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--Captions by VITAC--
www.vitac.com
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00:00:19,310 --> 00:00:22,310
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: TODAY
ON "HOW IT'S MADE"...
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00:00:25,965 --> 00:00:28,000
THROTTLE BODIES.
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LIMESTONE FIREPLACE MANTELS.
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00:00:38,206 --> 00:00:39,931
CANDIED FRUIT
AND FRUIT JELLIES.
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00:00:44,068 --> 00:00:46,310
AND LINEN UKULELES.
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THE THROTTLE BODY IS A DEVICE
THAT ALLOWS THE ENGINE
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00:00:56,551 --> 00:00:59,344
OF A FUEL-INJECTED
VEHICLE TO BREATHE.
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00:00:59,344 --> 00:01:01,172
PRESSING ON
THE ACCELERATOR PEDAL
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00:01:01,172 --> 00:01:05,689
OPENS THE THROTTLE BODY'S BLADES
TO ALLOW AIR INTO THE ENGINE.
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00:01:05,689 --> 00:01:09,275
THE GREATER THE AIRFLOW,
THE HIGHER THE RPM.
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00:01:09,275 --> 00:01:12,551
ALL THE DRIVER HAS TO DO
IS STEP ON THE GAS.
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DESIGNED FOR RACE CARS,
THE THROTTLE BODY COULD MAKE
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THE DIFFERENCE BETWEEN
WINNING AND LOSING.
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THAT'S DUE TO THE WAY
IT DELIVERS THE AIR
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THE ENGINE NEEDS FOR SPEED.
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MAKING A THROTTLE BODY STARTS
WITH THIS SOLID ALUMINUM DISK.
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A TECHNICIAN MOUNTS IT TO
A MACHINING FIXTURE
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00:01:32,448 --> 00:01:35,551
AND CLOSES THE DOOR.
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COMPUTER CONTROLLED
CUTTERS MOVE IN.
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00:01:38,103 --> 00:01:42,551
THE CUTTERS REDUCE THE THICKNESS
OF THE DISK AND CONTOUR IT.
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00:01:42,551 --> 00:01:46,137
THEY ALSO ROUGH OUT THE SHAPE
OF FOUR AIR PASSAGEWAYS.
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00:01:48,620 --> 00:01:50,482
THEN THEY FLIP THE PART OVER,
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00:01:50,482 --> 00:01:55,275
AND MORE CUTTING TOOLS WORK
ON IT FROM THE OTHER SIDE.
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00:01:55,275 --> 00:01:58,275
THE CUTTERS OPEN UP THE AIR
PASSAGEWAYS COMPLETELY
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00:01:58,275 --> 00:02:02,448
AND CREATE A HOLE
IN THE CENTER FOR A BOLT.
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00:02:02,448 --> 00:02:04,931
THE TECHNICIAN CLAMPS
A SQUARE CHUNK OF ALUMINUM
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00:02:04,931 --> 00:02:06,172
IN THE FIXTURE,
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00:02:06,172 --> 00:02:09,862
AND CUTTERS TRANSFORM IT
INTO THE MAIN BODY PART.
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00:02:09,862 --> 00:02:13,655
THIS IS A COMPUTER SIMULATION
OF THE PROCESS.
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00:02:13,655 --> 00:02:16,034
THE TOOLS CARVE FOUR HOLES
TO MATCH UP
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00:02:16,034 --> 00:02:18,137
TO THE ONES ON THE TOP PIECE.
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THESE HOLES WILL HOLD
THE THROTTLE MECHANISMS.
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00:02:22,206 --> 00:02:25,137
THE TRANSFORMATION
TAKES JUST MINUTES.
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00:02:28,068 --> 00:02:30,586
WITH THE PARTS NOW
ELECTRICALLY CHARGED,
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WORKERS PLUNGE THEM
INTO A POOL OF CHEMICALS
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CALLED AN ETCHING BATH.
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00:02:34,482 --> 00:02:37,793
THE CHEMICALS GRAVITATE TO THE
ELECTRICALLY CHARGED PARTS
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AND LIGHTLY ETCH THE SURFACE.
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A DIP IN SOAPY WATER
CLEANS THE PARTS.
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00:02:44,551 --> 00:02:46,655
THEY ARE NOW READY
FOR ANODIZING,
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A PROCESS THAT WILL FORM
AN ANTI-CORROSION FINISH
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00:02:49,448 --> 00:02:52,482
ON THE SURFACE.
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IN THE ANODIZING BATH,
AN ELECTRICAL CHARGE CAUSES
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A PROTECTIVE OXIDE LAYER
TO FORM ON THE METAL,
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00:02:59,172 --> 00:03:03,206
AND BLACK DYE
SEEPS INTO THE PORES.
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00:03:03,206 --> 00:03:06,965
HERE ARE THE PARTS BEFORE
AND AFTER ANODIZING.
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00:03:10,379 --> 00:03:12,482
A LASER THEN ENGRAVES
THE BRAND NAME
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ONTO THE SIDE OF
THE THROTTLE BODY PART.
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THE ETCHED ALUMINUM WORDING
STANDS OUT
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AGAINST THE BLACK
ANODIZED COATING.
