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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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HOSPITALS GENERATE
A LOT OF DIRTY LAUNDRY,
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00:00:55,854 --> 00:00:59,057
FROM PATIENT GOWNS AND SHEETS
TO CLEANING RAGS.
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00:00:59,058 --> 00:01:01,626
SOME FACILITIES DO THE WASHING
IN HOUSE.
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00:01:01,627 --> 00:01:04,797
BUT TO FREE UP HOSPITAL SPACE,
SOME SEND THEIRS OUT
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00:01:04,798 --> 00:01:07,533
TO INDUSTRIAL-SIZE
LAUNDRY OPERATIONS
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THAT DEAL IN HIGH-VOLUME WITH
BIGGER AND BETTER EQUIPMENT.
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00:01:13,204 --> 00:01:16,074
THE HOSPITAL SENDS ALL
FABRIC ITEMS TO THE LAUNDRY,
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00:01:16,075 --> 00:01:19,277
INCLUDING BED LINENS,
TOWELS, PATIENT GOWNS,
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00:01:19,278 --> 00:01:21,179
BIBS, AND CLEANING RAGS.
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00:01:21,180 --> 00:01:23,515
THE ONLY EXCEPTION
IS SURGICAL LINENS,
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00:01:23,516 --> 00:01:25,483
WHICH ARE USUALLY DISPOSABLE.
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00:01:25,484 --> 00:01:27,786
THE LAUNDRY COMPANY
PICKS UP THE ORDER
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00:01:27,787 --> 00:01:29,854
AND DELIVERS IT TO THE PLANT.
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NEXT, WORKERS UNLOAD THE BAGS
OF SOILED LAUNDRY
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ON LARGE ROLLING CARTS.
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THEY WEIGH EACH ONE FOR
INTERNAL STATISTICAL PURPOSES
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00:01:37,864 --> 00:01:42,033
AND SCAN ITS BAR CODE TO TRACK
THE LAUNDRY FOR EACH HOSPITAL.
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00:01:42,034 --> 00:01:46,536
WORKERS HANDLING THE BAGS
WEAR GLOVES AT ALL TIMES.
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00:01:46,537 --> 00:01:48,205
THE BAGS ARE PLASTIC,
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00:01:48,206 --> 00:01:49,908
WHICH IS MORE SUITABLE
THAN CLOTH
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00:01:49,909 --> 00:01:52,711
FOR CONTAINING LIQUID,
ODOR, AND BACTERIA.
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00:01:52,712 --> 00:01:54,713
WORKERS RIP EACH ONE OPEN AND,
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00:01:54,714 --> 00:01:58,649
WITHOUT TOUCHING THE CONTENTS,
DUMP THEM ON THE CONVEYOR.
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00:01:58,650 --> 00:02:00,952
THEY DISCARD THE BAG
IN A SUCTION DEVICE
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00:02:00,953 --> 00:02:03,521
THAT SENDS IT
TO A BALING SYSTEM.
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00:02:03,522 --> 00:02:06,456
THE BALES OF BAGS
GO TO A RECYCLING FACILITY
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00:02:06,457 --> 00:02:08,227
THAT TURNS THEM
INTO GARBAGE BAGS
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00:02:08,228 --> 00:02:10,129
AND OTHER POLYETHYLENE PRODUCTS.
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00:02:12,764 --> 00:02:16,467
FROM THIS POINT ON,
EVERYTHING IS AUTOMATED.
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THE CONVEYOR DROPS THE SOILED
LAUNDRY INTO A STURDY CLOTH BAG.
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00:02:21,074 --> 00:02:24,007
ONCE THE BAG REACHES 120 POUNDS,
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THE CONVEYOR
AUTOMATICALLY STOPS LOADING.
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00:02:30,750 --> 00:02:34,185
THE FILLED BAG TRAVELS
TO AN OVERHEAD CONVEYOR SYSTEM,
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WHICH LEADS TO ONE
OF SEVERAL STAINLESS STEEL,
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TUNNEL-SHAPED WASHING MACHINES.
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00:02:38,723 --> 00:02:42,126
INSIDE, A LARGE ROTATING SCREW
PUSHES THE LOAD
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00:02:42,127 --> 00:02:43,762
THROUGH TWO PRE-SOAKS,
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00:02:43,763 --> 00:02:46,531
THEN MOVES ON
TO SIX CHEMICAL WASH CYCLES
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00:02:46,532 --> 00:02:50,302
DESIGNED TO REMOVE TOUGH STAINS
SUCH AS BLOOD AND IODINE.
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00:02:50,303 --> 00:02:54,138
NEXT ARE FIVE TREATMENT CYCLES
TO SOFTEN THE FABRIC
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00:02:54,139 --> 00:02:56,907
AND NORMALIZE THE pH LEVEL.
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00:02:56,908 --> 00:02:59,210
THEN, THREE RINSES.
