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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator: alligator bags enjoyed
Their first wave of popularity
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00:00:54,862 --> 00:00:57,206
At the end of the 19th century.
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The material was chosen
For its exotic look,
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Rich texture,
High pliability, and durability.
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Since then,
Many legendary designer handbags
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Have been made
With alligator skin.
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00:01:11,620 --> 00:01:13,137
For some women,
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A handbag is more
Than a practical accessory.
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It's also a way
To express their personal style.
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00:01:19,068 --> 00:01:22,689
Depending on the bag's size,
Shape, and desired look,
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00:01:22,689 --> 00:01:25,137
Many exotic animal skins
Can be used --
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Alligator, lizard,
Python, or ostrich.
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This red skin
Is from the nile alligator.
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The cutter maintains the pattern
In place with a weight.
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He cuts out
The shape of the bag,
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Leaving a border,
Called a turning-in,
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00:01:53,931 --> 00:01:56,931
All along the pattern.
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The skiving machine
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Delicately shaves
The back of the alligator skin
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00:02:03,758 --> 00:02:06,448
To make it thin and pliable.
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00:02:09,724 --> 00:02:12,482
A polishing jack
Creates a sheen.
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00:02:18,448 --> 00:02:20,862
A plating machine
Applies heat and pressure
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00:02:20,862 --> 00:02:24,620
To remove creases
And make the skin shiny.
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00:02:24,620 --> 00:02:27,689
Now it is placed on a hot plate
For a few seconds
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00:02:27,689 --> 00:02:29,103
To raise the skin
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00:02:29,103 --> 00:02:31,310
And create what is called
French bombay.
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00:02:37,724 --> 00:02:40,620
They brush rubber cement
On the back of the skin
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00:02:40,620 --> 00:02:43,862
And apply it to a thin piece
Of leather called a pliver.
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This will keep the bombay
From flattening over time.
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00:02:51,655 --> 00:02:53,689
Then he cuts off
The excess skin,
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Creating a turning-in.
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00:02:57,724 --> 00:03:01,586
This heavy paper and foam
Will go inside the bag's cover
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00:03:01,586 --> 00:03:05,034
To give it structure
And a cushiony feel.
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00:03:05,034 --> 00:03:07,896
He removes
The center part of the paper
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To help the cover fold easily.
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He uses a bone folder to fold
The turning-in over the paper...
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Then carefully hammers it
In place.
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Now he's making the sides,
Called gussets,
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00:03:27,724 --> 00:03:29,586
And the bottom of the bag.
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He applies thin muslin
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And rubs it in place
Under a protective paper.
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Both gussets are sewn
To the bag's bottom
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00:03:38,689 --> 00:03:40,827
Using a very fine needle.
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The stitches
Must be as discreet as possible.
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The bag's lining is made
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Of soft lamb leather
Called cabretta.
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00:03:50,068 --> 00:03:52,793
The top half
Contains a magnetic circle
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00:03:52,793 --> 00:03:54,689
Which serves to close the bag.
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The brand's nameplate
Is also attached to the lining.
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The nameplate
Sits inside the bag
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So it will only be visible
When the bag is open.
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00:04:04,103 --> 00:04:05,482
The pocketbook maker
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Delicately glues the lining
To the bottom of the bag.
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00:04:09,965 --> 00:04:12,793
He folds the leather over
With the bone folder
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00:04:12,793 --> 00:04:14,482
And uses the hammer
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To make the juncture
As thin as possible.
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00:04:17,758 --> 00:04:20,137
Since the covers
Are glued in place,
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00:04:20,137 --> 00:04:22,137
There are no stitches visible
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On the front and back
Of the bag,
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Giving it a more luxurious look.
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00:04:29,758 --> 00:04:32,517
Now he scratches the border
To remove the sheen,
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Which will help the glue adhere
To the leather.
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00:04:40,965 --> 00:04:44,448
He applies the back and front
Cover to the lining of the bag,
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Making sure all the covers
Line up perfectly.
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This step is only performed
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By experienced
Pocketbook makers,
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As it is crucial
To the final look of the bag.
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Anything less than perfect
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Would look like
A cheap imitation.
