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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: what do you do
When you're the proud owner
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Of an ultra-luxurious
Vintage automobile
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That has
An original steering wheel
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That's several miles short
Of being as elegant as the car?
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You order yourself a handsome
Custom-made steering wheel
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00:01:07,068 --> 00:01:10,586
Designer to match
The vehicle's deluxe interior.
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From the plain, original
Steering wheel
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00:01:16,448 --> 00:01:20,344
To a deluxe edition
Befitting a vintage automobile,
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00:01:20,448 --> 00:01:26,068
Custom-matched to its woodwork
And leather interior.
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00:01:26,172 --> 00:01:29,275
They start
By skinning the original wheel,
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A steel ring covered in black
Plastic with some leather trim.
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After slicing and chiseling off
The covering,
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They file the ring clean
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Because they'll be reusing it
For the new wheel.
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00:01:42,241 --> 00:01:46,068
However, they'll encase it
Within two plywood rings
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00:01:46,172 --> 00:01:48,103
To beef up
The width and thickness
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00:01:48,206 --> 00:01:52,482
And to create a substrate on
Which to glue the wood veneer.
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00:01:52,586 --> 00:01:54,379
Using a jigsaw and bandsaw,
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They cut
A front ring and a back ring
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00:01:57,206 --> 00:01:59,586
Out of european birch plywood.
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00:02:01,241 --> 00:02:03,724
Then they mill the profile,
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00:02:03,827 --> 00:02:07,448
Including a groove inside
For the metal ring.
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00:02:10,241 --> 00:02:14,448
Once the shape is finalized,
They sand the surface smooth
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00:02:14,551 --> 00:02:17,103
To prep it
To receive the wood veneer.
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00:02:23,379 --> 00:02:25,758
Veneer is made
From a piece of wood
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00:02:25,862 --> 00:02:28,655
Sliced into ultra-thin sheets
Called leaves.
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For each steering wheel,
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00:02:30,413 --> 00:02:32,724
They take
Four consecutively cut leaves
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So that their wood-grain pattern
Is nearly identical.
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For each plywood ring,
They take two of those leaves
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00:02:39,931 --> 00:02:42,724
And tape them mirror-image
To each other.
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00:02:42,827 --> 00:02:45,310
They insert adhesive
Where the taped edges meet
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00:02:45,413 --> 00:02:47,379
And let it dry overnight.
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00:02:47,482 --> 00:02:50,206
Then they lay the ring pattern
Onto the veneer,
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00:02:50,310 --> 00:02:52,413
Trace, and cut out the shape.
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00:02:52,517 --> 00:02:54,862
Next, they notch the veneer ring
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00:02:54,965 --> 00:02:58,172
So that it can fold
Over the ring's edges.
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00:02:58,275 --> 00:03:01,551
After coating the plywood ring
With glue,
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00:03:01,655 --> 00:03:04,931
They center the veneer
And tape down the edges.
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00:03:13,758 --> 00:03:16,448
Next, they add
A layer of protective plastic
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00:03:16,551 --> 00:03:19,344
Followed by rubber cushioning.
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00:03:19,448 --> 00:03:22,862
These will protect the veneer
Surface in the next machine --
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00:03:22,965 --> 00:03:26,103
A vacuum press.
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00:03:28,172 --> 00:03:32,379
Powerful suction draws the bag
Tightly around the materials.
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00:03:32,482 --> 00:03:36,137
This locks the veneer
Onto the plywood substrate,
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00:03:36,241 --> 00:03:38,241
Forcing out any air
In between them
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00:03:38,344 --> 00:03:40,344
Which would hinder
Full adhesion.
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00:03:42,310 --> 00:03:44,551
Each plywood ring
Is now veneered
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00:03:44,655 --> 00:03:46,896
And ready to encase
The metal ring
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Of the original steering wheel.
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The workers apply glue
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To the underside of both rings,
Into the groove.
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00:03:59,620 --> 00:04:01,689
Then they assemble
The two veneered rings
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00:04:01,793 --> 00:04:03,413
Over the metal one.
