All language subtitles for How.Its.Made.S10E06.Wooden.Barrels.1080p.AMZN.WEB-DL.DDP2.0.H.264-SLAG_track4_[eng]

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Narrator:
TODAY ON "HOW IT'S MADE"...

WOODEN BARRELS...

FIRE HYDRANTS...

AUTOMOTIVE SEATS...

AND CATHODE-RAY TUBES.

IN THE OLD DAYS, WOODEN BARRELS
STORED ALL KINDS OF GOODS,

SIMPLY BECAUSE
THEY WERE EASY TO MOVE.

IF YOU COULDN'T LIFT THEM,
YOU COULD ROLL THEM.

TODAY MODERN MACHINERY
HAS MADE BARRELS OBSOLETE,

EXCEPT FOR STORING
FINE WINE AND SPIRITS.

AND SO THE TIME-HONORED
TRADITION OF BARREL MAKING

LIVES ON.

THESE WOODEN BARRELS
ARE FOR STORING WHISKEY.

THEY'RE MADE
FROM AMERICAN WHITE OAK

CUT INTO PIECES CALLED STAVES.

THE STAVES GO INTO A PLANER

THAT SHAVES THEM
TO ABOUT AN INCH THICK.

NEXT, A MACHINE PUNCHES
TWO QUARTER-INCH HOLES

ON EITHER SIDE OF EACH STAVE.

DOWEL PINS MADE OF HICKORY,
A VERY STRONG WOOD,

GO INTO THESE HOLES
TO HOLD THE STAVES TOGETHER.

WORKERS TAKE THE STAVES,

PLACE THEM ON A GUIDE,
AND PRESS THEM TOGETHER.

A SMALLER PIECE
COMPLETES THE SHAPE.

NOW IT'S ONTO THE ROUNDER,

A MACHINE THAT CUTS IT
INTO A CIRCULAR SHAPE.

THIS CREATES THE BARREL'S LID,
OR HEAD, AS IT'S CALLED.

AND EACH BARREL REQUIRES TWO,

ONE FOR THE TOP
AND ONE FOR THE BOTTOM.

THE BARREL HEAD
NOW GOES ONTO A CONTRAPTION

CALLED THE CHAR TUNNEL.

ITS GAS BURNERS SCORCH THE WOOD.

THIS CHARRING NOT ONLY CHANGES
THE WOOD'S APPEARANCE,

IT ALSO GIVES COLOR, FLAVOR,
AND AROMA

TO THE WHISKEY
THIS BARREL WILL HOLD.

THE WORKERS COAT THE HEAD'S EDGE
WITH LIQUID BEESWAX,

WHICH HELPS THEM SET IT
SNUGLY INTO THE BARREL BODY.

THEY RUN THE STAVES AGAINST THIS
MACHINE TO NARROW THEIR ENDS.

THIS GIVES THE BARREL
ITS CHARACTERISTIC SHAPE,

WITH A SMALLER RADIUS
AT THE ENDS THAN IN THE MIDDLE.

AT THE BARREL-RAISING STATION,
A WORKER POSITIONS AN IRON HOOP

AND STARTS TO ASSEMBLE
THE BARREL INSIDE IT.

HE SELECTS STAVES
THAT VARY IN WIDTH

IN ORDER TO USE
AS FEW AS POSSIBLE.

THIS REDUCES
THE NUMBERS OF JOINTS

AND POTENTIAL LEAK POINTS.

HE HAS TO BE GENTLE AS HE LASSOS
THE BARREL TOGETHER.

IF HE PULLS THAT DRY WOOD
TOO TIGHT,

IT'LL BREAK INTO PIECES.

A LOOSE HOOP GIVES THE WOOD
ROOM TO EXPAND.

NEXT, THE BARRELS PASS THROUGH
A STEAM TUNNEL

FOR ABOUT 15 MINUTES.

THIS ADDS MOISTURE TO THE WOOD
SO IT CAN FLEX WITHOUT SNAPPING.

WORKERS PULL OUT THE BARREL AND
REMOVE THE TOP AND BOTTOM HOOPS.

STURDIER HOOPS REPLACE THEM
AND ARE HAMMERED INTO PLACE.

WITHOUT THEM,
THE BARREL WOULD SPRING APART.

NEXT, TWO MORE HOOPS
AROUND THE BODY.

THE WOOD GROANS
FROM THE INTENSE PRESSURE

THAT FORCES THE STAVES TOGETHER,

BUT THERE CAN'T BE ANY GAPS
BETWEEN THE STAVES,

OR ELSE THE BARREL WILL LEAK.

