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Narrator: THE FOLDING KAYAK
IS A SEAWORTHY VESSEL
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00:00:54,068 --> 00:00:57,034
THAT CAN BE DISASSEMBLED
AND STUFFED INTO A DUFFEL BAG.
3
00:00:57,034 --> 00:00:59,000
THIS BOAT-IN-A-BAG CONCEPT
4
00:00:59,000 --> 00:01:01,655
WAS DEVELOPED IN GERMANY
A CENTURY AGO.
5
00:01:01,655 --> 00:01:04,379
IT'S A GOOD FIT FOR
THE MODERN TRAVELER'S LIFESTYLE
6
00:01:04,379 --> 00:01:06,551
BECAUSE IT CAN BE STOWED
IN A CAR TRUNK,
7
00:01:06,551 --> 00:01:10,586
CHECKED ON TO A PLANE,
OR STASHED IN THE CONDO CLOSET.
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00:01:12,344 --> 00:01:15,172
HISTORY HAS SHOWN
THAT WHEN GOING GETS ROUGH,
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00:01:15,172 --> 00:01:17,793
THE FOLDING KAYAK
DOESN'T FALL APART.
10
00:01:17,793 --> 00:01:20,068
ADVENTURERS HAVE CROSSED OCEANS
IN THEM,
11
00:01:20,068 --> 00:01:24,000
AND TODAY ITS STORY
CONTINUES TO UNFOLD.
12
00:01:24,000 --> 00:01:25,482
THE KAYAK FRAME
13
00:01:25,482 --> 00:01:29,137
STARTS WITH PARTS CUT FROM
SOLID ASH AND LAMINATED BIRCH.
14
00:01:29,137 --> 00:01:30,482
FOR WATERPROOFING,
15
00:01:30,482 --> 00:01:33,068
THEY DIP THEM IN MARINE-GRADE
VARNISH THREE TIMES,
16
00:01:33,068 --> 00:01:36,344
DRYING THEM FOR 24 HOURS
BETWEEN DIPS.
17
00:01:36,344 --> 00:01:38,517
A WORKER THEN RIVETS
METAL FITTINGS
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00:01:38,517 --> 00:01:40,275
TO A VARNISHED SECTION
OF THE KEEL BOARD.
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00:01:40,275 --> 00:01:42,827
IT'S THESE FITTINGS
THAT ENABLE THE FOLDING KAYAK
20
00:01:42,827 --> 00:01:45,586
TO MOVE WITH THE SEA
INSTEAD OF AGAINST IT.
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00:01:45,586 --> 00:01:48,724
THAT'S BECAUSE THEY'RE MADE
OF AN ALUMINUM-COPPER ALLOY,
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00:01:48,724 --> 00:01:52,413
A METAL WITH
A CERTAIN AMOUNT OF GIVE.
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00:01:52,413 --> 00:01:57,379
HE FASTENS MORE ALUMINUM-ALLOY
FITTINGS ON THE CROSS RIBS.
24
00:01:57,379 --> 00:01:59,413
THERE WILL BE A TOTAL
OF SEVEN CROSS RIBS
25
00:01:59,413 --> 00:02:01,448
IN THIS TWO-SEATER
FOLDING KAYAK.
26
00:02:01,448 --> 00:02:04,206
THE CENTER THREE
WILL CARRY MOST OF THE LOAD,
27
00:02:04,206 --> 00:02:07,206
SO THEY'RE MADE OF NINE LAYERS
OF LAMINATED BIRCH.
28
00:02:07,206 --> 00:02:10,517
IT'S SUPER STRONG
BECAUSE UNLIKE SOLID WOOD,
29
00:02:10,517 --> 00:02:13,206
IT HAS FEW KNOTS
OR IMPERFECTIONS.
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00:02:13,206 --> 00:02:16,103
HE APPLIES A LABEL WITH
THE PRODUCTION'S SERIAL NUMBER
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00:02:16,103 --> 00:02:18,758
TO A BOOMERANG-SHAPED PIECE
OF THE FRAME.
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00:02:18,758 --> 00:02:20,482
THIS IS HOW THE KAYAK OWNER
33
00:02:20,482 --> 00:02:22,896
WOULD ACTUALLY ASSEMBLE THE BOAT
ON-SITE.
34
00:02:22,896 --> 00:02:25,448
HE LOCKS TWO SECTIONS
OF THE KEEL BOARD TOGETHER
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00:02:25,448 --> 00:02:28,448
WITH THE FLEXIBLE FITTING
WE SAW INSTALLED EARLIER.
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00:02:31,000 --> 00:02:33,793
HE SNAPS THE BOW PIECE
TO THE FRONT
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00:02:33,793 --> 00:02:37,344
AND HOOKS RODS INTO FITTINGS
INSTALLED ON THE BOW.
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00:02:37,344 --> 00:02:42,310
HE FASTENS A COUPLE OF RIBS
TO THE KEEL BOARD.
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00:02:42,310 --> 00:02:46,206
THE GUNNELS, WHICH ARE THE TOP
SIDES OF THE BOAT, ARE NEXT.
40
00:02:46,206 --> 00:02:48,275
HE ATTACHES ONE END TO THE BOW
41
00:02:48,275 --> 00:02:49,931
AND THE OTHER
TO ONE OF THE RIBS.