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Custom-colored paints
Will fill in any gaps
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00:05:01,551 --> 00:05:04,241
And cover any variation
In the leather.
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00:05:09,482 --> 00:05:11,827
They finish
By polishing the bag,
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00:05:11,827 --> 00:05:13,586
Using a small amount
Of shoe polish
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And a buffing cloth.
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They must use very little polish
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To avoid buildup
In the grain of the leather.
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00:05:20,827 --> 00:05:24,655
This also removes
Any dirt or cement.
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00:05:27,379 --> 00:05:31,724
It takes about seven hours
To make an alligator bag.
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All the time, effort,
And materials
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Result in a stylish
Fashion accessory
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That's made to last for years.
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Narrator:
Lockers are a familiar sight
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In high-school corridors,
Gym changing rooms,
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And many workplaces,
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00:05:57,413 --> 00:05:59,724
And in the world
Of professional sports,
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Lockers are the backdrop
To many a post-game interview.
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00:06:03,310 --> 00:06:06,241
The latest trend is buying
Lockers for kids' bedrooms
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As cool and practical
Storage furniture.
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00:06:10,275 --> 00:06:13,172
While they vary
In size and design,
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00:06:13,172 --> 00:06:15,620
All lockers
Have ventilation holes.
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These help air circulate,
Which prevents odors.
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00:06:19,620 --> 00:06:22,172
Lockers are made
Of a hard type of steel
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00:06:22,172 --> 00:06:23,827
That's just flexible enough
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For presses to bend
To the required shape.
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00:06:27,275 --> 00:06:31,482
The steel sheets
Are 1/10 of an inch thick.
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00:06:31,482 --> 00:06:32,758
Workers feed one at a time
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Through a cutting tool
Called a square shear.
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00:06:36,068 --> 00:06:39,310
It slices from one end
Of the sheet to the other,
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00:06:39,310 --> 00:06:42,448
Cutting pieces
With the required width.
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Each door piece goes
Into a 100-ton punch press,
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00:06:45,724 --> 00:06:49,379
Which stamps out
The ventilation holes.
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The next press punches screw
And rivet holes around the edges
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00:06:53,103 --> 00:06:58,344
And a hole for the cup that
Houses the locker's closure.
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00:06:58,344 --> 00:06:59,689
The first bending press
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00:06:59,689 --> 00:07:02,586
Simultaneously folds over
The top and bottom edges,
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Forming flanges.
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00:07:05,344 --> 00:07:09,068
This bend sets
The finished height of the door.
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00:07:10,793 --> 00:07:14,310
The next bend sets
The finished widthof the door.
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00:07:14,310 --> 00:07:16,965
The press folds the side edges
Over twice,
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Forming a box-shaped rim.
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Next, workers position
A steel reinforcement panel
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Against the hinge side
Of the door.
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They affix one side of the panel
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Using a welding machine that
Fuses 12 spots simultaneously.
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Then they weld the other side
Manually.
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Now they mount the door
In an alignment fixture
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Hinge-side up
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00:08:01,344 --> 00:08:05,344
And clamp a piano hinge
To the edge.
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They fuse the hinge to the door
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By welding it
To the top row of screw holes.
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00:08:21,482 --> 00:08:23,655
Meanwhile,
They bend pieces of steel
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To form the locker's top,
Bottom, back, and sides.
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00:08:27,310 --> 00:08:31,206
Now they weld those parts
Together.
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Then they weld the hasp,
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The steel loop
Through which you hook a padlock
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To lock the locker.
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00:08:37,275 --> 00:08:39,793
The hasp
Goes on the edge of the body
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00:08:39,793 --> 00:08:43,896
And protrudes through a slot
In the closure cup in the door.
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00:08:43,896 --> 00:08:46,551
Next,
The locker's interior shelf.
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They set four rivets
Onto a positioning fixture --
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Two in the center,
Two on the edge --
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00:08:52,862 --> 00:08:54,931
Then position the shelf on top,
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00:08:54,931 --> 00:08:58,896
Aligning the shelf's four holes
With the four rivets.
