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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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00:00:26,965 --> 00:00:28,655
...Yacht wheels...
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...Braided rugs...
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...Automobile thermostats...
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...And chisels.
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A wheel is a fairly modern way
To steer a boat.
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Before the 18th century,
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Captains shifted a stake
Attached directly to the rudder.
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00:01:01,137 --> 00:01:03,655
Today ship wheels connect
To the rudder
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00:01:03,655 --> 00:01:05,931
Through a mechanical
Or hydraulic system.
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00:01:05,931 --> 00:01:08,310
Found mostly in yachts
Up to 200 feet long,
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They're a luxurious way to echo
The glory days of the sea.
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This company makes yacht wheels
As large as 5 feet in diameter.
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It uses two traditional
Shipbuilding woods --
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American holly and burmese teak,
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Species that are as beautiful
As they are durable.
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Workers use a table saw
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To cut both types of wood
Into long, thin strips
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That will become
The wheel's rim.
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They measure the strips
With digital calipers,
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Then sand them down
To a thickness
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Of just 1/8 of an inch.
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Using a disk sander now,
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A worker angles the ends into
What are called scarf joints.
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He'll join the strips by fitting
These angles together.
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After coating each strip
With epoxy,
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He attaches it with clamps
To a round jig,
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Waxed beforehand
To prevent sticking.
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The glue is waterproof
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Because the wheels
Are often exposed
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To rough weather up on deck.
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00:02:15,172 --> 00:02:20,068
The worker gradually bends
Each 6 1/2-foot-long strip
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All the way around the jig.
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And a spring-loaded clamp
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Temporarily holds
The end of each strip in place
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Until he aligns the scarf joint
With that of the next strip.
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00:02:30,068 --> 00:02:33,344
It takes up to eight hours
Of nonstop work
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To lay all the strips.
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He alternates between the
Blond holly and the darker teak
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For a total of seven layers.
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Then he leaves the rim
To set overnight.
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To make each spoke --
The wheel has five of them --
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A worker temporarily
Joins strips of holly and teak
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With double-sided tape.
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A computer-guided
Cutting machine then carves
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An opening through the middle
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And shapes the outer edge
Into a triangular shape.
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This reduces the spoke's weight
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00:03:08,000 --> 00:03:11,448
And helps it fit to the rim
Later on.
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Next he removes the tape and
Glues the wood strips together,
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Along with others
Made of carbon fiber.
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They strengthen the spoke
While keeping it lightweight.
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He places a waxed jig in
The center and clamps in place.
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He leaves the spoke
To set overnight.
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The next day,
He sands away the dried glue,
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Then uses a router
To round the edges.
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Together, the four wood
And three carbon-fiber layers
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Are just one inch thick.
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He traces a template
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On a stack of 14 pre-glued,
Curved strips of holly and teak.
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He follows his trace lines
With a band saw,
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Cutting out what's called
A fairing.
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This component will join
Each spoke to the rim.
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Now he drills a hole
In each fairing...
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...And inserts a temporary dowel
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00:04:20,724 --> 00:04:24,206
To position a reinforcing strip
Of carbon fiber at the top.
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It's time to join
The spokes to the rim.
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Earlier, he glued strong
Fiberglass dowels to the rim.
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Now he inserts them
Into the fairings
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And into holes in the spokes,
Also glued beforehand.
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Through the openings,
He clamps the spokes to the rim.
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00:04:44,344 --> 00:04:47,586
Then he positions
An aluminum hub in the center,
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Tapping it into place
With a mallet.
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Now, with a jigsaw,
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He cuts a sliver
Off the ends of the fairings
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So they'll curve into the rim.
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He uses a router to round off
The vertical edges of the wheel.
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He files the fairings by hand
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To complete the smooth
Transition to the rim.
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Just these
Finishing touches alone
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Can take up to five hours
To complete.
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Using a router,
It takes him another five hours
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To gradually round off
The horizontal edge.
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Now to protect the wheel
From the elements --
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Particularly sun damage.
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First, a polyester primer.
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Then they sand it and apply
Two coats of waterproof varnish.
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On the yacht,
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Five stainless-steel bolts
Attach the wheel to a pedestal
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That connects to the rest
Of the steering mechanism.
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To change
How fast the rudder moves,
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You simply turn a knob
At the center of the wheel.
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How's that for power steering?
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A relatively high-tech way
To navigate the open seas.
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Narrator: new england settlers
In the 1700s
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Were the first
To braid strips of used clothing
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And then sew them into rugs.
