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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Three-wheeled vehicles...
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...Baseball bats...
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...Artificial bonsais...
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...And trombones.
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Three-wheeled vehicles
Were introduced in the 1990s
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As exotic concept vehicles.
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This one is like
A motorcycle on steroids.
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00:01:01,379 --> 00:01:04,379
It has what's called
A reverse trike design --
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00:01:04,379 --> 00:01:06,758
Two wheels in front
And one in the back.
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00:01:06,758 --> 00:01:09,034
It hugs the road
Like a race car
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Yet is legal to drive
Through city streets.
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This vehicle goes from
0 to 60 miles per hour
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In just 4.1 seconds.
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It's no faster
Than a motorcycle,
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But it definitely turns heads.
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Production begins
With 34 steel-tube components
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That will form
The vehicle's chassis.
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A worker places them
In an assembly jig.
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This positions the tubes
For welding.
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After clamping
The components in place,
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It takes the worker
About 4 hours
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To weld 68 different areas
Together.
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00:01:49,482 --> 00:01:53,137
For efficiency, 13 of the
Larger, more complex structures
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Are pre-assembled.
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00:01:54,655 --> 00:01:58,344
The steel tubes measure
1.5 inches in diameter,
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00:01:58,344 --> 00:02:02,379
But the metal itself is only
1/16 of an inch thick.
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They're like those used
In the aviation industry --
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Strong, yet lightweight.
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00:02:08,344 --> 00:02:10,931
This company uses
A visual reference method
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To assemble smaller parts
Of the vehicle.
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Before starting, a worker
Places 80 components on a board
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With labels that identify them.
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This way, he's certain he won't
Forget any nuts, bolts,
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Bearings, brackets, or horns.
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00:02:27,448 --> 00:02:29,068
Using an electric crane,
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A worker hoists the vehicle's
4-cylinder, 152-horsepower,
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00:02:33,275 --> 00:02:37,620
1,200cc motorcycle engine into
The chassis, now tinted black.
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Using a pneumatic wrench,
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He attaches it with six bolts
And six nuts.
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Here, a worker assembles
The 50 parts
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00:02:53,896 --> 00:02:56,310
That make up what's called
The foot box.
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This includes aluminum clutch,
Brake, and gas pedals.
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00:03:05,344 --> 00:03:09,275
The brake pedal is thicker to
Withstand more aggressive use.
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00:03:09,275 --> 00:03:12,724
The vehicle decelerates
From 60 miles an hour to 0
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00:03:12,724 --> 00:03:16,862
In just less than 95 feet.
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00:03:16,862 --> 00:03:19,551
He coats part of the brake pedal
With a liquid sealant
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00:03:19,551 --> 00:03:22,000
So vibrations won't loosen it.
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00:03:23,689 --> 00:03:26,206
Another worker then mounts
Two output hoses
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00:03:26,206 --> 00:03:29,931
And two plastic reservoirs
For brake fluid.
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00:03:29,931 --> 00:03:34,482
The brake fluid must withstand
Heat of 650 degrees fahrenheit,
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86 degrees hotter than
What's required for most cars.
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This enables
Better engine performance.
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00:03:45,103 --> 00:03:48,034
He installs the foot box
Onto the front of the chassis
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Using three bolts.
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00:03:50,689 --> 00:03:53,724
Controlling the speed
With the foot box is crucial
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00:03:53,724 --> 00:03:57,758
Since top speed for the vehicle
Is 143 miles an hour.
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00:04:00,586 --> 00:04:03,517
Next, he installs
Part of the suspension system --
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00:04:03,517 --> 00:04:05,655
A cylindrical
Gas shock absorber.
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00:04:05,655 --> 00:04:07,758
This attaches
To the brake system,
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00:04:07,758 --> 00:04:12,448
Which is a zinc-plated rotor
And an aluminum caliper.
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00:04:12,448 --> 00:04:16,172
Then they attach what's called
The 4-into-1 exhaust manifold.
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00:04:16,172 --> 00:04:18,034
The four pipes merge into one
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00:04:18,034 --> 00:04:20,655
To vent the exhaust fumes
From the engine.
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00:04:22,862 --> 00:04:26,448
They install the electric fan
And radiator assembly.
