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--Captions by VITAC--
www.vitac.com
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00:00:04,896 --> 00:00:07,896
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
THE DRIVE IN YOUR COMPUTER
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00:00:54,793 --> 00:00:56,379
SAVES AND STORES YOUR DATA --
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EVERYTHING FROM DOCUMENTS
TO PHOTOS TO SOFTWARE PROGRAMS.
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00:01:00,379 --> 00:01:03,551
THE NEWER GENERATION DRIVES
ARE SOLID STATE DRIVES.
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00:01:03,551 --> 00:01:07,275
THEY'RE GRADUALLY REPLACING
TRADITIONAL HARD DISK DRIVES
8
00:01:07,275 --> 00:01:10,000
BECAUSE THEY'RE COMPACT,
MORE DURABLE,
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00:01:10,000 --> 00:01:12,620
AND PROCESS INFORMATION
MUCH FASTER.
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00:01:12,620 --> 00:01:16,896
JUST LIKE PORTABLE USB DRIVES
AND CAMERA MEMORY CARDS,
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00:01:16,896 --> 00:01:19,965
SOLID STATE DRIVES
STORE INFORMATION
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ON SEVERAL MEMORY CHIPS
INSTALLED ON A CIRCUIT BOARD.
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00:01:23,172 --> 00:01:26,379
EACH CHIP CONTAINS
HIGHLY COMPLEX CIRCUITRY
14
00:01:26,379 --> 00:01:28,655
COMPRISED OF ELECTRICAL PATHWAYS
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00:01:28,655 --> 00:01:31,862
2,000 TIMES NARROWER
THAN A HUMAN HAIR.
16
00:01:31,862 --> 00:01:34,241
TO MAKE THOSE MEMORY CHIPS,
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00:01:34,241 --> 00:01:37,275
THEY BEGIN WITH
A DISK-SHAPED SILICON WAFER.
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SILICON IS A NON-METALLIC
NATURAL ELEMENT
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00:01:40,413 --> 00:01:41,965
THAT CONDUCTS ELECTRICITY.
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IT'S HIGHLY SUSCEPTIBLE
TO CONTAMINATION,
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00:01:44,689 --> 00:01:47,517
SO THE PRODUCTION AREA
IS VIRTUALLY STERILE
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00:01:47,517 --> 00:01:50,413
TO THE POINT OF BEING
1,000 TIMES CLEANER
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00:01:50,413 --> 00:01:53,344
THAN THE AIR
IN A HOSPITAL OPERATING ROOM.
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00:01:53,344 --> 00:01:55,137
AN AUTOMATED ROBOTIC SYSTEM
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MOVES THE WAFERS THROUGH
MORE THAN 800 OPERATIONS,
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00:01:58,448 --> 00:02:01,724
WHICH TAKE MORE THAN A MONTH
TO COMPLETE.
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00:02:01,724 --> 00:02:05,172
EACH WAFER RECEIVES LAYER
AFTER LAYER OF MATERIALS --
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00:02:05,172 --> 00:02:07,241
SOME CONDUCTIVE, SUCH AS COPPER,
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00:02:07,241 --> 00:02:10,620
SOME NONCONDUCTIVE,
SUCH AS SILICON DIOXIDE.
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00:02:10,620 --> 00:02:12,724
AFTER APPLYING EACH LAYER,
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00:02:12,724 --> 00:02:16,482
THE MACHINE COATS THE WAFER
WITH A LIGHT-SENSITIVE FLUID
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00:02:16,482 --> 00:02:18,724
THEN FLASHES U.V. LIGHT ONTO IT
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00:02:18,724 --> 00:02:22,758
THROUGH A GLASS STENCIL OF THE
ELECTRICAL CIRCUITRY PATTERN.
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00:02:22,758 --> 00:02:26,137
IN THE AREAS WHERE THE FLUID
IS EXPOSED TO THE LIGHT,
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00:02:26,137 --> 00:02:28,448
THE CHEMICALS BREAK DOWN
AND DISSOLVE.
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00:02:28,448 --> 00:02:31,620
WHERE THE FLUID WAS SHIELDED
FROM LIGHT BY THE STENCIL,
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THE MATERIALS REMAIN INTACT,
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EFFECTIVELY PRINTING THE
CIRCUITRY PATTERN ON THE WAFER.
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00:02:37,379 --> 00:02:41,689
CHEMICAL BATHS THEN WASH AWAY
THE EXPOSED FLUID AND MATERIAL.
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00:02:41,689 --> 00:02:45,000
EACH FOOT-WIDE WAFER
YIELDS HUNDREDS OF MICROCHIPS,
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00:02:45,000 --> 00:02:47,620
WHICH NOW
HAVE TO BE SLICED APART.
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00:02:47,620 --> 00:02:49,586
THE ROBOTIC CUTTING MACHINE
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00:02:49,586 --> 00:02:52,448
COVERS THE WAFER
WITH AN ADHESIVE FILM
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00:02:52,448 --> 00:02:54,068
TO HOLD THE CHIPS IN PLACE
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00:02:54,068 --> 00:02:56,896
WHILE THEY'RE BEING CUT LOOSE
FROM EACH OTHER.
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00:02:56,896 --> 00:02:59,551
THE NEXT MACHINE
INSERTS EACH CLIP
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IN A PROTECTIVE PLASTIC HOUSING.
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00:03:03,931 --> 00:03:06,344
MEANWHILE,
SIX CIRCUIT BOARDS AT A TIME
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00:03:06,344 --> 00:03:07,758
ENTER A MACHINE
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00:03:07,758 --> 00:03:10,827
WHICH APPLIES A THIN LAYER
OF TIN ALLOY SOLDER PASTE
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00:03:10,827 --> 00:03:12,206
ONTO THE AREAS
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00:03:12,206 --> 00:03:15,586
WHERE THE MEMORY CHIPS
AND OTHER COMPONENTS WILL GO.
