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--Captions by VITAC--
www.vitac.com
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00:00:23,310 --> 00:00:26,310
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:51,620 --> 00:00:53,758
Narrator: SURGICAL INSTRUMENTS
HAVE EVOLVED
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00:00:53,758 --> 00:00:55,172
WITH THE SCIENCE OF MEDICINE.
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THEY ACTUALLY DATE BACK
THOUSANDS OF YEARS,
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00:00:57,517 --> 00:00:59,724
WHEN PRIMITIVE MAN
USED CRUDE IMPLEMENTS
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00:00:59,724 --> 00:01:03,103
TO CUT HOLES IN SKULLS
TO RELEASE EVIL SPIRITS.
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00:01:03,103 --> 00:01:05,965
MEDICAL SCIENCE
HAS COME A LONG WAY SINCE THEN,
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00:01:05,965 --> 00:01:09,344
AND TODAY'S SURGICAL TOOLS
ARE AMONG ITS ADVANCEMENTS.
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00:01:11,620 --> 00:01:13,586
IN THE HANDS
OF A SKILLED SURGEON,
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00:01:13,586 --> 00:01:15,724
THE RIGHT TOOL
CAN BE A LIFESAVER.
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00:01:15,724 --> 00:01:18,034
THERE ARE NOW HUNDREDS
TO CHOOSE FROM,
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00:01:18,034 --> 00:01:22,137
EACH DESIGNED FOR
A SPECIFIC TASK OR OPERATION.
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00:01:22,137 --> 00:01:24,068
MADE OF SURGICAL-GRADE STEEL --
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00:01:24,068 --> 00:01:26,655
WHICH IS EXTREMELY
CORROSION-RESISTANT --
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00:01:26,655 --> 00:01:30,103
THEY CAN WITHSTAND FREQUENT
CLEANING AND STERILIZING.
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00:01:30,103 --> 00:01:33,655
ONE OF THE MORE USEFUL TOOLS
IS A SELF-RETAINING RETRACTOR,
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00:01:33,655 --> 00:01:36,413
WHICH IS USED TO PULL BACK
TISSUES OR ORGANS
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00:01:36,413 --> 00:01:38,000
DURING SURGERY.
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00:01:38,000 --> 00:01:39,827
USING A CIRCULAR CUTTER,
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00:01:39,827 --> 00:01:43,034
THEY ROUND
THE PROFILE OF THE TOOL'S JOINT.
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00:01:43,034 --> 00:01:45,551
THIS ROUND JOINT
ALLOWS THE TOOL TO OPEN
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00:01:45,551 --> 00:01:48,724
WHEN THE SHANKS ARE SHUT, THE
OPPOSITE OF A PAIR OF SCISSORS.
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00:01:48,724 --> 00:01:51,551
NEXT, CUTTERS CARVE SLOTS
IN TWO PARTS
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00:01:51,551 --> 00:01:54,724
TO CREATE THE RETRACTOR'S
INTERMESHING JAWS.
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00:01:54,724 --> 00:01:58,793
THESE JAWS WILL BE USED
TO GRASP AND RETRACT BODY TISSUE
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00:01:58,793 --> 00:02:00,862
SO THE SURGEON CAN OPERATE.
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00:02:00,862 --> 00:02:04,724
A TECHNICIAN SANDS THE TEETH
DOWN TO A PRECISE SIZE.
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00:02:04,724 --> 00:02:08,448
HE MUST BE ACCURATE WITHIN
A QUARTER OF A MILLIMETER.
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00:02:10,620 --> 00:02:14,517
HE THEN SMOOTHES THE JAW'S TEETH
AGAINST A FINE-GRIT WHEEL
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00:02:14,517 --> 00:02:17,586
SO THEY'LL EASILY INTERMESH
WHEN NEEDED.
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HE ROUNDS THE TIPS OF THE TEETH
TO MAKE THEM BLUNT
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00:02:21,103 --> 00:02:23,275
SO THEY WON'T DAMAGE
HUMAN TISSUE.
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00:02:23,275 --> 00:02:25,551
HE HAMMERS BACK
THE TIPS OF THE TEETH,
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00:02:25,551 --> 00:02:28,000
GIVING THEM A CLAW-LIKE PROFILE.
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00:02:30,172 --> 00:02:31,862
WITH THE TEETH NOW COMPLETE,
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ATTENTION RETURNS TO THE ROUND
JOINT OF THE INSTRUMENT.
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THE CARVED SLOTS
AND COUNTER-SYNC
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ALLOW THE TWO SIDES
TO FIT TOGETHER PERFECTLY.
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THEY INSTALL A PART CALLED
THE RACK, BELOW THE JOINT,
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00:02:43,758 --> 00:02:45,896
AND FILE TEETH INTO IT.
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00:02:45,896 --> 00:02:49,241
IT WILL BE USED TO LOCK THE TOOL
IN AN OPEN POSITION.
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00:02:49,241 --> 00:02:50,620
AFTER HEAT TREATMENT,
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00:02:50,620 --> 00:02:53,034
A WORKER SANDS
ALL THE TOOL COMPONENTS
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00:02:53,034 --> 00:02:55,482
TO SMOOTH SHARP EDGES.
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00:02:58,965 --> 00:03:02,000
VIBRATING PORCELAIN CHIPS
AND POLISHING COMPOUND
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00:03:02,000 --> 00:03:06,517
SCRUB THEM CLEAN AND REMOVE
BURRS CAUSED BY MACHINING.
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00:03:06,517 --> 00:03:10,103
NEXT, THEY INSTALL THE PIVOT
SCREW AND TRIGGER FOR THE RACK.