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Today high-speed machines create
This classic look
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In a fraction of the time,
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But with synthetic as well
As natural fabric and yarns
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So the rugs last even longer.
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This company's most popular rugs
Are oval or rectangular,
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Some small enough
For your stairs.
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The rugs begin as yarn.
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They wind the yarn onto bobbins
That fit the factory's machines.
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The yarn ranges from pure wool
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To a blend of wool
And polypropylene
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That makes the rug durable
Even outdoors.
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This machine braids yarn
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From 24 bobbins around
A core of synthetic fabric.
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The result is a complicated
Weave called cable lock.
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Other rugs have
Just three braided segments,
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In what's called a flat braid.
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Here a worker uses
A powerful sewing machine
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To join flat braids
With sturdy nylon thread.
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This makes one enormous piece
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The length
Of half a tennis court.
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00:07:20,448 --> 00:07:22,482
The piece moves along a conveyer
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00:07:22,482 --> 00:07:25,620
To an automated rotary saw
That cuts it to size.
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The saw passes twice
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00:07:27,310 --> 00:07:30,172
To ensure a clean cut
Through the one-inch thickness.
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00:07:34,793 --> 00:07:38,344
Another industrial sewing
Machine attaches binding tape
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To seal the edge.
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This prevents rectangular
And square rugs from unraveling.
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Oval and round rugs
Don't need this
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Because their braids aren't cut.
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00:07:50,724 --> 00:07:53,413
This machine does
What's called serging.
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It sews yarn over
The binding tape to cover it,
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A purely aesthetic gesture.
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To make fabric rugs,
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00:08:11,827 --> 00:08:14,758
A seamstress joins several
Pieces of different fabric
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Along one edge.
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00:08:16,172 --> 00:08:18,758
They're a cotton-and-polyester
Blend that's durable
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And easy to wash.
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00:08:20,551 --> 00:08:25,068
The more patterns, the more
Complex the rug will look.
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00:08:26,206 --> 00:08:28,620
After they wind the fabric
Into a roll,
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00:08:28,620 --> 00:08:30,172
A rotary saw cuts the roll
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00:08:30,172 --> 00:08:32,551
To make strips
That are one inch wide.
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00:08:37,965 --> 00:08:40,172
The fabric strip then unwinds
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Into a machine
That folds it over filler.
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This forms the core
Of the fabric tubes
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They call spaghetti.
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The machine wraps the fabric
Around the filler,
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00:08:52,000 --> 00:08:54,689
Then sews the edges
Into a closed tube.
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00:09:06,413 --> 00:09:09,034
Rollers guide the spaghetti
Out of the machine
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00:09:09,034 --> 00:09:11,103
And onto bobbins.
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00:09:16,103 --> 00:09:18,931
This machine weaves spaghetti
From three bobbins
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00:09:18,931 --> 00:09:20,724
Into a flat braid.
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00:09:20,724 --> 00:09:22,862
Fabric rugs
Are made only as flat braids
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Because the material
Is too thick
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00:09:24,965 --> 00:09:28,620
To weave into a cable lock.
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The braids settle into barrels
For storage
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Until they're woven into rugs.
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Sometimes mats are assembled
From a variety of braids
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For a different look.
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To make an oval or round rug,
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A worker coils one
Continuous braid around itself.
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At the same time,
She sews each braid to the next.
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These rugs can have
Anywhere from 16 to 320 rows.
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This factory uses tables with
Holes that blow pressurized air
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To float rugs like this one
As they grow heavier.
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00:10:16,931 --> 00:10:18,448
The ovals range in size.
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They can be as small
As a doormat
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And as large as a swimming pool.
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00:10:27,655 --> 00:10:30,137
But when the rugs
Get really big,
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Some extra help may be required.
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00:10:34,344 --> 00:10:36,241
It takes her about two hours
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00:10:36,241 --> 00:10:40,896
To sew together
One of these huge rugs.
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Lastly, the worker
Staples a tag to the rug
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That reveals the style and size
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Before the rug
Heads off to shipping.
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Perhaps more
Than any other floor covering,
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These rugs don't just lie there.
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The variety of styles and shapes
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Means they really tell a story
At your feet.
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Narrator: only about 2 inches
In diameter,
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00:11:10,103 --> 00:11:13,689
A car's thermostat sits between
The engine and the radiator.
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00:11:13,689 --> 00:11:15,137
Until the engine warms up,
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00:11:15,137 --> 00:11:17,758
It blocks the flow of coolant
To the radiator.
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When the engine reaches
About 200 degrees fahrenheit,
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The thermostat opens,
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00:11:22,137 --> 00:11:25,172
Letting coolant flow through
The radiator and into the engine
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00:11:25,172 --> 00:11:27,206
To prevent overheating.