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00:03:15,586 --> 00:03:20,206
AS THE BOARDS EXIT THE MACHINE,
A ROBOTIC ARM PICKS OFF
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00:03:20,206 --> 00:03:24,103
THE COMPONENTS REQUIRED FOR
EACH DRIVE FROM FEEDER SPOOLS
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00:03:24,103 --> 00:03:25,586
AND DEPOSITS THEM
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00:03:25,586 --> 00:03:27,689
AT THEIR RESPECTIVE LOCATIONS
ON THE CIRCUIT BOARD.
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00:03:27,689 --> 00:03:31,586
THIS PARTICULAR MODEL
HAS 8 MICROCHIPS,
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00:03:31,586 --> 00:03:35,137
EACH ABLE TO STORE
64 GIGABYTES OF DATA,
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00:03:35,137 --> 00:03:39,689
GIVING THE DRIVE A CAPACITY
OF 5,012 GIGS.
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00:03:39,689 --> 00:03:42,620
THE CIRCUIT BOARDS NOW ENTER
A TUNNEL-SHAPED OVEN
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00:03:42,620 --> 00:03:44,344
WHICH MELTS THE SOLDER PASTE,
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00:03:44,344 --> 00:03:46,758
FUSING THE COMPONENTS
TO THE BOARD.
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00:03:50,275 --> 00:03:52,068
THE BRAIN
OF THE SOLID STATE DRIVE
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00:03:52,068 --> 00:03:53,517
IS NOW COMPLETE
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00:03:53,517 --> 00:03:56,965
AND READY FOR THE FIRST PHASE
OF QUALITY-CONTROL TESTING.
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00:03:56,965 --> 00:03:59,482
THIS MACHINE
PERFORMS AN OPTICAL SCAN
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00:03:59,482 --> 00:04:02,379
TO VERIFY THAT EVERY COMPONENT
ON THE BOARD
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00:04:02,379 --> 00:04:04,482
IS SET IN THE RIGHT PLACE.
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00:04:10,137 --> 00:04:12,620
THE NEXT MACHINE
X-RAYS THE BOARD
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00:04:12,620 --> 00:04:14,586
TO VERIFY THAT EACH COMPONENT
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00:04:14,586 --> 00:04:17,724
IS SECURELY SOLDERED
IN THE CORRECT LOCATION.
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00:04:17,724 --> 00:04:19,896
A LATER PHASE
OF QUALITY-CONTROL TESTING
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00:04:19,896 --> 00:04:22,344
WILL VERIFY
THE DRIVE'S PERFORMANCE.
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00:04:22,344 --> 00:04:25,586
UNTIL NOW, SIX CIRCUIT BOARDS
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00:04:25,586 --> 00:04:27,344
HAVE BEEN ATTACHED
TO EACH OTHER.
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00:04:27,344 --> 00:04:30,034
AN AUTOMATED ROUTER
NOW CUTS THEM APART,
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00:04:30,034 --> 00:04:31,965
AND WORKERS INSERT EACH BOARD
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00:04:31,965 --> 00:04:34,586
INTO A PROTECTIVE
PLASTIC HOUSING.
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00:04:34,586 --> 00:04:36,655
A SLOT ON THE OUTSIDE
OF THIS HOUSING
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00:04:36,655 --> 00:04:38,172
REVEALS THE BOARD'S CONNECTOR
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00:04:38,172 --> 00:04:41,931
BY WHICH THE DRIVE LINKS
TO THE COMPUTER.
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00:04:41,931 --> 00:04:45,931
SOLID STATE DRIVES
COME IN DIFFERENT SIZES.
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00:04:45,931 --> 00:04:48,000
THIS PARTICULAR MODEL
IS LARGE ENOUGH
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00:04:48,000 --> 00:04:50,206
TO REPLACE
A TRADITIONAL HARD DISK DRIVE.
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00:04:50,206 --> 00:04:52,413
HOWEVER,
MANY MODELS ARE SMALLER,
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00:04:52,413 --> 00:04:55,758
DESIGNED TO FIT
WHERE DISK DRIVES CAN'T --
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00:04:55,758 --> 00:04:58,931
FOR EXAMPLE,
IN ULTRA-SLIM LAPTOPS.
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00:04:58,931 --> 00:05:02,034
EVERY DRIVE IS LABELED
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00:05:02,034 --> 00:05:05,655
WITH ITS TECHNICAL SPECS, MODEL,
AND SERIAL NUMBERS AND SO ON,
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00:05:05,655 --> 00:05:08,344
ALONG WITH A BARCODE
FOR PRODUCTION TRACKING.
91
00:05:10,206 --> 00:05:13,896
THEN THEY PLUG THE DRIVE'S
CONNECTOR INTO A TESTER,
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00:05:13,896 --> 00:05:15,172
WHICH, AFTER VERIFYING
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00:05:15,172 --> 00:05:17,551
THAT EVERYTHING
FUNCTIONS ELECTRONICALLY,
94
00:05:17,551 --> 00:05:20,275
INSTALLS THE DRIVE'S
OPERATING SYSTEM.
95
00:05:20,275 --> 00:05:22,517
THE DRIVE MOVES
TO THE NEXT STATION,
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00:05:22,517 --> 00:05:23,724
WHERE IT UNDERGOES
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00:05:23,724 --> 00:05:26,724
UP TO 60 HOURS OF
EXTENSIVE PERFORMANCE TESTING
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00:05:26,724 --> 00:05:29,068
TO ENSURE THAT IT STORES
AND RETRIEVES DATA
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00:05:29,068 --> 00:05:32,000
CORRECTLY AND AT TARGET SPEED.