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00:03:10,103 --> 00:03:11,448
BY PRESSING IT,
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00:03:11,448 --> 00:03:15,103
THE SURGEON CAN OPEN THE PRONGS
TO THE DESIRED WIDTH
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00:03:15,103 --> 00:03:17,689
AND LOCK THE TOOL IN POSITION.
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00:03:19,689 --> 00:03:22,620
PRODUCTION NOW MOVES
TO THE SURGICAL CLAMP.
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00:03:22,620 --> 00:03:25,724
IT'S USED TO BLOCK THE FLOW
OF BLOOD DURING OPERATIONS
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00:03:25,724 --> 00:03:28,068
AND HAS
A MORE SCISSORS-LIKE JOINT --
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00:03:28,068 --> 00:03:30,379
RECTANGULAR INSTEAD OF ROUND.
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00:03:30,379 --> 00:03:34,862
MECHANIZED CUTTERS
CARVE THE JOINT AND CATCHES.
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A WORKER FORCES THE FINGER BOWS
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00:03:36,758 --> 00:03:38,931
AGAINST
A SPINNING GRINDING WHEEL
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00:03:38,931 --> 00:03:41,896
TO REMOVE SURFACE IMPERFECTIONS.
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00:03:43,862 --> 00:03:46,172
PRECISION IS AGAIN CRITICAL,
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00:03:46,172 --> 00:03:49,068
AS THE WORKER GRINDS
EACH OF THE TOOL'S SHANKS
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00:03:49,068 --> 00:03:50,655
TO THE CORRECT THICKNESS.
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00:03:50,655 --> 00:03:54,068
HE MEASURES TO CONFIRM
THAT THE SIZE IS CONSISTENT
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00:03:54,068 --> 00:03:55,586
ALONG THE LENGTH OF THE PART.
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00:03:55,586 --> 00:04:00,344
HE THEN FILES THE JOINTS
SO THEY MATE PERFECTLY.
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00:04:03,172 --> 00:04:07,137
HE PLACES THE JOINT PART OF
ONE OF THE SHANKS OVER HOT COALS
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00:04:07,137 --> 00:04:10,517
TO SOFTEN THE METAL
AND MAKE IT MALLEABLE.
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00:04:10,517 --> 00:04:14,000
THEN HE FORCES A SPIKE
THROUGH A SLIT IN THE JOINT,
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00:04:14,000 --> 00:04:18,206
AND THE NOW-COMPLIANT STEEL
STRETCHES TO OPEN THE SLIT.
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00:04:18,206 --> 00:04:21,206
THE OTHER SHANK NOW SLIDES
EASILY INTO THE OPENING.
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00:04:21,206 --> 00:04:23,862
HE HAMMERS THE JOINT
TO CLOSE THE OPENING,
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00:04:23,862 --> 00:04:26,310
AND THE TWO ARMS
OF THIS SURGICAL CLAMP
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00:04:26,310 --> 00:04:28,206
ARE NOW HINGED TOGETHER.
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NEXT HE FILES
THE TEETH OF THE CLAMP
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SO THEY'LL INTERLOCK
WHEN THE TOOL IS CLOSED.
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00:04:40,068 --> 00:04:42,655
HE BENDS THE TWO ENDS
AROUND A TOOL
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00:04:42,655 --> 00:04:45,103
TO FORM THE JAWS OF THE CLAMP.
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00:04:45,103 --> 00:04:47,551
THESE CURVED JAWS
WILL COME IN HANDY
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00:04:47,551 --> 00:04:50,965
WHEN THE SURGEON NEEDS TO REACH
AROUND ORGANS OR BONE.
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00:04:50,965 --> 00:04:54,103
NEXT, USING A VARIETY OF TOOLS,
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00:04:54,103 --> 00:04:56,586
HE ADJUSTS
THE SHANKS AND THE FINGER BOWS
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00:04:56,586 --> 00:04:58,758
TO GIVE THEM
A MORE ERGONOMIC FEEL.
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00:04:58,758 --> 00:05:02,379
THIS IS CALLED SOFT-SETTING
BECAUSE AT THIS POINT,
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00:05:02,379 --> 00:05:06,206
THE METAL IS STILL
SOFT ENOUGH TO BE MANIPULATED.
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00:05:06,206 --> 00:05:08,586
HE TWEAKS THE BEND OF THE JAWS
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00:05:08,586 --> 00:05:11,103
UNTIL HE'S SATISFIED
WITH THE CURVATURE.
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00:05:12,689 --> 00:05:15,310
HE SMOOTHES
THE INSIDE OF THE FINGER BOWS
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00:05:15,310 --> 00:05:17,482
WITH A FINE ABRASIVE BELT.
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00:05:17,482 --> 00:05:20,034
AFTER HEAT TREATMENT
TO STRENGTHEN THE METAL,
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00:05:20,034 --> 00:05:22,793
THEY BLAST IT
WITH FINE GLASS PARTICLES
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00:05:22,793 --> 00:05:24,620
TO GIVE IT A SATIN FINISH.
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00:05:24,620 --> 00:05:28,206
THEY LASER-ETCH THE COMPANY NAME
AND IDENTIFYING NUMBERS
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00:05:28,206 --> 00:05:29,827
ONTO THE SURGICAL CLAMP.
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00:05:29,827 --> 00:05:32,103
THE NUMBERS
WILL ALLOW THE TOOL TO BE TRACED
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00:05:32,103 --> 00:05:34,655
BACK TO A PARTICULAR
PRODUCTION RUN.
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00:05:34,655 --> 00:05:37,241
AND NOW IT'S READY
TO TAKE ITS PLACE
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00:05:37,241 --> 00:05:39,517
ON THE FRONT LINES
OF HEALTHCARE.
