
The signature scent
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00:11:50,103 --> 00:11:53,517
In this part of the world.
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00:11:53,517 --> 00:11:56,172
After harvesting lemongrass,
Workers select
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00:11:56,172 --> 00:12:00,000
The most fragrant
Specimens and dry them.
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00:12:00,000 --> 00:12:01,793
They transfer these plants,
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00:12:01,793 --> 00:12:04,655
Stalk and all,
To a distillation facility.
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00:12:04,655 --> 00:12:08,172
The heady aroma of lemongrass
Will now be concentrated
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00:12:08,172 --> 00:12:11,586
Into a potent essential oil.
208
00:12:11,586 --> 00:12:13,931
Workers unlock the top
Of the still
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00:12:13,931 --> 00:12:17,379
And pour in chlorine-free,
Deionized water.
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00:12:19,517 --> 00:12:21,586
Once the still is
One-quarter full,
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00:12:21,586 --> 00:12:24,551
They add the lemongrass.
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00:12:24,551 --> 00:12:27,172
They stack the bundles
In a crisscross fashion,
213
00:12:27,172 --> 00:12:31,137
Creating gaps for steam
To pass through.
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00:12:31,137 --> 00:12:33,379
They fill the still to the brim.
215
00:12:36,413 --> 00:12:39,241
It will take 66 pounds
Of lemongrass to make
216
00:12:39,241 --> 00:12:43,551
Roughly 1 quart of
Highly-fragrant essential oil.
217
00:12:43,551 --> 00:12:45,413
They screw the lid
Tightly to prevent
218
00:12:45,413 --> 00:12:47,965
The loss of steam
During distillation.
219
00:12:50,275 --> 00:12:51,758
They activate the still,
220
00:12:51,758 --> 00:12:55,724
And it heats the water
To the boiling point.
221
00:12:55,724 --> 00:12:59,241
Steam rises through the plants
And picks up the oils.
222
00:12:59,241 --> 00:13:01,586
It carries the oil vapor up
Through a pipe
223
00:13:01,586 --> 00:13:03,137
And into a condenser,
224
00:13:03,137 --> 00:13:06,620
Where the vapors cool
And return to a liquid form.
225
00:13:06,620 --> 00:13:12,517
The liquid oil and water
Drip out into a flask.
226
00:13:12,517 --> 00:13:13,931
Oil and water don't mix.
227
00:13:13,931 --> 00:13:16,275
So the oil floats to the top.
228
00:13:16,275 --> 00:13:17,724
And the water is drained off
229
00:13:17,724 --> 00:13:21,241
And recycled back
Into the distiller.
230
00:13:21,241 --> 00:13:23,586
The technician then collects
The lemongrass oil
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00:13:23,586 --> 00:13:27,241
In a bottle one drop at a time.
232
00:13:27,241 --> 00:13:29,068
The lemongrass oil undergoes
233
00:13:29,068 --> 00:13:32,172
A second distillation
In a laboratory,
234
00:13:32,172 --> 00:13:34,517
Using a more sensitive
Piece of equipment
235
00:13:34,517 --> 00:13:37,586
Known as
A rotary vacuum evaporator.
236
00:13:37,586 --> 00:13:39,586
The oil flows into a flask
237
00:13:39,586 --> 00:13:44,379
That's spinning in a hot bath
Of vegetable oil.
238
00:13:44,379 --> 00:13:46,275
The evaporator pumps out air
239
00:13:46,275 --> 00:13:48,758
And creates a vacuum
In the flask,
240
00:13:48,758 --> 00:13:51,137
Which lowers the boiling point.
241
00:13:51,137 --> 00:13:54,172
This prevents damage
To the delicate molecules
242
00:13:54,172 --> 00:13:57,448
Responsible
For the lemongrass scent.
243
00:13:57,448 --> 00:14:00,241
The oil vapors rise
To a condenser coil
244
00:14:00,241 --> 00:14:02,103
Where they reliquefy,
245
00:14:02,103 --> 00:14:06,620
Leaving any residual water
And impurities behind.
