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>> Narrator: THIS EDIBLE MONEY
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IS A SYMBOLIC TREAT.
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IN SOME PARTS OF THE WORLD,
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CHOCOLATE COINS ARE STUFFED IN
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CHRISTMAS STOCKINGS TO CELEBRATE
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THE CHARITY OF SAINT NICHOLAS.
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THEY'RE ALSO HANDED OUT TO
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JEWISH CHILDREN DURING THE
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FESTIVAL OF HANUKKAH TO TEACH
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THEM THE VALUE OF MONEY AND
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CHARITY.
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CHOCOLATE COINS DON'T HAVE ANY
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PURCHASING POWER, BUT THEY DO
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BUY A LOT OF APPRECIATIVE SMILES
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FROM THE KIDS.
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THEY START WITH GIANT CHOCOLATE
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BARS.
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EACH ONE IS 10 POUNDS OF PURE
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CHOCOLATE.
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THE WORKER TRANSFERS THE BIG
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BARS TO A KETTLE.
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IT'S A KIND OF DOUBLE BOILER.
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HOT WATER BUBBLES AND STEAMS
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INSIDE A SLEEVE SHELL TO HEAT
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AND MELT THE CHOCOLATE.
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THERE ARE 2 1/2 TONS OF LIQUID
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CHOCOLATE IN THIS KETTLE.
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THE MACHINE NOW PUMPS THE
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CHOCOLATE THROUGH A LONG PIPE
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WITH DIFFERENT COOLING ZONES.
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THE CHOCOLATE THICKENS BUT NOT
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TO THE POINT OF
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SOLIDIFICATION -- A PROCESS
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CALLED TEMPERING.
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IT CAUSES THE CHOCOLATE TO FORM
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A PRECISE CRYSTAL STRUCTURE FOR
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JUST THE RIGHT TEXTURE AND
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TASTE.
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THE THICK LIQUID CHOCOLATE FLOWS
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ONTO A CONVEYER THAT BRINGS THE
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CHOCOLATE UNDER A BROAD BLADE.
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THE BLADE LEVELS IT TO A
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SPECIFIC THICKNESS AND SPREADS
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IT EVENLY, CREATING A LONG SHEET
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OF CHOCOLATE.
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THE CHOCOLATE NOW BEGINS TO
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COAGULATE AND HARDEN.
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TO SPUR THAT PROCESS, IT TRAVELS
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THROUGH A REFRIGERATION TUNNEL
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THAT IS APPROXIMATELY 15 YARDS
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LONG.
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THIS JOURNEY TRANSFORMS THE
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LIQUID CHOCOLATE INTO A SOFT
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SOLID.
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NEXT, THEY CLEAN AND PREPARE THE
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DIE.
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IT'S A SPRING-LOADED DEVICE THAT
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WORKS COOKIE-CUTTER STYLE TO
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PUNCH OUT ROUND BLANKS.
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THERE IS ONE BIG DIFFERENCE.
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EACH CUTTER IS LONG AND TUBULAR,
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SO AS IT PUNCHES OUT THE
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CHOCOLATE BLANKS, THEY
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ACCUMULATE INSIDE.
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THE LATTICEWORK OF LEFTOVERS
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JOURNEYS FORWARD TO BE RE-MELTED
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INTO THE PROCESS...
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SO NOT A CRUMB OF CHOCOLATE GOES
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TO WASTE.
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AT THE END OF THE LINE, DOZENS
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OF COIN BLANKS HAVE STACKED UP
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IN EACH MAGAZINE.
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AND PILES OF LEFTOVER CHOCOLATE
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HAVE ACCUMULATED IN A BIN THAT
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WILL NOW BE TRANSFERRED BACK TO
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THE MELTING POT.
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NOW IT'S TIME TO PRINT SOME
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CHOCOLATE MONEY.
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TO DO THIS, THEY WRAP THE
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CHOCOLATE FIRST AND THEN EMBOSS
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BOTH THE WRAP AND THE CHOCOLATE
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BLANKS SIMULTANEOUSLY.
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HERE'S HOW IT WORKS.
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SHEETS OF GLOSSY GOLD FOIL
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TRAVEL BETWEEN ROLLERS TO
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ESTABLISH AN EVEN TENSION.
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AHEAD, A FORKED ARM MOVES TWO
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CHOCOLATE BLANKS BETWEEN THE
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FOIL SHEETS.
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PISTON-LIKE KNIVES MOVE IN TO
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WRAP, CUT, AND FOLD THE FOIL
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AROUND THE BLANKS.
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THE FORKED ARM THEN DELIVERS THE
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FOIL-WRAPPED BLANKS TO A DIE
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PRESS.
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IT STAMPS DESIGNS ON BOTH SIDES
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OF THE COINS, MAKING AN
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IMPRESSION ON THE FOIL THROUGH
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TO THE CHOCOLATE.
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THE CHOCOLATE, ALTHOUGH SOLID,
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IS STILL WARM ENOUGH TO RECEIVE
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THE IMAGE.
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REMOVED FROM THE MACHINE, HERE'S
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WHAT THE DIE HEADS LOOK LIKE.
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THESE ARE USED TO EMBOSS
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CHOCOLATE COINS WITH AMERICAN
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PENNY MARKINGS.
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AS FOR THE FOIL DISCARDS, THEY
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DON'T END UP ON THE SCRAP HEAP.