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Narrator:
KETCHUP HAS A QUESTIONABLE PAST.
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00:05:53,310 --> 00:05:54,689
ACCORDING TO ONE THEORY,
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00:05:54,689 --> 00:05:58,172
IT COMES FROM THE CHINESE
"Kê-CHIAP," A TYPE OF SAUCE.
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00:05:58,172 --> 00:06:01,068
ANOTHER THEORY TRACES IT
TO EUROPEAN PICKLING SAUCES,
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00:06:01,068 --> 00:06:03,413
AND YET ANOTHER
CLAIMS ARABIC ORIGINS.
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00:06:03,413 --> 00:06:06,448
BUT THERE'S WIDESPREAD AGREEMENT
ON WHERE IT ENDS UP --
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00:06:06,448 --> 00:06:09,896
ON HOT DOGS, HAMBURGERS,
AND FRENCH FRIES.
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00:06:12,586 --> 00:06:16,275
TOMATO KETCHUP RECIPES
VARY ONLY SLIGHTLY,
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00:06:16,275 --> 00:06:19,896
AS CONSUMERS EXPECT A CERTAIN
FAMILIAR TOMATOEY TASTE.
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00:06:19,896 --> 00:06:22,344
THIS U.S. COMPANY PRODUCES
ALL-NATURAL KETCHUP
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MADE ENTIRELY OF CERTIFIED
ORGANIC INGREDIENTS --
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00:06:26,344 --> 00:06:30,586
TOMATO PASTE, AGAVE NECTAR --
A NATURAL SWEETENER --
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00:06:30,586 --> 00:06:35,206
ONION POWDER, SPICES,
SALT, AND WHITE VINEGAR.
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00:06:37,068 --> 00:06:39,379
THE TOMATO PASTE,
NOT SURPRISINGLY,
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00:06:39,379 --> 00:06:41,137
IS THE BASE INGREDIENT.
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00:06:41,137 --> 00:06:44,517
IT ARRIVES AT THE PLANT
IN HUGE BINS,
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00:06:44,517 --> 00:06:48,310
WHICH HAVE BEEN VACUUM-PACKED
TO PRESERVE FRESHNESS.
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00:06:48,310 --> 00:06:50,758
AFTER UNSEALING EACH BIN,
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00:06:50,758 --> 00:06:53,137
THE FACTORY'S
QUALITY-CONTROL TECHNICIAN
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00:06:53,137 --> 00:06:55,241
SCOOPS A SAMPLE FOR TESTING.
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00:06:55,241 --> 00:06:58,137
THIS IS TO MAKE SURE THAT
THE THICKNESS IS JUST RIGHT.
119
00:06:58,137 --> 00:07:00,275
IF THE SAMPLE GETS THE OKAY,
120
00:07:00,275 --> 00:07:04,379
WORKERS SLIDE THE BIN UNDER
A POWERFUL AIR-DRIVEN PUMP.
121
00:07:10,586 --> 00:07:12,103
THEN THEY FLIP A SWITCH,
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00:07:12,103 --> 00:07:14,758
AND THE PUMP
BEGINS MOVING THE TOMATO PASTE
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00:07:14,758 --> 00:07:16,275
TO A LARGE HOLDING TANK,
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00:07:16,275 --> 00:07:19,793
TRANSFERRING NEARLY 310 POUNDS
OF THIS KETCHUP BASE
125
00:07:19,793 --> 00:07:21,931
IN LESS THAN 10 MINUTES.
126
00:07:30,517 --> 00:07:34,172
AT PRODUCTION TIME,
AN INTRICATE SYSTEM OF PIPING
127
00:07:34,172 --> 00:07:37,068
TRANSFERS A SPECIFIC AMOUNT
OF TOMATO PASTE
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00:07:37,068 --> 00:07:40,275
FROM THE HOLDING TANK
INTO A COOKING KETTLE.
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00:07:40,275 --> 00:07:44,517
AS THE PASTE COOKS,
A MIXER CONTINUOUSLY REVOLVES
130
00:07:44,517 --> 00:07:46,862
TO KEEP IT
FROM STICKING TO THE SIDES
131
00:07:46,862 --> 00:07:50,655
AND TO BLEND IN THE ONION POWDER
WORKERS ADD NEXT.
132
00:07:50,655 --> 00:07:52,448
THIS AND THE UPCOMING
INGREDIENTS
133
00:07:52,448 --> 00:07:53,896
HAVE BEEN PRE-MEASURED
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00:07:53,896 --> 00:07:56,793
TO BE IN CORRECT PROPORTION
TO THE BATCH SIZE.
135
00:07:58,275 --> 00:08:00,448
THE NEXT INGREDIENTS ARE SALT,
136
00:08:00,448 --> 00:08:04,724
THEN, AS A SUGAR REPLACEMENT,
NECTAR FROM THE AGAVE PLANT.
137
00:08:04,724 --> 00:08:07,275
THEY POUR IN AN INITIAL AMOUNT,
138
00:08:07,275 --> 00:08:10,655
MIX A BIT,
THEN PUMP IN THE REMAINDER.
139
00:08:16,517 --> 00:08:20,379
THE LAST INGREDIENT
IS WHITE VINEGAR.
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00:08:23,482 --> 00:08:26,275
FOR COMPETITIVE REASONS,
THE COMPANY WON'T DIVULGE
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00:08:26,275 --> 00:08:29,413
THE MIXING TIME, COOKING TIME,
OR COOKING TEMPERATURE,
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00:08:29,413 --> 00:08:34,689
ALL OF WHICH ARE KEY ELEMENTS
OF THIS TOP-SECRET RECIPE.