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00:04:09,724 --> 00:04:14,862
They set clamps all around and
Leave the glue to dry overnight.
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00:04:20,241 --> 00:04:23,137
The next day,
They remove the clamps
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00:04:23,241 --> 00:04:26,241
And put the steering wheel
In an oven for about eight hours
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00:04:26,344 --> 00:04:28,172
To cure the glue.
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00:04:28,275 --> 00:04:30,103
Once the steering wheel cools,
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They file away excess glue
That seeped out the seam,
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00:04:34,068 --> 00:04:37,655
Then sand the entire surface
Silky smooth.
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They protect the delicate veneer
With eight coats of resin,
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Cured in the oven
For optimal durability.
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00:04:44,896 --> 00:04:49,551
They then polish the surface
With a series of compounds
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00:04:49,655 --> 00:04:51,000
To produce a glossy finish
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00:04:51,103 --> 00:04:53,793
Which highlights
The richness of the wood grain.
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The perimeter of the
Steering wheel now completed,
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They cover the spokes and hub
With fine leather,
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00:05:04,034 --> 00:05:07,896
First gluing the pieces...
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00:05:08,000 --> 00:05:11,413
Then hand-stitching them.
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They put back the original
Steering wheel's hub,
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00:05:32,379 --> 00:05:35,482
Which they had removed
Before the makeover.
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00:05:38,689 --> 00:05:42,344
Then the finishing touch --
A veneered horn button.
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After all, when you're
Driving a luxury car,
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You might just
Want to toot your own horn.
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00:06:01,034 --> 00:06:03,965
Narrator: be they airplanes,
Satellites, or rockets,
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00:06:04,068 --> 00:06:07,448
Aerospace vehicles
All have one thing in common
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00:06:07,551 --> 00:06:09,586
Besides their capacity to fly.
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00:06:09,689 --> 00:06:11,172
Their internal construction
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00:06:11,275 --> 00:06:13,827
Includes several assemblies
Of tubes and ducts
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00:06:13,931 --> 00:06:15,206
Through which materials
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00:06:15,310 --> 00:06:19,758
Such as fuel, air,
Oil, and hydraulic fluid move.
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00:06:21,793 --> 00:06:24,137
Aerospace
Tube-and-duct assemblies
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00:06:24,241 --> 00:06:27,379
Are typically made of highly
Durable, lightweight materials,
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00:06:27,482 --> 00:06:29,931
Such as aluminum and titanium.
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00:06:30,034 --> 00:06:33,068
The choice of material
Depends on the application,
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00:06:33,172 --> 00:06:35,413
For example,
Whether the finished component
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Must be able to resist high heat
Or withstand high pressure.
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00:06:40,758 --> 00:06:43,103
These aluminum tubes
Are on their way
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00:06:43,206 --> 00:06:46,793
To becoming a fuel line
For a boeing 737.
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00:06:46,896 --> 00:06:50,931
The operator immobilizes a tube
With clamps,
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00:06:51,034 --> 00:06:53,620
Then saws it
To the length required.
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00:06:58,137 --> 00:07:02,275
This leaves burrs --
Sharp shards -- on the cut edge,
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00:07:02,379 --> 00:07:06,827
So they insert the tube
Into a deburring machine.
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00:07:12,827 --> 00:07:18,103
Here's what the tube looks like
Before deburring and after.
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00:07:18,206 --> 00:07:21,655
They squirt
Some lubricant inside,
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00:07:21,758 --> 00:07:23,275
Then slide the tube
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00:07:23,379 --> 00:07:27,000
Onto the mandrill
Of a computer-guided bender.
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00:07:28,862 --> 00:07:32,517
As the machine forms the tube
To the required shape,
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The mandrill
Provides counter-pressure,
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Preventing the tube walls
From collapsing inward.
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They'll repeat this process
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00:07:40,034 --> 00:07:43,103
With all the tubes which make up
The fuel-line assembly.
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00:07:47,724 --> 00:07:50,379
They clamp each part
Into a fixture,
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00:07:50,482 --> 00:07:53,655
Then pass a laser-measuring
Device over it.
