Original subtitles

--Captions by VITAC-- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

Narrator: ALLIGATOR BAGS ENJOYED THEIR FIRST WAVE OF POPULARITY

AT THE END OF THE 19th CENTURY.

THE MATERIAL WAS CHOSEN FOR ITS EXOTIC LOOK,

RICH TEXTURE, HIGH PLIABILITY, AND DURABILITY.

SINCE THEN, MANY LEGENDARY DESIGNER HANDBAGS

HAVE BEEN MADE WITH ALLIGATOR SKIN.

FOR SOME WOMEN,

A HANDBAG IS MORE THAN A PRACTICAL ACCESSORY.

IT'S ALSO A WAY TO EXPRESS THEIR PERSONAL STYLE.

DEPENDING ON THE BAG'S SIZE, SHAPE, AND DESIRED LOOK,

MANY EXOTIC ANIMAL SKINS CAN BE USED --

ALLIGATOR, LIZARD, PYTHON, OR OSTRICH.

THIS RED SKIN IS FROM THE NILE ALLIGATOR.

THE CUTTER MAINTAINS THE PATTERN IN PLACE WITH A WEIGHT.

HE CUTS OUT THE SHAPE OF THE BAG,

LEAVING A BORDER, CALLED A TURNING-IN,

ALL ALONG THE PATTERN.

THE SKIVING MACHINE

DELICATELY SHAVES THE BACK OF THE ALLIGATOR SKIN

TO MAKE IT THIN AND PLIABLE.

A POLISHING JACK CREATES A SHEEN.

A PLATING MACHINE APPLIES HEAT AND PRESSURE

TO REMOVE CREASES AND MAKE THE SKIN SHINY.

NOW IT IS PLACED ON A HOT PLATE FOR A FEW SECONDS

TO RAISE THE SKIN

AND CREATE WHAT IS CALLED FRENCH BOMBAY.

THEY BRUSH RUBBER CEMENT ON THE BACK OF THE SKIN

AND APPLY IT TO A THIN PIECE OF LEATHER CALLED A PLIVER.

THIS WILL KEEP THE BOMBAY FROM FLATTENING OVER TIME.

THEN HE CUTS OFF THE EXCESS SKIN,

CREATING A TURNING-IN.

THIS HEAVY PAPER AND FOAM WILL GO INSIDE THE BAG'S COVER

TO GIVE IT STRUCTURE AND A CUSHIONY FEEL.

HE REMOVES THE CENTER PART OF THE PAPER

TO HELP THE COVER FOLD EASILY.

HE USES A BONE FOLDER TO FOLD THE TURNING-IN OVER THE PAPER...

THEN CAREFULLY HAMMERS IT IN PLACE.

NOW HE'S MAKING THE SIDES, CALLED GUSSETS,

AND THE BOTTOM OF THE BAG.

HE APPLIES THIN MUSLIN

AND RUBS IT IN PLACE UNDER A PROTECTIVE PAPER.

BOTH GUSSETS ARE SEWN TO THE BAG'S BOTTOM

USING A VERY FINE NEEDLE.

THE STITCHES MUST BE AS DISCREET AS POSSIBLE.

THE BAG'S LINING IS MADE

OF SOFT LAMB LEATHER CALLED CABRETTA.

THE TOP HALF CONTAINS A MAGNETIC CIRCLE

WHICH SERVES TO CLOSE THE BAG.

THE BRAND'S NAMEPLATE IS ALSO ATTACHED TO THE LINING.

THE NAMEPLATE SITS INSIDE THE BAG

SO IT WILL ONLY BE VISIBLE WHEN THE BAG IS OPEN.

THE POCKETBOOK MAKER

DELICATELY GLUES THE LINING TO THE BOTTOM OF THE BAG.

HE FOLDS THE LEATHER OVER WITH THE BONE FOLDER

AND USES THE HAMMER

TO MAKE THE JUNCTURE AS THIN AS POSSIBLE.

SINCE THE COVERS ARE GLUED IN PLACE,

THERE ARE NO STITCHES VISIBLE

ON THE FRONT AND BACK OF THE BAG,

GIVING IT A MORE LUXURIOUS LOOK.

