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--Captions by VITAC--
www.vitac.com
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00:00:06,344 --> 00:00:09,344
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: MOUNTAIN BIKE TIRES
ARE TRUE TRAILBLAZERS,
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00:00:56,103 --> 00:00:59,310
SPECIFICALLY DESIGNED
FOR OFF-ROAD RIDING.
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WIDER THAN REGULAR ROAD TIRES,
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00:01:01,344 --> 00:01:04,344
MOUNTAIN BIKE TIRES
HAVE RAISED KNOBS OR LUGS
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THAT ADD STABILITY
ON UNEVEN TERRAIN.
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BUILT TO WITHSTAND THE TRAIL,
THESE TIRES CAN HANDLE IT ALL.
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00:01:14,344 --> 00:01:17,724
WHEN THE RUBBER HITS THE DIRT,
IT'S ALL ABOUT CONTROL.
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00:01:17,724 --> 00:01:20,379
MOUNTAIN BIKE TIRES ARE DESIGNED
TO GRIP THE GROUND
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AND PROVIDE TRACTION OFF-ROAD.
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FIRST, DESIGNERS USE
A COMPUTER MODEL OF A TIRE
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TO SIMULATE THE EFFECTS
OF DIFFERENT RUBBER COMPOUNDS.
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00:01:31,482 --> 00:01:34,241
CONSTRUCTION BEGINS WITH
RUBBER COMPOUNDS
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BEING MIXED TOGETHER
TO CREATE PARTS OF THE TIRE.
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INGREDIENTS INCLUDE SYNTHETIC
AND NATURAL RUBBERS,
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SULFUR,
AND OTHER CHEMICALS.
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ROTATING SPIRAL BLADES
BREAK DOWN THE MATERIALS.
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FRICTION FROM THE MIXING
HEATS AND SOFTENS THEM.
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THIS TRANSFORMS THE INGREDIENTS
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INTO A DOUGH-LIKE
RUBBER COMPOUND.
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POWERFUL ROLLERS SQUEEZE THE
COMPOUND INTO THICK LONG SHEETS
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00:01:59,758 --> 00:02:04,586
AND BLADES CUT THE ROLLED RUBBER
INTO NARROW STRIPS.
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00:02:04,586 --> 00:02:07,241
THEN THE RUBBER TRAVELS
THROUGH MORE ROLLERS
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00:02:07,241 --> 00:02:11,448
THAT SQUEEZE IT DOWN
TO THE DESIRED THICKNESS.
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THE RUBBER SHEETS LAND
ON A CART, READY FOR USE.
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TECHNICIANS INCASE
STEEL BEAD WIRE
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WITH ONE OF THESE COMPOUNDS.
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THE BEAD WIRE IS THE PART
OF THE TIRE
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THAT CONNECTS
TO THE WHEEL'S RIM.
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AS STEEL WIRE TRAVELS
THROUGH AN APERTURE,
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THE RUBBER IS EXTRUDED
TO FORM THE CASING.
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THE MACHINE DELIVERS
THE BEAD WIRE
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TO A SPINNING DISK.
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00:02:39,448 --> 00:02:41,482
THE DISK WINDS THE BEAD WIRE,
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00:02:41,482 --> 00:02:45,068
SHAPING IT INTO RINGS
WHICH FIT TO A WHEEL RIM.
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TO MAINTAIN THE DIAMETER
OF THE WIRE,
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THE TECHNICIAN TAPES
THE ENDS TOGETHER,
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HOLDING THE SHAPE UNTIL
THE NEXT STAGE OF PRODUCTION.
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NEXT, RUBBER SHEETS WITH
VARYING CHARACTERISTICS
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ENTER AN EXTRUDER.
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USING HEAT AND PRESSURE,
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THE EXTRUDER FORCES
THE RUBBER THROUGH DIES.
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00:03:10,206 --> 00:03:12,862
THIS PROCESS MERGES
THEIR CHARACTERISTICS
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INTO A SINGLE SHEET.
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THE SHEET WILL BE USED
TO MAKE THE BICYCLE'S TREAD.
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THE TREAD RUBBER TRAVELS
THROUGH A CHANNEL OF COOL WATER.
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MEANWHILE, ROLLERS COAT FABRIC
WITH RUBBER
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TO MAKE PLIES
FOR THE TIRE CASING.
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A MOVING BLADE CUTS IT
INTO STRIPS.
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THIS RUBBER IS NATURALLY TACKY,
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SO THE PIECES
CAN BE EASILY SPLICED.
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THE SYSTEM FEEDS THE STRIPS
TO TIRE-BUILDING MACHINE.