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INSTEAD, THEY ACCUMULATE IN A
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BIN TO BE SENT OUT FOR
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RECYCLING.
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THEY MAKE 150,000 FOIL-WRAPPED
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COINS A DAY.
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TO CHANGE THE CURRENCY TYPE,
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THEY SIMPLY SWITCH DIE HEADS.
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CHOCOLATE COINS CAN BE MADE IN
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MANY SIZES WITH A RANGE OF
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DIFFERENT ILLUSTRATIONS.
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THE COINS NOW SPILL OUT ONTO A
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CONVEYOR THAT TAKES THEM TO A
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BIN.
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ALL THAT'S LEFT NOW IS THE
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PACKAGING, WHICH WILL BE THE
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TRADITIONAL MESH BAG.
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FROM START TO FINISH, IT TAKES
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LESS THAN AN HOUR TO MAKE A
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CHOCOLATE COIN.
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GOLD DOLLARS OR $5 POKER
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CHIPS, EVERY DAY, IT'S A
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JACKPOT OF CHOCOLATE MONEY AT
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THIS FACTORY.
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SO THERE'S NEVER ANY SHORTAGE OF
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EDIBLE CASH, ONLY DECISIONS TO
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BE MADE -- POKER CHIP OR
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CHOCOLATE PENNY?
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YOU COULD ALWAYS FLIP A COIN.
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>> Narrator: IN-FLOOR HEATING
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SYSTEMS ARE HARDLY A NEW
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CONCEPT.
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THE ANCIENT ROMANS HEATED THE
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FLOORS OF THEIR BATHHOUSES.
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TODAY'S SYSTEMS USE EITHER
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ELECTRIC CABLES OR HOT-WATER
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PIPES INSTALLED BENEATH THE
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FLOOR'S SURFACE.
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AS THE FLOOR WARMS UP, THE HEAT
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RADIATES TO PEOPLE AND OBJECTS
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IN THE ROOM.
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FOR ELECTRIC RADIANT HEATING
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SYSTEMS, INSTALLERS AFFIX
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INSTALLATION GAUGES TO THE
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SUBFLOOR, THEN WIND ELECTRICAL
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CABLES AROUND THOSE GAUGES.
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WHEN THERE ARE NO OBJECTS SUCH
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AS BATHTUBS TO WORK AROUND,
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INSTALLERS CAN ROLL OUT A
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FIBERGLASS MAT THAT HAS THE
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CABLE EMBEDDED.
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ONCE THE CABLES ARE IN PLACE,
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THE INSTALLERS LAY DOWN THE
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FLOOR.
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RADIANT HEATING SYSTEMS CAN BE
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INSTALLED UNDER MOST TYPES OF
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FLOORING.
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IT'S UP TO 28% MORE ENERGY
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EFFICIENT THAN FORCED-AIR OR
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BASEBOARD HEATING.
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AT THE CORE OF THOSE ELECTRIC
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HEATING CABLES ARE COPPER OR
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COPPER-ALLOY WIRES CALLED
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CONDUCTORS.
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AN UNWINDING SYSTEM FEEDS EACH
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SPOOL OF CONDUCTOR TO AN
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EXTRUSION MACHINE.
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EXTRUSION MACHINES FORCE MOLTEN
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PLASTIC THROUGH A DIE TO FORM A
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PARTICULAR SHAPE.
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THEY LOAD THE RAW PLASTIC
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PELLETS INTO A RECEPTACLE CALLED
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A HOPPER AT THE TOP OF THE
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MACHINE.
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THE PELLETS DROP DOWN INTO A
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HEATING DEVICE THAT QUICKLY
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LIQUEFIES THEM.
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THE MACHINE THEN FORCES THE
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MOLTEN PLASTIC THROUGH A ROUND
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DIE, FORMING A PLASTIC JACKET
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AROUND THE CONDUCTOR PASSING
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THROUGH.
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THIS JACKET INSULATES THE BARE
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WIRE.
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A WATER BATH COOLS THE
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STILL-WARM PLASTIC TO PREVENT
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STICKING AS THEY WIND UP THE
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CONDUCTOR ON A SPOOL.
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THE NEXT MACHINE TAKES TWO
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INSULATED CONDUCTORS AND TWISTS
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THEM TOGETHER INTO A SINGLE
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STRAND.
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THIS FORMS A PAIRED CONDUCTOR.
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THEN THE NEXT MACHINE BRAIDS 16
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SPOOLS OF TRIPLE-STRAND COPPER
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WIRE AROUND THE PAIRED
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CONDUCTOR.
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THIS COPPER BRAID IS THE GROUND.
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THE GROUND WILL CAPTURE ANY
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ELECTRICAL LEAK SHOULD THE CABLE
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GET DAMAGED, PREVENTING
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ELECTROCUTION.
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THE CABLE'S INTERNAL WIRING IS
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COMPLETE.
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00:08:01,467 --> 00:08:03,233
NOW THEY RUN IT THROUGH AN
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ALIGNMENT JIG THAT STRAIGHTENS
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AND SMOOTHS EVERYTHING OUT IN
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PREPARATION FOR THE NEXT
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EXTRUSION PROCESS, WHICH COATS
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THE WIRING IN A FINAL PLASTIC
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JACKET.
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THEN THEY WIND UP THE CABLE ON A
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SPOOL TO PREPARE IT FOR
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PACKAGING...
