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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:
Today on "How it's made"...
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00:00:26,000 --> 00:00:28,000
Witness samples.
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00:00:32,172 --> 00:00:34,000
Pressure washers.
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00:00:38,137 --> 00:00:39,931
Bee hives.
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And cast iron cookers.
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00:00:53,310 --> 00:00:56,068
Special coatings applied
To optical glass
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00:00:56,068 --> 00:00:58,310
Change the way
It transmits light,
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00:00:58,310 --> 00:01:00,862
So that it becomes more
Or less reflective
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00:01:00,862 --> 00:01:03,344
Or even electrically conductive.
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00:01:03,344 --> 00:01:06,172
Testing beforehand on little
Glass discs
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00:01:06,172 --> 00:01:08,689
Known as witness samples
Bears witness
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00:01:08,689 --> 00:01:10,793
To the quality of the coatings.
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00:01:14,551 --> 00:01:17,620
With witness samples,
It's all about the optics.
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00:01:17,620 --> 00:01:19,793
They must be flawless
On the surface
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00:01:19,793 --> 00:01:21,275
In order for optical coatings
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00:01:21,275 --> 00:01:25,724
To be applied
And properly evaluated.
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00:01:25,724 --> 00:01:27,965
A diamond drill cuts
Solid cylinders
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00:01:27,965 --> 00:01:30,379
Out of a block of optical glass.
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00:01:30,379 --> 00:01:32,655
Each one is an inch in diameter.
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00:01:34,793 --> 00:01:38,862
A worker glues the cylinders
Together to a glass plate.
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00:01:38,862 --> 00:01:40,655
This keeps them in a tight pack
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00:01:40,655 --> 00:01:44,482
So that they can be
Cut into discs.
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00:01:44,482 --> 00:01:49,206
The worker suspends the cylinder
Pack above a grid of piano wire.
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00:01:49,206 --> 00:01:52,965
The wire moves back and forth
To grind a silicon carbide
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00:01:52,965 --> 00:01:55,551
Slurry into the glass cylinders,
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00:01:55,551 --> 00:01:59,068
To cut them at intervals
About a tenth of an inch.
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00:01:59,068 --> 00:02:03,586
The sliced cylinders then go
Into a hot bath for 15 minutes.
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00:02:03,586 --> 00:02:05,586
This dissolves the glue.
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00:02:07,896 --> 00:02:10,137
The glass discs separate,
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00:02:10,137 --> 00:02:12,482
And are released
From the base plate.
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00:02:15,517 --> 00:02:18,931
The worker rinses each disc
Individually to remove
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00:02:18,931 --> 00:02:21,034
Any remaining glue.
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00:02:21,034 --> 00:02:24,206
She sets the discs
On a cardboard surface to dry.
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00:02:27,482 --> 00:02:29,344
Once loaded into slots,
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00:02:29,344 --> 00:02:33,103
A robot collects the disc
Using suctioning fingers.
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00:02:35,172 --> 00:02:38,517
The robot inserts a disc
Into a suctioning clamp,
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00:02:38,517 --> 00:02:42,379
And nudges it to further
Establish it there.
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00:02:42,379 --> 00:02:46,068
A diamond cutting wheel meets up
With the disc held in the clamp,
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00:02:46,068 --> 00:02:49,965
And machines a bevel
Into the disc.
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00:02:49,965 --> 00:02:54,551
A technician places plastic
Carriers with disc-size slots
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00:02:54,551 --> 00:02:56,655
On a pad in a polishing machine.
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00:02:56,655 --> 00:02:59,827
The carrier's gear-style teeth
Intermesh with teeth
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00:02:59,827 --> 00:03:02,517
On the machine's
Hub and outer frame.
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00:03:02,517 --> 00:03:07,034
She transfers the glass discs
To the slots in the carriers.