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A SKILLED ASSEMBLER WRAPS
THE STRIPS TO THE MACHINE DRUM
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TO FORM THE TIRE CASING
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AND SPLICES
THE RUBBER WHERE THE ENDS MEET.
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NEXT, ROBOTS SLIDE TWO
WIRE BEADS AROUND THE CASING.
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00:04:01,137 --> 00:04:03,758
THE ENDS OF THE DRUM FOLD
THE SIDES OF THE CASING
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OVER THE BEAD WIRES.
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THE TECHNICIAN APPLIES
RUBBER-COATED FABRIC
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TO THE BEAD WIRES,
STRENGTHENING THE AREA.
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THE TREAD RUBBER IS PLACED
IN THE CENTER.
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00:04:16,896 --> 00:04:20,172
A ROLLER APPLIES PRESSURE
AS THE DRUM SPINS
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TO WIND THE TREAD
AROUND THE CASING.
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THEN THE ENDS ARE
PRESSED TOGETHER MANUALLY.
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AND ONE MORE TURN OF THE DRUM
SECURES THE TREAD RUBBER
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TO THE CASING.
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00:04:34,448 --> 00:04:37,241
ONCE VENT HOLES HAVE BEEN
CUT IN THE RUBBER,
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IT'S OVER TO AN EXPANDING MOLD,
WHERE THE TIRE TAKES SHAPE.
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THE TECHNICIAN INSERTS A RUBBER
CURING BLADDER
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TO MAINTAIN
THE SHAPE OF THE TIRE.
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THEN HE PLACES THE MOUNTAIN BIKE
TIRES IN CURING MOLDS.
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THESE INDIVIDUAL MOLDS
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WILL STEAM-COOK THE TIRES
UNDER PRESSURE
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TO FURTHER SHAPE THEM.
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00:05:08,103 --> 00:05:11,068
THIS PROCESS FORMS KNOBS
AND OTHER PROTRUSIONS
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ON THE TIRE SURFACE
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THAT ARE DESIGNED TO GRIP
A RUGGED TERRAIN.
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LIKE A BIG WAFFLE IRON,
THIS MOLD HAS COOKED
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00:05:20,206 --> 00:05:22,965
AND FORMED
THE MOUNTAIN BIKE TIRE.
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00:05:22,965 --> 00:05:25,896
THE TIRE IS THEN PLACED
ON A RACK TO COOL.
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00:05:29,689 --> 00:05:33,137
NEXT, THE BIKE TIRE UNDERGOES
A DURABILITY TEST
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00:05:33,137 --> 00:05:36,103
WHILE A COMPUTER MEASURES
ROLLING RESISTANCE.
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THAT'S THE ENERGY LOST
WHEN THE TIRE ROTATES
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AND AN INDICATION OF
HOW EASILY THE TIRE WILL ROLL.
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THIS MOUNTAIN BIKE TIRE
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IS NOW CLEARED
TO TRAVEL OFF THE BEATEN PATH.
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Narrator:
A LEAF AND DEBRIS VACUUM
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00:06:02,896 --> 00:06:06,931
AUTOMATICALLY COLLECTS
ALL TYPES OF FALLEN DEBRIS.
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00:06:06,931 --> 00:06:09,068
INSTEAD OF SPENDING HOURS
RAKING,
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00:06:09,068 --> 00:06:11,551
THIS DEVICE QUICKLY
DOES IT ALL,
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00:06:11,551 --> 00:06:14,137
MAKING YARD WORK
EASIER THAN EVER.
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00:06:18,068 --> 00:06:19,655
A LEAF AND DEBRIS VACUUM
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00:06:19,655 --> 00:06:22,413
IS POWERED BY
A GAS OR DIESEL ENGINE.
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00:06:22,413 --> 00:06:24,344
THE ENGINE SPINS AN IMPELLER,
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00:06:24,344 --> 00:06:30,000
WHICH CREATES THE SUCTION
AND ALSO SHREDS THE LEAVES.
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THE MACHINE IS COMPRISED
OF ABOUT 100 DIFFERENT PARTS,
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ALL CUT FROM 0.11-INCH-THICK
SHEETS OF STEEL
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USING THIS COMPUTER-GUIDED
PUNCH PRESS.
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00:06:41,000 --> 00:06:44,413
THIS PART IS THE REAR FLANGE
FOR THE IMPELLER HOUSING.