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00:11:29,310 --> 00:11:32,448
The key component
Inside the thermostat is wax.
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00:11:32,448 --> 00:11:34,310
When the engine heats up,
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The wax melts
And the thermostat opens,
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00:11:36,551 --> 00:11:38,655
Triggering the cooling system.
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00:11:38,655 --> 00:11:41,448
The wax melts quickly
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Because it contains
Powdered copper, graphite,
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00:11:43,965 --> 00:11:47,103
And/or aluminum.
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00:11:47,103 --> 00:11:51,206
As the wax transforms from solid
To liquid, it expands.
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00:11:51,206 --> 00:11:53,965
The pressure pushes a pin
That opens the valve
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00:11:53,965 --> 00:11:57,793
That enables the flow of coolant
To the engine.
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00:11:57,793 --> 00:12:00,344
After heating
And mixing in the powders,
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00:12:00,344 --> 00:12:03,310
Workers pour the wax
Into slab-shaped molds.
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00:12:05,310 --> 00:12:10,068
It takes about a half-hour
To cool and solidify.
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00:12:10,068 --> 00:12:13,241
Then they extract the slabs
And grind them up.
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00:12:16,586 --> 00:12:19,896
They feed the granulated wax
To a pill-making machine,
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00:12:19,896 --> 00:12:21,896
The kind
Pharmaceutical factories use.
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00:12:28,068 --> 00:12:31,241
It compress the granules
Into cylindrical pellets.
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00:12:35,275 --> 00:12:37,931
Meanwhile,
Workers feed a copper strip
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00:12:37,931 --> 00:12:41,379
Into a machine called
A high-speed transfer press.
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00:12:41,379 --> 00:12:43,586
Its successive stations
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00:12:43,586 --> 00:12:47,103
Shape the copper cup
That will house the wax pellet.
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00:12:50,206 --> 00:12:52,689
The first station
Stamps out a circle.
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00:12:52,689 --> 00:12:56,793
The others progressively stretch
And form the circle into a cup.
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00:13:03,275 --> 00:13:06,827
The cups go into
An automated assembly machine,
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00:13:06,827 --> 00:13:11,758
Which drops a pellet
Into each one.
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00:13:11,758 --> 00:13:16,379
A pin then bores a hole down
The center of each wax pellet.
212
00:13:16,379 --> 00:13:20,310
The machine inserts a rubber
Sleeve into the pellet hole
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00:13:20,310 --> 00:13:24,413
And caps the sleeve
With a brass cover.
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00:13:27,931 --> 00:13:30,965
Then it crimps the cup
Over the cover,
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00:13:30,965 --> 00:13:34,000
Forming a seal
That's leak-resistant.
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00:13:34,000 --> 00:13:37,413
Now the machine inserts
The stainless-steel pin
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00:13:37,413 --> 00:13:39,517
That opens and closes
The coolant valve.
218
00:13:39,517 --> 00:13:41,896
The pin goes
Right into the rubber sleeve
219
00:13:41,896 --> 00:13:45,310
In the center of the wax pellet.
220
00:13:49,000 --> 00:13:51,241
How do all these parts
Work together?
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00:13:51,241 --> 00:13:53,620
The melting wax expands
Within the cup,
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00:13:53,620 --> 00:13:55,896
Squeezing the rubber sleeve.
223
00:13:55,896 --> 00:13:59,551
That forces the pin upward,
Opening the coolant valve.
224
00:13:59,551 --> 00:14:01,103
Now they heat the parts
225
00:14:01,103 --> 00:14:04,241
To the temperature at which the
Engine coolant should kick in.
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00:14:04,241 --> 00:14:06,517
A calibration machine
Squeezes the cup
227
00:14:06,517 --> 00:14:09,896
Until the pin rises enough
To open the coolant valve.
228
00:14:15,448 --> 00:14:17,344
The components
Now enter a machine
229
00:14:17,344 --> 00:14:19,068
Which connects that valve.
230
00:14:24,620 --> 00:14:28,034
The valve is made up
Of two stainless-steel pieces.
231
00:14:28,034 --> 00:14:30,344
The machine loads
One on top of the other,
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00:14:30,344 --> 00:14:34,103
Over the thin end of the cup...
233
00:14:34,103 --> 00:14:36,827
Then pushes the valve
Over the end of the cup,
234
00:14:36,827 --> 00:14:39,103
Attaching it to the wide end.
