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--Captions by VITAC--
www.vitac.com
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00:00:19,758 --> 00:00:22,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
TODAY ON "HOW IT'S MADE"...
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AND...
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MANY INDUSTRIES REQUIRE PUMPING
A WIDE VARIETY OF LIQUIDS.
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00:00:57,724 --> 00:00:59,517
AND THERE ARE MANY
DIFFERENT KINDS OF PUMPS
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THAT CAN DO THAT.
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00:01:00,724 --> 00:01:03,482
ONE TYPE, THE HOLLOW
ROTARY DISK PUMP,
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00:01:03,482 --> 00:01:06,862
USES A ROTATING DISK
TO CREATE SUFFICIENT SUCTION
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00:01:06,862 --> 00:01:08,689
TO MOVE THIN
OR THICK LIQUIDS
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IN A FORWARD
OR REVERSE DIRECTION.
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00:01:13,482 --> 00:01:15,344
WHEN THE PUMP IN THE BLUE RUNS,
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A HOLLOW DISK
INSIDE IT OSCILLATES.
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THIS CREATES SUCTION,
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DRAWING LIQUID
INTO ONE SIDE OF THE PUMP
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00:01:22,241 --> 00:01:25,379
AND PUSHING IT OUT THE OTHER.
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00:01:25,379 --> 00:01:27,344
SOME OF THE PUMP COMPONENTS
ARE CAST
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IN SAND MOLDS LIKE THIS ONE
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FOR CASTING THE FIRST PART
OF THE PUMP'S TWO-PART BODY.
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THE MOLTEN IRON
TAKES A FEW HOURS
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TO COOL AND SOLIDIFY
INSIDE THE MOLD CAVITY.
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00:01:38,310 --> 00:01:40,241
THEN, A VIBRATING MACHINE
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BREAKS THE SAND MOLD
TO RELEASE THE CAST PART.
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A COMPUTER-GUIDED
MILLING MACHINE
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THEN FINISHES THE SHAPE.
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THE CUT-OFF PIECES OF IRON
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GO BACK INTO THE FURNACE
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00:01:51,413 --> 00:01:54,379
TO BE MELTED DOWN
FOR SUBSEQUENT CASTINGS.
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AFTER IT'S CAST,
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THE SECOND PART
OF THE PUMP'S BODY IS MACHINED
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00:02:01,758 --> 00:02:05,482
TO ITS FINAL SHAPE
ON A COMPUTER-GUIDED LATHE.
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00:02:05,482 --> 00:02:09,137
THE PUMP'S HOLLOW DISK,
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WHICH THE LATHE MACHINES
FROM A BAR OF STEEL,
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REQUIRES A COMPLEX CUT
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00:02:13,620 --> 00:02:17,482
THAT ONLY THIS ELECTRIC
DISK CHARGE MACHINE CAN PERFORM.
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ITS CUTTING TOOL
IS A GOLD WIRE CHARGED
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WITH A HIGH-VOLTAGE CURRENT
CONDUCTED BY WATER.
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GUIDED BY A COMPUTER,
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THE WIRE ERODES
THE METAL IN ITS PATH,
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CUTTING A TEARDROP-SHAPED
OPENING IN THE DISK.
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A LASER PRINTER ENGRAVES
A PART NUMBER
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AND A BATCH NUMBER
ON THE FINISHED DISK.
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TO ASSEMBLE THE PUMP,
A WORKER BEGINS
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WITH THE FIRST PART
OF THE TWO-PART BODY.
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THE WORKER APPLIES GLUE
TO THE SHAFT SLEEVE AND INSERTS
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IT INTO A CHANNEL
FROM THE FRONT.
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NEXT, THEY INSERT A LANTERN RING
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INTO THE SAME CHANNEL
FROM THE BACK.
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THE WORKER PLACES A BEARING
ON TOP OF THE LANTERN RING.
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THEN, FROM THE OTHER SIDE,
THEY INSERT ONE MORE BEARING.
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00:03:20,896 --> 00:03:23,068
THE WORKER INSERTS
THE PUMP SHAFT
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THROUGH ALL THE BEARINGS
IN THE CHANNEL.
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THE BEARINGS MINIMIZE FRICTION,
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ENABLING THE SHAFT
TO ROTATE SMOOTHLY.
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ALONG WITH THIS
RETAINING CLIP,
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THE BEARINGS ALSO PREVENT
THE SHAFT
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FROM MOVING UP AND DOWN
OR SHIFTING SIDE BY SIDE
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WITH THE PUMP'S MOVEMENT.
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00:03:42,275 --> 00:03:45,103
WORKERS TAKE THE SECOND PART
OF THE PUMP'S BODY
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AND GLUE A BRONZE PLATE,
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CALLED A DIAPHRAGM,
INTO A GROOVE AT THE TOP.
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00:03:51,206 --> 00:03:53,862
THEN THEY JOIN
THE TWO PARTS OF THE BODY,
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PLACING A GASKET IN BETWEEN
TO PREVENT LEAKS.
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THE GASKET IS MADE
OF SPECIAL GASKET PAPER
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00:04:00,275 --> 00:04:03,241
LIKE THE TYPE USED
IN CAR ENGINE PIPING.