NOW HE SCRATCHES THE BORDER TO REMOVE THE SHEEN,

WHICH WILL HELP THE GLUE ADHERE TO THE LEATHER.

HE APPLIES THE BACK AND FRONT COVER TO THE LINING OF THE BAG,

MAKING SURE ALL THE COVERS LINE UP PERFECTLY.

THIS STEP IS ONLY PERFORMED

BY EXPERIENCED POCKETBOOK MAKERS,

AS IT IS CRUCIAL TO THE FINAL LOOK OF THE BAG.

ANYTHING LESS THAN PERFECT

WOULD LOOK LIKE A CHEAP IMITATION.

CUSTOM-COLORED PAINTS WILL FILL IN ANY GAPS

AND COVER ANY VARIATION IN THE LEATHER.

THEY FINISH BY POLISHING THE BAG,

USING A SMALL AMOUNT OF SHOE POLISH

AND A BUFFING CLOTH.

THEY MUST USE VERY LITTLE POLISH

TO AVOID BUILDUP IN THE GRAIN OF THE LEATHER.

THIS ALSO REMOVES ANY DIRT OR CEMENT.

IT TAKES ABOUT SEVEN HOURS TO MAKE AN ALLIGATOR BAG.

ALL THE TIME, EFFORT, AND MATERIALS

RESULT IN A STYLISH FASHION ACCESSORY

THAT'S MADE TO LAST FOR YEARS.

Narrator: LOCKERS ARE A FAMILIAR SIGHT

IN HIGH-SCHOOL CORRIDORS, GYM CHANGING ROOMS,

AND MANY WORKPLACES,

AND IN THE WORLD OF PROFESSIONAL SPORTS,

LOCKERS ARE THE BACKDROP TO MANY A POST-GAME INTERVIEW.

THE LATEST TREND IS BUYING LOCKERS FOR KIDS' BEDROOMS

AS COOL AND PRACTICAL STORAGE FURNITURE.

WHILE THEY VARY IN SIZE AND DESIGN,

ALL LOCKERS HAVE VENTILATION HOLES.

THESE HELP AIR CIRCULATE, WHICH PREVENTS ODORS.

LOCKERS ARE MADE OF A HARD TYPE OF STEEL

THAT'S JUST FLEXIBLE ENOUGH

FOR PRESSES TO BEND TO THE REQUIRED SHAPE.

THE STEEL SHEETS ARE 1/10 OF AN INCH THICK.

WORKERS FEED ONE AT A TIME

THROUGH A CUTTING TOOL CALLED A SQUARE SHEAR.

IT SLICES FROM ONE END OF THE SHEET TO THE OTHER,

CUTTING PIECES WITH THE REQUIRED WIDTH.

EACH DOOR PIECE GOES INTO A 100-TON PUNCH PRESS,

WHICH STAMPS OUT THE VENTILATION HOLES.

THE NEXT PRESS PUNCHES SCREW AND RIVET HOLES AROUND THE EDGES

AND A HOLE FOR THE CUP THAT HOUSES THE LOCKER'S CLOSURE.

THE FIRST BENDING PRESS

SIMULTANEOUSLY FOLDS OVER THE TOP AND BOTTOM EDGES,

FORMING FLANGES.

THIS BEND SETS THE FINISHED HEIGHT OF THE DOOR.

THE NEXT BEND SETS THE FINISHED WIDTHOF THE DOOR.

THE PRESS FOLDS THE SIDE EDGES OVER TWICE,

FORMING A BOX-SHAPED RIM.

NEXT, WORKERS POSITION A STEEL REINFORCEMENT PANEL

AGAINST THE HINGE SIDE OF THE DOOR.

THEY AFFIX ONE SIDE OF THE PANEL

USING A WELDING MACHINE THAT FUSES 12 SPOTS SIMULTANEOUSLY.

THEN THEY WELD THE OTHER SIDE MANUALLY.

NOW THEY MOUNT THE DOOR IN AN ALIGNMENT FIXTURE

HINGE-SIDE UP

AND CLAMP A PIANO HINGE TO THE EDGE.