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A TECHNICIAN THEN INSERTS
TWO STAINLESS STEEL SHAFTS
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INTO SEALED BEARINGS
IN HOLES ON THE SIDE.
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00:03:27,827 --> 00:03:30,620
WHEN TURNED, THE SHAFTS
WILL OPEN AND CLOSE
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THE ROUND THROTTLE BLADES.
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HE INSTALLS RETAINING CLIPS
ON THE SHAFTS.
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THIS KEEPS THEM IN PLACE
AND CENTERS THEM PERFECTLY.
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00:03:41,655 --> 00:03:45,965
BUT AT THE SAME TIME, THEY ALLOW
THE BLADES TO TURN FREELY.
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00:03:50,137 --> 00:03:55,275
HE THEN SCREWS ROUND BLADES
TO THE FLAT PART OF EACH SHAFT.
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00:03:55,275 --> 00:03:59,137
AS THE SHAFTS TURN, THESE BLADES
WILL MOVE INTO AN OPEN
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00:03:59,137 --> 00:04:01,241
OR CLOSED POSITION.
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00:04:01,241 --> 00:04:02,862
THEY'LL ACT AS VALVES,
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00:04:02,862 --> 00:04:06,448
ALLOWING AIR INTO THE ENGINE
OR SHUTTING IT OFF.
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00:04:10,068 --> 00:04:14,724
HE ATTACHES A MECHANICAL LINKAGE
TO THE END OF EACH SHAFT.
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00:04:14,724 --> 00:04:18,068
THESE LINKAGES WILL ULTIMATELY
BE CONNECTED TO A CABLE
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00:04:18,068 --> 00:04:20,931
THAT RUNS TO THE GAS PEDAL.
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00:04:20,931 --> 00:04:23,034
WHEN THE DRIVER STEPS
ON THE GAS,
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00:04:23,034 --> 00:04:25,310
THE LINKAGES
WILL TURN THE SHAFTS,
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00:04:25,310 --> 00:04:27,793
AND THE BLADES
WILL OPEN AND CLOSE.
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00:04:32,413 --> 00:04:36,413
HE CONNECTS THE TWO LINKAGES
WITH A PART CALLED A TIE BAR.
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00:04:40,379 --> 00:04:41,758
NOW THAT THEY'RE CONNECTED,
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THE LINKAGES WILL MOVE
TOGETHER IN ONE ACTION.
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00:04:49,413 --> 00:04:51,758
THE TECHNICIAN TESTS
THE LINKAGES TO CONFIRM
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THAT THEY OPERATE SMOOTHLY.
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00:04:56,206 --> 00:05:00,068
HE NOW PLACES THE TOP PART
ONTO THE THROTTLE BODY.
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00:05:00,068 --> 00:05:02,862
HE APPLIES A THREAD-LOCK
SOLUTION TO A BOLT,
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00:05:02,862 --> 00:05:07,034
WHICH HE THEN INSERTS
IN THE CENTER OF THE ASSEMBLY.
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00:05:07,034 --> 00:05:09,034
THIS IS A CRUCIAL CONNECTION.
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00:05:09,034 --> 00:05:12,379
IT'S WHAT HOLDS THE TWO PARTS
OF THE THROTTLE BODY TOGETHER.
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00:05:16,241 --> 00:05:19,586
HE SECURES THE CENTER BOLT
WITH A THREADED INSERT.
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00:05:19,586 --> 00:05:25,103
THIS INSERT WILL ALSO BE USED TO
ATTACH AN INTAKE AIR CLEANER.
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00:05:25,103 --> 00:05:29,206
THIS THROTTLE BODY
IS NOW COMPLETE.
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WORKERS MEASURE AIR FLOW
THROUGH THE THROTTLE BODY
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00:05:31,896 --> 00:05:35,275
USING SMOKE SO OUR CAMERA
CAN PHOTOGRAPH IT.
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WITH THIS MEASUREMENT,
THEY GIVE THE THROTTLE BODY
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A PERFORMANCE RATING.
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00:05:41,931 --> 00:05:43,862
A CREW INSTALLS
THE THROTTLE BODY
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00:05:43,862 --> 00:05:47,724
BETWEEN THE RACE CAR'S
INTAKE MANIFOLD AND AIR FILTER.
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00:05:47,724 --> 00:05:49,793
THEN, THEY CHECK ITS FUNCTION.
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00:05:52,172 --> 00:05:56,379
THIS PERFORMANCE THROTTLE BODY
IS NOW READY TO COMPETE.
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00:06:07,413 --> 00:06:09,758
Narrator:
FOR HUNDREDS OF YEARS,
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STONE CARVERS HAVE
SKILLFULLY SCULPTED
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BLOCKS OF SOLID STONE
INTO ORNATE FIREPLACE MANTELS.
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00:06:16,000 --> 00:06:18,620
A WORK OF ART WITH
AN IMPOSING PRESENCE,
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00:06:18,620 --> 00:06:21,896
A STONE MANTEL IS THE DECORATIVE
CENTERPIECE OF A ROOM.
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00:06:21,896 --> 00:06:24,000
WHETHER OR NOT THERE'S
A FIRE BURNING,
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IT CREATES A WARM AMBIENCE.