100
00:05:33,862 --> 00:05:35,689
PACKAGING IS TWOFOLD.
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00:05:35,689 --> 00:05:37,103
FIRST, A FOIL SHIELD
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00:05:37,103 --> 00:05:40,517
TO PREVENT STATIC ELECTRICITY
FROM DAMAGING THE DRIVE,
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00:05:40,517 --> 00:05:42,620
THEN A CARTON,
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00:05:42,620 --> 00:05:44,862
AND FINALLY INTO A SHIPPING BOX
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00:05:44,862 --> 00:05:48,724
HEADED FOR A DESTINATION
SOMEWHERE AROUND THE WORLD.
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00:06:01,827 --> 00:06:03,241
Narrator: IN ANCIENT EGYPT,
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00:06:03,241 --> 00:06:05,310
BOTH MEN AND WOMEN
PAINTED THEIR EYES.
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00:06:05,310 --> 00:06:07,137
IT WAS THOUGHT THAT EYE MAKEUP
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00:06:07,137 --> 00:06:09,758
MADE ONE LESS VULNERABLE
TO THE EVIL EYE,
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00:06:09,758 --> 00:06:12,655
A GAZE OR STARE
MEANT TO CAUSE HARM.
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00:06:12,655 --> 00:06:15,068
TODAY, MOSTLY WOMEN WEAR IT.
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00:06:15,068 --> 00:06:16,931
AND OF COURSE, REPELLING EVIL
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00:06:16,931 --> 00:06:19,586
IS NO LONGER A REASON
TO WEAR EYE SHADOW.
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00:06:22,931 --> 00:06:24,931
WITH A PALETTE OF EYE SHADOW,
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00:06:24,931 --> 00:06:27,931
A WOMAN CAN WORK
A CERTAIN KIND OF MAGIC.
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00:06:27,931 --> 00:06:31,034
SKILLFUL SHADING CAN ADD DEPTH
AND DRAMA TO THE EYES.
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00:06:31,034 --> 00:06:33,758
THIS MAKEUP
CAN ALSO CREATE THE ILLUSION
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00:06:33,758 --> 00:06:38,896
THAT THE EYES ARE MUCH LARGER
THAN THEY REALLY ARE.
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00:06:38,896 --> 00:06:43,793
TO MAKE EYE SHADOW,
THEY FOLLOW SPECIFIC RECIPES.
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00:06:43,793 --> 00:06:46,551
A TECHNICIAN
WEIGHS THE INGREDIENTS,
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00:06:46,551 --> 00:06:50,586
BEGINNING WITH MICA,
A MINERAL THAT ACTS AS FILLER.
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00:06:50,586 --> 00:06:53,724
THE NEXT INGREDIENT
IS ZINC STEARATE.
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00:06:53,724 --> 00:06:55,068
IT'S A BINDER.
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00:06:55,068 --> 00:06:59,275
A COMBINATION OF PIGMENTS
PROVIDES THE DESIRED COLOR.
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00:06:59,275 --> 00:07:01,551
THESE PARTICULAR PIGMENTS
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00:07:01,551 --> 00:07:04,862
ARE DIFFERENT SHADES
OF THE MINERAL IRON OXIDE.
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00:07:07,551 --> 00:07:10,448
HE TRANSFERS
THE MEASURED INGREDIENTS
128
00:07:10,448 --> 00:07:12,103
TO A BIG BLENDER JAR.
129
00:07:12,103 --> 00:07:15,448
AS HE POURS THE INGREDIENTS,
THEY DUST UP,
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00:07:15,448 --> 00:07:18,206
AND A GAS MASK KEEPS HIM
FROM BREATHING IN THE PARTICLES.
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00:07:18,206 --> 00:07:22,827
HE PLACES THE JAR
ON THE BLENDER BASE,
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00:07:22,827 --> 00:07:27,586
COVERS THE TOP,
AND ACTIVATES THE BLADES.
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00:07:29,275 --> 00:07:32,517
THE BLENDER MIXES AND GRINDS
THE POWDERED INGREDIENTS
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00:07:32,517 --> 00:07:35,103
TO A VERY FINE STATE.
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00:07:35,103 --> 00:07:38,586
THEN IT'S INTO
A VERY LARGE MIXER.
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00:07:38,586 --> 00:07:40,551
HE ADDS COCONUT OIL --
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00:07:40,551 --> 00:07:42,862
JUST ENOUGH
FOR THE POWDERED INGREDIENTS
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00:07:42,862 --> 00:07:46,172
TO EVENTUALLY COAGULATE
INTO A CAKE FORM.
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00:07:46,172 --> 00:07:48,586
MORE MICA IS NEXT --
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00:07:48,586 --> 00:07:50,172
A LOT MORE.
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00:07:50,172 --> 00:07:52,931
EYE SHADOW IS 80% MICA.
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00:07:52,931 --> 00:07:56,517
THIS MICA IS DARKER
TO ADD INTENSITY TO THE COLOR.
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00:07:56,517 --> 00:07:58,620
IT ALSO HAS A BIT OF SHIMMER.
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00:07:58,620 --> 00:08:01,896
HE LATCHES THE LID
TO CONTAIN THE INGREDIENTS
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00:08:01,896 --> 00:08:04,827
AND POWERS UP
THIS HIGH-SPEED MIXER.
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00:08:04,827 --> 00:08:07,689
INSIDE, THE MIXING PADDLES
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00:08:07,689 --> 00:08:09,758
SWIVEL AROUND
FOR ABOUT 15 MINUTES
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00:08:09,758 --> 00:08:13,862
TO THOROUGHLY MIX
THE INGREDIENTS.