235
00:14:45,620 --> 00:14:49,068
On the left is before
The valve installation,
236
00:14:49,068 --> 00:14:51,379
And here's after.
237
00:14:53,896 --> 00:14:57,275
Meanwhile, a press forms
The top part of the thermostat,
238
00:14:57,275 --> 00:14:58,896
Called the flange.
239
00:14:58,896 --> 00:15:01,620
It's made of stainless steel
Coated with a lubricant.
240
00:15:01,620 --> 00:15:02,862
As with the cup,
241
00:15:02,862 --> 00:15:06,137
A series of dies
Progressively forms the flange.
242
00:15:08,137 --> 00:15:10,655
Now for the final assembly.
243
00:15:10,655 --> 00:15:13,620
First, the thermostat's
Stainless-steel frame.
244
00:15:13,620 --> 00:15:16,482
Next, a stainless-steel spring.
245
00:15:16,482 --> 00:15:19,551
Its job is to close the valve
When the engine cools.
246
00:15:22,413 --> 00:15:27,172
Now the assembled components
Go inside the spring.
247
00:15:27,172 --> 00:15:30,137
The flange goes on top.
248
00:15:33,137 --> 00:15:36,103
A tool called an orbital riveter
Flattens a tab
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On either side of the flange.
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This holds the frame
Onto the flange.
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00:15:41,034 --> 00:15:44,758
The assembly machine now crimps
Two little tabs against the pin,
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Keeping it from falling out
Of the rubber sleeve.
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And with that,
The thermostat is finished.
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00:15:54,827 --> 00:15:57,724
This demonstration shows how,
As the engine heats up,
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The melting wax
Pushes the pin upward,
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And when the engine cools,
The opposite happens
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So that even though you might
Boil over in heavy traffic,
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Your engine doesn't have to.
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Narrator: a chisel is
A metal tool with a sharp end
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00:16:17,448 --> 00:16:20,172
For shaping stone, metal,
Or wood.
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You use your hand, a hammer, or
A mallet to drive it in and cut.
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00:16:23,965 --> 00:16:26,379
Although chisels
Date back to ancient asia,
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Today's factories
Use heat-treated steel
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And high-tech machines to
Make them stay sharper longer.
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00:16:37,827 --> 00:16:40,344
A wood chisel
Needs to be very sharp,
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00:16:40,344 --> 00:16:42,827
Especially
For intricate carving.
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00:16:42,827 --> 00:16:45,172
Making chisels starts
When they insert
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00:16:45,172 --> 00:16:47,620
A 16 1/2-foot-long bar
Of high-carbon steel
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In a mechanical press.
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00:16:49,034 --> 00:16:51,655
The carbon lets them heat-treat
The steel
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00:16:51,655 --> 00:16:53,827
To give it a long-lasting edge.
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00:16:53,827 --> 00:16:58,965
But first the press cuts the bar
Into 8 1/2-inch-long rods.
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00:17:03,862 --> 00:17:06,379
The rods then go through
An induction heater.
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00:17:06,379 --> 00:17:09,241
In just six seconds,
A magnetic field heats them
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00:17:09,241 --> 00:17:11,793
To about 2,300 degrees
Fahrenheit,
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00:17:11,793 --> 00:17:14,413
A temperature at which
The steel can be forged.
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00:17:16,793 --> 00:17:22,206
A worker sets each hot rod
Into a die in a forging press.
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00:17:22,206 --> 00:17:25,931
The die slams down,
Applying 700 tons of pressure.
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00:17:25,931 --> 00:17:29,758
This produces what's called
A forging, a rough shaping.
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00:17:29,758 --> 00:17:33,931
The die can produce
As many as 60,000 forgings
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00:17:33,931 --> 00:17:35,724
Before it wears out.
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00:17:38,275 --> 00:17:41,103
Each one goes into
What's called a trimming press.
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00:17:41,103 --> 00:17:43,758
Here a die cuts out
The precise shape of the chisel,
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With the blade on one end
And the tang on the other.
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00:17:47,586 --> 00:17:52,275
The tang later fits
Into a plastic or wooden handle
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00:17:52,275 --> 00:17:54,344
So you can comfortably grip
The tool.
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00:17:54,344 --> 00:17:58,000
The factory sends the excess
Metal out for recycling.
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00:18:06,586 --> 00:18:09,241
After the chisels cool off
For several hours,
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00:18:09,241 --> 00:18:12,448
Workers run them through another
Induction-heating machine,
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00:18:12,448 --> 00:18:14,827
This one with two coils.
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00:18:19,448 --> 00:18:23,137
The first heats them
To 1,400 degrees fahrenheit.
