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These are the user uploaded subtitles that are being translated: 1 00:00:16,310 --> 00:00:19,310 --Captions by VITAC-- www.vitac.com 2 00:00:19,310 --> 00:00:22,310 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:22,310 --> 00:00:25,965 Narrator: TODAY ON "HOW IT'S MADE"... 4 00:00:25,965 --> 00:00:28,000 THROTTLE BODIES. 5 00:00:32,137 --> 00:00:34,000 LIMESTONE FIREPLACE MANTELS. 6 00:00:38,206 --> 00:00:39,931 CANDIED FRUIT AND FRUIT JELLIES. 7 00:00:44,068 --> 00:00:46,310 AND LINEN UKULELES. 8 00:00:52,482 --> 00:00:56,551 THE THROTTLE BODY IS A DEVICE THAT ALLOWS THE ENGINE 9 00:00:56,551 --> 00:00:59,344 OF A FUEL-INJECTED VEHICLE TO BREATHE. 10 00:00:59,344 --> 00:01:01,172 PRESSING ON THE ACCELERATOR PEDAL 11 00:01:01,172 --> 00:01:05,689 OPENS THE THROTTLE BODY'S BLADES TO ALLOW AIR INTO THE ENGINE. 12 00:01:05,689 --> 00:01:09,275 THE GREATER THE AIRFLOW, THE HIGHER THE RPM. 13 00:01:09,275 --> 00:01:12,551 ALL THE DRIVER HAS TO DO IS STEP ON THE GAS. 14 00:01:14,551 --> 00:01:17,517 DESIGNED FOR RACE CARS, THE THROTTLE BODY COULD MAKE 15 00:01:17,517 --> 00:01:20,551 THE DIFFERENCE BETWEEN WINNING AND LOSING. 16 00:01:20,551 --> 00:01:22,620 THAT'S DUE TO THE WAY IT DELIVERS THE AIR 17 00:01:22,620 --> 00:01:25,551 THE ENGINE NEEDS FOR SPEED. 18 00:01:25,551 --> 00:01:30,000 MAKING A THROTTLE BODY STARTS WITH THIS SOLID ALUMINUM DISK. 19 00:01:30,000 --> 00:01:32,448 A TECHNICIAN MOUNTS IT TO A MACHINING FIXTURE 20 00:01:32,448 --> 00:01:35,551 AND CLOSES THE DOOR. 21 00:01:35,551 --> 00:01:38,103 COMPUTER CONTROLLED CUTTERS MOVE IN. 22 00:01:38,103 --> 00:01:42,551 THE CUTTERS REDUCE THE THICKNESS OF THE DISK AND CONTOUR IT. 23 00:01:42,551 --> 00:01:46,137 THEY ALSO ROUGH OUT THE SHAPE OF FOUR AIR PASSAGEWAYS. 24 00:01:48,620 --> 00:01:50,482 THEN THEY FLIP THE PART OVER, 25 00:01:50,482 --> 00:01:55,275 AND MORE CUTTING TOOLS WORK ON IT FROM THE OTHER SIDE. 26 00:01:55,275 --> 00:01:58,275 THE CUTTERS OPEN UP THE AIR PASSAGEWAYS COMPLETELY 27 00:01:58,275 --> 00:02:02,448 AND CREATE A HOLE IN THE CENTER FOR A BOLT. 28 00:02:02,448 --> 00:02:04,931 THE TECHNICIAN CLAMPS A SQUARE CHUNK OF ALUMINUM 29 00:02:04,931 --> 00:02:06,172 IN THE FIXTURE, 30 00:02:06,172 --> 00:02:09,862 AND CUTTERS TRANSFORM IT INTO THE MAIN BODY PART. 31 00:02:09,862 --> 00:02:13,655 THIS IS A COMPUTER SIMULATION OF THE PROCESS. 32 00:02:13,655 --> 00:02:16,034 THE TOOLS CARVE FOUR HOLES TO MATCH UP 33 00:02:16,034 --> 00:02:18,137 TO THE ONES ON THE TOP PIECE. 34 00:02:18,137 --> 00:02:22,206 THESE HOLES WILL HOLD THE THROTTLE MECHANISMS. 35 00:02:22,206 --> 00:02:25,137 THE TRANSFORMATION TAKES JUST MINUTES. 36 00:02:28,068 --> 00:02:30,586 WITH THE PARTS NOW ELECTRICALLY CHARGED, 37 00:02:30,586 --> 00:02:33,068 WORKERS PLUNGE THEM INTO A POOL OF CHEMICALS 38 00:02:33,068 --> 00:02:34,482 CALLED AN ETCHING BATH. 39 00:02:34,482 --> 00:02:37,793 THE CHEMICALS GRAVITATE TO THE ELECTRICALLY CHARGED PARTS 40 00:02:37,793 --> 00:02:41,310 AND LIGHTLY ETCH THE SURFACE. 