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With utmost precision,
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The laser
Analyses the dimensions
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From five different angles
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00:07:59,448 --> 00:08:02,655
To ensure the part
Meets technical specifications.
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00:08:05,172 --> 00:08:07,413
Next, workers submerge the part
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00:08:07,517 --> 00:08:11,034
In hot water and cleaning
Solution, then rinse twice.
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00:08:11,137 --> 00:08:15,758
This washes away
The lubricant and any dirt.
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00:08:15,862 --> 00:08:18,689
Now the high-tech precision work
Can begin.
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00:08:20,448 --> 00:08:24,137
A robotic laser-cutting system
Finalizes the shape
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00:08:24,241 --> 00:08:27,482
And cuts all the required
Holes and slots.
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00:08:40,965 --> 00:08:45,931
Just a bit of pressure, and
The cut pieces easily pop out.
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00:08:49,862 --> 00:08:54,620
Meanwhile, a stereolithography
Machine makes the fixtures,
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00:08:54,724 --> 00:08:57,758
Which will position the various
Parts of the fuel line together
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00:08:57,862 --> 00:08:58,793
For welding.
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00:08:58,896 --> 00:09:00,724
A computer-guided laser beam
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00:09:00,827 --> 00:09:03,241
Repeatedly flashes
The shape of the fixtures
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00:09:03,344 --> 00:09:04,413
Onto liquid ceramic.
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Each flash solidifies
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A 250th-of-an-inch-thick layer
Of the liquid.
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00:09:14,068 --> 00:09:16,379
Thousands
Of hardened layers later,
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00:09:16,482 --> 00:09:19,517
The weld fixtures
Are fully formed.
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00:09:30,000 --> 00:09:32,931
Welders use
These ceramic fixtures
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00:09:33,034 --> 00:09:37,931
To correctly assembly the
Connecting fuel-line components.
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00:09:38,034 --> 00:09:42,931
Once everything's precisely
In position, the welding begins.
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00:09:48,620 --> 00:09:49,931
For aircraft safety,
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00:09:50,034 --> 00:09:54,103
It's critical that every
Fuel line be leak-free.
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00:09:54,206 --> 00:09:58,103
To test for leaks, they fill it
With nitrogen at high pressure,
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00:09:58,206 --> 00:10:02,241
Submerge it in a water tank,
Then watch closely for bubbles,
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00:10:02,344 --> 00:10:05,517
Which would indicate
Nitrogen escaping.
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00:10:05,620 --> 00:10:07,758
They use nitrogen
Rather than air
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00:10:07,862 --> 00:10:09,413
Because its molecules
Are smaller,
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00:10:09,517 --> 00:10:13,482
Making it possible
To detect smaller leaks.
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00:10:13,586 --> 00:10:15,034
After this,
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00:10:15,137 --> 00:10:18,172
They heat-treat the fuel line
To harden the metal
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00:10:18,275 --> 00:10:20,758
And apply
An anti-corrosion coating.
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00:10:20,862 --> 00:10:22,586
They wrap the fuel line
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00:10:22,689 --> 00:10:25,758
With high-heat-resistant
Foam insulation
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00:10:25,862 --> 00:10:29,344
Secured with high-heat-resistant
Polyester tape.
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00:10:29,448 --> 00:10:32,241
This insulation
Prevents fuel from freezing
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00:10:32,344 --> 00:10:33,689
In cold temperatures.
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00:10:33,793 --> 00:10:34,931
It also blocks heat
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00:10:35,034 --> 00:10:37,827
Coming from other components
Of the aircraft,
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00:10:37,931 --> 00:10:40,862
Keeping the fuel
At a safe working temperature.
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00:10:43,103 --> 00:10:44,931
After a final inspection,
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00:10:45,034 --> 00:10:47,965
The fuel line is ready
To be shipped to the customer.
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It leaves the factory
With a few un-insulated spaces
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00:10:51,103 --> 00:10:53,758
For installation clamps.
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00:10:53,862 --> 00:10:55,827
These areas will get insulated
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00:10:55,931 --> 00:10:59,137
After the fuel line is mounted
In the aircraft.
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Narrator: the apple pie
Is a mouth-watering treat.