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00:08:13,862 --> 00:08:17,862
THE EYE SHADOW MIXTURE
FLOWS INTO A PLASTIC BAG.
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00:08:17,862 --> 00:08:19,965
A TECHNICIAN EXAMINES IT
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00:08:19,965 --> 00:08:23,310
TO CONFIRM THAT THE COLOR
HAS BEEN EVENLY DISPERSED
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00:08:23,310 --> 00:08:25,379
AND THAT THE POWDER
IS SUFFICIENTLY MOIST.
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00:08:25,379 --> 00:08:29,206
ANOTHER WORKER NOW PIECES
FOUR EYE SHADOW TINS
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00:08:29,206 --> 00:08:32,965
IN PODS ON A METAL PLATTER.
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00:08:32,965 --> 00:08:36,793
THE PLATTER ROTATES TO DELIVER
THE TINS TO A MIXING DISPENSER
156
00:08:36,793 --> 00:08:39,620
THAT'S BEEN FILLED
WITH THE EYE SHADOW INGREDIENTS.
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00:08:39,620 --> 00:08:43,655
THE MIXER PUSHES PRECISE AMOUNTS
THROUGH HOLES IN THE BOTTOM
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00:08:43,655 --> 00:08:45,103
AND INTO THE TINS.
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00:08:46,965 --> 00:08:49,551
A SCRAPER LEVELS OFF THE TOPS.
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00:08:54,758 --> 00:08:58,758
THE NEXT STOP IS A PRESS
WITH FOUR CIRCULAR HEADS.
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00:08:58,758 --> 00:09:01,827
A RIBBON OF FABRIC
KEEPS THINGS HYGIENIC
162
00:09:01,827 --> 00:09:05,068
AS THE PRESS COMPRESSES
THE MOIST EYE SHADOW POWDER
163
00:09:05,068 --> 00:09:06,896
AND TURNS IT
INTO A CAKE-LIKE FORM.
164
00:09:08,896 --> 00:09:12,379
MOVING FORWARD,
THE PODS EJECT THE TINS,
165
00:09:12,379 --> 00:09:16,724
AND AN AUTOMATED DEVICE
PULLS THEM OFF THE MACHINE.
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00:09:16,724 --> 00:09:19,620
WHAT A DIFFERENCE
THE COMPRESSION HAS MADE.
167
00:09:19,620 --> 00:09:21,517
NO LONGER A LOOSE POWDER,
168
00:09:21,517 --> 00:09:26,310
THE EYE SHADOW INGREDIENTS
HAVE CAKED UP NICELY.
169
00:09:26,310 --> 00:09:28,241
THE TINS NOW MOVE INTO A LANE
170
00:09:28,241 --> 00:09:30,793
AND COME UP AGAINST
AN ABRASIVE BELT
171
00:09:30,793 --> 00:09:33,448
THAT CLEANS THE LOOSE POWDER
FROM THE SIDES.
172
00:09:33,448 --> 00:09:37,413
A BLAST OF AIR ALSO GETS RID
OF SOME OF THE RESIDUAL POWDER.
173
00:09:37,413 --> 00:09:41,241
FOR ONE OUT OF EVERY 100
EYE SHADOWS PRODUCED,
174
00:09:41,241 --> 00:09:46,241
A TECHNICIAN DOES A DROP TEST
FROM A HEIGHT OF 18 INCHES.
175
00:09:46,241 --> 00:09:48,275
HE CHECKS
FOR CHIPPING OR DAMAGE.
176
00:09:48,275 --> 00:09:52,517
AND IF HE FINDS ANY,
HE'LL ADD POWER TO THE PRESS.
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00:09:52,517 --> 00:09:54,482
FOR A COLOR TEST,
178
00:09:54,482 --> 00:09:57,034
HE BRUSHES SOME EYE SHADOW
ONTO HIS ARM,
179
00:09:57,034 --> 00:09:59,482
BEGINNING WITH
A LABORATORY STANDARD.
180
00:10:02,896 --> 00:10:04,068
HE THEN APPLIES
181
00:10:04,068 --> 00:10:06,620
NEWLY MANUFACTURED EYE SHADOW
TO HIS ARM
182
00:10:06,620 --> 00:10:08,206
AND COMPARES THE TWO.
183
00:10:08,206 --> 00:10:09,517
IT'S A MATCH.
184
00:10:09,517 --> 00:10:11,000
AND WITH HIS APPROVAL,
185
00:10:11,000 --> 00:10:13,448
THE BATCH IS ALMOST READY
FOR RETAIL.
186
00:10:13,448 --> 00:10:15,827
ANOTHER WORKER INSERTS THE TINS
187
00:10:15,827 --> 00:10:19,034
INTO MORE SUBSTANTIAL
PLASTIC CONTAINERS
188
00:10:19,034 --> 00:10:22,000
WITH MAGNETS ON THE BOTTOM
TO SECURE THEM.
189
00:10:23,827 --> 00:10:26,517
SHE SCREWS THE CLEAR CAPS
ONTO THE JARS,
190
00:10:26,517 --> 00:10:30,655
AND THE EYE SHADOW IS ON ITS WAY
TO THE COSMETIC COUNTER.
191
00:10:33,965 --> 00:10:37,793
THEY ALSO MANUFACTURE
ENTIRE PALETTES OF EYE SHADOW
192
00:10:37,793 --> 00:10:39,551
FOR A RAINBOW OF CHOICES.
193
00:10:43,517 --> 00:10:47,586
IT TAKES ABOUT A DAY
TO MANUFACTURE EYE SHADOW.
194
00:10:49,655 --> 00:10:53,413
AND THE RESULT IS TRULY
A THING OF BEAUTY.
