Original subtitles

Narrator: THE FOLDING KAYAK IS A SEAWORTHY VESSEL

THAT CAN BE DISASSEMBLED AND STUFFED INTO A DUFFEL BAG.

THIS BOAT-IN-A-BAG CONCEPT

WAS DEVELOPED IN GERMANY A CENTURY AGO.

IT'S A GOOD FIT FOR THE MODERN TRAVELER'S LIFESTYLE

BECAUSE IT CAN BE STOWED IN A CAR TRUNK,

CHECKED ON TO A PLANE, OR STASHED IN THE CONDO CLOSET.

HISTORY HAS SHOWN THAT WHEN GOING GETS ROUGH,

THE FOLDING KAYAK DOESN'T FALL APART.

ADVENTURERS HAVE CROSSED OCEANS IN THEM,

AND TODAY ITS STORY CONTINUES TO UNFOLD.

THE KAYAK FRAME

STARTS WITH PARTS CUT FROM SOLID ASH AND LAMINATED BIRCH.

FOR WATERPROOFING,

THEY DIP THEM IN MARINE-GRADE VARNISH THREE TIMES,

DRYING THEM FOR 24 HOURS BETWEEN DIPS.

A WORKER THEN RIVETS METAL FITTINGS

TO A VARNISHED SECTION OF THE KEEL BOARD.

IT'S THESE FITTINGS THAT ENABLE THE FOLDING KAYAK

TO MOVE WITH THE SEA INSTEAD OF AGAINST IT.

THAT'S BECAUSE THEY'RE MADE OF AN ALUMINUM-COPPER ALLOY,

A METAL WITH A CERTAIN AMOUNT OF GIVE.

HE FASTENS MORE ALUMINUM-ALLOY FITTINGS ON THE CROSS RIBS.

THERE WILL BE A TOTAL OF SEVEN CROSS RIBS

IN THIS TWO-SEATER FOLDING KAYAK.

THE CENTER THREE WILL CARRY MOST OF THE LOAD,

SO THEY'RE MADE OF NINE LAYERS OF LAMINATED BIRCH.

IT'S SUPER STRONG BECAUSE UNLIKE SOLID WOOD,

IT HAS FEW KNOTS OR IMPERFECTIONS.

HE APPLIES A LABEL WITH THE PRODUCTION'S SERIAL NUMBER

TO A BOOMERANG-SHAPED PIECE OF THE FRAME.

THIS IS HOW THE KAYAK OWNER

WOULD ACTUALLY ASSEMBLE THE BOAT ON-SITE.

HE LOCKS TWO SECTIONS OF THE KEEL BOARD TOGETHER

WITH THE FLEXIBLE FITTING WE SAW INSTALLED EARLIER.

HE SNAPS THE BOW PIECE TO THE FRONT

AND HOOKS RODS INTO FITTINGS INSTALLED ON THE BOW.

HE FASTENS A COUPLE OF RIBS TO THE KEEL BOARD.

THE GUNNELS, WHICH ARE THE TOP SIDES OF THE BOAT, ARE NEXT.

HE ATTACHES ONE END TO THE BOW

AND THE OTHER TO ONE OF THE RIBS.

THE BOW AND STERN PARTS ARE COLOR-CODED

WITH RED-PAINTED FITTINGS FOR THE BOW

AND BLUE ONES FOR THE STERN.

ALL THE PARTS FIT TOGETHER LIKE A TOY MODEL.

WITH BOTH GUNNELS NOW ATTACHED,

HE'S READY TO INSTALL MORE RIBS --

THE LAMINATED BIRCH ONES THAT FORM THE COCKPIT.

HE COMPLETES THE ASSEMBLY OF RODS.

ALL THESE RODS WILL GIVE THE KAYAK DIRECTIONAL STABILITY.

HE UNFOLDS PART OF THE KAYAK DECK ASSEMBLY,

KNOWN AS THE COAMING,

AND ARRANGES IT TO SURROUND THE COCKPIT.

HE ATTACHES IT TO THE GUNNELS

USING METAL CLAMPS AND FITTINGS.

HE SLIDES THE TWO SEATS INTO PLACE ON THE KEEL BOARD.