143
00:08:37,655 --> 00:08:39,103
ON THE PACKAGING LINE,
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00:08:39,103 --> 00:08:42,344
AN ALIGNMENT MACHINE STANDS
THE PLASTIC BOTTLES UPRIGHT
145
00:08:42,344 --> 00:08:45,793
AS THEY MAKE THEIR WAY
TO THE FILLING MACHINE.
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00:08:45,793 --> 00:08:48,931
THE FINISHED KETCHUP, MEANWHILE,
IS PASSING THROUGH
147
00:08:48,931 --> 00:08:52,655
AN ELABORATE SYSTEM OF COOLING
PIPES EN ROUTE TO THE FILLER.
148
00:08:52,655 --> 00:08:54,896
AND LET THE BOTTLING BEGIN.
149
00:08:58,103 --> 00:09:01,931
THE MACHINE FILLS
EIGHT BOTTLES AT A TIME...
150
00:09:03,758 --> 00:09:06,793
...150 BOTTLES PER MINUTE.
151
00:09:13,275 --> 00:09:16,655
THE FACTORY TESTS EVERY BATCH
OF KETCHUP IT PRODUCES
152
00:09:16,655 --> 00:09:20,000
TO ENSURE THE CORRECT
CONSISTENCY IN EVERY BOTTLE.
153
00:09:24,344 --> 00:09:27,344
THE NEXT MACHINE,
APPROPRIATELY CALLED THE CAPPER,
154
00:09:27,344 --> 00:09:30,344
PLACES A PLASTIC FLIP-CAP
ON EACH BOTTLE,
155
00:09:30,344 --> 00:09:35,034
THEN, WITH SPINNING CIRCULAR
BELTS, TWISTS IT ON SECURELY.
156
00:09:38,344 --> 00:09:40,206
THE NEXT MACHINE
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00:09:40,206 --> 00:09:42,793
CUTS A DECORATIVE NECK BAND
MADE OF PLASTIC FILM
158
00:09:42,793 --> 00:09:44,758
AND SLIPS IT OVER THE CAP.
159
00:09:51,758 --> 00:09:54,896
EACH BOTTLE
THEN PASSES UNDER AN AIR JET.
160
00:09:54,896 --> 00:09:57,931
THE AIR
BLOWS THE NECK BAND DOWNWARD
161
00:09:57,931 --> 00:10:00,896
UNTIL IT'S POSITIONED
UNDER THE CAP.
162
00:10:00,896 --> 00:10:05,172
THEN A QUICK BLAST OF HOT STEAM
SHRINKS THE BAND TO A TIGHT FIT.
163
00:10:10,551 --> 00:10:13,827
THE NEXT MACHINE PRESSES ON
TWO ADHESIVE LABELS --
164
00:10:13,827 --> 00:10:17,137
ONE ON THE FRONT OF THE BOTTLE,
THE OTHER ON THE BACK.
165
00:10:17,137 --> 00:10:21,379
THEN IT'S OFF TO
THE PACKING-AND-SHIPPING AREA.
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00:10:21,379 --> 00:10:25,103
A SEALED BOTTLE OF KETCHUP
STAYS FRESH FOR AT LEAST A YEAR
167
00:10:25,103 --> 00:10:28,448
BECAUSE THE VINEGAR IN IT
ACTS AS A NATURAL PRESERVATIVE.
168
00:10:28,448 --> 00:10:30,517
KETCHUP ALSO HAS HEALTH BENEFITS
169
00:10:30,517 --> 00:10:33,068
BECAUSE IT'S
CHOCK FULL OF TOMATOES,
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00:10:33,068 --> 00:10:36,206
WHICH ARE HIGH IN LYCOPENE --
A POWERFUL ANTIOXIDANT
171
00:10:36,206 --> 00:10:40,620
BELIEVED TO PROTECT
AGAINST MANY TYPES OF CANCER.
172
00:10:50,655 --> 00:10:53,413
Narrator: DOUBLE-DECKER BUSES
HAVE LONG BEEN A FIXTURE
173
00:10:53,413 --> 00:10:55,275
ON THE STREETS
OF LONDON, ENGLAND.
174
00:10:55,275 --> 00:10:56,724
A TYPICAL DOUBLE-DECKER
175
00:10:56,724 --> 00:11:00,241
CARRIES 60% MORE RIDERS
THAN A REGULAR BUS.
176
00:11:00,241 --> 00:11:02,206
AND THOUGH
QUINTESSENTIALLY BRITISH,
177
00:11:02,206 --> 00:11:05,379
NOWADAYS YOU'LL FIND
LONDON STYLE DOUBLE-DECKERS
178
00:11:05,379 --> 00:11:09,137
ON THE STREETS OF SEVERAL MAJOR
CITIES THROUGHOUT THE WORLD.
179
00:11:10,793 --> 00:11:14,413
EVERY BUS DESIGN UNDERGOES
RIGOROUS STABILITY TESTING.
180
00:11:14,413 --> 00:11:16,758
THEY FILL THE PROTOTYPE
WITH LEAD WEIGHTS
181
00:11:16,758 --> 00:11:19,137
TO SIMULATE
A FULL PASSENGER LOAD,
182
00:11:19,137 --> 00:11:22,379
THEN TIPS THE BUS
TO A 28-DEGREE ANGLE,
183
00:11:22,379 --> 00:11:25,068
THE SIDE WHEELS LIFTING ABOUT
SHOULDER HEIGHT OFF THE GROUND.
184
00:11:25,068 --> 00:11:27,172
IF THE VEHICLE
DOESN'T KEEL OVER,
185
00:11:27,172 --> 00:11:30,689
THE DESIGN PASSES THE TEST.