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THE LOAD OF NOW CLEAN LAUNDRY
EXITS THE TUNNEL WASHER
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00:03:02,814 --> 00:03:04,683
AND ENTERS A HYDRAULIC PRESS.
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00:03:07,051 --> 00:03:10,155
THE PRESS APPLIES
AROUND 12 TONS OF WEIGHT
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00:03:10,156 --> 00:03:12,325
TO SQUEEZE OUT
THE RESIDUAL WATER.
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00:03:16,528 --> 00:03:20,330
THE LOAD COMES OUT COMPRESSED
INTO WHAT THEY CALL A CAKE.
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00:03:20,331 --> 00:03:22,799
A CONVEYOR TRANSFERS IT
TO AN ELEVATOR,
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00:03:22,800 --> 00:03:26,905
WHICH TRANSPORTS IT
TO THE DRYING AREA.
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00:03:26,906 --> 00:03:30,841
THE CONVEYOR PUTS TWO CAKES
AT A TIME INTO THE DRYER.
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00:03:30,842 --> 00:03:32,978
AN INFRARED SENSOR
INSIDE SIGNALS
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00:03:32,979 --> 00:03:36,047
THE DRYER TO STOP
WHEN THE LOAD IS DRY,
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ABOUT 22 MINUTES LATER.
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00:03:39,318 --> 00:03:41,754
A REVOLVING PADDLE
CALLED A CAKE BREAKER
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SEPARATES
THE STUCK-TOGETHER ITEMS
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00:03:43,756 --> 00:03:45,290
TO PREPARE THEM FOR SORTING.
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00:03:48,526 --> 00:03:49,794
FROM THIS POINT ON,
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00:03:49,795 --> 00:03:53,999
AUTOMATION ENDS
AND MANUAL SORTING BEGINS.
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WORKERS PULL
DIFFERENT CATEGORIES OF ITEMS
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00:03:56,534 --> 00:03:58,902
AND TOSS THEM
INTO DESIGNATED LINEN HOPPERS
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00:03:58,903 --> 00:04:00,539
THAT ARE HOOKED UP TO SCALES.
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00:04:04,376 --> 00:04:06,511
WHEN A BAG
HITS THE TARGET WEIGHT,
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00:04:06,512 --> 00:04:09,347
IT AUTOMATICALLY
DROPS DOWN ONTO A CONVEYOR,
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00:04:09,348 --> 00:04:11,882
WHICH LEADS
TO THE FINAL PROCESSING AREA.
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00:04:11,883 --> 00:04:13,617
HERE, ITEMS ARE EITHER FOLDED
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00:04:13,618 --> 00:04:17,321
OR BULK PACKAGED
IN PLASTIC BAGS.
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00:04:17,322 --> 00:04:20,357
WORKERS LOAD THE BULK ITEMS
INTO A VACUUM SYSTEM,
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00:04:20,358 --> 00:04:23,761
WHICH FEEDS
INTO AUTOMATED BAGGING MACHINES.
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00:04:23,762 --> 00:04:26,164
THE MACHINES HAVE EITHER
A BUILT-IN SCALE,
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00:04:26,165 --> 00:04:29,801
WHICH WEIGHS THE BAG
AS IT FILLS, OR A PHOTO CELL,
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00:04:29,802 --> 00:04:32,337
WHICH COUNTS THE ITEMS
DROPPING INTO THE BAG.
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00:04:32,338 --> 00:04:36,241
ONCE THE BAG REACHES
THE TARGET WEIGHT OR COUNT,
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00:04:36,242 --> 00:04:38,677
THE MACHINE HEAT-SEALS
AND RELEASES IT.
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00:04:42,447 --> 00:04:44,449
CERTAIN ITEMS HAVE TO BE FOLDED.
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00:04:48,153 --> 00:04:51,088
LUCKILY, A MACHINE
AUTOMATICALLY FOLDS BED PADS,
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00:04:51,089 --> 00:04:53,458
BATH TOWELS, AND PATIENT GOWNS
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00:04:53,459 --> 00:04:56,528
BY FLIPPING OVER THE ENDS
WITH SHORT BLASTS OF AIR.
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00:05:06,271 --> 00:05:09,640
THE NEATLY FOLDED ITEMS
COLLECT UNDERNEATH THE MACHINE,
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00:05:09,641 --> 00:05:13,143
THEN TRAVEL BY CONVEYOR TO
THE SHIPPING PREPARATION AREA.
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00:05:13,144 --> 00:05:15,814
HERE, WORKERS
STACK THEM ONTO ROLLING CARTS.
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00:05:19,418 --> 00:05:22,054
A DIFFERENT FOLDING MACHINE
HANDLES THE LARGER ITEMS,
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00:05:22,055 --> 00:05:25,523
SUCH AS BED SHEETS
AND FLANNEL BLANKETS.
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A WORKER CLAMPS AN ITEM
TO THE FEEDER.
