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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: the inuit and yupik
Native alaskan tribes invented
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Specialized goggles
To prevent snow blindness.
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00:00:59,793 --> 00:01:01,724
In the early 20th century,
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A new kind of eyewear
Was created for airline pilots
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In order to protect
Their faces from wind.
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00:01:07,275 --> 00:01:09,793
Soon, motorcyclists started
Wearing the eyewear
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For the same purpose.
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This manufacturer uses
The same tooling process
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Used to produce
The iconic eye protection
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Worn by the ace pilots
Of the royal air force
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During world war ii.
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Production begins
With a coil feeder,
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Which feeds a strip of soft-coil
Brass into a press tool.
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The tool stamps out
A series of flat blanks.
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The press simultaneously punches
Two guide holes
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That will help position
The blanks on the other tools.
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00:01:42,620 --> 00:01:44,931
Two raised press tools form
The blank
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Around a left and right die.
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The press tools add new folds
And contours to the blanks.
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Another press tool stamps out
The center aperture.
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A device punches out
Stitching holes
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That will allow an attachment
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To connect
To a leather face pad.
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A different press tool punctures
The stitching holes
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Located along the goggle frame.
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00:02:13,793 --> 00:02:15,793
Due to the age of the machinery,
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00:02:15,793 --> 00:02:19,379
The distance between the holes
Has become slightly uneven,
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Giving the goggles
Their distinctive character.
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Next, the nose-bridge bracket
Is positioned on a rivet shaft.
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With the eyepiece in place,
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The craftsman triggers
The device
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To rivet
The components together.
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00:02:34,137 --> 00:02:36,620
Before he attaches
The two eyepieces,
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00:02:36,620 --> 00:02:39,931
The craftsman polishes each
Piece against a grinding wheel.
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This is a two-step process
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Starting with an operation
Called scarfing,
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Which prepares the surface,
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Followed by polishing
With a special compound.
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The goggle lenses will be
Installed into the frames
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At a 45-degree angle,
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So a grinding wheel casts
A 22.5-degree angle
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00:03:00,724 --> 00:03:03,068
On each section of glass.
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The craftswoman removes
The slight burr
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Left by the grinding process
With a sanding wheel.
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The lenses are made out of
Shatterproof laminate
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For additional protection.
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00:03:13,689 --> 00:03:17,551
The lens frame is made out
Of a painted brass channel.
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The brass has been annealed
For strength
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00:03:20,034 --> 00:03:24,241
And to remove
Any internal stresses.
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00:03:24,241 --> 00:03:27,965
A small rod is inserted
As a temporary support.
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She places the assembly
In a clamp
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And secures the channel in place
With a brass cleat.
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She uses a manual hand press
To bend the channel
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To 45 degrees.
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The craftswoman removes
The support rod
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And applies epoxy glue
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To the seam between
The two sections of glass.
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She inserts a brass cleat
To hold the assembly in place,
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And this time the cleat
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Is permanently fastened
To the assembly.
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Now the eyepiece is ready for
The next phase of production.
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The eyepieces are attached
To a leather face pad
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Made from lamb nappa leather.
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A craftsperson starts
The process
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By using a custom die
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And a 10-ton press
To stamp out the required shape.
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00:04:21,034 --> 00:04:24,000
Then she uses a leatherworking
Sewing machine
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To stitch the two layers
Of the face pad together.
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With exactly 1.5 millimeters
Between each stitch,
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The attachment is durable
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Without overperforating
The leather.
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She sews the inner perimeter
Of the face mask
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With an overlocking stitch.
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This operation is not easy.
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It takes a skilled leatherworker
Up to seven months of training
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To become truly proficient.
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Before sewing the nose-cover
Section of the face pad,
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The craftswoman glues
The layers together
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To ensure
They're assembled correctly.
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After the glue has cured,
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The goggle eyepieces are placed
In position over the face pad,
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And the components
Are stitched together by hand.
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The goggle assembly
Is almost complete.
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The goggle lenses are placed
Into position
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In the channels
Of the eyepiece frames.
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Now they just need to be
Secured in place.
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The headband clips attach
To the goggles
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And lock in the lenses.