246
00:14:06,620 --> 00:14:10,551
The pure lemongrass oil drips
Into a receiver flask.
247
00:14:12,551 --> 00:14:15,689
As distilled lemongrass
Oil is collected,
248
00:14:15,689 --> 00:14:19,379
More flows into the evaporator
Beaker for purification.
249
00:14:22,482 --> 00:14:26,620
The distilling process
Is continuous.
250
00:14:26,620 --> 00:14:29,068
The rotary vacuum
Evaporator processes
251
00:14:29,068 --> 00:14:32,241
Roughly 2 to 3 quarts
Of fragrant oil per hour.
252
00:14:35,103 --> 00:14:37,689
They store the lemongrass oil
In a cold room
253
00:14:37,689 --> 00:14:40,965
With other essential oils.
254
00:14:40,965 --> 00:14:43,551
Like fine wine,
It must be kept cool,
255
00:14:43,551 --> 00:14:46,413
Or it could spoil
And ruin its bouquet.
256
00:14:50,000 --> 00:14:51,758
When it's time
To formulate ingredients
257
00:14:51,758 --> 00:14:53,655
For a cream or lotion,
258
00:14:53,655 --> 00:14:55,586
A technician
Blends lemongrass oil
259
00:14:55,586 --> 00:14:57,689
With other essential oils.
260
00:15:00,448 --> 00:15:03,689
Just a few drops make
A difference you can smell.
261
00:15:08,482 --> 00:15:10,896
They also use lemongrass
Oil to enhance
262
00:15:10,896 --> 00:15:14,000
The soothing qualities
Of bath crystals.
263
00:15:14,000 --> 00:15:17,413
The technician first
Sifts epsom salts
264
00:15:17,413 --> 00:15:20,344
And baking soda into a bowl.
265
00:15:20,344 --> 00:15:24,241
He adds measured amounts of
The blend to sea salt crystals.
266
00:15:26,379 --> 00:15:28,310
He stirs the ingredients by hand
267
00:15:28,310 --> 00:15:31,620
To evenly distribute
Them in the mix.
268
00:15:31,620 --> 00:15:34,000
The bath salts are now ready
For an infusion
269
00:15:34,000 --> 00:15:38,344
Of the double-distilled
Lemongrass oil.
270
00:15:38,344 --> 00:15:41,310
He adds it to a submixture
Of other essential oils
271
00:15:41,310 --> 00:15:43,931
To create a blend
With calming effect.
272
00:15:46,448 --> 00:15:49,241
He pours the essential
Oils onto the crystals.
273
00:15:49,241 --> 00:15:53,310
And they soak into the tiny
Spaces in the particles.
274
00:15:53,310 --> 00:15:56,241
They then add some
More aromatic spice --
275
00:15:56,241 --> 00:15:58,241
A freshly-ground
Blend of lemongrass,
276
00:15:58,241 --> 00:16:00,379
Turmeric, and other ingredients.
277
00:16:03,620 --> 00:16:05,655
He sprinkles the herbs
Onto the crystals
278
00:16:05,655 --> 00:16:09,275
And folds them into the blend.
279
00:16:09,275 --> 00:16:14,793
The final effect will be
Skin-tingling and rejuvenating.
280
00:16:14,793 --> 00:16:17,034
Incorporated into many products,
281
00:16:17,034 --> 00:16:20,068
Lemongrass oil will
Awaken the senses.
282
00:16:31,724 --> 00:16:35,413
Narrator: fly fishing uses
Artificial lures called flies
283
00:16:35,413 --> 00:16:38,103
Rather than natural
Bait like worms.
284
00:16:38,103 --> 00:16:40,241
A fly is a hook
That has materials
285
00:16:40,241 --> 00:16:42,517
Like feathers
Tied to it with thread
286
00:16:42,517 --> 00:16:43,896
To trick the fish into thinking
287
00:16:43,896 --> 00:16:46,379
There's an insect
Floating on the water.
288
00:16:46,379 --> 00:16:50,103
To make your own flies,
You use a fly tying vise.