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00:06:48,379 --> 00:06:51,413
TO MAKE THE SIDE WALL
OF THE HOUSING, CALLED THE WRAP,
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00:06:51,413 --> 00:06:53,551
A TECHNICIAN BENDS
THIS STEEL STRIP
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00:06:53,551 --> 00:06:55,275
WITH A PINCH ROLLER.
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ANOTHER TECHNICIAN POSITIONS
THE WRAP ON THE REAR FLANGE
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00:07:03,758 --> 00:07:05,827
AND TACK WELDS THEM TOGETHER.
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00:07:13,862 --> 00:07:16,379
THE CRAFTSMAN PLACES
THE HOUSING'S FRONT FLANGE
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ON TOP OF THE WRAP,
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ALIGNS ITS NOTCHES
WITH THE WRAP'S TABS,
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00:07:20,517 --> 00:07:22,827
AND TACK WELDS
THE PARTS TOGETHER.
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00:07:27,827 --> 00:07:31,068
HE COMPLETES THE HOUSING
WITH THIS RECTANGULAR PIECE.
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00:07:33,896 --> 00:07:35,896
THE SHREDDED LEAVES
EXIT THE HOUSING
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00:07:35,896 --> 00:07:37,482
THROUGH THIS OPENING.
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00:07:43,862 --> 00:07:47,344
NEXT, THE PARTS ARE PLACED
ON A ROTARY WELDING TABLE,
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00:07:47,344 --> 00:07:50,137
AND THE TACKED JOINTS
ARE WELDED TOGETHER.
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00:07:50,137 --> 00:07:54,896
THE FUSED SEAMS ENSURE
THE HOUSING IS AIRTIGHT.
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00:07:54,896 --> 00:07:57,965
A COMPUTER GUIDES
THIS FIBER-OPTIC LASER CUTTER,
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SLICING OUT THE IMPELLER BLADES
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FROM A SHEET
OF ABRASION-RESISTANCE STEEL.
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00:08:02,758 --> 00:08:04,827
THIS STEEL IS FOUR TIMES THICKER
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00:08:04,827 --> 00:08:07,241
THAN THE STEEL USED
FOR THE BODY PARTS.
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00:08:10,620 --> 00:08:13,896
EACH IMPELLER HAS FOUR BLADES
WITH SHARP EDGES
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THAT HELP SHRED THE LEAVES.
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00:08:18,068 --> 00:08:23,551
THE WELDER MOUNTS THE IMPELLER
COMPONENTS ONTO A FIXTURE.
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00:08:23,551 --> 00:08:25,758
EACH BLADE HAS ALIGNMENT TABS
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00:08:25,758 --> 00:08:29,000
WHICH FIT INTO NOTCHES
ON A BACKING PLATE.
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00:08:29,000 --> 00:08:31,724
AFTER CLAMPING EACH BLADE
IN POSITION,
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00:08:31,724 --> 00:08:34,241
HE FUSES THEM
TO THE BACKING PLATE.
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00:08:41,931 --> 00:08:44,793
NEXT, HE WELDS STEEL
REINFORCEMENT STRAPS
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00:08:44,793 --> 00:08:47,482
BETWEEN EACH
OF THE FOUR BLADES.
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00:08:47,482 --> 00:08:49,862
THE STRAPS ADD STRENGTH
AND STABILITY,
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00:08:49,862 --> 00:08:52,793
THEREBY INCREASING
THE LIFE-SPAN OF THE IMPELLER.
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00:08:56,344 --> 00:08:58,448
THE TECHNICIAN
COMPLETES THE ASSEMBLY
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00:08:58,448 --> 00:09:01,275
BY BOLTING A COMPRESSION HUB
TO THE CENTER.
134
00:09:01,275 --> 00:09:04,034
THE HUB HOLDS THE ENGINE
CRANKSHAFT TOGETHER,
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00:09:04,034 --> 00:09:05,862
WHICH ROTATES THE IMPELLER.
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00:09:08,793 --> 00:09:11,758
THEN HE INSERTS
A SIMULATED CRANKSHAFT
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00:09:11,758 --> 00:09:13,758
AND TIGHTENS
THE COMPRESSION HUB.
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00:09:17,689 --> 00:09:21,793
HE PLACES THE IMPELLER
ON THIS MACHINE TO BALANCE IT.
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00:09:21,793 --> 00:09:23,965
SINCE THE IMPELLER
CAN SPIN AT A SPEED
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00:09:23,965 --> 00:09:27,000
OF MORE THAN 3,000 REVOLUTIONS
PER MINUTE,
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00:09:27,000 --> 00:09:31,241
THIS STEP IS CRITICAL
FOR THE MACHINE TO RUN SMOOTHLY.
