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These are the user uploaded subtitles that are being translated: 1 00:00:03,172 --> 00:00:06,137 --Captions by VITAC-- www.vitac.com 2 00:00:06,137 --> 00:00:09,137 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:53,379 --> 00:00:55,896 Narrator: SPIRAL STAIRS WERE PART OF A STRATEGY 4 00:00:55,896 --> 00:00:58,827 TO DEFEND THE TOWERS OF MEDIEVAL CASTLES. 5 00:00:58,827 --> 00:01:01,103 ATTACKERS HAD TO CLIMB SINGLE-FILE 6 00:01:01,103 --> 00:01:04,241 AND COULDN'T STORM THE CASTLE ALL AT ONCE. 7 00:01:04,241 --> 00:01:05,793 AND AT THE TOP OF THE STAIRS, 8 00:01:05,793 --> 00:01:09,068 THE GUARDSMEN COULD MORE EASILY MANEUVER THEIR SWORDS, 9 00:01:09,068 --> 00:01:11,068 GIVING THEM THE UPPER HAND. 10 00:01:14,413 --> 00:01:17,000 SPIRAL STAIRS TAKE PEOPLE TO THE NEXT LEVEL 11 00:01:17,000 --> 00:01:20,241 WITHOUT TAKING UP A LOT OF SPACE. 12 00:01:20,241 --> 00:01:23,482 THEY'RE COMPACT, AND WITH THEIR CORKSCREW CURVATURE, 13 00:01:23,482 --> 00:01:27,620 THEY CAN ALSO BE ARCHITECTURAL FEATURES. 14 00:01:27,620 --> 00:01:30,068 PRODUCTION STARTS WITH THE STEEL HUBS 15 00:01:30,068 --> 00:01:32,689 CUT TO THE DESIRED RISER HEIGHT. 16 00:01:32,689 --> 00:01:35,413 A WORKER FILES THE SHARP EDGES SMOOTH 17 00:01:35,413 --> 00:01:36,793 AND DRILLS A THREADED HOLE 18 00:01:36,793 --> 00:01:40,034 WHICH WILL BE USED TO FASTEN THE TREADS IN PLACE. 19 00:01:42,482 --> 00:01:46,517 A COMPUTER-DRIVEN PLASMA SYSTEM CUTS THROUGH A SHEET OF STEEL 20 00:01:46,517 --> 00:01:51,344 TO PRODUCE THE PIE-SHAPED STAIR TREADS. 21 00:01:51,344 --> 00:01:53,758 A WORKER NESTLES A TREAD TO THE HUB 22 00:01:53,758 --> 00:01:56,275 AND CLAMPS THEM IN A WELD FIXTURE. 23 00:01:56,275 --> 00:01:58,482 HE ALSO CLAMPS STRUCTURAL SUPPORTS 24 00:01:58,482 --> 00:02:02,241 TO THE BASE OF THE TREAD. 25 00:02:02,241 --> 00:02:04,689 WITH EVERYTHING IN THE RIGHT CONFIGURATION, 26 00:02:04,689 --> 00:02:07,965 HE WELDS THE SUPPORTS TO THE TREAD AND THE HUB. 27 00:02:07,965 --> 00:02:12,517 HE'LL MAKE 12 OF THESE HUB AND TREAD ASSEMBLIES. 28 00:02:12,517 --> 00:02:16,655 HE CHIPS OFF THE WELD SLAG FOR CLEANER SEAMS. 29 00:02:16,655 --> 00:02:19,482 A TEAM SLIDES THE HUB AND TREAD ASSEMBLIES 30 00:02:19,482 --> 00:02:21,034 ON TO THE CENTER POLE 31 00:02:21,034 --> 00:02:24,103 AND ROTATES THEM TO THE CORRECT POSITION. 32 00:02:24,103 --> 00:02:27,448 THE DESIGN GEOMETRY DICTATES THE ROTATION. 