289
00:16:52,448 --> 00:16:55,034
This fly tying vise
Has pockets at its base
290
00:16:55,034 --> 00:16:56,586
To hold your materials
291
00:16:56,586 --> 00:16:59,137
And sturdy steel jaws
To grip the fishhook
292
00:16:59,137 --> 00:17:02,827
While you tie
Those materials onto it.
293
00:17:02,827 --> 00:17:04,724
This machine makes
The sand molds
294
00:17:04,724 --> 00:17:08,068
For casting
The metal pocket bases.
295
00:17:08,068 --> 00:17:10,689
It deposits moist
Sand into a flask
296
00:17:10,689 --> 00:17:13,137
To form one half of a mold,
297
00:17:13,137 --> 00:17:16,793
Then rolls over the flask
To a pattern on the other side.
298
00:17:16,793 --> 00:17:19,620
After spraying the pattern
With a nonstick coating,
299
00:17:19,620 --> 00:17:23,034
A worker sifts sand onto it.
300
00:17:23,034 --> 00:17:25,758
Then the machine
Deposits sand on top
301
00:17:25,758 --> 00:17:28,655
To form the other
Half of the mold.
302
00:17:28,655 --> 00:17:30,137
It compresses the sand
303
00:17:30,137 --> 00:17:33,206
With roughly 4 1/2 tons
Of hydraulic pressure.
304
00:17:33,206 --> 00:17:37,344
The pattern sandwiched at the
Center forms the mold cavity.
305
00:17:37,344 --> 00:17:40,448
A machine separates the halves
To remove the pattern,
306
00:17:40,448 --> 00:17:44,103
Then puts them back together.
307
00:17:44,103 --> 00:17:47,034
In the casting area,
Workers heat pieces of bronze
308
00:17:47,034 --> 00:17:51,275
To approximately
1,922 degrees fahrenheit,
309
00:17:51,275 --> 00:17:54,241
Melting them down.
310
00:17:54,241 --> 00:17:56,620
They remove the pot
From the electric furnace
311
00:17:56,620 --> 00:18:00,413
And place it in a pouring shank.
312
00:18:00,413 --> 00:18:03,034
They pour the molten bronze
Down a channel leading
313
00:18:03,034 --> 00:18:05,689
To the mold cavity.
314
00:18:05,689 --> 00:18:07,517
After about a half hour,
315
00:18:07,517 --> 00:18:10,310
Once the bronze has cooled
And solidified,
316
00:18:10,310 --> 00:18:13,827
The flip the mold onto
A vibrating grate.
317
00:18:13,827 --> 00:18:17,896
First the impact and then
The shaking break the mold.
318
00:18:17,896 --> 00:18:20,137
The sand falls
Through the grate
319
00:18:20,137 --> 00:18:24,620
While four connected bronze
Pocket bases remain on top.
320
00:18:24,620 --> 00:18:26,586
Once they're cool
Enough to be handled,
321
00:18:26,586 --> 00:18:30,103
A worker saws them apart.
322
00:18:30,103 --> 00:18:32,206
The bases go into
A rotating drum
323
00:18:32,206 --> 00:18:35,482
Filled with tiny steel beads.
324
00:18:35,482 --> 00:18:36,931
As the drum spins,
325
00:18:36,931 --> 00:18:41,137
The centrifugal force throws
The beads against the bases.
326
00:18:41,137 --> 00:18:43,586
This removes
All remnants of sand
327
00:18:43,586 --> 00:18:48,000
And polishes the surface smooth.
328
00:18:48,000 --> 00:18:51,551
The bases go onto
A computer-guided
Milling machine.
329
00:18:51,551 --> 00:18:54,793
It drills a hole to affix
The mounting piece for the stem
330
00:18:54,793 --> 00:18:57,379
That holds the head
Of the vise.
331
00:18:57,379 --> 00:18:59,655
The mill also cuts
A circular hole
332
00:18:59,655 --> 00:19:02,137
At the center of the base
For a decorative coin
333
00:19:02,137 --> 00:19:05,931
Bearing the manufacturer's logo.