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00:05:28,894 --> 00:05:31,628
THEN, THE MACHINE,
USING ROLLERS AND STRAPS,
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00:05:31,629 --> 00:05:34,033
PROCESSES THE ITEM
UNTIL IT'S NEATLY FOLDED.
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00:05:41,273 --> 00:05:44,477
THE CLEAN LAUNDRY
GOES BACK ONTO CARTS...
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00:05:46,177 --> 00:05:49,581
...INTO THE TRUCK,
AND BACK TO THE HOSPITAL.
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Narrator:
LIFE ON THE CONCERT CIRCUIT
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CAN BE PUNISHING,
NOT JUST FOR THE MUSICIANS,
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00:06:01,837 --> 00:06:03,805
BUT ALSO THEIR INSTRUMENTS.
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00:06:03,806 --> 00:06:06,108
DENTS, SCUFFS, AND GENERAL WEAR
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00:06:06,109 --> 00:06:09,043
CAN RUIN THE TONE
OF A BRASS INSTRUMENT.
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00:06:09,044 --> 00:06:11,211
BUT WITH A PROFESSIONAL
RESTORATION,
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A BADLY DAMAGED HORN CAN ONCE
AGAIN SHINE IN THE SPOTLIGHT.
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THEY MAY LOOK READY
FOR THE SCRAP HEAP,
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00:06:23,558 --> 00:06:24,992
BUT INCREDIBLY,
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00:06:24,993 --> 00:06:27,696
THESE NOT-SO-GENTLY-USED
BRASS INSTRUMENTS
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CAN BE SALVAGED.
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TECHNICIANS WILL USE
A COMBINATION OF TECHNIQUES
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TO MAKE THEM
LOOK AND SOUND LIKE NEW.
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00:06:37,606 --> 00:06:41,541
THE RESTORATION WORK STARTS
WITH THIS SOLID STEEL BALL.
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00:06:41,542 --> 00:06:44,913
THE TECHNICIAN INSERTS IT
IN THE BORE OF THE SAXOPHONE,
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JUST UNDER SOME DEEP DENTS.
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HE PLACES A PLASTIC SHEET
ON THE DENTS FROM THE OUTSIDE.
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00:06:50,954 --> 00:06:53,355
IT PROTECTS THE FINISH
FROM SCRATCHES
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00:06:53,356 --> 00:06:57,692
AS HE NOW MOVES A POWERFUL
MAGNET OVER THE DENTS.
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00:06:57,693 --> 00:06:59,994
THE MAGNET PULLS THE BALL
AGAINST THE INSIDE
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OF THE INSTRUMENT
WITH SUCH FORCE
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00:07:02,097 --> 00:07:05,634
THAT IT PUSHES OUT THE DENTS.
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00:07:05,635 --> 00:07:08,836
AFTER 30 SECONDS
OF THIS MAGNETIC MANIPULATION,
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THE DENTS ARE COMPLETELY GONE.
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00:07:13,775 --> 00:07:16,110
USING A SERIES
OF ENGRAVING TOOLS,
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00:07:16,111 --> 00:07:17,444
ANOTHER MEMBER OF THE TEAM
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00:07:17,445 --> 00:07:20,682
RESTORES THE ARTWORK
ON THE INSTRUMENT.
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00:07:20,683 --> 00:07:23,151
HE FOLLOWS THE TRACES
THAT REMAIN,
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00:07:23,152 --> 00:07:27,089
AND RECREATES DESIGNS
THAT HAVE COMPLETELY WORN AWAY.
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00:07:31,560 --> 00:07:34,197
HE ONLY HAS ONE CHANCE
TO GET THIS RIGHT.
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00:07:37,532 --> 00:07:39,902
THIS TAKES SKILL
AND A STEADY HAND.
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00:07:42,572 --> 00:07:46,341
THE NEXT TECHNICIAN REATTACHES
A KEY CUP TO THE HINGE ROD,
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00:07:46,342 --> 00:07:48,209
AND MELTS SOLDER INTO THE JOINT
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00:07:48,210 --> 00:07:50,178
TO MAKE THE CONNECTION
PERMANENT.
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00:07:53,614 --> 00:07:56,182
THE BRASS LOOKS VERY TARNISHED,
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00:07:56,183 --> 00:07:59,621
SO HE BUFFS THE KEY CUP AND ROD
TO A MIRROR FINISH.
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00:08:06,628 --> 00:08:10,165
HE NOW ATTACHES THE RESTORED
KEY AND ROD TO THE SAXOPHONE
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00:08:10,166 --> 00:08:12,101
AND SCREWS IT INTO POSITION.
129
00:08:16,637 --> 00:08:18,372
HE PRESSES
THE END OF THE KEY LEVER
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00:08:18,373 --> 00:08:20,542
TO CONFIRM
THAT IT MOVES AS IT SHOULD.
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00:08:23,645 --> 00:08:25,478
HE NOW INSERTS
A FLUORESCENT LIGHT
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00:08:25,479 --> 00:08:27,581
INTO THE BODY OF THE SAXOPHONE.