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AND PUT ONE END INTO A MACHINE
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THAT CUTS OFF AN INCH OR SO OF
225
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JACKET.
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AFTER SOLDERING THE TWO
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CONDUCTORS TO EACH OTHER SO THAT
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THE ELECTRICAL CURRENT GOES OUT
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ON ONE AND RETURNS ON THE OTHER,
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THEY INSULATE THIS CONNECTION
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FROM THE BRAIDED GROUND WITH
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TRANSPARENT HEAT-SHRINK PLASTIC.
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THEN THEY PULL THE GROUND OVER
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THE NOW-INSULATED END AND COVER
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IT WITH A BLACK HEAT-SHRINK
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PLASTIC.
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THIS SEALS THE END OF THE CABLE
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SO THAT WATER CAN'T SEEP IN AND
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SHORT OUT THE WIRING.
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ANOTHER MACHINE PRODUCES THE
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CABLE THAT BRINGS POWER FROM THE
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WALL-MOUNTED THERMOSTAT TO THE
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HEATING CABLES UNDER THE FLOOR.
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IT'S CALLED THE COLD LEAD
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BECAUSE IT LEADS TO THE HEATING
246
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CABLE, YET ITSELF DOESN'T HEAT
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UP.
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00:09:09,400 --> 00:09:11,233
THIS MACHINE CUTS THE AVERAGE
249
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PRODUCTION RUN OF 8 1/2 MILES OF
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COLD-LEAD CABLE INTO SEVERAL
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CABLES OF STANDARD LENGTH,
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EITHER 2 OR 3 YARDS LONG
253
00:09:19,067 --> 00:09:21,967
DEPENDING ON THE PRODUCT FORMAT.
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THE COLD LEAD IS COMPRISED OF
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TWO CONDUCTORS AND A SEPARATE
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GROUND WIRE.
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00:09:29,733 --> 00:09:31,300
WORKERS CONNECT IT TO THE
258
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HEATING CABLE BY FUSING
259
00:09:32,733 --> 00:09:34,333
CONDUCTOR TO CONDUCTOR AND
260
00:09:34,333 --> 00:09:36,833
GROUND TO GROUND.
261
00:09:36,833 --> 00:09:38,567
THEY PROTECT THIS JUNCTION WITH
262
00:09:38,567 --> 00:09:40,067
A HARD PLASTIC COVER CALLED A
263
00:09:40,067 --> 00:09:41,267
MECHANICAL JOINT.
264
00:09:41,267 --> 00:09:43,067
THIS, TOO, MUST BE SEALED TO
265
00:09:43,067 --> 00:09:45,067
PREVENT ANY WATER INFILTRATION.
266
00:09:45,067 --> 00:09:46,833
AFTER ALL, HEATING CABLES ARE
267
00:09:46,833 --> 00:09:48,767
OFTEN INSTALLED UNDER FLOORS IN
268
00:09:48,767 --> 00:09:50,333
WET ENVIRONMENTS SUCH AS
269
00:09:50,333 --> 00:09:51,167
BATHROOMS.
270
00:09:51,167 --> 00:09:52,900
SO, THEY SEAL THE JOINT BY
271
00:09:52,900 --> 00:09:54,967
INJECTING ENOUGH POLYURETHANE TO
272
00:09:54,967 --> 00:09:56,767
FILL EVERY NOOK AND CRANNY.
273
00:09:56,767 --> 00:09:58,767
THE POLYURETHANE TAKES THREE TO
274
00:09:58,767 --> 00:10:00,267
FOUR MINUTES TO DRY, THEN
275
00:10:00,267 --> 00:10:02,300
ANOTHER 24 HOURS TO FULLY
276
00:10:02,300 --> 00:10:04,933
HARDEN.
277
00:10:04,933 --> 00:10:06,567
THIS MACHINE ASSEMBLES THE
278
00:10:06,567 --> 00:10:08,433
OTHER FORMAT -- THE ROLL-OUT MAT
279
00:10:08,433 --> 00:10:10,533
WITH HEATING CABLE EMBEDDED.
280
00:10:10,533 --> 00:10:12,433
FIRST, IT WINDS CABLE THE SAME
281
00:10:12,433 --> 00:10:14,200
WAY AN INSTALLER WOULD ONTO
282
00:10:14,200 --> 00:10:16,767
INSTALLATION GAUGES.
283
00:10:16,767 --> 00:10:18,333
THEN IT SECURES IT TO AN
284
00:10:18,333 --> 00:10:20,367
ADHESIVE-BACKED FIBERGLASS MESH.
285
00:10:20,367 --> 00:10:22,033
THREE STRIPS OF ADHESIVE TAPE
286
00:10:22,033 --> 00:10:24,333
ABOVE AND BELOW REINFORCE THE
287
00:10:24,333 --> 00:10:26,533
BOND.
288
00:10:26,533 --> 00:10:28,267
THE MAT FORMAT IS SOLD BY THE
289
00:10:28,267 --> 00:10:30,033
ROLL, WHILE THE LOOSE CABLE IS
290
00:10:30,033 --> 00:10:31,400
PACKAGED IN A KIT WITH
291
00:10:31,400 --> 00:10:33,067
INSTALLATION GAUGES AND GLUE
292
00:10:33,067 --> 00:10:34,833
STICKS TO ADHERE THE GAUGES TO
293
00:10:34,833 --> 00:10:36,767
THE SUBFLOOR.
