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Narrator:
We can't all rub shoulders
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With political greats
And movie stars.
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00:00:55,482 --> 00:00:58,448
But for the price of admission
To a wax attraction,
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00:00:58,448 --> 00:01:01,137
Anyone can mingle
With their wax replicas.
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00:01:01,137 --> 00:01:03,862
These look-alikes
Aren't much for conversation,
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00:01:03,862 --> 00:01:05,965
But the likeness
Can be startling,
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00:01:05,965 --> 00:01:09,275
Thanks to a process
Honed over centuries.
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00:01:13,344 --> 00:01:15,931
Famous faces
Come to life in beeswax,
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00:01:15,931 --> 00:01:18,931
So it's almost like seeing them
In the flesh.
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00:01:18,931 --> 00:01:20,241
But how do they do it?
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00:01:20,241 --> 00:01:22,793
It often starts
With a face-to-face meeting
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00:01:22,793 --> 00:01:24,413
With the subject,
During which they take
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00:01:24,413 --> 00:01:27,413
More than 200 measurements
Of the face alone
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00:01:27,413 --> 00:01:29,413
And still more of the body.
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00:01:29,413 --> 00:01:31,068
Drawing on those measurements
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00:01:31,068 --> 00:01:33,862
And using photos
And additional research,
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00:01:33,862 --> 00:01:37,241
An artist sculpts a clay body
Onto a metal skeleton.
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This clay sculpture
Will be used to make a mold.
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The head, of course,
Receives special attention.
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00:01:43,275 --> 00:01:47,413
They sculpt it in stages,
And this takes about six weeks.
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00:01:47,413 --> 00:01:50,275
To check the symmetry
Of the sculptured face,
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00:01:50,275 --> 00:01:53,689
The artist stretches a wire
From the temple to the chin.
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00:01:53,689 --> 00:01:57,137
She measures it from all angles
And compares the numbers
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00:01:57,137 --> 00:02:00,517
To measurements
Of the actual subject.
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00:02:00,517 --> 00:02:02,965
Every single aspect
Of the clay face
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00:02:02,965 --> 00:02:05,655
Must mirror that
Of the subject's precisely
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00:02:05,655 --> 00:02:09,482
So if it's even slightly off,
She makes adjustments.
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00:02:09,482 --> 00:02:13,310
Here, she redefines the teeth
A bit more.
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00:02:13,310 --> 00:02:16,827
And then
She tweaks the hairline.
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00:02:20,862 --> 00:02:22,896
They're now ready
For the next step --
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00:02:22,896 --> 00:02:24,896
The making of the head mold.
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The worker paints plaster
Onto the sculpture
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00:02:27,620 --> 00:02:29,137
In 14 different sections.
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00:02:29,137 --> 00:02:30,413
This multi-part mold
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00:02:30,413 --> 00:02:32,931
Can be easily removed
From the clay head
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00:02:32,931 --> 00:02:35,103
Once the plaster dries.
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00:02:38,034 --> 00:02:41,034
After the clay head
Has been discarded,
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00:02:41,034 --> 00:02:45,275
They give the reassembled mold
A quick rinse.
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00:02:45,275 --> 00:02:48,448
The wax artist turns the
Plaster head mold upside down
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00:02:48,448 --> 00:02:50,620
And slots it into the wax bench,
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00:02:50,620 --> 00:02:55,620
So named because it secures
The mold during the wax casting.
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00:02:55,620 --> 00:02:58,034
They melt
Blocks of japanese beeswax
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And funnel the liquid wax
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Into the neck
Of the plaster cast.
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00:03:02,206 --> 00:03:04,137
They let it set for an hour,
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00:03:04,137 --> 00:03:07,034
Just long enough
For the wax to solidify
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00:03:07,034 --> 00:03:10,310
And form a thick crust
Around the inside of the cast.
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00:03:10,310 --> 00:03:12,724
The artist
Removes crust at the neck
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00:03:12,724 --> 00:03:15,000
And pours out
The rest of the wax,
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00:03:15,000 --> 00:03:17,758
Leaving
A hollow wax face inside.