33 00:02:27,448 --> 00:02:29,137 ONCE ROTATED CORRECTLY, 34 00:02:29,137 --> 00:02:31,689 THE WORKERS FASTEN THE HUBS TO THE POLE 35 00:02:31,689 --> 00:02:34,103 AND ADD A PLATFORM FOR THE TOP STEP. 36 00:02:36,862 --> 00:02:40,965 A BALUSTER SPINS IN A LATHE, AS TOOLS CUT IT TO LENGTH 37 00:02:40,965 --> 00:02:44,103 AND ROUND THE END TO THE CORRECT DIAMETER. 38 00:02:44,103 --> 00:02:46,689 THE OPERATOR MEASURES THE DIAMETER. 39 00:02:46,689 --> 00:02:48,793 HE INSERTS THE ROUNDED END IN A DYE 40 00:02:48,793 --> 00:02:52,965 THAT CARVES THE THREAD INTO IT. 41 00:02:52,965 --> 00:02:54,862 A WORKER WELDS A STEEL CUP 42 00:02:54,862 --> 00:02:57,896 JUST ABOVE THE THREADED PART OF THE BALUSTER. 43 00:02:57,896 --> 00:02:59,724 THIS CUP WILL SUPPORT THE BALUSTER 44 00:02:59,724 --> 00:03:02,172 ONCE IT'S BEEN INSTALLED ON THE THREAD. 45 00:03:02,172 --> 00:03:04,896 HE GRINDS THE WELD SCALE FROM THE CUP. 46 00:03:04,896 --> 00:03:07,034 HE INSERTS THE BALUSTER THROUGH HOLES 47 00:03:07,034 --> 00:03:09,206 IN A METAL SPACER IN THE TREAD. 48 00:03:09,206 --> 00:03:12,344 HE SCREWS A NUT ON TO THE END TO SECURE IT. 49 00:03:14,758 --> 00:03:18,586 USING ROLLERS NOW, ANOTHER WORKER TWISTS LONG STRIPS 50 00:03:18,586 --> 00:03:21,413 OF METAL INTO SPIRALING HAND RAILS THAT MATCH 51 00:03:21,413 --> 00:03:23,758 THE RISE OF THE STAIRS. 52 00:03:23,758 --> 00:03:26,068 HE FITS THE RAIL TO THE TOP BALUSTERS 53 00:03:26,068 --> 00:03:29,655 AND CLAMPS IT IN PLACE. 54 00:03:29,655 --> 00:03:33,172 HE THEN WELDS THE BALUSTERS TO THE RAIL. 55 00:03:33,172 --> 00:03:36,241 HE ADDS MORE RAILING UNTIL IT SPIRALS ALL THE WAY DOWN 56 00:03:36,241 --> 00:03:39,310 TO THE FIRST STEP. 57 00:03:39,310 --> 00:03:42,793 THE TEAM SECURES IT TO THE PLATFORM. 58 00:03:42,793 --> 00:03:46,620 THE SPIRAL STAIRCASE'S METAL STRUCTURE IS NOW COMPLETE. 59 00:03:46,620 --> 00:03:48,931 IT'S READY FOR THE WOODEN ACCENTS. 60 00:03:51,068 --> 00:03:54,551 A WORKER APPLIES GLUE TO PIECES OF RED OAK. 61 00:03:54,551 --> 00:03:57,724 HE'LL USE TWO OF THEM TO MAKE ONE STAIR TREAD. 62 00:03:57,724 --> 00:04:01,655 HE CLAMPS TWO TREAD SETS IN A FIXTURE WHILE THE GLUE SETS. 63 00:04:01,655 --> 00:04:03,206 HE INSERTS A SHIM 64 00:04:03,206 --> 00:04:07,344 AND TIGHTENS THE CLAMP TO APPLY DOWNWARD PRESSURE. 65 00:04:07,344 --> 00:04:10,862 ONCE THE GLUE HAS CURED, A PLANER SHAVES THE TREAD 66 00:04:10,862 --> 00:04:15,000 PERFECTLY FLAT AND TO THE DESIRED THICKNESS. 67 00:04:15,000 --> 00:04:16,931 AFTER REFINING THE PROFILE, 68 00:04:16,931 --> 00:04:21,206 A WORKER ROUNDS THE EDGE OF THE STAIR TREAD USING A ROUTER. 