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Not only do these handcrafted
Goggles protect your face,
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You can be assured
They will never go out of style.
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Narrator: today we can listen
To music instantly
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From a smartphone
Or in our car,
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But to enjoy a bit of nostalgia,
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You can still enjoy
A more tactile and visual
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Musical experience
By pushing down a button
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And waiting for a jukebox
To load
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And play a song
On a vinyl record.
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This classic 1940s dome-top
Jukebox is built by hand.
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It plays vinyl records,
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Which are loaded into
The machine after purchase.
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A technician builds the cabinet
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Out of thin, flexible sheets
Of plywood.
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Once five sheets of wood
Have been glued together,
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The technician places them
In a dome-shaped mold.
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After glue is applied
To the inside of the cabinet,
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Team members insert
The wood back panel.
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The layers are then
Held together
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By hydraulic rams for 24 hours.
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Then workers remove the cabinet
From the mold
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And install shelving
And brackets.
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The brackets, or knuckles,
Are made out of zinc
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And will hold
The cabinet door together.
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When a knuckle
Comes out of the mold,
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The edges are rough
And contain excess metal,
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So a technician smoothes
The knuckle with a belt sander
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And then uses a guide
To drill screw holes.
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00:07:25,827 --> 00:07:29,724
The factory sends the knuckles
Out to a specialty metal plater,
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00:07:29,724 --> 00:07:31,517
Who plates them with chrome.
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00:07:34,931 --> 00:07:39,103
The cabinet door consists of
A front hoop and a front panel.
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Technicians place both parts
In an assembly jig
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00:07:42,310 --> 00:07:45,344
To ensure they are
Positioned correctly.
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Then eight knuckles
Are connected --
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Two at the top
And three on each side.
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Every jukebox is
Uniquely handmade,
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So a technician verifies
That the door and cabinet
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Are aligned accordingly.
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00:07:59,586 --> 00:08:03,413
Next, both components are moved
To the cabinet-finishing area
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To be painted or stained,
Depending on the wood.
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00:08:07,620 --> 00:08:10,379
The customer selects the color
And any options,
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00:08:10,379 --> 00:08:12,827
Such as programmable
L.E.D. Lighting
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00:08:12,827 --> 00:08:16,206
Or bluetooth connectivity
For streaming digital music.
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00:08:18,827 --> 00:08:23,068
The bubble tubes are handcrafted
From standard glass tubing.
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An artisan seals the tube
At the bottom
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Then passes a probe
To check for any small cracks.
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If the tube is intact,
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00:08:30,896 --> 00:08:34,344
Tiny silicon crystals
Are placed at the bottom,
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00:08:34,344 --> 00:08:37,137
And fluid that turns
From liquid into gas
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00:08:37,137 --> 00:08:41,103
Is poured into the tube
At very low temperature.
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00:08:41,103 --> 00:08:43,655
The artisan melts the glass
With a torch
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To seal the top of the tube.
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00:08:46,689 --> 00:08:49,724
Each jukebox has four straight
Bubble tubes
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00:08:49,724 --> 00:08:51,793
And four curved ones.
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00:08:51,793 --> 00:08:55,068
Making a curved tube
Requires two artisans.
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One heats the tube,
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00:08:56,689 --> 00:08:59,758
While the other bends it
Around a form.
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00:08:59,758 --> 00:09:02,379
Next, the tubes are placed
In a tester,
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00:09:02,379 --> 00:09:05,655
Which heats the fluid,
Turning it into gas.
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00:09:05,655 --> 00:09:07,689
The silicon crystals
At the bottom
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00:09:07,689 --> 00:09:09,931
Disrupt the gas as it rises,
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00:09:09,931 --> 00:09:12,551
Creating hundreds
Of rising bubbles.
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00:09:12,551 --> 00:09:15,068
As the bubbles reach
The top of the tube,
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They cool
And turn back into liquid.
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A technician installs the tubes
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00:09:19,413 --> 00:09:22,620
Inside transparent
Protective covers.
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He connects each tube
To a heating plate
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Hidden inside the cabinet.
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00:09:28,448 --> 00:09:29,896
Another specialist wires
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The jukebox electrical systems
And speakers.