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00:08:27,582 --> 00:08:29,518
IT WILL HELP HIM FIND AIR LEAKS.
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00:08:33,521 --> 00:08:36,890
BUT FIRST, HE ACTIVATES
AN ADHESIVE WITH A TORCH
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00:08:36,891 --> 00:08:40,561
AND APPLIES IT TO THE BACK
OF A LEATHER PAD.
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00:08:40,562 --> 00:08:44,500
HE PRIES AN OLD AND DETERIORATED
PAD OUT OF ONE OF THE KEY CUPS.
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00:08:46,568 --> 00:08:49,739
HE TRANSFERS THE NEW
GLUE-BACKED PAD TO THE KEY CUP.
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00:08:54,544 --> 00:08:57,211
HE CLOSES THE KEY
AGAINST THE TONE HOLE,
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00:08:57,212 --> 00:08:59,448
AND THE ESCAPING LIGHT
INDICATES A LEAK.
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00:09:02,518 --> 00:09:05,588
SO, HE HEATS THE PAD
TO REACTIVATE THE ADHESIVE,
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00:09:05,589 --> 00:09:07,956
AND SHIFTS IT A BIT
IN THE KEY CUP.
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00:09:07,957 --> 00:09:12,693
NOW, THE KEY COMPLETELY CLOSES
THE TONE HOLE WHEN PRESSED.
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00:09:12,694 --> 00:09:14,260
THE NEXT THING TO BE REPAIRED
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00:09:14,261 --> 00:09:17,400
IS A KEY GUARD FOOT THAT'S
BROKEN AWAY FROM THE HORN.
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00:09:18,567 --> 00:09:20,234
THIS IS DELICATE WORK.
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00:09:20,235 --> 00:09:24,371
TO RESOLDER IT, THE TECHNICIAN
USES A HYDROGEN GAS TORCH
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00:09:24,372 --> 00:09:26,808
BECAUSE ITS FLAME
IS MORE PRECISE.
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00:09:29,845 --> 00:09:33,648
AT ANOTHER STATION,
A NEW PART TAKES SHAPE.
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00:09:33,649 --> 00:09:36,017
THEY CARVE A BRASS CYLINDER
TO TRANSFORM IT
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00:09:36,018 --> 00:09:38,454
INTO A NEW SPRING BARREL
FOR A TRUMPET VALVE.
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00:09:41,823 --> 00:09:46,259
HE INSERTS THE SPRING BARREL
INTO THE TOP OF THE PISTON,
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00:09:46,260 --> 00:09:47,996
AND THE FIT IS GOOD.
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00:09:50,665 --> 00:09:52,933
HE THEN PLACES
ALL THE TRUMPET VALVE PARTS
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00:09:52,934 --> 00:09:55,437
IN A WATER-AND-SOLVENT SOLUTION.
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00:09:55,438 --> 00:09:57,837
HE SWITCHES ON
AN ULTRASONIC DEVICE,
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00:09:57,838 --> 00:10:01,676
WHICH SENDS HIGH FREQUENCY SOUND
WAVES THROUGH THE SOLUTION.
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00:10:01,677 --> 00:10:04,745
MICROSCOPIC BUBBLES
BOMBARD THE PARTS
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00:10:04,746 --> 00:10:06,549
AND REMOVE OIL AND GREASE.
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00:10:08,983 --> 00:10:12,253
THE TRUMPET NOW CHILLS
IN A CRYOGENIC FREEZER
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00:10:12,254 --> 00:10:14,655
AT MINUS 301 DEGREES FAHRENHEIT
161
00:10:14,656 --> 00:10:16,925
TO RELIEVE IT
OF RESIDUAL STRESSES.
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00:10:19,627 --> 00:10:21,162
BACK TO ROOM TEMPERATURE,
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00:10:21,163 --> 00:10:23,297
THE TECHNICIAN
INSERTS A TINY CAMERA
164
00:10:23,298 --> 00:10:25,166
INTO THE BORE OF THE HORN.
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00:10:25,167 --> 00:10:27,335
IT GIVES HIM AN INSIDE LOOK
AT THE ALIGNMENT
166
00:10:27,336 --> 00:10:30,239
OF THE PISTON PORTS
AS HE PRESSES THE VALVES.
167
00:10:38,813 --> 00:10:41,816
AS WITH ANY INSTRUMENT,
THE PROOF IS IN THE PLAYING.
168
00:10:41,817 --> 00:10:44,387
[ SAXOPHONE PLAYS ]
169
00:10:47,823 --> 00:10:50,057
THIS SAX IS SURE
TO MEET THE APPROVAL
170
00:10:50,058 --> 00:10:51,928
OF CROWDS OF MUSIC LOVERS.