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00:06:28,965 --> 00:06:32,172
MODERN-DAY STONE CARVERS
CARRY ON A TRADE PASSED DOWN
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00:06:32,172 --> 00:06:33,724
THROUGH THE CENTURIES,
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00:06:33,724 --> 00:06:36,379
CRAFTING LIMESTONE
FIREPLACE MANTELS
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00:06:36,379 --> 00:06:39,896
THAT EXUDE OLD-WORLD ELEGANCE.
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00:06:39,896 --> 00:06:42,896
ARTISANS SKETCH OUT
A CREATIVE DESIGN,
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00:06:42,896 --> 00:06:47,172
THEN PRODUCE A TECHNICAL DRAWING
AND 3-D MODEL ON A COMPUTER.
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00:06:47,172 --> 00:06:50,931
THIS PARTICULAR MANTEL,
CARVED FROM BEIGE LIMESTONE,
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00:06:50,931 --> 00:06:53,965
WILL FEATURE A MEDALLION
OF RED SANDSTONE.
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00:06:53,965 --> 00:06:56,931
THE RED MEDALLION WILL BE SET
INTO THE KEYSTONE,
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00:06:56,931 --> 00:06:59,793
WHICH IS THE CENTRAL BLOCK
OF WHAT'S CALLED THE LINTEL,
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00:06:59,793 --> 00:07:01,965
THE HORIZONTAL PART
OF THE MANTEL.
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00:07:01,965 --> 00:07:04,103
AFTER FINALIZING
THE MEASUREMENTS,
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00:07:04,103 --> 00:07:07,034
THE ARTISANS LAY DOWN A SHEET
OF THICK WHITE PLASTIC
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00:07:07,034 --> 00:07:09,206
AND DRAW THE MANTEL'S
OVERALL SHAPE,
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00:07:09,206 --> 00:07:12,517
AS SEEN FROM THE FRONT,
IN ITS ACTUAL DIMENSIONS.
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00:07:12,517 --> 00:07:15,379
THE MANTEL WILL BE COMPOSED
OF SEVERAL PARTS
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00:07:15,379 --> 00:07:18,965
SO THEY WILL ALSO MARK THE
JOINTS WHERE THOSE PARTS MEET.
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00:07:20,965 --> 00:07:24,000
USING THIS PATTERN, THEY CUT
A CLEAR PLASTIC TEMPLATE
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00:07:24,000 --> 00:07:27,758
FOR EACH PART.
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00:07:27,758 --> 00:07:30,586
THE ARTISANS USE A COMBINATION
OF TRADITIONAL
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00:07:30,586 --> 00:07:33,068
AND MODERN STONE-CARVING TOOLS.
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00:07:35,655 --> 00:07:40,068
FIRST, FOR EACH PART, THEY USE
AN AUTOMATED DIAMOND-BLADE SAW
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00:07:40,068 --> 00:07:41,896
TO CUT A BLOCK TO SIZE.
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00:07:45,724 --> 00:07:49,068
THEY THEN MEASURE AND MARK
WHERE THEY NEED TO REMOVE STONE
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00:07:49,068 --> 00:07:52,103
TO SHAPE THE BLOCK
TO THE BASIC PROFILE.
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00:07:59,862 --> 00:08:03,000
THE ARTISAN GRADUALLY REMOVES
THAT PORTION OF STONE
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00:08:03,000 --> 00:08:06,344
WITH A HAMMER
AND DIFFERENT TYPES OF CHISELS.
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00:08:06,344 --> 00:08:10,482
LIMESTONE CAN BE HARD LIKE
MARBLE, OR SOFT LIKE CHALK.
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00:08:10,482 --> 00:08:12,068
THERE'S LESS MARGIN FOR ERROR
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00:08:12,068 --> 00:08:14,827
WHEN CARVING SOFTER
LIMESTONE, LIKE THIS,
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00:08:14,827 --> 00:08:18,137
BECAUSE EVERY STRIKE OF THE
HAMMER REMOVES MORE STONE
130
00:08:18,137 --> 00:08:22,034
THAN THE SAME STRIKE
ON A HARD LIMESTONE WOULD.
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00:08:22,034 --> 00:08:25,000
THIS TOOL,
DESIGNED FOR SOFT LIMESTONE,
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00:08:25,000 --> 00:08:29,896
WEARS AWAY THE SURFACE LIKE
A PLANE DOES TO A PIECE OF WOOD.
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00:08:29,896 --> 00:08:33,103
ONCE THE ARTISAN HAS REMOVED
ALL THE EXCESS STONE,
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00:08:33,103 --> 00:08:36,620
HE CHECKS THAT
THE SURFACE IS LEVEL.
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00:08:36,620 --> 00:08:39,482
THEN, IN THE SIDE OF THE BLOCK,
HE TRACES A TEMPLATE
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00:08:39,482 --> 00:08:41,379
FOR THE PROFILE.
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00:08:41,379 --> 00:08:43,310
THIS BLOCK WILL BECOME
THE KEYSTONE
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00:08:43,310 --> 00:08:47,655
FOR THE HORIZONTAL
PART OF THE MANTEL.
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00:08:47,655 --> 00:08:51,620
HE MEASURES OUT AND MARKS
THE CENTER OF THE KEYSTONE...