195
00:11:09,551 --> 00:11:10,862
Narrator:
THE FIRST STRETCH LIMOUSINES,
196
00:11:10,862 --> 00:11:12,344
BUILT AROUND 1928,
197
00:11:12,344 --> 00:11:16,310
USUALLY TRANSPORTED BIG BANDS
AND THEIR MUSICAL EQUIPMENT.
198
00:11:16,310 --> 00:11:19,793
LUXURY SEDANS
WITH AN EXTENDED CHASSIS
199
00:11:19,793 --> 00:11:22,689
ARE TYPICALLY ASSOCIATED
WITH SPECIAL OCCASIONS
200
00:11:22,689 --> 00:11:26,586
SUCH AS WEDDINGS, PROMS,
OR A NIGHT ON THE TOWN.
201
00:11:28,275 --> 00:11:33,275
IT TAKES ABOUT 475 HOURS OF WORK
AND PAINSTAKING DETAIL
202
00:11:33,275 --> 00:11:38,206
TO TRANSFORM A LUXURY SEDAN
INTO A STRETCH LIMO.
203
00:11:38,206 --> 00:11:43,413
WORKERS CUT AN ORDINARY-SIZE CAR
IN HALF USING CUTTING WHEELS.
204
00:11:43,413 --> 00:11:44,827
BEFORE CUTTING BEGINS,
205
00:11:44,827 --> 00:11:47,310
THE INSIDE OF THE CAR
IS STRIPPED AWAY,
206
00:11:47,310 --> 00:11:48,965
ALONG WITH OTHER COMPONENTS
207
00:11:48,965 --> 00:11:51,344
SUCH AS THE GAS TANK
AND DRIVE SHAFT.
208
00:11:51,344 --> 00:11:54,241
WORKERS CUT AWAY
THE INNER SUPPORT STRUCTURE
209
00:11:54,241 --> 00:11:56,655
AND CUT ACROSS
THE FLOOR OF THE CAR
210
00:11:56,655 --> 00:11:59,000
WITH A RECIPROCATING SAW.
211
00:12:02,137 --> 00:12:07,620
THE CAR IS NOW
COMPLETELY CUT IN HALF.
212
00:12:07,620 --> 00:12:09,724
WORKERS WHEEL
THE BACK HALF OF THE CAR
213
00:12:09,724 --> 00:12:12,000
AWAY FROM THE FRONT HALF.
214
00:12:14,689 --> 00:12:17,448
THEY PLACE THE BACK HALF
ON THE EXACT SPOT
215
00:12:17,448 --> 00:12:22,275
WHERE THE LIMOUSINE
WILL GRADUALLY BE ASSEMBLED.
216
00:12:22,275 --> 00:12:24,724
THE CONSTRUCTION DEPARTMENT
EMPLOYEES
217
00:12:24,724 --> 00:12:28,172
INSERT STEEL FRAME RAILS
INTO THE FRONT HALF OF THE CAR.
218
00:12:31,034 --> 00:12:34,517
THEY INSERT THE RAILS
ON BOTH SIDES OF THE FRONT HALF
219
00:12:34,517 --> 00:12:37,965
BEFORE INSERTING THE RAILS
INTO THE BACK HALF OF THE CAR.
220
00:12:41,482 --> 00:12:43,344
THEY MEASURE THE LENGTH
OF THE FRAME RAILS
221
00:12:43,344 --> 00:12:45,034
TO MAKE SURE
THAT THE FRAME IS SQUARE
222
00:12:45,034 --> 00:12:48,689
AND THAT THE TWO HALVES
ARE THE CORRECT DISTANCE APART
223
00:12:48,689 --> 00:12:53,137
TO BUILD THE LIMOUSINE.
224
00:12:53,137 --> 00:12:55,793
A WORKER WELDS THE RAILS
TO THE FRAMES
225
00:12:55,793 --> 00:12:58,758
OF THE FRONT AND BACK HALVES
OF THE ORIGINAL CAR.
226
00:12:58,758 --> 00:13:01,103
THEY POSITION
THE DRIVE SHAFT TUNNEL,
227
00:13:01,103 --> 00:13:04,206
WHICH HOUSES THE STEEL
DRIVE SHAFT AND EXHAUST PIPES,
228
00:13:04,206 --> 00:13:08,827
AND WELD IT
TO THE ORIGINAL VEHICLE TUNNEL.
229
00:13:08,827 --> 00:13:12,103
THEY POSITION THE FLOOR,
230
00:13:12,103 --> 00:13:15,344
WHICH IS MADE
OF GALVANIZED STEEL,
231
00:13:15,344 --> 00:13:19,448
AND WELD IT TO THE FRAME RAILS
AND TUNNEL.
232
00:13:19,448 --> 00:13:24,206
THEY WELD THE STEEL ROOF RAILS
INTO PLACE.
233
00:13:24,206 --> 00:13:26,517
THEY CONNECT THE NEW RAILS
234
00:13:26,517 --> 00:13:29,034
TO THE ROOF RAILS
IN THE ORIGINAL VEHICLE.
235
00:13:33,206 --> 00:13:37,034
A WORKED WELDS A VERTICAL
SIDE POST INTO PLACE.
236
00:13:37,034 --> 00:13:38,344
WITH A LEVEL,
237
00:13:38,344 --> 00:13:40,379
HE CHECKS THAT
THE POST OF HARDENED STEEL
238
00:13:40,379 --> 00:13:41,448
IS PERFECTLY VERTICAL
239
00:13:41,448 --> 00:13:44,413
BEFORE WELDING
THE BASE OF THE POST
240
00:13:44,413 --> 00:13:47,068
TO THE FLOOR FRAME.