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00:04:28,172 --> 00:04:31,586
Next, a worker attaches
A removable leather-covered
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Aluminum driving wheel
To the steering column.
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00:04:35,275 --> 00:04:36,965
The driving wheel
Locks into place
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With a spring-loaded
Latch system.
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Just like a race car,
You attach the steering wheel
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After you sit
In the driver's seat
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00:04:46,310 --> 00:04:49,413
So that you can get inside
The vehicle.
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00:04:49,413 --> 00:04:50,965
The collapsible steering column
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00:04:50,965 --> 00:04:52,793
Is part
Of the instrument cluster.
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This includes dials
Showing the vehicle's speed,
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Mileage, and fuel.
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There are also switches
For turn signals,
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Hazard flashers,
High- and low-beam lights,
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And to start
And kill the engine.
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00:05:04,551 --> 00:05:07,172
Next, workers install
The rear wheel
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00:05:07,172 --> 00:05:10,241
To another part of the
Suspension called a swing arm.
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They attach it with one bolt
That's a foot and a half long
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And two smaller bolts.
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00:05:15,931 --> 00:05:19,655
Workers then install a chain
On the rear-wheel assembly.
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When the vehicle's running,
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The chain's 94 links
Revolve on two sprockets
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To make the wheel turn.
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Rubber "O" rings on each link
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Prevent dust
From damaging the chain.
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Finally, workers attach
19 molded fiberglass body parts.
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This factory offers
6 standard colors
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And several custom colors.
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When assembled, the vehicle
Is nearly 11 1/2 feet long,
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6 1/2 feet wide,
And just over 3 feet high.
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If you have a motorcycle license
And a spare $50,000,
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You too can burn the pavement
On this mean set of wheels.
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Narrator:
If you think a baseball bat
Is a pretty simple thing,
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Well, you're out in left field.
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Making a bat
Means balancing things
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Like weight and thickness.
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The material it's made from
Can make a difference.
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00:06:10,896 --> 00:06:12,965
Metal bats hit the ball farther.
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00:06:12,965 --> 00:06:16,034
However, the pros use wood bats
Because of league regulations,
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00:06:16,034 --> 00:06:19,137
And even the type of wood
Might impact the score.
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00:06:23,827 --> 00:06:27,137
Barry bonds cracked
A home-run record in 2001
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With a wood bat like this --
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One made of maple
Instead of the usual white ash.
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They can never tell
Just by looking at it
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That a chunk of maple has what
It takes to make a good bat,
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So they weigh it to make sure
The wood is really as thick
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And heavy as it appears.
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Next, pointed prongs
Grip the wood and spin it
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While a carbide cutter
Rounds it.
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00:06:48,586 --> 00:06:52,413
This is a very modern lathe
Called an xy machine.
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The rounded blank goes into
A room called the library,
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Joining others on the shelf
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00:06:56,827 --> 00:06:59,172
That are waiting for their
Chance at the big leagues.
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00:06:59,172 --> 00:07:03,172
A worker selects one of
The blanks to fill an order
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00:07:03,172 --> 00:07:05,931
That specifies a certain model
And size.
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00:07:05,931 --> 00:07:09,068
He weighs it again
To make sure it measures up
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00:07:09,068 --> 00:07:10,689
To what the player has ordered.
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00:07:12,448 --> 00:07:17,068
The blank goes onto
The xy machine and spins.
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00:07:17,068 --> 00:07:20,448
A computer guides the cutter
As it moves on rails
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00:07:20,448 --> 00:07:23,310
And carves into the blank.
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00:07:23,310 --> 00:07:25,793
It whittles one inch of wood
From the blank
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00:07:25,793 --> 00:07:28,241
In order to form a handle.
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00:07:28,241 --> 00:07:31,000
It takes a total of three passes
On this cutter
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00:07:31,000 --> 00:07:33,724
To make the rough shape
Of a baseball bat.
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00:07:33,724 --> 00:07:36,965
But it's quick work --
Completed in just 3 minutes.
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00:07:43,275 --> 00:07:45,551
Now it's time
For another weighing-in.
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The bat is substantially
Lighter,
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Which is what they want.
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00:07:50,517 --> 00:07:54,620
Next, he measures the end of
A completed bat with a caliper.