294
00:10:50,700 --> 00:10:52,367
Narrator: IT LOOKS LIKE A CAR
295
00:10:52,367 --> 00:10:54,167
AND IT DRIVES LIKE A TRICYCLE --
296
00:10:54,167 --> 00:10:55,533
A CHILD-SIZE VERSION OF A
297
00:10:55,533 --> 00:10:57,367
MOTORIZED THREE-WHEELER VEHICLE,
298
00:10:57,367 --> 00:10:58,467
POPULAR IN THE EARLY
299
00:10:58,467 --> 00:10:59,600
20th CENTURY.
300
00:10:59,600 --> 00:11:01,533
INSTEAD OF GAS, PEDAL POWER
301
00:11:01,533 --> 00:11:03,500
PROPELS THIS REPLICA FORWARD.
302
00:11:03,500 --> 00:11:05,667
BASED ON ACTUAL VEHICLES, A WAVE
303
00:11:05,667 --> 00:11:08,067
OF NOSTALGIA HAS PUT PEDAL CARS
304
00:11:08,067 --> 00:11:12,967
ON THE ROAD TO A COMEBACK.
305
00:11:12,967 --> 00:11:14,933
AN OLD-STYLE PEDAL CAR IS A
306
00:11:14,933 --> 00:11:17,067
SNAZZY TOY WITH A SLEEK METAL
307
00:11:17,067 --> 00:11:19,367
BODY AND REAL RUBBER TIRES.
308
00:11:19,367 --> 00:11:21,533
HIGHLY COLLECTIBLE, OWNING ONE
309
00:11:21,533 --> 00:11:24,133
IS A TRIP DOWN MEMORY LANE.
310
00:11:24,133 --> 00:11:25,967
PRODUCTION STARTS WITH THE PEDAL
311
00:11:25,967 --> 00:11:27,067
CAR'S WOOD FLOOR.
312
00:11:27,067 --> 00:11:28,533
THE WORKER PLACES A METAL
313
00:11:28,533 --> 00:11:30,233
TEMPLATE OF THE FLOOR UNDER A
314
00:11:30,233 --> 00:11:31,667
SHEET OF ASH PLYWOOD AND
315
00:11:31,667 --> 00:11:33,333
TRANSFERS THE TWO TO A ROUTER
316
00:11:33,333 --> 00:11:34,467
TABLE.
317
00:11:34,467 --> 00:11:36,267
WITH A PIN IN THE TEMPLATE BELOW
318
00:11:36,267 --> 00:11:37,767
TO GUIDE HIM, HE MOVES THE
319
00:11:37,767 --> 00:11:40,333
PLYWOOD AS THE ROUTER CUTS IT.
320
00:11:40,333 --> 00:11:42,267
THIS PRODUCES A PART THAT'S THE
321
00:11:42,267 --> 00:11:44,067
PRECISE SIZE AND SHAPE NEEDED
322
00:11:44,067 --> 00:11:49,067
FOR THE PEDAL-CAR FLOOR.
323
00:11:49,067 --> 00:11:51,133
USING THE SAME SYSTEM, HE CUTS A
324
00:11:51,133 --> 00:11:53,167
SLOT FOR THE PEDALS AND ANOTHER
325
00:11:53,167 --> 00:11:55,067
ONE FOR THE REAR WHEEL.
326
00:12:00,900 --> 00:12:02,800
HE EVENS THE EDGES WITH A HAND
327
00:12:02,800 --> 00:12:04,467
ROUTER, GIVING THE PEDAL-CAR
328
00:12:04,467 --> 00:12:06,367
FLOOR A FINER LOOK AND FEEL.
329
00:12:10,767 --> 00:12:12,333
HE GLUES SUPPORTS FOR THE
330
00:12:12,333 --> 00:12:14,100
BACKREST CLOSE TO THE REAR OF
331
00:12:14,100 --> 00:12:15,600
THE FLOORBOARD.
332
00:12:15,600 --> 00:12:17,433
HE PROPS THE BACKREST AGAINST
333
00:12:17,433 --> 00:12:19,367
THE SUPPORTS AND SCREWS IT INTO
334
00:12:19,367 --> 00:12:22,233
POSITION.
335
00:12:22,233 --> 00:12:23,633
HE INSTALLS THE DASHBOARD
336
00:12:23,633 --> 00:12:25,233
FRAMEWORK FURTHER TOWARDS THE
337
00:12:25,233 --> 00:12:26,267
FRONT.
338
00:12:26,267 --> 00:12:28,233
NEXT, THEY VARNISH THE LAMINATED
339
00:12:28,233 --> 00:12:30,133
ASH DASHBOARD A DEEP, RICH HUE,
340
00:12:30,133 --> 00:12:32,100
TO REPLICATE THE LOOK OF THE ONE
341
00:12:32,100 --> 00:12:33,933
IN THE ORIGINAL THREE-WHEELER
342
00:12:33,933 --> 00:12:34,633
VEHICLE.
343
00:12:34,633 --> 00:12:36,200
AND NOW FOR THE BODY OF THE
344
00:12:36,200 --> 00:12:37,733
PEDAL CAR.
345
00:12:37,733 --> 00:12:39,567
A WELDER TACKS TOGETHER THE TWO
346
00:12:39,567 --> 00:12:41,367
PARTS OF THE ALUMINUM SHELL AND
347
00:12:41,367 --> 00:12:42,800
SEALS THEM WITH SPECIAL
348
00:12:42,800 --> 00:12:45,567
ADHESIVE.