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00:04:07,172 --> 00:04:09,724
THE WORKERS FASTEN
THE TWO PARTS OF THE BODY
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WITH 10 MASSIVE BOLTS
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AND INSTALL A HEAVY-DUTY
STEEL SPRING
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IN A GROOVE IN THE SHAFT.
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A STEEL CAP KEEPS THE SPRING
FIRMLY IN POSITION.
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THE WORKER COMPRESSES THE SPRING
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WITH A TOOL AND INSERTS
A BRONZE STEM BUSHING.
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THIS SPRING LOADING IS CRITICAL
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BECAUSE IT ENABLES THE DISK
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TO ADAPT TO THIN
OR THICK LIQUIDS
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WITHOUT CLOGGING
OR GETTING DAMAGED.
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NOW, THEY MOUNT THE HOLLOW
DISK ONTO THE BUSHING
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AND BOLT ON THE FRONT COVER.
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WHEN THE MOTOR TURNS
THE PUMP'S SHAFT,
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00:04:44,586 --> 00:04:47,344
THE HOLLOW DISK OSCILLATES
AROUND THE DIAPHRAGM,
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00:04:47,344 --> 00:04:50,724
WHICH ACTS AS A BARRIER,
SEPARATING THE SUCTION SIDE
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OF THE PUMP
FROM THE DISCHARGE SIDE.
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THIS PLATE COVERS
WHERE THE CUSTOMER
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WILL LATER
INSTALL A SAFETY VALVE.
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THE OSCILLATING HOLLOW DISK
PRODUCES SUCTION,
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00:05:02,379 --> 00:05:04,620
WHICH PULLS LIQUID
THROUGH THE INLET PORT,
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THEN OUT THE OPPOSITE SIDE,
THROUGH THE OUTLET PORT.
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00:05:08,551 --> 00:05:10,931
WORKERS MASK THE INLET
AND OUTLET PORTS
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00:05:10,931 --> 00:05:14,413
BEFORE SPRAY-PAINTING THE PUMP.
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00:05:14,413 --> 00:05:17,517
NEXT, THE WORKER INSTALLS
A METAL COUPLING JOINT,
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00:05:17,517 --> 00:05:19,551
WHICH IS COMPRISED
OF SEVERAL PARTS,
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INCLUDING RUBBER MEMBERS,
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00:05:21,172 --> 00:05:22,965
WHICH MAKE THE JOINT
FLEXIBLE ENOUGH
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00:05:22,965 --> 00:05:24,655
TO WITHSTAND SOME VIBRATION
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00:05:24,655 --> 00:05:26,862
OR SLIGHT MISALIGNMENT
OF THE CONNECTION
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00:05:26,862 --> 00:05:30,310
BETWEEN THE PUMP
AND THE GEAR REDUCER.
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THE GEAR REDUCER ACTS
AS THE MIDDLEMAN
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00:05:32,586 --> 00:05:35,448
BETWEEN THE MOTOR
AND THE PUMP,
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00:05:35,448 --> 00:05:38,448
LOWERING THE MOTOR SPEED
OF 1,800 REVOLUTIONS
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00:05:38,448 --> 00:05:41,241
PER MINUTE
TO THE DISK OSCILLATION SPEED
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00:05:41,241 --> 00:05:43,896
OF APPROXIMATELY 300 REVOLUTIONS
PER MINUTE.
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SUCH SLOW ROTATION
SPEED IS CRITICAL,
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AS IT ENABLES THE PUMP TO MOVE
EVEN VERY THICK FLUIDS.
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THE DISK CAN ALSO
ROTATE IN REVERSE
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SO THAT LIQUID CAN BE LOADED
OR UNLOADED USING THE SAME PUMP.
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Narrator:
PALMYRA PALM SUGAR IS DERIVED
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FROM THE PALMYRA PALM TREE
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00:06:12,172 --> 00:06:14,344
AND IS CONSIDERED
A HEALTHIER FORM OF SWEETENER
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00:06:14,344 --> 00:06:15,689
THAN MANY OTHERS,
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00:06:15,689 --> 00:06:18,310
JUST 41 ON THE GLYCEMIC INDEX
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00:06:18,310 --> 00:06:22,000
WITH ONLY 1/10th OUNCE
OF FRUCTOSE PER 3 1/2 OUNCES.
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00:06:22,000 --> 00:06:23,896
IT'S ALSO ONE
OF THE FEW PLANT-BASED
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SOURCES OF VITAMIN B12.
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00:06:29,206 --> 00:06:31,103
PALMYRA PALM SUGAR
DOESN'T COME OUT
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00:06:31,103 --> 00:06:32,413
OF THE PALMYRA PALM TREE
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LOOKING LIKE THIS.
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FROM HARVESTING
TO PROCESSING,
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THERE ARE MANY STEPS
BETWEEN THE TREE
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AND THE ULTIMATE PRODUCT.
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THE TREE PRODUCES THE ROUND
FRUIT SEEN ON THE RIGHT
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00:06:44,379 --> 00:06:49,172
AND THE CYLINDRICAL FLOWER
CLUSTER ON THE LEFT.