AND HE ATTACHES THE BACK REST TO THE GUNNELS.

THE FRAME OF THIS FOLDING KAYAK

IS NOW COMPLETE AND READY FOR ITS CUSTOM-MADE SKIN.

OVER IN THE SEWING DEPARTMENT,

THE SEAMSTRESS TRACES THE PATTERNS FOR THE KAYAK DECK

ONTO COTTON-HEMP MATERIAL AND CUTS ALONG THE PENCILED LINES.

THIS NATURAL FABRIC WILL ALLOW THE DECK TO BREATHE

AND YET KEEP IT WATER-TIGHT.

IT'S NOW TIME TO PIECE TOGETHER ALL OF THE PARTS,

INCLUDING TWO LONG SLEEVES FOR INSERTING INFLATABLE TUBES.

DEFLATED, THE TUBES WILL CREATE SLACK,

MAKING IT EASIER TO FIT THE FRAME INTO THE SKIN.

INFLATED, THEY MAKE THE KAYAK VIRTUALLY UNSINKABLE.

ONCE THE THICK LAYERS HAVE BEEN STITCHED TOGETHER,

SHE'S READY TO INSERT THE INFLATABLE TUBES.

THEY WERE PUMPED FULL OF AIR TO BE EXAMINED FOR HOLES,

SO SHE DEFLATES THEM.

SHE USES A LONG POLE TO EXTEND HER REACH

AND PUSH THE INFLATABLE TUBE INTO THE SLEEVE.

WITH A SYNTHETIC RUBBER HULL NOW STITCHED TO THE DECK FABRIC,

THE SKIN IS COMPLETE AND READY FOR THE KAYAK'S WOODEN FRAME.

THIS PARTICULAR MODEL HAS BEEN PAINTED BLACK.

IF THE FIT IS EVEN SLIGHTLY OFF,

THE KAYAK WON'T PERFORM PROPERLY.

THE SKIN FITS LIKE A GLOVE.

HE BRUSHES GLUE ONTO THE TIPS OF THE BOW AND STERN

AND THEN PRESSES MOLDED RUBBER BUMPERS ONTO THOSE AREAS.

THE BUMPERS WILL PROTECT THE ENDS OF THE HULL CASING,

WHICH TAKES A LOT OF HARD KNOCKS.

IN TOTAL, IT TAKES ABOUT 50 PERSON-HOURS

TO MAKE A FOLDING KAYAK.

IT SHOULD TAKE THE OWNER ABOUT 15 MINUTES

TO DISASSEMBLE OR ASSEMBLE ONE.

FOR SOME, IT WILL BECOME A TRAVELING ESSENTIAL,

PART OF THE LUGGAGE ON ANY TRIP.

Narrator: THE PIÑATA IS A COLORFUL PAPER-MACHE OBJECT

TYPICALLY FILLED WITH CANDY OR SMALL TOYS,

THEN SUSPENDED HIGH FROM A STRING.

BLINDFOLDED PARTIERS TAKE TURNS

TRYING TO HIT THE PIÑATA WITH A STICK TO BREAK IT OPEN

AND RELEASE A SHOWER OF GOODIES.

FROM POPULAR CARTOON CHARACTERS TO COLORFUL, GLITTERY SHAPES,

TODAY'S PIÑATAS ARE A BIG HIT AT KID'S PARTIES

WHERE CHILDREN EAGERLY AWAIT THE DECISIVE BLOW

THAT BREAKS OPEN THE PIÑATA, RELEASING THE TREATS INSIDE.

THE TRADITIONAL WAY TO BUILD ONE

STARTS WITH A CLAY POT SUSPENDED FROM A STRING.

THE PIÑATA-MAKER GLUES CARDBOARD SHAPES TO IT

AND SECURES THEM BY GLUING ON PIECES OF NEWSPAPER.

THEN SHE COVERS THE REST OF THE POT.

WHEN THE GLUE DRIES,

SHE DECORATES THE SURFACE WITH COLORFUL PAPER.

THE MODERN METHOD IS TO USE A BALLOON INSTEAD OF A CLAY POT.

AFTER INFLATING THE BALLOON,

SHE PASTES PIECES OF NEWSPAPER ALL OVER IT.

