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--Captions by VITAC--
www.vitac.com
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00:00:06,137 --> 00:00:09,137
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: SPIRAL STAIRS
WERE PART OF A STRATEGY
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TO DEFEND THE TOWERS
OF MEDIEVAL CASTLES.
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ATTACKERS HAD TO
CLIMB SINGLE-FILE
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00:01:01,103 --> 00:01:04,241
AND COULDN'T STORM
THE CASTLE ALL AT ONCE.
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00:01:04,241 --> 00:01:05,793
AND AT THE TOP OF THE STAIRS,
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00:01:05,793 --> 00:01:09,068
THE GUARDSMEN COULD MORE EASILY
MANEUVER THEIR SWORDS,
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00:01:09,068 --> 00:01:11,068
GIVING THEM THE UPPER HAND.
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00:01:14,413 --> 00:01:17,000
SPIRAL STAIRS TAKE PEOPLE
TO THE NEXT LEVEL
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WITHOUT TAKING UP
A LOT OF SPACE.
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THEY'RE COMPACT, AND WITH
THEIR CORKSCREW CURVATURE,
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00:01:23,482 --> 00:01:27,620
THEY CAN ALSO BE
ARCHITECTURAL FEATURES.
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00:01:27,620 --> 00:01:30,068
PRODUCTION STARTS WITH
THE STEEL HUBS
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00:01:30,068 --> 00:01:32,689
CUT TO THE DESIRED RISER HEIGHT.
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00:01:32,689 --> 00:01:35,413
A WORKER FILES
THE SHARP EDGES SMOOTH
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00:01:35,413 --> 00:01:36,793
AND DRILLS A THREADED HOLE
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WHICH WILL BE USED TO FASTEN
THE TREADS IN PLACE.
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A COMPUTER-DRIVEN PLASMA SYSTEM
CUTS THROUGH A SHEET OF STEEL
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TO PRODUCE THE PIE-SHAPED
STAIR TREADS.
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00:01:51,344 --> 00:01:53,758
A WORKER NESTLES A TREAD
TO THE HUB
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00:01:53,758 --> 00:01:56,275
AND CLAMPS THEM
IN A WELD FIXTURE.
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00:01:56,275 --> 00:01:58,482
HE ALSO CLAMPS
STRUCTURAL SUPPORTS
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00:01:58,482 --> 00:02:02,241
TO THE BASE OF THE TREAD.
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00:02:02,241 --> 00:02:04,689
WITH EVERYTHING IN
THE RIGHT CONFIGURATION,
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00:02:04,689 --> 00:02:07,965
HE WELDS THE SUPPORTS
TO THE TREAD AND THE HUB.
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00:02:07,965 --> 00:02:12,517
HE'LL MAKE 12 OF THESE HUB
AND TREAD ASSEMBLIES.
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HE CHIPS OFF THE WELD SLAG
FOR CLEANER SEAMS.
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00:02:16,655 --> 00:02:19,482
A TEAM SLIDES THE HUB
AND TREAD ASSEMBLIES
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00:02:19,482 --> 00:02:21,034
ON TO THE CENTER POLE
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00:02:21,034 --> 00:02:24,103
AND ROTATES THEM
TO THE CORRECT POSITION.
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THE DESIGN GEOMETRY
DICTATES THE ROTATION.
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ONCE ROTATED CORRECTLY,
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THE WORKERS FASTEN THE HUBS
TO THE POLE
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00:02:31,689 --> 00:02:34,103
AND ADD A PLATFORM
FOR THE TOP STEP.
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00:02:36,862 --> 00:02:40,965
A BALUSTER SPINS IN A LATHE,
AS TOOLS CUT IT TO LENGTH
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00:02:40,965 --> 00:02:44,103
AND ROUND THE END
TO THE CORRECT DIAMETER.
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THE OPERATOR MEASURES
THE DIAMETER.
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HE INSERTS THE ROUNDED END
IN A DYE
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THAT CARVES THE THREAD INTO IT.
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A WORKER WELDS A STEEL CUP
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JUST ABOVE THE THREADED PART
OF THE BALUSTER.
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THIS CUP WILL SUPPORT
THE BALUSTER
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00:02:59,724 --> 00:03:02,172
ONCE IT'S BEEN INSTALLED
ON THE THREAD.
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HE GRINDS THE WELD SCALE
FROM THE CUP.
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HE INSERTS THE BALUSTER
THROUGH HOLES
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IN A METAL SPACER IN THE TREAD.
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HE SCREWS A NUT ON TO THE END
TO SECURE IT.
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00:03:14,758 --> 00:03:18,586
USING ROLLERS NOW, ANOTHER
WORKER TWISTS LONG STRIPS
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00:03:18,586 --> 00:03:21,413
OF METAL INTO SPIRALING
HAND RAILS THAT MATCH
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THE RISE OF THE STAIRS.
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HE FITS THE RAIL
TO THE TOP BALUSTERS
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AND CLAMPS IT IN PLACE.
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HE THEN WELDS THE BALUSTERS
TO THE RAIL.
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HE ADDS MORE RAILING UNTIL
IT SPIRALS ALL THE WAY DOWN
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TO THE FIRST STEP.