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00:03:07,034 --> 00:03:09,310
The upper polishing pad
Descends,
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00:03:09,310 --> 00:03:11,137
And the carriers rotate
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00:03:11,137 --> 00:03:15,275
As the pads
Buff the discs on both sides.
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00:03:15,275 --> 00:03:18,586
The glass goes from frosty
To transparent.
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00:03:18,586 --> 00:03:20,827
She rinses off
The polishing compound.
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00:03:23,620 --> 00:03:27,068
Then, for an intensive cleaning,
An automated rack system
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00:03:27,068 --> 00:03:30,758
Lowers the discs
Into a series of tubs.
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00:03:30,758 --> 00:03:33,206
In the first one,
They undergo another rinse.
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00:03:35,413 --> 00:03:38,000
In the next tub,
A special cleaning solution
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Has been added to water --
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One that won't leave
A soapy residue.
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Sound waves bubble
Through this washtub
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To gently scrub the disc.
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00:03:48,344 --> 00:03:51,655
After another rinse,
It's into a dryer.
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00:03:51,655 --> 00:03:54,620
It blows hot air onto the glass
Samples to dry them
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00:03:54,620 --> 00:03:56,206
Without leaving streaks.
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00:03:59,517 --> 00:04:01,413
A worker tests
One witness sample
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00:04:01,413 --> 00:04:03,724
From every production run.
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00:04:03,724 --> 00:04:06,620
Both a camera and a laser scan
The sample,
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00:04:06,620 --> 00:04:09,448
And a computer analyzes
The information.
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00:04:11,689 --> 00:04:14,413
The witness samples are now
Ready for coating.
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The technician loads the sample
Into fixtures
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00:04:18,896 --> 00:04:20,517
In the coating machine.
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00:04:20,517 --> 00:04:22,034
Using a lift,
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00:04:22,034 --> 00:04:25,827
He elevates the fixtures to
The top of the coating chamber.
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00:04:25,827 --> 00:04:28,931
He inserts small crucibles
Of coating material
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In the base
Of the coating machine.
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00:04:31,241 --> 00:04:34,034
The materials are metal
Oxide compounds
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00:04:34,034 --> 00:04:37,275
That make glass less reflective.
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00:04:37,275 --> 00:04:40,965
For demonstration purposes,
The chamber remains open,
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00:04:40,965 --> 00:04:43,551
And he sets the fixtures
In motion.
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00:04:43,551 --> 00:04:46,448
As they spin, the coating
Materials will be heated
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To the point of evaporation,
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Forming a cloud that
Will condense on the samples
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At a certain thickness.
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The technician closes the
Chamber, and the process begins.
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An intense electron beam heats
The coating materials.
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00:05:04,448 --> 00:05:07,000
Once the coatings have cured
To the glass,
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They can be evaluated.
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00:05:09,310 --> 00:05:12,586
A computerized machine
Takes measurements to confirm
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00:05:12,586 --> 00:05:16,482
That the reflective properties
Are correct.
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The witness sample
Has done its job,
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00:05:18,931 --> 00:05:21,448
And the coatings are ready
For production.
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Narrator:
Armed with a pressure washer,
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00:05:35,689 --> 00:05:37,379
It's easy to get carried away
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00:05:37,379 --> 00:05:39,379
And go on an outdoor
Cleaning spree.
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It can be used to wash down
The driveway,
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00:05:43,517 --> 00:05:45,482
Clean the siding on the house,
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Remove dirt from the deck,
Wash the car, and much more.
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A pressure washer contains
An electric motor,
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Which drives a pump
That propels water
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00:05:58,724 --> 00:06:00,655
At high pressure down a hose,
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00:06:00,655 --> 00:06:03,034
And out
A trigger-operated nozzle.
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00:06:04,965 --> 00:06:07,000
The machine's mechanics
And electronics
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00:06:07,000 --> 00:06:10,137
Are hidden from view
By a two-part plastic cover.
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00:06:13,793 --> 00:06:15,965
The two main parts
Of the electric motor
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00:06:15,965 --> 00:06:18,413
Are the rotor and the stator.