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TO MAINTAIN STABILITY,
THE WELDER ADDS BEADS OF WELD
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00:09:34,862 --> 00:09:38,413
TO THE LIGHTER SIDE
UNTIL THE IMPELLER BALANCES.
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00:09:40,551 --> 00:09:43,482
THEN HE REMOVES THE SIMULATED
CRANKSHAFT.
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00:09:47,689 --> 00:09:51,827
MEANWHILE AN ASSEMBLER MOUNTS
THE 29-HORSEPOWER GAS ENGINE
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00:09:51,827 --> 00:09:54,655
TO THE ENGINE DECK
OF THE TRAILER FRAME.
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00:09:54,655 --> 00:10:00,103
THE CRANKSHAFT POKES THROUGH
A HOLE IN THE FRAME'S FACEPLATE.
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00:10:00,103 --> 00:10:02,517
HE BOLTS THE IMPELLER HOUSING,
WHICH HAS BEEN PAINTED,
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00:10:02,517 --> 00:10:04,241
TO THE FACEPLATE.
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00:10:12,137 --> 00:10:14,965
THE TECHNICIAN INSTALLS
THE IMPELLER ON THE CRANKSHAFT
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00:10:14,965 --> 00:10:16,689
WITH A SHEAR KEY.
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00:10:20,896 --> 00:10:23,793
THEN HE BOLTS
A PROTECTIVE STEEL COVER PLATE
153
00:10:23,793 --> 00:10:26,517
AND ATTACHES EVERYTHING
WITH A CENTRAL BOLT.
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00:10:30,413 --> 00:10:34,620
NEXT, HE APPLIES A BRAND DECAL
ON THE HOUSING'S FRONT COVER...
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00:10:39,517 --> 00:10:43,482
...AND BOLTS THE COVER
TO THE HOUSING.
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00:10:43,482 --> 00:10:47,965
WHEN READY FOR USE,
THE DEBRIS CHUTE, THE HOSE,
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00:10:47,965 --> 00:10:51,344
AND THE INTAKE HOSE
ARE ATTACHED TO THE FRONT END.
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00:10:53,965 --> 00:10:57,965
AS THIS DEMONSTRATION SHOWS,
THE IMPELLER CAN SHRED LEAVES
159
00:10:57,965 --> 00:11:02,344
INTO PARTICLES SMALL ENOUGH
TO BE USED AS COMPOST.
160
00:11:13,241 --> 00:11:15,137
Narrator:
WITH SO MUCH ON THEIR PLATES,
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00:11:15,137 --> 00:11:19,448
BUSY PEOPLE RELY ON SHORTCUTS
TO HELP PREPARE MEALS.
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00:11:19,448 --> 00:11:21,482
NOWADAYS,
YOU CAN STOCK YOUR PANTRY
163
00:11:21,482 --> 00:11:23,655
WITH CANS OF PRECOOKED MEAT
164
00:11:23,655 --> 00:11:26,724
SO THERE'S ALWAYS SOMETHING
ON HAND TO USE IN SANDWICHES,
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00:11:26,724 --> 00:11:30,482
STEWS, STIR-FRIES,
AND OTHER TASTY DISHES.
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00:11:33,103 --> 00:11:36,206
THIS CANNED MEAT IS
METICULOUSLY HAND PRODUCED
167
00:11:36,206 --> 00:11:40,000
BY A CRAFT CANNERY
AND MADE IN SMALL BATCHES.
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00:11:42,310 --> 00:11:45,758
IT CONTAINS NO ARTIFICIAL
INGREDIENTS OR PRESERVATIVES,
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00:11:45,758 --> 00:11:48,379
JUST MEAT AND SEA SALT.
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00:11:48,379 --> 00:11:50,965
WHEN A SHIPMENT OF MEAT
ARRIVES AT THE CANNERY,
171
00:11:50,965 --> 00:11:53,724
THE QUALITY CONTROL MANAGER
RECORDS ITS LOT CODE
172
00:11:53,724 --> 00:11:56,413
FOR TRACKING PURPOSES.
173
00:11:56,413 --> 00:11:58,103
AS A FOOD-SAFETY PRECAUTION,
174
00:11:58,103 --> 00:12:00,482
HE CONFIRMS THE TEMPERATURE
OF THE MEAT,
175
00:12:00,482 --> 00:12:05,413
WHICH MUST COME IN BETWEEN
0 TO 39 DEGREES FAHRENHEIT.
176
00:12:05,413 --> 00:12:08,448
A SKILLED BUTCHER
THEN INSPECTS THE MEAT
177
00:12:08,448 --> 00:12:10,724
AND TRIMS OFF THE EXCESS FAT.