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00:07:54,620 --> 00:07:57,931
Using a square-edged scraper,
He rounds the knob
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00:07:57,931 --> 00:08:00,620
As the bat spins on a more
Traditional lathe.
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00:08:00,620 --> 00:08:03,344
He measures as he cuts.
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00:08:03,344 --> 00:08:06,931
With another caliper, he checks
The thickness of a completed bat
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00:08:06,931 --> 00:08:10,724
And compares it
To the one he's just carved.
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00:08:10,724 --> 00:08:13,758
Now he takes a turning tool
Called a skew chisel.
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00:08:13,758 --> 00:08:16,689
With its pointed tip,
He cuts into the bat's handle,
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00:08:16,689 --> 00:08:19,241
Just above the knob,
To narrow the shoulder.
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00:08:19,241 --> 00:08:21,275
Again, he measures as he cuts
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00:08:21,275 --> 00:08:23,482
To make sure the diameter
Is just right.
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00:08:27,137 --> 00:08:30,724
Using the skew chisel,
He shapes the slope of the bat,
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00:08:30,724 --> 00:08:32,758
Repeatedly checking
With the caliper
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To make sure it meets
Specifications.
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00:08:36,620 --> 00:08:39,172
He slims down the handle
A little more.
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00:08:41,896 --> 00:08:45,448
Then, he angles the top
Of the knob with the chisel.
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00:08:47,517 --> 00:08:50,965
He shapes the rest of it
With a square-end chisel.
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00:08:54,931 --> 00:08:59,206
Next, he curves the bat's barrel
Using the same tool.
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00:08:59,206 --> 00:09:00,620
This gets rid of sharp edges
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00:09:00,620 --> 00:09:03,034
That would cause a ball's impact
To ripple down
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And jar the player.
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00:09:05,586 --> 00:09:07,448
Then he goes back to the knob
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00:09:07,448 --> 00:09:10,793
And completes the shaping
With the skew-end chisel.
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00:09:10,793 --> 00:09:13,241
Because the tool
Is extremely sharp,
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00:09:13,241 --> 00:09:15,068
He can carve very precisely.
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00:09:15,068 --> 00:09:18,275
The bat is now within a half
Ounce of its final weight.
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00:09:22,206 --> 00:09:24,034
Using an electric sander,
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00:09:24,034 --> 00:09:27,344
He smoothes down
Some of the rough edges.
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He switches to a finer grit
To finish off the job.
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As he sands, he measures
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00:09:36,965 --> 00:09:40,137
Because this isn't just about
Getting the surface smooth.
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The bat has to be exactly
The right size and weight
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For the player
It's being made for.
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00:09:45,103 --> 00:09:49,206
Now he places the bat's knob
In an end mill.
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00:09:49,206 --> 00:09:51,689
A spinning carbide disc
Cuts around the holes
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00:09:51,689 --> 00:09:54,068
Made by the pointed grippers
On the lathes,
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Producing a gentle scoop.
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00:09:58,241 --> 00:10:03,103
Next, a bigger disc carves
Into the barrel, cupping it.
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00:10:03,103 --> 00:10:08,103
Some players prefer a cupped bat
Because it balances differently.
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00:10:08,103 --> 00:10:11,413
Now he places the bat on the
Scale for the final weighing,
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00:10:11,413 --> 00:10:15,103
And it is exactly
What the player ordered.
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00:10:15,103 --> 00:10:17,206
He brushes paint
On the barrel
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00:10:17,206 --> 00:10:20,275
And rubs stain into
The lower half of the bat.
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He presses decals onto the bat
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00:10:29,103 --> 00:10:33,827
So it sports both the brand name
And distributor.
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00:10:33,827 --> 00:10:37,793
Then, he stamps the model number
In gold ink.
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00:10:39,827 --> 00:10:42,793
And tops everything off
With a light coat of varnish.
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Now this maple bat
Is ready for the big leagues
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00:10:53,724 --> 00:10:55,965
And some heavy hitting.
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00:11:07,689 --> 00:11:11,137
Narrator: bonsai is a japanese
Word that means plant in a pot.
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00:11:11,137 --> 00:11:14,206
Growing trees in pots
Is a revered art
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00:11:14,206 --> 00:11:17,827
That actually began in china
More than 2,000 years ago.