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00:08:58,896 --> 00:09:01,793
They position a single hook
Over each edge rivet
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And weld it on.
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00:09:11,551 --> 00:09:12,965
Then they take a double hook
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00:09:12,965 --> 00:09:16,620
And position it
Over the two center rivets...
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00:09:16,620 --> 00:09:20,000
Then weld that on.
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00:09:22,758 --> 00:09:26,034
Then they weld the shelf
Into the locker body.
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00:09:26,034 --> 00:09:29,241
All the parts now head
Into the factory's paint shop.
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00:09:29,241 --> 00:09:31,482
The powder paint
They use for this model
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00:09:31,482 --> 00:09:34,034
Contains electrically charged
Silver particles --
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00:09:34,034 --> 00:09:35,689
A natural disinfectant
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00:09:35,689 --> 00:09:38,862
That kills any bacteria,
Viruses, and fungi
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On the locker's surface.
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00:09:40,482 --> 00:09:43,241
Once coated, the parts go
Into an oven for a half-hour
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To bake the paint.
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00:09:46,827 --> 00:09:49,517
Then final assembly begins.
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First, workers mount the
Closure cup and the door hole
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With a screw
And a retaining washer.
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00:09:59,551 --> 00:10:01,137
Next,
They install magnet catches
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00:10:01,137 --> 00:10:03,586
To hold the door closed...
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00:10:03,586 --> 00:10:05,551
And apply an adhesive sticker
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Indicating this locker has
An antimicrobial paint coating.
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00:10:14,413 --> 00:10:16,862
Then they attach the door
To the body
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00:10:16,862 --> 00:10:19,793
By driving rivets
Through the lower row of holes
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On the piano hinge.
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00:10:26,793 --> 00:10:28,620
They make sure
The door moves smoothly
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And that the hasp aligns
With the slot in the cup.
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The factory makes lockers
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Of various sizes,
Shapes, and configurations.
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Some models even have
Built-in combination locks.
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Narrator: since roman times,
Woodworking planes
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Have been part
Of the carpenter's tool kit.
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And despite the invention of
Power tools for wood surfacing,
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00:10:58,862 --> 00:11:03,000
Many still prefer the hands-on
Approach of this simple tool.
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Using it is a skill
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00:11:04,448 --> 00:11:08,103
That can take a piece of timber
From rough to refined.
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If wood needs shaping,
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00:11:12,241 --> 00:11:14,517
It's time to reach
For the bench plane.
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00:11:14,517 --> 00:11:16,103
On the push stroke,
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00:11:16,103 --> 00:11:18,482
It shaves down
Bumps and high spots on wood
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00:11:18,482 --> 00:11:21,137
To make the surface
Level and true.
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Production begins
With bench-plane patterns.
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00:11:23,896 --> 00:11:25,655
They place several in a box
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00:11:25,655 --> 00:11:30,793
And pour fine sand, mixed with
A bonding chemical, over them.
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00:11:30,793 --> 00:11:33,413
The bonding chemical
Solidifies the sand.
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00:11:33,413 --> 00:11:37,551
They poke holes
To vent gases later on.
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00:11:37,551 --> 00:11:39,413
And with the patterns removed,
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00:11:39,413 --> 00:11:43,793
It's clear that the bonding
Chemical has worked its magic.
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The patterns have left
A definite impression
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00:11:45,586 --> 00:11:48,620
In the hardened sand.
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They apply glue
To one half of the mold
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00:11:52,103 --> 00:11:57,310
So it adheres to the half
With the impressions in it.
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00:11:57,310 --> 00:12:00,241
They then glue
Two square-shaped spouts
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Around holes in the sand mold.
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00:12:04,551 --> 00:12:07,000
Next, they fire up
The foundry furnace
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00:12:07,000 --> 00:12:12,241
And melt iron
Into a white-hot liquid.
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00:12:12,241 --> 00:12:14,896
Workers then carefully pour
The molten metal
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00:12:14,896 --> 00:12:18,241
Down the square spouts
And into the sand molds.
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00:12:18,241 --> 00:12:21,620
Gases are released through the
Holes poked in the sand earlier,
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00:12:21,620 --> 00:12:25,896
While weights keep the lids
From lifting from the pressure.