THEY FUSE THE HINGE TO THE DOOR

BY WELDING IT TO THE TOP ROW OF SCREW HOLES.

MEANWHILE, THEY BEND PIECES OF STEEL

TO FORM THE LOCKER'S TOP, BOTTOM, BACK, AND SIDES.

NOW THEY WELD THOSE PARTS TOGETHER.

THEN THEY WELD THE HASP,

THE STEEL LOOP THROUGH WHICH YOU HOOK A PADLOCK

TO LOCK THE LOCKER.

THE HASP GOES ON THE EDGE OF THE BODY

AND PROTRUDES THROUGH A SLOT IN THE CLOSURE CUP IN THE DOOR.

NEXT, THE LOCKER'S INTERIOR SHELF.

THEY SET FOUR RIVETS ONTO A POSITIONING FIXTURE --

TWO IN THE CENTER, TWO ON THE EDGE --

THEN POSITION THE SHELF ON TOP,

ALIGNING THE SHELF'S FOUR HOLES WITH THE FOUR RIVETS.

THEY POSITION A SINGLE HOOK OVER EACH EDGE RIVET

AND WELD IT ON.

THEN THEY TAKE A DOUBLE HOOK

AND POSITION IT OVER THE TWO CENTER RIVETS...

THEN WELD THAT ON.

THEN THEY WELD THE SHELF INTO THE LOCKER BODY.

ALL THE PARTS NOW HEAD INTO THE FACTORY'S PAINT SHOP.

THE POWDER PAINT THEY USE FOR THIS MODEL

CONTAINS ELECTRICALLY CHARGED SILVER PARTICLES --

A NATURAL DISINFECTANT

THAT KILLS ANY BACTERIA, VIRUSES, AND FUNGI

ON THE LOCKER'S SURFACE.

ONCE COATED, THE PARTS GO INTO AN OVEN FOR A HALF-HOUR

TO BAKE THE PAINT.

THEN FINAL ASSEMBLY BEGINS.

FIRST, WORKERS MOUNT THE CLOSURE CUP AND THE DOOR HOLE

WITH A SCREW AND A RETAINING WASHER.

NEXT, THEY INSTALL MAGNET CATCHES

TO HOLD THE DOOR CLOSED...

AND APPLY AN ADHESIVE STICKER

INDICATING THIS LOCKER HAS AN ANTIMICROBIAL PAINT COATING.

THEN THEY ATTACH THE DOOR TO THE BODY

BY DRIVING RIVETS THROUGH THE LOWER ROW OF HOLES

ON THE PIANO HINGE.

THEY MAKE SURE THE DOOR MOVES SMOOTHLY

AND THAT THE HASP ALIGNS WITH THE SLOT IN THE CUP.

THE FACTORY MAKES LOCKERS

OF VARIOUS SIZES, SHAPES, AND CONFIGURATIONS.

SOME MODELS EVEN HAVE BUILT-IN COMBINATION LOCKS.

Narrator: SINCE ROMAN TIMES, WOODWORKING PLANES

HAVE BEEN PART OF THE CARPENTER'S TOOL KIT.

AND DESPITE THE INVENTION OF POWER TOOLS FOR WOOD SURFACING,

MANY STILL PREFER THE HANDS-ON APPROACH OF THIS SIMPLE TOOL.

USING IT IS A SKILL

THAT CAN TAKE A PIECE OF TIMBER FROM ROUGH TO REFINED.

IF WOOD NEEDS SHAPING,

IT'S TIME TO REACH FOR THE BENCH PLANE.

ON THE PUSH STROKE,

IT SHAVES DOWN BUMPS AND HIGH SPOTS ON WOOD

TO MAKE THE SURFACE LEVEL AND TRUE.

PRODUCTION BEGINS WITH BENCH-PLANE PATTERNS.

THEY PLACE SEVERAL IN A BOX

AND POUR FINE SAND, MIXED WITH A BONDING CHEMICAL, OVER THEM.

THE BONDING CHEMICAL SOLIDIFIES THE SAND.