41 00:02:41,310 --> 00:02:44,551 A DIP IN SOAPY WATER CLEANS THE PARTS. 42 00:02:44,551 --> 00:02:46,655 THEY ARE NOW READY FOR ANODIZING, 43 00:02:46,655 --> 00:02:49,448 A PROCESS THAT WILL FORM AN ANTI-CORROSION FINISH 44 00:02:49,448 --> 00:02:52,482 ON THE SURFACE. 45 00:02:52,482 --> 00:02:55,862 IN THE ANODIZING BATH, AN ELECTRICAL CHARGE CAUSES 46 00:02:55,862 --> 00:02:59,172 A PROTECTIVE OXIDE LAYER TO FORM ON THE METAL, 47 00:02:59,172 --> 00:03:03,206 AND BLACK DYE SEEPS INTO THE PORES. 48 00:03:03,206 --> 00:03:06,965 HERE ARE THE PARTS BEFORE AND AFTER ANODIZING. 49 00:03:10,379 --> 00:03:12,482 A LASER THEN ENGRAVES THE BRAND NAME 50 00:03:12,482 --> 00:03:15,413 ONTO THE SIDE OF THE THROTTLE BODY PART. 51 00:03:15,413 --> 00:03:17,689 THE ETCHED ALUMINUM WORDING STANDS OUT 52 00:03:17,689 --> 00:03:21,241 AGAINST THE BLACK ANODIZED COATING. 53 00:03:21,241 --> 00:03:24,620 A TECHNICIAN THEN INSERTS TWO STAINLESS STEEL SHAFTS 54 00:03:24,620 --> 00:03:27,827 INTO SEALED BEARINGS IN HOLES ON THE SIDE. 55 00:03:27,827 --> 00:03:30,620 WHEN TURNED, THE SHAFTS WILL OPEN AND CLOSE 56 00:03:30,620 --> 00:03:34,379 THE ROUND THROTTLE BLADES. 57 00:03:34,379 --> 00:03:37,862 HE INSTALLS RETAINING CLIPS ON THE SHAFTS. 58 00:03:37,862 --> 00:03:41,655 THIS KEEPS THEM IN PLACE AND CENTERS THEM PERFECTLY. 59 00:03:41,655 --> 00:03:45,965 BUT AT THE SAME TIME, THEY ALLOW THE BLADES TO TURN FREELY. 60 00:03:50,137 --> 00:03:55,275 HE THEN SCREWS ROUND BLADES TO THE FLAT PART OF EACH SHAFT. 61 00:03:55,275 --> 00:03:59,137 AS THE SHAFTS TURN, THESE BLADES WILL MOVE INTO AN OPEN 62 00:03:59,137 --> 00:04:01,241 OR CLOSED POSITION. 63 00:04:01,241 --> 00:04:02,862 THEY'LL ACT AS VALVES, 64 00:04:02,862 --> 00:04:06,448 ALLOWING AIR INTO THE ENGINE OR SHUTTING IT OFF. 65 00:04:10,068 --> 00:04:14,724 HE ATTACHES A MECHANICAL LINKAGE TO THE END OF EACH SHAFT. 66 00:04:14,724 --> 00:04:18,068 THESE LINKAGES WILL ULTIMATELY BE CONNECTED TO A CABLE 67 00:04:18,068 --> 00:04:20,931 THAT RUNS TO THE GAS PEDAL. 68 00:04:20,931 --> 00:04:23,034 WHEN THE DRIVER STEPS ON THE GAS, 69 00:04:23,034 --> 00:04:25,310 THE LINKAGES WILL TURN THE SHAFTS, 70 00:04:25,310 --> 00:04:27,793 AND THE BLADES WILL OPEN AND CLOSE. 71 00:04:32,413 --> 00:04:36,413 HE CONNECTS THE TWO LINKAGES WITH A PART CALLED A TIE BAR. 72 00:04:40,379 --> 00:04:41,758 NOW THAT THEY'RE CONNECTED, 73 00:04:41,758 --> 00:04:44,758 THE LINKAGES WILL MOVE TOGETHER IN ONE ACTION. 74 00:04:49,413 --> 00:04:51,758 THE TECHNICIAN TESTS THE LINKAGES TO CONFIRM 75 00:04:51,758 --> 00:04:53,862 THAT THEY OPERATE SMOOTHLY. 76 00:04:56,206 --> 00:05:00,068 HE NOW PLACES THE TOP PART ONTO THE THROTTLE BODY. 77 00:05:00,068 --> 00:05:02,862 HE APPLIES A THREAD-LOCK SOLUTION TO A BOLT, 78 00:05:02,862 --> 00:05:07,034 WHICH HE THEN INSERTS IN THE CENTER OF THE ASSEMBLY. 