186
00:11:30,689 --> 00:11:33,034
THE BUS'S UNDERFRAME --
THE CHASSIS --
187
00:11:33,034 --> 00:11:35,482
IS MADE OF WELDED STEEL.
188
00:11:35,482 --> 00:11:37,931
THEY CONSTRUCT IT
IN THREE SEPARATE MODULES --
189
00:11:37,931 --> 00:11:39,827
FRONT, CENTER, AND REAR --
190
00:11:39,827 --> 00:11:42,206
THEN SET THE THREE MODULES
IN AN ALIGNMENT JIG
191
00:11:42,206 --> 00:11:44,000
TO BE WELDED TOGETHER.
192
00:11:44,000 --> 00:11:47,275
ONCE THAT'S DONE,
WELDERS ADD A STEEL STRUCTURE
193
00:11:47,275 --> 00:11:50,758
THAT'LL SUPPORT THE FLOORS,
SEATS, AND BODY PANELS.
194
00:11:50,758 --> 00:11:54,931
THEN THEY CLEAN THE CHASSIS AND
PAINT IT WITH ANTI-RUST EPOXY.
195
00:11:54,931 --> 00:11:56,689
AFTER BAKING ON THE PAINT,
196
00:11:56,689 --> 00:12:00,689
THEY SEAL THE GAPS BETWEEN THE
WELDED PARTS WITH POLYURETHANE.
197
00:12:00,689 --> 00:12:02,862
THIS PREVENTS WATER PENETRATION,
198
00:12:02,862 --> 00:12:05,448
WHICH WOULD CAUSE
INTERNAL CORROSION.
199
00:12:05,448 --> 00:12:07,620
MEANWHILE, TECHNICIANS BOLT
200
00:12:07,620 --> 00:12:10,827
THE 6-CYLINDER,
250-HORSEPOWER ENGINE
201
00:12:10,827 --> 00:12:12,862
TO THE AUTOMATIC TRANSMISSION
202
00:12:12,862 --> 00:12:16,241
AND CONNECT THE HYDRAULIC LINES
AND OTHER PIPING.
203
00:12:16,241 --> 00:12:20,689
THEN THEY WHEEL THIS ENGINE PACK
OVER TO THE ASSEMBLY LINE
204
00:12:20,689 --> 00:12:24,034
AND BOLT IT TO A BAR
AT THE REAR OF THE CHASSIS.
205
00:12:24,034 --> 00:12:27,310
BY SUSPENDING THE ENGINE, THEY
SHIELD IT FROM IMPACT DAMAGE
206
00:12:27,310 --> 00:12:30,068
IN THE EVENT
OF A REAR-END COLLISION.
207
00:12:30,068 --> 00:12:34,517
THEY ALSO INSTALL THE RADIATOR,
BATTERY, AND OTHER COMPONENTS.
208
00:12:38,655 --> 00:12:40,448
AT THE FRONT OF THE CHASSIS,
209
00:12:40,448 --> 00:12:42,586
THEY INSTALL
THE DRIVER'S BINNACLE --
210
00:12:42,586 --> 00:12:45,344
ON WHICH
ALL THE CONTROLS ARE LOCATED.
211
00:12:45,344 --> 00:12:47,551
UNLIKE A STATIONARY
CAR DASHBOARD,
212
00:12:47,551 --> 00:12:51,310
FOR DRIVER COMFORT, THE BINNACLE
TILTS WITH THE STEERING COLUMN.
213
00:12:51,310 --> 00:12:54,413
AFTER INSTALLING
THE FRONT AND REAR AXLES,
214
00:12:54,413 --> 00:12:56,379
TECHNICIANS MOUNT THE WHEELS.
215
00:12:56,379 --> 00:13:01,413
EACH ONE IS MORE THAN A YARD IN
DIAMETER AND WEIGHS 100 POUNDS.
216
00:13:01,413 --> 00:13:02,896
THE ENGINEERING SPECS
217
00:13:02,896 --> 00:13:05,620
REQUIRE THE WHEEL NUTS TO BE
TURNED TO A SPECIFIC TIGHTNESS.
218
00:13:05,620 --> 00:13:08,551
WORKERS ALSO INSTALL
THE DRIVER'S SEAT
219
00:13:08,551 --> 00:13:11,413
AND THE VEHICLE'S
73-GALLON GAS TANK.
220
00:13:11,413 --> 00:13:14,482
THE COMPLETE CHASSIS
GOES ONTO A TEST-DRIVE MACHINE
221
00:13:14,482 --> 00:13:16,896
WHICH SIMULATES
VARYING PASSENGER LOADS
222
00:13:16,896 --> 00:13:18,758
AND ROAD CONDITIONS.
223
00:13:18,758 --> 00:13:21,241
A CAMERA POINTED AT THE BINNACLE
224
00:13:21,241 --> 00:13:22,896
RECORDS THE ACCURACY
OF THE SPEEDOMETER
225
00:13:22,896 --> 00:13:25,517
AND WHETHER
ANY WARNING LIGHTS ILLUMINATE.
226
00:13:25,517 --> 00:13:27,344
THEN IT'S IN TO THE BODY SHOP,
227
00:13:27,344 --> 00:13:31,206
WHERE WORKERS MOUNT FIBERGLASS
BOXES OVER THE WHEELS.
228
00:13:31,206 --> 00:13:33,862
ANOTHER TEAM
BUILDS THE INTER-DECK FLOOR,
229
00:13:33,862 --> 00:13:35,586
THE ALUMINUM-FRAME STRUCTURE
230
00:13:35,586 --> 00:13:37,862
THAT SEPARATES
THE BUS'S TWO LEVELS.