241
00:13:47,068 --> 00:13:50,413
A ROOF PANEL
MADE OF GALVANIZED STEEL
242
00:13:50,413 --> 00:13:52,896
IS PUT IN PLACE.
243
00:13:52,896 --> 00:13:56,620
WORKERS INSTALL
THE LIMOUSINE'S BAR.
244
00:13:56,620 --> 00:14:01,448
THEY'VE ALREADY INSTALLED
THE STEEL SEAT FRAMES.
245
00:14:01,448 --> 00:14:04,724
NEXT, THEY INSTALL
AN OUTER BODY PANEL
246
00:14:04,724 --> 00:14:08,379
COMPLETE WITH
A HARDENED STEEL CRASH BAR.
247
00:14:08,379 --> 00:14:10,724
THEY SCREW THE PANEL INTO PLACE.
248
00:14:10,724 --> 00:14:12,103
THE SCREWS WILL BE REMOVED
249
00:14:12,103 --> 00:14:17,586
ONCE THE PANEL HAS BONDED
SOLIDLY TO THE LIMOUSINE FRAME.
250
00:14:17,586 --> 00:14:21,448
A WORKER SPRAYS ON
THREE COATS OF PAINT,
251
00:14:21,448 --> 00:14:25,965
THEN APPLIES TWO COATS
OF PROTECTIVE CLEAR COATING.
252
00:14:25,965 --> 00:14:30,241
ONCE THE PAINTING PROCESS
IS COMPLETE,
253
00:14:30,241 --> 00:14:33,931
WORKERS INSTALL
THE LAMINATED SAFETY SIDE GLASS.
254
00:14:33,931 --> 00:14:37,793
ANOTHER WORKER
SPRAYS CONTACT CEMENT
255
00:14:37,793 --> 00:14:39,517
ON THE ROOF OF THE LIMOUSINE
256
00:14:39,517 --> 00:14:42,103
IN PREPARATION
FOR THE VINYL TOP.
257
00:14:42,103 --> 00:14:44,034
HE STRETCHES THE VINYL
ACROSS THE ROOF
258
00:14:44,034 --> 00:14:48,517
AND WITH HIS HAND PRESSES THE
FABRIC DOWN INTO THE CREVICES.
259
00:14:48,517 --> 00:14:52,862
THEN HE CAREFULLY TRIMS OFF
THE EXCESS.
260
00:14:52,862 --> 00:14:56,379
HE PRESSES A STRIP
OF CHROME MOLDING INTO PLACE
261
00:14:56,379 --> 00:15:00,379
ON THE TOP OF THE VINYL.
262
00:15:00,379 --> 00:15:03,482
WORKERS
IN THE INTERIOR DEPARTMENT
263
00:15:03,482 --> 00:15:06,379
INSTALL THE BACK
OF A LEATHER SEAT...
264
00:15:06,379 --> 00:15:09,206
AND THE LEATHER BENCH SEAT.
265
00:15:11,689 --> 00:15:14,758
AFTER REUPHOLSTERING
THE ORIGINAL REAR SEAT TO MATCH,
266
00:15:14,758 --> 00:15:16,758
THEY RETURN IT
TO ITS ORIGINAL SPOT
267
00:15:16,758 --> 00:15:20,896
IN THE BACK OF THE LIMOUSINE.
268
00:15:20,896 --> 00:15:22,758
A SYSTEMS INSTALLER
269
00:15:22,758 --> 00:15:25,620
CONNECTS THE ELECTRICAL SYSTEMS
FOR THE CONTROL CENTER,
270
00:15:25,620 --> 00:15:27,724
LOCATED
BEHIND THE DRIVER'S SEAT.
271
00:15:27,724 --> 00:15:31,551
A PANEL LISTS RELAYS AND FUSES.
272
00:15:31,551 --> 00:15:34,827
THE ORIGINAL CENTER CONSOLE
IS THEN REINSTALLED.
273
00:15:36,413 --> 00:15:39,517
A WORKER INSTALLS
A VIDEO MONITOR
274
00:15:39,517 --> 00:15:41,000
IN THE LIMOUSINE.
275
00:15:43,724 --> 00:15:46,620
NEXT, HE ROLLS OUT
THE FLOOR MATS.
276
00:15:46,620 --> 00:15:51,206
THE ACRYLIC DISCO BAR
LIGHTING SYSTEM IS TESTED.
277
00:15:53,034 --> 00:15:55,206
IN JUST 21 DAYS,
278
00:15:55,206 --> 00:15:59,827
THE ORIGINAL CAR IS TRANSFORMED
INTO A LUXURIOUS LIMOUSINE.
279
00:15:59,827 --> 00:16:03,344
WITH TEST DRIVES AND
QUALITY-CONTROL CHECKS COMPLETE,
280
00:16:03,344 --> 00:16:06,724
ENJOY A RIDE
IN THE LAP OF LUXURY.
281
00:16:16,586 --> 00:16:17,793
Narrator: A HAMMER
282
00:16:17,793 --> 00:16:19,551
IS ONE OF THE MOST USEFUL TOOLS
OUT THERE.
283
00:16:19,551 --> 00:16:22,896
THE ONLY PROBLEM IS
YOU HAVE TO CONTROL THE REBOUND.
284
00:16:22,896 --> 00:16:26,034
THAT IS, UNLESS YOU HAVE
A DEAD BLOW HAMMER.
285
00:16:26,034 --> 00:16:28,896
THESE TOOLS ARE ACCURATE
AND EASY TO USE
286
00:16:28,896 --> 00:16:32,137
BECAUSE THIS PARTICULAR TYPE
ABSORBS THE BOUNCE.
287
00:16:35,482 --> 00:16:38,931
THIS FACILITY MAKES A VARIETY
OF DEAD BLOW HAMMERS.