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00:06:49,172 --> 00:06:52,448
A PALM SUGAR HARVESTER
PREPARES SPECIALIZED CONTAINERS
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00:06:52,448 --> 00:06:54,103
FOR HARVESTING THE SAP
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00:06:54,103 --> 00:06:57,344
BY THREADING TWINE
THROUGH A HOLE NEAR THE RIM.
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00:06:57,344 --> 00:07:00,000
THESE TUBES ARE
MADE FROM BAMBOO.
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AND IN THAILAND, THEY'RE
CALLED...
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THE HARVESTER ADDS WOOD CHIPS
TO THE TUBES.
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00:07:07,827 --> 00:07:10,551
THE WOOD CHIPS COME
FROM THE SHOREA TREE,
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00:07:10,551 --> 00:07:12,413
WHICH IS CALLED...
IN THAILAND.
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00:07:12,413 --> 00:07:16,413
THE CHIPS WELL HELP PREVENT
THE SAP FROM FERMENTING.
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00:07:19,034 --> 00:07:23,206
SOME PALMYRA TREES ARE
MORE THAN 100 YEARS OLD.
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HERE, THE HARVESTER CLIMBS
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00:07:24,931 --> 00:07:28,000
A LADDER THAT REACHES UP
AROUND 66 FEET.
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00:07:31,586 --> 00:07:32,862
AT THE TOP OF THE TREE,
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00:07:32,862 --> 00:07:35,034
THE HARVESTER USES A MACHETE
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00:07:35,034 --> 00:07:37,793
TO CUT THE TIP OFF
THE PALMYRA FLOWERS.
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00:07:41,206 --> 00:07:43,000
SAFELY ON THE GROUND,
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00:07:43,000 --> 00:07:46,448
HE DEMONSTRATES
WHAT HE DOES UP IN THE TREE.
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00:07:46,448 --> 00:07:49,965
HE STARTS BY BINDING TOGETHER
TWO OF THE CYLINDRICAL FLOWERS
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00:07:49,965 --> 00:07:52,862
AND THEN CAREFULLY
TRIMMING OFF THEIR TIPS.
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WHERE THEY'VE BEEN CUT,
THE FLOWERS EXUDE DROPS OF SAP,
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00:08:00,344 --> 00:08:04,551
WHICH WILL COLLECT
IN THE BAMBOO TUBES.
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00:08:04,551 --> 00:08:08,862
UP IN THE TREE, THE HARVESTER
SECURES THE TUBES IN PLACE.
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00:08:08,862 --> 00:08:11,379
HAVING SWAPPED EMPTY TUBES
FOR FULL ONES,
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00:08:11,379 --> 00:08:16,344
HE BRINGS THE SAP HE'S COLLECTED
TO AN OUTDOOR STOVE.
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00:08:16,344 --> 00:08:19,689
THE HARVESTER PREPARES
A BASKET COVERED
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00:08:19,689 --> 00:08:24,344
WITH SEVERAL LAYERS OF GAUZE
TO FILTER THE LIQUID.
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00:08:24,344 --> 00:08:26,206
HE THEN SLOWLY AND CAREFULLY
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00:08:26,206 --> 00:08:28,379
POURS THE SAP
THROUGH THE FILTERS,
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00:08:28,379 --> 00:08:30,034
INTO THE WOK BELOW.
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00:08:30,034 --> 00:08:33,068
THE HARVESTING
STAGE IS COMPLETE.
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00:08:33,068 --> 00:08:35,655
PRODUCTION NOW BEGINS.
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00:08:35,655 --> 00:08:39,172
THE FILTERED SAP
NOW BOILS AWAY IN THE WOK
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00:08:39,172 --> 00:08:41,448
FOR APPROXIMATELY 45 MINUTES
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00:08:41,448 --> 00:08:43,793
AS IT THICKENS INTO A SUGAR.
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00:08:47,000 --> 00:08:48,965
THE WORKER TAKES ADVANTAGE
OF THE HOT OVEN FIRE
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00:08:48,965 --> 00:08:52,482
TO STERILIZE HIS BAMBOO TUBES.
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00:08:52,482 --> 00:08:54,965
HE TURNS THEM UPSIDE-DOWN,
ONE BY ONE,
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00:08:54,965 --> 00:08:57,379
OVER SMALL HOLES IN THE OVEN.
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00:08:57,379 --> 00:09:02,034
THE WORKER MUST
HARVEST TWICE A DAY.
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00:09:02,034 --> 00:09:04,793
IF HE DOESN'T, THE CUTS
WILL HEAL OVER TOO MUCH.
162
00:09:04,793 --> 00:09:07,517
AND HE'LL BE FORCED TO WAIT
FOR A SPECIFIC PERIOD OF TIME
163
00:09:07,517 --> 00:09:09,793
BEFORE MAKING ADDITIONAL CUTS
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00:09:09,793 --> 00:09:12,310
IN ORDER TO PREVENT DAMAGE
TO THE TREE.
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00:09:16,068 --> 00:09:18,896
THE BOILING PROCESS
THICKENS THE SAP.