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00:06:18,413 --> 00:06:20,793
To make the stator,
This automated station
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00:06:20,793 --> 00:06:24,172
Winds 1,640 feet
Of copper wire --
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Or, for certain models,
Aluminum wire --
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00:06:26,689 --> 00:06:28,758
Then inserts the winding
Into the slots
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Of a steel cylindrical frame.
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00:06:33,689 --> 00:06:36,413
The rotor is also
A steel cylinder.
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00:06:36,413 --> 00:06:38,103
It will sit inside the stator,
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00:06:38,103 --> 00:06:41,793
Attached at one end
To the motor shaft.
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00:06:41,793 --> 00:06:43,896
When the power washer
Is turned on,
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The a/c current passing
Through the stator winding
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00:06:46,931 --> 00:06:49,827
Creates
A rotating magnetic field.
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00:06:49,827 --> 00:06:52,655
This turns the rotor,
Driving the motor shaft,
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Which drives the pump.
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At the next station, a worker
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Prepares the stator's
Electrical connections,
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00:06:58,965 --> 00:07:01,827
Securing them with a cable tie.
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00:07:01,827 --> 00:07:05,413
She contains and protects
The copper winding with tape.
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00:07:05,413 --> 00:07:09,758
Then, the stator moves on
To receive the rotor.
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00:07:09,758 --> 00:07:11,379
On another assembly line,
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00:07:11,379 --> 00:07:14,586
A worker mates the guide
For the motor's three pistons
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00:07:14,586 --> 00:07:17,586
With the aluminum cylinder head
And the motor,
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00:07:17,586 --> 00:07:20,379
Now in an oil-filled
Aluminum housing.
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00:07:20,379 --> 00:07:23,931
The motor drives a rubber plate
Which moves the pistons,
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00:07:23,931 --> 00:07:26,206
Which move various
Internal components
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00:07:26,206 --> 00:07:28,137
That pressurize the water.
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00:07:30,689 --> 00:07:33,482
A worker places a new stator
On the carrier
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00:07:33,482 --> 00:07:36,344
To prepare it
For motor assembly.
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00:07:36,344 --> 00:07:40,862
Then on the pumpset, he installs
A plastic water inlet pipe.
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00:07:40,862 --> 00:07:43,241
He places the bottom section
Of the motor housing
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00:07:43,241 --> 00:07:44,793
Around the new stator
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00:07:44,793 --> 00:07:46,862
That's heading
To the motor assembly.
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00:07:48,689 --> 00:07:52,448
The automated handling system
Removes the completed pumpset
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00:07:52,448 --> 00:07:54,620
And transfers it
To another carrier,
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00:07:54,620 --> 00:07:57,517
Which transports it
To the final assembly line.
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00:07:59,551 --> 00:08:01,517
A worker installs a rubber tube,
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00:08:01,517 --> 00:08:04,344
Which keeps water
Out of the motor.
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00:08:04,344 --> 00:08:07,551
He pulls the stator electrical
Connections through it,
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00:08:07,551 --> 00:08:10,241
Then installs a watertight
Plastic box
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00:08:10,241 --> 00:08:14,206
Containing all the electronics
And the power switch.
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00:08:14,206 --> 00:08:16,655
He plugs the power cord
Into the circuit board
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00:08:16,655 --> 00:08:18,310
Inside the box,
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00:08:18,310 --> 00:08:21,034
Then screws down
The stator's ground wire.
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00:08:22,827 --> 00:08:26,241
A worker connects both
Power and water.
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00:08:26,241 --> 00:08:28,896
Then a test machine
Automatically runs the unit
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00:08:28,896 --> 00:08:30,517
Through all the functions.
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00:08:33,689 --> 00:08:36,448
Remember that two-part
Plastic cover?
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00:08:36,448 --> 00:08:38,724
An injection-molding machine
Makes the parts
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00:08:38,724 --> 00:08:44,241
In separate operations --
A yellow top and a black bottom.