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This pie's popularity has been
Centuries in the making.
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00:11:15,310 --> 00:11:17,724
It dates back
To the 14th century,
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00:11:17,827 --> 00:11:21,000
When countries like
England, denmark, and sweden
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Developed
Slightly different versions,
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All leaving fans
Hungry for more.
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Today, apple pie
Is mass-produced to meet demand.
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So you can throw away
Your rolling pin
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And let the folks at the factory
Do all the work.
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To make the filling,
They empty loads of apple slices
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00:11:42,965 --> 00:11:46,275
Into a huge steam-heated kettle.
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These apples
Are a firm and tart type
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And have been organically grown.
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They add honey and apple juice,
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And the apple slices
Simmer in the liquids
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While mixing blades
Gently blend the ingredients.
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And with the slices
Now partially cooked,
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00:12:01,931 --> 00:12:04,931
They spice up the mix with
A generous dash of cinnamon.
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To thicken it
To a syrupy sweetness,
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They add tapioca flour.
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00:12:12,344 --> 00:12:15,758
The blades fold
The dry ingredients into the mix
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00:12:15,862 --> 00:12:18,758
As the apple slices
Continue to cook.
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00:12:18,862 --> 00:12:21,655
The fruit softens
And releases juices.
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00:12:21,758 --> 00:12:24,793
The liquids thicken
To a syrupy consistency.
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When the apple slices
Are lightly browned,
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This filling mix is done.
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00:12:29,517 --> 00:12:31,655
These browned and syrupy slices
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00:12:31,758 --> 00:12:34,724
Are now prepared
And ready for the pastry shell.
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00:12:34,827 --> 00:12:38,000
The shell starts with
Chilled premium-grade butter.
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00:12:38,103 --> 00:12:39,551
It's the creamiest.
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00:12:39,655 --> 00:12:42,103
Organic
And 100% whole-wheat flour
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Is the next ingredient in
This high-fiber pastry recipe.
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They pour
A measured amount of honey
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00:12:51,689 --> 00:12:54,241
Into the pastry mix
To sweeten it.
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00:12:54,344 --> 00:12:56,793
They add ice-cold water.
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It's cold to keep the butter
From melting too quickly,
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00:12:59,758 --> 00:13:03,000
And that means
The crust will turn out flaky.
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00:13:03,103 --> 00:13:04,758
Inside the pastry mixer,
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00:13:04,862 --> 00:13:07,379
A dough hook blends and kneads
The ingredients
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00:13:07,482 --> 00:13:09,862
Until they congeal into dough.
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00:13:09,965 --> 00:13:13,310
The dough is moist,
But not too wet and sticky.
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00:13:13,413 --> 00:13:16,034
Inside an apparatus
Called a sheeter,
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00:13:16,137 --> 00:13:20,034
A mechanized roller
Presses the dough into sheets.
200
00:13:20,137 --> 00:13:22,137
A worker drapes a sheet of dough
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00:13:22,241 --> 00:13:25,206
Over groupings
Of four paper pie plates,
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00:13:25,310 --> 00:13:28,413
Which then move forward
On a carousel.
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00:13:28,517 --> 00:13:32,172
Meanwhile, overhead,
That syrupy apple filling
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00:13:32,275 --> 00:13:35,000
Funnels into a device
Called a depositor.
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00:13:35,103 --> 00:13:39,344
The depositor pumps the filling
Into the uncooked pie crusts
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00:13:39,448 --> 00:13:42,620
As they circle around
On the loop conveyor.
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00:13:42,724 --> 00:13:44,172
This automated system
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00:13:44,275 --> 00:13:47,689
Fills every second grouping
Of crusts right on cue.
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00:13:47,793 --> 00:13:50,655
Now full of sweet fruit,
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00:13:50,758 --> 00:13:52,620
A worker tops them
With more dough,
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00:13:52,724 --> 00:13:55,413
Giving the pies the upper crust.