166
00:09:18,896 --> 00:09:20,310
AND THE WORKER MUST STIR IT
FREQUENTLY
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00:09:20,310 --> 00:09:22,241
TO KEEP IT FROM STICKING.
168
00:09:25,172 --> 00:09:29,862
AFTER ROUGHLY 30 MINUTES,
THE SAP BEGINS TO TURN WHITE.
169
00:09:29,862 --> 00:09:32,344
THE TUBES ARE NOW
THOROUGHLY STERILIZED.
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00:09:32,344 --> 00:09:35,137
AND THE WORKER CAN REMOVE THEM
AND LET THEM COOL.
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00:09:37,827 --> 00:09:41,793
THE BUBBLING SAP HAS NOW BEEN
REDUCED TO A THICK SUBSTANCE.
172
00:09:41,793 --> 00:09:45,551
THE WORKER REMOVES THE PAN
FROM THE HEAT SOURCE.
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00:09:45,551 --> 00:09:50,275
IT'S READY FOR THE NEXT PHASE
ON ITS PATH TO BECOMING SUGAR.
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00:09:50,275 --> 00:09:52,965
ALTHOUGH IT'S OFTEN REFERRED TO
AS PALM SUGAR,
175
00:09:52,965 --> 00:09:55,275
IT'S ALSO KNOWN AS JAGGERY.
176
00:09:58,586 --> 00:10:01,931
THE WORKER NOW USES
A CUSTOM-MADE WHISKING TOOL
177
00:10:01,931 --> 00:10:05,310
TO THOROUGHLY MIX THE JAGGERY.
178
00:10:05,310 --> 00:10:07,137
SHAPED LIKE A LARGE SPRING,
179
00:10:07,137 --> 00:10:11,448
THE WHISK HELPS COOL THE SUGAR
WHILE MIXING IT.
180
00:10:11,448 --> 00:10:14,827
HE CONTINUES MIXING THE JAGGERY
UNTIL IT THICKENS AND COOLS
181
00:10:14,827 --> 00:10:17,000
TO A PASTE-LIKE CONSISTENCY.
182
00:10:20,344 --> 00:10:23,586
AT THIS POINT, THE JAGGERY
IS TOO THICK FOR THE WHISK.
183
00:10:23,586 --> 00:10:26,862
SO THE WORKER CONTINUES
MIXING IT WITH A SIMPLE STICK.
184
00:10:28,896 --> 00:10:31,827
FINALLY, THE SUGAR COOLS
AND DRIES TO A THICK,
185
00:10:31,827 --> 00:10:33,310
FLAKY TEXTURE,
186
00:10:33,310 --> 00:10:37,551
READY TO BE PACKAGED
AND SHIPPED AROUND THE WORLD.
187
00:10:37,551 --> 00:10:40,482
IT HAS TAKEN NEARLY
A GALLON OF PALMYRA PALM SAP
188
00:10:40,482 --> 00:10:43,172
TO CREATE ROUGHLY 2 1/4 POUNDS
189
00:10:43,172 --> 00:10:46,413
OF THIS HIGHLY NUTRITIOUS
ALTERNATIVE SWEETENER.
190
00:10:58,827 --> 00:11:01,586
Narrator: THE FIRST YACHTS
WERE SIMPLE, STURDY VESSELS
191
00:11:01,586 --> 00:11:05,206
USED TO TAKE EXPLORERS
ON VOYAGES OF DISCOVERY.
192
00:11:05,206 --> 00:11:08,137
TODAY'S YACHTS ARE
FLOATING VACATION HOMES.
193
00:11:08,137 --> 00:11:10,000
EQUIPPED WITH EVERY CONVENIENCE,
194
00:11:10,000 --> 00:11:13,379
THE LUXURIES INCREASE
WITH THE SCALE OF THE VESSEL.
195
00:11:13,379 --> 00:11:15,137
MODERN YACHTS ARE
THE ULTIMATE WAY
196
00:11:15,137 --> 00:11:17,137
TO EXPLORE THE COASTLINE.
197
00:11:20,793 --> 00:11:22,620
IF YOU CAN AFFORD ONE OF THESE,
198
00:11:22,620 --> 00:11:24,344
YOU'RE LIVING THE DREAM.
199
00:11:24,344 --> 00:11:25,689
THIS MOTOR YACHT OFFERS
200
00:11:25,689 --> 00:11:29,931
ALL THE COMFORTS OF HOME
ON THE WATER.
201
00:11:29,931 --> 00:11:34,379
MAKING THIS MID-SIZED YACHT
STARTS WITH A MOLD FOR THE HULL.
202
00:11:34,379 --> 00:11:36,793
THE TEAM SPRAYS
A GEL-COAT PAINT
203
00:11:36,793 --> 00:11:39,793
ONTO THE ENTIRE INNER SURFACE
OF THE MOLD.
204
00:11:39,793 --> 00:11:44,517
THIS PAINT WILL TRANSFER
TO THE HULL DURING MOLDING.
205
00:11:44,517 --> 00:11:48,827
THEY LAYER FIBERGLASS STRIPS
AROUND A P.V.C FOAM CORE
206
00:11:48,827 --> 00:11:52,310
AND CREATE A SERIES OF
DISTRIBUTION CHANNELS FOR RESIN.