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00:08:44,241 --> 00:08:47,413
The automated handling system
Extracts the part
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00:08:47,413 --> 00:08:51,137
And places them on a carrier
Headed to the pad printer.
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00:08:54,862 --> 00:08:57,586
The printer stamps
The model name in quick-dry ink
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00:08:57,586 --> 00:08:59,379
On the top cover.
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00:08:59,379 --> 00:09:01,758
Workers will later attach
The company name
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00:09:01,758 --> 00:09:03,448
To the front of the machine.
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00:09:05,689 --> 00:09:09,172
The next station takes the top
To the final assembly line,
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00:09:09,172 --> 00:09:12,344
Where the handling system
Turns it upside down
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00:09:12,344 --> 00:09:15,068
And places the pumpset inside.
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00:09:17,758 --> 00:09:20,413
At the next stop,
A worker installs a guide
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00:09:20,413 --> 00:09:24,827
For the machine's water hose,
Then positions the bottom cover.
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00:09:26,310 --> 00:09:29,517
An automated machine screws
The covers together.
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00:09:32,827 --> 00:09:35,862
Another worker installs
A galvanized-steel axle
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00:09:35,862 --> 00:09:37,896
And two rugged plastic wheels.
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00:09:41,275 --> 00:09:44,000
He applies a decal
With safety instructions,
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00:09:44,000 --> 00:09:45,655
Plastic wheel covers,
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00:09:45,655 --> 00:09:51,310
And a 33-foot-long rubber water
Hose wound on a plastic reel.
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00:09:51,310 --> 00:09:54,413
The pressure washer then
Goes off to the packaging area,
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00:09:54,413 --> 00:09:57,000
Where it's boxed with
The handle, accessories,
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00:09:57,000 --> 00:09:58,655
And detergents.
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00:10:00,586 --> 00:10:02,482
In the product-development
Stage,
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00:10:02,482 --> 00:10:05,862
A sound engineer tests
The prototype at a sound lab
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00:10:05,862 --> 00:10:08,551
To make sure the noise
The pressure washer emits
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00:10:08,551 --> 00:10:10,758
Isn't too loud and shrill.
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00:10:10,758 --> 00:10:14,586
He runs the machine
Amid nine microphones,
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00:10:14,586 --> 00:10:18,517
Each positioned three feet away
In a different direction.
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00:10:18,517 --> 00:10:22,586
To pass the test, the noise
Must be a low bass-range hum.
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00:10:25,379 --> 00:10:27,310
To operate the pressure washer,
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00:10:27,310 --> 00:10:30,827
The user connects a garden hose
To the water-inlet pipe,
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00:10:30,827 --> 00:10:33,344
Connects the handle
To the machine's hose,
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00:10:33,344 --> 00:10:38,000
Turns on the water and power,
Then pulls the trigger to spray.
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Narrator: for centuries,
Beekeepers used dome baskets
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Called skeps as hives.
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00:10:53,241 --> 00:10:56,482
But to harvest the honey,
The skeps had to be destroyed.
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00:10:56,482 --> 00:10:59,655
In the mid-19th century,
They came up with a box hive
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00:10:59,655 --> 00:11:01,379
With removable frames.
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00:11:01,379 --> 00:11:03,758
Bees built their honeycombs
On the frames,
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00:11:03,758 --> 00:11:07,344
Which beekeepers could remove
Without destroying them.
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00:11:09,586 --> 00:11:12,482
A hive is home
For thousands of bees.
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00:11:12,482 --> 00:11:14,896
The queen resides
On the bottom level.
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00:11:14,896 --> 00:11:16,793
Worker bees have the run
Of the house
193
00:11:16,793 --> 00:11:18,655
And move around
Making honey.
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00:11:20,862 --> 00:11:22,344
Construction of this beehive
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00:11:22,344 --> 00:11:25,137
Starts with the inner
Cover of the hive.
