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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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Lacrosse sticks...
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...Frozen fish products...
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...Flashlights...
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...And paintbrushes.
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Lacrosse is north america's
Oldest sport.
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It was back in the 1400s
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That native people
Got the ball rolling,
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Playing with a distinctive
Netted stick.
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French missionaries
Decided the stick resembled
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The stafflike crosier, or cross,
Carried by bishops.
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And so the game became lacrosse.
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Lacrosse has never been
More popular than it is today.
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To make a lacrosse stick,
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They split a hickory log
Down the middle.
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This tree was cut in the fall
When the sap is out,
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So it's easier to work with.
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They continue subdividing
The log into eight pieces.
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Each piece then goes through
A band saw,
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Which trims it to a width
Of 2 1/2 inches.
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Hickory is the wood of choice
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Because it's tough
And can withstand
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The high-impact game
Of lacrosse.
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But to work with it,
They need to soften it up,
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So they steam the sticks
For 45 minutes.
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Then a craftsman places
The hickory stick in a jig.
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In this steamy state,
The wood is completely flexible.
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He easily curls one end
Around a form by hand.
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He loops wire around it so it
Will hold its crooklike shape
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While the wood dries
For one month.
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At the end of that month,
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He puts the other end
Of the stick in a steamy jig
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And bends it back
Just below the crook.
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This is called the back bend.
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He sets it on a rack
To dry and harden.
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This is the basic form,
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And as you can see, it resembles
The bishop's crosier,
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The one that inspired
The name of the game.
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After two weeks of drying,
The stick is ready to be carved.
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Using a drawknife, he shaves
The bark from the stick.
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Then he sculpts it thinner,
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Following the bends
Of the stick.
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The carver is an artisan
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Who has the experience and skill
To do this job well,
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Which is important
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Because the stick must be
Approved by the toughest judge,
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The player.
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Next they drill holes
In the curve of the stick --
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21 in total.
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Then they give it
A heavy sanding.
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The surface has to be
Absolutely smooth
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So the player
Won't get any splinters.
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Then, using a rag, they rub
Linseed oil into the stick
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To keep the wood
From getting too dry.
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The brand name goes on.
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And now it's time for the weaver
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To build the sidewall
Of the net.
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In the old days,
They used rawhide for this,
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But today they weave
With nylon string.
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He interlaces it
With leather runners
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That have been threaded through
The holes at the back bend.
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He brushes polyurethane
On the completed side web
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To stiffen it.
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Next he attaches the other end
Of the leather runners
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To the top of the crook.
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The player will be able
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To change the depth
Of the netted pocket
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To his or her preference.
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He interlaces the leather runner
Weave with the nylon sidewall...
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...And then pulls
The woven pocket over a post
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To give it some shape.
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He loops the ends of the leather
Runners in a half hitch
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And snips off the excess.
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Every detail of this lacrosse
Stick has been handcrafted.
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It's a process
That's taken three months.
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And now let the games begin.
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Narrator:
Since prehistoric times,
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The innuit have used
Quick-freezing to preserve fish.
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They threw their catch
Onto the arctic ice
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To instantly freeze it.
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It wasn't until
The early 20th century
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That the rest of the world
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Discovered that this was better
Than slow freezing.
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It's a case of progress
Moving at a glacial pace.
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Fish that's rapidly frozen
Right on the ship
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Is more flavorful
And retains its texture.
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This is minced cod frozen solid.
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It underwent quick-freezing
In china
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And was shipped
In this frozen state
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All the way
To this nova scotia facility
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Where it will be turned into
Fish sticks.
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A worker loads the fish blocks
Into a machine.
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A powerful ram forces the blocks
Through knives,
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Which slice them into logs
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That are about 19 inches
In length.
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Workers load the logs
Vertically into slots.
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Below, more knives
Slice the logs into sticks.
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They get 85 fish sticks
From one log.
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They check for breaks as the
Sticks move to the next station.
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At another production line,
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They dump quick-frozen
Haddock fillets
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Into a big, steel hopper.
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It funnels them
To a flighted conveyor.