THIS TECHNIQUE IS KNOWN AS PAPER-MACHE.

THE TRICK IS TO COMPLETELY SATURATE THE NEWSPAPER

WITH A THICK PASTE

AND MAKE SURE NO PART OF THE BALLOON IS LEFT UNCOVERED.

SHE CONTINUES THIS PROCESS

UNTIL SHE'S BUILT UP TWO OR THREE EVEN LAYERS OF NEWSPAPER

ALL OVER THE BALLOON.

THEN SHE SUSPENDS IT FROM A CLOTHESPIN TO DRY.

HOURS LATER, THE PAPER-MACHE

IS HARDENED INTO A SHELL AROUND THE BALLOON,

WHICH SHE NOW BREAKS AND REMOVES.

NEXT, SHE CUTS AN OPENING AT THE TOP OF THE SHELL.

THIS IS THE HOLE

THROUGH WHICH THE BUYER WILL FILL THE PIÑATA WITH TREATS.

SHE'LL LATER REATTACH THE CUT PIECE TO MAKE A TRAP DOOR.

BUT FIRST, WITH THE SHARP TIPS OF HER SCISSORS,

SHE PIERCES A ROW OF HOLES ALONG THE CIRCUMFERENCE

AND THREADS TWINE THROUGH THEM.

SHE LEAVES LONG ENDS AT THE TOP

WITH WHICH TO SUSPEND THE PIÑATA.

THIS PIÑATA WILL BE STAR-SHAPED.

TO MAKE EACH POINT,

SHE ROLLS THIN CARDBOARD INTO A CONE, TAPING IT CLOSED.

SHE TRIMS IT TO THE REQUIRED SIZE,

THEN CUTS TABS AT THE BASE AND BENDS THEM BACK.

SHE MAKES SEVEN OF THESE CARDBOARD POINTS,

THEN TAPES THEM ONTO THE SHELL ONE BY ONE.

ONCE ALL SEVEN ARE POSITIONED,

THE DECORATING WITH COLORFUL, GLITTERY FOIL WRAPPING PAPER

CAN BEGIN.

SHE TAPES A SHEET AROUND EACH POINT OF THE STAR.

THEN SHE APPLIES GLUE IN BETWEEN THE POINTS

AND ADHERES PIECES OF WRAPPING PAPER TO THOSE AREAS.

SHE FOLDS OTHER PIECES INTO FLOWER SHAPES

AND GLUES THEM ON, AS WELL.

ONCE THE ENTIRE PIÑATA IS COVERED,

SHE TAPES MATCHING STREAMERS TO THE END OF EACH POINT.

HISTORIANS BELIEVE SPANISH MISSIONARIES

USED STAR PIÑATAS LIKE THIS ONE

TO CONVERT THE NATIVE PEOPLES IN THE AMERICAS TO CHRISTIANITY.

THE STAR SYMBOLIZED SATAN,

ITS SEVEN POINTS, THE SEVEN DEADLY SINS,

ITS BEAUTIFUL COLORS, TEMPTATION.

WEARING A BLINDFOLD REPRESENTED BLIND FAITH IN GOD.

STRIKING THE PIÑATA WITH A STICK MEANT GOODNESS

AND VIRTUE BATTLING EVIL.

BREAKING THE PIÑATA, RELEASING A SHOWER OF TREATS OR TRINKETS,

SYMBOLIZED HEAVENLY REWARDS.

Narrator: HUMAN BEINGS HAVE ALWAYS GENERATED GARBAGE.

IN THE BATTLE TO KEEP THE STREETS CLEAN,

THE MECHANIZED GARBAGE TRUCK IS A COMBAT VEHICLE.

IT CRUSHES TONS OF TRASH

EN ROUTE TO DELIVER IT TO LANDFILLS,

INCINERATORS, AND RECYCLING FACILITIES.

WITHOUT IT, WE'D ALL BE KNEE-DEEP IN GARBAGE.

GARBAGE TRUCKS HAVE DIFFERENT APPROACHES TO HANDLING GARBAGE.

SOME LOAD FROM THE FRONT, OTHER FROM THE REAR OR SIDE.

AND SOME ARE ENTIRELY MECHANIZED LIKE THIS SIDE-LOADER TRUCK.