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The speaker assembly is located
Behind the front door
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Of the cabinet.
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A 1950s-style jukebox is made
With shaped glass and chrome.
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It has a curved,
See-through front door,
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Which allows the user to watch
As the vinyl system finds,
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Pulls, and plays
The selected record.
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Each machine contains
A 70-slot circular basket
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That holds a two-sided record.
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The motor in this reproduction
Jukebox is guided
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00:10:07,689 --> 00:10:09,862
By computer software.
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The motor rotates the basket
To bring the selected record
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To the lift arm.
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Another motor rotates
The turntable to play the song.
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00:10:18,517 --> 00:10:21,275
The software reads the position
Of each record
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Via an optical sensor
And a rotating slotted disc.
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The software calculates
The quickest route
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To the requested record,
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Then spins the basket to bring
The record to the lift arm.
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So when your jukebox arrives,
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All you have to do is drop in
Your favorite records,
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Make title cards
Using the labeling software,
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And insert them
In the title display.
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This jukebox is ready to provide
The listener with good times
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And good vibes
For many years to come.
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Narrator: standard excavators
Shovel and dig,
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00:11:03,965 --> 00:11:05,344
But due to their size,
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They can sometimes break
Underground utilities.
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00:11:08,758 --> 00:11:10,896
Vacuum excavators dig
With a technique
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That doesn't cause damage,
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00:11:12,655 --> 00:11:15,896
Softening the soil with
A high-pressure stream of water,
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00:11:15,896 --> 00:11:18,689
Then sucking up the mud
Into a debris tank.
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00:11:22,827 --> 00:11:24,689
A vacuum excavator functions
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00:11:24,689 --> 00:11:28,137
As a pressure washer
And shop vacuum.
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00:11:28,137 --> 00:11:30,206
Using a high-pressure water jet,
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00:11:30,206 --> 00:11:33,793
The excavator removes materials
With a vacuum hose
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00:11:33,793 --> 00:11:36,551
And deposits it
Into a debris tank.
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00:11:36,551 --> 00:11:40,655
The tank holds up to
1,188 gallons of debris
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00:11:40,655 --> 00:11:43,448
And is made from
High-strength sheet steel.
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00:11:43,448 --> 00:11:48,448
A steel rolling machine curves
The sheet under pressure.
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00:11:48,448 --> 00:11:51,310
A welder clamps
The ends of the sheet together
201
00:11:51,310 --> 00:11:53,689
And tacks them
To form a cylinder.
202
00:11:57,827 --> 00:12:01,586
Next, he transfers the cylinder
To a welding fixture
203
00:12:01,586 --> 00:12:05,000
And fully welds the seam.
204
00:12:05,000 --> 00:12:07,137
Then the welder mounts
A steel dome
205
00:12:07,137 --> 00:12:09,034
To the front end of the tank.
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00:12:11,379 --> 00:12:15,379
Using an assembly jig, he clamps
The dome into position.
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00:12:21,896 --> 00:12:24,000
He strikes the dome
With a mallet
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00:12:24,000 --> 00:12:27,379
To close any gaps between
The dome and the cylinder.
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00:12:29,724 --> 00:12:32,344
He tack-welds the parts
To each other.
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00:12:37,000 --> 00:12:39,482
He removes the cylinder
From the jig
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00:12:39,482 --> 00:12:43,068
And fully welds the exterior
Seam around the perimeter.
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00:12:45,206 --> 00:12:48,000
Another machinist welds
The inner seam.
213
00:12:51,655 --> 00:12:55,034
Other components are welded
To the tank.
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00:12:55,034 --> 00:12:58,517
These include a large hinge
For the tank's rear door,
215
00:12:58,517 --> 00:13:02,689
Side pins that allow the tank
To tilt when emptied,
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00:13:02,689 --> 00:13:05,827
A pair of windows,
Storage hooks,
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00:13:05,827 --> 00:13:09,068
And an inlet
For the suction hose.
218
00:13:09,068 --> 00:13:12,551
Once all the steel parts
Have been cleaned with hot water
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00:13:12,551 --> 00:13:14,862
And a chemical
That inhibits rust,
220
00:13:14,862 --> 00:13:17,275
A technician sprays them
With primer.