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00:13:55,517 --> 00:13:58,206
Like a big, revolving
Cookie-cutter,
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00:13:58,310 --> 00:14:01,206
A rolling die punch-cuts
The dough around the pie plates,
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00:14:01,310 --> 00:14:03,172
Separating them,
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00:14:03,275 --> 00:14:06,724
Trimming and crimping the edges
All in one action.
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00:14:08,827 --> 00:14:11,137
Pedestal lifts hoist the pies,
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00:14:11,241 --> 00:14:14,827
And a worker transfers them
To the next conveyor.
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00:14:14,931 --> 00:14:18,206
They finish one group of pies
And then start another,
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00:14:18,310 --> 00:14:22,172
For a continuous cycle
Of pie production.
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00:14:22,275 --> 00:14:25,551
The pies now
Head into the baking zone.
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00:14:30,206 --> 00:14:33,655
Here, workers arrange the pies
On baking sheets.
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00:14:33,758 --> 00:14:36,310
They slice holes
In the top crusts
223
00:14:36,413 --> 00:14:40,103
To vent steam and prevent
Fruit juices from overflowing.
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00:14:43,034 --> 00:14:45,448
They stack
The pie-laden baking sheets
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00:14:45,551 --> 00:14:47,793
On racks in a convection oven.
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00:14:47,896 --> 00:14:51,000
The racks spin
For a more even baking job.
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00:14:52,551 --> 00:14:55,241
They send one apple pie
From each batch
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00:14:55,344 --> 00:14:57,862
To the quality assurance
Department.
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00:14:57,965 --> 00:15:00,448
Here, the inspector
Takes in the aromas
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00:15:00,551 --> 00:15:02,448
From the freshly baked pie.
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00:15:02,551 --> 00:15:04,034
She examines its form
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00:15:04,137 --> 00:15:07,379
And compares it
To an existing perfect pie.
233
00:15:07,482 --> 00:15:10,862
Slicing it confirms
That the crust is flaky.
234
00:15:10,965 --> 00:15:13,482
But does it have
That melt-in-your-mouth flavor?
235
00:15:13,586 --> 00:15:17,103
There's only one way
To verify that.
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00:15:17,206 --> 00:15:20,275
If the quality assurance people
Approve the pie,
237
00:15:20,379 --> 00:15:23,931
Then the whole batch
Moves forward.
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00:15:24,034 --> 00:15:27,448
They flash-freeze the pies,
Then seal them in cellophane.
239
00:15:27,551 --> 00:15:30,517
Suctioning arms
Open cardboard containers,
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00:15:30,620 --> 00:15:33,103
And a worker slides in the pies.
241
00:15:35,172 --> 00:15:38,482
Rollers close
The pre-glued flaps.
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00:15:41,241 --> 00:15:44,344
They produce
More than 2,100 apple pies
243
00:15:44,448 --> 00:15:47,344
Every hour at this factory.
244
00:15:47,448 --> 00:15:51,482
Once the job is done, there
Are big decisions to be made --
245
00:15:51,586 --> 00:15:53,620
Like one scoop or two?
246
00:15:53,724 --> 00:15:56,172
One slice or the whole pie?
247
00:15:58,413 --> 00:16:02,379
Perhaps it's best just to dig in
And decide later.
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Narrator: invented
In 19th century america,
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The radiator brought warmth
To people's lives.
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It made central heating
Possible.
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Before that,
Several fireplaces and stoves
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Were needed to warm a home.
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But with a radiator
In every room,
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One boiler
Could heat an entire house.
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00:16:36,827 --> 00:16:39,172
While the traditional
Cast-iron radiator
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Is still a source of warmth,
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It now competes
With modern steel versions.
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These steel radiators are
Lighter and heat a room faster.
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00:16:48,896 --> 00:16:51,379
They also come
In a range of styles
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And can make
A colorful design statement.
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Production begins with a series
Of powerful punch presses.
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They punch holes
In steel plates,
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And they shape the parts
By pressing the metal onto dies.
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These punched and pressed parts
Are called half pieces.
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They'll be used
To make radiator headers,
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The connector part
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That interlinks
The tubular heating elements.
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The half pieces
Exit the punch-press station
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And slide into the clutch
Of a robotic device.