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00:11:05,006 --> 00:11:08,208
Narrator: DISPLAYING
A LIFE-SIZE REPLICA OF A HORSE
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00:11:08,209 --> 00:11:11,612
MAKES A GALLOPING STATEMENT
AT A FARM, A RACETRACK,
173
00:11:11,613 --> 00:11:14,781
OR A WESTERN-THEMED VENUE.
174
00:11:14,782 --> 00:11:16,983
SOME HORSE OWNERS
EVEN COMMISSION A REPLICA
175
00:11:16,984 --> 00:11:19,320
IN THE LIKENESS
OF THEIR FAVORITE ANIMAL.
176
00:11:24,993 --> 00:11:29,463
A LIFE-SIZE FIBERGLASS HORSE
CAN BE AN ATTRACTION,
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00:11:29,464 --> 00:11:31,265
BUT BEFORE THIS REPLICA,
178
00:11:31,266 --> 00:11:33,000
THERE WAS AN ARTIST'S SCULPTURE
179
00:11:33,001 --> 00:11:36,502
IN EITHER WOOD, PLASTER,
OR STYROFOAM.
180
00:11:36,503 --> 00:11:38,304
THE SCULPTURE
SERVED AS THE MODEL
181
00:11:38,305 --> 00:11:43,276
TO PRODUCE THIS THREE-PART MOLD
TO CAST ONE OR MORE REPLICAS.
182
00:11:43,277 --> 00:11:44,844
THEY APPLY A RELEASE AGENT,
183
00:11:44,845 --> 00:11:47,647
SO THE CASTING
WON'T STICK TO THE MOLD.
184
00:11:47,648 --> 00:11:50,751
THEN THEY PARTIALLY BRUSH ON
AND PARTIALLY SPRAY
185
00:11:50,752 --> 00:11:53,786
A .4mm-THICK LAYER OF GEL COAT.
186
00:11:53,787 --> 00:11:57,290
GEL COAT IS AN EASY-TO-REPAIR
RESIN-BASED MATERIAL
187
00:11:57,291 --> 00:12:01,795
THAT PRODUCES A SMOOTH,
SHINY FINISH ON FIBERGLASS.
188
00:12:01,796 --> 00:12:05,232
THREE HOURS LATER,
THE GEL COAT IS DRY.
189
00:12:05,233 --> 00:12:06,900
NEXT, THEY APPLY TWO LAYERS
190
00:12:06,901 --> 00:12:09,303
OF RESIN-SATURATED
FIBERGLASS FABRIC
191
00:12:09,304 --> 00:12:11,838
IN THE HARD-TO-ACCESS AREA
OF THE MOLD.
192
00:12:11,839 --> 00:12:14,674
THEN THEY ROLL THE FIBERGLASS
FLAT AGAINST THE MOLD
193
00:12:14,675 --> 00:12:17,646
TO PREVENT AIR BUBBLES,
WHICH WOULD CAUSE DEFECTS.
194
00:12:19,914 --> 00:12:22,083
WITH A TOOL
CALLED A CHOPPER GUN,
195
00:12:22,084 --> 00:12:25,185
THEY SHOOT SHREDDED FIBERGLASS
MIXED WITH RESIN
196
00:12:25,186 --> 00:12:27,855
OVER ALL THE OTHER
GEL-COATED AREAS OF THE MOLD.
197
00:12:36,765 --> 00:12:40,135
THEY ROLL OUT THE AIR BUBBLES
AND PACK DOWN THE FIBERGLASS
198
00:12:40,136 --> 00:12:44,070
TO A CONSISTENT THICKNESS
OF 3 MILLIMETERS.
199
00:12:44,071 --> 00:12:46,839
THIS ENSURES THE HOLLOW HORSE
WILL BE STRONG ENOUGH
200
00:12:46,840 --> 00:12:50,712
TO WITHSTAND UP TO 400 POUNDS
OF PEOPLE SITTING ON IT.
201
00:12:52,881 --> 00:12:55,149
THE RESIN-FILLED FIBERGLASS
CURES
202
00:12:55,150 --> 00:12:57,684
WITHIN APPROXIMATELY TWO HOURS.
203
00:12:57,685 --> 00:12:59,553
THEN THEY DRIVE IN WOODEN WEDGES
204
00:12:59,554 --> 00:13:01,955
TO PRY THE CASTING
FROM THE MOLD
205
00:13:01,956 --> 00:13:04,857
JUST ENOUGH TO GRAB HOLD
OF THE EDGE AND PULL.
206
00:13:04,858 --> 00:13:07,493
THANKS TO THE RELEASE AGENT
THEY APPLIED EARLIER,
207
00:13:07,494 --> 00:13:09,195
EXTRACTION IS EFFORTLESS
208
00:13:09,196 --> 00:13:13,867
AND CAUSES NO DAMAGE
TO THE CASTING OR MOLD.
209
00:13:13,868 --> 00:13:16,603
NONETHELESS, THEY
CAREFULLY INSPECT THE SURFACE
210
00:13:16,604 --> 00:13:18,706
TO BE SURE IT'S FREE OF DEFECTS.