196
00:11:25,137 --> 00:11:27,620
A worker cuts a piece
Of pine plywood
197
00:11:27,620 --> 00:11:29,827
To the correct dimensions.
198
00:11:29,827 --> 00:11:34,172
He places the plywood in a jig,
And carves an oblong-shaped hole
199
00:11:34,172 --> 00:11:37,275
Into it
Using a hand-held router.
200
00:11:37,275 --> 00:11:40,103
This hole will provide
Both ventilation
201
00:11:40,103 --> 00:11:42,413
And an upper exit point
For the bees.
202
00:11:45,000 --> 00:11:48,034
For the body of the hive,
He uses cypress wood
203
00:11:48,034 --> 00:11:52,310
Because it's resistant
To insect damage and rot.
204
00:11:52,310 --> 00:11:53,655
With a table saw,
205
00:11:53,655 --> 00:11:56,137
The worker trims
One edge of the wall panel,
206
00:11:56,137 --> 00:11:58,310
Taking it from rough to smooth.
207
00:12:00,379 --> 00:12:03,103
He cuts a little more off
The other side of the panel
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00:12:03,103 --> 00:12:05,275
To make it the correct width.
209
00:12:05,275 --> 00:12:08,517
This gives this side
A clean edge, too.
210
00:12:12,586 --> 00:12:15,655
A circular saw automatically
Carves a drawer pull
211
00:12:15,655 --> 00:12:17,137
Into the panel.
212
00:12:17,137 --> 00:12:20,172
This pull is known
As a handhold.
213
00:12:20,172 --> 00:12:22,931
There will be handholds
On all sides of the hive box
214
00:12:22,931 --> 00:12:24,413
For easy access.
215
00:12:28,827 --> 00:12:31,137
The panel, front-side down now,
216
00:12:31,137 --> 00:12:34,827
Rides a conveyer
To the next operation.
217
00:12:34,827 --> 00:12:37,965
Numerous saws cut long grooves
Along the bottom
218
00:12:37,965 --> 00:12:40,137
And the sides of the panel.
219
00:12:40,137 --> 00:12:42,517
This creates joints
That will fit the hive panels
220
00:12:42,517 --> 00:12:44,068
Tightly together.
221
00:12:47,586 --> 00:12:49,517
A worker stacks the panels
To await
222
00:12:49,517 --> 00:12:51,413
The next stage of assembly.
223
00:12:54,586 --> 00:12:56,241
Meanwhile,
At another station,
224
00:12:56,241 --> 00:12:58,551
The next worker notches
Pieces of wood
225
00:12:58,551 --> 00:13:01,344
To make a part
Called the entrance reducer.
226
00:13:02,620 --> 00:13:04,827
It's the doorway to the hive.
227
00:13:04,827 --> 00:13:06,724
It will allow the bees to enter,
228
00:13:06,724 --> 00:13:09,310
But keep intruders
Like mice out.
229
00:13:11,000 --> 00:13:13,551
He makes a wide entranceway
On one side
230
00:13:13,551 --> 00:13:15,620
And a narrower one on the other.
231
00:13:18,172 --> 00:13:21,172
A worker then cuts
Tongue-and-groove joints in wood
232
00:13:21,172 --> 00:13:24,689
That will be used for the bottom
And the cover of the beehive.
233
00:13:28,310 --> 00:13:32,206
Moving to the beehive stand,
He cuts a 45-degree angle
234
00:13:32,206 --> 00:13:34,793
On both sides
Of a piece of wood.
235
00:13:34,793 --> 00:13:39,448
This part will serve
As a landing strip for the bees.
236
00:13:39,448 --> 00:13:42,068
A team slices a sheet
Of galvanized steel
237
00:13:42,068 --> 00:13:43,689
To the desired length.
238
00:13:47,344 --> 00:13:48,689
Using a press brake,
239
00:13:48,689 --> 00:13:52,793
A worker bends the edges
Of the sheet against a die.