231
00:13:37,862 --> 00:13:41,689
THEY AFFIX THE LOWER LEVEL'S
MELAMINE CEILING TO ONE SIDE
232
00:13:41,689 --> 00:13:44,965
AND THE UPPER DECK'S
PLYWOOD FLOOR TO THE OTHER.
233
00:13:44,965 --> 00:13:48,034
TO MAKE THE ROOF,
THEY CONSTRUCT AN ALUMINUM FRAME
234
00:13:48,034 --> 00:13:50,827
THEN GLUE AN ALUMINUM SHEET
ONTO IT.
235
00:13:50,827 --> 00:13:53,862
MOST OF THE BUS'S BODY
IS MADE OF ALUMINUM
236
00:13:53,862 --> 00:13:56,310
BECAUSE,
COMPARED TO OTHER METALS,
237
00:13:56,310 --> 00:13:59,448
IT'S LIGHTWEIGHT, DURABLE,
AND EASY TO REPAIR.
238
00:13:59,448 --> 00:14:01,793
NEXT, THEY PAINT THE ROOF
239
00:14:01,793 --> 00:14:04,689
AND INSTALL COMPONENTS
INTEGRATED WITHIN IT,
240
00:14:04,689 --> 00:14:07,965
SUCH AS THE AERIAL ANTENNA
AND WIRES FOR LIGHTING.
241
00:14:07,965 --> 00:14:10,241
AS THIS COMPUTER ANIMATION
ILLUSTRATES,
242
00:14:10,241 --> 00:14:14,310
STEP BY STEP,
THE BUS IS SLOWLY TAKING SHAPE.
243
00:14:14,310 --> 00:14:17,206
WORKERS INSERT THE PEGS
UNDERNEATH THE ROOF
244
00:14:17,206 --> 00:14:21,103
INTO ALUMINUM PILLARS RUNNING
THE PERIMETER OF THE UPPER DECK.
245
00:14:23,758 --> 00:14:27,931
ALONG THE SIDES, WORKERS
SANDWICH THE STRUCTURAL FRAME
246
00:14:27,931 --> 00:14:31,275
BETWEEN INNER AND OUTER
ALUMINUM BODY PANELS.
247
00:14:31,275 --> 00:14:33,275
FIRST,
THEY AFFIX THE INNER ONES,
248
00:14:33,275 --> 00:14:35,344
THEN THEY FILL
THE SPACES IN BETWEEN
249
00:14:35,344 --> 00:14:39,344
WITH BLOCKS OF FOAM INSULATION.
250
00:14:39,344 --> 00:14:42,413
FINALLY, THEY GLUE ON
THE OUTER SIDE PANELS,
251
00:14:42,413 --> 00:14:45,586
PRESSING OUT THE EXCESS ADHESIVE
WITH A ROLLER
252
00:14:45,586 --> 00:14:47,758
SO THAT THE PANEL LAYS FLAT.
253
00:14:49,448 --> 00:14:53,448
THE FRONT AND BACK OF THE BUS
ARE MADE OF MOLDED FIBERGLASS.
254
00:14:53,448 --> 00:14:55,551
THEY HAVE OPENINGS FOR WINDOWS,
255
00:14:55,551 --> 00:14:58,034
AND IN THE BACK,
A CUT-OUT BENEATH THE TOP WINDOW
256
00:14:58,034 --> 00:15:00,482
FOR THE UPPER-DECK
AIR-CONDITIONER.
257
00:15:00,482 --> 00:15:04,103
AS ONE CREW GLUES
ALL THE WINDOW GLASS INTO PLACE,
258
00:15:04,103 --> 00:15:08,000
OTHERS INSTALL THE DOORS AND,
INSIDE, THE UPHOLSTERED SEATS
259
00:15:08,000 --> 00:15:11,551
AND A DURABLE
NON-SLIP FLOOR COVERING.
260
00:15:11,551 --> 00:15:14,793
ONCE THE BUS COMES BACK
FROM THE PAINT SHOP,
261
00:15:14,793 --> 00:15:17,206
THE FACTORY'S
QUALITY-CONTROL DEPARTMENT
262
00:15:17,206 --> 00:15:18,551
INSPECTS THE INTERIOR.
263
00:15:20,724 --> 00:15:23,655
THE SEAT FABRIC
IS DARK AND PATTERNED
264
00:15:23,655 --> 00:15:25,413
TO DISCOURAGE GRAFFITI.
265
00:15:25,413 --> 00:15:29,000
THE BUS ALSO HAS 12 CAMERAS
HIDDEN IN VARIOUS LOCATIONS
266
00:15:29,000 --> 00:15:31,344
TO DETER VANDALISM.
267
00:15:31,344 --> 00:15:33,310
THE TYPICAL DOUBLE-DECKER
268
00:15:33,310 --> 00:15:36,551
IS 11 YARDS LONG
AND NEARLY 15 FEET HIGH.
269
00:15:36,551 --> 00:15:39,896
IT CARRIES UP TO 92 PASSENGERS.
270
00:15:50,896 --> 00:15:53,586
Narrator: WHEN YOU NEED
SOMETHING TO LEAN ON,
271
00:15:53,586 --> 00:15:56,551
A WALKING STICK CAN PROVIDE
THE NECESSARY SUPPORT.
272
00:15:56,551 --> 00:15:58,724
WOODEN WALKING STICKS
HAVE BEEN COMING IN HANDY
273
00:15:58,724 --> 00:16:00,482
SINCE PRIMITIVE TIMES.
274
00:16:00,482 --> 00:16:03,310
THE FIRST VERSIONS
WERE LIKELY CRUDE BRANCHES,
275
00:16:03,310 --> 00:16:06,586
BUT THEY'VE EVOLVED
INTO SOMETHING MUCH FINER.