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The conveyor meters the fillets
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00:07:42,206 --> 00:07:45,000
And drops each bunch
Onto a vibrating table.
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The vibrations
Separate the fillets
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As they move into lanes...
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And shuffle down
To an inspection station
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Where flaws
Can be easily spotted.
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Now it's time for a hot shower.
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It lasts just a second.
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The hot water melts the fillets'
Protective glaze
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But doesn't thaw
The fish itself.
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Deglazing allows the coating
Mixture to stick to the fish.
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The fish sticks
Are now traveling
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Through a curtain of batter
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Made of flour, water,
And spices.
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The excess collects
In a pan below
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00:08:38,551 --> 00:08:40,965
And coats the bottoms
Of the fish sticks.
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Back on the haddock
Production line,
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They're loading
A toasted wheat blend
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Into a machine called a breader.
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00:08:51,137 --> 00:08:54,931
It creates a thick shower
Of crumbs below
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That evenly coats the fillets
As they journey through.
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Then the breaded, frozen fillets
Head for the fryer.
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The fish sticks go through
A fryer, too, for 28 seconds,
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Just long enough
To cook the outside coating,
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00:09:19,413 --> 00:09:22,034
But the fish remains frozen
On the inside.
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With the coating baked on,
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The fish sticks and fillets are
Now en route to the freezers.
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Meanwhile, over on a third
Production line,
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They dump oil and red peppers
Into a high-speed mixer.
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They add some parsley
For seasoning,
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00:09:47,689 --> 00:09:51,275
Then hand-stir it
While it steam-cooks.
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The red-pepper sauce
Cascades from an applicator,
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Saturating these frozen
Tilapia fillets.
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This coating sticks
Without being fried,
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00:10:03,448 --> 00:10:05,000
So the tilapia fillets
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Head straight
For the spiraling freezer.
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The fish sticks
And breaded haddock fillets
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Are in similar freezers.
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00:10:13,448 --> 00:10:15,655
After 45 minutes,
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00:10:15,758 --> 00:10:18,068
The haddock slides down a chute
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00:10:18,172 --> 00:10:20,517
Which weighs it
To portion it out.
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00:10:20,620 --> 00:10:23,758
Heated jaws seal the bagged
Haddock fillets.
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00:10:31,379 --> 00:10:35,241
An oscillating feeder deposits
The fish sticks into boxes.
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00:10:38,931 --> 00:10:42,206
One last inspection
And they're ready for retail.
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They vacuum-pack
The tilapia fillets,
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00:10:45,517 --> 00:10:47,655
And this meal is sealed.
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00:10:50,517 --> 00:10:53,000
And now there's
Plenty of fish to fry,
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Depending on
Where your tastes lie.
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Narrator: the flashlight
Can illuminate any situation,
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00:11:11,137 --> 00:11:14,241
But the first version, invented
In the late 19th century,
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Wasn't all that efficient.
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It produced
Only flashes of light,
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So it was named "Flashlight."
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00:11:34,275 --> 00:11:38,068
The flashlight shows us the way
When things look dim.
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00:11:38,172 --> 00:11:40,206
To make a military flashlight,
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They place an aluminum bar
In a computerized lathe.
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Blades go to work and shape it
Into a flashlight body.
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00:11:52,034 --> 00:11:54,103
As a drill hollows out the bar,
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Coolant flushes over it to
Prevent the metal from expanding
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00:11:57,310 --> 00:11:59,275
As the tooling heats things up.
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This blade cuts threads
On the outside
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00:12:04,000 --> 00:12:06,931
So they can screw on
A flashlight lens cap later.
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00:12:08,931 --> 00:12:10,862
A gripper now pulls out the tube
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00:12:10,965 --> 00:12:13,310
So tools can work
On the back half.
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00:12:13,413 --> 00:12:16,586
A blade slims that section down
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00:12:16,689 --> 00:12:19,482
And then carves
The cross weave onto it.
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00:12:27,000 --> 00:12:30,689
This heavy texture will make
The flashlight easier to grip.