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00:02:49,931 --> 00:02:52,827
THE BOW AND STERN PARTS
ARE COLOR-CODED
43
00:02:52,827 --> 00:02:54,758
WITH RED-PAINTED FITTINGS
FOR THE BOW
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00:02:54,758 --> 00:02:56,000
AND BLUE ONES FOR THE STERN.
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00:02:58,103 --> 00:03:02,655
ALL THE PARTS FIT TOGETHER
LIKE A TOY MODEL.
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00:03:02,655 --> 00:03:05,172
WITH BOTH GUNNELS NOW ATTACHED,
47
00:03:05,172 --> 00:03:07,413
HE'S READY TO INSTALL
MORE RIBS --
48
00:03:07,413 --> 00:03:10,344
THE LAMINATED BIRCH ONES
THAT FORM THE COCKPIT.
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00:03:14,000 --> 00:03:16,758
HE COMPLETES
THE ASSEMBLY OF RODS.
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00:03:16,758 --> 00:03:20,758
ALL THESE RODS WILL GIVE
THE KAYAK DIRECTIONAL STABILITY.
51
00:03:20,758 --> 00:03:23,758
HE UNFOLDS PART
OF THE KAYAK DECK ASSEMBLY,
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00:03:23,758 --> 00:03:25,206
KNOWN AS THE COAMING,
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00:03:25,206 --> 00:03:28,448
AND ARRANGES IT TO SURROUND
THE COCKPIT.
54
00:03:28,448 --> 00:03:31,034
HE ATTACHES IT TO THE GUNNELS
55
00:03:31,034 --> 00:03:34,655
USING METAL CLAMPS AND FITTINGS.
56
00:03:34,655 --> 00:03:39,862
HE SLIDES THE TWO SEATS
INTO PLACE ON THE KEEL BOARD.
57
00:03:39,862 --> 00:03:42,965
AND HE ATTACHES THE BACK REST
TO THE GUNNELS.
58
00:03:45,379 --> 00:03:47,068
THE FRAME OF THIS FOLDING KAYAK
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00:03:47,068 --> 00:03:52,448
IS NOW COMPLETE AND READY
FOR ITS CUSTOM-MADE SKIN.
60
00:03:52,448 --> 00:03:54,655
OVER IN THE SEWING DEPARTMENT,
61
00:03:54,655 --> 00:03:57,827
THE SEAMSTRESS TRACES
THE PATTERNS FOR THE KAYAK DECK
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00:03:57,827 --> 00:04:02,103
ONTO COTTON-HEMP MATERIAL AND
CUTS ALONG THE PENCILED LINES.
63
00:04:02,103 --> 00:04:05,241
THIS NATURAL FABRIC WILL ALLOW
THE DECK TO BREATHE
64
00:04:05,241 --> 00:04:06,758
AND YET KEEP IT WATER-TIGHT.
65
00:04:09,655 --> 00:04:12,655
IT'S NOW TIME TO PIECE TOGETHER
ALL OF THE PARTS,
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00:04:12,655 --> 00:04:16,862
INCLUDING TWO LONG SLEEVES
FOR INSERTING INFLATABLE TUBES.
67
00:04:16,862 --> 00:04:19,448
DEFLATED, THE TUBES
WILL CREATE SLACK,
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00:04:19,448 --> 00:04:22,517
MAKING IT EASIER TO FIT
THE FRAME INTO THE SKIN.
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00:04:22,517 --> 00:04:26,172
INFLATED, THEY MAKE THE KAYAK
VIRTUALLY UNSINKABLE.
70
00:04:26,172 --> 00:04:28,965
ONCE THE THICK LAYERS
HAVE BEEN STITCHED TOGETHER,
71
00:04:28,965 --> 00:04:31,620
SHE'S READY TO INSERT
THE INFLATABLE TUBES.
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00:04:31,620 --> 00:04:34,379
THEY WERE PUMPED FULL OF AIR
TO BE EXAMINED FOR HOLES,
73
00:04:34,379 --> 00:04:37,689
SO SHE DEFLATES THEM.
74
00:04:37,689 --> 00:04:41,068
SHE USES A LONG POLE
TO EXTEND HER REACH
75
00:04:41,068 --> 00:04:44,413
AND PUSH THE INFLATABLE TUBE
INTO THE SLEEVE.
76
00:04:44,413 --> 00:04:48,000
WITH A SYNTHETIC RUBBER HULL
NOW STITCHED TO THE DECK FABRIC,
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00:04:48,000 --> 00:04:52,034
THE SKIN IS COMPLETE AND READY
FOR THE KAYAK'S WOODEN FRAME.
78
00:04:52,034 --> 00:04:55,172
THIS PARTICULAR MODEL
HAS BEEN PAINTED BLACK.
79
00:04:55,172 --> 00:04:57,275
IF THE FIT IS EVEN SLIGHTLY OFF,
80
00:04:57,275 --> 00:05:00,448
THE KAYAK WON'T PERFORM
PROPERLY.
81
00:05:00,448 --> 00:05:02,724
THE SKIN FITS LIKE A GLOVE.
82
00:05:05,793 --> 00:05:09,172
HE BRUSHES GLUE ONTO THE TIPS
OF THE BOW AND STERN
83
00:05:09,172 --> 00:05:12,793
AND THEN PRESSES MOLDED RUBBER
BUMPERS ONTO THOSE AREAS.
84
00:05:12,793 --> 00:05:15,620
THE BUMPERS WILL PROTECT
THE ENDS OF THE HULL CASING,
85
00:05:15,620 --> 00:05:17,344
WHICH TAKES
A LOT OF HARD KNOCKS.