207
00:11:52,310 --> 00:11:54,379
THE CREW NOW DRAPES
AN ENORMOUS SHEET
208
00:11:54,379 --> 00:11:57,758
OF CLEAR PLASTIC
OVER THE MATERIALS IN THE MOLD
209
00:11:57,758 --> 00:12:00,517
AND SEALS THE EDGES WITH TAPE.
210
00:12:00,517 --> 00:12:03,344
THE CREW LEAVES A LOT OF SLACK
IN THE PLASTIC
211
00:12:03,344 --> 00:12:06,517
TO CONFORM
TO THE MOLD'S DEEP RECESSES.
212
00:12:06,517 --> 00:12:10,586
A VACUUM HOSE SUCTIONS OUT
THE AIR BENEATH THE PLASTIC.
213
00:12:10,586 --> 00:12:13,827
THE CREW THEN CONNECTS
PLASTIC TUBING TO THE PORTS
214
00:12:13,827 --> 00:12:16,758
IN THE DISTRIBUTION CHANNELS.
215
00:12:16,758 --> 00:12:21,758
ALL THIS PLASTIC TUBING LEADS
TO ONE PLACE -- THE VACUUM PUMP.
216
00:12:21,758 --> 00:12:24,793
THE VACUUM PULLS RESIN
THROUGH THE NETWORK OF TUBING,
217
00:12:24,793 --> 00:12:28,517
INTO THE PORTS AND THROUGH
THE DISTRIBUTION CHANNELS.
218
00:12:28,517 --> 00:12:31,137
THE RESIN SATURATES
THE FIBERGLASS STRIPS
219
00:12:31,137 --> 00:12:33,965
THAT SURROUND
THE P.V.C. FOAM CORE.
220
00:12:33,965 --> 00:12:37,482
THE VACUUM SUCKS THE LAYERS
INTO A TIGHT SANDWICH
221
00:12:37,482 --> 00:12:41,586
AND PULLS OUT MORE AIR
AND EXCESS RESIN.
222
00:12:41,586 --> 00:12:44,517
A WORKER PULLS THE PLASTIC AWAY
FROM DRY SPOTS
223
00:12:44,517 --> 00:12:47,586
SO THE RESIN FLOWS
INTO THESE AREAS.
224
00:12:47,586 --> 00:12:49,344
THE RESIN CURES,
225
00:12:49,344 --> 00:12:52,310
AND THE FIBERGLASS
LAYERS HARDEN.
226
00:12:52,310 --> 00:12:54,379
THE NEXT DAY,
THE TEAM REMOVES
227
00:12:54,379 --> 00:12:57,000
THE PLASTIC SHEET
FROM THE MOLDED PART.
228
00:13:02,517 --> 00:13:05,000
THEY PULL OFF
THE RESIN DISTRIBUTION CHANNELS
229
00:13:05,000 --> 00:13:08,034
AND THE PORTS.
230
00:13:08,034 --> 00:13:11,448
A CRANE LIFTS THE NEWLY MOLDED
HULL OUT OF THE MOLD.
231
00:13:13,827 --> 00:13:18,689
THE GEL COAT HAS ADHERED TO IT,
GIVING IT A GLOSSY FINISH.
232
00:13:18,689 --> 00:13:22,068
THE CRANE TRANSFERS THE HULL
TO A WOODEN CRADLE.
233
00:13:24,551 --> 00:13:28,758
NEXT, THEY CREATE
THE YACHT'S DECK.
234
00:13:28,758 --> 00:13:30,310
THE CREW COVERS SOME AREAS
235
00:13:30,310 --> 00:13:32,620
OF THE MOLD IN PLASTIC
TO PROTECT THEM
236
00:13:32,620 --> 00:13:35,896
FROM THE FIRST GEL COAT
IN A 2-TONED PAINT JOB.
237
00:13:39,655 --> 00:13:43,000
AFTER THE FIRST COLOR GOES ON,
THEY GEL-COAT THE AREAS
238
00:13:43,000 --> 00:13:45,827
THAT HAD BEEN
COVERED IN PLASTIC.
239
00:13:45,827 --> 00:13:49,344
THIS TWO-TONED PAINT JOB
IS DONE FOR AESTHETIC REASONS.
240
00:13:49,344 --> 00:13:51,379
BUT IT ALSO COLOR-CODES
THE AREAS
241
00:13:51,379 --> 00:13:54,482
THAT HAVE A NONSKID TEXTURE.
242
00:13:54,482 --> 00:14:00,620
LIKE THE HULL, THE CREW MAKES
THE DECK MAINLY FROM FIBERGLASS.
243
00:14:00,620 --> 00:14:04,448
A WORKER CUTS OUT THE STRIPS
IN DIFFERENT SIZES.
244
00:14:04,448 --> 00:14:07,344
THE FABRICS HAVE
VARIOUS THICKNESSES AND WEAVES,
245
00:14:07,344 --> 00:14:11,413
ALL GEARED TO THE DECK'S
STRUCTURAL REQUIREMENTS.