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THE TEAM SECURES IT
TO THE PLATFORM.
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THE SPIRAL STAIRCASE'S METAL
STRUCTURE IS NOW COMPLETE.
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IT'S READY FOR
THE WOODEN ACCENTS.
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A WORKER APPLIES GLUE
TO PIECES OF RED OAK.
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00:03:54,551 --> 00:03:57,724
HE'LL USE TWO OF THEM
TO MAKE ONE STAIR TREAD.
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HE CLAMPS TWO TREAD SETS IN
A FIXTURE WHILE THE GLUE SETS.
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00:04:01,655 --> 00:04:03,206
HE INSERTS A SHIM
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00:04:03,206 --> 00:04:07,344
AND TIGHTENS THE CLAMP
TO APPLY DOWNWARD PRESSURE.
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00:04:07,344 --> 00:04:10,862
ONCE THE GLUE HAS CURED,
A PLANER SHAVES THE TREAD
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PERFECTLY FLAT
AND TO THE DESIRED THICKNESS.
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00:04:15,000 --> 00:04:16,931
AFTER REFINING THE PROFILE,
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A WORKER ROUNDS THE EDGE OF
THE STAIR TREAD USING A ROUTER.
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00:04:22,965 --> 00:04:25,344
AFTER GLUING STRIPS OF WOOD
TOGETHER TO CREATE
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00:04:25,344 --> 00:04:28,896
A CURVED RAILING,
HE SANDS THE EXCESS ADHESIVE,
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00:04:28,896 --> 00:04:32,344
AND WITH A FILE,
REMOVES MORE OF THE GLUE.
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00:04:32,344 --> 00:04:36,448
HE TURNS THE RAILING OVER
AND CARVES A GROOVE IN THE WOOD.
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00:04:36,448 --> 00:04:38,724
THIS WILL ENABLE THE RAILING
TO BE INSTALLED
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00:04:38,724 --> 00:04:40,965
OVER THE METAL RAIL SUPPORT.
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HE ADDS SOME DETAILING
ALONG THE EDGE.
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00:04:44,758 --> 00:04:46,758
A TEAM THEN FITS
THE WOODEN RAILING
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TO THE METAL SUPPORT STRUCTURE.
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ALL OF THE RAIL SECTIONS
FIT TOGETHER PERFECTLY.
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00:04:53,275 --> 00:04:56,068
AFTER THE PRE-FIT,
THEY REMOVE THE RAILING
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00:04:56,068 --> 00:04:58,482
AND SCULPT THE EDGES
TO BE ROUNDER.
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THE ROUNDED EDGES COMPLEMENT
THE OVERALL SPIRAL DESIGN.
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00:05:03,413 --> 00:05:07,103
A WORKER PRE-FITS THE WOODEN
TREADS TO THE METAL STRUCTURE
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00:05:07,103 --> 00:05:10,517
AND THEN DISASSEMBLES
THE ENTIRE SPIRAL STAIRCASE
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FOR PAINTING AND STAINING.
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00:05:14,413 --> 00:05:17,965
THE SPIRAL STAIRS ARE THEN READY
FOR REASSEMBLY IN THE BUILDING
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THEY WERE DESIGNED FOR.
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THEY'LL DEFINITELY ADD A CERTAIN
TWIST TO THE INTERIOR DESIGN.
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Narrator:
ORIGINATING IN THE MIDDLE EAST,
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PITA BREAD HAS BEEN AROUND
FOR THOUSANDS OF YEARS.
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00:05:39,206 --> 00:05:43,241
TODAY, ITS POPULARITY CONTINUES
TO GROW AROUND THE GLOBE.
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00:05:43,241 --> 00:05:45,965
PART OF ITS APPEAL
IS ITS VERSATILITY.
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00:05:45,965 --> 00:05:48,206
PEOPLE CAN STUFF
THEIR PITA'S POCKETS,
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USE IT AS A SANDWICH WRAP,
OR SLICE IT FOR DIPPING.
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PITA BREAD MAY BE FLAT,
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BUT THAT DOESN'T MEAN
IT'S BORING.
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ANYONE CAN USE PITA
TO MAKE ANY NUMBER
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OF INTERESTING
LUNCHTIME COMBINATIONS.
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00:06:05,241 --> 00:06:09,034
MAKING PITA BREAD STARTS
WITH SILOS FULL OF FLOUR.
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00:06:09,034 --> 00:06:12,758
A BLOWER SYSTEM DELIVERS THE
FLOUR TO AN AUTOMATED SIFTER.
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00:06:12,758 --> 00:06:15,965
THE SIFTER SHAKES THE FLOUR
THROUGH THREE LEVELS OF MESH
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00:06:15,965 --> 00:06:18,103
TO FILTER OUT IMPURITIES.
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00:06:18,103 --> 00:06:21,862
MAGNETS EXTRACT
ANY METAL CONTAMINANTS.
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00:06:21,862 --> 00:06:25,482
WORKERS PREPARE A PRE-MIX
OF SUGAR, SALT, YEAST,
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00:06:25,482 --> 00:06:27,241
AND PRESERVATIVES.