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00:08:56,827 --> 00:09:00,448
...THEN CENTERS THE MEDALLION
AND TRACES IT.
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00:09:00,448 --> 00:09:04,137
HE'LL DRAW THE REMAINDER OF
THE KEYSTONE'S DESIGN FREEHAND.
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00:09:06,448 --> 00:09:08,310
THE DESIGN IS SYMMETRICAL,
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00:09:08,310 --> 00:09:11,517
SO THE ARTISAN DRAWS
ON ONE SIDE OF THE CENTER LINE,
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00:09:11,517 --> 00:09:14,034
TRACES HIS DRAWING
ONTO THE CLEAR PLASTIC
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00:09:14,034 --> 00:09:15,689
TO MAKE A TEMPLATE,
146
00:09:15,689 --> 00:09:18,137
THEN FLIPS THE TEMPLATE ONTO THE
OTHER SIDE OF THE CENTER LINE
147
00:09:18,137 --> 00:09:21,482
TO TRACE THE SAME DESIGN
IN MIRROR IMAGE.
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00:09:27,034 --> 00:09:31,413
HE BEGINS REMOVING STONE WITH
A HAMMER AND ROUGHING TOOLS.
149
00:09:31,413 --> 00:09:35,172
FIRST, HE BREAKS OFF BIG CHUNKS
WITH A CHIPPER.
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00:09:35,172 --> 00:09:39,896
HE WORKS HIS WAY DOWN TO JUST
ABOVE THE PENCIL LINE.
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00:09:39,896 --> 00:09:44,965
THEN, WITH A FINER TOOTH CHISEL,
HE REMOVES THE LAST BIT.
152
00:09:44,965 --> 00:09:47,689
THEN HE SWITCHES
TO FINISHING TOOLS.
153
00:09:47,689 --> 00:09:50,793
HE MOUNTS CHISELS OF VARYING
WIDTHS ON AN AIR HAMMER
154
00:09:50,793 --> 00:09:53,689
TO REMOVE A PRECISE,
EVEN LAYER OF STONE.
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00:09:55,758 --> 00:09:58,482
WORKING ON THE MORE
COMPLEX DETAILS,
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00:09:58,482 --> 00:10:00,758
HE USES A COMBINATION SQUARE
157
00:10:00,758 --> 00:10:04,275
TO MARK A CONSISTENT HEIGHT
ACROSS THE KEYSTONE.
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00:10:04,275 --> 00:10:06,586
EVERY DETAIL OF
THE KEYSTONE PROFILE
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00:10:06,586 --> 00:10:09,137
MUST ALIGN WITH
THE SAME PROFILE DETAIL
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00:10:09,137 --> 00:10:11,655
OF THE LENTIL PIECES
ON EITHER SIDE OF IT.
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00:10:14,034 --> 00:10:16,965
ONCE HE HAS FINISHED
THE ENTIRE PROFILE OF THE PIECE,
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00:10:16,965 --> 00:10:21,758
HE SANDS THE SURFACE SMOOTH
AND BRUSHES AWAY THE DUST.
163
00:10:24,896 --> 00:10:26,793
NOW THE ARTISAN TURNS
HIS ATTENTION
164
00:10:26,793 --> 00:10:30,172
TO THE KEYSTONE'S ORNATE
SCULPT DESIGN.
165
00:10:30,172 --> 00:10:33,344
WITH FINE, FLAT,
AND POINTED CHISELS,
166
00:10:33,344 --> 00:10:36,137
HE REMOVES THE STONE
AROUND HIS PENCIL LINES
167
00:10:36,137 --> 00:10:39,137
UNTIL THE DESIGN
HE DREW EMERGES.
168
00:10:43,620 --> 00:10:46,034
BY SWITCHING TO
A SCULPTOR'S RASP,
169
00:10:46,034 --> 00:10:48,689
HE SMOOTHES ALL THE ROUGH EDGES.
170
00:10:50,758 --> 00:10:53,655
HE CHECKS THE FIT OF THE RED
SANDSTONE MEDALLION
171
00:10:53,655 --> 00:10:54,931
AND GLUES IT IN.
172
00:10:58,482 --> 00:11:01,448
ONCE THE ARTISAN FINISHES
SCULPTING ALL THE PARTS,
173
00:11:01,448 --> 00:11:03,000
HE LAYS THEM ON THE PATTERN
174
00:11:03,000 --> 00:11:06,172
TO MAKE SURE ALL
THE DIMENSIONS ARE PERFECT.
175
00:11:06,172 --> 00:11:10,344
ON INSTALLATION DAY, HE MOUNTS
THE MANTEL, PIECE BY PIECE,
176
00:11:10,344 --> 00:11:13,206
AROUND THE FIREPLACE.
177
00:11:21,931 --> 00:11:24,344
Narrator: CANDIED FRUIT
AND FRUIT JELLIES
178
00:11:24,344 --> 00:11:26,034
ARE MIDDLE EASTERN IN ORIGIN
179
00:11:26,034 --> 00:11:28,931
AND SPREAD TO EUROPE
AROUND THE 12th CENTURY.