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00:18:23,137 --> 00:18:25,896
Then warm water cools them down.
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00:18:25,896 --> 00:18:28,827
This rapid reduction in
Temperature is called quenching.
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00:18:28,827 --> 00:18:31,275
It's what hardens the chisels
Enough to be strong
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00:18:31,275 --> 00:18:33,172
And stay sharp.
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00:18:33,172 --> 00:18:36,793
The next coil heats them
To about 700 degrees fahrenheit.
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00:18:36,793 --> 00:18:38,413
This step is called tempering.
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00:18:38,413 --> 00:18:39,931
It relieves the stresses
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00:18:39,931 --> 00:18:44,344
That the quenching phase
Created inside the metal.
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00:18:46,103 --> 00:18:49,482
Spring-loaded clamps now release
The chisels from the machine,
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00:18:49,482 --> 00:18:52,793
And they drop into a container
To cool overnight.
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00:18:56,206 --> 00:18:58,000
The next day,
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00:18:58,000 --> 00:19:00,793
Workers can start to polish
And sharpen the chisels.
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00:19:00,793 --> 00:19:03,034
That removes
The metal discoloration
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00:19:03,034 --> 00:19:05,034
The heat-treating caused.
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00:19:05,034 --> 00:19:07,758
To polish the barrels,
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00:19:07,758 --> 00:19:10,310
The round areas joining
The blade and the tang,
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00:19:10,310 --> 00:19:14,241
Workers load the chisels
Into devices called chucks.
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00:19:14,241 --> 00:19:16,827
These clamp the chisels
Securely by the blade
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00:19:16,827 --> 00:19:20,517
As the barrels spin against
A rough-grit sanding wheel.
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00:19:20,517 --> 00:19:23,448
After about
Seven seconds of sanding,
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00:19:23,448 --> 00:19:25,862
The blades are ready
For polishing.
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00:19:30,655 --> 00:19:35,862
A powerful magnet locks them
In place on a round table.
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00:19:35,862 --> 00:19:37,482
It rotates,
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00:19:37,482 --> 00:19:40,620
Running the blades against
An abrasive grinding wheel.
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00:19:40,620 --> 00:19:42,241
As water cools the metal,
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00:19:42,241 --> 00:19:46,137
It also applies a rust-proofing
Chemical to the steel.
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00:19:46,137 --> 00:19:49,379
This polishing cycle
Takes about 20 seconds.
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00:19:51,793 --> 00:19:55,344
The highly polished finish
Is a key selling point.
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00:19:57,689 --> 00:19:59,655
Now to sharpen the blades.
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00:19:59,655 --> 00:20:02,586
A worker loads the chisels
Into another machine.
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00:20:02,586 --> 00:20:04,655
It moves the chisels
Back and forth
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00:20:04,655 --> 00:20:07,275
Against another grinding wheel.
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00:20:07,275 --> 00:20:10,896
After about five minutes
Of this,
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00:20:10,896 --> 00:20:13,206
The blades are razor-sharp.
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00:20:15,758 --> 00:20:18,448
Only the last 1/2 inch
Of the chisel,
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00:20:18,448 --> 00:20:22,965
Sloping at a 22-degree angle,
Is the cutting edge.
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00:20:22,965 --> 00:20:26,827
This factory uses preformed
Extruded-plastic handles
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00:20:26,827 --> 00:20:28,689
For its chisels.
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00:20:28,689 --> 00:20:30,931
A hot metal die
With raised lettering
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00:20:30,931 --> 00:20:34,413
Presses and melts a colored
Plastic ribbon into each handle.
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00:20:34,413 --> 00:20:37,413
This imprints the company logo,
The model size,
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00:20:37,413 --> 00:20:40,068
And a reminder
To wear safety goggles.
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00:20:42,310 --> 00:20:45,103
The next machine
Puts a steel cap on top
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00:20:45,103 --> 00:20:47,586
And forces the tang
Inside the hole.
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00:20:47,586 --> 00:20:50,724
The cap reinforces the handle
Against hammer blows.
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00:20:50,724 --> 00:20:54,206
The tang stays put because
It's actually a bit bigger
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Than the hole it goes into --
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00:20:57,068 --> 00:20:59,655
In industry lingo,
An interference fit.
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The finished tools
Come off the line.
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00:21:08,310 --> 00:21:11,931
Now you can chisel your crafts
For years to come.
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If you have any comments
About the show,
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00:21:19,862 --> 00:21:22,620
Or if you'd like to suggest
Topics for future shows,
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00:21:22,620 --> 00:21:24,655
Drop us a line at...
27724
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