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00:12:37,931 --> 00:12:41,724
Next they drill a hole
In the flashlight's tail stud.
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00:12:41,827 --> 00:12:44,793
It's an attachment
For the wrist strap.
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00:12:49,620 --> 00:12:52,034
After the flashlight body
Has taken shape,
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They give it
A black, protective coating.
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00:12:58,034 --> 00:12:59,793
Next, using tons of force,
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00:12:59,896 --> 00:13:02,862
A machine injects hot plastic
Into a mold,
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00:13:02,965 --> 00:13:05,758
Which forms the lens
For the flashlight.
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00:13:08,103 --> 00:13:11,724
They place the lens in a jig
And unscrew the mold core.
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00:13:11,827 --> 00:13:14,000
The core has formed threads
In the lens
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00:13:14,103 --> 00:13:16,965
So it can be screwed onto
The flashlight body later.
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00:13:21,689 --> 00:13:23,586
They use another injection mold
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00:13:23,689 --> 00:13:26,827
To make plastic
Flashlight bodies.
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00:13:26,931 --> 00:13:28,068
The plastic flashlights
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00:13:28,172 --> 00:13:30,620
Are for more general use
Than the aluminum ones.
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00:13:34,241 --> 00:13:37,620
For custom orders, they stamp
A logo onto the flashlight
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00:13:37,724 --> 00:13:39,896
Using a hot-foil press.
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00:13:43,103 --> 00:13:47,379
Next they insert light-emitting
Diodes into a circuit board.
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00:13:50,137 --> 00:13:53,172
The diodes are electronic lamps
That are very bright
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00:13:53,275 --> 00:13:56,758
And can be used instead of
Traditional incandescent bulbs.
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00:13:59,689 --> 00:14:02,586
They solder the diodes'
Lead wires to a circuit board
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00:14:02,689 --> 00:14:05,103
And then trim them
With snippers.
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00:14:08,896 --> 00:14:12,586
The diodes are now secured and
Connected to the circuit board.
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00:14:17,758 --> 00:14:20,482
For bigger flashlights,
They use a lot of diodes --
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00:14:20,586 --> 00:14:22,862
Up to 60 of them
For this flashlight
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00:14:22,965 --> 00:14:25,965
That's being made
For search-and-rescue work.
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00:14:31,310 --> 00:14:36,896
Next a stamping press shapes
The bronze battery contacts.
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00:14:37,000 --> 00:14:40,931
An ultrasonic welder
Bonds them to a plastic plate.
200
00:14:43,206 --> 00:14:46,482
Then they solder a wire
From the diodes to the contacts.
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00:14:50,758 --> 00:14:54,000
The lamp part of the flashlight
Is now built.
202
00:14:56,551 --> 00:15:00,068
Now they insert springs into
The aluminum flashlight bodies.
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00:15:05,827 --> 00:15:07,344
They load the batteries,
204
00:15:07,448 --> 00:15:09,827
And the springs
Hold them in place.
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00:15:12,655 --> 00:15:15,482
They slide the lamp assembly
Into the flashlight cavity
206
00:15:15,586 --> 00:15:17,241
And screw the lens on.
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00:15:17,344 --> 00:15:20,241
This aluminum flashlight
208
00:15:20,344 --> 00:15:22,827
Has just been put together
In a flash.
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00:15:22,931 --> 00:15:25,517
They move on
To the plastic flashlight.
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00:15:25,620 --> 00:15:28,827
The battery contact
And spring assembly goes in,
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00:15:28,931 --> 00:15:31,413
Followed by the batteries.
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00:15:31,517 --> 00:15:34,586
The light-emitting diode lamp
Is next.
213
00:15:40,103 --> 00:15:42,793
They screw the lens
Onto the lamp.
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00:15:46,793 --> 00:15:50,000
The plastic glare shield
Is the final touch.
215
00:15:50,103 --> 00:15:54,137
And now these flashlights
Are ready to shine.
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00:16:14,586 --> 00:16:16,655
Narrator:
If you've got a paint job to do,
217
00:16:16,758 --> 00:16:19,620
The right type of brush
Can make all the difference.