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During the past century,
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Creating artificial trees
Known as bonsai zokei
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00:11:23,448 --> 00:11:26,137
Has evolved into a hobby
With global appeal.
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00:11:28,551 --> 00:11:33,379
Whether it's rustic pine,
Flowering cherry,
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00:11:33,379 --> 00:11:35,275
Or chinese elm,
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00:11:35,275 --> 00:11:39,517
Bonsai zokei can be made
To resemble a variety of trees.
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00:11:39,517 --> 00:11:42,379
Some include stones
And small statues,
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00:11:42,379 --> 00:11:45,206
A chinese tradition
Known as penjing.
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00:11:45,206 --> 00:11:48,413
A craftsman starts by wrapping
13 strands of wire
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00:11:48,413 --> 00:11:51,896
With stretchy, sticky tape
Used by florists.
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00:11:51,896 --> 00:11:54,275
He uses 13 partly out of respect
198
00:11:54,275 --> 00:11:57,586
For a traditional asian
Preference for odd numbers.
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00:11:57,586 --> 00:12:01,517
Later, these wires will form
Parts of the trunk and branches.
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00:12:01,517 --> 00:12:05,068
Next, he wraps the wires
With strips of paper towel
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00:12:05,068 --> 00:12:07,137
For thickness and flexibility.
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00:12:07,137 --> 00:12:09,275
To hold the paper towel
In place,
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00:12:09,275 --> 00:12:13,310
He wraps the ends of the wires
With more floral tape.
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00:12:13,310 --> 00:12:16,068
He then separates clumps
Of plastic pine needles
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00:12:16,068 --> 00:12:17,793
From their branches.
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00:12:17,793 --> 00:12:21,655
Ironically, this fake vegetation
Is imported from china.
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00:12:23,965 --> 00:12:26,758
Next, he snips off the ends
Of the branches,
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00:12:26,758 --> 00:12:29,413
Creating segments
About one inch long.
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00:12:32,000 --> 00:12:34,586
To reinforce and support
These segments,
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00:12:34,586 --> 00:12:36,586
He wraps them with
Tiny wire
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00:12:36,586 --> 00:12:39,241
That's 2/100 of an inch
In diameter.
212
00:12:41,827 --> 00:12:44,448
Next, he wraps the segments
With floral tape
213
00:12:44,448 --> 00:12:48,034
To give them a more natural,
Branch-like appearance.
214
00:12:48,034 --> 00:12:51,517
Then he inserts these segments
Into the pine-needle clumps.
215
00:12:51,517 --> 00:12:53,310
The thicker end becomes the bud
216
00:12:53,310 --> 00:12:57,655
And holds the clump
On the segment.
217
00:12:57,655 --> 00:13:01,586
The craftsman now places three
Of these leafy segments together
218
00:13:01,586 --> 00:13:03,793
And attaches them with wire.
219
00:13:07,034 --> 00:13:09,689
He bends them sideways
In the same direction.
220
00:13:09,689 --> 00:13:11,965
This mimics the tendency
Of natural branches
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00:13:11,965 --> 00:13:15,413
To lean toward the sun.
222
00:13:15,413 --> 00:13:17,931
For more mature-looking buds,
223
00:13:17,931 --> 00:13:21,655
He uses different, 3-headed
Artificial segments.
224
00:13:21,655 --> 00:13:23,724
For integrity,
Two different types of buds
225
00:13:23,724 --> 00:13:28,172
Are never used
On the same tree.
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00:13:28,172 --> 00:13:29,448
To add character,
227
00:13:29,448 --> 00:13:32,172
The craftsman uses a piece
Of weathered driftwood
228
00:13:32,172 --> 00:13:34,724
As the base of the trunk.
229
00:13:34,724 --> 00:13:37,724
He anchors the long
Wrapped wires into styrofoam
230
00:13:37,724 --> 00:13:39,758
Around the bottom
Of the base.
231
00:13:41,758 --> 00:13:44,068
He staples the wires
To the driftwood,
232
00:13:44,068 --> 00:13:47,724
And wraps floral tape around
The wires surrounding the base.