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00:03:17,758 --> 00:03:21,965
They set it aside for another
Hour to further solidify.
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00:03:24,724 --> 00:03:26,724
The wax artist
Removes the plaster mold
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00:03:26,724 --> 00:03:30,034
And comes face to face
With the wax creation.
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She examines it thoroughly,
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00:03:32,206 --> 00:03:34,137
Confirming
That the detail from the mold
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00:03:34,137 --> 00:03:36,206
Has been effectively transferred
To the wax
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00:03:36,206 --> 00:03:37,517
And that the wax face
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Is a dead ringer
For the human subject.
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00:03:40,275 --> 00:03:43,241
The team then
Casts the wax figure's hands,
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00:03:43,241 --> 00:03:46,344
And an artist
Matches the subject's skin tone
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Against a chart.
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00:03:48,034 --> 00:03:50,862
She mixes paint
And dabs the brush in it.
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00:03:50,862 --> 00:03:53,275
She then strikes her brush
With another one
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So the paint splatters
Across the hand.
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00:03:55,724 --> 00:03:58,068
She blots up the paint
To blend it in.
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00:03:58,068 --> 00:04:00,724
This technique
Gives the wax a speckled look
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00:04:00,724 --> 00:04:04,482
That mimics human pores.
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00:04:04,482 --> 00:04:08,241
She paints on knuckles, veins,
And distinctive markings
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00:04:08,241 --> 00:04:11,000
To mimic those
On the subject's hands.
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00:04:11,000 --> 00:04:13,034
She gives the nails a manicure
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00:04:13,034 --> 00:04:17,241
To make the hands
Look identical to the subject's.
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00:04:17,241 --> 00:04:19,413
In the hands
Of a skilled artist,
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00:04:19,413 --> 00:04:22,413
These wax hands
Have come to life.
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00:04:22,413 --> 00:04:25,586
As a medical glass eye spins,
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The artist blots on
A very wide pupil first
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00:04:28,862 --> 00:04:32,689
And then paints the periphery
To mimic the person's iris.
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Iris color and pattern
Are unique to the individual,
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00:04:35,862 --> 00:04:38,448
And the artist
Replicates those qualities
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As closely as possible.
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00:04:43,931 --> 00:04:47,310
She glues red silk threads
Onto the whites of the eyes
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To simulate
Broken blood vessels.
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It's another touch of realism.
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They slot the eyes into sockets
In the wax head.
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00:05:00,965 --> 00:05:04,034
Then the wax figure
Is ready for its hair --
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Actual human hair
Matched to the subject's.
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They pierce the wax
With a hot needle
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To insert
Each hair individually.
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00:05:11,827 --> 00:05:14,896
The wax melts
And closes around the hair.
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00:05:14,896 --> 00:05:17,448
This process
Can take four weeks.
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00:05:17,448 --> 00:05:20,068
They also plug in
Brows and lashes
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00:05:20,068 --> 00:05:22,862
And then brush on paint
Like makeup.
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With his face on, the wax figure
Now looks true to life.
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Once completed,
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Wax figures
Get movie-star treatment.
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Their hair is washed
And styled regularly,
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And their clothing
Is routinely dry-cleaned.
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After all, even wax versions
Of famous people
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Have to keep up appearances.
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Narrator:
The unfurling of awnings
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Usually marks
The roll-out of patio season.
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It's a long tradition, one that
Actually dates back centuries.
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Early romans
Were among the first
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00:06:01,655 --> 00:06:04,931
To seek refuge from the hot sun
Under fabric awnings.
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00:06:04,931 --> 00:06:06,827
And today, design innovations
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00:06:06,827 --> 00:06:09,931
Mean there's always
Something new under the sun.
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00:06:12,827 --> 00:06:14,517
With modern mechanisms,
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00:06:14,517 --> 00:06:17,241
Unfolding an awning
Has never been easier.