218
00:16:19,724 --> 00:16:21,310
When you opt for latex paint,
219
00:16:21,413 --> 00:16:24,413
It's best to use a paintbrush
With synthetic bristles.
220
00:16:24,517 --> 00:16:26,862
They're typically
Made of nylon or polyester.
221
00:16:26,965 --> 00:16:29,034
If you're painting
With oil-based paint,
222
00:16:29,137 --> 00:16:31,068
You can use
Either a synthetic brush
223
00:16:31,172 --> 00:16:34,413
Or one with bristles
Made of natural animal hair.
224
00:16:39,482 --> 00:16:40,965
For natural bristles,
225
00:16:41,068 --> 00:16:43,620
This factory uses pig hair
Imported from china
226
00:16:43,724 --> 00:16:46,620
That arrives in bundles
Sorted by length.
227
00:16:46,724 --> 00:16:50,103
Each paintbrush contains
Up to five different lengths.
228
00:16:50,206 --> 00:16:53,448
This bristle structure makes
The brush sufficiently stiff.
229
00:16:56,413 --> 00:16:57,655
All five lengths
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00:16:57,758 --> 00:17:00,517
Go into a specially designed
Mixing machine.
231
00:17:00,620 --> 00:17:02,137
First it combs the bristles,
232
00:17:02,241 --> 00:17:05,103
Straightening them out
And removing any curved hairs.
233
00:17:05,206 --> 00:17:07,310
Then it spreads
The bristles flat
234
00:17:07,413 --> 00:17:09,724
And mixes the lengths together.
235
00:17:14,793 --> 00:17:18,655
Now a worker takes a handful
Of bristles from the mixer
236
00:17:18,758 --> 00:17:20,551
And pats them
On a vibrating table.
237
00:17:20,655 --> 00:17:23,241
Like human hairs, animal hairs
Have a root and a tip.
238
00:17:23,344 --> 00:17:27,275
The vibrations make
All the butt ends line up flat.
239
00:17:29,689 --> 00:17:32,586
Each handful
Goes into a storage box
240
00:17:32,689 --> 00:17:35,275
Until it's time to install
The bristles in the ferrule,
241
00:17:35,379 --> 00:17:38,310
The steel band
That goes around the paintbrush.
242
00:17:42,724 --> 00:17:45,000
This machine makes the ferrules.
243
00:17:45,103 --> 00:17:49,793
It shapes a thin steel strip
That's 1.1 to 1.6 inches wide.
244
00:17:49,896 --> 00:17:53,103
Rollers imprint beads
To make the strip more rigid
245
00:17:53,206 --> 00:17:56,000
And a herringbone pattern
That is purely cosmetic.
246
00:17:57,965 --> 00:17:59,931
Then a blade cuts the strip
Into pieces
247
00:18:00,034 --> 00:18:02,655
That are long enough
To wrap around the brush.
248
00:18:05,517 --> 00:18:08,379
The machine bends each piece
Around a forming horn,
249
00:18:08,482 --> 00:18:12,551
Then joins the ends
In a strong lock seam.
250
00:18:15,862 --> 00:18:19,413
Hammers flatten the seam,
And the ferrule is finished.
251
00:18:24,517 --> 00:18:26,103
Back to the bristles now.
252
00:18:26,206 --> 00:18:29,655
A brush-making machine
Will join them to the ferrules.
253
00:18:29,758 --> 00:18:31,758
Workers load
The mixed batches of bristles
254
00:18:31,862 --> 00:18:33,551
Into one of the machine's
Feeders
255
00:18:33,655 --> 00:18:35,862
And the ferrules into the other.
256
00:18:39,034 --> 00:18:42,724
The machine picks up
The required amount of bristles.
257
00:18:42,827 --> 00:18:46,000
Transfer jaws grab the tips
And insert them in a ferrule.
258
00:18:46,103 --> 00:18:48,103
A vibrating device
Called a patter
259
00:18:48,206 --> 00:18:50,000
Pushes the bristles in straight.