79 00:05:07,034 --> 00:05:09,034 THIS IS A CRUCIAL CONNECTION. 80 00:05:09,034 --> 00:05:12,379 IT'S WHAT HOLDS THE TWO PARTS OF THE THROTTLE BODY TOGETHER. 81 00:05:16,241 --> 00:05:19,586 HE SECURES THE CENTER BOLT WITH A THREADED INSERT. 82 00:05:19,586 --> 00:05:25,103 THIS INSERT WILL ALSO BE USED TO ATTACH AN INTAKE AIR CLEANER. 83 00:05:25,103 --> 00:05:29,206 THIS THROTTLE BODY IS NOW COMPLETE. 84 00:05:29,206 --> 00:05:31,896 WORKERS MEASURE AIR FLOW THROUGH THE THROTTLE BODY 85 00:05:31,896 --> 00:05:35,275 USING SMOKE SO OUR CAMERA CAN PHOTOGRAPH IT. 86 00:05:35,275 --> 00:05:37,689 WITH THIS MEASUREMENT, THEY GIVE THE THROTTLE BODY 87 00:05:37,689 --> 00:05:39,586 A PERFORMANCE RATING. 88 00:05:41,931 --> 00:05:43,862 A CREW INSTALLS THE THROTTLE BODY 89 00:05:43,862 --> 00:05:47,724 BETWEEN THE RACE CAR'S INTAKE MANIFOLD AND AIR FILTER. 90 00:05:47,724 --> 00:05:49,793 THEN, THEY CHECK ITS FUNCTION. 91 00:05:52,172 --> 00:05:56,379 THIS PERFORMANCE THROTTLE BODY IS NOW READY TO COMPETE. 92 00:06:07,413 --> 00:06:09,758 Narrator: FOR HUNDREDS OF YEARS, 93 00:06:09,758 --> 00:06:11,827 STONE CARVERS HAVE SKILLFULLY SCULPTED 94 00:06:11,827 --> 00:06:16,000 BLOCKS OF SOLID STONE INTO ORNATE FIREPLACE MANTELS. 95 00:06:16,000 --> 00:06:18,620 A WORK OF ART WITH AN IMPOSING PRESENCE, 96 00:06:18,620 --> 00:06:21,896 A STONE MANTEL IS THE DECORATIVE CENTERPIECE OF A ROOM. 97 00:06:21,896 --> 00:06:24,000 WHETHER OR NOT THERE'S A FIRE BURNING, 98 00:06:24,000 --> 00:06:27,137 IT CREATES A WARM AMBIENCE. 99 00:06:28,965 --> 00:06:32,172 MODERN-DAY STONE CARVERS CARRY ON A TRADE PASSED DOWN 100 00:06:32,172 --> 00:06:33,724 THROUGH THE CENTURIES, 101 00:06:33,724 --> 00:06:36,379 CRAFTING LIMESTONE FIREPLACE MANTELS 102 00:06:36,379 --> 00:06:39,896 THAT EXUDE OLD-WORLD ELEGANCE. 103 00:06:39,896 --> 00:06:42,896 ARTISANS SKETCH OUT A CREATIVE DESIGN, 104 00:06:42,896 --> 00:06:47,172 THEN PRODUCE A TECHNICAL DRAWING AND 3-D MODEL ON A COMPUTER. 105 00:06:47,172 --> 00:06:50,931 THIS PARTICULAR MANTEL, CARVED FROM BEIGE LIMESTONE, 106 00:06:50,931 --> 00:06:53,965 WILL FEATURE A MEDALLION OF RED SANDSTONE. 107 00:06:53,965 --> 00:06:56,931 THE RED MEDALLION WILL BE SET INTO THE KEYSTONE, 108 00:06:56,931 --> 00:06:59,793 WHICH IS THE CENTRAL BLOCK OF WHAT'S CALLED THE LINTEL, 109 00:06:59,793 --> 00:07:01,965 THE HORIZONTAL PART OF THE MANTEL. 110 00:07:01,965 --> 00:07:04,103 AFTER FINALIZING THE MEASUREMENTS, 111 00:07:04,103 --> 00:07:07,034 THE ARTISANS LAY DOWN A SHEET OF THICK WHITE PLASTIC 112 00:07:07,034 --> 00:07:09,206 AND DRAW THE MANTEL'S OVERALL SHAPE, 113 00:07:09,206 --> 00:07:12,517 AS SEEN FROM THE FRONT, IN ITS ACTUAL DIMENSIONS. 