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00:06:27,241 --> 00:06:29,793
THEY COMBINE THESE INGREDIENTS
WITH THE SIFTED FLOUR
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IN A BIG MIXER AND ADD WATER.
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00:06:33,000 --> 00:06:35,172
THE MIXER IS EQUIPPED
WITH NUMEROUS BARS
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THAT ROTATE HORIZONTALLY
TO BLEND THE INGREDIENTS.
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00:06:40,241 --> 00:06:44,172
THE OPERATOR OPENS THE MIXER
AND SPINS IT ONE MORE TIME
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00:06:44,172 --> 00:06:46,586
TO EJECT THE DOUGH INTO A BIN.
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00:06:50,068 --> 00:06:53,965
HE ROLLS THE BIN
TO THE NEXT STATION.
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00:06:53,965 --> 00:06:57,172
HERE THE PITA DOUGH
GOES INTO A HOPPER.
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00:06:57,172 --> 00:06:59,689
AND FROM THERE,
IT DROPS INTO A MACHINE
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00:06:59,689 --> 00:07:01,344
CALLED A DOUGH DIVIDER.
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00:07:07,137 --> 00:07:12,000
THIS MACHINE TURNS BIG CHUNKS
OF DOUGH INTO MANY SMALL BLOBS.
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00:07:12,000 --> 00:07:15,724
TO DO THIS, IT FORCES THE DOUGH
THROUGH A ROUND HOLE,
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00:07:15,724 --> 00:07:21,137
AND A GUILLOTINE BLADE CHOPS IT
TO THE CORRECT THICKNESS.
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00:07:21,137 --> 00:07:24,310
THE DOUGH BLOBS RIDE A CONVEYOR
AND PASS UNDER A ROLLER
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00:07:24,310 --> 00:07:27,034
THAT FLATTENS THEM.
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00:07:27,034 --> 00:07:30,965
FLOUR FROM AN OVERHEAD SIFTER
DUSTS THE DOUGH BLOBS
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00:07:30,965 --> 00:07:35,206
TO KEEP THEM FROM STICKING
TO THE MACHINERY.
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00:07:35,206 --> 00:07:37,068
EACH ONE OF THESE FLATTENED
DOUGH BLOBS
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WILL EVENTUALLY BECOME A PITA.
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00:07:42,241 --> 00:07:44,068
THE ROUND PIECES OF DOUGH
NOW RIDE
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00:07:44,068 --> 00:07:46,758
A CONVEYOR UP TO A WARM ZONE.
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00:07:46,758 --> 00:07:50,413
OVER A PERIOD OF 15 MINUTES,
THE YEAST FERMENTS,
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00:07:50,413 --> 00:07:53,068
CAUSING THE DOUGH TO RISE.
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00:07:53,068 --> 00:07:55,034
OUT OF THE FERMENTATION STATION,
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00:07:55,034 --> 00:08:00,103
A ROLLER FLATTENS
THE PITA DOUGH SEGMENTS AGAIN.
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00:08:00,103 --> 00:08:02,586
THEY'RE NOW READY
TO BE ROLLED VERY THIN
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00:08:02,586 --> 00:08:04,931
IN A PROCESS KNOWN AS SHEETING.
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00:08:07,310 --> 00:08:10,724
THE NEXT ROLLER PRESSES
THE PITA DOUGH MUCH THINNER.
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00:08:10,724 --> 00:08:12,413
ROLLING IT IN ONE DIRECTION
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00:08:12,413 --> 00:08:14,965
MAKES THE DOUGH SEGMENTS
OVAL-SHAPED.
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00:08:18,137 --> 00:08:20,310
THE OVAL PITAS RIDE BY A PUSHER
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00:08:20,310 --> 00:08:25,275
THAT NOW SHOVES THEM
TOWARDS THE FINAL ROLLER.
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00:08:25,275 --> 00:08:28,862
IT ROLLS THE DOUGH IN THE OTHER
DIRECTION TO ROUND OUT THE SHAPE
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00:08:28,862 --> 00:08:30,620
AND MAKE IT EVEN THINNER.
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00:08:34,379 --> 00:08:36,275
PERFECTLY ROUND AND THIN,
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00:08:36,275 --> 00:08:40,068
THE PITAS NOW TRAVEL UP TO
ANOTHER FERMENTATION OPERATION.
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00:08:42,275 --> 00:08:44,931
INSIDE, THE TEMPERATURE
IS TOASTY.
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00:08:44,931 --> 00:08:47,310
IT'S WARM ENOUGH TO REAWAKEN
THE YEAST
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00:08:47,310 --> 00:08:49,655
AND CAUSE THE DOUGH
TO RISE AGAIN.
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00:08:53,034 --> 00:08:56,551
CONVEYORS MOVE IN CRISS-CROSS
DIRECTIONS TO TAKE THE PITAS
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00:08:56,551 --> 00:08:58,206
BACK AND FORTH.
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00:08:58,206 --> 00:09:03,137
THIS ZIG-ZAGGING JOURNEY
LASTS ABOUT 15 MINUTES.
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00:09:03,137 --> 00:09:05,413
WHEN THE PITAS EMERGE
FROM THE CHAMBER,
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00:09:05,413 --> 00:09:09,137
THEY HAVE THICKENED UP
SUBSTANTIALLY.
