All language subtitles for S06E10 - Windshields; English Saddles; Butter; Post Clocks (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]

Narrator:
Today on "How it's made"...

Fiberglass insulation...

...Wooden ducks...

...Gumball machines...

...And exhaust systems.

It's pink and fluffy,
And it keeps us warm.

Fiberglass insulation
Is a great way

To prevent heat loss
From our buildings.

It has a woolly texture,
But it is, as the name suggests,

Made of very fine threads
Of glass.

That's why it's sometimes
Referred to as glass wool.

Fiberglass insulation
Will reduce energy consumption,

But it also reduces waste

Because it's made from at least
35% recycled glass.

The recipe also includes
What's called the batch --

A lot of sand and smaller
Portions of soda ash,

Limestone, and other minerals.

The glass, called cullet,
Used to be bottles and windows.

This will be
Its second recycling.

The cullet and batch ingredients

Spill onto
A conveyer-belt system,

Which transports it all
To an electric furnace.

The conveyer
Moves back and forth

To evenly distribute the cullet
And batch ingredients.

They seep down
And melt into a previous mix,

Which is now a pool of glass
At the bottom of the furnace.

The glass liquid
Now flows out of the furnace

And into sloped channels.

Inside these channels,

The temperature is kept red-hot
By natural-gas burners.

This keeps the glass mix
In a liquid form,

As it oozes out of the holes
In the bottoms of the channels.

The melted glass falls about
3 feet into a spinning bowl.

It's called a fiberizer.

The spinning action
Flings the glass

Through thousands of holes
In the bowl,

Creating thousands
Of feathery glass fibers.

Gas and compressed air pull the
Fibers, stretching them thinner.

The process is a lot like
Making cotton candy,

And the spun glass
Even has a similar texture.

But the fibers will soon become
Even more like cotton candy.

Nozzles spray them
With a polymer glue tinted pink.

The now-pink and sticky fibers

Drop into a hole
In the ground and amass.

Then a conveyer belt

Takes the mounds of sticky glass
To an oven.

Steel plates compress the pack
As it enters the oven

That's heated
To 500 degrees fahrenheit.

Hot air blows through it,
Setting the glue.

As the pack exits the oven,
Circular saws cut through it,

Making 15-
To 24-inch-wide strips

That are called lanes.

The lanes pass by a series
Of poles that push them apart.

Next, an ink jet
Brands each lane with a number

That conveys the "R" value.

"R" stands for
"Resistance to heat flow."

It's a measure of how well
The insulation will stop heat

From going through the roof and
Your energy bill along with it.

A chopper with big steel teeth
Now cuts the lanes,

Making chunks
That could easily be installed

In an attic or wall.

After chopping,
The conveyer belt accelerates,

Transporting the fiberglass
Batts to the next station.

A few at a time,
The batts plunge down a chute,

To a mechanical arm

Which slides the batts
Into a compression chamber.

There, a hydraulic ram
Squishes the batts down,

Reducing their bulk
5 to 10 times.

This compaction will make them
Easier to transport.

Now another ram
Comes from the side

And pushes the stack
Of compressed batts forward

Into a spout.

The spout
Is a hollow batt-shaped frame.

A worker
Pulls a plastic bag over it.

Then the ram pushes
The fiberglass-insulation batt

Into the plastic bag,

And the process begins again.

A conveyer belt
Transports the batt-filled bags

To a machine
That heat-seals them.

Then they're sent off
To be installed.

Narrator: for centuries,
Hunters have used wooden ducks

To lure live ones
To within shooting range.

Stringing together decoys
And floating them in the water,

Hunters trick the birds down
From the sky with duck calls.

Nowadays, hunters generally
Prefer cheaper, plastic decoys.

Wooden ducks are mostly
Decorative items for the home.

This company's flock
Includes males, females,

And androgynous models
Like this one.

This more elaborate male
Is inspired

By another aquatic bird,
The loon.

To make them, these craftsmen
Use eastern white pine

Because it's easy to carve
And has a nice grain.

First, a machine shapes
A 2-inch-thick slab.

They cut the slab lengthwise.

They'll use four to six
Of these smaller pieces

To make most of the duck's body.

The birds range in size from
Baby ducks just 4 inches long

To geese at more than
19 inches long.

A craftsman now applies

A generous amount
Of carpenter's glue

To one side of the wood.

Using a lot
Ensures a strong bond

And prevents splitting later on.

The pieces then go
Into what's called a wood clamp.

He tightens a vice,
Squeezing them together.

It takes about two hours
For the pieces to bond properly.

Then he'll shave away the excess
Glue and even up the surfaces.

Once that's done,

They run the block
Over what's called a joiner.