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00:06:17,241 --> 00:06:21,724
This manual crank system is
Designed for a smooth roll-out.
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00:06:21,724 --> 00:06:23,586
And for extra convenience,
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There are motorized awnings
Operated by remote control.
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Production begins
With the fabric,
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Which comes in a range
Of weather-resistant synthetics.
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The seamstress cuts out patterns
From thick acrylic material
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And sews the pieces together.
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Here she works on
The awning's front valance.
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A roller keeps
The fabric correctly aligned
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00:06:45,413 --> 00:06:48,931
And stops it
From bunching up as she sews.
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00:06:48,931 --> 00:06:52,551
She stitches
A long pocket along the border.
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00:06:52,551 --> 00:06:55,413
A plastic rod will later
Be channeled through it
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To connect the valance
To the awning framework.
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00:07:01,931 --> 00:07:05,413
She traces a scalloped edge
Onto the bottom of the valance
122
00:07:05,413 --> 00:07:09,586
And then carefully
Cuts along the penciled line.
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00:07:09,586 --> 00:07:12,758
With a steady hand, she follows
The outline precisely
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00:07:12,758 --> 00:07:17,068
To give the valance those
Distinctive curves and notches.
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00:07:19,586 --> 00:07:21,827
Workers
Then position the awning panel
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00:07:21,827 --> 00:07:23,517
In front of an aluminum tube.
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00:07:23,517 --> 00:07:25,965
They thread
The pocketed end of the awning
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00:07:25,965 --> 00:07:27,655
Into a channel in the tube
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00:07:27,655 --> 00:07:30,586
And then slide a plastic rod
Into the pocket.
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00:07:30,586 --> 00:07:33,827
This secures the end
Of the fabric to the tube.
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00:07:33,827 --> 00:07:37,482
It takes two people to avoid
Any buckling of the fabric.
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They insert a plastic cap
Into one end of the tube
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00:07:43,482 --> 00:07:47,000
But leave the other end open for
The installation of the motor.
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00:07:47,000 --> 00:07:50,586
They now wind the awning panel
Around the tube,
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Synchronizing their efforts
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00:07:52,068 --> 00:07:54,724
So the tension in the roll
Is equal at both ends.
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00:07:57,172 --> 00:08:00,689
Next, rollers carry
A squared aluminum tube
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00:08:00,689 --> 00:08:02,551
To a circular saw.
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00:08:06,103 --> 00:08:09,241
Once in position,
Arms descend to steady the tube,
140
00:08:09,241 --> 00:08:12,482
And the saw slices it
To the correct length.
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00:08:12,482 --> 00:08:15,275
The cut tube
Will be the carrier bar,
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00:08:15,275 --> 00:08:18,379
An important part
Of the awning framework.
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00:08:18,379 --> 00:08:20,379
A worker
Now builds that framework,
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00:08:20,379 --> 00:08:22,379
Starting with the carrier bar.
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00:08:22,379 --> 00:08:25,344
He slides a bracket
Partway down the tube
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00:08:25,344 --> 00:08:28,793
And uses it
To attach the retractable arms,
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00:08:28,793 --> 00:08:31,620
Securing the assembly
With a heavy-duty steel pin.
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00:08:34,620 --> 00:08:36,827
Two workers
Slide connector pieces
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00:08:36,827 --> 00:08:38,931
Into the grooves
In the drop bar
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00:08:38,931 --> 00:08:40,620
For the valance.
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00:08:40,620 --> 00:08:44,793
Then they raise the bar
And attach the retractable arms.
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00:08:47,241 --> 00:08:51,448
They install a side bearing
In the end of the connector bar.
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00:08:51,448 --> 00:08:55,517
It's one of two that will
Support the awning's main tube.
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00:08:56,413 --> 00:08:59,586
Next up
Is that fabric-wrapped tube.
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00:09:01,655 --> 00:09:03,241
They attach it to the framework
156
00:09:03,241 --> 00:09:05,551
And tuck the other end
Of the awning fabric
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00:09:05,551 --> 00:09:08,206
Into a round slot
In the drop bar.