221
00:13:19,379 --> 00:13:22,896
Then a coat of durable,
Epoxy-based paint is applied.
222
00:13:22,896 --> 00:13:25,517
The paint takes
A couple of hours to dry.
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00:13:28,551 --> 00:13:32,344
The vacuum excavator is built
Into a welded steel trailer
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00:13:32,344 --> 00:13:35,137
That has upright steel posts
On each side
225
00:13:35,137 --> 00:13:37,862
To hold the water tanks.
226
00:13:37,862 --> 00:13:40,517
A technician installs
L.E.D. Brake lights
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00:13:40,517 --> 00:13:42,620
And side indicator lights.
228
00:13:45,379 --> 00:13:48,551
Next, wiring is run along
The length of the trailer.
229
00:13:48,551 --> 00:13:51,206
The wires control the machine's
Trailer brakes
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00:13:51,206 --> 00:13:53,172
And safety lights.
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00:13:53,172 --> 00:13:57,379
Then the wiring is connected
To the lights.
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00:13:57,379 --> 00:13:59,379
A technician covers
Every connection
233
00:13:59,379 --> 00:14:01,172
With heat-shrink plastic.
234
00:14:01,172 --> 00:14:05,517
This will ensure the connected
Wires are water-resistant.
235
00:14:05,517 --> 00:14:08,586
Next, the hydraulic pump
Is installed,
236
00:14:08,586 --> 00:14:10,172
As well as rubber cushions
237
00:14:10,172 --> 00:14:12,586
To protect the bottom
Of the debris tank,
238
00:14:12,586 --> 00:14:17,275
And reflective red-and-white
Safety tape, as required by law.
239
00:14:17,275 --> 00:14:20,103
A technician installs
Two industrial tires
240
00:14:20,103 --> 00:14:22,310
On each side of the trailer.
241
00:14:22,310 --> 00:14:25,241
He runs hydraulic lines
From the hydraulic pump
242
00:14:25,241 --> 00:14:28,517
To the lift cylinders
That tilt the debris tank
243
00:14:28,517 --> 00:14:30,862
And to its rear-door mechanism.
244
00:14:33,931 --> 00:14:38,172
The empty debris tank weighs
More than 1,500 pounds.
245
00:14:38,172 --> 00:14:40,000
Using an overhead crane,
246
00:14:40,000 --> 00:14:42,517
A team lifts and positions
The tank
247
00:14:42,517 --> 00:14:44,793
Over the rear part
Of the trailer,
248
00:14:44,793 --> 00:14:49,103
Lowering it into
The hydraulic lift system.
249
00:14:49,103 --> 00:14:51,241
Next, the power pack
Is installed
250
00:14:51,241 --> 00:14:52,862
On the front of the trailer.
251
00:14:52,862 --> 00:14:55,482
The pack contains
The gas or diesel engine,
252
00:14:55,482 --> 00:14:58,172
The vacuum and water pumps,
The battery,
253
00:14:58,172 --> 00:15:01,551
And belts that connect
The pumps and engine pulleys.
254
00:15:01,551 --> 00:15:04,482
After the first of two
Polyethylene water tanks
255
00:15:04,482 --> 00:15:08,068
Are assembled, technicians
Install an air-filtration unit.
256
00:15:08,068 --> 00:15:13,206
The unit protects the inner
Components of the vacuum pump.
257
00:15:13,206 --> 00:15:16,000
Two technicians install
The second water tank,
258
00:15:16,000 --> 00:15:19,931
Placing it in between
The trailer's support posts.
259
00:15:19,931 --> 00:15:24,793
Then the tank is secured
With two crossbars.
260
00:15:24,793 --> 00:15:26,862
To dig with a vacuum excavator,
261
00:15:26,862 --> 00:15:29,758
The suction hose is attached
To the debris tank
262
00:15:29,758 --> 00:15:31,862
While the other end digs.
263
00:15:31,862 --> 00:15:36,344
Then the ignition, water,
And vacuum pumps are started.