THE BARRELS PASS OVER
A GAS BURNER

THAT BLASTS A FLAME INSIDE
EACH ONE TO CHAR ITS INTERIOR.

SECONDS LATER,
WATER SHOOTS INTO THE BARREL

TO PUT OUT THE FLAMES.

AN AUTOMATED SAW
CUTS A V-SHAPED NOTCH

INTO THE TOP AND BOTTOM
OF EACH BARREL.

THIS IS WHERE THE BARREL HEAD
WILL SLIDE IN.

A FAN BLOWS AWAY THE SAWDUST.

NOW A MACHINE REMOVES
THE IRON HOOP ON EACH END.

A WORKER POURS IN A GALLON
OF WATER TO COOL THE BARREL,

STILL HOT
FROM THE CHARRING PROCESS.

THEN HE PUTS ON A BARREL HEAD

AND STRONGER, PERMANENT
IRON HOOPS ON BOTH ENDS.

NOW MACHINES REMOVE
THE TWO IRON BODY HOOPS

AND REPLACE THEM
WITH STRONGER ONES.

THESE BARRELS HOLD THEIR SHAPE
BY SHEER PRESSURE.

THERE'S NOT A DROP OF GLUE
HOLDING THEM TOGETHER.

THAT GALLON OF WATER
IS STILL INSIDE THE BARREL.

WORKERS DRILL A HOLE
IN THE SIDE,

THEN PLUG IT BY HAMMERING IN
A RUBBER STOPPER WITH A SPOUT.

AN INSPECTOR CHECKS THE BARREL
FOR LEAKS, STAMPS IT APPROVED,

AND LABELS IT WITH A BAR CODE
FOR INVENTORY.

THEN THEY REMOVE THE STOPPER
AND OUT COMES THE WATER,

TURNED TO STEAM
BECAUSE OF THE HEAT.

THE BARRELS ARE NOW READY
TO GO ON TO THE DISTILLERY,

WHERE THEY'LL GET THEIR FILL
OF SOME FINE KENTUCKY WHISKEY.

WHEN WE RETURN, YOU SEE THEM
ON EVERY STREET CORNER,

BUT HOW ARE THEY MADE?

Narrator: FIRE HYDRANTS
HAVE BEEN IN USE

FOR MORE THAN 200 YEARS.

IN THE OLD DAYS,
THEIR MAIN PURPOSE

WAS TO SUPPLY WATER
TO FIGHT FIRES,

BUT THEY ALSO PROVIDED
THE PUBLIC

WITH A HANDY WATER SUPPLY.

TODAY FIRE CREWS
RELY ON THE NEAREST HYDRANT

TO HELP THEM DOUSE FLAMES

WHENEVER AND WHEREVER
THEY BREAK OUT.

FIRE HYDRANTS ARE ESSENTIAL
TO EVERY COMMUNITY.

THEY NEED TO BE INSTANTLY
RECOGNIZABLE, EASILY ACCESSIBLE,

AND SIMPLE TO OPERATE.

THE ONES IN RESIDENTIAL AREAS
ARE DESIGNED TO DELIVER

AN IMPRESSIVE
1,500 GALLONS A MINUTE.

THE HYDRANT-MAKING PROCESS
STARTS WITH RECYCLED SCRAP IRON,

ALONG WITH STEEL AND RAW IRON.

USING A MAGNETIC CRANE,

WORKERS LOAD THE METALS
INTO A FURNACE

AND MELT THEM
AT 2,800 DEGREES FAHRENHEIT.

THIS TURNS THE SCRAP METAL
INTO MOLTEN IRON.

THIS SUPERHOT MIXTURE

IS TRANSFERRED INTO
A REMOTE-CONTROLLED LADLE...

AND EMPTIED INTO
AN AUTOMATED POURING SYSTEM.

TO CAST THE HYDRANTS, WORKERS
FIRST MAKE TWO-PART MOLDS

BY COMPRESSING A MIXTURE
OF SAND AND BONDING MATERIALS.

ONE PART, CALLED THE MOLD, FORMS
THE HYDRANT'S EXTERIOR SHAPE,

WHILE THE OTHER PART, CALLED THE
CORE, FORMS THE INTERIOR SHAPE.

AN AUTOMATIC CORE SETTER
POSITIONS A CORE IN EACH MOLD.

THEN A CONVEYER ADVANCES
THE MOLD UNDER THE POURING BOX,

WHICH FILLS THE CAVITY
BETWEEN THE MOLD AND CORE

WITH MOLTEN IRON.