178
00:12:16,206 --> 00:12:17,620
IF IT'S A LARGE PIECE,
179
00:12:17,620 --> 00:12:20,241
THE BUTCHER SLICES
IT INTO SMALLER PIECES
180
00:12:20,241 --> 00:12:22,793
SO THAT IT CAN PASS THROUGH
THE DICING MACHINE.
181
00:12:25,689 --> 00:12:28,931
THE DICER CUTS THE MEAT
INTO ONE-INCH CUBES.
182
00:12:35,310 --> 00:12:36,724
AT THE FILLING STATION,
183
00:12:36,724 --> 00:12:40,655
ALUMINUM CANS CIRCULATE
AROUND A ROTATING TABLE.
184
00:12:40,655 --> 00:12:44,655
AS ONE WORKER SHOVELS CUBED MEAT
ONTO THE CENTER OF THE TABLE,
185
00:12:44,655 --> 00:12:47,000
OTHERS MANUALLY FILL CANS
186
00:12:47,000 --> 00:12:50,655
WHILE SIMULTANEOUSLY PERFORMING
A QUALITY INSPECTION.
187
00:12:50,655 --> 00:12:53,689
WORKERS WILL DISCARD ANY CUBES
THAT ARE DISCOLORED
188
00:12:53,689 --> 00:12:57,344
OR TOO FATTY.
189
00:12:57,344 --> 00:13:00,862
NEXT, TECHNICIANS PLACE
A SINGLE CUBE OF SEA SALT
190
00:13:00,862 --> 00:13:03,103
IN EACH CAN FILLED WITH MEAT.
191
00:13:06,344 --> 00:13:08,793
THIS IS THE ONLY
ADDED INGREDIENT.
192
00:13:17,275 --> 00:13:20,862
AT THE NEXT STATION, WORKERS
WEIGH EACH CAN INDIVIDUALLY
193
00:13:20,862 --> 00:13:25,000
AND EITHER ADD OR REMOVE MEAT
TO REACH THE REQUIRED WEIGHT.
194
00:13:28,137 --> 00:13:30,931
THE FILLED CANS
NOW TRAVEL ON A CONVEYER BELT
195
00:13:30,931 --> 00:13:33,689
TO THE COOK ROOM.
196
00:13:33,689 --> 00:13:35,620
THERE, THEY ENTER
THE PRE-HEATER,
197
00:13:35,620 --> 00:13:39,413
WHICH BLASTS THEM WITH STEAM
FOR 20 SECONDS.
198
00:13:39,413 --> 00:13:42,827
THIS EXPELS AIR THAT'S TRAPPED
BETWEEN THE CUBES OF MEAT.
199
00:13:45,000 --> 00:13:48,310
NEXT, THE CANS MOVE
INTO THE CLOSING MACHINE.
200
00:13:48,310 --> 00:13:51,620
THE MACHINE COMPRESSES THE MEAT
TO PROVIDE SUFFICIENT CLEARANCE
201
00:13:51,620 --> 00:13:53,344
AT THE TOP OF THE CAN.
202
00:13:53,344 --> 00:13:56,379
THIS HEAD SPACE
CREATES A VACUUM ON THE CAN
203
00:13:56,379 --> 00:13:59,206
TO DRAW OUT
THE REMAINING AIR.
204
00:14:02,000 --> 00:14:04,310
THEN A DEVICE ATTACHES THE LID
205
00:14:04,310 --> 00:14:07,620
BY A PROCESS
KNOWN AS DOUBLE SEAMING.
206
00:14:07,620 --> 00:14:11,551
THE PROCESS ROLLS THE EDGES
OF THE LID AND CAN TOGETHER,
207
00:14:11,551 --> 00:14:14,551
FORMING A RIM
THAT PROVIDES AN AIRTIGHT SEAL.
208
00:14:17,413 --> 00:14:20,172
IT'S TIME TO GET COOKING.
209
00:14:20,172 --> 00:14:21,827
A WORKER LOWERS THE CANS
210
00:14:21,827 --> 00:14:24,827
INTO A COMMERCIAL-SIZED
PRESSURE COOKER.
211
00:14:27,793 --> 00:14:29,620
COOKING UNDER STEAM PRESSURE
212
00:14:29,620 --> 00:14:32,275
PRODUCES THE TENDERIZING EFFECTS
OF SLOW COOKING
213
00:14:32,275 --> 00:14:34,241
IN A FRACTION OF THE TIME.