349
00:12:45,567 --> 00:12:47,100
THEY THEN SCREW THE WOODEN
350
00:12:47,100 --> 00:12:49,600
FRAMEWORK TO THE ALUMINUM BODY.
351
00:12:49,600 --> 00:12:51,367
AFTER A THOROUGH CLEANING, THEY
352
00:12:51,367 --> 00:12:53,067
PAINT A PRIMER COAT ONTO THE
353
00:12:53,067 --> 00:12:55,767
METAL.
354
00:12:55,767 --> 00:12:57,400
THEN IT'S IN TO THE PAINT BOOTH
355
00:12:57,400 --> 00:12:59,067
FOR A GLOSSY COAT OF AUTOMOTIVE
356
00:12:59,067 --> 00:13:03,433
PAINT.
357
00:13:03,433 --> 00:13:04,833
IN THE MEANTIME, THE METAL
358
00:13:04,833 --> 00:13:06,200
CHASSIS OF THE PEDAL CAR
359
00:13:06,200 --> 00:13:07,833
COMES TOGETHER.
360
00:13:07,833 --> 00:13:09,767
A WORKER MOUNTS A DUMMY TWIN
361
00:13:09,767 --> 00:13:10,900
ENGINE TO THE FRONT.
362
00:13:10,900 --> 00:13:12,733
IN THIS PEDAL-POWERED REPLICA,
363
00:13:12,733 --> 00:13:14,567
THE ENGINE'S PURPOSE IS PURELY
364
00:13:14,567 --> 00:13:16,267
DECORATIVE.
365
00:13:16,267 --> 00:13:17,933
THE HEADLIGHTS, THOUGH, ARE
366
00:13:17,933 --> 00:13:18,667
REAL.
367
00:13:18,667 --> 00:13:20,100
HE ATTACHES THOSE TO THE
368
00:13:20,100 --> 00:13:21,633
CHASSIS, COMPLETE WITH THE
369
00:13:21,633 --> 00:13:23,433
HOODED FRAMEWORK DISTINCTIVE TO
370
00:13:23,433 --> 00:13:24,833
THE ORIGINAL, FULL-SIZE
371
00:13:24,833 --> 00:13:26,667
THREE-WHEELED CAR FROM A CENTURY
372
00:13:26,667 --> 00:13:32,100
AGO.
373
00:13:32,100 --> 00:13:34,133
HE THEN FITS THE TIRES TO THE
374
00:13:34,133 --> 00:13:35,133
CHASSIS.
375
00:13:35,133 --> 00:13:36,567
THEY'RE CYCLE TIRES,
376
00:13:36,567 --> 00:13:38,700
CHILD-SIZED, TO FIT THE SCALE OF
377
00:13:38,700 --> 00:13:40,300
THIS TOY-CAR REPLICA.
378
00:13:40,300 --> 00:13:42,267
A QUICK SPIN CONFIRMS THEY'RE
379
00:13:42,267 --> 00:13:44,967
OPERATIONAL.
380
00:13:44,967 --> 00:13:46,767
HE MOUNTS THE FENDERS TO THE
381
00:13:46,767 --> 00:13:48,633
FRAME JUST ABOVE THE TIRES AND
382
00:13:48,633 --> 00:13:50,067
SECURES THEM WITH METAL
383
00:13:50,067 --> 00:13:51,133
BRACKETS.
384
00:13:51,133 --> 00:13:52,567
THE FENDERS WILL GUARD AGAINST
385
00:13:52,567 --> 00:13:57,667
SPLASHING MUD AND WATER.
386
00:13:57,667 --> 00:13:59,467
HE NOW TRANSFERS THE CAR BODY TO
387
00:13:59,467 --> 00:14:01,067
THE THREE-WHEELED CHASSIS.
388
00:14:01,067 --> 00:14:02,700
HE ALIGNS IT WITH FIXING POINTS
389
00:14:02,700 --> 00:14:04,500
ON THE CHASSIS AND THEN SCREWS
390
00:14:04,500 --> 00:14:09,133
IT INTO PLACE.
391
00:14:09,133 --> 00:14:11,100
NEXT, HE HOOKS UP THE EXHAUST
392
00:14:11,100 --> 00:14:12,767
PIPE.
393
00:14:12,767 --> 00:14:14,367
LIKE THE ENGINE, IT'S AN
394
00:14:14,367 --> 00:14:17,067
IMITATION, BUT IT LOOKS REAL.
395
00:14:17,067 --> 00:14:18,467
HE FITS AN ALUMINUM GRILLE
396
00:14:18,467 --> 00:14:20,133
TO THE FRONT OF THE PEDAL CAR,
397
00:14:20,133 --> 00:14:23,667
JUST BEHIND THE MOCK ENGINE.
398
00:14:23,667 --> 00:14:25,333
HE INSTALLS A SMALL WINDSHIELD
399
00:14:25,333 --> 00:14:26,767
IN FRONT OF THE PEDAL-CAR
400
00:14:26,767 --> 00:14:30,600
COCKPIT.
401
00:14:30,600 --> 00:14:32,600
AND NOW HE POPS THE DASHBOARD,
402
00:14:32,600 --> 00:14:34,700
EQUIPPED WITH A SPEED DIAL, INTO
403
00:14:34,700 --> 00:14:35,667
PLACE.