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00:09:09,137 --> 00:09:12,413
THEY HEAD INTO AN OVEN
WHERE THE MAGIC HAPPENS.
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00:09:12,413 --> 00:09:15,482
THE OVEN'S TEMPERATURE IS
BETWEEN 750
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00:09:15,482 --> 00:09:18,034
AND 930 DEGREES FAHRENHEIT.
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00:09:18,034 --> 00:09:20,517
THEY SPEND JUST
15 SECONDS IN IT.
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00:09:20,517 --> 00:09:23,206
THIS FLASH-BAKING CAUSES
THE WATER IN THE DOUGH
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00:09:23,206 --> 00:09:24,655
TO TURN TO STEAM.
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00:09:24,655 --> 00:09:28,896
THE STEAM PUFFS THE PITAS,
CREATING POCKETS INSIDE.
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THE PITAS THEN TRAVEL
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00:09:30,241 --> 00:09:33,034
ON CONVEYORS
FOR A 20 MINUTE COOL DOWN.
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00:09:33,034 --> 00:09:36,000
AS THEY COOL, THEY DEFLATE.
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00:09:36,000 --> 00:09:39,241
THE PROCESS HAS CREATED POCKETS
IN THE PITAS.
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00:09:39,241 --> 00:09:40,655
ONCE SLICED OPEN,
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00:09:40,655 --> 00:09:44,344
THE POCKETS CAN BE STUFFED
TO CREATE SANDWICHES.
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00:09:44,344 --> 00:09:49,103
WORKERS STACK THE PITAS
SIX HIGH FOR PACKAGING.
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00:09:49,103 --> 00:09:51,689
THE NEXT CONVEYOR DELIVERS
THE STACKS INTO THE CLUTCH
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00:09:51,689 --> 00:09:55,103
OF AN AUTOMATED ARM.
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00:09:55,103 --> 00:09:58,344
JUST AHEAD, A BURST OF AIR
OPENS A BAG
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00:09:58,344 --> 00:10:00,965
AND THE ARM INSERTS
THE PITAS INTO IT.
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00:10:00,965 --> 00:10:06,379
AT THE SAME TIME, IT PUSHES
THE BAG ON TO THE NEXT CONVEYOR.
168
00:10:06,379 --> 00:10:09,517
MOVING FORWARD, ANOTHER DEVICE
AUTOMATICALLY TWISTS
169
00:10:09,517 --> 00:10:12,310
THE OPEN END OF THE BAG.
170
00:10:12,310 --> 00:10:14,517
THE DEVICE APPLIES
A PLASTIC LOCK TAB
171
00:10:14,517 --> 00:10:20,137
TO THE TWISTED END OF THE BAG,
SEALING THE PITA BREADS INSIDE.
172
00:10:20,137 --> 00:10:22,655
THE BAGS PASS BY
A METAL DETECTOR,
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00:10:22,655 --> 00:10:25,068
AND THEN THEY'RE ON THEIR WAY
TO THE SUPERMARKET.
174
00:10:29,413 --> 00:10:33,689
THIS PITA BREAD HAS TAKEN
45 MINUTES TO MAKE AND PACKAGE,
175
00:10:33,689 --> 00:10:37,517
BUT IT SHOULD ENABLE LUNCH
TO COME TOGETHER VERY QUICKLY.
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00:10:47,758 --> 00:10:49,241
Narrator:
INSTALLING EXHAUST HEADERS
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00:10:49,241 --> 00:10:52,172
WILL ADD EXTRA POWER
FROM A CAR'S ENGINE.
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00:10:52,172 --> 00:10:54,689
THEY BOLT ON TO THE ENGINE,
GIVING EACH CYLINDER
179
00:10:54,689 --> 00:10:57,206
ITS OWN EXHAUST PIPE
LEADING TO THE COLLECTOR,
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00:10:57,206 --> 00:11:00,517
WHICH CONNECTS TO THE CAR'S
MAIN EXHAUST PIPE.
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00:11:00,517 --> 00:11:03,310
THAT'S MORE EFFICIENT THAN
HAVING ALL THE CYLINDERS EXHAUST
182
00:11:03,310 --> 00:11:05,206
INTO A COMMON MANIFOLD.
183
00:11:07,793 --> 00:11:11,482
A HEADER DRAWS OUT SIGNIFICANTLY
MORE SPENT EXHAUST GASSES
184
00:11:11,482 --> 00:11:14,655
AFTER COMBUSTION, LEAVING ROOM
FOR A GREATER AMOUNT
185
00:11:14,655 --> 00:11:16,310
OF NEW GAS AND FRESH AIR
186
00:11:16,310 --> 00:11:20,724
TO ENTER THE CYLINDER
FOR THE NEXT COMBUSTION CYCLE.
187
00:11:20,724 --> 00:11:23,931
HEADERS ARE MADE OF STEEL
OR STAINLESS STEEL.
188
00:11:23,931 --> 00:11:27,344
A WORKER USES A ROLL CUTTER
TO SLICE TUBES INTO NEARLY
189
00:11:27,344 --> 00:11:31,517
6-INCH-LONG PIECES
FOR THE HEADER'S COLLECTOR.