180
00:11:28,931 --> 00:11:31,137
THIS REGION OF FRANCE
HAS BEEN PRODUCING THEM
181
00:11:31,137 --> 00:11:33,137
SINCE THE 15th CENTURY.
182
00:11:33,137 --> 00:11:35,689
WHEN WARS BLOCKED ACCESS
TO CANE SUGAR,
183
00:11:35,689 --> 00:11:38,448
FRUIT FARMERS BEGAN
PLANTING SUGAR BEETS
184
00:11:38,448 --> 00:11:41,931
TO PRESERVE THIS
CONFECTIONERY TRADITION.
185
00:11:44,310 --> 00:11:47,655
THIS COMPANY IN FRANCE HAS BEEN
CATERING TO PEOPLE'S SWEET TOOTH
186
00:11:47,655 --> 00:11:50,413
SINCE 1880 WITH ITS GIFT BOXES
187
00:11:50,413 --> 00:11:55,862
CONTAINING TRADITIONAL CANDIED
FRUIT AND FRUIT JELLIES.
188
00:11:55,862 --> 00:11:59,827
TO MAKE CANDIED FRUIT, A MASTER
CONFECTIONER BOILS FRESH FRUIT
189
00:11:59,827 --> 00:12:02,862
FOR MANY HOURS
TO SOFTEN THE FIBERS.
190
00:12:02,862 --> 00:12:06,827
THIS PROCESS WILL LATER HELP
SUGAR TO PENETRATE THE FRUIT.
191
00:12:06,827 --> 00:12:10,551
HE POKES THE FRUIT TO SEE
IF IT'S READY.
192
00:12:10,551 --> 00:12:13,965
BOILING TIME VARIES
FROM 1 HOUR FOR APRICOTS
193
00:12:13,965 --> 00:12:16,379
TO 8 HOURS FOR CHESTNUTS.
194
00:12:16,379 --> 00:12:20,482
CITRUS FRUITS ARE SLICED
BEFORE BOILING.
195
00:12:20,482 --> 00:12:23,482
AFTER BOILING, THE MORE
FRAGILE TYPES OF FRUIT,
196
00:12:23,482 --> 00:12:26,655
SUCH AS APRICOTS,
PEARS AND CLEMENTINES,
197
00:12:26,655 --> 00:12:30,931
GO INTO LARGE HOT-AIR
DEHYDRATORS FOR UP TO 3 WEEKS.
198
00:12:30,931 --> 00:12:33,448
EVERY DAY, THE MASTER
CONFECTIONER REPLACES
199
00:12:33,448 --> 00:12:36,103
THE EVAPORATED WATER
WITH SUGAR SYRUP,
200
00:12:36,103 --> 00:12:40,068
WHICH CONCENTRATES OVER TIME.
201
00:12:40,068 --> 00:12:43,172
FOR LESS FRAGILE FRUITS,
THE TECHNIQUE IS DIFFERENT.
202
00:12:43,172 --> 00:12:47,413
WORKERS HEAT THEM IN VATS OF
SUGAR SYRUP FOR ABOUT 10 DAYS.
203
00:12:47,413 --> 00:12:51,068
THE MOISTURE EVAPORATES,
AND THE SYRUP CONCENTRATES.
204
00:12:53,344 --> 00:12:56,275
THE FACTORY SELLS
WHOLE CANDIED FRUITS
205
00:12:56,275 --> 00:12:58,379
LIKE THIS COLLECTION
OF CLEMENTINES,
206
00:12:58,379 --> 00:13:01,206
APRICOTS, PEARS, FIGS,
AND PLUMS,
207
00:13:01,206 --> 00:13:03,103
TO GOURMET FOOD SHOPS,
208
00:13:03,103 --> 00:13:05,827
WHICH SELL THEM BY THE PIECE
OR IN ELEGANT,
209
00:13:05,827 --> 00:13:08,103
PRIVATE-LABEL GIFT BOXES.
210
00:13:13,551 --> 00:13:15,620
WHOLE CANDIED FRUIT
ARE ALSO POPULAR
211
00:13:15,620 --> 00:13:19,310
FOR DESIGNING
EDIBLE ARRANGEMENTS.
212
00:13:19,310 --> 00:13:22,620
MAKING FRUIT JELLIES
IS A DIFFERENT PROCESS.
213
00:13:22,620 --> 00:13:25,000
THE RECIPE COMBINES FRUIT PULP,
214
00:13:25,000 --> 00:13:27,310
MAKING UP MORE THAN
50 PERCENT OF THE MIXTURE,
215
00:13:27,310 --> 00:13:30,241
WITH POWDERED SUGAR,
LIQUID GLUCOSE,
216
00:13:30,241 --> 00:13:32,068
A FORM OF PLANT SUGAR,
217
00:13:32,068 --> 00:13:34,551
PECTIN TO MAKE
THE MIXTURE GELATINOUS,
218
00:13:34,551 --> 00:13:37,172
AND NATURAL FRUIT FLAVORING.
219
00:13:37,172 --> 00:13:39,793
A WORKER BOILS DOWN THE MIX
FOR A HALF HOUR
220
00:13:39,793 --> 00:13:41,551
TO CONCENTRATE THE SUGAR,
221
00:13:41,551 --> 00:13:44,000
THEN ADDS MORE FRUIT FLAVORING.