276
00:16:11,965 --> 00:16:13,931
TODAY'S WOODEN WALKING STICKS
277
00:16:13,931 --> 00:16:16,448
ARE DESIGNED TO SUPPORT
THE USER IN STYLE.
278
00:16:16,448 --> 00:16:19,862
THERE ARE RUSTIC VERSIONS
FOR THE OUTDOOR ADVENTURER
279
00:16:19,862 --> 00:16:22,896
AND DISTINGUISHED-LOOKING ONES
FOR GETTING AROUND TOWN.
280
00:16:22,896 --> 00:16:24,310
BUT, WHATEVER THE STYLE,
281
00:16:24,310 --> 00:16:28,068
A WALKING STICK ADDS STABILITY
TO THE HUMAN JOURNEY.
282
00:16:28,068 --> 00:16:32,241
IT ALL BEGINS WITH
THESE 3-YEAR-OLD SAPLINGS.
283
00:16:32,241 --> 00:16:35,896
THESE ARE CHESTNUT --
A LIGHTWEIGHT AND DURABLE WOOD.
284
00:16:35,896 --> 00:16:38,241
ONCE THE STICKS
HAVE BEEN PEELED AND DRIED,
285
00:16:38,241 --> 00:16:39,758
IT'S INTO THE WASHING MACHINE
286
00:16:39,758 --> 00:16:42,655
TO SCRUB OFF ANY DIRT OR MOLD
THAT MAY HAVE ACCUMULATED.
287
00:16:45,137 --> 00:16:48,137
AND IT'S NOT
YOUR USUAL WASHING MACHINE --
288
00:16:48,137 --> 00:16:52,586
THIS ONE IS A LONG TANK SIZED
SPECIFICALLY FOR THESE STICKS.
289
00:16:52,586 --> 00:16:56,896
A WORKER CLOSES THE LID TIGHTLY
SO NO STICKS WILL SPILL OUT
290
00:16:56,896 --> 00:16:59,931
AS THE TANK ROTATES
IN A TROUGH OF SOAPY WATER.
291
00:16:59,931 --> 00:17:02,482
AFTER A FEW MINUTES
OF TOSSING ABOUT,
292
00:17:02,482 --> 00:17:04,896
THESE STICKS COME OUT
SQUEAKY-CLEAN,
293
00:17:04,896 --> 00:17:06,965
AND THEY'RE READY
FOR THE STEAMER.
294
00:17:06,965 --> 00:17:09,172
THE STICKS ARE STEAMED
FOR 20 MINUTES,
295
00:17:09,172 --> 00:17:12,241
AND THIS MAKES THEM
SOFT ENOUGH TO BEND.
296
00:17:12,241 --> 00:17:14,379
SO NEXT, HE SECURES THE STICK
297
00:17:14,379 --> 00:17:16,724
AND ACTIVATES
A SPRING-LOADED ARM.
298
00:17:16,724 --> 00:17:20,517
IT WRAPS ONE END AROUND A FORM
TO CURL IT INTO A CROOK.
299
00:17:20,517 --> 00:17:22,965
HE TIES IT
SO IT HOLDS THE CROOK SHAPE
300
00:17:22,965 --> 00:17:24,758
AND RETRACTS THE BENDING ARM.
301
00:17:24,758 --> 00:17:27,965
THIS CROOK WILL SERVE
AS THE WALKING STICK'S HANDLE.
302
00:17:27,965 --> 00:17:31,206
A CENTURY AGO, CROOKS
WERE FORMED ENTIRELY BY HAND,
303
00:17:31,206 --> 00:17:32,931
WHICH TOOK BRUTE STRENGTH.
304
00:17:32,931 --> 00:17:35,965
BUT WITH THE INVENTION
OF THIS NIFTY MACHINE,
305
00:17:35,965 --> 00:17:38,344
THE JOB
BECAME A WHOLE LOT EASIER.
306
00:17:38,344 --> 00:17:41,758
NEXT, IT'S OVER TO A DEVICE
CALLED THE STRAIGHTENING HORSE,
307
00:17:41,758 --> 00:17:44,517
BECAUSE IT'S USED
TO STRAIGHTEN THE STICK'S SHAFT.
308
00:17:44,517 --> 00:17:46,862
THIS JOB
DOES TAKE A BIT OF MUSCLE,
309
00:17:46,862 --> 00:17:49,310
AS THE WORKER
WRENCHES THE SHAFT BETWEEN POSTS
310
00:17:49,310 --> 00:17:50,620
TO SET IT STRAIGHT.
311
00:17:50,620 --> 00:17:52,586
WITH THE SHAFT NOW QUITE LINEAR
312
00:17:52,586 --> 00:17:55,620
AND THE END CURLED INTO A CROOK
AND STILL TIED,
313
00:17:55,620 --> 00:17:58,793
IT'S TIME TO SET
THE SHAPE OF THIS WALKING STICK.
314
00:17:58,793 --> 00:18:02,379
AND SO IT'S IN TO THE DRYING
ROOM FOR A COUPLE OF DAYS.
315
00:18:02,379 --> 00:18:06,551
THE TEMPERATURE IN HERE IS
AROUND 175 DEGREES FAHRENHEIT.
316
00:18:06,551 --> 00:18:09,931
AND AS THE STICKS DRY,
THE SHAPE SOLIDIFIES.
317
00:18:09,931 --> 00:18:12,931
A WORKER THEN CUTS THE STICK
TO THE CORRECT LENGTH,
318
00:18:12,931 --> 00:18:17,034
AND HE ALSO PARES DOWN THE END
TO PREPARE IT FOR CAPPING LATER.