214
00:14:37,068 --> 00:14:39,586
THE MEAT COOKS
IN ITS OWN JUICES.
215
00:14:39,586 --> 00:14:42,586
THE COOKING TEMPERATURE VARIES
DEPENDING ON THE TYPE OF MEAT
216
00:14:42,586 --> 00:14:44,310
AND THE CAN SIZE.
217
00:14:47,896 --> 00:14:51,448
WHEN THE MEAT IS READY,
THE TECHNICIAN REMOVES THE CANS
218
00:14:51,448 --> 00:14:53,655
AND SETS THEM ASIDE
FOR ABOUT AN HOUR
219
00:14:53,655 --> 00:14:55,241
TO COOL AND DRY.
220
00:14:58,862 --> 00:15:01,827
THE CANS ARE THEN MOVED
TO THE PACKAGING AREA.
221
00:15:04,068 --> 00:15:06,517
AS A WORKER LOADS
THE LABELING MACHINE,
222
00:15:06,517 --> 00:15:12,517
HE INSPECTS EACH CAN
FOR DENTS OR DAMAGED SEALS.
223
00:15:12,517 --> 00:15:16,000
ONE BY ONE, THE CANS ROLL OVER
A GLUE APPLICATOR,
224
00:15:16,000 --> 00:15:17,896
THEN A STACK OF LABELS,
225
00:15:17,896 --> 00:15:21,241
WRAPPING THEMSELVES
AND THE TOP SEAL.
226
00:15:21,241 --> 00:15:25,034
AT THE SAME TIME, THE MACHINE
COUNTS THE NUMBER OF CANS.
227
00:15:29,862 --> 00:15:32,068
AFTER ROLLING OFF
THE LABELING MACHINE,
228
00:15:32,068 --> 00:15:34,517
THE CANS PASS THROUGH
AN INK-JET PRINTER
229
00:15:34,517 --> 00:15:37,103
WHICH APPLIES
THE BEST-USED-BY DATE.
230
00:15:41,310 --> 00:15:43,965
THAT DATE IS NEXT
TO THE LOT CODE,
231
00:15:43,965 --> 00:15:48,172
WHICH THE CLOSING MACHINE
PRINTED WHILE ATTACHING THE LID.
232
00:15:48,172 --> 00:15:51,103
THIS CAN OF MEAT
HAS A FIVE-YEAR SHELF LIFE
233
00:15:51,103 --> 00:15:53,448
DUE TO TWO CRUCIAL FACTORS --
234
00:15:53,448 --> 00:15:58,103
IT IS COOKED PROPERLY,
AND THE CAN'S SEAL IS AIRTIGHT.
235
00:16:11,344 --> 00:16:12,793
Narrator:
HAVE FISH TO FRY?
236
00:16:12,793 --> 00:16:14,310
IF IT'S FRESH AND WHOLE,
237
00:16:14,310 --> 00:16:16,689
A FILLET KNIFE
WILL COME IN HANDY.
238
00:16:16,689 --> 00:16:18,965
THIS IS NO ORDINARY
KITCHEN KNIFE,
239
00:16:18,965 --> 00:16:23,034
EQUIPPED WITH A THIN,
FLEXIBLE BLADE AND A SHARP TIP.
240
00:16:23,034 --> 00:16:27,068
THIS DESIGN ALLOWS THE USER TO
MOVE EASILY ALONG THE BACKBONE
241
00:16:27,068 --> 00:16:29,137
AND UNDER THE SKIN OF THE MEAT.
242
00:16:32,655 --> 00:16:35,517
A FILLET KNIFE
IS A PRECISION CUTTING TOOL.
243
00:16:35,517 --> 00:16:36,793
IT MAKES THE WORK
244
00:16:36,793 --> 00:16:41,482
OF REMOVING BONES AND SKIN
FROM FISH POSSIBLE.
245
00:16:41,482 --> 00:16:43,000
MAKING A FILLET KNIFE
246
00:16:43,000 --> 00:16:46,793
STARTS WITH A SHEET OF THIN
AND PLIABLE STAINLESS STEEL.
247
00:16:46,793 --> 00:16:51,551
A COMPUTER-GUIDED LASER CUTS
THE STEEL INTO BLADE BLANKS.
248
00:16:51,551 --> 00:16:54,620
A CRAFTSMAN CLAMPS THE BLANK
IN A FIXTURE.
249
00:16:54,620 --> 00:16:57,655
THE FIXTURE MOVES THE BLANK
ACROSS A GRINDING WHEEL,
250
00:16:57,655 --> 00:17:03,379
BEVELING IT FROM THE SPINE TO
THE CUTTING EDGE ON BOTH SIDES.