86
00:05:21,655 --> 00:05:24,241
IN TOTAL, IT TAKES
ABOUT 50 PERSON-HOURS
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00:05:24,241 --> 00:05:26,000
TO MAKE A FOLDING KAYAK.
88
00:05:26,000 --> 00:05:28,551
IT SHOULD TAKE THE OWNER
ABOUT 15 MINUTES
89
00:05:28,551 --> 00:05:31,310
TO DISASSEMBLE OR ASSEMBLE ONE.
90
00:05:31,310 --> 00:05:34,413
FOR SOME, IT WILL BECOME
A TRAVELING ESSENTIAL,
91
00:05:34,413 --> 00:05:37,724
PART OF THE LUGGAGE ON ANY TRIP.
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00:05:50,068 --> 00:05:53,068
Narrator: THE PIÑATA IS
A COLORFUL PAPER-MACHE OBJECT
93
00:05:53,068 --> 00:05:56,034
TYPICALLY FILLED
WITH CANDY OR SMALL TOYS,
94
00:05:56,034 --> 00:05:58,827
THEN SUSPENDED HIGH
FROM A STRING.
95
00:05:58,827 --> 00:06:01,413
BLINDFOLDED PARTIERS TAKE TURNS
96
00:06:01,413 --> 00:06:04,620
TRYING TO HIT THE PIÑATA
WITH A STICK TO BREAK IT OPEN
97
00:06:04,620 --> 00:06:07,034
AND RELEASE A SHOWER OF GOODIES.
98
00:06:11,793 --> 00:06:15,517
FROM POPULAR CARTOON CHARACTERS
TO COLORFUL, GLITTERY SHAPES,
99
00:06:15,517 --> 00:06:18,344
TODAY'S PIÑATAS ARE A BIG HIT
AT KID'S PARTIES
100
00:06:18,344 --> 00:06:21,137
WHERE CHILDREN EAGERLY AWAIT
THE DECISIVE BLOW
101
00:06:21,137 --> 00:06:25,655
THAT BREAKS OPEN THE PIÑATA,
RELEASING THE TREATS INSIDE.
102
00:06:27,206 --> 00:06:29,000
THE TRADITIONAL WAY TO BUILD ONE
103
00:06:29,000 --> 00:06:33,586
STARTS WITH A CLAY POT
SUSPENDED FROM A STRING.
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00:06:33,586 --> 00:06:36,172
THE PIÑATA-MAKER GLUES
CARDBOARD SHAPES TO IT
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00:06:36,172 --> 00:06:39,482
AND SECURES THEM BY GLUING
ON PIECES OF NEWSPAPER.
106
00:06:42,310 --> 00:06:45,137
THEN SHE COVERS
THE REST OF THE POT.
107
00:06:45,137 --> 00:06:46,896
WHEN THE GLUE DRIES,
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00:06:46,896 --> 00:06:50,655
SHE DECORATES THE SURFACE
WITH COLORFUL PAPER.
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00:06:56,275 --> 00:07:00,620
THE MODERN METHOD IS TO USE
A BALLOON INSTEAD OF A CLAY POT.
110
00:07:03,275 --> 00:07:05,137
AFTER INFLATING THE BALLOON,
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00:07:05,137 --> 00:07:08,241
SHE PASTES PIECES OF NEWSPAPER
ALL OVER IT.
112
00:07:08,241 --> 00:07:10,724
THIS TECHNIQUE IS KNOWN
AS PAPER-MACHE.
113
00:07:17,551 --> 00:07:20,586
THE TRICK IS TO COMPLETELY
SATURATE THE NEWSPAPER
114
00:07:20,586 --> 00:07:21,896
WITH A THICK PASTE
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00:07:21,896 --> 00:07:25,310
AND MAKE SURE NO PART OF
THE BALLOON IS LEFT UNCOVERED.
116
00:07:32,482 --> 00:07:34,413
SHE CONTINUES THIS PROCESS
117
00:07:34,413 --> 00:07:37,655
UNTIL SHE'S BUILT UP TWO OR
THREE EVEN LAYERS OF NEWSPAPER
118
00:07:37,655 --> 00:07:39,310
ALL OVER THE BALLOON.
119
00:07:41,620 --> 00:07:44,862
THEN SHE SUSPENDS IT
FROM A CLOTHESPIN TO DRY.
120
00:07:50,724 --> 00:07:52,827
HOURS LATER, THE PAPER-MACHE
121
00:07:52,827 --> 00:07:55,241
IS HARDENED INTO A SHELL
AROUND THE BALLOON,
122
00:07:55,241 --> 00:07:59,241
WHICH SHE NOW BREAKS
AND REMOVES.
123
00:08:01,482 --> 00:08:04,379
NEXT, SHE CUTS AN OPENING
AT THE TOP OF THE SHELL.
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00:08:04,379 --> 00:08:05,793
THIS IS THE HOLE
125
00:08:05,793 --> 00:08:08,586
THROUGH WHICH THE BUYER WILL
FILL THE PIÑATA WITH TREATS.
126
00:08:08,586 --> 00:08:14,137
SHE'LL LATER REATTACH THE CUT
PIECE TO MAKE A TRAP DOOR.
127
00:08:14,137 --> 00:08:17,137
BUT FIRST, WITH THE SHARP TIPS
OF HER SCISSORS,
128
00:08:17,137 --> 00:08:20,655
SHE PIERCES A ROW OF HOLES
ALONG THE CIRCUMFERENCE
129
00:08:20,655 --> 00:08:23,793
AND THREADS TWINE THROUGH THEM.