222
00:13:44,000 --> 00:13:46,241
AS THE MIX CONTINUES TO COOK,
223
00:13:46,241 --> 00:13:49,517
SHE DRAWS SAMPLES TO MEASURE
THE SUGAR CONTENT.
224
00:13:49,517 --> 00:13:51,206
SHE DOES THIS UNTIL THE MIX
225
00:13:51,206 --> 00:13:55,724
HITS ITS TARGET
CONCENTRATION OF 78 PERCENT.
226
00:13:59,448 --> 00:14:01,862
ANOTHER WORKER POURS
THE BATCH FROM THE POT
227
00:14:01,862 --> 00:14:03,448
INTO A LARGE PITCHER,
228
00:14:03,448 --> 00:14:06,310
THEN INTO A SQUARE
STAINLESS STEEL MOLD.
229
00:14:08,517 --> 00:14:11,517
IT TAKES THE JELLY A DAY TO SET.
230
00:14:11,517 --> 00:14:14,689
ONCE SET, A WORKER REMOVES IT
FROM THE MOLD --
231
00:14:14,689 --> 00:14:16,517
THIS ONE'S
A DIFFERENT FLAVOR --
232
00:14:16,517 --> 00:14:21,517
AND COATS IT WITH CRYSTALLIZED
SUGAR TO PRESERVE IT.
233
00:14:21,517 --> 00:14:24,275
THE WORKER THEN LAYS
THE JELLY SQUARE ON CUTTER
234
00:14:24,275 --> 00:14:26,206
THE COMPANY CALLS A GUITAR
235
00:14:26,206 --> 00:14:29,931
BECAUSE ITS STEEL WIRES
LOOK LIKE GUITAR STRINGS.
236
00:14:29,931 --> 00:14:33,827
THE WIRES CUT ONCE IN EACH
DIRECTION TO MAKE CUBES.
237
00:14:33,827 --> 00:14:37,896
THEN, ANOTHER WORKER APPLIES
A SECOND COATING OF SUGAR.
238
00:14:37,896 --> 00:14:40,517
IN ADDITION TO THIS
SMALL-BATCH PRODUCTION,
239
00:14:40,517 --> 00:14:42,965
THE FACTORY
HAS ONE AUTOMATED MACHINE,
240
00:14:42,965 --> 00:14:44,172
WHICH MAKES FRUIT JELLIES
241
00:14:44,172 --> 00:14:47,206
IN A VARIETY OF GEOMETRIC
OR FRUIT SHAPES
242
00:14:47,206 --> 00:14:49,413
CREATED BY TEMPLATES
MADE OF PLASTER.
243
00:14:52,379 --> 00:14:56,655
THIS PROCESS IS MUCH FASTER
THAN THE HANDMADE APPROACH.
244
00:14:56,655 --> 00:15:01,379
FIRST, THE MACHINE
MAKES A BED OF STARCH.
245
00:15:01,379 --> 00:15:04,034
THEN IT PRESSES
THE PLASTER FORM INTO THE BED
246
00:15:04,034 --> 00:15:06,517
TO CREATE MOLD CAVITIES.
247
00:15:11,068 --> 00:15:12,965
THE NEXT STATION FILLS
THE CAVITIES
248
00:15:12,965 --> 00:15:15,551
WITH HOT LIQUID FRUIT JELLY.
249
00:15:15,551 --> 00:15:19,448
THEN, THE MOLDS
ARE SET ASIDE FOR A DAY.
250
00:15:19,448 --> 00:15:24,517
THE STARCH ABSORBS THE RESIDUAL
MOISTURE AS THE JELLY SETS.
251
00:15:24,517 --> 00:15:27,034
THE NEXT DAY,
WORKERS LOAD THE MOLDS
252
00:15:27,034 --> 00:15:28,827
ON TOP OF THE SAME MACHINE,
253
00:15:28,827 --> 00:15:31,862
WHICH FLIPS THEM TO DUMP OUT
THE JELLIES.
254
00:15:31,862 --> 00:15:35,241
THE JELLIES TUMBLE DOWN
A VIBRATING CONVEYOR BELT.
255
00:15:35,241 --> 00:15:38,793
THE STARCH SHAKES OFF
WITH EACH BOUNCE.
256
00:15:38,793 --> 00:15:40,689
THEN THEY PASS
UNDER A SPINNING BRUSH,
257
00:15:40,689 --> 00:15:44,482
WHICH REMOVES
ANY REMAINING STARCH.
258
00:15:44,482 --> 00:15:47,344
THE CONVEYOR MOVES THEM
INTO A ROTATING DRUM,
259
00:15:47,344 --> 00:15:49,310
WHICH SHOWERS THEM WITH SUGAR.
260
00:15:51,310 --> 00:15:54,448
ON THE PACKAGING LINE,
A SLOW CONVEYOR BELT MOVES
261
00:15:54,448 --> 00:15:58,034
RETAIL BOXES
IN FRONT OF A ROW OF WORKERS.
262
00:15:58,034 --> 00:16:01,586
EACH WORKER IS RESPONSIBLE
FOR A SINGLE FLAVOR.