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00:09:08,206 --> 00:09:10,068
They slide
Another long plastic rod
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Through a pocket
In the fabric to secure it.
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00:09:13,034 --> 00:09:15,689
They're now ready for the motor.
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00:09:15,689 --> 00:09:18,793
It's a tubular model.
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00:09:18,793 --> 00:09:20,137
He attaches a metal bracket
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00:09:20,137 --> 00:09:23,379
For assembling the motor
To the main framework.
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00:09:23,379 --> 00:09:27,103
He then equips the tubular motor
With two plastic rings,
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One at each end.
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00:09:29,206 --> 00:09:31,724
Powered by the motor,
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00:09:31,724 --> 00:09:35,724
These rings will revolve
To open and close the awning.
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00:09:35,724 --> 00:09:39,931
A test confirms
That it's fully operational.
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00:09:43,896 --> 00:09:49,034
He slides the tubular motor into
The open end of the awning tube.
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00:09:51,724 --> 00:09:55,724
He attaches the second side
Bearing to the metal bracket...
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00:09:58,379 --> 00:10:02,206
...And caps
The open end of the drop bar.
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00:10:02,206 --> 00:10:06,689
A few taps with a hammer
Drives it down the shaft.
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00:10:06,689 --> 00:10:09,068
He now tests the awning
174
00:10:09,068 --> 00:10:12,379
To confirm that
Everything unfolds as it should.
175
00:10:15,034 --> 00:10:16,448
He tightens some screws.
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00:10:16,448 --> 00:10:18,655
And when
It's perfectly operational,
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00:10:18,655 --> 00:10:21,103
He'll install the valance.
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00:10:26,862 --> 00:10:31,000
It takes about an hour to
Manufacture a motorized awning,
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00:10:32,931 --> 00:10:36,517
And it should supply
About a decade of shade.
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00:10:50,103 --> 00:10:52,103
Narrator:
Sandwich crackers
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Are one of
Life's little conveniences --
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Crispy wafers with peanut butter
Or cheese spread between them,
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00:10:57,586 --> 00:10:59,586
All wrapped up
In a neat package.
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00:10:59,586 --> 00:11:03,379
In north america, factories have
Been mass-producing these snacks
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00:11:03,379 --> 00:11:05,827
Since the early part
Of the 20th century
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00:11:05,827 --> 00:11:08,344
To satisfy the need to nibble.
187
00:11:12,344 --> 00:11:16,241
Sandwich crackers come in handy
For a quick refuel.
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00:11:16,241 --> 00:11:20,931
Just unwrap and snack while
Continuing on your routine.
189
00:11:20,931 --> 00:11:24,310
They start with the smaller
Ingredients for the dough,
190
00:11:24,310 --> 00:11:28,931
Which include baking soda,
A powdered cheese additive,
191
00:11:28,931 --> 00:11:30,448
And a kind of phosphate,
192
00:11:30,448 --> 00:11:34,275
Which, like the baking soda,
Is a leavening agent.
193
00:11:34,275 --> 00:11:37,103
Next are enzyme tablets
And the yeast,
194
00:11:37,103 --> 00:11:40,379
Two ingredients that will
Later cause the dough to ferment
195
00:11:40,379 --> 00:11:43,034
To give the crackers
Textural strength.
196
00:11:43,034 --> 00:11:44,379
They add water
197
00:11:44,379 --> 00:11:47,862
And thicken the liquefied blend
With a little flour.
198
00:11:47,862 --> 00:11:51,310
This makes it easier
To pump into the next mixer.
199
00:11:51,310 --> 00:11:54,793
This one is a big trough
Full of flour.
200
00:11:54,793 --> 00:11:56,413
They add ice to chill it
201
00:11:56,413 --> 00:11:59,172
And then pipe in
The small-ingredient blend.