260
00:18:57,068 --> 00:18:59,413
A continuous strip of cardboard
261
00:18:59,517 --> 00:19:01,758
Feeds the next part
Of the equipment.
262
00:19:01,862 --> 00:19:03,758
The machine parts the bristles,
Cuts off,
263
00:19:03,862 --> 00:19:05,689
And slots in
A piece of cardboard.
264
00:19:05,793 --> 00:19:07,586
This centerpiece,
As it's called,
265
00:19:07,689 --> 00:19:09,586
Creates a well
Inside the brush head
266
00:19:09,689 --> 00:19:12,448
To help hold the paint.
267
00:19:12,551 --> 00:19:14,931
The machine
Then pulls the bristles out
268
00:19:15,034 --> 00:19:16,275
To the proper length,
269
00:19:16,379 --> 00:19:20,275
Leaving about a quarter inch
Inside the ferrule.
270
00:19:20,379 --> 00:19:22,862
Once the brush heads
Come off the machine,
271
00:19:22,965 --> 00:19:25,000
Workers pick out
The loose bristles.
272
00:19:25,103 --> 00:19:27,827
The lightweight
Paintbrush handles
273
00:19:27,931 --> 00:19:30,724
Are made of plastic pellets.
274
00:19:30,827 --> 00:19:32,241
A vacuum loader
275
00:19:32,344 --> 00:19:34,344
Sucks the material
Up to a molding machine
276
00:19:34,448 --> 00:19:37,344
Which melts the pellets
At about 400 degrees fahrenheit.
277
00:19:37,448 --> 00:19:40,275
The machine then injects
The molten plastic
278
00:19:40,379 --> 00:19:42,275
Into handle-shaped molds.
279
00:19:42,379 --> 00:19:43,517
Five minutes later,
280
00:19:43,620 --> 00:19:46,379
The machine ejects the handles
From the molds.
281
00:19:50,206 --> 00:19:53,275
Workers attach
30 handles at a time to sticks
282
00:19:53,379 --> 00:19:55,448
And hang them across paint vats,
283
00:19:55,551 --> 00:19:57,793
Then lower the handles
Into the paint slowly
284
00:19:57,896 --> 00:20:00,379
To avoid creating air bubbles.
285
00:20:00,482 --> 00:20:03,206
The first coat is a primer.
286
00:20:03,310 --> 00:20:06,862
After a half-hour, the handles
Are ready for the next coat.
287
00:20:06,965 --> 00:20:10,551
This time, the vat contains
Colored paint.
288
00:20:10,655 --> 00:20:14,275
It dries to a matte finish
In 30 minutes.
289
00:20:14,379 --> 00:20:17,586
The third vat
Contains clear lacquer.
290
00:20:17,689 --> 00:20:21,275
This coat protects the paint
And makes the surface glossy.
291
00:20:24,896 --> 00:20:27,655
Now it's time to glue
The bristles to the ferrules
292
00:20:27,758 --> 00:20:29,724
With strong epoxy glue.
293
00:20:29,827 --> 00:20:32,172
It seeps down
Into the bristle base.
294
00:20:37,137 --> 00:20:39,655
Workers now load the finished
Brush heads and handles
295
00:20:39,758 --> 00:20:42,551
Into an assembly machine.
296
00:20:45,034 --> 00:20:48,000
The machine inserts a handle
Into each brush head,
297
00:20:48,103 --> 00:20:51,103
Shooting two or three nails
Into each side to secure it.
298
00:20:57,310 --> 00:21:00,620
Finally, a printing machine
Stamps the company name
299
00:21:00,724 --> 00:21:03,241
Onto one side of each handle.
300
00:21:03,344 --> 00:21:06,551
Paintbrushes come in a wide
Range of widths and thicknesses,
301
00:21:06,655 --> 00:21:09,793
Providing different strokes
For different folks.
302
00:21:18,275 --> 00:21:20,275
If you have any comments
About the show,
303
00:21:20,379 --> 00:21:22,862
Or if you'd like to suggest
Topics for future shows,
304
00:21:22,965 --> 00:21:24,965
Drop us a line at...
24418
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