114 00:07:12,517 --> 00:07:15,379 THE MANTEL WILL BE COMPOSED OF SEVERAL PARTS 115 00:07:15,379 --> 00:07:18,965 SO THEY WILL ALSO MARK THE JOINTS WHERE THOSE PARTS MEET. 116 00:07:20,965 --> 00:07:24,000 USING THIS PATTERN, THEY CUT A CLEAR PLASTIC TEMPLATE 117 00:07:24,000 --> 00:07:27,758 FOR EACH PART. 118 00:07:27,758 --> 00:07:30,586 THE ARTISANS USE A COMBINATION OF TRADITIONAL 119 00:07:30,586 --> 00:07:33,068 AND MODERN STONE-CARVING TOOLS. 120 00:07:35,655 --> 00:07:40,068 FIRST, FOR EACH PART, THEY USE AN AUTOMATED DIAMOND-BLADE SAW 121 00:07:40,068 --> 00:07:41,896 TO CUT A BLOCK TO SIZE. 122 00:07:45,724 --> 00:07:49,068 THEY THEN MEASURE AND MARK WHERE THEY NEED TO REMOVE STONE 123 00:07:49,068 --> 00:07:52,103 TO SHAPE THE BLOCK TO THE BASIC PROFILE. 124 00:07:59,862 --> 00:08:03,000 THE ARTISAN GRADUALLY REMOVES THAT PORTION OF STONE 125 00:08:03,000 --> 00:08:06,344 WITH A HAMMER AND DIFFERENT TYPES OF CHISELS. 126 00:08:06,344 --> 00:08:10,482 LIMESTONE CAN BE HARD LIKE MARBLE, OR SOFT LIKE CHALK. 127 00:08:10,482 --> 00:08:12,068 THERE'S LESS MARGIN FOR ERROR 128 00:08:12,068 --> 00:08:14,827 WHEN CARVING SOFTER LIMESTONE, LIKE THIS, 129 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. 131 00:08:22,034 --> 00:08:25,000 THIS TOOL, DESIGNED FOR SOFT LIMESTONE, 132 00:08:25,000 --> 00:08:29,896 WEARS AWAY THE SURFACE LIKE A PLANE DOES TO A PIECE OF WOOD. 133 00:08:29,896 --> 00:08:33,103 ONCE THE ARTISAN HAS REMOVED ALL THE EXCESS STONE, 134 00:08:33,103 --> 00:08:36,620 HE CHECKS THAT THE SURFACE IS LEVEL. 135 00:08:36,620 --> 00:08:39,482 THEN, IN THE SIDE OF THE BLOCK, HE TRACES A TEMPLATE 136 00:08:39,482 --> 00:08:41,379 FOR THE PROFILE. 137 00:08:41,379 --> 00:08:43,310 THIS BLOCK WILL BECOME THE KEYSTONE 138 00:08:43,310 --> 00:08:47,655 FOR THE HORIZONTAL PART OF THE MANTEL. 139 00:08:47,655 --> 00:08:51,620 HE MEASURES OUT AND MARKS THE CENTER OF THE KEYSTONE... 140 00:08:56,827 --> 00:09:00,448 ...THEN CENTERS THE MEDALLION AND TRACES IT. 141 00:09:00,448 --> 00:09:04,137 HE'LL DRAW THE REMAINDER OF THE KEYSTONE'S DESIGN FREEHAND. 142 00:09:06,448 --> 00:09:08,310 THE DESIGN IS SYMMETRICAL, 143 00:09:08,310 --> 00:09:11,517 SO THE ARTISAN DRAWS ON ONE SIDE OF THE CENTER LINE, 144 00:09:11,517 --> 00:09:14,034 TRACES HIS DRAWING ONTO THE CLEAR PLASTIC 145 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. 148 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. 150 00:09:35,172 --> 00:09:39,896 HE WORKS HIS WAY DOWN TO JUST ABOVE THE PENCIL LINE. 151 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. 155 00:09:55,758 --> 00:09:58,482 WORKING ON THE MORE COMPLEX DETAILS, 156 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. 158 00:10:04,275 --> 00:10:06,586 EVERY DETAIL OF THE KEYSTONE PROFILE 159 00:10:06,586 --> 00:10:09,137 MUST ALIGN WITH THE SAME PROFILE DETAIL 160 00:10:09,137 --> 00:10:11,655 OF THE LENTIL PIECES ON EITHER SIDE OF IT. 161 00:10:14,034 --> 00:10:16,965 ONCE HE HAS FINISHED THE ENTIRE PROFILE OF THE PIECE, 162 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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