246
00:14:11,413 --> 00:14:13,793
HE NUMBERS THE PIECES
TO DESIGNATE THEIR PLACEMENT
247
00:14:13,793 --> 00:14:16,448
IN THE MOLD.
248
00:14:16,448 --> 00:14:19,000
AND THE WORKER STACKS THEM
SEQUENTIALLY.
249
00:14:22,724 --> 00:14:24,586
AFTER ARRANGING SOME
OF THE FIBERGLASS STRIPS
250
00:14:24,586 --> 00:14:25,896
IN THE MOLD,
251
00:14:25,896 --> 00:14:28,068
THE CREW BUILDS UP THE DECK
IN CERTAIN AREAS
252
00:14:28,068 --> 00:14:31,724
USING PIECES OF BALSA WOOD.
253
00:14:31,724 --> 00:14:33,965
BALSA WOOD IS
EXTREMELY LIGHTWEIGHT.
254
00:14:33,965 --> 00:14:35,241
BUT IT WILL ADD STRENGTH
255
00:14:35,241 --> 00:14:38,965
WHEN LAMINATED INTO
THE FIBERGLASS SANDWICH.
256
00:14:38,965 --> 00:14:41,068
THE STRATEGIC PLACEMENT
OF THE BALSA WOOD
257
00:14:41,068 --> 00:14:44,068
IN HIGH-TRAFFIC AREAS
CREATES A SOLID CORE
258
00:14:44,068 --> 00:14:46,137
THAT WILL HOLD UP TO HEAVY USE.
259
00:14:48,655 --> 00:14:50,793
A WORKER LAYS
MORE FIBERGLASS STRIPS,
260
00:14:50,793 --> 00:14:54,379
ENCAPSULATING THE BALSA WOOD.
261
00:14:54,379 --> 00:14:55,827
THEY'LL LAMINATE THE LAYERS
262
00:14:55,827 --> 00:14:59,034
WITH RESIN THE WAY
THEY DID WITH THE HULL.
263
00:14:59,034 --> 00:15:03,310
THE CREW ALSO MAKES
THE ROOF STRUCTURE THE SAME WAY.
264
00:15:03,310 --> 00:15:05,896
A BOAT BUILDER APPLIES
PUTTY TO THE FIBERGLASS
265
00:15:05,896 --> 00:15:08,379
TO EVEN OUT ANY IRREGULARITIES.
266
00:15:10,965 --> 00:15:13,448
AND AFTER GRINDING
THE HARDENED PUTTY SMOOTH,
267
00:15:13,448 --> 00:15:17,310
THEY SPREAD POLISHING COMPOUND
ON ALL THE YACHT'S BODY PARTS.
268
00:15:19,827 --> 00:15:21,517
THE WORKER BUFFS THE FIBERGLASS
269
00:15:21,517 --> 00:15:24,482
UNTIL THE GLOSSY SURFACE
GLEAMS EVEN MORE.
270
00:15:29,000 --> 00:15:32,241
USING A ROUTER, THE CREW CUTS
OUT HOLES FOR LIGHTS,
271
00:15:32,241 --> 00:15:35,586
PORTHOLES AND OTHER FEATURES.
272
00:15:35,586 --> 00:15:37,620
AN INSPECTOR TAPS THE FIBERGLASS
273
00:15:37,620 --> 00:15:40,068
TO CHECK FOR AIR VOIDS
THAT WOULD COMPROMISE
274
00:15:40,068 --> 00:15:42,793
THE YACHT'S STRUCTURAL
INTEGRITY.
275
00:15:42,793 --> 00:15:45,862
HE CONFIRMS THAT
EVERYTHING IS SHIPSHAPE.
276
00:15:45,862 --> 00:15:49,586
PRODUCTION NOW MOVES
TO THE YACHT'S INTERIOR.
277
00:15:49,586 --> 00:15:52,310
WE'LL HAVE THE INSIDE
INFORMATION COMING UP.
278
00:16:02,275 --> 00:16:05,034
Narrator: A MOTOR YACHT IS
A HOME AWAY FROM HOME.
279
00:16:05,034 --> 00:16:07,310
IT'S USUALLY EQUIPPED
WITH A FULL KITCHEN,
280
00:16:07,310 --> 00:16:08,724
ONE OR MORE BATHROOMS,
281
00:16:08,724 --> 00:16:11,931
AND LUXURIOUS COMMON AREAS
CALLED SALONS.
282
00:16:11,931 --> 00:16:13,275
EVERYTHING IS DESIGNED TO FIT
283
00:16:13,275 --> 00:16:15,862
INTO THE LIMITED SPACE
BELOW DECK.
284
00:16:15,862 --> 00:16:17,482
THE WATERS MAY GET ROUGH.
285
00:16:17,482 --> 00:16:19,068
BUT IN THE YACHT'S
PRIVATE QUARTERS,
286
00:16:19,068 --> 00:16:22,448
THE LIVING IS EASY.
287
00:16:22,448 --> 00:16:24,206
WITH THE BULKHEADS
NOW IN PLACE,
288
00:16:24,206 --> 00:16:27,413
THE HULL IS READY
FOR FURNISHINGS AND FITTINGS.