240
00:13:52,793 --> 00:13:56,103
This forms a cover that will fit
Over the roof of the hive.
241
00:14:00,448 --> 00:14:01,965
At another station,
242
00:14:01,965 --> 00:14:05,517
A worker pipes glue along the
Inside groove of the roof frame.
243
00:14:08,310 --> 00:14:10,413
He arranges
The tongue-and-groove boards
244
00:14:10,413 --> 00:14:11,793
In a tight interlock
245
00:14:11,793 --> 00:14:14,793
And inserts them in
The glued groove of the frame.
246
00:14:17,724 --> 00:14:20,413
He applies pressure to further
Entrench them,
247
00:14:20,413 --> 00:14:25,551
And drives nails into the wood
Frame to secure the boards.
248
00:14:25,551 --> 00:14:29,275
He fits the metal
Cladding over the wood roof.
249
00:14:29,275 --> 00:14:31,344
It's been made
To fit like a glove,
250
00:14:31,344 --> 00:14:33,413
So it takes a bit
Of maneuvering.
251
00:14:36,448 --> 00:14:39,448
He now joins four of the panels
To make a box.
252
00:14:39,448 --> 00:14:41,758
And thanks to
The grooved joints,
253
00:14:41,758 --> 00:14:44,586
The corners fit together neatly.
254
00:14:44,586 --> 00:14:49,000
He glues them, and then secures
The joints with nails.
255
00:14:49,000 --> 00:14:51,068
This assembly will be
The brood box
256
00:14:51,068 --> 00:14:53,000
That houses the queen bee.
257
00:14:55,448 --> 00:14:58,965
He now builds the frame for the
Inner cover of the hive ceiling.
258
00:15:01,241 --> 00:15:03,379
He applies glue to the frame.
259
00:15:05,862 --> 00:15:07,862
He inserts the cover
And pounds it
260
00:15:07,862 --> 00:15:09,827
To drive it further into place.
261
00:15:12,413 --> 00:15:15,241
It's now time
For the final assembly.
262
00:15:15,241 --> 00:15:18,034
They install the floor
On the stand and position
263
00:15:18,034 --> 00:15:20,586
The entranceway piece
At the front.
264
00:15:20,586 --> 00:15:22,586
The brood box is next.
265
00:15:22,586 --> 00:15:25,517
They hang frames with starter
Honeycomb beeswax
266
00:15:25,517 --> 00:15:27,137
On the inner ledges.
267
00:15:30,827 --> 00:15:34,000
They place a wire mesh excluder
Over the brood box
268
00:15:34,000 --> 00:15:37,137
To keep the queen bee
Out of the upper chamber.
269
00:15:37,137 --> 00:15:40,000
The smaller worker bees
Will be able to move through it
270
00:15:40,000 --> 00:15:44,241
To deposit honey
On more honeycomb frames.
271
00:15:44,241 --> 00:15:46,344
They stack the inner cover
On top,
272
00:15:46,344 --> 00:15:48,896
Followed by the metal-clad roof.
273
00:15:48,896 --> 00:15:53,448
This empty hive will soon be
A-buzz with activity and honey.
274
00:16:03,241 --> 00:16:05,206
Narrator: humans have been
Cooking over fire
275
00:16:05,206 --> 00:16:08,586
With iron implements
Since, well, the iron age.
276
00:16:08,586 --> 00:16:13,137
Today, most outdoor cooking
Requires some type of appliance.
277
00:16:13,137 --> 00:16:16,068
And because of iron's
Superior ability to retain
278
00:16:16,068 --> 00:16:17,862
And diffuse heat evenly,
279
00:16:17,862 --> 00:16:21,586
A cast-iron cooker is sure
To get everyone fired up.
280
00:16:23,620 --> 00:16:27,275
This cast-iron cooker may look
Like an ordinary barbecue,
281
00:16:27,275 --> 00:16:29,827
But it does so much
More than grill.