190
00:11:31,517 --> 00:11:33,344
A FORMING TOOL ON A PRESS
191
00:11:33,344 --> 00:11:36,862
STRETCHES ONE SIDE
OF THE COLLECTOR OUTWARD.
192
00:11:36,862 --> 00:11:41,344
THEN THE WORKER PLACES THE SAME
SIDE ON AN END-FORMING MACHINE,
193
00:11:41,344 --> 00:11:44,586
WHICH SHAPES IT LIKE
A FOUR-LEAF CLOVER.
194
00:11:44,586 --> 00:11:47,689
HE SLIPS A FLANGE OVER
THE UNSHAPED SIDE
195
00:11:47,689 --> 00:11:51,172
AND WIDENS THAT SIDE TO CREATE
THE BALL PORTION
196
00:11:51,172 --> 00:11:53,758
OF THE GASKETLESS BALL
AND SOCKET CONNECTION
197
00:11:53,758 --> 00:11:55,896
TO THE CAR'S MAIN EXHAUST PIPE.
198
00:11:58,551 --> 00:12:02,137
MEANWHILE, ANOTHER WORKER
ROLL CUTS NARROWER TUBES
199
00:12:02,137 --> 00:12:06,551
INTO 32-INCH-LONG PIECES TO MAKE
THE HEADER'S PRIMARY TUBES,
200
00:12:06,551 --> 00:12:11,655
THE ONES THAT ATTACH AT THE TOP
TO ENGINE'S CYLINDERS.
201
00:12:11,655 --> 00:12:14,379
A WORKER SLIDES A TUBE
ON TO A MANDREL,
202
00:12:14,379 --> 00:12:16,758
THEN THE COMPUTER-GUIDED
MANDREL BENDER
203
00:12:16,758 --> 00:12:19,344
BENDS THE TUBE IN FOUR PLACES.
204
00:12:19,344 --> 00:12:22,034
THE MANDREL FILLS THE INSIDE
OF THE TUBE
205
00:12:22,034 --> 00:12:24,965
JUST UP TO THE BEND POINT,
PREVENTING THE TUBE FROM
206
00:12:24,965 --> 00:12:28,793
COMPRESSING OR COLLAPSING
UNDER PRESSURE.
207
00:12:28,793 --> 00:12:32,172
THE HEADER THEY'RE MAKING HERE
IS FOR A FOUR-CYLINDER ENGINE,
208
00:12:32,172 --> 00:12:34,793
SO IT HAS FOUR PRIMARY TUBES.
209
00:12:34,793 --> 00:12:37,689
AN EIGHT-CYLINDER ENGINE
REQUIRES A PAIR OF HEADERS,
210
00:12:37,689 --> 00:12:39,137
WHEREAS A SIX-CYLINDER ENGINE
211
00:12:39,137 --> 00:12:43,551
REQUIRES A PAIR
OF THREE-TUBE HEADERS.
212
00:12:43,551 --> 00:12:45,965
A WORKER TRIMS THE BENT
PRIMARY TUBES
213
00:12:45,965 --> 00:12:48,517
TO THE REQUIRED LENGTH
WITH A BANDSAW.
214
00:12:52,517 --> 00:12:55,862
THE SAWED EDGES OF THE TUBE
ARE RAGGED,
215
00:12:55,862 --> 00:12:58,448
SO THE NEXT STEP
IS TO GRIND THEM SMOOTH.
216
00:13:03,586 --> 00:13:07,551
AFTER GRINDING, THE EDGE
NO LONGER LOOKS LIKE THIS.
217
00:13:13,517 --> 00:13:15,482
WORKERS HEAT THE TOP END
OF THE TUBE
218
00:13:15,482 --> 00:13:18,000
WITH A TORCH
TO SOFTEN THE STEEL.
219
00:13:23,689 --> 00:13:27,068
THEY PLACE THE END
INTO AN END-FORMING MACHINE.
220
00:13:27,068 --> 00:13:28,586
THE MACHINE SHAPES THE END
221
00:13:28,586 --> 00:13:31,068
TO MATCH THE TOP PROFILE
OF THE CYLINDER,
222
00:13:31,068 --> 00:13:34,793
TO WHICH THE TUBE
WILL BE MOUNTED.
223
00:13:34,793 --> 00:13:38,000
CYLINDER PROFILES VARY
FROM ENGINE TO ENGINE,
224
00:13:38,000 --> 00:13:41,482
SO WORKERS SIMPLY CHANGE
THE FORMING TOOL ON THE MACHINE.
225
00:13:45,551 --> 00:13:48,758
A WORKER CLAMPS THE HEADER
FLANGE WITH ITS FOUR
226
00:13:48,758 --> 00:13:52,206
EXHAUST PORTS ON TO
AN ASSEMBLY JIG AND POSITIONS
227
00:13:52,206 --> 00:13:56,655
THE TOP END OF
A PRIMARY TUBE IN EACH PORT.
228
00:13:56,655 --> 00:13:58,310
HE INSERTS THE BOTTOM ENDS
229
00:13:58,310 --> 00:14:02,103
INTO THE FOUR-LEAF-CLOVER-SHAPED
COLLECTOR.