289
00:16:27,413 --> 00:16:30,275
A COMPUTERIZED ROUTER CUTS
AMERICAN CHERRY WOOD
290
00:16:30,275 --> 00:16:33,275
TO A SET OF EXACT MEASUREMENTS.
291
00:16:33,275 --> 00:16:37,689
THIS PARTICULAR PIECE WILL BE
PART OF A STORAGE LOCKER.
292
00:16:37,689 --> 00:16:40,000
AT ANOTHER STATION,
A CRAFTSMAN GLUES
293
00:16:40,000 --> 00:16:43,551
A DOZEN CHERRY STRIPS
TOGETHER FOR A VALENCE.
294
00:16:43,551 --> 00:16:45,586
THESE LAMINATED STRIPS
WILL BE EASIER
295
00:16:45,586 --> 00:16:49,724
TO BEND TO THE DESIRED SHAPE
THAN A THICK BOARD.
296
00:16:49,724 --> 00:16:52,413
HE WRAPS THEM IN WAX PAPER
TO PREVENT THE GLUE
297
00:16:52,413 --> 00:16:55,413
FROM SEEPING OUT
DURING BENDING.
298
00:16:55,413 --> 00:16:57,482
THE TEAM PLACES
THE LAMINATED STRIPS
299
00:16:57,482 --> 00:16:59,965
BETWEEN THE TWO PARTS
OF A BENDING JIG.
300
00:17:02,413 --> 00:17:05,206
THEY CLAMP THE JIG
TO CLOSE IT TIGHTLY.
301
00:17:07,448 --> 00:17:09,551
THE ADHESIVE SETS OVERNIGHT.
302
00:17:09,551 --> 00:17:11,517
AND THE WOOD HARDENS
TO THE CURVED SHAPE
303
00:17:11,517 --> 00:17:15,310
OF THE BENDING JIG.
304
00:17:15,310 --> 00:17:17,344
THE WOODWORKER NOW CLAMPS
THE VALENCE
305
00:17:17,344 --> 00:17:20,965
TO THE WORKBENCH TO STEADY IT
AS HE TRIMS THE EDGES.
306
00:17:23,448 --> 00:17:25,724
HE POSITIONS A TEMPLATE
ON THE VALENCE
307
00:17:25,724 --> 00:17:27,310
AND FOLLOWS IT
WITH A ROUTER
308
00:17:27,310 --> 00:17:30,724
TO CUT OUT A HOLE
FOR AN AIR-CONDITIONING VENT.
309
00:17:30,724 --> 00:17:32,137
YES.
THE YACHT WILL BE EQUIPPED
310
00:17:32,137 --> 00:17:34,655
WITH AIR CONDITIONING.
311
00:17:40,344 --> 00:17:42,206
THE WOODWORKER INSERTS
THE CUSTOM
312
00:17:42,206 --> 00:17:44,034
WOODEN VENT IN THE HOLE.
313
00:17:46,344 --> 00:17:49,448
TURNING NOW TO
THE SALON'S COFFEE TABLE,
314
00:17:49,448 --> 00:17:51,586
A ROUTER CUTS HOLES
IN THE CHERRY WOOD
315
00:17:51,586 --> 00:17:55,551
WHILE BRISTLES
KEEP THE DUST DOWN.
316
00:17:55,551 --> 00:17:57,172
A WORKER APPLIES GLUE
317
00:17:57,172 --> 00:18:01,344
AND INSERTS PIECES OF MAPLE
INTO THE CUTOUTS.
318
00:18:01,344 --> 00:18:02,896
HE LIGHTLY HAMMERS THE PIECES
319
00:18:02,896 --> 00:18:07,310
TO DRIVE THEM FURTHER
INTO THE HOLES.
320
00:18:07,310 --> 00:18:10,827
THEN, IT'S INTO
AN AUTOMATED SANDER.
321
00:18:10,827 --> 00:18:14,620
IT SANDS THE INLAID WOOD
FLUSH TO THE CHERRY TABLETOP.
322
00:18:17,655 --> 00:18:21,793
A CREW NOW BRUSHES VARNISH
ONTO ALL THE WOOD PIECES.
323
00:18:21,793 --> 00:18:23,965
THE VARNISH ENHANCES
THE WOOD GRAIN.
324
00:18:23,965 --> 00:18:25,931
AND IT PROTECTS THE SURFACE.
325
00:18:28,724 --> 00:18:30,517
AFTER THE VARNISH DRIES,
326
00:18:30,517 --> 00:18:33,793
ANOTHER WORKER POLISHES
THE WOOD TO A HIGH SHEEN.
327
00:18:36,827 --> 00:18:38,896
A WORKER THEN SCREWS
PEDESTAL HARDWARE
328
00:18:38,896 --> 00:18:40,379
INTO THE BACK OF EACH TABLE
329
00:18:40,379 --> 00:18:43,241
TO PREPARE THEM FOR
INSTALLATION IN THE YACHT.
330
00:18:47,310 --> 00:18:48,482
THE HULL HAS BEEN EQUIPPED
331
00:18:48,482 --> 00:18:51,000
WITH THE TWO DIESEL ENGINES
AT THE BACK.