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00:12:27,620 --> 00:12:29,620
After a two-hour cooldown,
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00:12:29,620 --> 00:12:34,137
They break the molds and
Pick out the cast-iron parts.
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00:12:34,137 --> 00:12:36,586
The planes
Have a knobby protuberance,
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00:12:36,586 --> 00:12:38,896
Formed as metal flowed
Into the mold.
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00:12:38,896 --> 00:12:40,413
They slice that off.
200
00:12:40,413 --> 00:12:43,931
And after strengthening the
Cast iron's physical properties,
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00:12:43,931 --> 00:12:45,758
They mill
The bottom of the bench plane
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00:12:45,758 --> 00:12:48,206
To make it reasonably flat.
203
00:12:48,206 --> 00:12:52,586
They also expose a slit
Formed during molding.
204
00:12:52,586 --> 00:12:54,931
They now lock the bench plane
In position
205
00:12:54,931 --> 00:12:56,862
To allow the spiked teeth
Of a cutting wheel
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00:12:56,862 --> 00:12:59,310
To carve into the molded slit.
207
00:12:59,310 --> 00:13:02,551
It enlarges the slit to form
The mouth of the bench plane,
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00:13:02,551 --> 00:13:06,275
The opening through which
The plane's blade will protrude.
209
00:13:11,034 --> 00:13:13,103
Some precision work is needed,
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00:13:13,103 --> 00:13:16,793
So a tapered and serrated tool
Is forced through the mouth.
211
00:13:16,793 --> 00:13:18,793
This opens it up a little more
212
00:13:18,793 --> 00:13:21,517
To give it
The exact dimensions required.
213
00:13:21,517 --> 00:13:24,517
Coolant now flows
To prevent overheating,
214
00:13:24,517 --> 00:13:27,758
As a grinding wheel machines
The base of each bench plane
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00:13:27,758 --> 00:13:30,103
Until it's completely flat.
216
00:13:34,413 --> 00:13:37,206
They now try to slip
A very thin steel strip
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00:13:37,206 --> 00:13:40,068
Between a level bar
And the base of the bench plane.
218
00:13:40,068 --> 00:13:43,379
Failure confirms
It's perfectly flat.
219
00:13:43,379 --> 00:13:46,206
Next, a cutting tool
Evens a sloped pad
220
00:13:46,206 --> 00:13:48,344
Molded onto the front
Of the bench plane.
221
00:13:48,344 --> 00:13:51,655
This pad, called the frog,
Will hold the sliding wedge
222
00:13:51,655 --> 00:13:54,000
That sets the angle
Of the plane blade.
223
00:13:54,000 --> 00:13:56,689
Production
Now focuses on the blade.
224
00:13:56,689 --> 00:13:58,586
They heat a steel rod
In a furnace
225
00:13:58,586 --> 00:14:01,586
Until it's white-hot
And malleable.
226
00:14:01,586 --> 00:14:03,827
They then place it
Under a mechanized hammer
227
00:14:03,827 --> 00:14:06,137
Which pounds it until it's flat.
228
00:14:06,137 --> 00:14:08,413
They turn the flattened steel
Sideways,
229
00:14:08,413 --> 00:14:13,068
And the pulsating hammer
Squares the edges.
230
00:14:13,068 --> 00:14:16,000
Then another tool
Stamps the company's insignia
231
00:14:16,000 --> 00:14:19,827
Onto one end of the blade.
232
00:14:19,827 --> 00:14:24,482
The steel rod has been
Flattened, squared, and stamped.
233
00:14:24,482 --> 00:14:26,896
It's then cut to the desired
Shape and dimensions
234
00:14:26,896 --> 00:14:30,758
And given
A beveled cutting edge.
235
00:14:30,758 --> 00:14:33,344
The next part
Is called a lever cap,
236
00:14:33,344 --> 00:14:37,241
And it will be used to clamp the
Blade to the bench-plane frog.
237
00:14:37,241 --> 00:14:41,379
They sand it smooth to
Improve its look and function.