130
00:08:29,551 --> 00:08:31,965
SHE LEAVES LONG ENDS AT THE TOP
131
00:08:31,965 --> 00:08:35,551
WITH WHICH TO SUSPEND
THE PIÑATA.
132
00:08:40,103 --> 00:08:44,379
THIS PIÑATA WILL BE STAR-SHAPED.
133
00:08:44,379 --> 00:08:46,137
TO MAKE EACH POINT,
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00:08:46,137 --> 00:08:50,000
SHE ROLLS THIN CARDBOARD
INTO A CONE, TAPING IT CLOSED.
135
00:08:55,482 --> 00:08:59,413
SHE TRIMS IT
TO THE REQUIRED SIZE,
136
00:08:59,413 --> 00:09:03,034
THEN CUTS TABS AT THE BASE
AND BENDS THEM BACK.
137
00:09:05,931 --> 00:09:09,448
SHE MAKES SEVEN
OF THESE CARDBOARD POINTS,
138
00:09:09,448 --> 00:09:12,517
THEN TAPES THEM ONTO THE SHELL
ONE BY ONE.
139
00:09:20,793 --> 00:09:23,724
ONCE ALL SEVEN ARE POSITIONED,
140
00:09:23,724 --> 00:09:26,758
THE DECORATING WITH COLORFUL,
GLITTERY FOIL WRAPPING PAPER
141
00:09:26,758 --> 00:09:28,586
CAN BEGIN.
142
00:09:31,931 --> 00:09:35,137
SHE TAPES A SHEET AROUND
EACH POINT OF THE STAR.
143
00:09:41,655 --> 00:09:43,965
THEN SHE APPLIES GLUE
IN BETWEEN THE POINTS
144
00:09:43,965 --> 00:09:49,724
AND ADHERES PIECES OF WRAPPING
PAPER TO THOSE AREAS.
145
00:09:49,724 --> 00:09:52,482
SHE FOLDS OTHER PIECES
INTO FLOWER SHAPES
146
00:09:52,482 --> 00:09:55,793
AND GLUES THEM ON, AS WELL.
147
00:10:02,344 --> 00:10:05,137
ONCE THE ENTIRE PIÑATA
IS COVERED,
148
00:10:05,137 --> 00:10:08,827
SHE TAPES MATCHING STREAMERS
TO THE END OF EACH POINT.
149
00:10:08,827 --> 00:10:11,000
HISTORIANS BELIEVE
SPANISH MISSIONARIES
150
00:10:11,000 --> 00:10:12,517
USED STAR PIÑATAS LIKE THIS ONE
151
00:10:12,517 --> 00:10:17,034
TO CONVERT THE NATIVE PEOPLES
IN THE AMERICAS TO CHRISTIANITY.
152
00:10:17,034 --> 00:10:19,689
THE STAR SYMBOLIZED SATAN,
153
00:10:19,689 --> 00:10:22,275
ITS SEVEN POINTS,
THE SEVEN DEADLY SINS,
154
00:10:22,275 --> 00:10:24,586
ITS BEAUTIFUL COLORS,
TEMPTATION.
155
00:10:24,586 --> 00:10:28,103
WEARING A BLINDFOLD REPRESENTED
BLIND FAITH IN GOD.
156
00:10:28,103 --> 00:10:30,413
STRIKING THE PIÑATA
WITH A STICK MEANT GOODNESS
157
00:10:30,413 --> 00:10:32,241
AND VIRTUE BATTLING EVIL.
158
00:10:32,241 --> 00:10:36,206
BREAKING THE PIÑATA, RELEASING
A SHOWER OF TREATS OR TRINKETS,
159
00:10:36,206 --> 00:10:38,344
SYMBOLIZED HEAVENLY REWARDS.
160
00:10:50,724 --> 00:10:53,586
Narrator: HUMAN BEINGS
HAVE ALWAYS GENERATED GARBAGE.
161
00:10:53,586 --> 00:10:55,689
IN THE BATTLE
TO KEEP THE STREETS CLEAN,
162
00:10:55,689 --> 00:10:58,689
THE MECHANIZED GARBAGE TRUCK
IS A COMBAT VEHICLE.
163
00:10:58,689 --> 00:11:00,793
IT CRUSHES TONS OF TRASH
164
00:11:00,793 --> 00:11:02,758
EN ROUTE TO DELIVER IT
TO LANDFILLS,
165
00:11:02,758 --> 00:11:05,517
INCINERATORS,
AND RECYCLING FACILITIES.
166
00:11:05,517 --> 00:11:09,413
WITHOUT IT, WE'D ALL BE
KNEE-DEEP IN GARBAGE.
167
00:11:12,758 --> 00:11:16,034
GARBAGE TRUCKS HAVE DIFFERENT
APPROACHES TO HANDLING GARBAGE.
168
00:11:16,034 --> 00:11:20,379
SOME LOAD FROM THE FRONT,
OTHER FROM THE REAR OR SIDE.
169
00:11:20,379 --> 00:11:24,517
AND SOME ARE ENTIRELY MECHANIZED
LIKE THIS SIDE-LOADER TRUCK.
170
00:11:24,517 --> 00:11:28,310
THE OPERATOR INSIDE THE CAB
BARELY NEEDS TO LIFT A FINGER
171
00:11:28,310 --> 00:11:31,724
AS THE HYDRAULIC LIFT-ARM
DOES ALL THE HEAVY WORK.