69 00:04:22,965 --> 00:04:25,344 AFTER GLUING STRIPS OF WOOD TOGETHER TO CREATE 70 00:04:25,344 --> 00:04:28,896 A CURVED RAILING, HE SANDS THE EXCESS ADHESIVE, 71 00:04:28,896 --> 00:04:32,344 AND WITH A FILE, REMOVES MORE OF THE GLUE. 72 00:04:32,344 --> 00:04:36,448 HE TURNS THE RAILING OVER AND CARVES A GROOVE IN THE WOOD. 73 00:04:36,448 --> 00:04:38,724 THIS WILL ENABLE THE RAILING TO BE INSTALLED 74 00:04:38,724 --> 00:04:40,965 OVER THE METAL RAIL SUPPORT. 75 00:04:40,965 --> 00:04:44,758 HE ADDS SOME DETAILING ALONG THE EDGE. 76 00:04:44,758 --> 00:04:46,758 A TEAM THEN FITS THE WOODEN RAILING 77 00:04:46,758 --> 00:04:49,172 TO THE METAL SUPPORT STRUCTURE. 78 00:04:49,172 --> 00:04:53,275 ALL OF THE RAIL SECTIONS FIT TOGETHER PERFECTLY. 79 00:04:53,275 --> 00:04:56,068 AFTER THE PRE-FIT, THEY REMOVE THE RAILING 80 00:04:56,068 --> 00:04:58,482 AND SCULPT THE EDGES TO BE ROUNDER. 81 00:04:58,482 --> 00:05:03,413 THE ROUNDED EDGES COMPLEMENT THE OVERALL SPIRAL DESIGN. 82 00:05:03,413 --> 00:05:07,103 A WORKER PRE-FITS THE WOODEN TREADS TO THE METAL STRUCTURE 83 00:05:07,103 --> 00:05:10,517 AND THEN DISASSEMBLES THE ENTIRE SPIRAL STAIRCASE 84 00:05:10,517 --> 00:05:12,275 FOR PAINTING AND STAINING. 85 00:05:14,413 --> 00:05:17,965 THE SPIRAL STAIRS ARE THEN READY FOR REASSEMBLY IN THE BUILDING 86 00:05:17,965 --> 00:05:19,689 THEY WERE DESIGNED FOR. 87 00:05:19,689 --> 00:05:24,413 THEY'LL DEFINITELY ADD A CERTAIN TWIST TO THE INTERIOR DESIGN. 88 00:05:34,310 --> 00:05:36,206 Narrator: ORIGINATING IN THE MIDDLE EAST, 89 00:05:36,206 --> 00:05:39,206 PITA BREAD HAS BEEN AROUND FOR THOUSANDS OF YEARS. 90 00:05:39,206 --> 00:05:43,241 TODAY, ITS POPULARITY CONTINUES TO GROW AROUND THE GLOBE. 91 00:05:43,241 --> 00:05:45,965 PART OF ITS APPEAL IS ITS VERSATILITY. 92 00:05:45,965 --> 00:05:48,206 PEOPLE CAN STUFF THEIR PITA'S POCKETS, 93 00:05:48,206 --> 00:05:51,517 USE IT AS A SANDWICH WRAP, OR SLICE IT FOR DIPPING. 94 00:05:54,931 --> 00:05:56,586 PITA BREAD MAY BE FLAT, 95 00:05:56,586 --> 00:05:58,689 BUT THAT DOESN'T MEAN IT'S BORING. 96 00:05:58,689 --> 00:06:00,862 ANYONE CAN USE PITA TO MAKE ANY NUMBER 97 00:06:00,862 --> 00:06:05,241 OF INTERESTING LUNCHTIME COMBINATIONS. 98 00:06:05,241 --> 00:06:09,034 MAKING PITA BREAD STARTS WITH SILOS FULL OF FLOUR. 99 00:06:09,034 --> 00:06:12,758 A BLOWER SYSTEM DELIVERS THE FLOUR TO AN AUTOMATED SIFTER. 100 00:06:12,758 --> 00:06:15,965 THE SIFTER SHAKES THE FLOUR THROUGH THREE LEVELS OF MESH 101 00:06:15,965 --> 00:06:18,103 TO FILTER OUT IMPURITIES. 102 00:06:18,103 --> 00:06:21,862 MAGNETS EXTRACT ANY METAL CONTAMINANTS. 