288
00:16:38,931 --> 00:16:40,965
SOME ARE SOFT-FACED
289
00:16:40,965 --> 00:16:44,620
AND SOME ARE BALL-PEENS,
WHICH ARE USED BY MACHINISTS.
290
00:16:44,620 --> 00:16:46,344
ALL IN ALL, THEY COME IN HANDY
291
00:16:46,344 --> 00:16:48,862
EVERYWHERE
FROM NASCAR RACETRACKS
292
00:16:48,862 --> 00:16:51,655
TO OPERATING ROOMS.
293
00:16:51,655 --> 00:16:55,827
TO FIRST CREATE THE INTERNAL
STRUCTURE OF THE HAMMER,
294
00:16:55,827 --> 00:16:59,034
THEY DRILL THROUGH A SHORT
LENGTH OF WELDED STEEL TUBING
295
00:16:59,034 --> 00:17:00,586
WITH A DRILL PRESS.
296
00:17:00,586 --> 00:17:02,724
THE WORKER DRILLS
STRAIGHT THROUGH THE TUBE,
297
00:17:02,724 --> 00:17:05,344
CREATING A HOLE ON BOTH SIDES.
298
00:17:05,344 --> 00:17:08,862
THIS TUBE WILL BECOME
THE INTERNAL HEAD OF THE HAMMER.
299
00:17:10,862 --> 00:17:12,896
THE HEAD NEEDS A HANDLE.
300
00:17:12,896 --> 00:17:16,310
A WORKER PLACES THE TUBE
ON A JIG
301
00:17:16,310 --> 00:17:18,344
AND THEN POSITIONS A ROD
ON THE HOLE.
302
00:17:18,344 --> 00:17:22,758
A PRESS FORCES THE ROD
THROUGH THE TUBE.
303
00:17:22,758 --> 00:17:24,034
AT THE NEXT STATION,
304
00:17:24,034 --> 00:17:26,241
A WORKER PLACES
THE INTERNAL HAMMER ASSEMBLAGE
305
00:17:26,241 --> 00:17:30,448
BEHIND A PANE OF TINTED GLASS
TO PROTECT HER EYES
306
00:17:30,448 --> 00:17:33,689
AS SHE WELDS
THE HEAD AND HANDLE TOGETHER.
307
00:17:33,689 --> 00:17:35,655
SHE ONLY WELDS
THE TOP OF THE TUBE
308
00:17:35,655 --> 00:17:37,172
SO AS NOT TO ALTER THE METAL.
309
00:17:39,724 --> 00:17:44,413
A MACHINE DRILLS A SET OF SMALL
CONICAL INDENTS IN THE HANDLE.
310
00:17:44,413 --> 00:17:46,965
FITTING A SET OF PINS
INSIDE THE MOLD,
311
00:17:46,965 --> 00:17:50,896
THESE INDENTS WILL BE CRUCIAL
TO THE PROCESS.
312
00:17:50,896 --> 00:17:54,000
BECAUSE THE INTERNAL HANDLE
IS ROUND,
313
00:17:54,000 --> 00:17:56,413
THE URETHANE EXTERIOR
COULD TWIST ON IT
314
00:17:56,413 --> 00:17:58,172
WHEN THE HAMMER IS BEING USED.
315
00:17:58,172 --> 00:18:02,482
TO PREVENT THIS,
A WORKER WELDS ON A FLAT TAB.
316
00:18:02,482 --> 00:18:06,206
THE URETHANE WILL LOCK IN PLACE
AROUND THE TAB.
317
00:18:06,206 --> 00:18:09,448
NEXT, A WORKER CRIMPS
A METAL CAP
318
00:18:09,448 --> 00:18:13,241
ON ONE END OF THE TUBE.
319
00:18:13,241 --> 00:18:16,344
THIS CREATES AN OPEN CANISTER,
320
00:18:16,344 --> 00:18:19,344
WHICH THE WORKER PARTIALLY FILLS
WITH A CRUCIAL INGREDIENT --
321
00:18:19,344 --> 00:18:21,793
HARDENED STEEL SHOT.
322
00:18:21,793 --> 00:18:24,379
HE THEN CRIMPS A CAP
ON THE OPEN END,
323
00:18:24,379 --> 00:18:26,379
SEALING IN THE SHOT.
324
00:18:26,379 --> 00:18:28,241
WITH THE HEAD CANISTER DONE,
325
00:18:28,241 --> 00:18:31,896
THE CORE OF THE DEAD BLOW HAMMER
IS NOW COMPLETE.
326
00:18:31,896 --> 00:18:34,275
WHILE THE BASIC COMPONENTS
ARE SIMPLE,
327
00:18:34,275 --> 00:18:38,827
WORKERS MUST ASSEMBLE
EVERY ELEMENT WITH PRECISION.
328
00:18:38,827 --> 00:18:41,655
THE MOLD HAS
A SET OF PINS INSIDE IT.
329
00:18:41,655 --> 00:18:43,896
A WORKER ALIGNS THE INDENTS
ON THE METAL HANDLE
330
00:18:43,896 --> 00:18:45,103
WITH THESE PINS.
331
00:18:45,103 --> 00:18:49,172
THE PINS ENSURE THAT
THE INTERNAL HAMMER HANGS
332
00:18:49,172 --> 00:18:52,931
IN A PERFECTLY CENTERED POSITION
INSIDE THE MOLD.
333
00:18:52,931 --> 00:18:54,896
WORKERS SECURE THE MOLD
IN A SUPPORT FRAME
334
00:18:54,896 --> 00:18:58,103
BEFORE PLACING IT ON A CONVEYOR
335
00:18:58,103 --> 00:19:01,551
THAT WILL TAKE IT THROUGH
A PREHEATING OVEN.