404
00:14:35,667 --> 00:14:37,433
IT FITS INTO THE PEDAL CAR'S
405
00:14:37,433 --> 00:14:40,233
HOOPED FRAME PERFECTLY.
406
00:14:40,233 --> 00:14:41,933
HE WIRES THE BATTERY-OPERATED
407
00:14:41,933 --> 00:14:43,533
HEADLIGHTS TO THE DASHBOARD
408
00:14:43,533 --> 00:14:45,067
SWITCH.
409
00:14:45,067 --> 00:14:46,767
HE ATTACHES THE HAND BRAKE TO
410
00:14:46,767 --> 00:14:48,667
THE SIDE OF THE CAB AND RUNS THE
411
00:14:48,667 --> 00:14:49,933
BRAKING CABLES TO THE REAR
412
00:14:49,933 --> 00:14:55,333
WHEEL.
413
00:14:55,333 --> 00:14:56,967
HE THREADS THE STEERING-WHEEL
414
00:14:56,967 --> 00:14:58,300
COLUMN DOWN THROUGH THE
415
00:14:58,300 --> 00:15:00,067
DASHBOARD TO STEERING ARMS ON
416
00:15:00,067 --> 00:15:02,067
THE FRONT WHEEL AXLE.
417
00:15:02,067 --> 00:15:03,400
HE CLAMPS IT TO THE STEERING
418
00:15:03,400 --> 00:15:06,367
ARMS...
419
00:15:06,367 --> 00:15:07,900
AND MAKES SOME ADJUSTMENTS TO
420
00:15:07,900 --> 00:15:09,567
PRECISELY POSITION THE COLUMN TO
421
00:15:09,567 --> 00:15:12,367
THE SHAFT.
422
00:15:12,367 --> 00:15:14,067
HE FITS THE PADDED LEATHER SEAT
423
00:15:14,067 --> 00:15:15,833
INTO THE CAB, AND THIS COMPLETES
424
00:15:15,833 --> 00:15:17,200
THE CONSTRUCTION OF THIS
425
00:15:17,200 --> 00:15:19,900
PEDAL-POWERED REPLICA CAR.
426
00:15:19,900 --> 00:15:22,100
IT TAKES ABOUT 40 HOURS TO MAKE
427
00:15:22,100 --> 00:15:24,267
ONE OF THOSE RETRO TOYS.
428
00:15:24,267 --> 00:15:26,400
WHEN IT COMES TO THE AUTHENTIC
429
00:15:26,400 --> 00:15:28,567
TOUCHES, DAVE SPARED NO EXPENSE
430
00:15:28,567 --> 00:15:30,700
AND EXPENDED GREAT EFFORT.
431
00:15:30,700 --> 00:15:32,500
IT'S TIME FOR A SPIN TO THE
432
00:15:32,500 --> 00:15:34,067
PLAYGROUND AND SOME GOOD
433
00:15:34,067 --> 00:15:35,867
OLD-FASHIONED FUN.
434
00:15:50,467 --> 00:15:52,067
Narrator: SOME PEOPLE ENJOY
435
00:15:52,067 --> 00:15:53,667
PLAYING COMBAT GAMES ON VIDEO
436
00:15:53,667 --> 00:15:55,567
SYSTEMS, WHILE OTHERS PREFER TO
437
00:15:55,567 --> 00:15:57,300
EXCHANGE THE CONTROLLER FOR A
438
00:15:57,300 --> 00:15:58,800
FAKE WEAPON, DRESS UP IN
439
00:15:58,800 --> 00:16:00,767
COSTUME, AND ACT OUT THE FANTASY
440
00:16:00,767 --> 00:16:02,500
WITH THOSE WHO SHARE THE SAME
441
00:16:02,500 --> 00:16:03,500
PASSION.
442
00:16:03,500 --> 00:16:05,633
IT'S CALLED LIVE-ACTION
443
00:16:05,633 --> 00:16:07,933
ROLE-PLAYING, AND THERE'S
444
00:16:07,933 --> 00:16:10,067
TYPICALLY A MEDIEVAL OR
445
00:16:10,067 --> 00:16:12,267
APOCALYPTIC THEME TO IT.
446
00:16:12,267 --> 00:16:14,367
THESE WEAPONS SURE LOOK LIKE THE
447
00:16:14,367 --> 00:16:16,300
REAL THING -- SO MUCH SO THAT
448
00:16:16,300 --> 00:16:18,333
THIS COMPANY ALSO SELLS THEM AS
449
00:16:18,333 --> 00:16:23,100
FILM AND THEATER PROPS.
450
00:16:23,100 --> 00:16:24,967
BUT AS MENACING AS THESE AXES
451
00:16:24,967 --> 00:16:27,067
AND SWORDS APPEAR, THEY COULDN'T
452
00:16:27,067 --> 00:16:28,633
EVEN HURT A FLY BECAUSE THEY'RE
453
00:16:28,633 --> 00:16:31,167
BLADES ARE MADE OF LATEX.
454
00:16:31,167 --> 00:16:33,067
IN THE WEAPONS WORKSHOP, THEY
455
00:16:33,067 --> 00:16:34,933
BEGIN THE SWORD-MAKING PROCESS
456
00:16:34,933 --> 00:16:37,133
BY CONSTRUCTING THE BLADE.