172
00:11:31,724 --> 00:11:33,448
THE GARBAGE TRUCK
HAS COME A LONG WAY
173
00:11:33,448 --> 00:11:36,689
SINCE IT HIT THE STREET
IN 1952.
174
00:11:36,689 --> 00:11:38,965
PRODUCTION
ON A MODERN SIDE-LOADER TRUCK
175
00:11:38,965 --> 00:11:41,172
BEGINS WITH A WELDING ROBOT.
176
00:11:41,172 --> 00:11:43,482
THE ROBOT FUSES
NUMEROUS STEEL SUPPORTS
177
00:11:43,482 --> 00:11:45,172
TO THE TRUCK BODY FLOOR.
178
00:11:45,172 --> 00:11:47,241
THESE SUPPORTS
WILL ALLOW THE TRUCK
179
00:11:47,241 --> 00:11:52,172
TO HOLD UP TO THE FORCE OF TONS
OF TRASH BEING COMPACTED INSIDE.
180
00:11:52,172 --> 00:11:55,965
MEANWHILE, DOWN THE LINE, OTHER
PARTS LIKE THE ROOF AND SIDES
181
00:11:55,965 --> 00:11:58,310
TAKE SHAPE
IN SEPARATE ASSEMBLIES.
182
00:11:58,310 --> 00:11:59,724
ONCE THEY'RE COMPLETE,
183
00:11:59,724 --> 00:12:02,413
THEY HOIST THE LARGE STEEL PARTS
INTO PLACE
184
00:12:02,413 --> 00:12:04,241
AND ASSEMBLE THEM
WITHIN A METAL FRAMEWORK.
185
00:12:04,241 --> 00:12:06,689
THE FRAMEWORK SERVES AS A GUIDE
186
00:12:06,689 --> 00:12:09,724
TO PIECE TOGETHER
ALL THE PARTS OF THE TRUCK BOX.
187
00:12:09,724 --> 00:12:13,206
ONCE ASSEMBLED, THE WORKERS
CLAMP THE PARTS TOGETHER
188
00:12:13,206 --> 00:12:16,655
TO SECURE THE ASSEMBLY
AS THEY WELD THE SEAMS.
189
00:12:16,655 --> 00:12:20,000
THE GARBAGE TRUCK BODY IS THEN
READY FOR THE MECHANIZED PARTS,
190
00:12:20,000 --> 00:12:22,103
BEGINNING WITH A HOPPER.
191
00:12:22,103 --> 00:12:24,793
IT'S EQUIPPED WITH
A POWERFUL, HYDRAULIC COMPACTOR
192
00:12:24,793 --> 00:12:28,310
TO SQUEEZE AS MUCH TRASH
AS POSSIBLE INTO THE TRUCK.
193
00:12:28,310 --> 00:12:31,586
THEY FIT THE HOPPER SNUGLY
TO THE FRONT OF THE TRUCK BODY
194
00:12:31,586 --> 00:12:34,413
AND WELD IT TO IT.
195
00:12:34,413 --> 00:12:36,655
THEN THEY LIFT THE TAILGATE
INTO POSITION
196
00:12:36,655 --> 00:12:39,517
AT THE REAR OF THE TRUCK BOX.
197
00:12:39,517 --> 00:12:42,689
THEY HINGE IT TO THE TRUCK
198
00:12:42,689 --> 00:12:45,344
BY SLIDING HEAVY-DUTY STEEL PINS
THROUGH BRACKETS.
199
00:12:48,275 --> 00:12:51,862
ONCE HINGED, THE TAILGATE CAN
SWING UP AND OUT OF THE WAY
200
00:12:51,862 --> 00:12:54,896
TO ALLOW GARBAGE
TO BE DISCHARGED.
201
00:12:54,896 --> 00:12:56,620
THE DRIVING FORCE FOR THIS
202
00:12:56,620 --> 00:13:00,310
IS A PAIR OF HYDRAULIC CYLINDERS
ATTACHED BY BRACKETS,
203
00:13:00,310 --> 00:13:02,137
WELDED TO THE TAILGATE
AT ONE END
204
00:13:02,137 --> 00:13:04,344
AND THE TRUCK BODY AT THE OTHER.
205
00:13:06,241 --> 00:13:08,931
WITH THAT JOB DONE,
THESE CYLINDERS
206
00:13:08,931 --> 00:13:10,896
CAN NOW EXTEND
TO LIFT THE TAILGATE
207
00:13:10,896 --> 00:13:13,275
AND RETRACT TO CLOSE IT.
208
00:13:13,275 --> 00:13:15,241
ACROSS THE FACTORY FLOOR,
209
00:13:15,241 --> 00:13:18,448
ANOTHER TEAM ASSEMBLES
A PAIR OF STEEL LIFT-ARMS.
210
00:13:18,448 --> 00:13:21,551
THESE LIFT-ARMS ARE DESIGNED
FOR ANOTHER KIND OF TRUCK,
211
00:13:21,551 --> 00:13:22,931
THE FRONT-END LOADER.
212
00:13:22,931 --> 00:13:24,620
IT'S MAINLY USED TO COLLECT
213
00:13:24,620 --> 00:13:28,862
HEFTY COMMERCIAL
GARBAGE CONTAINERS.