THEY POKE HOLES TO VENT GASES LATER ON.

AND WITH THE PATTERNS REMOVED,

IT'S CLEAR THAT THE BONDING CHEMICAL HAS WORKED ITS MAGIC.

THE PATTERNS HAVE LEFT A DEFINITE IMPRESSION

IN THE HARDENED SAND.

THEY APPLY GLUE TO ONE HALF OF THE MOLD

SO IT ADHERES TO THE HALF WITH THE IMPRESSIONS IN IT.

THEY THEN GLUE TWO SQUARE-SHAPED SPOUTS

AROUND HOLES IN THE SAND MOLD.

NEXT, THEY FIRE UP THE FOUNDRY FURNACE

AND MELT IRON INTO A WHITE-HOT LIQUID.

WORKERS THEN CAREFULLY POUR THE MOLTEN METAL

DOWN THE SQUARE SPOUTS AND INTO THE SAND MOLDS.

GASES ARE RELEASED THROUGH THE HOLES POKED IN THE SAND EARLIER,

WHILE WEIGHTS KEEP THE LIDS FROM LIFTING FROM THE PRESSURE.

AFTER A TWO-HOUR COOLDOWN,

THEY BREAK THE MOLDS AND PICK OUT THE CAST-IRON PARTS.

THE PLANES HAVE A KNOBBY PROTUBERANCE,

FORMED AS METAL FLOWED INTO THE MOLD.

THEY SLICE THAT OFF.

AND AFTER STRENGTHENING THE CAST IRON'S PHYSICAL PROPERTIES,

THEY MILL THE BOTTOM OF THE BENCH PLANE

TO MAKE IT REASONABLY FLAT.

THEY ALSO EXPOSE A SLIT FORMED DURING MOLDING.

THEY NOW LOCK THE BENCH PLANE IN POSITION

TO ALLOW THE SPIKED TEETH OF A CUTTING WHEEL

TO CARVE INTO THE MOLDED SLIT.

IT ENLARGES THE SLIT TO FORM THE MOUTH OF THE BENCH PLANE,

THE OPENING THROUGH WHICH THE PLANE'S BLADE WILL PROTRUDE.

SOME PRECISION WORK IS NEEDED,

SO A TAPERED AND SERRATED TOOL IS FORCED THROUGH THE MOUTH.

THIS OPENS IT UP A LITTLE MORE

TO GIVE IT THE EXACT DIMENSIONS REQUIRED.

COOLANT NOW FLOWS TO PREVENT OVERHEATING,

AS A GRINDING WHEEL MACHINES THE BASE OF EACH BENCH PLANE

UNTIL IT'S COMPLETELY FLAT.

THEY NOW TRY TO SLIP A VERY THIN STEEL STRIP

BETWEEN A LEVEL BAR AND THE BASE OF THE BENCH PLANE.

FAILURE CONFIRMS IT'S PERFECTLY FLAT.

NEXT, A CUTTING TOOL EVENS A SLOPED PAD

MOLDED ONTO THE FRONT OF THE BENCH PLANE.

THIS PAD, CALLED THE FROG, WILL HOLD THE SLIDING WEDGE

THAT SETS THE ANGLE OF THE PLANE BLADE.

PRODUCTION NOW FOCUSES ON THE BLADE.

THEY HEAT A STEEL ROD IN A FURNACE

UNTIL IT'S WHITE-HOT AND MALLEABLE.

THEY THEN PLACE IT UNDER A MECHANIZED HAMMER

WHICH POUNDS IT UNTIL IT'S FLAT.

THEY TURN THE FLATTENED STEEL SIDEWAYS,

AND THE PULSATING HAMMER SQUARES THE EDGES.

THEN ANOTHER TOOL STAMPS THE COMPANY'S INSIGNIA

ONTO ONE END OF THE BLADE.

THE STEEL ROD HAS BEEN FLATTENED, SQUARED, AND STAMPED.

IT'S THEN CUT TO THE DESIRED SHAPE AND DIMENSIONS

AND GIVEN A BEVELED CUTTING EDGE.