AFTER THE IRON COOLS
AND SOLIDIFIES,

THE MOLDS ENTER
A TUMBLING BARREL.

AS THEY REVOLVE, THE SAND
GRADUALLY DISINTEGRATES,

FREEING THE IRON CASTING INSIDE.

WORKERS DRILL AND THREAD
THE HYDRANT CASTINGS

TO PREPARE THEM FOR ASSEMBLY.

THEN THEY PREASSEMBLE
AND PAINT THEM.

THE FIRE HYDRANT'S
INTERNAL WORKINGS,

CALLED THE VALVE ASSEMBLY,

ALLOW WATER TO FLOW THROUGH
WHEN THE HYDRANT'S OPEN.

A SERIES OF RUBBER "O" RINGS
ON THE MAIN VALVE

WILL PREVENT LEAKS
WHEN THE HYDRANT IS CLOSED.

NOW THE HYDRANT IS READY
FOR FINAL ASSEMBLY.

WORKERS ATTACH
THE NOZZLE SECTION

TO THE TOP OF THE HYDRANT BARREL

AND FASTEN NOZZLE CAP CHAINS
WITH A CRIMPING TOOL.

USING A TORQUE WRENCH, THEY
ATTACH CAST-IRON SAFETY RINGS.

THESE RINGS ARE DESIGNED

TO DISENGAGE THE TOP
FROM THE BOTTOM OF THE HYDRANT

SO IT DOESN'T GET DAMAGED
IF A VEHICLE HITS IT.

WORKERS CLAMP THE WATER-MAIN
CONNECTOR INTO PLACE

AND PRESSURIZE THE HYDRANT
TO NORMAL CITY PRESSURE

TO CHECK FOR LEAKS.

USING A HOIST, THEY LOWER THE
PREASSEMBLED NOZZLE SECTION

OVER THE STEM...

AND FASTEN IT
TO THE WATER-MAIN CONNECTOR

WITH STAINLESS STEEL BOLTS.

THEY LOWER THE BONNET
INTO PLACE...

BOLT IT TO THE NOZZLE SECTION...

THEN OPEN THE HYDRANT
FOR A HIGH-PRESSURE TEST.

THEY TURN THE OPERATING NUT
TO ALLOW WATER TO FLOW THROUGH.

BUT FIRST, THEY HAVE TO
FORCE OUT THE AIR

INSIDE THE HYDRANT WITH WATER.

WORKERS TRANSFER
THE FINISHED HYDRANT TO A PALLET

AND APPLY FINAL PAINT TOUCH-UPS.

SOME FIRE HYDRANTS
THAT WERE INSTALLED

MORE THAN 100 YEARS AGO
ARE STILL IN USE TODAY.

COMING UP, IT'S A CUSHY JOB,
BUT SOMEBODY'S GOT TO DO IT.

Narrator: MOST PEOPLE
DON'T PAY TOO MUCH ATTENTION

TO CAR SEATING, BUT THIS FEATURE
HAS COME A LONG WAY

SINCE THE CAR WAS INVENTED
IN THE 19th CENTURY.

BACK THEN, SEATS HAD NO SPRINGS
AND NOT MUCH PADDING.

SO YOU COULD FEEL
EVERY BUMP ON THE ROAD.

IN TODAY'S CAR SEATS,
WE HAVE A MUCH EASIER RIDE.

PADDED AND BELTED,
MODERN AUTOMOTIVE SEATS

ARE DESIGNED TO BE SAFE
AND COMFORTABLE.

THE COMPONENTS
ARE MANUFACTURED SEPARATELY

AND SHIPPED TO THIS FACTORY
FOR ASSEMBLY.

THEY ARRIVE AS NEEDED
ON THE PRODUCTION LINE

SO THERE'S NOT
A LOT OF STOCKPILING.

IT MEANS THE FLOW OF PARTS
INTO THIS PLANT

HAS TO BE HIGHLY ORGANIZED

BECAUSE THEY MAKE
OVER 400 SEAT VARIATIONS HERE.

THE PARTS ARE CARTED
TO THE ASSEMBLY LINE

IN THE ORDER THEY'RE NEEDED.

ON THIS ASSEMBLY LINE,
THERE ARE 60 WORKERS,

EACH WITH SPECIFIC TASKS
TO PERFORM.

THEY RECEIVE A BUILD TICKET
FOR EACH PART AND SCAN IT.

THIS ALLOWS A CENTRAL COMPUTER
TO TRACK PRODUCTION

AND VERIFY THAT THE RIGHT PARTS
ARE BEING USED

TO BUILD THE RIGHT SEAT.