A roller with 3 blades
Shaves about 3/4 of an inch

From what will become
The top and bottom of the duck.

Each model
Has three wooden patterns

For the top, the bottom,
And the profile.

Here, a worker traces the
Outline of the bird's profile

In pencil on the wood.

Since this is a small model,

He'll make two birds
With one block.

Using a band saw,
He trims along the trace line.

This company
Recycles the cutoffs

Into fireplace kindling
And shavings for farm stables.

Next, he uses another pattern
To create the top of the bird.

These patterns provide
Only the general shape

Of a particular model.

The craftsman
Will later carve the details

Using smaller electric tools
And by hand.

Now he sands the wood
With a pneumatic drum sander --

A tube of pressurized air with
Sandpaper stretched over it.

He uses higher pressure
For sharper curves,

Lower pressure for softer edges.

To sculpt the bird's plumage,

The craftsman
Uses this band sander

Whose rounded edge
Presses sandpaper into the wood.

Here, he makes
Three long grooves --

One on top, and one
On each side of the duck.

The head's made from a different
Piece of wood than the body.

Here, he sands down the piece
To smooth out the curves.

Using various shaping tools
And the band sander,

He sculpts the bird's
Head and bill area,

Then the underside and rear end
Of this waddling duck.

He also carves depressions
For eye sockets to come later.

Here, he puts glue on the neck

To attach it
To the rest of the body.

Using a nail gun,

He reinforces the area
With two nails on each side.

To hide the nails
And smooth out the neck,

The craftsman uses wood putty.

Once it dries,
He'll sand it smooth.

Next, he tints the duck bill
Using an orange wood stain...

...Then a forest-green stain
To tint the head and neck areas.

Males have colorful feathers
To better attract mates.

Females
Have more neutral colors

To blend into their surroundings
And protect their ducklings.

The craftsman
Covers the duck's lower body

With a clear wood stain.

This way, the natural grain
Of the wood shows through.

The front gets a clear but
Darker stain to mark the chest.

And darker stain also highlights
The plumage in the long grooves.

Then, some green accents
For the feathers

On the sides in the back.

Next, two coats of white paint
To mark the duck's collar.

Then he glues plastic eyes
In the eye sockets.

The irises are black, brown,
Or red, depending on the model.

He then sprays on a protective,
Water-based varnish,

And elevates the duck on nails

So that the underside will dry
Along with the rest.

Finally, the craftsman rubs
The entire carving in wood wax.

This makes the varnish
Appear uneven in places,

Giving the duck
A worn, antique finish,

Like he's been
Around the pond a few times.

The prices of wooden ducks vary
According to size and detail.

$500 will buy you
This magnificent canada goose

With wings stretched and ready
For a graceful landing.

Narrator:
For a century,

There have been machines
To give us gumballs.

Vending machines that dispensed
Gumballs were introduced in 1907

On a new york city
Subway platform.

Today's machines are more modern
Versions of the originals,

But they still perform,
Basically, the same function.

The gumball machine is all about
Instant gratification.

Insert a coin, turn a handle,
And out comes the merchandise.

To make a gumball machine,

A designer first sketches out
The exact proportions.

Then, a worker ladles molten
Zinc into a holding furnace,

Where a steel plunger
Pushes the metal

Through a die that forms
A gumball machine base.

A mechanical claw removes the
Newly shaped base from the die

And places it
On a conveyor belt to cool.

A similar die shapes

The coin mechanism handle
And drive gears.

A worker places a braided hose
With a natural-gas flame

Under a mold that will shape
The gumball-dispensing chute.

He pours piping-hot
Liquid aluminum into the mold.

The flame below warms the mold
Enough to prevent condensation,

Which would ruin the shape.

But the mold is still cooler
Than the aluminum,

And that allows it to solidify
Into a chute shape in seconds.

Now, using a punch press,
A worker trims the waste away

From the lid
For the gumball machine.

They also trim the front plate
Of the coin mechanism,

Using a similar press.

A computerized cutter mills out
A hole in the top of the globe

That will hold the gumballs.

The globe is made
Of shatterproof plastic.

At another station,

They press the base
Of the gumball machine

Against
A cloth-covered buffing wheel

To give it a shine.

A worker now assembles
The coin mechanism,

Layering the front plate,
The coin carrier,

The back plate,
And ending with a cam,

The part that ensures the
Coin mechanism moves clockwise.

She screws it tightly together,

Then inserts the handle
On the front plate.

The handle will turn the coins
That pay for the gumballs.

She places a little spacer and
Drive gear on the handle stem

That protrudes through the back
Of the assembly

And then screws the drive gear
Onto the handle stem.