THE OPERATOR INSIDE THE CAB BARELY NEEDS TO LIFT A FINGER

AS THE HYDRAULIC LIFT-ARM DOES ALL THE HEAVY WORK.

THE GARBAGE TRUCK HAS COME A LONG WAY

SINCE IT HIT THE STREET IN 1952.

PRODUCTION ON A MODERN SIDE-LOADER TRUCK

BEGINS WITH A WELDING ROBOT.

THE ROBOT FUSES NUMEROUS STEEL SUPPORTS

TO THE TRUCK BODY FLOOR.

THESE SUPPORTS WILL ALLOW THE TRUCK

TO HOLD UP TO THE FORCE OF TONS OF TRASH BEING COMPACTED INSIDE.

MEANWHILE, DOWN THE LINE, OTHER PARTS LIKE THE ROOF AND SIDES

TAKE SHAPE IN SEPARATE ASSEMBLIES.

ONCE THEY'RE COMPLETE,

THEY HOIST THE LARGE STEEL PARTS INTO PLACE

AND ASSEMBLE THEM WITHIN A METAL FRAMEWORK.

THE FRAMEWORK SERVES AS A GUIDE

TO PIECE TOGETHER ALL THE PARTS OF THE TRUCK BOX.

ONCE ASSEMBLED, THE WORKERS CLAMP THE PARTS TOGETHER

TO SECURE THE ASSEMBLY AS THEY WELD THE SEAMS.

THE GARBAGE TRUCK BODY IS THEN READY FOR THE MECHANIZED PARTS,

BEGINNING WITH A HOPPER.

IT'S EQUIPPED WITH A POWERFUL, HYDRAULIC COMPACTOR

TO SQUEEZE AS MUCH TRASH AS POSSIBLE INTO THE TRUCK.

THEY FIT THE HOPPER SNUGLY TO THE FRONT OF THE TRUCK BODY

AND WELD IT TO IT.

THEN THEY LIFT THE TAILGATE INTO POSITION

AT THE REAR OF THE TRUCK BOX.

THEY HINGE IT TO THE TRUCK

BY SLIDING HEAVY-DUTY STEEL PINS THROUGH BRACKETS.

ONCE HINGED, THE TAILGATE CAN SWING UP AND OUT OF THE WAY

TO ALLOW GARBAGE TO BE DISCHARGED.

THE DRIVING FORCE FOR THIS

IS A PAIR OF HYDRAULIC CYLINDERS ATTACHED BY BRACKETS,

WELDED TO THE TAILGATE AT ONE END

AND THE TRUCK BODY AT THE OTHER.

WITH THAT JOB DONE, THESE CYLINDERS

CAN NOW EXTEND TO LIFT THE TAILGATE

AND RETRACT TO CLOSE IT.

ACROSS THE FACTORY FLOOR,

ANOTHER TEAM ASSEMBLES A PAIR OF STEEL LIFT-ARMS.

THESE LIFT-ARMS ARE DESIGNED FOR ANOTHER KIND OF TRUCK,

THE FRONT-END LOADER.

IT'S MAINLY USED TO COLLECT

HEFTY COMMERCIAL GARBAGE CONTAINERS.

IN ACTION, THESE ARMS PIVOT AROUND THE TRUCK CAB

AND EXTEND TO THE FRONT TO FORK UP THE TRASH CONTAINER

AND DEPOSIT THE CONTENTS IN THE HOPPER.

HYDRAULIC CYLINDERS ALSO POWER THESE LIFT-ARMS.

WHEN THE TASK IS COMPLETE, THE FORKS AT THE END OF THE ARMS

FOLD BACK OUT OF THE WAY.

NEARBY, WORKERS TEST THIS REAR-LOADER GARBAGE TRUCK.

ITS TAILGATE IS SPLIT INTO TWO HOPPERS --

ONE FOR RECYCLABLES AND THE OTHER FOR TRASH.

HYDRAULIC SYSTEMS LIFT THEM ONE AT A TIME OR SIMULTANEOUSLY.

COLLECTING GARBAGE AND DISPOSING OF IT

CAN BE TOUGH ON A TRUCK'S PAINT JOB,

SO THEY APPLY AN EXTRA-DURABLE FINISH.