230
00:14:04,517 --> 00:14:07,068
HE THEN WELDS THE TOP END
OF EACH TUBE
231
00:14:07,068 --> 00:14:10,551
TO ITS EXHAUST PORT
ON THE HEADER FLANGE.
232
00:14:10,551 --> 00:14:13,310
THEN HE WELDS A TAG
WITH THE COMPANY NAME
233
00:14:13,310 --> 00:14:15,034
ON TO ONE OF THE TUBES.
234
00:14:17,586 --> 00:14:20,275
FINALLY, HE WELDS
THE BOTTOM END OF THE TUBES
235
00:14:20,275 --> 00:14:22,137
TO THE COLLECTOR.
236
00:14:26,620 --> 00:14:29,448
THE HEADER'S THREE SECTIONS --
FLANGE, TUBES,
237
00:14:29,448 --> 00:14:33,551
AND COLLECTOR -- ARE NOW FUSED.
238
00:14:33,551 --> 00:14:36,379
THE WORKER GRINDS DOWN THE WELD
AROUND THE PORTS
239
00:14:36,379 --> 00:14:39,413
UNTIL IT'S NEARLY FLUSH.
240
00:14:39,413 --> 00:14:42,551
THE REMAINING BIT OF WELD
MATERIAL ENCIRCLING THE PORT
241
00:14:42,551 --> 00:14:45,137
WILL ACT
AS A SEAL TO PREVENT LEAKAGE.
242
00:14:49,517 --> 00:14:52,206
DURING THE WELDING,
SOME WELDING MATERIAL DRIPS
243
00:14:52,206 --> 00:14:55,137
INTO THE HEADER FLANGE'S
OPENINGS,
244
00:14:55,137 --> 00:14:57,896
SO A WORKER REAMS
THE BOLT HOLES WITH A DRILL
245
00:14:57,896 --> 00:15:00,206
AND GRINDS
THE EDGES OF EACH PORT.
246
00:15:03,241 --> 00:15:05,724
HE MOUNTS THE HEADER ON
THE CORRESPONDING ENGINE'S
247
00:15:05,724 --> 00:15:10,310
CYLINDER HEAD TO MAKE SURE BOLT
HOLES ARE SUFFICIENTLY CLEARED.
248
00:15:10,310 --> 00:15:14,896
THEN HE RUNS A TORCH OVER ALL
THE JOINTS TO CHECK THE WELDS.
249
00:15:14,896 --> 00:15:17,896
THE FLAME WOULD SHOOT THROUGH
ANY HOLE IN A WELD,
250
00:15:17,896 --> 00:15:20,551
ALERTING THEM TO REPAIR IT.
251
00:15:23,241 --> 00:15:27,758
THIS FACTORY APPLIES ONE OF TWO
FINISHES ON ITS EXHAUST HEADERS.
252
00:15:27,758 --> 00:15:31,103
THE BASIC ONE IS A COAT
OF BLACK WATER-BASED PAINT
253
00:15:31,103 --> 00:15:33,551
SPRAYED ON AND AIR-DRIED.
254
00:15:33,551 --> 00:15:35,758
IT PREVENTS SURFACE RUST
FROM FORMING
255
00:15:35,758 --> 00:15:38,068
WHILE THE PART IS WAREHOUSED.
256
00:15:38,068 --> 00:15:41,827
THE HIGHER-END FINISH IS AN
AEROSPACE-GRADE CERAMIC COATING,
257
00:15:41,827 --> 00:15:44,448
AVAILABLE IN BLACK OR SILVER.
258
00:15:44,448 --> 00:15:47,793
THIS BAKED-ON FINISH PROTECTS
THE HEADERS FROM RUST
259
00:15:47,793 --> 00:15:50,827
FOR MANY YEARS
OF HIGH-PERFORMANCE DRIVING.
260
00:16:01,724 --> 00:16:03,586
Narrator:
THIS MAY LOOK LIKE IVORY,
261
00:16:03,586 --> 00:16:05,551
BUT IT'S ACTUALLY LIMESTONE.
262
00:16:05,551 --> 00:16:08,241
IT LOOKS AS THOUGH
IT'S A SCULPTED WORK OF ART,
263
00:16:08,241 --> 00:16:10,068
BUT IT'S ACTUALLY MOLDED.
264
00:16:10,068 --> 00:16:12,310
HOW DOES ONE MOLD LIMESTONE?
265
00:16:12,310 --> 00:16:16,310
200 YEARS AGO, SOME PEOPLE
IN FRANCE FIGURED OUT HOW,
266
00:16:16,310 --> 00:16:22,206
AND THEIR DESCENDENTS ARE STILL
MOLDING LIMESTONE ARTWORK TODAY.
267
00:16:22,206 --> 00:16:25,896
THIS UNIQUE ART FORM EXISTS
BECAUSE, TWO CENTURIES AGO,
268
00:16:25,896 --> 00:16:30,620
A FAMILY IN FRANCE DISCOVERED
SPRINGS AMID VOLCANIC ROCK,
269
00:16:30,620 --> 00:16:34,310
SPRINGS WITH WATER SO RICH
IN CALCIUM CARBONATE
270
00:16:34,310 --> 00:16:36,379
THAT IT PETRIFIED INTO STONE.