233
00:13:47,724 --> 00:13:50,896
Then he twists the wires
To form a sinuous shape,
234
00:13:50,896 --> 00:13:54,344
What the japanese call moyogi.
235
00:13:54,344 --> 00:13:57,379
He covers the trunk with soft
Gray modelling clay,
236
00:13:57,379 --> 00:14:00,758
Adhering closely to the shape
Of the driftwood underneath.
237
00:14:00,758 --> 00:14:04,379
This will later be covered
By artificial bark and moss.
238
00:14:04,379 --> 00:14:07,068
This process
Can take several hours --
239
00:14:07,068 --> 00:14:09,413
Just part of the 4 to 6 days
240
00:14:09,413 --> 00:14:13,103
It takes one worker
To make a bonsai zokei.
241
00:14:13,103 --> 00:14:15,827
The craftsman then applies
Slow-drying glue
242
00:14:15,827 --> 00:14:18,275
To one side
Of strips of rice paper.
243
00:14:18,275 --> 00:14:21,655
The strips are two inches long
And one inch wide.
244
00:14:21,655 --> 00:14:25,931
He uses about 50 to cover
The trunk like bark on a tree.
245
00:14:25,931 --> 00:14:27,689
He dabs them with a wet rag
246
00:14:27,689 --> 00:14:31,034
So that the creases will remain
When the glue dries.
247
00:14:31,034 --> 00:14:34,103
The creases make the bark
Look realistically aged,
248
00:14:34,103 --> 00:14:37,068
One of the hallmarks
Of a good bonsai zokei.
249
00:14:39,896 --> 00:14:42,275
Craftsmen are careful
To place the branches
250
00:14:42,275 --> 00:14:44,655
In the traditional
Triangle shape.
251
00:14:44,655 --> 00:14:46,551
The lower branches must droop
252
00:14:46,551 --> 00:14:49,000
As if weighed down
By the elements.
253
00:14:49,000 --> 00:14:52,517
They add the leafy segments to
The ends of the wire branches,
254
00:14:52,517 --> 00:14:55,586
Attaching them with wire
And floral tape.
255
00:15:01,103 --> 00:15:02,344
Using a knife,
256
00:15:02,344 --> 00:15:05,241
The craftsmen trim away
The excess styrofoam
257
00:15:05,241 --> 00:15:06,724
Around the tree trunk.
258
00:15:06,724 --> 00:15:09,689
He then places the tree
Into an argyle pot
259
00:15:09,689 --> 00:15:13,862
That's 8 1/2 inches in diameter
And 2 inches high.
260
00:15:13,862 --> 00:15:15,862
Using a sculpting tool,
261
00:15:15,862 --> 00:15:19,965
He covers the styrofoam in the
Pot with brown modelling clay.
262
00:15:19,965 --> 00:15:21,448
Using slow-drying glue,
263
00:15:21,448 --> 00:15:24,758
He now covers the clay
In several shades of fake moss.
264
00:15:24,758 --> 00:15:28,586
They range in color
From dark brown to light green.
265
00:15:28,586 --> 00:15:31,379
He doesn't let the glue dry
Between each layer
266
00:15:31,379 --> 00:15:33,310
Because the blending
Of moss and glue
267
00:15:33,310 --> 00:15:36,310
Ensures a more natural-looking
Ground cover.
268
00:15:38,344 --> 00:15:42,793
He gently blows on the moss
To scatter it across the base.
269
00:15:42,793 --> 00:15:45,241
He also applies glue
Further up the trunk,
270
00:15:45,241 --> 00:15:47,965
Adhering moss that's thicker
And lighter in color
271
00:15:47,965 --> 00:15:49,379
To resemble lichen.
272
00:15:51,379 --> 00:15:55,551
The finished bonsai zokei
Is 17 1/2 inches high.
273
00:15:55,551 --> 00:15:57,344
It needs none
Of the constant care
274
00:15:57,344 --> 00:15:58,758
Required by its natural twin.
275
00:15:58,758 --> 00:16:01,827
Depending on their size
And complexity,
276
00:16:01,827 --> 00:16:06,000
Artificial bonsais range
In price from $50 to $800.