211
00:13:22,877 --> 00:13:25,713
NEXT, THEY PASS A GRINDER
ALONG THE PERIMETER
212
00:13:25,714 --> 00:13:28,247
TO TRIM OFF
ALL THE EXCESS FIBERGLASS
213
00:13:28,248 --> 00:13:29,550
AND SMOOTH THE EDGE.
214
00:13:33,787 --> 00:13:36,623
EACH PART OF THE MOLD
PRODUCES HALF A HORSE,
215
00:13:36,624 --> 00:13:41,228
SO THE NEXT STEP IS
TO JOIN THE HALVES INTO A WHOLE.
216
00:13:41,229 --> 00:13:43,597
THE ATTACHMENT MUST BE
HIDDEN ON THE INSIDE
217
00:13:43,598 --> 00:13:45,133
SO IT DOESN'T SHOW.
218
00:13:46,968 --> 00:13:50,538
THEY FIRST TEMPORARILY
ATTACH THE HALVES ON THE OUTSIDE
219
00:13:50,539 --> 00:13:54,576
WITH GALVANIZED STEEL BRACKETS
220
00:13:55,574 --> 00:13:56,811
AND STRAPS AROUND THE LEGS.
221
00:13:59,748 --> 00:14:02,315
THEN THEY CUT A LARGE OPENING
TOWARDS THE FRONT OF THE HORSE
222
00:14:02,316 --> 00:14:05,186
TO BE ABLE TO ACCESS THE INSIDE.
223
00:14:06,353 --> 00:14:08,054
THEY FIRST FILL THE SMALL SPACE
224
00:14:08,055 --> 00:14:10,156
BETWEEN THE TWO HALVES
WITH PUTTY
225
00:14:10,157 --> 00:14:12,760
THAT AUTO BODY REPAIR SHOPS
USE ON CARS.
226
00:14:15,897 --> 00:14:18,565
THEN THEY REINFORCE THE JOINT
WITH A DOUBLE LAYER
227
00:14:18,566 --> 00:14:21,036
OF RESIN-SATURATED
FIBERGLASS FABRIC.
228
00:14:28,675 --> 00:14:31,846
THEY CUT A SECOND OPENING
TOWARD THE BACK OF THE HORSE,
229
00:14:31,847 --> 00:14:34,483
TO REPEAT THE PROCESS
ON A DIFFERENT AREA.
230
00:14:35,816 --> 00:14:37,883
THEN THEY CLOSE UP THE OPENINGS.
231
00:14:37,884 --> 00:14:40,521
THEY TEMPORARILY HOLD
THE CUTOUTS IN POSITION
232
00:14:40,522 --> 00:14:42,555
WITH GALVANIZED STEEL BRACKETS
233
00:14:42,556 --> 00:14:44,458
AND FILL ALL AROUND WITH PUTTY.
234
00:14:44,459 --> 00:14:48,362
THE PUTTY AND INSIDE STRIPS
DRY IN AN HOUR, AT WHICH POINT
235
00:14:48,363 --> 00:14:51,799
ALL THE BRACKETS CAN COME OFF.
236
00:14:51,800 --> 00:14:53,799
NOW THEY WORK ON THE OUTSIDE,
237
00:14:53,800 --> 00:14:56,772
SEALING THE SPACE BETWEEN
THE PARTS WITH MORE PUTTY.
238
00:15:02,743 --> 00:15:04,045
ONCE IT DRIES,
239
00:15:04,046 --> 00:15:07,113
THEY FLATTEN THE SEAM
WITH AN ELECTRIC SANDER.
240
00:15:07,114 --> 00:15:09,382
THEN THEY REMOVE
MARKS LEFT BY THE SANDER
241
00:15:09,383 --> 00:15:13,154
BY MANUALLY USING
A VERY FINE SANDPAPER.
242
00:15:13,155 --> 00:15:16,124
THE SEAMS ARE NOW FLUSH
WITH THE REST OF THE SURFACE.
243
00:15:16,125 --> 00:15:19,358
ONCE PAINTED,
THEY WON'T SHOW AT ALL.
244
00:15:19,359 --> 00:15:22,062
AFTER CLEANING THE ENTIRE HORSE
WITH ACETONE,
245
00:15:22,063 --> 00:15:25,466
THEY SPRAY A COAT OF PRIMER
OVER THE PUTTIED SEAMS.
246
00:15:25,467 --> 00:15:27,266
THEN, WITH FINE SANDPAPER,
247
00:15:27,267 --> 00:15:29,738
THEY PREP THE SURFACE
TO RECEIVE AUTOMOTIVE PAINT.
248
00:15:31,772 --> 00:15:34,474
THE HORSE IS READY
TO BE PAINTED.
249
00:15:34,475 --> 00:15:36,609
WITH DELICATE STROKES
OF AN AIRBRUSH,
250
00:15:36,610 --> 00:15:39,313
AN ARTIST GRADUALLY
PAINTS THE ANIMAL TO LIFE.