336
00:19:02,896 --> 00:19:05,827
BALL-PEEN HAMMERS
ARE ASSEMBLED DIFFERENTLY.
337
00:19:05,827 --> 00:19:08,068
INSTEAD OF CRIMPING A CAP ON,
338
00:19:08,068 --> 00:19:11,344
THEY SCREW THE FACE OF
THE HAMMER ONTO A THREADED TUBE.
339
00:19:11,344 --> 00:19:14,103
THE METAL CORE OF THE BALL-PEEN
IS PLACED IN A MOLD
340
00:19:14,103 --> 00:19:17,137
THAT LEAVES THE METAL FACE
AND BALL EXPOSED.
341
00:19:19,448 --> 00:19:22,103
AFTER THE MOLDS
GO THROUGH THE PREHEATER,
342
00:19:22,103 --> 00:19:24,551
THEY ARRIVE
AT THE FILLING STATION.
343
00:19:24,551 --> 00:19:25,827
A HIGH-SPEED MIX HEAD
344
00:19:25,827 --> 00:19:28,931
BLENDS URETHANE
WITH HARDENERS AND CATALYSTS
345
00:19:28,931 --> 00:19:32,034
AND PUMPS THE MIX
THROUGH A FLEXIBLE HOSE.
346
00:19:32,034 --> 00:19:34,655
A WORKER USES THE HOSE
347
00:19:34,655 --> 00:19:37,965
TO FILL THE MOLDS TO THE BRIM
WITH THE ORANGE FLUID.
348
00:19:37,965 --> 00:19:39,758
SHE THEN SENDS THEM
INTO THE OVEN,
349
00:19:39,758 --> 00:19:42,586
WHERE THEY'LL SPEND
30 MINUTES CURING
350
00:19:42,586 --> 00:19:46,655
AT ABOUT 300 DEGREES FAHRENHEIT.
351
00:19:46,655 --> 00:19:48,793
ON THE OTHER SIDE OF THE OVEN,
352
00:19:48,793 --> 00:19:51,965
A WORKER REMOVES THE MOLDS
FROM THEIR FRAMES
353
00:19:51,965 --> 00:19:54,931
AND THEN RELEASES
THE NEWLY FORMED HAMMERS.
354
00:19:54,931 --> 00:19:56,827
THANKS
TO A SPECIAL RELEASE AGENT
355
00:19:56,827 --> 00:19:59,344
THAT WAS SPRAYED
INSIDE THE MOLD,
356
00:19:59,344 --> 00:20:03,551
THE HAMMERS COME OUT EASILY.
357
00:20:03,551 --> 00:20:05,551
AT THE FINISHING STATION,
358
00:20:05,551 --> 00:20:08,068
WORKERS USE
A HIGH-SPEED CIRCULAR BRUSH
359
00:20:08,068 --> 00:20:11,172
TO REMOVE THE EXCESS MATERIAL,
OR FLASH,
360
00:20:11,172 --> 00:20:13,655
PRODUCED BY THE MOLDING PROCESS.
361
00:20:13,655 --> 00:20:15,689
THIS IS
THE MOST DIFFICULT OPERATION
362
00:20:15,689 --> 00:20:17,689
IN THE MAKING
OF DEAD BLOW HAMMERS,
363
00:20:17,689 --> 00:20:20,965
AND THESE WORKERS
ARE HIGHLY SKILLED.
364
00:20:23,482 --> 00:20:25,896
WHEN MOLDING BALL-PEEN HAMMERS,
365
00:20:25,896 --> 00:20:29,413
THE FRONT AND BACK OF THE HEAD
ARE LEFT EXPOSED.
366
00:20:29,413 --> 00:20:33,482
FOR PERFORMANCE REASONS,
THIS STEEL IS NOT STAINLESS.
367
00:20:33,482 --> 00:20:37,620
WORKERS DIP THE EXPOSED STEEL
IN HOT WAX.
368
00:20:37,620 --> 00:20:40,310
THE WAX COATING WILL PROTECT
THE HAMMER FROM RUST
369
00:20:40,310 --> 00:20:44,379
UNTIL IT'S TAKEN OFF
THE STORE SHELF AND PUT TO USE.
370
00:20:44,379 --> 00:20:46,793
SOFT-FACED BALL-PEENS
AND SLEDGES
371
00:20:46,793 --> 00:20:49,103
ARE AMONG THE 20 MODELS
OF DEAD BLOW HAMMERS
372
00:20:49,103 --> 00:20:50,620
MANUFACTURED HERE.
373
00:20:52,655 --> 00:20:54,655
A WORKER ATTACHES A LABEL
374
00:20:54,655 --> 00:20:58,379
WHICH INCLUDES ALL THE RELEVANT
INFORMATION AND WARNINGS.
375
00:20:58,379 --> 00:21:02,827
THE LABELED HAMMERS THEN GO
IN A BOX READY FOR SHIPPING.
376
00:21:02,827 --> 00:21:05,482
DEAD BLOW HAMMERS
HAVE MANY APPLICATIONS,
377
00:21:05,482 --> 00:21:07,793
FROM FOOD PROCESSING PLANTS
378
00:21:07,793 --> 00:21:10,482
TO WOODWORKING SHOPS
TO THE OIL INDUSTRY.
379
00:21:10,482 --> 00:21:12,000
SOME SURGEONS EVEN USE THEM
380
00:21:12,000 --> 00:21:14,655
TO DRIVE ARTIFICIAL HIPS
INTO PLACE.
381
00:21:20,551 --> 00:21:23,068
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
382
00:21:23,068 --> 00:21:25,517
OR YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
383
00:21:25,517 --> 00:21:28,000
DROP US A LINE AT...
30161
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