277
00:16:14,965 --> 00:16:17,275
Narrator: the adage "It's hard
To improve on a good thing"
278
00:16:17,275 --> 00:16:19,482
Certainly applies
To the trombone.
279
00:16:19,482 --> 00:16:21,275
The modern trombone
Isn't really much different
280
00:16:21,275 --> 00:16:23,724
From its medieval predecessor,
281
00:16:23,724 --> 00:16:26,862
Known as the sackbut,
With its distinctive "S" shape,
282
00:16:26,862 --> 00:16:28,620
Hand slide, and bell section.
283
00:16:28,620 --> 00:16:31,620
It's a blast from the past,
And a pretty loud one,
284
00:16:31,620 --> 00:16:34,827
But it can also sound
Smooth and mellow.
285
00:16:39,000 --> 00:16:41,965
The trombone literally
Slides down to the low notes.
286
00:16:41,965 --> 00:16:44,413
It's the only instrument
With a hand slide
287
00:16:44,413 --> 00:16:47,793
To lengthen it
In order to change pitch.
288
00:16:47,793 --> 00:16:49,172
To make a trombone,
289
00:16:49,172 --> 00:16:52,482
They cut sheet brass
In the pattern of a bell stem.
290
00:16:52,482 --> 00:16:56,275
They shape it by wrapping it
Around a steel rod.
291
00:16:56,275 --> 00:16:58,482
Using a nylon-headed mallet,
292
00:16:58,482 --> 00:17:01,586
The worker hammers the brass
To shape it further.
293
00:17:01,586 --> 00:17:03,586
It takes just a few minutes
294
00:17:03,586 --> 00:17:06,931
For him to hammer out
A rough bell stem form.
295
00:17:06,931 --> 00:17:09,275
He spreads open
The stem slightly
296
00:17:09,275 --> 00:17:12,758
So he can make small notches
On one edge with snippers.
297
00:17:12,758 --> 00:17:15,965
Then,
With a brass-headed hammer,
298
00:17:15,965 --> 00:17:19,379
He taps down the notches
So they hold the edges together.
299
00:17:22,241 --> 00:17:25,655
With an acetylene torch,
He joins the notched seam,
300
00:17:25,655 --> 00:17:30,551
Melting in a brass alloy wire
To bond it securely.
301
00:17:30,551 --> 00:17:33,172
But the seam overlaps
And it's too thick,
302
00:17:33,172 --> 00:17:35,586
So he runs it through
A seam roller.
303
00:17:35,586 --> 00:17:37,413
Two tons of pressure thins it,
304
00:17:37,413 --> 00:17:41,241
But now the bell stem
Is too flat.
305
00:17:41,241 --> 00:17:44,724
To round it out, he shoves it
Onto a bell-shaped rod
306
00:17:44,724 --> 00:17:47,862
And hammers it back into shape.
307
00:17:47,862 --> 00:17:52,827
Then he irons out
The hammer marks with rollers.
308
00:17:52,827 --> 00:17:55,586
The bell stem, fitting loosely
On a steel mandrel,
309
00:17:55,586 --> 00:17:57,068
Goes through a draw bench.
310
00:17:57,068 --> 00:18:00,689
A hydraulic cylinder pushes it
Through a thick lead washer,
311
00:18:00,689 --> 00:18:05,931
Pressing it tightly around
The mandrel to its shape.
312
00:18:05,931 --> 00:18:08,448
To make the bell flare
To attach to the stem,
313
00:18:08,448 --> 00:18:11,034
He puts a brass disc
On a spinning lathe.
314
00:18:11,034 --> 00:18:13,862
Using pliers,
He turns the edges of the disc
315
00:18:13,862 --> 00:18:17,724
To prevent it from
Flapping while spinning.
316
00:18:17,724 --> 00:18:21,241
With a lever, he manipulates
A scissors spinning tool,
317
00:18:21,241 --> 00:18:24,068
Pressing it against
The turning brass disc.
318
00:18:24,068 --> 00:18:26,241
This shapes the disc
Into a flare.
319
00:18:29,413 --> 00:18:32,931
Making a trombone flare
Is a delicate business
320
00:18:32,931 --> 00:18:36,517
And is the work
Of a skilled craftsman.
321
00:18:36,517 --> 00:18:38,379
Getting it right is critical
322
00:18:38,379 --> 00:18:41,172
Because the shape will affect
The tone of the trombone.