103 00:06:21,862 --> 00:06:25,482 WORKERS PREPARE A PRE-MIX OF SUGAR, SALT, YEAST, 104 00:06:25,482 --> 00:06:27,241 AND PRESERVATIVES. 105 00:06:27,241 --> 00:06:29,793 THEY COMBINE THESE INGREDIENTS WITH THE SIFTED FLOUR 106 00:06:29,793 --> 00:06:33,000 IN A BIG MIXER AND ADD WATER. 107 00:06:33,000 --> 00:06:35,172 THE MIXER IS EQUIPPED WITH NUMEROUS BARS 108 00:06:35,172 --> 00:06:39,379 THAT ROTATE HORIZONTALLY TO BLEND THE INGREDIENTS. 109 00:06:40,241 --> 00:06:44,172 THE OPERATOR OPENS THE MIXER AND SPINS IT ONE MORE TIME 110 00:06:44,172 --> 00:06:46,586 TO EJECT THE DOUGH INTO A BIN. 111 00:06:50,068 --> 00:06:53,965 HE ROLLS THE BIN TO THE NEXT STATION. 112 00:06:53,965 --> 00:06:57,172 HERE THE PITA DOUGH GOES INTO A HOPPER. 113 00:06:57,172 --> 00:06:59,689 AND FROM THERE, IT DROPS INTO A MACHINE 114 00:06:59,689 --> 00:07:01,344 CALLED A DOUGH DIVIDER. 115 00:07:07,137 --> 00:07:12,000 THIS MACHINE TURNS BIG CHUNKS OF DOUGH INTO MANY SMALL BLOBS. 116 00:07:12,000 --> 00:07:15,724 TO DO THIS, IT FORCES THE DOUGH THROUGH A ROUND HOLE, 117 00:07:15,724 --> 00:07:21,137 AND A GUILLOTINE BLADE CHOPS IT TO THE CORRECT THICKNESS. 118 00:07:21,137 --> 00:07:24,310 THE DOUGH BLOBS RIDE A CONVEYOR AND PASS UNDER A ROLLER 119 00:07:24,310 --> 00:07:27,034 THAT FLATTENS THEM. 120 00:07:27,034 --> 00:07:30,965 FLOUR FROM AN OVERHEAD SIFTER DUSTS THE DOUGH BLOBS 121 00:07:30,965 --> 00:07:35,206 TO KEEP THEM FROM STICKING TO THE MACHINERY. 122 00:07:35,206 --> 00:07:37,068 EACH ONE OF THESE FLATTENED DOUGH BLOBS 123 00:07:37,068 --> 00:07:39,000 WILL EVENTUALLY BECOME A PITA. 124 00:07:42,241 --> 00:07:44,068 THE ROUND PIECES OF DOUGH NOW RIDE 125 00:07:44,068 --> 00:07:46,758 A CONVEYOR UP TO A WARM ZONE. 126 00:07:46,758 --> 00:07:50,413 OVER A PERIOD OF 15 MINUTES, THE YEAST FERMENTS, 127 00:07:50,413 --> 00:07:53,068 CAUSING THE DOUGH TO RISE. 128 00:07:53,068 --> 00:07:55,034 OUT OF THE FERMENTATION STATION, 129 00:07:55,034 --> 00:08:00,103 A ROLLER FLATTENS THE PITA DOUGH SEGMENTS AGAIN. 130 00:08:00,103 --> 00:08:02,586 THEY'RE NOW READY TO BE ROLLED VERY THIN 131 00:08:02,586 --> 00:08:04,931 IN A PROCESS KNOWN AS SHEETING. 132 00:08:07,310 --> 00:08:10,724 THE NEXT ROLLER PRESSES THE PITA DOUGH MUCH THINNER. 133 00:08:10,724 --> 00:08:12,413 ROLLING IT IN ONE DIRECTION 134 00:08:12,413 --> 00:08:14,965 MAKES THE DOUGH SEGMENTS OVAL-SHAPED. 135 00:08:18,137 --> 00:08:20,310 THE OVAL PITAS RIDE BY A PUSHER 136 00:08:20,310 --> 00:08:25,275 THAT NOW SHOVES THEM TOWARDS THE FINAL ROLLER. 137 00:08:25,275 --> 00:08:28,862 IT ROLLS THE DOUGH IN THE OTHER DIRECTION TO ROUND OUT THE SHAPE 138 00:08:28,862 --> 00:08:30,620 AND MAKE IT EVEN THINNER. 