202
00:11:59,172 --> 00:12:00,689
Cooling the mix with ice
203
00:12:00,689 --> 00:12:04,379
Preserves the yeast and enzymes
To hold off on fermentation.
204
00:12:04,379 --> 00:12:07,275
If fermentation
Happens too soon,
205
00:12:07,275 --> 00:12:09,620
The dough could turn to mush.
206
00:12:09,620 --> 00:12:12,689
They lower a lid equipped
With three spiraling blades
207
00:12:12,689 --> 00:12:14,310
And set the blades in motion,
208
00:12:14,310 --> 00:12:16,724
Pumping in more water
To augment the moisture
209
00:12:16,724 --> 00:12:19,241
From the melting ice
And small-ingredient blend.
210
00:12:19,241 --> 00:12:24,068
It's now ready for fermentation,
So it's into a warm room
211
00:12:24,068 --> 00:12:27,068
To activate
The yeast and the enzymes.
212
00:12:27,068 --> 00:12:28,655
The dough swells,
213
00:12:28,655 --> 00:12:32,517
And a worker breaks the crust
To release gas.
214
00:12:32,517 --> 00:12:36,862
An automated system tips
The trough of dough into a chute
215
00:12:36,862 --> 00:12:40,172
That takes it one floor down
To the rolling station.
216
00:12:40,172 --> 00:12:43,103
The chemical changes
Caused by fermentation
217
00:12:43,103 --> 00:12:45,448
Have made this dough
Less sticky,
218
00:12:45,448 --> 00:12:47,172
So it can now
Be rolled into sheets
219
00:12:47,172 --> 00:12:50,068
Without adhering
To the equipment.
220
00:12:50,068 --> 00:12:52,344
The dough
Now travels between rollers
221
00:12:52,344 --> 00:12:56,689
That flatten it and squeeze it
To a specific thickness.
222
00:12:56,689 --> 00:13:00,517
The sheets of dough
Exit and accumulate.
223
00:13:00,517 --> 00:13:02,827
When several layers
Have piled up,
224
00:13:02,827 --> 00:13:05,241
The dough is on the move again.
225
00:13:05,241 --> 00:13:06,931
Several layers at a time now,
226
00:13:06,931 --> 00:13:09,206
It moves between
A series of rollers,
227
00:13:09,206 --> 00:13:12,000
Which compress the dough
To its final thickness.
228
00:13:12,000 --> 00:13:14,482
A quick dust with flour,
229
00:13:14,482 --> 00:13:17,448
And the dough
Now goes under a rolling cutter
230
00:13:17,448 --> 00:13:20,310
That scores it
To cracker-size proportions.
231
00:13:20,310 --> 00:13:24,206
The cutter is also spiked with
Pins that puncture the dough.
232
00:13:24,206 --> 00:13:26,793
The holes give the crackers
A dimpled look,
233
00:13:26,793 --> 00:13:28,931
And they have
A practical purpose,
234
00:13:28,931 --> 00:13:33,068
Allowing steam to escape during
Cooking for a crispier snack.
235
00:13:34,241 --> 00:13:35,551
A sprinkle of salt,
236
00:13:35,551 --> 00:13:38,931
And the cracker dough
Now heads into the oven.
237
00:13:38,931 --> 00:13:41,517
This oven
Is more than 65 yards long,
238
00:13:41,517 --> 00:13:43,344
With several heating zones.
239
00:13:43,344 --> 00:13:48,344
The hottest is around
700 degrees fahrenheit.
240
00:13:48,344 --> 00:13:52,482
A roller breaks them
Cleanly along the score lines.
241
00:13:52,482 --> 00:13:56,172
A quick spray with vegetable oil
Adds flavor.
242
00:13:58,034 --> 00:14:01,689
The crackers then transfer
From one conveyer to another
243
00:14:01,689 --> 00:14:04,206
And land in neat stacks.
244
00:14:04,206 --> 00:14:06,344
They head into
An inspection station,
245
00:14:06,344 --> 00:14:08,793
Where workers pick out
Any damaged crackers
246
00:14:08,793 --> 00:14:11,965
And adjust the alignment
Of the shingled rows
247
00:14:11,965 --> 00:14:15,965
So it's a smooth transition
As the crackers move into lanes.