334
00:19:05,931 --> 00:19:09,068
They finish the bases
With a clear protective coat,
335
00:19:09,068 --> 00:19:10,275
A proprietary formula
336
00:19:10,275 --> 00:19:12,551
That prevents
The bronze from oxidizing.
337
00:19:15,379 --> 00:19:20,000
The vise's other parts are
Machined out of metal bars.
338
00:19:20,000 --> 00:19:22,517
Here, a computer-guided
Lathe transforms
339
00:19:22,517 --> 00:19:27,103
Two square steel bars
Into the vise's jaws.
340
00:19:27,103 --> 00:19:30,413
First, it cuts a small
Half circle on one piece
341
00:19:30,413 --> 00:19:35,034
For the cam that opens
And closes the jaws.
342
00:19:35,034 --> 00:19:37,655
Then, it turns the ends
To form a point.
343
00:19:43,034 --> 00:19:45,206
The entire transformation
From bars
344
00:19:45,206 --> 00:19:49,620
To jaws takes
About 90 seconds.
345
00:19:49,620 --> 00:19:52,862
They place the jaws,
One at a time, into a press
346
00:19:52,862 --> 00:19:54,241
And make a slight bend
347
00:19:54,241 --> 00:19:57,620
To set the correct
Spring tension.
348
00:19:57,620 --> 00:19:59,482
They verify the depth
Of the bend
349
00:19:59,482 --> 00:20:02,068
With a specialized
Measuring tool,
350
00:20:02,068 --> 00:20:04,448
Then send the jaws
To an outside facility
351
00:20:04,448 --> 00:20:08,344
That applies
A black protective finish.
352
00:20:08,344 --> 00:20:11,620
When the jaws come back,
Workers assemble them.
353
00:20:11,620 --> 00:20:16,172
First, they put the cam
Through the semicircular hole.
354
00:20:16,172 --> 00:20:18,517
Then, they compress
The jaws in a vise
355
00:20:18,517 --> 00:20:22,379
And slide an aluminum
Head onto the back.
356
00:20:22,379 --> 00:20:24,172
When the jaws
Come out of the vise,
357
00:20:24,172 --> 00:20:26,275
They expand to their
Original position,
358
00:20:26,275 --> 00:20:28,689
Retaining the head.
359
00:20:28,689 --> 00:20:31,482
Workers apply
The manufacturer's sticker,
360
00:20:31,482 --> 00:20:33,793
Then thread a brass thumbscrew
361
00:20:33,793 --> 00:20:35,896
That you turn to lock
In the position of the head,
362
00:20:35,896 --> 00:20:42,517
Which swivels left,
Right, or 360 degrees.
363
00:20:42,517 --> 00:20:45,689
They then bolt
The handle into the cam.
364
00:20:45,689 --> 00:20:47,068
When you depress the handle,
365
00:20:47,068 --> 00:20:50,724
The cam opens,
Opening the jaws.
366
00:20:50,724 --> 00:20:52,379
On the reverse side of the jaws,
367
00:20:52,379 --> 00:20:54,689
They mount a clip
For holding the feathers,
368
00:20:54,689 --> 00:20:59,620
Yarn, or other materials
You're using to tie your fly.
369
00:20:59,620 --> 00:21:03,000
Then, they glue the logo coin
Into the pocket base.
370
00:21:05,103 --> 00:21:08,655
They install the mounting
Piece for the stem,
371
00:21:08,655 --> 00:21:11,344
Then the stem itself.
372
00:21:11,344 --> 00:21:14,448
A thumbscrew on the mount
Holds the stem in place.
373
00:21:16,931 --> 00:21:20,482
The head connects to a swivel
At the top of the stem.
374
00:21:22,793 --> 00:21:27,379
The jaws securely hold the hook
While you tie your fly
375
00:21:27,379 --> 00:21:31,724
Using anything from feathers
And fur to tinsel and beads,
376
00:21:31,724 --> 00:21:34,724
Creating your imitation
Of an appetizing insect
377
00:21:34,724 --> 00:21:36,793
Or tiny fish.
29746
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