238
00:14:41,379 --> 00:14:43,379
They then buff
Each part of the bench plane
239
00:14:43,379 --> 00:14:47,448
Against a cloth wheel
To a mirror-like finish.
240
00:14:53,103 --> 00:14:55,344
It's now time
To fit the bench-plane frog
241
00:14:55,344 --> 00:14:59,137
Into the pad
Machined especially for it.
242
00:14:59,137 --> 00:15:01,586
They secure it with screws.
243
00:15:01,586 --> 00:15:03,172
The cutting blade,
244
00:15:03,172 --> 00:15:05,931
By now reinforced
By a part called the cap iron,
245
00:15:05,931 --> 00:15:07,862
Fits flush to the frog.
246
00:15:07,862 --> 00:15:10,931
They top off the assembly
With a lever cap
247
00:15:10,931 --> 00:15:14,620
And clamp it all together
With a spring system.
248
00:15:14,620 --> 00:15:18,068
They fit a knob
Made of tropical wood
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On a threaded rod
On the front of the bench plane.
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00:15:22,517 --> 00:15:25,275
The knob and the back handle
Will allow the user
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To firmly grip the bench plane
And push it forward.
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And with the blade
Now protruding
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From the base on an angle,
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It's ready
To level any piece of wood,
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Leaving only shavings
In its wake.
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Narrator:
A flight data recorder,
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Or a black box,
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Records every detail
Of an aircraft's operations,
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From engine speed
To cabin pressure.
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After a crash,
Investigators extract the data
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To determine what went wrong.
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Black boxes
Are actually bright orange
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So they'll stand out
Amid the wreckage.
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These black boxes
Are the deployable type,
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Meaning they separate
From the aircraft upon impact.
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This makes them easier
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For search-and-rescue crews
To recover.
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00:16:21,310 --> 00:16:24,379
To make the outer shell
That houses the components,
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00:16:24,379 --> 00:16:26,413
They use a two-part mold,
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00:16:26,413 --> 00:16:29,655
First waxing it
To ease extraction later on.
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Then they brush on
An orange-tinted gel coat,
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A liquid that, after four hours,
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Hardens into a durable,
Waterproof finish.
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00:16:38,103 --> 00:16:40,000
Over the hardened gel coat,
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00:16:40,000 --> 00:16:42,275
They apply pieces
Of fiberglass cloth,
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Saturating them
With orange-tinted resin.
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They apply extra pieces in
The corners for reinforcement.
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They continue
Until they've built up
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Three layers of fiberglass.
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00:17:02,724 --> 00:17:07,275
The rectangular box on this mold
Half-casts a cavity in the shell
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00:17:07,275 --> 00:17:10,137
That will house
The device's key components.
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00:17:10,137 --> 00:17:12,931
They embed aluminum plates
Within the fiberglass
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00:17:12,931 --> 00:17:14,482
To reinforce the area
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00:17:14,482 --> 00:17:18,413
Where screws will attach
The cavity cover.
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00:17:22,620 --> 00:17:24,310
A computer-guided
Milling machine
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Contours a piece of foam
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That will fit the empty space
Inside the shell.
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00:17:29,482 --> 00:17:31,896
This foam
Absorbs the force of impact
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So the flight data recorder
Can survive a crash.
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00:17:35,379 --> 00:17:38,413
They coat one side of
The foam core with resin paste,
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Then lay it into the mold.
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00:17:40,931 --> 00:17:43,827
They fill voids with
A temporary retaining block
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00:17:43,827 --> 00:17:46,448
To prevent the foam core
From collapsing inward
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During the vacuum process
That comes next.
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00:17:49,413 --> 00:17:52,413
They wrap the mold in felt
To protect the surface,
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00:17:52,413 --> 00:17:55,241
Put it in a plastic bag,
Attach a hose,
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00:17:55,241 --> 00:17:56,931
Then start the suction.
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00:17:56,931 --> 00:18:01,000
Over four hours, the vacuum
Slowly extracts the air,
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00:18:01,000 --> 00:18:04,034
Drawing the fiberglass
Tightly against the foam core
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00:18:04,034 --> 00:18:06,931
Without any wrinkles or puckers.