282
00:16:29,827 --> 00:16:33,275
It also slow-smokes,
Caramelizes, sears,
283
00:16:33,275 --> 00:16:35,586
And even bakes.
284
00:16:35,586 --> 00:16:37,379
To produce the cast iron,
285
00:16:37,379 --> 00:16:41,517
The company buys scrap pieces
Of new steel from steel mills
286
00:16:41,517 --> 00:16:45,689
And from factories that use
Steel to make their products.
287
00:16:45,689 --> 00:16:49,379
Manufacturers heat the steel
In a pre-heat furnace.
288
00:16:49,379 --> 00:16:52,206
This evaporates any
Residual moisture
289
00:16:52,206 --> 00:16:55,275
And speeds up melting
In the main furnace.
290
00:16:55,275 --> 00:16:58,241
The main furnace operator
Adds a powdered chemical
291
00:16:58,241 --> 00:17:02,827
That solidifies the impurities
So that he can scoop them out.
292
00:17:02,827 --> 00:17:05,241
He also adds carbon, silicon,
293
00:17:05,241 --> 00:17:09,827
And other alloys to transform
The steel into iron.
294
00:17:09,827 --> 00:17:14,344
The molds are made of a sand,
Clay, finely ground coal,
295
00:17:14,344 --> 00:17:17,758
And water mix compressed
At high pressure.
296
00:17:17,758 --> 00:17:19,758
The molten iron
Causes the moisture
297
00:17:19,758 --> 00:17:22,000
In the mold to evaporate.
298
00:17:22,000 --> 00:17:26,137
The resulting steam escapes
Through vent holes at the top.
299
00:17:26,137 --> 00:17:28,482
This machine lowers the top
Half of the mold
300
00:17:28,482 --> 00:17:30,413
Over the bottom half.
301
00:17:30,413 --> 00:17:33,275
The furnace empties
The molten iron into a ladle,
302
00:17:33,275 --> 00:17:36,551
Which contains
Additional alloys.
303
00:17:36,551 --> 00:17:38,965
A worker positions the ladle
Over an opening
304
00:17:38,965 --> 00:17:43,068
At the top of the mold
And pours in the molten iron.
305
00:17:43,068 --> 00:17:44,793
After about two hours,
306
00:17:44,793 --> 00:17:47,931
He breaks the sand mold
And extracts the casting.
307
00:17:49,517 --> 00:17:52,758
Workers use a sledgehammer
To break off excess metal.
308
00:17:55,482 --> 00:17:58,896
The cast-iron parts are still
Encrusted in sand,
309
00:17:58,896 --> 00:18:02,724
So workers load them
Into a shot-blasting machine.
310
00:18:02,724 --> 00:18:05,172
Shot blasting is like
Sandblasting,
311
00:18:05,172 --> 00:18:07,965
Except instead of sand,
The machine pummels
312
00:18:07,965 --> 00:18:11,103
The surface
With tiny steel balls.
313
00:18:11,103 --> 00:18:14,586
The shot-blasting cycle
Thoroughly cleans the surface.
314
00:18:16,586 --> 00:18:19,172
The surface is still
Quite rough, however.
315
00:18:19,172 --> 00:18:21,862
So workers refine it
With hand tools,
316
00:18:21,862 --> 00:18:24,655
Hammering off any remaining
Excess metal
317
00:18:24,655 --> 00:18:27,275
And grinding the surface smooth.
318
00:18:32,517 --> 00:18:35,275
The top half of the cooker
Has a handle on the front
319
00:18:35,275 --> 00:18:37,517
And half a hinge on the back.
320
00:18:37,517 --> 00:18:40,724
The bottom half has the other
Half of the hinge.
321
00:18:42,344 --> 00:18:45,482
A worker drills a hole
Through each hinge half
322
00:18:45,482 --> 00:18:48,275
For the shaft
That will connect them.