THE NEXT PART IS CALLED A LEVER CAP,

AND IT WILL BE USED TO CLAMP THE BLADE TO THE BENCH-PLANE FROG.

THEY SAND IT SMOOTH TO IMPROVE ITS LOOK AND FUNCTION.

THEY THEN BUFF EACH PART OF THE BENCH PLANE

AGAINST A CLOTH WHEEL TO A MIRROR-LIKE FINISH.

IT'S NOW TIME TO FIT THE BENCH-PLANE FROG

INTO THE PAD MACHINED ESPECIALLY FOR IT.

THEY SECURE IT WITH SCREWS.

THE CUTTING BLADE,

BY NOW REINFORCED BY A PART CALLED THE CAP IRON,

FITS FLUSH TO THE FROG.

THEY TOP OFF THE ASSEMBLY WITH A LEVER CAP

AND CLAMP IT ALL TOGETHER WITH A SPRING SYSTEM.

THEY FIT A KNOB MADE OF TROPICAL WOOD

ON A THREADED ROD ON THE FRONT OF THE BENCH PLANE.

THE KNOB AND THE BACK HANDLE WILL ALLOW THE USER

TO FIRMLY GRIP THE BENCH PLANE AND PUSH IT FORWARD.

AND WITH THE BLADE NOW PROTRUDING

FROM THE BASE ON AN ANGLE,

IT'S READY TO LEVEL ANY PIECE OF WOOD,

LEAVING ONLY SHAVINGS IN ITS WAKE.

Narrator: A FLIGHT DATA RECORDER,

OR A BLACK BOX,

RECORDS EVERY DETAIL OF AN AIRCRAFT'S OPERATIONS,

FROM ENGINE SPEED TO CABIN PRESSURE.

AFTER A CRASH, INVESTIGATORS EXTRACT THE DATA

TO DETERMINE WHAT WENT WRONG.

BLACK BOXES ARE ACTUALLY BRIGHT ORANGE

SO THEY'LL STAND OUT AMID THE WRECKAGE.

THESE BLACK BOXES ARE THE DEPLOYABLE TYPE,

MEANING THEY SEPARATE FROM THE AIRCRAFT UPON IMPACT.

THIS MAKES THEM EASIER

FOR SEARCH-AND-RESCUE CREWS TO RECOVER.

TO MAKE THE OUTER SHELL THAT HOUSES THE COMPONENTS,

THEY USE A TWO-PART MOLD,

FIRST WAXING IT TO EASE EXTRACTION LATER ON.

THEN THEY BRUSH ON AN ORANGE-TINTED GEL COAT,

A LIQUID THAT, AFTER FOUR HOURS,

HARDENS INTO A DURABLE, WATERPROOF FINISH.

OVER THE HARDENED GEL COAT,

THEY APPLY PIECES OF FIBERGLASS CLOTH,

SATURATING THEM WITH ORANGE-TINTED RESIN.

THEY APPLY EXTRA PIECES IN THE CORNERS FOR REINFORCEMENT.

THEY CONTINUE UNTIL THEY'VE BUILT UP

THREE LAYERS OF FIBERGLASS.

THE RECTANGULAR BOX ON THIS MOLD HALF-CASTS A CAVITY IN THE SHELL

THAT WILL HOUSE THE DEVICE'S KEY COMPONENTS.

THEY EMBED ALUMINUM PLATES WITHIN THE FIBERGLASS

TO REINFORCE THE AREA

WHERE SCREWS WILL ATTACH THE CAVITY COVER.

A COMPUTER-GUIDED MILLING MACHINE

CONTOURS A PIECE OF FOAM

THAT WILL FIT THE EMPTY SPACE INSIDE THE SHELL.

THIS FOAM ABSORBS THE FORCE OF IMPACT

SO THE FLIGHT DATA RECORDER CAN SURVIVE A CRASH.

THEY COAT ONE SIDE OF THE FOAM CORE WITH RESIN PASTE,

THEN LAY IT INTO THE MOLD.

THEY FILL VOIDS WITH A TEMPORARY RETAINING BLOCK

TO PREVENT THE FOAM CORE FROM COLLAPSING INWARD

DURING THE VACUUM PROCESS THAT COMES NEXT.