332
00:18:53,482 --> 00:18:55,724
A WORKER NOW ASSEMBLES
THE CLOTHING LOCKER
333
00:18:55,724 --> 00:18:57,724
IN THE GUEST STATEROOM.
334
00:19:02,689 --> 00:19:04,724
AND IN THE MASTER STATEROOM,
335
00:19:04,724 --> 00:19:09,310
CONSTRUCTION ON THE EN SUITE
BATHROOM IS UNDERWAY.
336
00:19:09,310 --> 00:19:12,862
THE WORKER SCREWS
THE TOILET IN PLACE
337
00:19:12,862 --> 00:19:15,413
AND CONNECTS THE WATER
AND WASTE HOSES.
338
00:19:18,551 --> 00:19:20,206
THEY ROUGHEN A UTILITY ROOM
339
00:19:20,206 --> 00:19:23,000
FOR A WASHER AND DRYER
AT THE BACK OF THE YACHT,
340
00:19:23,000 --> 00:19:25,275
NEXT TO THE MECHANICAL SYSTEMS.
341
00:19:27,310 --> 00:19:29,344
THE CREW SITUATES
THE PROPELLERS
342
00:19:29,344 --> 00:19:32,000
IN THE MOLDED NICHES
IN THE BOTTOM OF THE HULL.
343
00:19:32,000 --> 00:19:33,482
AND THE TECHNICIAN
CONNECTS THEM
344
00:19:33,482 --> 00:19:36,862
TO SWIVELING MECHANISMS
CALLED PODS.
345
00:19:36,862 --> 00:19:38,655
HE HOOKS UP A PUMP
THAT WILL REPLACE
346
00:19:38,655 --> 00:19:40,689
THE LUBRICATING OIL
WHEN NEEDED,
347
00:19:40,689 --> 00:19:41,931
SO THERE'LL BE NO NEED
348
00:19:41,931 --> 00:19:44,379
TO PULL IT INTO PORT
FOR OIL CHANGES.
349
00:19:47,000 --> 00:19:49,137
THE TECHNICIAN
INSTALLS INTAKE SYSTEMS
350
00:19:49,137 --> 00:19:51,758
THAT WILL SUCTION LAKE
OR OCEAN WATER INTO THE HULL
351
00:19:51,758 --> 00:19:54,655
TO COOL THE DIESEL ENGINES.
352
00:19:54,655 --> 00:19:57,586
THE OTHER MECHANICS INCLUDE
THE AIR-CONDITIONING SYSTEM,
353
00:19:57,586 --> 00:20:01,689
WATER HEATER AND A GENERATOR.
354
00:20:01,689 --> 00:20:03,862
AND NOW, THE BIG MOMENT.
355
00:20:03,862 --> 00:20:06,620
USING A CRANE, THE CREW LOWERS
THE YACHT'S DECK
356
00:20:06,620 --> 00:20:10,000
AND PILOTHOUSE ONTO THE HULL.
357
00:20:10,000 --> 00:20:14,448
THIS DECK ASSEMBLY
WEIGHS 3 TONS.
358
00:20:14,448 --> 00:20:16,206
LOOKS LIKE
IT'S A GOOD FIT.
359
00:20:18,448 --> 00:20:21,310
USING CROWBARS,
THE TEAM PULLS THE RIM,
360
00:20:21,310 --> 00:20:25,551
ALSO KNOWN AS THE FLANGE
OF THE DECK, OVER THE HULL.
361
00:20:25,551 --> 00:20:28,655
THEY DRILL THREADED HOLES
THROUGH THE FIBERGLASS FLANGE
362
00:20:28,655 --> 00:20:30,551
AND THE HULL AND SCREW BOLTS
363
00:20:30,551 --> 00:20:33,310
INTO THOSE HOLES
TO CONNECT THE TWO.
364
00:20:33,310 --> 00:20:35,379
SPECIAL
ADHESIVE HAS BEEN APPLIED
365
00:20:35,379 --> 00:20:37,310
TO THESE BOLTS
TO KEEP WATER
366
00:20:37,310 --> 00:20:40,103
FROM PENETRATING THE VESSEL.
367
00:20:40,103 --> 00:20:42,000
HERE'S THE VIEW INSIDE.
368
00:20:42,000 --> 00:20:44,068
THE CHERRY PANELING
IN THE PILOTHOUSE
369
00:20:44,068 --> 00:20:48,000
SEAMLESSLY MATCHES THE PANELING
IN THE LIVING QUARTERS.
370
00:20:48,000 --> 00:20:50,413
THE BUILDERS COMPLETE
THE FURNISHINGS,
371
00:20:50,413 --> 00:20:53,344
GIVING THE CABIN THE LOOK
AND FEEL OF LUXURY.
372
00:20:55,379 --> 00:20:57,965
THEY INSTALL
A HIGH-END GALLEY KITCHEN.
373
00:20:57,965 --> 00:21:00,344
AND THIS YACHT IS COMPLETE.
374
00:21:00,344 --> 00:21:05,172
AFTER 6 MONTHS OF WORK,
LET THE GOOD TIMES BEGIN.
29396
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