AN OPERATOR TUCKS
THE SEAT-WARMER PAD AND CABLES

INTO THE CUSHIONING
FOR THE BOTTOM HALF OF THE SEAT.

SHE LOOSELY PLACES THE FABRIC
COVER OVER THE ASSEMBLY

AND ATTACHES IT WITH WIRE.

THEN IT'S OVER
TO THE NEXT STATION,

WHERE THE OPERATOR COMPLETES
THE UPHOLSTERY JOB.

EACH WORKER HAS JUST 88 SECONDS
TO PERFORM HIS OR HER TASKS,

SO THERE'S NO SITTING DOWN
ON THIS JOB.

THEY INSTALL
A SEAT-WARMER SYSTEM

ON THE BACKREST SECTION
OF THE SEAT AND COVER IT.

THEN THEY SLIDE AN AIR BAG
INTO A SPECIAL SLEEVE.

THESE SEATS COME WITH SPRINGS

THAT CLIP ON
TO THEIR METAL FRAMEWORK

TO PROVIDE LUMBAR SUPPORT.

WORKERS FIT THE CUSHION ASSEMBLY
ONTO THE SPRING FRAMEWORK

AND PULL IT TIGHT.

THEY SMOOTH OUT ANY WRINKLES,
A PROCESS CALLED FINESSING.

THEN THEY INSTALL THE HEADREST.

NEXT THEY TACKLE
THE LOWER FRAMEWORK.

THEY EQUIP IT WITH A MECHANISM

THAT ADJUSTS
THE HEIGHT OF THE SEAT.

ELECTRICAL CONNECTORS
GO IN NEXT.

THEN THEY BOLT
THE LOWER FRAMEWORK

TO THE CUSHIONED BACKREST.

THEY ATTACH
THE PRETENSIONER APPARATUS,

WHICH LOCKS THE SEAT BELT
INTO POSITION,

THEN WIRE THE CONNECTOR BOX.

THEY FIT THE LOWER CUSHIONING
ON THE FRAMEWORK

AND ADD THE RECLINER SPRING.

A PLASTIC VALANCE
MAKES IT ALL LOOK NEATER.

NOW IT'S TIME TO TAKE THIS
DRIVER'S SEAT FOR A TEST RUN.

INSPECTORS HOOK IT UP
TO A POWER SOURCE

AND MAKE SURE THE AIR BAG
AND SEAT WARMER ARE OPERATIONAL.

THEY IRON OUT ALL THE WRINKLES

BECAUSE THE AUTOMAKER
WILL REJECT ANY SEAT

THAT'S LESS THAN PERFECT.

THEN THEY SLIDE
AND TILT THE SEAT

TO MAKE SURE THE ADJUSTMENT
MECHANISMS ARE WORKING PROPERLY.

WORKERS ASSEMBLE THE REAR SEATS
USING THE SAME TECHNIQUES.

AGAIN, EACH OPERATOR
GETS EXACTLY 88 SECONDS

TO COMPLETE HIS OR HER JOB.

WHEN YOU ADD IT ALL UP,

AN ENTIRE SEAT SET TAKES
JUST 62 MINUTES TO ASSEMBLE.

BEFORE THEY SHIP
THE SEAT SET TO THE CAR FACTORY,

THEY SNAP A PHOTO
AS A PRODUCTION RECORD.

IT PROVES EACH SET
WAS IN PERFECT CONDITION

WHEN IT LEFT THE FACTORY.

NOW THESE SEATS
ARE READY TO HIT THE ROAD.

WORKERS STRAP THEM
ONTO DELIVERY PALLETS

AND LOAD THEM INTO A BIG TRUCK,
60 SETS AT A TIME.

THEY'LL ARRIVE AT THE CAR PLANT

JUST AS THE VEHICLES
THEY WERE MADE FOR

ARE ROLLING OFF
THE ASSEMBLY LINE.

ONCE THEY'RE INSTALLED,

ALL YOU NEED TO DO
IS SIT BACK AND ENJOY THE RIDE.

NEXT, MAKING THE TUBES
THAT BRING TVs TO LIFE.

Narrator: THE CRT,
SHORT FOR CATHODE-RAY TUBE,

PRODUCES THE IMAGE THAT WE SEE

ON OUR TVs
AND COMPUTER MONITORS --

THE ONES THAT AREN'T
LCD OR PLASMA, THAT IS.

BELIEVE IT OR NOT,

THE CATHODE-RAY TUBE
WAS INVENTED BACK IN 1879.