263
00:16:01,586 --> 00:16:03,793
WHILE PLACING THE REQUIRED
NUMBER OF FRUIT JELLIES
264
00:16:03,793 --> 00:16:04,931
IN THE BOX,
265
00:16:04,931 --> 00:16:07,931
SHE ALSO PERFORMS
A QUALITY CONTROL CHECK,
266
00:16:07,931 --> 00:16:11,241
REMOVING AND REPLACING
ANY THAT ARE MISSHAPEN.
267
00:16:11,241 --> 00:16:14,034
THIS ENSURES THAT THESE
TRADITIONAL FRUIT JELLIES
268
00:16:14,034 --> 00:16:16,517
LOOK AS GOOD AS THEY TASTE.
269
00:16:25,206 --> 00:16:27,448
Narrator:
LINEN IS BELIEVED TO BE
270
00:16:27,448 --> 00:16:30,482
THE OLDEST OF WOVEN TEXTILES.
271
00:16:30,482 --> 00:16:34,689
BUT FOR THE MAKING OF UKULELES,
IT'S DEFINITELY A NEW MATERIAL.
272
00:16:34,689 --> 00:16:36,482
INFUSED WITH RESIN,
273
00:16:36,482 --> 00:16:40,482
LINEN CAN ACTUALLY BE MOLDED
INTO A SOLID UKULELE
274
00:16:40,482 --> 00:16:43,551
THAT HAS A LOOK AND SOUND
THAT'S SIMILAR TO WOOD.
275
00:16:46,793 --> 00:16:51,068
LINEN MAY SEEM TO BE AN UNLIKELY
MATERIAL FOR MAKING UKULELES,
276
00:16:51,068 --> 00:16:54,068
BUT THESE INSTRUMENTS ARE PROOF
THAT THE FABRIC CAN BE USED
277
00:16:54,068 --> 00:16:58,275
FOR MORE THAN JUST
DRAPES AND TABLECLOTHS.
278
00:16:58,275 --> 00:17:00,655
FOLLOWING
A COMPUTER-AIDED DESIGN,
279
00:17:00,655 --> 00:17:03,931
WORKERS CUT PATTERN PIECES
FROM LINEN FABRIC,
280
00:17:03,931 --> 00:17:08,724
INFUSED WITH PLANT RESIN
AND WITH PROTECTIVE LINERS.
281
00:17:08,724 --> 00:17:10,689
AFTER PEELING OFF THE LINERS,
282
00:17:10,689 --> 00:17:15,310
A TECHNICIAN LAYERS THE LINEN
PIECES IN A UKULELE MOLD.
283
00:17:15,310 --> 00:17:18,931
THE RESIN HAS GIVEN THE FABRIC
A CLAY-LIKE CONSISTENCY,
284
00:17:18,931 --> 00:17:22,896
SO IT CAN BE EASILY SHAPED
TO THE MOLD'S CURVES.
285
00:17:22,896 --> 00:17:25,862
HE LAYERS 65 LINEN
PIECES IN TOTAL.
286
00:17:27,896 --> 00:17:30,655
HE DRAPES A NYLON FABRIC
OVER THE LINEN
287
00:17:30,655 --> 00:17:32,517
AND TUCKS IT INTO THE CREVICES.
288
00:17:32,517 --> 00:17:34,965
THE FABRIC WILL ULTIMATELY
CONTAIN THE RESIN
289
00:17:34,965 --> 00:17:37,689
WHEN IT'S HEATED AND LIQUEFIED.
290
00:17:37,689 --> 00:17:41,275
POLYESTER BATTING IN THE CENTER
WILL SOAK UP EXCESS RESIN
291
00:17:41,275 --> 00:17:43,689
DURING BAKING.
292
00:17:43,689 --> 00:17:46,931
HE COOKS THE LINEN LAYERS
FOR SEVERAL HOURS.
293
00:17:46,931 --> 00:17:50,172
THE RESIN IN THE FABRIC
SUBSEQUENTLY LIQUIFIES
294
00:17:50,172 --> 00:17:53,517
AND FINALLY HARDENS,
FUSING THE LAYERS TOGETHER,
295
00:17:53,517 --> 00:17:57,758
TO CREATE A SOLID UKULELE
BODY, NEXT AND HEAD.
296
00:17:57,758 --> 00:17:59,724
AFTER REINFORCING THE NECK,
297
00:17:59,724 --> 00:18:04,655
A COMPUTERIZED ROUTER TRIMS
THE ENTIRE UKULELE BODY.
298
00:18:04,655 --> 00:18:07,172
ANOTHER ROUTER TRIMS
THE SOUND BOARD,
299
00:18:07,172 --> 00:18:08,793
WHICH IS THE RESONANT PART
300
00:18:08,793 --> 00:18:11,827
THAT SERVES AS THE FRONT
OF THE INSTRUMENT.
301
00:18:11,827 --> 00:18:14,448
IT, TOO, HAS BEEN MOLDED
FROM LINEN MATERIAL.