248
00:14:15,965 --> 00:14:17,275
Down the line,
249
00:14:17,275 --> 00:14:20,103
Workers pull off samples
To weigh them.
250
00:14:20,103 --> 00:14:22,413
Then equipment
Flips the crackers upright,
251
00:14:22,413 --> 00:14:25,758
Positioning them
To enter the filling line.
252
00:14:25,758 --> 00:14:28,310
The peanut-butter filling
Is ready and kept warm
253
00:14:28,310 --> 00:14:31,758
So it's smooth and creamy enough
To pump.
254
00:14:31,758 --> 00:14:33,241
The top crackers
255
00:14:33,241 --> 00:14:36,206
Now head downward
In a precise configuration,
256
00:14:36,206 --> 00:14:37,620
While below,
257
00:14:37,620 --> 00:14:41,068
The bottom crackers whiz by
The peanut-butter depositor.
258
00:14:41,068 --> 00:14:43,896
It pumps
A dollop of peanut butter
259
00:14:43,896 --> 00:14:45,931
Onto each bottom cracker.
260
00:14:51,379 --> 00:14:53,379
The peanut-butter-covered
Bottom crackers
261
00:14:53,379 --> 00:14:56,241
Now move forward to meet up
With the top crackers.
262
00:14:57,586 --> 00:14:59,827
And again, with perfect timing,
263
00:14:59,827 --> 00:15:03,655
The top crackers land on the
Bottom ones in exact alignment.
264
00:15:03,655 --> 00:15:07,793
Equipment separates them
Into sets of three
265
00:15:07,793 --> 00:15:09,517
As they head into packaging.
266
00:15:09,517 --> 00:15:11,862
Plastic wrap envelops them,
267
00:15:11,862 --> 00:15:15,379
And a heat sealer
Cuts and closes the packets.
268
00:15:17,413 --> 00:15:19,482
Suctioning arms
Collect the packets
269
00:15:19,482 --> 00:15:22,482
And transfer them
To cardboard boxes.
270
00:15:22,482 --> 00:15:27,103
From mixing to packaging,
It has taken about 24 hours
271
00:15:27,103 --> 00:15:29,758
To produce a packet
Of sandwich crackers.
272
00:15:29,758 --> 00:15:32,000
Once it reaches
A hungry snacker,
273
00:15:32,000 --> 00:15:34,965
It will be gone
In no time at all.
274
00:15:50,379 --> 00:15:54,137
Narrator: a traditional drinking
Vessel typically used for beer,
275
00:15:54,137 --> 00:15:56,068
A tankard often has a hinged lid
276
00:15:56,068 --> 00:15:58,517
You raise and lower
With a thumb lever.
277
00:15:58,517 --> 00:16:01,034
Dating back
To 15th-century england,
278
00:16:01,034 --> 00:16:04,724
They were initially made
Of wood, then silver or pewter.
279
00:16:04,724 --> 00:16:09,793
The tradition of hand-crafting
Pewter tankards continues today.
280
00:16:09,793 --> 00:16:13,172
This manufacturer makes
Pewter tankards in many styles,
281
00:16:13,172 --> 00:16:14,517
One of which
282
00:16:14,517 --> 00:16:17,310
Has the legend of the
King's shilling engraved on it
283
00:16:17,310 --> 00:16:20,655
And a reproduction
Of a shilling coin from 1816
284
00:16:20,655 --> 00:16:22,620
Encased in the glass bottom.
285
00:16:22,620 --> 00:16:26,689
Every step is done by hand,
Beginning with a sheet of pewter
286
00:16:26,689 --> 00:16:29,034
That's just
1/14 of an inch thick.
287
00:16:29,034 --> 00:16:31,931
Using a punch press,
They cut it into the shape
288
00:16:31,931 --> 00:16:35,551
Required
To form the tankard's body.