Now it's time
To put the money up front.

They insert a coin in the slot

And turn the handle
To make sure the system works.

People in many countries
Like gumballs,

And so these coin mechanisms
Can be made to accept currencies

From around the world.

They can also be used in other
Types of vending machines.

Now they spray powder paint
Onto the lids,

Giving them a coating that's
Almost 1/16 of an inch thick.

They bake the paint
Onto the lids

At 400 degrees fahrenheit
For 25 minutes.

Now it's time
To put all the pieces together.

They place the dispensing wheels
In hoppers,

Then cover them with a part
That stops free gumballs

From spilling out.

The next part
Is the adaptor ring,

And the plastic globes
Fit on top of them.

They place aluminum rings
On top of the globes.

Then they slide two side rods
Through the top rings,

Down into the bottom
Of the globes.

They screw them down
Very tightly,

And then they set
The assembly aside.

Now they place
Plastic bodies on bases

And install the chute doors
On the front.

They place the chute covers
In the plastic body...

...And mount the coin mechanism
Just above the chute.

Next, they slide
The globe assemblies

Over center rods and
Onto the plastic foundations.

They put a lid on every globe...

And then lock them on.

And now we're at
The vending part of the story.

Gumball, anyone?

Narrator:
The job it does is exhausting.

The exhaust system
On your vehicle

Gets rid of harmful gases
That could damage the engine.

It also cleans up
The gases a bit

Before venting them
Into the air.

A properly functioning exhaust
System does another big job --

Muffling the airborne noise
Of the engine.

It's a system
Of metal tubes and plates

We only seem to notice
When it breaks down.

And when it does,
Everyone can hear it.

To make an exhaust system,

A mechanical puller draws
A stainless-steel strip

Up into a punch press,

Shuffling it back and forth
To allow for a precise cut

With little waste.

The press brings 60 tons
Of force to bear

As it pushes the steel
Into a die.

It punches out a baffle shape
With holes in it,

Which will form the skeleton
For the muffler box.

The finished baffles
Fall onto a conveyor

And go into a storage cage.

Now a long steel tube
Tumbles to automated blades

Which score the tube crosswise
To prevent denting

And then cut it
To produce smaller tubes

That go inside a muffler.

A circular saw descends
On another tube

To make a tail pipe.

Its length depends on
The type of muffler being made.

A louver machine
Spins and punctures

One of the inside tubes.

The holes will regulate airflow
In the muffler.

A cnc bending machine

Grips and bends a pipe
In several spots.

This is how they make inlet,
Intermediate, and outlet tubes.

These tubes run the length
Of the exhaust system.

Then they place a tube
In a circular hydraulic vice,

Which pinches the end down
To a prescribed diameter

To allow
For further assembly.

A worker now places two baffles
In a jig.

He fits the tubes
Through the holes in the baffles

So that the tubes
Connect the baffles.

Three mandrels
Slide into the tubes.

The mandrels expand, locking
The tubes to the baffles.

Then they contract
And slide out.

Now the baffles and tubes
Are one piece.

Next, a robotic arm
Picks up metal sheets,

Which will become the outer skin
Of the muffler box.

It pushes them
Under an oval mold.

Another arm
With numerous rollers on it

Moves up and wraps the steel
Around the oval form.

Then a metal block
Moves over the ends,

Double-folding them.

This locks them together,

And it completes the assembly
Of the muffler's outside skin.

Magnets pick up the new skin,
And, sliding on rails,

They relay it
To a mechanical claw

Which, in turn,
Feeds it to a flanger.

The flanger bends the edges,

Creating a lip on either end
Of the muffler skin.

A carousel turns,

And a mechanical claw transfers
The newly flanged muffler skin

To the stuffing position.

Hydraulic pushers press the
Pre-assembled baffles and tubes

Inside the skin.

After the muffler is stuffed,

The robotic claw transfers it
To a conveyor belt.

Next, a worker presses each end
Of the muffler

Against a set
Of steel expansion fingers.

The fingers move forward
Into holes in the muffler.

They expand and lock
The baffles and tubes inside

To form one solid,
Internal unit.

Grippers place the muffler

On a spinning machine
That will fasten the caps on.

Rollers press against the flared
Edges of the revolving muffler,

Tightly locking the end cap
To the rest of the body.

Here, you see the rolling
In slow motion.

It takes only a few revolutions
To do the job.

Then the roller backs away,

And a mechanical arm
Grabs the muffler

And transfers it
To a conveyor belt.

Now these mufflers are ready

To help keep the traffic noise
At a minimum.

If you have any comments
About the show,

Or if you'd like to suggest
Topics for future shows,

Drop us a line at...

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