214
00:13:28,862 --> 00:13:33,034
IN ACTION, THESE ARMS PIVOT
AROUND THE TRUCK CAB
215
00:13:33,034 --> 00:13:35,931
AND EXTEND TO THE FRONT TO FORK
UP THE TRASH CONTAINER
216
00:13:35,931 --> 00:13:38,172
AND DEPOSIT THE CONTENTS
IN THE HOPPER.
217
00:13:38,172 --> 00:13:42,000
HYDRAULIC CYLINDERS
ALSO POWER THESE LIFT-ARMS.
218
00:13:42,000 --> 00:13:44,896
WHEN THE TASK IS COMPLETE,
THE FORKS AT THE END OF THE ARMS
219
00:13:44,896 --> 00:13:47,965
FOLD BACK OUT OF THE WAY.
220
00:13:47,965 --> 00:13:52,448
NEARBY, WORKERS TEST
THIS REAR-LOADER GARBAGE TRUCK.
221
00:13:52,448 --> 00:13:55,034
ITS TAILGATE IS SPLIT
INTO TWO HOPPERS --
222
00:13:55,034 --> 00:13:57,655
ONE FOR RECYCLABLES
AND THE OTHER FOR TRASH.
223
00:13:57,655 --> 00:14:03,034
HYDRAULIC SYSTEMS LIFT THEM
ONE AT A TIME OR SIMULTANEOUSLY.
224
00:14:03,034 --> 00:14:05,206
COLLECTING GARBAGE
AND DISPOSING OF IT
225
00:14:05,206 --> 00:14:07,206
CAN BE TOUGH
ON A TRUCK'S PAINT JOB,
226
00:14:07,206 --> 00:14:11,103
SO THEY APPLY
AN EXTRA-DURABLE FINISH.
227
00:14:11,103 --> 00:14:14,310
THEY SPRAY SEALER
ON THE SANDED OUTER SURFACE,
228
00:14:14,310 --> 00:14:17,206
FOLLOWED BY TWO COATS
OF EPOXY PAINT.
229
00:14:17,206 --> 00:14:20,620
AFTER THAT,
THEY BAKE ON THE LAYERS.
230
00:14:20,620 --> 00:14:24,172
MEANWHILE, THE TRUCK CHASSIS HAS
ARRIVED FROM ANOTHER FACTORY.
231
00:14:24,172 --> 00:14:25,793
IT'S A STANDARD SIZE,
232
00:14:25,793 --> 00:14:29,137
SO THEY CHOP A PIECE OFF TO SIZE
IT FOR THE GARBAGE-TRUCK BODY.
233
00:14:29,137 --> 00:14:32,137
THEY INSTALL BRACKET PLATES
AT THE BACK
234
00:14:32,137 --> 00:14:34,517
AND SLIDE THICK PINS
THROUGH THE HOLES
235
00:14:34,517 --> 00:14:36,689
TO JOIN THE TRUCK BODY
TO THE CHASSIS.
236
00:14:39,344 --> 00:14:43,034
USING A CRANE, THEY LIFT THE
AUTOMATED SIDE-LOADER TRUCK BODY
237
00:14:43,034 --> 00:14:45,000
ONTO THE MODIFIED CHASSIS.
238
00:14:52,172 --> 00:14:55,275
ONCE IT'S INSTALLED,
THEY TEST THE COMPACTOR.
239
00:14:55,275 --> 00:14:56,482
DUAL HYDRAULIC CYLINDERS
240
00:14:56,482 --> 00:14:59,965
PUSH THE EJECTOR BLADE
TO THE BACK OF THE TRUCK.
241
00:15:01,862 --> 00:15:05,344
THEY TEST THE TAILGATE --
WHICH HAS BY NOW BEEN EQUIPPED
242
00:15:05,344 --> 00:15:08,000
WITH SIGNAL LIGHTS, MUD FLAPS,
AND OTHER PARTS --
243
00:15:08,000 --> 00:15:13,758
AND VERIFY THAT EVERYTHING
FUNCTIONS PROPERLY.
244
00:15:13,758 --> 00:15:15,965
ONCE A TRUCK PASSES MUSTER,
245
00:15:15,965 --> 00:15:17,137
IT'S READY TO HANDLE
246
00:15:17,137 --> 00:15:20,448
WHATEVER GARBAGE
SOCIETY THROWS ITS WAY.
247
00:15:25,206 --> 00:15:27,586
AND WITH THESE AUTOMATED
GARBAGE TRUCKS,
248
00:15:27,586 --> 00:15:30,517
THERE'S NO NEED FOR ANYONE
TO STRAIN THEIR BACK
249
00:15:30,517 --> 00:15:32,137
OR GET THEIR HANDS DIRTY,
250
00:15:32,137 --> 00:15:36,068
BECAUSE THESE ROBOT ARMS
CAN HANDLE IT.
251
00:15:48,965 --> 00:15:51,000
Narrator:
HIGH-PERFORMANCE CARS
252
00:15:51,000 --> 00:15:53,379
TYPICALLY HAVE CERAMIC COMPOSITE
BRAKE DISKS
253
00:15:53,379 --> 00:15:56,034
RATHER THAN
REGULAR CAST-IRON ONES.
254
00:15:56,034 --> 00:15:58,931
THAT KIND OF POWER ON WHEELS
REQUIRES BEING LIGHTWEIGHT,
255
00:15:58,931 --> 00:16:01,206
AND CAST IRON IS VERY HEAVY.