289
00:16:35,551 --> 00:16:38,965
Next, they place the pewter on
A copper plate that has on it,
290
00:16:38,965 --> 00:16:42,620
In raised lettering, the story
Of the king's shilling.
291
00:16:42,620 --> 00:16:45,310
They feed this
In between two rollers
292
00:16:45,310 --> 00:16:46,827
That press
The lettering into the pewter.
293
00:16:46,827 --> 00:16:50,000
A soft metal, pewter
Is composed mostly of tin,
294
00:16:50,000 --> 00:16:52,758
Along with smaller quantities
Of two other metals --
295
00:16:52,758 --> 00:16:55,931
Antimony and copper.
296
00:16:55,931 --> 00:16:58,724
Next, a metalsmith takes over.
297
00:16:58,724 --> 00:17:00,482
He manually bends the pewter
298
00:17:00,482 --> 00:17:03,620
Into the cylindrical shape
Of the tankard's body.
299
00:17:06,448 --> 00:17:08,137
He brushes on flux,
300
00:17:08,137 --> 00:17:11,482
A chemical which helps
Molten metal flow more easily.
301
00:17:11,482 --> 00:17:13,310
Then, with a soldering tool,
302
00:17:13,310 --> 00:17:16,586
He fuses the edges of the body
With pure tin solder.
303
00:17:16,586 --> 00:17:19,862
Traditionally, both the pewter
And solder contained lead,
304
00:17:19,862 --> 00:17:22,896
But today, both are lead-free.
305
00:17:22,896 --> 00:17:26,862
Next, the metalsmith slides
The cylinder onto a steel form
306
00:17:26,862 --> 00:17:29,344
And hammers
The solder seam flat,
307
00:17:29,344 --> 00:17:31,862
Rendering it
Virtually invisible.
308
00:17:34,103 --> 00:17:37,068
Now a specialized tradesman
Known as a pewter spinner
309
00:17:37,068 --> 00:17:39,448
Slips the body onto a lathe.
310
00:17:39,448 --> 00:17:41,827
As the lathe rotates,
311
00:17:41,827 --> 00:17:45,241
He uses a series of tools
To smooth the surface,
312
00:17:45,241 --> 00:17:47,379
Trim excess
Off the top and bottom,
313
00:17:47,379 --> 00:17:51,241
And turn the top edge over
To form a lip.
314
00:17:51,241 --> 00:17:55,275
Next, a buffer uses pumice
And a cloth buffing wheel
315
00:17:55,275 --> 00:17:59,482
To remove imperfections and
Make the surface silky-smooth.
316
00:17:59,482 --> 00:18:02,448
Meanwhile,
In the casting department,
317
00:18:02,448 --> 00:18:05,517
They heat solid pewter
To 465 degrees fahrenheit
318
00:18:05,517 --> 00:18:09,965
Then carefully pour the now
Molten metal into a rubber mold.
319
00:18:09,965 --> 00:18:14,275
Inside are several cavities
For shillings and large rings.
320
00:18:14,275 --> 00:18:17,448
After about 30 seconds,
The pewter solidifies,
321
00:18:17,448 --> 00:18:19,448
And the parts can come out.
322
00:18:19,448 --> 00:18:21,551
To make the tankard's handle,
323
00:18:21,551 --> 00:18:25,172
The casters pour molten pewter
Into a steel mold,
324
00:18:25,172 --> 00:18:27,586
Then tilt the mold
In all directions
325
00:18:27,586 --> 00:18:29,551
To spread
The rapidly setting metal
326
00:18:29,551 --> 00:18:31,448
All along
The wall of the cavity.
327
00:18:31,448 --> 00:18:34,965
This makes the handle hollow
And therefore lightweight.
328
00:18:34,965 --> 00:18:37,551
They grind the ends
On an abrasive belt
329
00:18:37,551 --> 00:18:40,965
So the handle will fit flush
Against the tankard body.