457
00:16:37,133 --> 00:16:38,600
AFTER TRACING A TEMPLATE ON A
458
00:16:38,600 --> 00:16:40,100
4/10-OF-AN-INCH-THICK PIECE OF
459
00:16:40,100 --> 00:16:42,133
FLEXIBLE WATERPROOF FOAM, THEY
460
00:16:42,133 --> 00:16:43,867
CUT OUT TWO BLADE HALVES WITH A
461
00:16:43,867 --> 00:16:46,067
UTILITY KNIFE.
462
00:16:46,067 --> 00:16:47,900
AFTER SLITTING ONE OF THEM DOWN
463
00:16:47,900 --> 00:16:49,833
THE MIDDLE, THEY GLUE IN A RIGID
464
00:16:49,833 --> 00:16:51,767
4/10-OF-AN-INCH FIBERGLASS CORE.
465
00:16:51,767 --> 00:16:53,667
THIS MAKES THE SWORD BLADE STIFF
466
00:16:53,667 --> 00:16:55,533
ENOUGH FOR COMBAT, YET FLEXIBLE
467
00:16:55,533 --> 00:16:57,767
ENOUGH TO NOT BREAK.
468
00:16:57,767 --> 00:16:59,567
NEXT, THEY GLUE A STRIP OF
469
00:16:59,567 --> 00:17:01,633
DURABLE POLYESTER FABRIC OVER
470
00:17:01,633 --> 00:17:02,300
THE CORE.
471
00:17:02,300 --> 00:17:03,833
THIS ACTS AS REINFORCEMENT,
472
00:17:03,833 --> 00:17:05,433
PREVENTING THE TIP OF THE CORE
473
00:17:05,433 --> 00:17:08,233
FROM POKING THROUGH THE FOAM.
474
00:17:08,233 --> 00:17:09,733
NOW THEY GLUE THE SECOND BLADE
475
00:17:09,733 --> 00:17:11,067
HALF OVER THE FIRST ONE,
476
00:17:11,067 --> 00:17:14,600
SANDWICHING THE CORE.
477
00:17:14,600 --> 00:17:16,200
THE GLUE IS A RUBBER-BASED
478
00:17:16,200 --> 00:17:17,667
ADHESIVE THAT BONDS WITH
479
00:17:17,667 --> 00:17:19,533
PRESSURE THAT THEY APPLY WITH A
480
00:17:19,533 --> 00:17:26,100
HEAVY MARBLE ROLLING PIN.
481
00:17:26,100 --> 00:17:27,967
NEXT, USING A BAND SANDER, THEY
482
00:17:27,967 --> 00:17:29,600
SCULPT THE BLADE'S CUTTING
483
00:17:29,600 --> 00:17:35,067
EDGES.
484
00:17:35,067 --> 00:17:36,533
THEN THEY REMOVE THE FOAM
485
00:17:36,533 --> 00:17:41,700
RESIDUE WITH A ROTARY TOOL.
486
00:17:41,700 --> 00:17:43,767
NEXT, THEY TAKE A WOOD-BURNING
487
00:17:43,767 --> 00:17:45,967
IRON AND MELT THE FOAM IN SELECT
488
00:17:45,967 --> 00:17:47,867
SPOTS TO CREATE THE LOOK OF
489
00:17:47,867 --> 00:17:50,767
BATTLE SCARS.
490
00:17:50,767 --> 00:17:52,700
THEN THEY SPRAY ON FIVE TO SIX
491
00:17:52,700 --> 00:17:54,200
COATS OF LATEX RUBBER.
492
00:17:54,200 --> 00:17:56,233
THIS FORMS A PROTECTIVE SHIELD
493
00:17:56,233 --> 00:17:58,333
OVER THE FOAM WITHOUT HINDERING
494
00:17:58,333 --> 00:18:00,367
THE BLADE'S FLEXIBILITY.
495
00:18:00,367 --> 00:18:02,367
NEXT, USING AN AIR BRUSH, THEY
496
00:18:02,367 --> 00:18:04,467
APPLY TWO COATS OF ACRYLIC-BASED
497
00:18:04,467 --> 00:18:06,667
LATEX PAINT -- FIRST BLACK, THEN
498
00:18:06,667 --> 00:18:09,967
SILVER.
499
00:18:09,967 --> 00:18:11,467
THEY BRUSH ON A THICK COAT OF
500
00:18:11,467 --> 00:18:13,333
BLACK PAINT, THEN WIPE IT OFF.
501
00:18:13,333 --> 00:18:15,367
THIS WASH, AS IT'S CALLED,
502
00:18:15,367 --> 00:18:19,633
CREATES THE LOOK OF AGED METAL.
503
00:18:19,633 --> 00:18:21,600
AND FINALLY, THEY LIGHTLY DAB
504
00:18:21,600 --> 00:18:23,600
SOME SILVER ACRYLIC PAINT OVER
505
00:18:23,600 --> 00:18:25,300
SELECT SPOTS TO HIGHLIGHT
506
00:18:25,300 --> 00:18:29,733
DETAILS.
507
00:18:29,733 --> 00:18:32,067
FROM FOAM TO MAIN COMPONENT OF A
508
00:18:32,067 --> 00:18:34,233
LETHAL WEAPON IN JUST A FEW EASY
509
00:18:34,233 --> 00:18:37,300
STEPS.