256
00:16:01,206 --> 00:16:03,068
IT WOULD ALSO WEAR OUT
TOO QUICKLY
257
00:16:03,068 --> 00:16:05,793
DUE TO THE INTENSE HEAT
FRICTION GENERATES
258
00:16:05,793 --> 00:16:09,448
WHEN YOU BRAKE A CAR
WITH SUCH A POWERFUL ENGINE.
259
00:16:09,448 --> 00:16:14,482
CERAMIC IS HEAT-RESISTANT
UP TO 1,830 DEGREES FAHRENHEIT.
260
00:16:14,482 --> 00:16:17,275
THEREFORE, THESE CERAMIC
COMPOSITE BRAKE DISKS
261
00:16:17,275 --> 00:16:20,896
LAST ABOUT 60 TIMES LONGER
THAN STANDARD CAST-IRON DISKS.
262
00:16:20,896 --> 00:16:24,068
CERAMIC COMPOSITE MEANS
THE CERAMIC MATERIAL SILICON
263
00:16:24,068 --> 00:16:27,724
IS COMBINED
WITH CARBON FIBER FOR STRENGTH.
264
00:16:27,724 --> 00:16:29,965
THE DISK FACTORY
PREPARES THE CARBON FIBER
265
00:16:29,965 --> 00:16:31,517
BY MIXING TWO INGREDIENTS --
266
00:16:31,517 --> 00:16:35,482
A HEAT-MOLDED RESIN AND CHOPPED
PIECES OF RAW CARBON FIBER,
267
00:16:35,482 --> 00:16:37,655
THE STRENGTH OF WHICH
LIES IN THE INTERWEAVING
268
00:16:37,655 --> 00:16:41,827
OF ITS MINISCULE
CARBON FILAMENTS.
269
00:16:41,827 --> 00:16:45,482
AUTOMATED MACHINES POUR THE
CARBON FIBER INTO ALUMINUM MOLDS
270
00:16:45,482 --> 00:16:47,517
IN THE SHAPE OF THE DISK RING.
271
00:16:47,517 --> 00:16:51,793
THE FIRST FILLING STATION FILLS
THE MOLD CAVITY ONLY HALFWAY.
272
00:16:55,931 --> 00:16:59,034
WORKERS THEN FIT A SLOTTED BELT
AROUND THE MOLD
273
00:16:59,034 --> 00:17:02,310
AND INSERT ALUMINUM CORES
INTO THE SLOTS.
274
00:17:02,310 --> 00:17:04,931
THESE CORES WILL FORM
A VENTILATION CHANNEL
275
00:17:04,931 --> 00:17:08,413
IN THE DISK RING TO KEEP
THE DISK FROM OVERHEATING.
276
00:17:19,137 --> 00:17:22,551
NOW THE MOLD MOVES ON
TO THE NEXT FILLING STATION.
277
00:17:22,551 --> 00:17:26,413
IT FILLS THE REMAINDER
OF THE CAVITY WITH CARBON FIBER.
278
00:17:29,413 --> 00:17:31,620
A ROLLER LEVELS THE TOP.
279
00:17:35,172 --> 00:17:37,620
THEN WORKERS CLOSE UP THE MOLD,
280
00:17:37,620 --> 00:17:40,206
AND A SMALL PRESS
PUSHES DOWN THE COVER
281
00:17:40,206 --> 00:17:42,758
TO LIGHTLY COMPACT THE CONTENTS.
282
00:17:42,758 --> 00:17:44,931
THE MOLD ENTERS A LARGE PRESS
283
00:17:44,931 --> 00:17:47,586
WHICH APPLIES 20 TONS
OF PRESSURE
284
00:17:47,586 --> 00:17:51,172
WHILE HEATING TO ALMOST
400 DEGREES FAHRENHEIT.
285
00:17:51,172 --> 00:17:53,862
THIS COMPACTS THE CARBON FIBER
286
00:17:53,862 --> 00:17:57,275
AND TRANSFORMS THE RESIN POWDER
INTO PLASTIC.
287
00:17:57,275 --> 00:18:00,103
ONCE THE MOLD HAS COOLED DOWN
ENOUGH TO BE HANDLED,
288
00:18:00,103 --> 00:18:03,793
WORKERS SUBMERGE IT IN COLD
WATER FOR FIVE TO EIGHT MINUTES.
289
00:18:03,793 --> 00:18:06,068
THIS COOLS THE DISK RING
COMPLETELY,
290
00:18:06,068 --> 00:18:08,724
ENABLING THEM
TO PULL OUT THE CORES.
291
00:18:08,724 --> 00:18:12,448
A COMPUTER-GUIDED LASER
THEN EXAMINES THE MOLD
292
00:18:12,448 --> 00:18:16,068
TO MAKE SURE EVERY LAST CORE
HAS BEEN REMOVED.
293
00:18:16,068 --> 00:18:17,724
WHEN THEY GET THE ALL-CLEAR,
294
00:18:17,724 --> 00:18:20,413
THEY OPEN THE TOP AND BOTTOM
SECTIONS OF THE MOLD
295
00:18:20,413 --> 00:18:22,344
AND EXTRACT THE DISK RING.
296
00:18:24,965 --> 00:18:28,172
COMPUTER-GUIDED MACHINES
THEN SMOOTH OUT THE ROUGH AREAS
297
00:18:28,172 --> 00:18:30,275
AND DRILL
TINY VENTILATION HOLES.