251
00:17:03,379 --> 00:17:07,172
THEN SANDING BELTS ARE USED
TO SHAPE THE BLADE BLANK.
252
00:17:10,000 --> 00:17:12,586
A CRAFTSMAN ROUNDS
THE SPINE OF THE BLANK
253
00:17:12,586 --> 00:17:14,655
USING A ROUGH-GRIT SANDING BELT,
254
00:17:14,655 --> 00:17:17,620
EVENTUALLY GRADUATING
TO A FINER ONE.
255
00:17:17,620 --> 00:17:23,275
WITH A ROUNDER SPINE, THE BLADE
WILL BE SAFER TO HANDLE.
256
00:17:23,275 --> 00:17:26,103
AT THE NEXT STATION,
A CRAFTSMAN DRILLS A HOLE
257
00:17:26,103 --> 00:17:28,551
INTO A SOLID BLOCK
OF COMPOSITE MATERIAL
258
00:17:28,551 --> 00:17:31,517
THAT CONTAINS RESIN.
259
00:17:31,517 --> 00:17:34,103
THE MATERIAL IS CUT
INTO SMALLER CHUNKS.
260
00:17:34,103 --> 00:17:37,862
EACH ONE WILL BE FORMED
INTO A HANDLE END CAP OR POMMEL.
261
00:17:37,862 --> 00:17:40,689
THE CENTER HOLE WILL HOUSE
THE TANG.
262
00:17:40,689 --> 00:17:44,827
HE SLICES OTHER PIECES OF
THE MATERIAL ALMOST WAFER THIN.
263
00:17:44,827 --> 00:17:48,172
THEY'LL BECOME SPACERS
FOR THE HANDLE'S OTHER END.
264
00:17:48,172 --> 00:17:51,068
THESE COMPOUND PARTS WILL
SUPPORT THE CENTER MATERIAL
265
00:17:51,068 --> 00:17:52,793
FOR THE CORK HANDLE.
266
00:17:55,034 --> 00:17:59,586
THE CRAFTSMAN STACKS THE PARTS
OF THE HANDLE ON A STAND.
267
00:17:59,586 --> 00:18:02,586
HE BRUSHES WATERPROOF GLUE
ONTO THE SPACER
268
00:18:02,586 --> 00:18:06,172
AND SLIDES EIGHT PIECES OF CORK
ONTO THE PRONG.
269
00:18:06,172 --> 00:18:09,137
HE APPLIES GLUE
BETWEEN EACH ONE.
270
00:18:09,137 --> 00:18:11,965
HE PLACES THE POMMEL
PIECE ON THE END.
271
00:18:11,965 --> 00:18:13,655
SINCE CORK IS BUOYANT,
272
00:18:13,655 --> 00:18:15,482
IF THE KNIFE
IS DROPPED IN WATER,
273
00:18:15,482 --> 00:18:19,206
IT WILL FLOAT
AND CAN BE EASILY RETRIEVED.
274
00:18:19,206 --> 00:18:22,758
ONCE THE GLUE DRIES, THE HANDLES
ARE TRANSFERRED,
275
00:18:22,758 --> 00:18:25,068
TWO AT A TIME, TO A FIXTURE.
276
00:18:25,068 --> 00:18:29,068
THE FIXTURE MOVES BACK AND FORTH
AS A ROTOR ROUNDS THE SPACER,
277
00:18:29,068 --> 00:18:31,620
CARVING THE CORK AND THE POMMEL.
278
00:18:31,620 --> 00:18:33,965
AT THE NEXT STATION,
A WORKER PLACES
279
00:18:33,965 --> 00:18:38,655
ONE OF THE FILLET
KNIFE BLADES IN A RUBBER HOLDER.
280
00:18:38,655 --> 00:18:40,724
HE CLAMPS THE HOLDER
IN A FIXTURE,
281
00:18:40,724 --> 00:18:45,241
STABILIZING THE BLADE FOR
THE INSTALLATION OF THE BOLSTER.
282
00:18:45,241 --> 00:18:48,655
THE BOLSTER IS THE STEEL RING
THAT ACTS AS A TRANSITION PIECE
283
00:18:48,655 --> 00:18:51,241
BETWEEN THE BLADE AND HANDLE.
284
00:18:51,241 --> 00:18:53,241
THEN THE CRAFTSMAN APPLIES GLUE
285
00:18:53,241 --> 00:18:55,655
TO THE COMPOSITE SPACER
ON THE HANDLE.