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00:17:32,206 --> 00:17:35,965
It brings two half pieces
Together in perfect alignment
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And delivers them
To an automated welder,
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Which joins them at the seam.
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00:17:41,068 --> 00:17:44,517
The process is usually shielded
By a protective cover,
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00:17:44,620 --> 00:17:48,793
But it's been lifted
To allow our camera to video it.
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00:17:50,068 --> 00:17:53,620
Next, a press
Pares down the bulging seam.
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00:17:53,724 --> 00:17:56,551
This is called deburring.
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00:17:56,655 --> 00:18:00,068
With perfect timing,
A robot then moves in
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00:18:00,172 --> 00:18:04,206
And transfers the assembly
To a grinding station.
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00:18:06,275 --> 00:18:09,206
Here, it rotates
Between two sanding belts
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00:18:09,310 --> 00:18:12,724
To smooth the seam
To a flawless finish.
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00:18:12,827 --> 00:18:16,379
A circular saw
Spins towards the part
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And slices it in the center
To create two radiator headers.
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These radiator headers
Are now complete.
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00:18:27,965 --> 00:18:30,137
A gripper with rounded claws
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00:18:30,241 --> 00:18:33,206
Transfers six steel tubes
To a welder.
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00:18:35,551 --> 00:18:38,241
The welder
Fuses the tubes to the headers,
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And while the welding
Is being done,
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Another feeder robot ensures
A steady supply of headers.
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00:18:44,413 --> 00:18:46,827
There's one header
For two tubes,
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So three radiator modules
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Are coming together
Simultaneously.
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00:18:51,655 --> 00:18:55,724
Sharp, pinscher-like knives
Sheer down the protruding welds
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00:18:55,827 --> 00:18:59,137
So they're flush
To the rest of the parts.
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00:19:00,758 --> 00:19:05,551
The welded modules then chaff
Against two grinding belts.
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00:19:05,655 --> 00:19:09,344
The process smoothes the seams
Substantially.
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00:19:13,344 --> 00:19:17,793
But this grinding misses the
Spaces between the steel tubes,
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So a smaller sander
Tucks into that location,
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Making the weld smooth
All the way around.
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00:19:28,413 --> 00:19:29,931
Now a test.
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00:19:30,034 --> 00:19:32,827
They immerse
A four-element module in water
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And pump air into it.
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00:19:34,965 --> 00:19:39,344
No bubbles in the water mean no
Leaks, and production continues.
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00:19:39,448 --> 00:19:42,827
They now build the radiator
Section by section.
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00:19:42,931 --> 00:19:46,620
They layer the modules and weld
Them together at the headers.
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This sectional approach
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Allows them to assemble
Radiators of virtually any size.
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00:19:55,758 --> 00:19:57,758
Each radiator is custom-ordered
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00:19:57,862 --> 00:20:02,068
To fit into a specific space and
To meet a specific heating need.
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00:20:02,172 --> 00:20:04,793
Of course,
The larger the radiator,
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The more heat it delivers.
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Here's an inside look
At a steel radiator header.
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With the radiator now complete,
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They repeat the test
Done earlier
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00:20:18,896 --> 00:20:21,517
And confirm
That it's completely leak-proof.
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00:20:21,620 --> 00:20:25,413
They now run an electrical
Charge through the radiator,
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00:20:25,517 --> 00:20:28,137
As they immerse it in a primer.
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00:20:28,241 --> 00:20:31,620
The charge causes the primer
To cling to the metal.
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00:20:31,724 --> 00:20:35,827
Once baked on, it will
Protect it from corrosion.
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00:20:35,931 --> 00:20:39,827
This household radiator
Is ready for a coat of paint.
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The customer
Selects the color beforehand
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00:20:43,000 --> 00:20:47,206
To suit the home's interior
Design and his personal taste.
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They bake on the finish,
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00:20:49,103 --> 00:20:52,448
And once it cools,
They wrap up the job.
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These radiators
Are now homeward bound.
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Fueled by a furnace,
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Hot water will move through them
In a continuous loop,
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And they'll exude warmth.
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That's why
The radiator continues to be
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A nice thing to come home to.
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