298
00:18:32,689 --> 00:18:34,827
THEY PUT THE DISK RING
INTO AN OVEN
299
00:18:34,827 --> 00:18:36,896
WHICH, OVER THE COURSE
OF TWO DAYS,
300
00:18:36,896 --> 00:18:40,965
GRADUALLY HEATS IT TO JUST OVER
1,800 DEGREES FAHRENHEIT.
301
00:18:40,965 --> 00:18:43,034
THIS CAUSES A CHEMICAL CHANGE
302
00:18:43,034 --> 00:18:46,827
WHICH TRANSFORMS THE PLASTIC
INTO CARBON.
303
00:18:46,827 --> 00:18:48,931
NEXT, THEY TAKE A CRUCIBLE --
304
00:18:48,931 --> 00:18:51,103
A HIGH-HEAT RESISTANT
CONTAINER --
305
00:18:51,103 --> 00:18:53,586
AND POSITION FIVE MOUNTS INSIDE.
306
00:18:56,965 --> 00:19:00,551
THEY PLACE THE DISK RING
ON THE MOUNTS.
307
00:19:00,551 --> 00:19:02,758
THEN IN THE MIDDLE, A FUNNEL,
308
00:19:02,758 --> 00:19:08,172
INTO WHICH THEY POUR A CERAMIC
MATERIAL, A FINE SILICON POWDER.
309
00:19:08,172 --> 00:19:11,586
THEN THEY LOAD THE CRUCIBLE
INTO AN OVEN FOR 24 HOURS.
310
00:19:11,586 --> 00:19:13,758
IT GRADUALLY HEATS THE DISK RING
311
00:19:13,758 --> 00:19:17,620
TO MORE THAN 3,000 DEGREES
FAHRENHEIT, MELTING THE SILICON.
312
00:19:17,620 --> 00:19:19,758
THEN IT APPLIES
LOW-LEVEL SUCTION,
313
00:19:19,758 --> 00:19:22,896
DRAWING THE NOW-LIQUID SILICON
INTO THE DISK RING.
314
00:19:22,896 --> 00:19:25,724
THIS CREATES AN EXCEPTIONALLY
HARD NEW MATERIAL
315
00:19:25,724 --> 00:19:29,103
CALLED SILICON CARBIDE.
316
00:19:29,103 --> 00:19:32,551
AFTER A COMPUTER-GUIDED DRILL
BORES MOUNTING HOLES,
317
00:19:32,551 --> 00:19:34,482
THE DISK RING
GOES INTO A CHAMBER
318
00:19:34,482 --> 00:19:37,000
WHERE IT RECEIVES
A COAT OF PROTECTIVE PAINT.
319
00:19:37,000 --> 00:19:40,689
THE PAINT SHIELDS THE CARBON
IN THIS DISK RING FROM OXYGEN,
320
00:19:40,689 --> 00:19:45,379
WHICH IS CRITICAL BECAUSE AT
HIGH HEAT, OXYGEN BURNS CARBON.
321
00:19:45,379 --> 00:19:47,206
THIS ANTI-OXIDATION TREATMENT
322
00:19:47,206 --> 00:19:50,965
SIGNIFICANTLY EXTENDS THE LIFE
OF THE BRAKE DISK.
323
00:19:50,965 --> 00:19:56,586
THE PAINT IS CURED IN AN OVEN,
LEAVING BEHIND A WHITE RESIDUE.
324
00:19:56,586 --> 00:19:58,724
A ROBOT SANDS IT OFF,
325
00:19:58,724 --> 00:20:01,931
THEN POLISHES
THE ENTIRE DISK-RING SURFACE.
326
00:20:07,931 --> 00:20:09,655
HERE'S WHAT
THE FINISHED DISK RING
327
00:20:09,655 --> 00:20:12,000
LOOKS LIKE BEFORE IT'S CLEANED
AND POLISHED...
328
00:20:14,068 --> 00:20:17,448
...AND AFTER.
329
00:20:17,448 --> 00:20:18,620
EVERY SINGLE BRAKE DISK RING
330
00:20:18,620 --> 00:20:21,068
UNDERGOES
A METICULOUS INSPECTION.
331
00:20:21,068 --> 00:20:23,655
THIS SOPHISTICATED MACHINE
TAKES THOUSANDS
332
00:20:23,655 --> 00:20:26,448
OF HIGH-DEFINITION PHOTOGRAPHS
OF THE SURFACE,
333
00:20:26,448 --> 00:20:30,551
WHICH A COMPUTER THEN ANALYZES
IN MICRON-LEVEL DETAIL.
334
00:20:30,551 --> 00:20:33,206
TO COMPLETE THE BRAKE DISK,
THEY AFFIX THE BELL,
335
00:20:33,206 --> 00:20:35,758
A CIRCULAR COMPONENT
IN THE MIDDLE
336
00:20:35,758 --> 00:20:38,793
WHICH CONNECTS THE BRAKE DISK
TO THE VEHICLE.
337
00:20:38,793 --> 00:20:42,034
THE BELL IS MADE OF EITHER
ALUMINUM OR STAINLESS STEEL
338
00:20:42,034 --> 00:20:45,206
AND BOLTED INTO THE MOUNTING
HOLES IN THE DISK RING.
339
00:20:45,206 --> 00:20:48,172
--Captions by VITAC--
www.vitac.com
340
00:20:48,172 --> 00:20:51,827
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
341
00:20:51,827 --> 00:20:54,206
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
342
00:20:54,206 --> 00:20:56,793
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TOPICS FOR FUTURE SHOWS,
343
00:20:56,793 --> 00:20:58,827
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