THEY WRAP THE MOLD IN FELT TO PROTECT THE SURFACE,

PUT IT IN A PLASTIC BAG, ATTACH A HOSE,

THEN START THE SUCTION.

OVER FOUR HOURS, THE VACUUM SLOWLY EXTRACTS THE AIR,

DRAWING THE FIBERGLASS TIGHTLY AGAINST THE FOAM CORE

WITHOUT ANY WRINKLES OR PUCKERS.

IT TAKES ANOTHER FOUR HOURS FOR THE RESIN TO COMPLETELY CURE.

THEN THEY REMOVE THE MOLD FROM THE VACUUM BAG,

COAT THE OTHER SIDE OF THE FOAM CORE WITH RESIN PASTE,

AND EMBED STEEL REINFORCEMENTS.

BESIDES ABSORBING THE FORCE OF IMPACT,

THE FOAM CORE MAKES THE FLIGHT DATA RECORDER BUOYANT

SHOULD THE AIRCRAFT GO DOWN IN A BODY OF WATER.

THE DEVICE CONTAINS TWO ANTENNAS,

THE FIRST OF WHICH GETS PASTED

INTO A DESIGNATED SPOT IN THE FOAM CORE.

ONE ANTENNA TRANSMITS A DISTRESS SIGNAL,

THE OTHER A HOMING SIGNAL

TO HELP SEARCH-AND-RESCUE CREWS LOCATE THE DOWNED AIRCRAFT.

NOW THEY MATE THE TWO PARTS OF THE MOLD,

CAREFULLY SLIDING THE ANTENNA THAT PROTRUDES FROM ONE HALF

THROUGH AND OUT AN OPENING IN THE OTHER HALF.

THEY BOLT THE MOLD CLOSED

AND LEAVE THE PASTE TO AIR-CURE OVERNIGHT.

THE NEXT DAY, THEY UNBOLT THE MOLD AND EXTRACT THE SHELL,

THE TWO HALVES OF WHICH ARE NOW BONDED

WITH THE FIRST ANTENNA INSIDE.

NOW THEY CAN INSTALL THE OTHER COMPONENTS,

SUCH AS THIS MEMORY MODULE CONTAINING THE CIRCUIT BOARDS

THAT RECORD THE FLIGHT DATA AND COCKPIT AUDIO.

ALL THE COMPONENTS, PRIOR TO INSTALLATION,

UNDERGO EXTENSIVE TESTING TO ENSURE THEY OPERATE PROPERLY

WHEN SUBJECTED TO VIBRATION AND EXTREME TEMPERATURES.

THE MEMORY MODULE GOES INTO A FIREPROOF BOX,

ALONG WITH THE TRANSMITTER THAT SENDS OUT THE LOCATING SIGNAL

VIA THE ANTENNAS,

THE SECOND OF WHICH THEY NOW INSTALL

INTO THE COMPONENT CAVITY AT THE TOP OF THE BOX.

THEN THEY INSTALL THE BATTERY

THAT POWERS THE TRANSMITTER FOR 150 HOURS.

THEY CONNECT THE BATTERY TO THE TRANSMITTER

IN THE FIREPROOF BOX...

CONNECT THE TRANSMITTER TO THE ANTENNAS,

THEN SCREW THE COVER TO THE ALUMINUM PLATES

EMBEDDED AROUND THE CAVITY'S PERIMETER.

THE FINISHED DEVICE UNDERGOES A SERIES OF PERFORMANCE TESTS.

THIS ONE, IN A SPECIAL ECHO-FREE CHAMBER,

VERIFIES THE SIGNAL THE TRANSMITTER SENDS OUT

VIA THE ANTENNAS.

THE CHAMBER'S RECEIVING ANTENNA IS CONNECTED TO A COMPUTER

THAT ANALYZES THE SIGNAL'S FREQUENCY

AND TRANSMISSION PATTERN --

CRITICAL FACTORS IN RECOVERING THE BOX

THAT PROVIDES VITAL CLUES FOR CRASH INVESTIGATORS.

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