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00:18:06,931 --> 00:18:10,551
It takes another four hours for
The resin to completely cure.
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00:18:10,551 --> 00:18:13,310
Then they remove the mold
From the vacuum bag,
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00:18:13,310 --> 00:18:16,137
Coat the other side of
The foam core with resin paste,
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00:18:16,137 --> 00:18:20,000
And embed steel reinforcements.
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00:18:20,000 --> 00:18:22,413
Besides absorbing
The force of impact,
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00:18:22,413 --> 00:18:25,241
The foam core makes
The flight data recorder buoyant
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00:18:25,241 --> 00:18:29,241
Should the aircraft go down
In a body of water.
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00:18:29,241 --> 00:18:31,793
The device
Contains two antennas,
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The first of which gets pasted
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Into a designated spot
In the foam core.
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One antenna
Transmits a distress signal,
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The other a homing signal
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To help search-and-rescue crews
Locate the downed aircraft.
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00:18:45,137 --> 00:18:47,413
Now they mate
The two parts of the mold,
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00:18:47,413 --> 00:18:50,758
Carefully sliding the antenna
That protrudes from one half
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00:18:50,758 --> 00:18:54,517
Through and out an opening
In the other half.
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00:19:00,896 --> 00:19:02,931
They bolt the mold closed
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00:19:02,931 --> 00:19:06,413
And leave the paste
To air-cure overnight.
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00:19:08,620 --> 00:19:12,586
The next day, they unbolt
The mold and extract the shell,
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00:19:12,586 --> 00:19:14,931
The two halves of which
Are now bonded
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00:19:14,931 --> 00:19:17,103
With the first antenna inside.
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00:19:19,862 --> 00:19:21,931
Now they can install
The other components,
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00:19:21,931 --> 00:19:24,793
Such as this memory module
Containing the circuit boards
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00:19:24,793 --> 00:19:27,482
That record the flight data
And cockpit audio.
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00:19:27,482 --> 00:19:30,344
All the components,
Prior to installation,
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00:19:30,344 --> 00:19:34,413
Undergo extensive testing
To ensure they operate properly
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00:19:34,413 --> 00:19:38,241
When subjected to vibration
And extreme temperatures.
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00:19:38,241 --> 00:19:41,931
The memory module
Goes into a fireproof box,
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00:19:41,931 --> 00:19:45,241
Along with the transmitter that
Sends out the locating signal
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00:19:45,241 --> 00:19:46,413
Via the antennas,
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00:19:46,413 --> 00:19:48,931
The second of which
They now install
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00:19:48,931 --> 00:19:51,482
Into the component cavity
At the top of the box.
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00:19:51,482 --> 00:19:53,379
Then they install the battery
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00:19:53,379 --> 00:19:57,068
That powers the transmitter
For 150 hours.
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00:19:57,068 --> 00:19:59,724
They connect the battery
To the transmitter
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00:19:59,724 --> 00:20:01,241
In the fireproof box...
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00:20:01,241 --> 00:20:04,241
Connect the transmitter
To the antennas,
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00:20:04,241 --> 00:20:07,413
Then screw the cover
To the aluminum plates
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00:20:07,413 --> 00:20:09,931
Embedded
Around the cavity's perimeter.
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00:20:16,517 --> 00:20:20,413
The finished device undergoes
A series of performance tests.
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00:20:20,413 --> 00:20:23,758
This one,
In a special echo-free chamber,
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00:20:23,758 --> 00:20:26,241
Verifies the signal
The transmitter sends out
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00:20:26,241 --> 00:20:27,827
Via the antennas.
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00:20:27,827 --> 00:20:31,241
The chamber's receiving antenna
Is connected to a computer
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00:20:31,241 --> 00:20:33,448
That analyzes
The signal's frequency
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00:20:33,448 --> 00:20:35,000
And transmission pattern --
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Critical factors
In recovering the box
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That provides vital clues
For crash investigators.
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If you have any comments
About the show,
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00:20:53,862 --> 00:20:56,655
Or if you'd like to suggest
Topics for future shows,
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00:20:56,655 --> 00:20:58,793
Drop us a line at...
28191
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