319
00:18:21,275 --> 00:18:24,068
HE ALSO SANDS DOWN
THE KNOTS IN THE WOOD,
320
00:18:24,068 --> 00:18:27,551
CREATING A SMOOTHER SURFACE.
321
00:18:31,413 --> 00:18:34,103
FROM A SIMPLE SAPLING
TO A CANE SHAPE,
322
00:18:34,103 --> 00:18:36,034
IT'S QUITE A TRANSFORMATION.
323
00:18:36,034 --> 00:18:37,689
AND IT'S NOT OVER.
324
00:18:37,689 --> 00:18:41,103
THE NEXT WORKER
EXPOSES THE WOOD TO A FLAME,
325
00:18:41,103 --> 00:18:43,482
JUST LONG ENOUGH TO BLACKEN IT.
326
00:18:43,482 --> 00:18:45,862
THIS IS STAINING
WITHOUT THE CHEMICALS,
327
00:18:45,862 --> 00:18:48,448
AND THE FINISH IS DISTINCTIVE.
328
00:18:48,448 --> 00:18:50,655
HE NOW TURNS THE WALKING STICK
329
00:18:50,655 --> 00:18:53,379
AGAINST A VERY SHARP
CIRCULAR BLADE
330
00:18:53,379 --> 00:18:57,000
TO CARVE SPIRALS ON THE CROOK
AND DOWN THE SHAFT.
331
00:18:57,000 --> 00:19:00,551
IT'S A CANDY-CANE LOOK, AND
ACHIEVING IT IS A BIT TRICKY.
332
00:19:00,551 --> 00:19:04,344
THIS IS WHERE
ON-THE-JOB EXPERIENCE COUNTS.
333
00:19:07,206 --> 00:19:11,034
ANOTHER WORKER THEN TRIMS
THE END OF THE HANDLE CROOK.
334
00:19:11,034 --> 00:19:12,793
THE CUTOFFS WON'T GO TO WASTE --
335
00:19:12,793 --> 00:19:15,655
THEY'LL HELP FIRE
THE FACTORY FURNACE.
336
00:19:15,655 --> 00:19:17,931
NEXT, A WORKER INSERTS THE CROOK
337
00:19:17,931 --> 00:19:21,413
IN A MACHINE THAT WORKS
LIKE A PENCIL SHARPENER,
338
00:19:21,413 --> 00:19:24,517
EXCEPT THE BLADE INSIDE
ROUNDS THE END.
339
00:19:24,517 --> 00:19:27,586
THIS PROCESS IS CALLED
"NOSING THE STICK."
340
00:19:27,586 --> 00:19:30,482
THE STICK THAT STARTED OUT
AS A PEELED SAPLING
341
00:19:30,482 --> 00:19:32,724
NOW LOOKS
DRAMATICALLY DIFFERENT.
342
00:19:32,724 --> 00:19:35,862
NEXT, A DIP
IN WATER-BASED LACQUER
343
00:19:35,862 --> 00:19:39,310
GIVES THIS WALKING STICK
A HIGH GLOSS.
344
00:19:39,413 --> 00:19:41,896
THEY HANG IT TO DRIP-DRY
FOR AN HOUR,
345
00:19:41,896 --> 00:19:43,758
AFTER WHICH THE WALKING STICK
346
00:19:43,758 --> 00:19:47,000
IS READY FOR THE END CAP,
OR FERRULE.
347
00:19:47,000 --> 00:19:50,206
FERRULES COME
IN A VARIETY OF STYLES.
348
00:19:50,206 --> 00:19:53,931
THERE ARE BLUNT ONES, FOR
A GOOD GRIP ON INDOOR SURFACES,
349
00:19:53,931 --> 00:19:55,586
AND THERE ARE POINTED FERRULES,
350
00:19:55,586 --> 00:19:57,793
FOR NAVIGATING
ROUGHER, OUTDOOR TERRAIN.
351
00:19:57,793 --> 00:20:00,689
AFTER HAMMERING THE FERRULE
ONTO THE STICK,
352
00:20:00,689 --> 00:20:03,758
HE DRIVES A NAIL THROUGH IT
TO SECURE IT.
353
00:20:06,206 --> 00:20:08,931
AND THESE WALKING STICKS
ARE NOW COMPLETE.
354
00:20:08,931 --> 00:20:11,206
ALL THAT'S LEFT
IS TO HANG AROUND
355
00:20:11,206 --> 00:20:13,068
UNTIL THE ORDERS COME IN.
356
00:20:13,068 --> 00:20:16,275
AND THOSE ORDERS
ARE USUALLY VERY SPECIFIC.
357
00:20:16,275 --> 00:20:17,689
CUSTOMERS GET TO CHOOSE
358
00:20:17,689 --> 00:20:20,827
THE LENGTH OF STICK THAT'S
APPROPRIATE FOR THEIR HEIGHT,
359
00:20:20,827 --> 00:20:24,793
AS WELL AS THE STYLE AND FINISH
THEY PREFER.
360
00:20:24,793 --> 00:20:28,586
FROM A SIMPLE STICK
TO A DIGNIFIED-LOOKING CANE,
361
00:20:28,586 --> 00:20:31,827
IT'S BEEN QUITE A JOURNEY.
362
00:20:31,827 --> 00:20:33,896
THE PATH AHEAD MAY BE UNCERTAIN,
363
00:20:33,896 --> 00:20:36,793
BUT WITH ONE OF THESE
WALKING STICKS IN HAND,
364
00:20:36,793 --> 00:20:38,344
A PERSON IS WELL-EQUIPPED
365
00:20:38,344 --> 00:20:42,034
TO MAKE HIS OR HER WAY
IN THE WORLD.
29748
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