330
00:18:40,965 --> 00:18:43,103
Another worker, meanwhile,
331
00:18:43,103 --> 00:18:46,103
Assembles
The tankard's glass base.
332
00:18:46,103 --> 00:18:48,965
A glass disk,
A shilling, a ring,
333
00:18:48,965 --> 00:18:50,586
Then a second glass disk.
334
00:18:50,586 --> 00:18:52,241
The ring acts as a spacer,
335
00:18:52,241 --> 00:18:55,275
Creating enough of a gap
Between the glass disks
336
00:18:55,275 --> 00:18:58,275
To allow the coin
To slide around.
337
00:18:58,275 --> 00:19:01,344
He applies waterproof glue
Around the perimeter
338
00:19:01,344 --> 00:19:03,517
To adhere everything together.
339
00:19:03,517 --> 00:19:07,517
Next, he places this shilling
Sandwich in a pewter base
340
00:19:07,517 --> 00:19:12,000
And adheres a second ring
To hide the glue.
341
00:19:14,827 --> 00:19:16,482
Back to the metalsmith now.
342
00:19:16,482 --> 00:19:21,482
He dabs the tankard's body onto
A pad impregnated with flux.
343
00:19:21,482 --> 00:19:24,827
He then solders together
The body and base.
344
00:19:29,137 --> 00:19:31,103
Once the parts are attached,
345
00:19:31,103 --> 00:19:34,000
A final buffing
With a soft felt wheel.
346
00:19:35,448 --> 00:19:39,931
Next, the metalsmith
Dips the handle ends in flux
347
00:19:39,931 --> 00:19:42,793
And solders them to the body.
348
00:19:42,793 --> 00:19:44,896
To avoid
Scorching the tankard's surface,
349
00:19:44,896 --> 00:19:47,586
This time he uses
A bismuth-and-tin solder,
350
00:19:47,586 --> 00:19:50,275
Which requires
A lower temperature to melt.
351
00:19:51,793 --> 00:19:55,172
The tankard
Is now fully constructed.
352
00:19:55,172 --> 00:19:59,413
They clean it in a dishwasher,
Then shine it up.
353
00:19:59,413 --> 00:20:01,586
First,
The polisher does the inside,
354
00:20:01,586 --> 00:20:03,758
Using a rough-grid
Abrasive compound,
355
00:20:03,758 --> 00:20:06,034
Producing a matte finish.
356
00:20:06,034 --> 00:20:10,034
Then he polishes the outside,
Using a finer-grid compound.
357
00:20:10,034 --> 00:20:13,137
This produces
A contrasting mirror finish.
358
00:20:13,137 --> 00:20:16,068
In 18th- and 19th-century
England,
359
00:20:16,068 --> 00:20:19,206
A volunteer
For army or naval service
360
00:20:19,206 --> 00:20:21,896
Accepted a shilling as a bonus
Upon signing up.
361
00:20:21,896 --> 00:20:24,551
However,
Volunteers were in short supply,
362
00:20:24,551 --> 00:20:27,344
So recruiters are said
To have visited pubs
363
00:20:27,344 --> 00:20:28,758
And slipped shillings
364
00:20:28,758 --> 00:20:31,517
Into the pewter tankards
Of inebriated men,
365
00:20:31,517 --> 00:20:33,172
Who, upon their last sip,
366
00:20:33,172 --> 00:20:35,827
Discovered they'd been
Duped into serving.
367
00:20:35,827 --> 00:20:37,482
It may well be a myth,
368
00:20:37,482 --> 00:20:41,517
But it still makes a darn good
Story to share over a pint.
369
00:20:51,034 --> 00:20:53,896
If you have any comments
About the show,
370
00:20:53,896 --> 00:20:56,000
Or if you'd like to
Suggest topics for future shows,
371
00:20:56,000 --> 00:20:58,344
Drop us a line at...
372
00:21:00,827 --> 00:21:03,896
--captions by vitac--
Www.Vitac.Com
373
00:21:03,896 --> 00:21:06,862
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