510
00:18:37,300 --> 00:18:39,067
THEY FINISH OFF THEIR HANDIWORK
511
00:18:39,067 --> 00:18:40,600
BY STENCILING ON THE COMPANY
512
00:18:40,600 --> 00:18:46,133
LOGO IN GOLD ACRYLIC PAINT.
513
00:18:46,133 --> 00:18:48,367
NOW FOR THE SWORD'S HANDLE.
514
00:18:48,367 --> 00:18:49,933
THEY DRILL A HOLE LENGTHWISE
515
00:18:49,933 --> 00:18:51,300
THROUGH A CYLINDER MADE OF
516
00:18:51,300 --> 00:18:53,067
WALNUT AND GLUE A STEEL TUBE
517
00:18:53,067 --> 00:18:56,067
INSIDE.
518
00:18:56,067 --> 00:18:57,900
THEN THEY GLUE LEATHER AROUND
519
00:18:57,900 --> 00:19:03,167
THE WOOD...
520
00:19:03,167 --> 00:19:04,700
AND WRAP A LEATHER RIBBON AROUND
521
00:19:04,700 --> 00:19:06,600
IT FOR DECORATION.
522
00:19:12,167 --> 00:19:13,800
TO GIVE IT A WORN APPEARANCE,
523
00:19:13,800 --> 00:19:15,500
THEY LIGHTLY SAND PARTS OF THE
524
00:19:15,500 --> 00:19:18,300
SURFACE.
525
00:19:18,300 --> 00:19:20,067
TO MAKE ORNATE HANDLES, AN
526
00:19:20,067 --> 00:19:22,067
ARTIST FIRST SCULPTS A MODEL OUT
527
00:19:22,067 --> 00:19:23,900
OF LINDENWOOD.
528
00:19:29,200 --> 00:19:31,200
USING THAT WOODEN MODEL, THEY
529
00:19:31,200 --> 00:19:32,667
CAST A SILICON MOLD.
530
00:19:32,667 --> 00:19:34,733
THEN THEY POUR RUBBER INTO THE
531
00:19:34,733 --> 00:19:40,067
MOLD TO CAST A HANDLE.
532
00:19:40,067 --> 00:19:41,900
FOR THAT LEATHER-COVERED WOODEN
533
00:19:41,900 --> 00:19:43,467
HANDLE, THEY CAST ONLY THE
534
00:19:43,467 --> 00:19:45,333
COMPONENTS ABOVE AND BELOW IT IN
535
00:19:45,333 --> 00:19:48,100
RUBBER.
536
00:19:48,100 --> 00:19:49,767
AFTER TRIMMING OFF THE EXCESS
537
00:19:49,767 --> 00:19:51,900
RUBBER, THEY PAINT IT TO LOOK
538
00:19:51,900 --> 00:19:54,333
LIKE METAL.
539
00:19:54,333 --> 00:19:56,333
TO ASSEMBLE THE SWORD, THEY GLUE
540
00:19:56,333 --> 00:19:58,200
THE HANDLE COMPONENTS ONTO THE
541
00:19:58,200 --> 00:20:00,100
CORE, WHICH PROTRUDES FROM THE
542
00:20:00,100 --> 00:20:01,000
BASE OF THE BLADE.
543
00:20:01,000 --> 00:20:03,100
FIRST, THEY POSITION THE GUARD.
544
00:20:03,100 --> 00:20:04,867
IT STOPS THE OPPOSING SWORD FROM
545
00:20:04,867 --> 00:20:06,600
SLIDING DOWN PAST THE BLADE AND
546
00:20:06,600 --> 00:20:08,600
CUTTING YOUR HAND.
547
00:20:08,600 --> 00:20:12,033
NEXT, THE HANDLE.
548
00:20:12,033 --> 00:20:13,967
AND LAST, THE POMMEL.
549
00:20:14,133 --> 00:20:15,667
IT BLOCKS THE END OF THE HANDLE
550
00:20:15,667 --> 00:20:16,967
TO PREVENT THE SWORD FROM
551
00:20:16,967 --> 00:20:22,100
SLIDING OUT OF YOUR HAND.
552
00:20:22,100 --> 00:20:23,967
EACH SWORD THIS WORKSHOP CREATES
553
00:20:23,967 --> 00:20:25,400
COMES WITH A SCABBARD, A
554
00:20:25,400 --> 00:20:27,700
PROTECTIVE LEATHER SHEATH.
555
00:20:27,700 --> 00:20:29,133
THEY BOIL AND WAX THE LEATHER
556
00:20:29,133 --> 00:20:31,567
TO MAKE IT RIGID.
557
00:20:31,567 --> 00:20:33,433
THE WORKSHOP ALSO MAKES DAGGERS
558
00:20:33,433 --> 00:20:35,100
AND OTHER REALISTIC-LOOKING
559
00:20:35,100 --> 00:20:37,500
WEAPONRY -- ALL YOU NEED TO
560
00:20:37,500 --> 00:20:38,567
BRING OUT YOUR INNER WARRIOR.
561
00:20:39,767 --> 00:20:42,767
-- Captions by VITAC --
www.vitac.com
562
00:20:51,833 --> 00:20:53,467
IF YOU HAVE ANY COMMENTS ABOUT
563
00:20:53,467 --> 00:20:55,033
THE SHOW OR IF YOU'D LIKE TO
564
00:20:55,033 --> 00:20:56,767
SUGGEST TOPICS FOR FUTURE SHOWS,
565
00:20:56,767 --> 00:20:58,667
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