251
00:15:50,925 --> 00:15:52,861
BEFORE FINISHING HER ARTWORK,
252
00:15:52,862 --> 00:15:55,862
SHE'LL APPLY TWO COATS
OF TRANSPARENT VARNISH
253
00:15:55,863 --> 00:15:58,064
TO PROTECT THE PAINT
FROM PRECIPITATION
254
00:15:58,065 --> 00:16:01,002
AND THE FADING EFFECT
OF THE SUN'S RAYS.
255
00:16:08,500 --> 00:16:10,600
Narrator: EXCAVATION BUCKETS
ARE GROUND-BREAKING TOOLS.
256
00:16:12,001 --> 00:16:14,001
ATTACHED TO THE BOTTOM ARM
OF BACKHOES
257
00:16:14,002 --> 00:16:15,804
OR OTHER HEAVY EQUIPMENT,
258
00:16:15,805 --> 00:16:18,173
THEY SCOOP UP
TONS OF SOIL AND ROCK
259
00:16:18,174 --> 00:16:19,942
TO MAKE HOLES IN THE GROUND.
260
00:16:19,943 --> 00:16:21,811
FOR JOBS
LIKE BUILDING FOUNDATIONS
261
00:16:21,812 --> 00:16:23,880
AND LAYING
WATER AND SEWER PIPES,
262
00:16:23,881 --> 00:16:26,382
EXCAVATION BUCKETS DIG RIGHT IN.
263
00:16:30,987 --> 00:16:35,258
FOR SOIL EXCAVATION,
THERE'S QUITE A BUCKET LIST.
264
00:16:35,259 --> 00:16:37,326
MANUFACTURERS MAKE
EXCAVATION BUCKETS
265
00:16:37,327 --> 00:16:40,562
IN A RANGE
OF SIZES AND PROFILES.
266
00:16:40,563 --> 00:16:43,066
THEY COULD HAVE TEETH
OR A SMOOTH BLADE,
267
00:16:43,067 --> 00:16:45,268
DEPENDING ON THE KIND OF SOIL
THEY'LL BE DIGGING.
268
00:16:47,871 --> 00:16:50,340
THEY CUSTOM DESIGN
EACH EXCAVATION BUCKET
269
00:16:50,341 --> 00:16:53,142
ON A COMPUTER
AND MAP OUT THE DIMENSIONS.
270
00:16:56,746 --> 00:16:59,280
THE COMPUTER
THEN GUIDES A PLASMA TORCH
271
00:16:59,281 --> 00:17:02,952
AS IT CUTS PARTS
FROM HIGH-STRENGTH STEEL.
272
00:17:02,953 --> 00:17:05,453
HERE, THE TORCH
PRODUCES ATTACHMENT PLATES
273
00:17:05,454 --> 00:17:08,958
FOR HOLDING THE BUCKET
TO THE EXCAVATOR ARMS.
274
00:17:08,959 --> 00:17:10,928
IT EVEN CUTS
THE HOLES FOR THE PINS
275
00:17:10,929 --> 00:17:12,695
THAT WILL HINGE IT
TO A BOOM ARM.
276
00:17:15,865 --> 00:17:19,301
EACH PART
WEIGHS OVER 200 POUNDS.
277
00:17:19,302 --> 00:17:22,203
A POWERFUL MAGNET
LIFTS IT OVER TO A METAL PALETTE
278
00:17:22,204 --> 00:17:23,339
TO AWAIT REFINING.
279
00:17:28,978 --> 00:17:31,582
NEXT, THE COMPUTER-GUIDED TORCH
CARVES THROUGH
280
00:17:31,583 --> 00:17:34,017
A THINNER SHEET OF STEEL
TO PRODUCE A TEMPLATE.
281
00:17:37,953 --> 00:17:41,257
PARTS OF THE EXCAVATION BUCKET
WILL BE SHAPED IN THIS TEMPLATE
282
00:17:41,258 --> 00:17:43,761
SO THEY'LL MATCH UP
WHEN ASSEMBLED.
283
00:17:48,965 --> 00:17:52,033
WITH AN OXYGEN-FUELED TORCH,
THEY BEVEL THE BLADE
284
00:17:52,034 --> 00:17:54,804
TO GIVE IT THE EDGE IT NEEDS
TO BITE INTO THE GROUND.
285
00:17:56,940 --> 00:18:00,075
THIS BLADE PROFILE
IS FOR SANDY SOIL.
286
00:18:00,076 --> 00:18:03,146
A JAGGED EDGE IS PREFERRED
FOR ROCKY OR CLAY TERRAIN.
287
00:18:05,982 --> 00:18:09,985
NEXT,
IT'S OVER TO A POWERFUL PRESS.
288
00:18:09,986 --> 00:18:13,021
IT BENDS ANOTHER PART
INTO AN ARCH.