271
00:16:36,379 --> 00:16:39,137
THAT IS LIMESTONE.
272
00:16:39,137 --> 00:16:42,379
THE FAMILY CARVED OUT CAVES,
THEN INVENTED A WAY
273
00:16:42,379 --> 00:16:46,620
TO CAPTURE THE CALCIUM CARBONATE
AND MOLD SCULPTURES WITH IT.
274
00:16:46,620 --> 00:16:50,896
THE DESCENDENTS OF THE FAMILY
CONTINUE THAT TRADITION TODAY.
275
00:16:50,896 --> 00:16:54,655
THE SPRINGWATER CONTAINS
TWO GRAMS OF CALCIUM CARBONATE
276
00:16:54,655 --> 00:16:57,413
PER LITER AND A LOT
OF IRON OXIDE,
277
00:16:57,413 --> 00:16:59,758
WHICH MAKES THE WATER ORANGE.
278
00:16:59,758 --> 00:17:01,931
THE ORIGINAL TROUGHS
DIRECT THE WATER
279
00:17:01,931 --> 00:17:04,413
ON TO A BED OF WOOD SHAVINGS.
280
00:17:04,413 --> 00:17:06,793
THE SHAVINGS TRAP
THE IRON OXIDE,
281
00:17:06,793 --> 00:17:11,103
AND THE CALCIUM CARBONATE FLOATS
TO THE SURFACE.
282
00:17:11,103 --> 00:17:13,689
IN THE WORKSHOP,
THE OWNER OF THE COMPANY --
283
00:17:13,689 --> 00:17:16,310
THE SEVENTH GENERATION
OF THE FOUNDING FAMILY --
284
00:17:16,310 --> 00:17:17,827
MAKES THE MOLD.
285
00:17:17,827 --> 00:17:20,034
HE HEATS SOMETHING CALLED
GUTTA-PERCHA
286
00:17:20,034 --> 00:17:22,620
IN A POT OF WATER
TO SOFTEN IT UP.
287
00:17:22,620 --> 00:17:25,068
GUTTA-PERCHA IS A NATURAL LATEX
288
00:17:25,068 --> 00:17:27,344
MADE FROM THE SAP
OF THE GUTTA TREE.
289
00:17:27,344 --> 00:17:30,482
ONCE IT'S SOFT, HE WEIGHS OUT
THE REQUIRED AMOUNT
290
00:17:30,482 --> 00:17:32,965
USING THE WORKSHOP'S
ORIGINAL SCALE.
291
00:17:36,172 --> 00:17:39,379
THEN HE KNEADS IT TO FORCE OUT
TRAPPED AIR
292
00:17:39,379 --> 00:17:41,172
AND MAKE IT MORE MALLEABLE.
293
00:17:44,172 --> 00:17:48,275
AFTER FORMING IT INTO A BALL,
HE PLACES IT IN AN OLD PRESS
294
00:17:48,275 --> 00:17:50,793
MADE MY HIS GREAT-GRANDFATHER.
295
00:17:50,793 --> 00:17:52,965
THE PRESS SHAPES
THE GUTTA-PERCHA
296
00:17:52,965 --> 00:17:56,344
INTO A RECTANGLE MEASURING
7-BY-10 INCHES.
297
00:18:00,068 --> 00:18:02,586
AFTER COOLING IN THE PRESS
FOR 30 MINUTES,
298
00:18:02,586 --> 00:18:04,379
THE GUTTA-PERCHA HAS HARDENED
299
00:18:04,379 --> 00:18:08,344
JUST ENOUGH TO MAINTAIN
THE RECTANGULAR SHAPE.
300
00:18:08,344 --> 00:18:10,137
HE REMOVES IT FROM THE PRESS
301
00:18:10,137 --> 00:18:14,310
AND PLACES A SILICONE-DESIGNED
TEMPLATE ON TOP.
302
00:18:14,310 --> 00:18:17,620
HE CUTS THE GUTTA-PERCHA
TO THE SHAPE OF THE TEMPLATE.
303
00:18:23,172 --> 00:18:25,965
HE PLACES THE GUTTA-PERCHA
ON TOP OF A PATTERN
304
00:18:25,965 --> 00:18:29,379
CREATED BY AN ARTIST.
305
00:18:29,379 --> 00:18:32,034
HE PLACES THE TEMPLATE
ON THE GUTTA-PERCHA,
306
00:18:32,034 --> 00:18:34,413
THEN A PLANK OF WOOD
ON TOP OF THAT.
307
00:18:37,172 --> 00:18:41,068
HE PUTS THE ENTIRE ASSEMBLY
UNDER AN OLD SCREW PRESS.
308
00:18:45,172 --> 00:18:48,586
AN HOUR LATER, HE REMOVES
THE ASSEMBLY FROM THE PRESS
309
00:18:48,586 --> 00:18:51,000
AND GENTLY SEPARATES THE LAYERS.