264
00:15:36,344 --> 00:15:39,827
The water pump pressurizes
The water flowing from the tanks
265
00:15:39,827 --> 00:15:43,689
Through the hose and out
The nozzle of an attached wand.
266
00:15:43,689 --> 00:15:46,551
The water pressure turns
The soil into mud,
267
00:15:46,551 --> 00:15:49,931
And the suction hose
Removes the material.
268
00:15:49,931 --> 00:15:52,413
Thanks to
This shovel-free process,
269
00:15:52,413 --> 00:15:56,379
Operators can now dig without
Damaging underground utilities.
270
00:16:06,448 --> 00:16:08,413
Narrator:
Inside a pewter shaving set
271
00:16:08,413 --> 00:16:11,379
Is a double-barreled mug
Called scuttle.
272
00:16:11,379 --> 00:16:14,896
In one compartment,
It keeps shaving water hot,
273
00:16:14,896 --> 00:16:17,413
While holding soap in the other.
274
00:16:17,413 --> 00:16:19,724
The set's badger-bristle
Shaving brush
275
00:16:19,724 --> 00:16:23,379
Is used to work the soap
And water into a hot lather.
276
00:16:27,206 --> 00:16:29,000
With a pewter shaving set,
277
00:16:29,000 --> 00:16:33,068
The user employs nostalgic tools
To shave.
278
00:16:33,068 --> 00:16:36,448
It's elegant,
And it helps get the job done.
279
00:16:39,275 --> 00:16:41,000
Pewter of made of tin,
280
00:16:41,000 --> 00:16:44,172
With a small amount
Of copper and antimony.
281
00:16:44,172 --> 00:16:47,862
Tin is a soft metal, while
The other metals add strength.
282
00:16:50,206 --> 00:16:52,241
A metal worker places
A filter gate
283
00:16:52,241 --> 00:16:53,965
At one end of the mold.
284
00:16:57,068 --> 00:16:59,103
He scoops up molten pewter
285
00:16:59,103 --> 00:17:03,310
And pours it in the mold
In front of the filter gate.
286
00:17:03,310 --> 00:17:05,724
The filter gate
Captures impurities
287
00:17:05,724 --> 00:17:10,034
As the pewter flows
To the other side.
288
00:17:10,034 --> 00:17:13,206
Heat causes any air pockets
To rise to the surface
289
00:17:13,206 --> 00:17:14,551
And dissipate.
290
00:17:14,551 --> 00:17:16,793
Spraying the pewter
With cool water
291
00:17:16,793 --> 00:17:19,448
Accelerates the solidification.
292
00:17:19,448 --> 00:17:23,586
After 10 seconds, the pewter has
Hardened into a thick slab
293
00:17:23,586 --> 00:17:26,241
Called an ingot.
294
00:17:26,241 --> 00:17:28,862
A metal worker breaks off
The excess material
295
00:17:28,862 --> 00:17:30,862
Left by the filter gate.
296
00:17:30,862 --> 00:17:35,448
The pewter is now
In a workable form.
297
00:17:35,448 --> 00:17:40,068
A technician places the ingot
In a machine with steel rollers
298
00:17:40,068 --> 00:17:43,827
And adjusts the space between
The upper and lower rollers.
299
00:17:46,172 --> 00:17:50,862
Using 66 tons of pressure,
The rollers flatten the ingot.
300
00:17:50,862 --> 00:17:53,000
It takes several passes
Through the rollers
301
00:17:53,000 --> 00:17:55,965
To reduce the ingot
To its desired thickness.
302
00:17:58,689 --> 00:18:01,655
Additionally, the rolling
Stretches the ingot,
303
00:18:01,655 --> 00:18:04,448
Transforming it
Into a large sheet.
304
00:18:04,448 --> 00:18:07,379
Later, the sheet will be used
To make the shaving scuttle
305
00:18:07,379 --> 00:18:09,344
And brush handle.
306
00:18:09,344 --> 00:18:13,206
Now it's time to construct
The beard combs.
307
00:18:13,206 --> 00:18:17,034
A technician ladles molten
Pewter into a rubber mold.