286
00:18:55,655 --> 00:18:58,758
HE SLIDES THE HANDLE
ONTO THE TANG OF THE KNIFE.
287
00:19:01,896 --> 00:19:05,517
HE INSERTS A HEXAGONAL NUT
INTO THE HOLE AND THE POMMEL
288
00:19:05,517 --> 00:19:08,655
AS WELL AS SOME EPOXY.
289
00:19:08,655 --> 00:19:11,034
HE SCREWS THE NUT ONTO THE TANG,
290
00:19:11,034 --> 00:19:13,689
SECURING THE BLADE
TO THE HANDLE.
291
00:19:13,689 --> 00:19:18,034
THE EPOXY PROVIDES
REINFORCEMENT.
292
00:19:18,034 --> 00:19:22,827
THE CRAFTSMAN UNCLAMPS THE KNIFE
AND WORKS ON SHAPING THE HANDLE.
293
00:19:22,827 --> 00:19:25,482
HE SCULPTS IT WITH ROUGH-GRIT
SANDPAPER.
294
00:19:30,068 --> 00:19:32,344
HE ANGLES THE OUTSIDE
OF THE POMMEL,
295
00:19:32,344 --> 00:19:36,724
MAKING IT SMOOTHER
AND MORE ATTRACTIVE.
296
00:19:36,724 --> 00:19:38,965
SWITCHING TO A FINER ABRASIVE,
297
00:19:38,965 --> 00:19:42,172
HE SANDS THE CORK
TO BLEND THE LAYERS TOGETHER
298
00:19:42,172 --> 00:19:45,034
SO THEY APPEAR TO BE
ONE UNIFORM PIECE.
299
00:19:47,827 --> 00:19:50,310
NEXT, A WORKER DRILLS
INTO THE POMMEL
300
00:19:50,310 --> 00:19:52,827
TO WIDEN AND SLOPE THE OPENING.
301
00:19:52,827 --> 00:19:56,551
HE PIPES MORE EPOXY
INTO THE RECESS.
302
00:19:56,551 --> 00:19:58,034
HE INSERTS A SNAP
303
00:19:58,034 --> 00:20:00,896
THAT WILL BE USED
TO RETAIN THE KNIFE IN A SHEATH
304
00:20:00,896 --> 00:20:05,827
AND DRIVES IT FURTHER
INTO THE RECESS USING A PRESS.
305
00:20:05,827 --> 00:20:07,793
ONCE THE EPOXY CURES,
306
00:20:07,793 --> 00:20:10,620
HE SUBMERGES
THE KNIVES INTO WATER.
307
00:20:10,620 --> 00:20:14,655
THIS STEP IS A TEST TO CONFIRM
THE KNIVES CAN FLOAT.
308
00:20:14,655 --> 00:20:16,482
AFTER THE HANDLE DRIES,
309
00:20:16,482 --> 00:20:18,448
THE KNIFE UNDERGOES
A FINAL SANDING
310
00:20:18,448 --> 00:20:20,620
FOR THE USER'S GRIPPING COMFORT.
311
00:20:22,724 --> 00:20:24,827
YOU CAN SEE THE DIFFERENCE
THE SANDING MAKES
312
00:20:24,827 --> 00:20:26,551
IN THE KNIFE ON THE RIGHT.
313
00:20:28,620 --> 00:20:32,344
NEXT, THE CRAFTSMAN WORKS ON
THE FILLET KNIFE'S CUTTING EDGE,
314
00:20:32,344 --> 00:20:34,724
SHARPENING IT AGAINST
A SANDING BELT.
315
00:20:36,862 --> 00:20:40,827
THE BLADE SLICES A SHEET OF
PAPER CLEANLY WITHOUT SNAGGING,
316
00:20:40,827 --> 00:20:43,034
PROVING THAT IT'S BEEN
WELL-HONED.
317
00:20:45,310 --> 00:20:49,758
FINALLY, ANOTHER WORKER CLEANS
AND LUBRICATES THE FILLET KNIFE.
318
00:20:49,758 --> 00:20:52,068
SHE SLIDES IT
INTO A LEATHER SHEATH
319
00:20:52,068 --> 00:20:56,241
AND SNAPS THE TAB OF THE SHEATH
TO THE END OF THE POMMEL.
320
00:20:56,241 --> 00:20:59,758
WITH ALL THE WORK THAT'S GONE
INTO THIS FILLET KNIFE,
321
00:20:59,758 --> 00:21:04,793
THE CUSTOMER WILL BE IN
FOR ONE TASTY, WELL-CUT MEAL.
26057
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