302
00:18:17,827 --> 00:18:21,655
A TECHNICIAN PIPES EPOXY GLUE
ALONG THE RIM OF THE BODY
303
00:18:21,655 --> 00:18:23,379
TO ATTACH THE SOUNDBOARD,
304
00:18:23,379 --> 00:18:26,517
WHICH IS BEING REINFORCED
WITH CARBON FIBER
305
00:18:26,517 --> 00:18:29,965
AND A PLASTIC LINER APPLIED
FOR THE FRONT TO PROTECT IT
306
00:18:29,965 --> 00:18:31,965
DURING THIS STAGE
OF FABRICATION.
307
00:18:35,034 --> 00:18:39,931
HE GLUES A FRONT PLATE
TO THE HEADSTOCK OF THE UKULELE.
308
00:18:39,931 --> 00:18:43,206
HE THEN PLACES THE UKULELE
IN A FIXTURE.
309
00:18:43,206 --> 00:18:46,862
HE CLAMPS THE FIXTURE TOGETHER
TO KEEP THE PARTS IN POSITION
310
00:18:46,862 --> 00:18:51,724
AS THE GLUE HARDENS
FOR 24 HOURS.
311
00:18:51,724 --> 00:18:54,793
HE PROPS UP THE HEADSTOCK
WITH A BLOCK OF WOOD
312
00:18:54,793 --> 00:18:59,896
AND USES A SEPARATE CLAMP
TO KEEP THE ASSEMBLY TIGHT.
313
00:18:59,896 --> 00:19:03,275
A ROUTER CARVES AN OPENING
IN THE SOUNDBOARD.
314
00:19:03,275 --> 00:19:05,862
THIS SOUND HOLE WITH
ALLOW THE INSTRUMENT
315
00:19:05,862 --> 00:19:10,000
TO PROJECT MUSIC
MORE EFFICIENTLY.
316
00:19:10,000 --> 00:19:15,000
THE ROUTER ALSO DRILLS
TUNING HOLES IN THE HEAD PLATE.
317
00:19:15,000 --> 00:19:18,241
ANOTHER MEMBER OF THE TEAM
NOW APPLIES A WOOD STAIN
318
00:19:18,241 --> 00:19:22,000
TO THE LINEN COMPOSITE SURFACE.
319
00:19:22,000 --> 00:19:24,620
THIS GIVES IT
A MORE UNIFORM FINISH.
320
00:19:28,172 --> 00:19:30,413
THE NEXT PART
IS THE FINGER BOARD,
321
00:19:30,413 --> 00:19:33,620
MADE OF A WOOD FIBER
AND PLASTIC COMPOSITE.
322
00:19:33,620 --> 00:19:36,586
ANOTHER TECHNICIAN HAMMERS
NICKEL SILVER FRETS
323
00:19:36,586 --> 00:19:38,793
INTO THE FINGERBOARD'S SLOTS.
324
00:19:41,137 --> 00:19:46,620
HE THEN CLIPS THE ENDS TO MAKE
THEM FLUSH TO THE FINGERBOARD.
325
00:19:46,620 --> 00:19:51,206
HE FILES THE ENDS TO MAKE THEM
SMOOTH TO THE TOUCH.
326
00:19:51,206 --> 00:19:55,758
HE THEN GLUES THE FINGERBOARD
TO THE UKULELE NECK.
327
00:19:55,758 --> 00:19:58,793
THE TECHNICIAN INSTALLS
THE BRIDGE ON THE SOUNDBOARD.
328
00:19:58,793 --> 00:20:00,482
USING A SPECIAL FIXTURE,
329
00:20:00,482 --> 00:20:02,448
HE CLAMPS THE FINGERBOARD
AND BRIDGE
330
00:20:02,448 --> 00:20:06,413
TO THE INSTRUMENT TO APPLY
PRESSURE WHILE THE GLUE DRIES.
331
00:20:08,517 --> 00:20:11,862
IT TAKES ANOTHER 24 HOURS
FOR THE GLUE TO SET.
332
00:20:16,448 --> 00:20:20,310
THE NEXT DAY, A TECHNICIAN
APPLIES AN ADHESIVE-BACKED LABEL
333
00:20:20,310 --> 00:20:22,172
WITH THE SERIAL NUMBER
PRINTED ON IT
334
00:20:22,172 --> 00:20:24,517
TO THE INSIDE OF THE UKULELE.
335
00:20:29,724 --> 00:20:32,137
HE INSERTS TUNING PEGS
INTO HOLES DRILLED
336
00:20:32,137 --> 00:20:35,620
INTO THE HEADSTOCK.
337
00:20:35,620 --> 00:20:39,068
HE SECURES THE PEGS WITH BOLTS
AT THE BACK OF THE HEADSTOCK
338
00:20:39,068 --> 00:20:41,586
AND TIGHTENS THE BOLTS
WITH A NUT DRIVER.
339
00:20:44,034 --> 00:20:47,793
THEN HE RUNS STRINGS FROM
THE BRIDGE TO THE TUNING PEGS
340
00:20:47,793 --> 00:20:50,137
AND KNOTS THEM TO
HOLD THEM IN PLACE.
341
00:20:53,724 --> 00:20:55,896
HE TURNS THE TUNERS
TO PULL THE STRINGS
342
00:20:55,896 --> 00:20:57,862
TO A SPECIFIC TENSION,
343
00:20:57,862 --> 00:21:01,827
AND THIS LINEN-COMPOSITE UKULELE
IS READY FOR A SHOW.
28047
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