139 00:08:34,379 --> 00:08:36,275 PERFECTLY ROUND AND THIN, 140 00:08:36,275 --> 00:08:40,068 THE PITAS NOW TRAVEL UP TO ANOTHER FERMENTATION OPERATION. 141 00:08:42,275 --> 00:08:44,931 INSIDE, THE TEMPERATURE IS TOASTY. 142 00:08:44,931 --> 00:08:47,310 IT'S WARM ENOUGH TO REAWAKEN THE YEAST 143 00:08:47,310 --> 00:08:49,655 AND CAUSE THE DOUGH TO RISE AGAIN. 144 00:08:53,034 --> 00:08:56,551 CONVEYORS MOVE IN CRISS-CROSS DIRECTIONS TO TAKE THE PITAS 145 00:08:56,551 --> 00:08:58,206 BACK AND FORTH. 146 00:08:58,206 --> 00:09:03,137 THIS ZIG-ZAGGING JOURNEY LASTS ABOUT 15 MINUTES. 147 00:09:03,137 --> 00:09:05,413 WHEN THE PITAS EMERGE FROM THE CHAMBER, 148 00:09:05,413 --> 00:09:09,137 THEY HAVE THICKENED UP SUBSTANTIALLY. 149 00:09:09,137 --> 00:09:12,413 THEY HEAD INTO AN OVEN WHERE THE MAGIC HAPPENS. 150 00:09:12,413 --> 00:09:15,482 THE OVEN'S TEMPERATURE IS BETWEEN 750 151 00:09:15,482 --> 00:09:18,034 AND 930 DEGREES FAHRENHEIT. 152 00:09:18,034 --> 00:09:20,517 THEY SPEND JUST 15 SECONDS IN IT. 153 00:09:20,517 --> 00:09:23,206 THIS FLASH-BAKING CAUSES THE WATER IN THE DOUGH 154 00:09:23,206 --> 00:09:24,655 TO TURN TO STEAM. 155 00:09:24,655 --> 00:09:28,896 THE STEAM PUFFS THE PITAS, CREATING POCKETS INSIDE. 156 00:09:28,896 --> 00:09:30,241 THE PITAS THEN TRAVEL 157 00:09:30,241 --> 00:09:33,034 ON CONVEYORS FOR A 20 MINUTE COOL DOWN. 158 00:09:33,034 --> 00:09:36,000 AS THEY COOL, THEY DEFLATE. 159 00:09:36,000 --> 00:09:39,241 THE PROCESS HAS CREATED POCKETS IN THE PITAS. 160 00:09:39,241 --> 00:09:40,655 ONCE SLICED OPEN, 161 00:09:40,655 --> 00:09:44,344 THE POCKETS CAN BE STUFFED TO CREATE SANDWICHES. 162 00:09:44,344 --> 00:09:49,103 WORKERS STACK THE PITAS SIX HIGH FOR PACKAGING. 163 00:09:49,103 --> 00:09:51,689 THE NEXT CONVEYOR DELIVERS THE STACKS INTO THE CLUTCH 164 00:09:51,689 --> 00:09:55,103 OF AN AUTOMATED ARM. 165 00:09:55,103 --> 00:09:58,344 JUST AHEAD, A BURST OF AIR OPENS A BAG 166 00:09:58,344 --> 00:10:00,965 AND THE ARM INSERTS THE PITAS INTO IT. 167 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, 173 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. 176 00:10:47,758 --> 00:10:49,241 Narrator: INSTALLING EXHAUST HEADERS 177 00:10:49,241 --> 00:10:52,172 WILL ADD EXTRA POWER FROM A CAR'S ENGINE. 178 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, 180 00:10:57,206 --> 00:11:00,517 WHICH CONNECTS TO THE CAR'S MAIN EXHAUST PIPE. 181 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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