308
00:18:17,034 --> 00:18:19,965
The centrifugal force
Forces the liquid pewter
309
00:18:19,965 --> 00:18:22,206
Into the mold's crevices.
310
00:18:22,206 --> 00:18:25,655
After 2 1/2 minutes,
The mold is removed,
311
00:18:25,655 --> 00:18:30,034
Producing seven
Pewter beard combs.
312
00:18:30,034 --> 00:18:32,965
The technician extracts
The combs from the runners
313
00:18:32,965 --> 00:18:34,827
Formed from the molten pewter.
314
00:18:38,551 --> 00:18:40,689
After sanding,
The combs are dipped
315
00:18:40,689 --> 00:18:42,655
In a specialized solution.
316
00:18:46,310 --> 00:18:47,827
In a vibrating machine,
317
00:18:47,827 --> 00:18:52,034
The ceramic pellets shake off
Most of the excess solution.
318
00:18:52,034 --> 00:18:55,655
But the solution that's seeped
Into the embossed logo remains,
319
00:18:55,655 --> 00:18:57,344
Adding definition.
320
00:19:00,482 --> 00:19:03,310
Back to the shaving scuttle
And brush assembly,
321
00:19:03,310 --> 00:19:06,275
A large sheet of pewter
Is cut into discs.
322
00:19:08,931 --> 00:19:11,448
A technician pours resin
Into a mold
323
00:19:11,448 --> 00:19:14,241
To create
The shaving-brush handle.
324
00:19:14,241 --> 00:19:17,275
After the handle's cured
For 25 minutes,
325
00:19:17,275 --> 00:19:20,689
The resin transitions
From a liquid to a solid.
326
00:19:20,689 --> 00:19:23,586
Now he has a handle form
To work with.
327
00:19:23,586 --> 00:19:25,896
As the handle spins in a lathe,
328
00:19:25,896 --> 00:19:28,034
The technician
Shaves off imperfections
329
00:19:28,034 --> 00:19:29,482
With a cutting tool.
330
00:19:31,620 --> 00:19:35,896
A sharp, circular die cuts out
Discs from the pewter sheet.
331
00:19:40,482 --> 00:19:42,896
With the handle core
Still spinning,
332
00:19:42,896 --> 00:19:45,000
The worker shapes
The pewter disc,
333
00:19:45,000 --> 00:19:47,724
Essentially giving the part
A pewter skin.
334
00:19:51,448 --> 00:19:53,827
Using the same spinning
Techniques,
335
00:19:53,827 --> 00:19:58,172
The scuttle shaving mug
Are now complete.
336
00:19:58,172 --> 00:20:01,000
Using a natural abrasive
Mixed with oil,
337
00:20:01,000 --> 00:20:03,275
The pewter parts are buffed.
338
00:20:03,275 --> 00:20:08,931
This step removes flaws
And provides an initial polish.
339
00:20:08,931 --> 00:20:12,965
Then the maker's mark is carved
Into the shaving-scuttle base,
340
00:20:12,965 --> 00:20:17,241
Stamping the logo
Into the pewter.
341
00:20:17,241 --> 00:20:20,931
Now that the scuttle-mug parts
Are assembled,
342
00:20:20,931 --> 00:20:23,655
A technician solders the base
To the scuttle body.
343
00:20:28,793 --> 00:20:31,896
A decorative cured handle adds
Visual interest
344
00:20:31,896 --> 00:20:34,344
And will provide the user
A place to grip.
345
00:20:36,965 --> 00:20:38,586
A technician adds more solder
346
00:20:38,586 --> 00:20:41,827
To seal the handle
To the scuttle body.
347
00:20:41,827 --> 00:20:44,448
This shaving scuttle
Is now complete.
348
00:20:44,448 --> 00:20:47,413
All the parts will undergo
An extensive polishing,
349
00:20:47,413 --> 00:20:51,655
Giving the pewter
A mirror finish.
350
00:20:51,655 --> 00:20:53,137
Using a buffing wheel,
351
00:20:53,137 --> 00:20:56,931
A technician polishes the
Shaving scuttle one last time.
352
00:20:59,379 --> 00:21:05,000
Finally, this pewter shaving set
Is ready to take on stubble.
28578
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