323
00:18:48,275 --> 00:18:50,448
He drills holes in the fire box
324
00:18:50,448 --> 00:18:52,896
That will let in air
To feed the fire.
325
00:18:55,586 --> 00:18:57,758
Using a template
And laser cutter,
326
00:18:57,758 --> 00:19:01,517
He cuts an opening in the bottom
For the ventilation-draft door.
327
00:19:03,586 --> 00:19:06,000
He drills mounting holes
Around the vent,
328
00:19:06,000 --> 00:19:09,241
And installs the draft door.
329
00:19:09,241 --> 00:19:12,034
Its perforated hole cover
Lets air in.
330
00:19:12,034 --> 00:19:14,793
Its solid sliding door
Shuts it out.
331
00:19:14,793 --> 00:19:18,137
The air intake feeding the fire
Regulates cooking temperature.
332
00:19:20,379 --> 00:19:24,551
The cooker sits
In a hand-crafted steel cart.
333
00:19:24,551 --> 00:19:27,275
A welder places the parts
For the cart's frame
334
00:19:27,275 --> 00:19:31,551
In an assembly fixture,
Which positions them correctly.
335
00:19:31,551 --> 00:19:34,827
After welding the frame,
He files down the welds
336
00:19:34,827 --> 00:19:36,655
So that they'll be
Virtually invisible
337
00:19:36,655 --> 00:19:38,413
Once the frame is painted.
338
00:19:41,793 --> 00:19:44,103
This computer-guided
Lathe machines
339
00:19:44,103 --> 00:19:48,551
The cart's cast-iron wheels
To the final dimensions.
340
00:19:48,551 --> 00:19:51,551
The sand molds used to cast
The wheels were designed
341
00:19:51,551 --> 00:19:56,275
Using century-old
Patterns for cast-iron pulleys.
342
00:19:56,275 --> 00:19:58,517
Once workers have mounted
The two wheels,
343
00:19:58,517 --> 00:20:01,827
The cart goes off to be painted.
344
00:20:01,827 --> 00:20:05,620
Then, a worker installs shelves
Made of either stainless steel,
345
00:20:05,620 --> 00:20:08,482
Hardwood,
Or composite decking planks.
346
00:20:10,103 --> 00:20:13,551
Workers bolt the bottom half
Of the cooker to the cart.
347
00:20:13,551 --> 00:20:15,482
Then they lower in the fire box,
348
00:20:15,482 --> 00:20:17,655
Which holds the fuel
For cooking.
349
00:20:17,655 --> 00:20:21,034
The recommended fuel
Is hardwood lump charcoal.
350
00:20:23,482 --> 00:20:26,724
Next, a worker mounts
The cooker's temperature gauge.
351
00:20:28,586 --> 00:20:30,862
Then he installs the top vent.
352
00:20:30,862 --> 00:20:33,413
It consists of two
Cast-iron discs
353
00:20:33,413 --> 00:20:37,241
Which rotate to let in more air
Or less air.
354
00:20:37,241 --> 00:20:38,724
Having adjustable ventilation
355
00:20:38,724 --> 00:20:41,034
At both the top
And bottom of the cooker
356
00:20:41,034 --> 00:20:45,655
Enables more precise
Temperature control.
357
00:20:45,655 --> 00:20:48,586
They position the top of the
Cooker over the bottom,
358
00:20:48,586 --> 00:20:51,586
And mate the two hinge halves
With the steel shaft
359
00:20:51,586 --> 00:20:54,724
And two stainless-steel springs.
360
00:20:54,724 --> 00:20:57,413
Fiber gaskets ensure good seal
When the cooker
361
00:20:57,413 --> 00:21:00,965
Is closed
Over the cast-iron grates.
362
00:21:00,965 --> 00:21:02,655
Those grates are reversible,
363
00:21:02,655 --> 00:21:05,206
With one side higher
Than the other,
364
00:21:05,206 --> 00:21:08,344
Providing a choice of cooking
Heights above the fire.
29360
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