323
00:18:45,310 --> 00:18:49,758
Next, with a torch, he brazes
The flare to the bell stem.
324
00:18:51,931 --> 00:18:54,862
The bell stem and flare
Now turn on a mandrel
325
00:18:54,862 --> 00:18:58,275
While he presses against
The seam with a wooden tool.
326
00:18:58,275 --> 00:19:03,620
This flattens the seam and gives
The bell its final shape.
327
00:19:03,620 --> 00:19:05,896
Now it's time
To make the tubing.
328
00:19:05,896 --> 00:19:09,413
A hydraulic cylinder pulls it
On a mandrel through a die,
329
00:19:09,413 --> 00:19:11,137
Stretching it considerably.
330
00:19:11,137 --> 00:19:14,655
In this way, both the diameter
And thickness of the tubing
331
00:19:14,655 --> 00:19:17,275
Are precisely controlled.
332
00:19:17,275 --> 00:19:19,000
Then, they become ice tubes
333
00:19:19,000 --> 00:19:22,379
After they're filled with water
And put in the freezer.
334
00:19:22,379 --> 00:19:25,965
The ice will keep
The thin tubing from buckling
335
00:19:25,965 --> 00:19:27,586
In the next process.
336
00:19:27,586 --> 00:19:31,758
With a lever, he bends the tube
Around a u-shaped block.
337
00:19:31,758 --> 00:19:35,517
As he works it into a "U" shape,
The tubing hardens.
338
00:19:38,758 --> 00:19:40,551
After the ice melts,
339
00:19:40,551 --> 00:19:44,275
He places the "U" bend
In a balling out die.
340
00:19:44,275 --> 00:19:46,931
He lubricates the tubing
With oil
341
00:19:46,931 --> 00:19:49,827
And places a steel ball
At the top of the tube
342
00:19:49,827 --> 00:19:51,172
And presses it down.
343
00:19:51,172 --> 00:19:52,896
He drops in smaller balls
344
00:19:52,896 --> 00:19:56,275
And they push the first, larger
Ball through the "U" tube.
345
00:19:56,275 --> 00:19:58,655
This stretches
The inside of the tube,
346
00:19:58,655 --> 00:20:01,344
Rounding it to
The correct diameter.
347
00:20:01,344 --> 00:20:04,551
And then the balls exit
At the other end.
348
00:20:04,551 --> 00:20:07,068
Now he pieces
The tubes together
349
00:20:07,068 --> 00:20:12,172
And solders them the same way
A plumber joins copper tubing.
350
00:20:12,172 --> 00:20:15,413
He adds a loop
For the valve section.
351
00:20:15,413 --> 00:20:19,862
In total, a bass trombone
Has nine feet of tubing.
352
00:20:19,862 --> 00:20:21,482
Straightened, that's enough
353
00:20:21,482 --> 00:20:23,931
To reach from the floor
To the ceiling.
354
00:20:23,931 --> 00:20:26,586
But, of course, trombone makers
Are more interested
355
00:20:26,586 --> 00:20:28,689
In musical highs and lows.
356
00:20:31,137 --> 00:20:33,793
Finally, he solders a brace
Into place
357
00:20:33,793 --> 00:20:36,793
To add structural strength
To one of the loops.
358
00:20:39,448 --> 00:20:42,517
A diamond-tipped tool
Engraves the company logo
359
00:20:42,517 --> 00:20:45,000
Onto the trombone's bell stem.
360
00:20:45,000 --> 00:20:46,758
And a cloth buffing wheel
361
00:20:46,758 --> 00:20:49,931
Spins against the trombone flare
To polish it.
362
00:20:52,000 --> 00:20:53,344
This custom trombone
363
00:20:53,344 --> 00:20:56,137
Has been built
In approximately 50 hours --
364
00:20:56,137 --> 00:20:59,413
Something worth
Blowing a horn about.
365
00:21:17,586 --> 00:21:20,344
If you have any comments
About the show
366
00:21:20,344 --> 00:21:22,862
Or if you'd like to suggest
Topics for future shows,
367
00:21:22,862 --> 00:21:25,344
Drop us a line at...
30016
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