THEY SPRAY SEALER ON THE SANDED OUTER SURFACE,

FOLLOWED BY TWO COATS OF EPOXY PAINT.

AFTER THAT, THEY BAKE ON THE LAYERS.

MEANWHILE, THE TRUCK CHASSIS HAS ARRIVED FROM ANOTHER FACTORY.

IT'S A STANDARD SIZE,

SO THEY CHOP A PIECE OFF TO SIZE IT FOR THE GARBAGE-TRUCK BODY.

THEY INSTALL BRACKET PLATES AT THE BACK

AND SLIDE THICK PINS THROUGH THE HOLES

TO JOIN THE TRUCK BODY TO THE CHASSIS.

USING A CRANE, THEY LIFT THE AUTOMATED SIDE-LOADER TRUCK BODY

ONTO THE MODIFIED CHASSIS.

ONCE IT'S INSTALLED, THEY TEST THE COMPACTOR.

DUAL HYDRAULIC CYLINDERS

PUSH THE EJECTOR BLADE TO THE BACK OF THE TRUCK.

THEY TEST THE TAILGATE -- WHICH HAS BY NOW BEEN EQUIPPED

WITH SIGNAL LIGHTS, MUD FLAPS, AND OTHER PARTS --

AND VERIFY THAT EVERYTHING FUNCTIONS PROPERLY.

ONCE A TRUCK PASSES MUSTER,

IT'S READY TO HANDLE

WHATEVER GARBAGE SOCIETY THROWS ITS WAY.

AND WITH THESE AUTOMATED GARBAGE TRUCKS,

THERE'S NO NEED FOR ANYONE TO STRAIN THEIR BACK

OR GET THEIR HANDS DIRTY,

BECAUSE THESE ROBOT ARMS CAN HANDLE IT.

Narrator: HIGH-PERFORMANCE CARS

TYPICALLY HAVE CERAMIC COMPOSITE BRAKE DISKS

RATHER THAN REGULAR CAST-IRON ONES.

THAT KIND OF POWER ON WHEELS REQUIRES BEING LIGHTWEIGHT,

AND CAST IRON IS VERY HEAVY.

IT WOULD ALSO WEAR OUT TOO QUICKLY

DUE TO THE INTENSE HEAT FRICTION GENERATES

WHEN YOU BRAKE A CAR WITH SUCH A POWERFUL ENGINE.

CERAMIC IS HEAT-RESISTANT UP TO 1,830 DEGREES FAHRENHEIT.

THEREFORE, THESE CERAMIC COMPOSITE BRAKE DISKS

LAST ABOUT 60 TIMES LONGER THAN STANDARD CAST-IRON DISKS.

CERAMIC COMPOSITE MEANS THE CERAMIC MATERIAL SILICON

IS COMBINED WITH CARBON FIBER FOR STRENGTH.

THE DISK FACTORY PREPARES THE CARBON FIBER

BY MIXING TWO INGREDIENTS --

A HEAT-MOLDED RESIN AND CHOPPED PIECES OF RAW CARBON FIBER,

THE STRENGTH OF WHICH LIES IN THE INTERWEAVING

OF ITS MINISCULE CARBON FILAMENTS.

AUTOMATED MACHINES POUR THE CARBON FIBER INTO ALUMINUM MOLDS

IN THE SHAPE OF THE DISK RING.

THE FIRST FILLING STATION FILLS THE MOLD CAVITY ONLY HALFWAY.

WORKERS THEN FIT A SLOTTED BELT AROUND THE MOLD

AND INSERT ALUMINUM CORES INTO THE SLOTS.

THESE CORES WILL FORM A VENTILATION CHANNEL

IN THE DISK RING TO KEEP THE DISK FROM OVERHEATING.

NOW THE MOLD MOVES ON TO THE NEXT FILLING STATION.

IT FILLS THE REMAINDER OF THE CAVITY WITH CARBON FIBER.

A ROLLER LEVELS THE TOP.

THEN WORKERS CLOSE UP THE MOLD,

AND A SMALL PRESS PUSHES DOWN THE COVER

TO LIGHTLY COMPACT THE CONTENTS.