310
00:18:53,137 --> 00:18:56,517
THE ARTWORK DESIGN IS NOW
TRANSFERRED FROM THE PATTERN
311
00:18:56,517 --> 00:18:58,413
TO THE GUTTA-PERCHA.
312
00:18:58,413 --> 00:19:02,413
HE SETS IT ASIDE TO COOL
TO A HARD STATE.
313
00:19:03,275 --> 00:19:06,275
WHEN THE WORK OF ART
IS EITHER TOO WIDE OR HIGH
314
00:19:06,275 --> 00:19:08,310
TO FIT INTO
THE TRADITIONAL SCREW PRESS,
315
00:19:08,310 --> 00:19:11,379
THE ARTISAN THEN SCULPTS
THE PATTERN OUT OF CLAY.
316
00:19:11,379 --> 00:19:16,379
ONCE THE CLAY HARDENS, HE COATS
IT IN SILICONE TO MAKE THE MOLD.
317
00:19:16,379 --> 00:19:19,758
THIS MODERN MOLD-MAKING
TECHNIQUE IS A BIT TRICKIER
318
00:19:19,758 --> 00:19:22,068
BECAUSE SILICONE
CAN'T BE REHEATED
319
00:19:22,068 --> 00:19:24,310
AND REWORKED LIKE GUTTA-PERCHA.
320
00:19:26,758 --> 00:19:28,862
THE SILICONE TAKES ABOUT
24 HOURS
321
00:19:28,862 --> 00:19:31,862
TO HARDEN INTO A FLEXIBLE MOLD.
322
00:19:31,862 --> 00:19:34,827
A SILICONE MOLD CAN BE USED
ONLY ONCE.
323
00:19:34,827 --> 00:19:38,586
AND BECAUSE IT'S SO FLEXIBLE,
IT HAS TO SIT ON A SUPPORT TRAY
324
00:19:38,586 --> 00:19:43,206
SO THAT IT DOESN'T BUCKLE
WHEN FILLED OR MOVED.
325
00:19:43,206 --> 00:19:45,517
NOW IT'S TIME TO MOLD
THE LIMESTONE.
326
00:19:45,517 --> 00:19:48,206
A CRAFTSMAN POSITIONS
THE MOLDS UNDER THESE
327
00:19:48,206 --> 00:19:50,551
LIQUID LIMESTONE WATERFALLS.
328
00:19:50,551 --> 00:19:54,310
THE CARBONIC GAS IN THE LIQUID
GRADUALLY EVAPORATES,
329
00:19:54,310 --> 00:19:59,275
LEAVING ACCUMULATING DEPOSITS OF
CALCIUM CARBONATE IN THE MOLDS.
330
00:19:59,275 --> 00:20:03,275
AN ARTISAN MOVES EVERY MOLD
TO A NEW POSITION DAILY
331
00:20:03,275 --> 00:20:06,931
SO THAT THE DRIPPING WATER
HITS ALL PARTS OF IT.
332
00:20:06,931 --> 00:20:10,413
ARTWORK JUST ONE 1/5 OF AN INCH
THICK REQUIRES
333
00:20:10,413 --> 00:20:12,793
SIX MONTHS UNDER THE FOUNTAIN.
334
00:20:12,793 --> 00:20:16,931
ARTWORK 4/5 OF AN INCH THICK
REQUIRES TWO YEARS.
335
00:20:19,206 --> 00:20:22,689
TO EXTRACT THE LIMESTONE ARTWORK
FROM A TRADITIONAL MOLD,
336
00:20:22,689 --> 00:20:25,034
THE ARTISAN IMMERSES IT
IN HOT WATER
337
00:20:25,034 --> 00:20:29,206
TO SOFTEN THE GUTTA-PERCHA SO
THAT HE CAN GENTLY PEEL IT OFF.
338
00:20:29,206 --> 00:20:31,310
EVERY INTRICATE DETAIL
OF THE DESIGN
339
00:20:31,310 --> 00:20:35,827
IN THE GUTTA-PERCHA
IS NOW REPLICATED IN LIMESTONE.
340
00:20:35,827 --> 00:20:40,758
THIS MOLDED ROCK IS AS STRONG
AND HARD AS MARBLE.
341
00:20:40,758 --> 00:20:43,724
TO EXTRA THE ARTWORK
FROM A SILICONE MOLD,
342
00:20:43,724 --> 00:20:48,310
AN ARTISAN REMOVES THE SUPPORT
TRAY AND LIFTS OFF THE SILICONE.
343
00:20:48,310 --> 00:20:52,206
THE COMPANY HAS MORE THAN 500
ARTWORK PATTERNS IN STOCK
344
00:20:52,206 --> 00:20:55,206
DATING BACK TO 1821.
345
00:20:55,206 --> 00:20:58,034
NOT ALL THE MOLDED LIMESTONE
LOOKS THE SAME.
346
00:20:58,034 --> 00:21:01,689
THE ARTISANS CAN TAILOR
THE SHADE FROM WHITE TO IVORY
347
00:21:01,689 --> 00:21:04,000
BY CONTROLLING
HOW MUCH IRON OXIDE
348
00:21:04,000 --> 00:21:06,379
THEY REMOVE FROM THE WATER.
28390
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