A CRT IS MADE UP
OF TWO MAIN COMPONENTS,

A LARGE GLASS BULB
AND AN ELECTRIC GUN.

CRTs START
WITH A MOLDED GLASS BULB.

WORKERS REMOVE
MICROSCOPIC DEBRIS

WITH A HIGH-PRESSURE
WATER RINSE.

THEN THEY SPRAY
HYDROFLUORIC ACID

TO CLEAN THE GLASS
AT AN ATOMIC LEVEL.

PHOSPHOR SOLUTION
IS POURED INTO THE BULB.

PHOSPHOR IS AN ORGANIC COMPOUND
THAT EMITS LIGHT

WHEN STRUCK BY ELECTRONS.

THE PHOSPHOR PARTICLES SETTLE

AND FORM A CHEMICAL BOND
WITH THE BULB FACE.

WORKERS POUR OFF
THE EXCESS SOLUTION...

AND CLAMP THE BULB OVER A NOZZLE

THAT SPRAYS CLEAR LACQUER
OVER THE PHOSPHOR.

THE CENTRIFUGAL FORCE
GUARANTEES AN EVEN COAT.

THIS WORKER PAINTS A CONDUCTIVE
COATING OVER THE ANODE BUTTON

WHICH WILL PROVIDE A FLOW PATH
FOR THE ELECTRONS

THAT WILL LIGHT UP
THE PHOSPHOR PARTICLES.

MEANWHILE, ANOTHER WORKER
DROPS AN ALUMINUM PELLET

INTO A TUNGSTEN COIL.

HE PLACES THE BULB OVER A VACUUM
DEVICE AND DRAWS OUT THE AIR.

THEN HE APPLIES AN ELECTRICAL
CURRENT TO THE COIL.

IT EVAPORATES
THE ALUMINUM PELLET,

WHICH SPREADS
A MIRRORLIKE COATING

ON THE INSIDE OF THE BULB.

NOW THEY HEAT THE BULB TO 425
DEGREES FAHRENHEIT FOR ONE HOUR.

THIS BAKES OUT THE LACQUER
AND ANY TRACE OF MOISTURE.

USING A HIGH-TEMPERATURE FLAME,

A WORKER ALIGNS AND FUSES
A GLASS NECK TO THE BULB.

THEN HE PAINTS IT WITH THE SAME
CONDUCTIVE COATING.

THIS ASSEMBLY
IS PART OF THE ELECTRON GUN

THAT GOES INSIDE THE BULB.

IT SHOOTS ELECTRONS
AT THE BULB'S PHOSPHOR PARTICLES

THAT LIGHTS THEM UP,

CREATING THE IMAGE
WE SEE ON SCREEN.

WORKERS STACK THE GRIP CUPS

THAT FOCUS THE ELECTRONS
ON THE SCREEN.

THEN, USING BEADING GLASS,

THEY ALIGN AND FUSE THEM
INTO POSITION.

ROBOTS HEAT
AND AFFIX THE BEADING GLASS

TO ASSEMBLE
THE ELECTRON-GUN COMPONENTS.

THEN THE GUN IS COOLED
WITH PRESSURIZED AIR.

ONCE COOL,
A WORKER BUILDS UP THE GUN

AND INSERTS THE COMPLETED GUN
ASSEMBLY INTO THE BULB.

NEXT HE POSITIONS THE BULB
ON A GLASS-BLOWING LATHE

AND CUTS EXCESS GLASS
FROM THE NECK.

USING A GRAPHITE PADDLE
AND A HIGH-TEMPERATURE TORCH,

HE MATES THE GLASS NECK
TO THE ELECTRON-GUN STEM.

THIS CERAMIC HEATING COIL
MELTS THAT GREEN GLASS PELLET

TO KEEP THE BULB UNDER VACUUM.

THE TUBE IS HEATED
TO 750 DEGREES FAHRENHEIT

FOR TWO HOURS, AND ONCE AGAIN
A VACUUM IS DRAWN.

TO MINIMIZE IMAGE FLICKER
OVER THE TUBE'S LIFE-SPAN,

WORKERS CONDITION THE BULB
USING A HIGH-VOLTAGE COIL.

IT SMOOTHES ANY ROUGH SURFACES

THAT MIGHT REMAIN
ON THE ELECTRON GUN.

FINALLY, WORKERS APPLY
ELECTRICAL CONNECTIONS

TO THE ELECTRON GUN TO BRING
THE CATHODE-RAY TUBE TO LIFE.

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ABOUT THE SHOW,

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