THE MOLD ENTERS A LARGE PRESS

WHICH APPLIES 20 TONS OF PRESSURE

WHILE HEATING TO ALMOST 400 DEGREES FAHRENHEIT.

THIS COMPACTS THE CARBON FIBER

AND TRANSFORMS THE RESIN POWDER INTO PLASTIC.

ONCE THE MOLD HAS COOLED DOWN ENOUGH TO BE HANDLED,

WORKERS SUBMERGE IT IN COLD WATER FOR FIVE TO EIGHT MINUTES.

THIS COOLS THE DISK RING COMPLETELY,

ENABLING THEM TO PULL OUT THE CORES.

A COMPUTER-GUIDED LASER THEN EXAMINES THE MOLD

TO MAKE SURE EVERY LAST CORE HAS BEEN REMOVED.

WHEN THEY GET THE ALL-CLEAR,

THEY OPEN THE TOP AND BOTTOM SECTIONS OF THE MOLD

AND EXTRACT THE DISK RING.

COMPUTER-GUIDED MACHINES THEN SMOOTH OUT THE ROUGH AREAS

AND DRILL TINY VENTILATION HOLES.

THEY PUT THE DISK RING INTO AN OVEN

WHICH, OVER THE COURSE OF TWO DAYS,

GRADUALLY HEATS IT TO JUST OVER 1,800 DEGREES FAHRENHEIT.

THIS CAUSES A CHEMICAL CHANGE

WHICH TRANSFORMS THE PLASTIC INTO CARBON.

NEXT, THEY TAKE A CRUCIBLE --

A HIGH-HEAT RESISTANT CONTAINER --

AND POSITION FIVE MOUNTS INSIDE.

THEY PLACE THE DISK RING ON THE MOUNTS.

THEN IN THE MIDDLE, A FUNNEL,

INTO WHICH THEY POUR A CERAMIC MATERIAL, A FINE SILICON POWDER.

THEN THEY LOAD THE CRUCIBLE INTO AN OVEN FOR 24 HOURS.

IT GRADUALLY HEATS THE DISK RING

TO MORE THAN 3,000 DEGREES FAHRENHEIT, MELTING THE SILICON.

THEN IT APPLIES LOW-LEVEL SUCTION,

DRAWING THE NOW-LIQUID SILICON INTO THE DISK RING.

THIS CREATES AN EXCEPTIONALLY HARD NEW MATERIAL

CALLED SILICON CARBIDE.

AFTER A COMPUTER-GUIDED DRILL BORES MOUNTING HOLES,

THE DISK RING GOES INTO A CHAMBER

WHERE IT RECEIVES A COAT OF PROTECTIVE PAINT.

THE PAINT SHIELDS THE CARBON IN THIS DISK RING FROM OXYGEN,

WHICH IS CRITICAL BECAUSE AT HIGH HEAT, OXYGEN BURNS CARBON.

THIS ANTI-OXIDATION TREATMENT

SIGNIFICANTLY EXTENDS THE LIFE OF THE BRAKE DISK.

THE PAINT IS CURED IN AN OVEN, LEAVING BEHIND A WHITE RESIDUE.

A ROBOT SANDS IT OFF,

THEN POLISHES THE ENTIRE DISK-RING SURFACE.

HERE'S WHAT THE FINISHED DISK RING

LOOKS LIKE BEFORE IT'S CLEANED AND POLISHED...

...AND AFTER.

EVERY SINGLE BRAKE DISK RING

UNDERGOES A METICULOUS INSPECTION.

THIS SOPHISTICATED MACHINE TAKES THOUSANDS

OF HIGH-DEFINITION PHOTOGRAPHS OF THE SURFACE,

WHICH A COMPUTER THEN ANALYZES IN MICRON-LEVEL DETAIL.

TO COMPLETE THE BRAKE DISK, THEY AFFIX THE BELL,

A CIRCULAR COMPONENT IN THE MIDDLE

WHICH CONNECTS THE BRAKE DISK TO THE VEHICLE.

THE BELL IS MADE OF EITHER ALUMINUM OR STAINLESS STEEL

AND BOLTED INTO THE MOUNTING HOLES IN THE DISK RING.

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

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

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