289
00:18:13,022 --> 00:18:14,890
THIS ARCHED PART
WITH STRADDLE THE TOP
290
00:18:14,891 --> 00:18:16,126
OF THE EXCAVATION BUCKET.
291
00:18:19,995 --> 00:18:21,829
MEANWHILE, AT ANOTHER STATION,
292
00:18:21,830 --> 00:18:24,200
A PRESS BEARS DOWNS
ON THE BEVELED BLADE
293
00:18:24,201 --> 00:18:25,501
TO SHAPE IT TO THE TEMPLATE.
294
00:18:29,906 --> 00:18:33,975
THE TEMPLATE IS A CARDBOARD COPY
OF THE STEEL ONE CUT EARLIER.
295
00:18:33,976 --> 00:18:37,380
THE OPERATOR CONFIRMS THAT THE
FIRST BEND IS ANGLED CORRECTLY.
296
00:18:39,915 --> 00:18:42,751
HE THEN SPRINKLES LUBRICANT
AND AIMS THE PRESS
297
00:18:42,752 --> 00:18:45,121
A FEW CENTIMETERS
AWAY FROM THE FIRST BEND.
298
00:18:47,924 --> 00:18:50,026
IT TAKES SIX TO EIGHT HITS
TO ACHIEVE
299
00:18:50,027 --> 00:18:52,629
THE DESIRED 90-DEGREE ANGLE.
300
00:18:55,865 --> 00:18:57,266
ONCE SATISFIED,
301
00:18:57,267 --> 00:18:59,570
HE'LL BEND THE OTHER END
TO THE SAME DEGREE.
302
00:19:07,978 --> 00:19:11,747
USING ROLLERS, THE FACTORY
TRANSFORMS A FLAT PIECE OF STEEL
303
00:19:11,748 --> 00:19:14,117
INTO THE BOTTOM
AND BACK WALL OF THE BUCKET.
304
00:19:18,221 --> 00:19:19,855
THE OPERATOR
CHECKS THE CURVATURE
305
00:19:19,856 --> 00:19:22,791
OF THE PART WITH EACH PASS
UNTIL IT'S SPOT ON.
306
00:19:22,792 --> 00:19:26,595
THEY'RE NOW READY
TO PULL ALL THE PIECES
307
00:19:26,596 --> 00:19:29,366
OF THE EXCAVATION BUCKET
TOGETHER.
308
00:19:32,735 --> 00:19:35,337
USING CHAINS
AND A HYDRAULIC SYSTEM,
309
00:19:35,338 --> 00:19:37,808
THEY PULL THE SIDES UP
TO MEET THE BACK WALL.
310
00:19:41,043 --> 00:19:43,878
THE STEEL TEMPLATE
IS NOW PUT TO USE.
311
00:19:43,879 --> 00:19:46,314
IT'S POSITIONED
ON THE FRONT LOWER LIP,
312
00:19:46,315 --> 00:19:49,486
AND SERVES AS A GUIDE
AS THE CHAINS BEND THE SIDES.
313
00:19:51,989 --> 00:19:54,423
WITH THE SIDES
NOW FLUSH TO THE BACK,
314
00:19:54,424 --> 00:19:56,724
A WELDER
FIRST TACKS THEM TOGETHER
315
00:19:56,725 --> 00:19:58,494
AND THEN DOES PERMANENT WELDS.
316
00:20:05,969 --> 00:20:07,102
HE GUIDES THE BLADE
317
00:20:07,103 --> 00:20:10,739
INTO POSITION
AT THE FRONT OF THE BUCKET
318
00:20:10,740 --> 00:20:13,075
AND WELDS IT TO IT.
319
00:20:13,076 --> 00:20:14,745
WHEN THIS WELD IS COMPLETE,
320
00:20:14,746 --> 00:20:16,280
HE'LL REMOVE THE STEEL TEMPLATE.
321
00:20:17,880 --> 00:20:21,983
THE ATTACHMENT PLATES HAVE BY
NOW BEEN LINKED BY THICK PINS.
322
00:20:21,984 --> 00:20:24,185
THEY LOWER IT ONTO THE TOP
OF THE BUCKET,
323
00:20:24,186 --> 00:20:28,624
AND IT FITS SNUGLY TO THE ARCH
AND THE TO THE BACK WALL.
324
00:20:28,625 --> 00:20:30,894
HE WELDS THE ATTACHMENT ASSEMBLY
TO THE BUCKET.
325
00:20:33,930 --> 00:20:36,066
THEY PAINT THE BUCKET
INSIDE AND OUT.
326
00:20:40,002 --> 00:20:45,206
YELLOW OR BLACK ARE POPULAR
CHOICES FOR EXCAVATION BUCKETS.
327
00:20:45,207 --> 00:20:47,608
CLIENTS USUALLY MATCH THE COLOR
OF THE BUCKET
328
00:20:47,609 --> 00:20:49,045
TO THE MACHINE THAT MOVES IT.
329
00:20:55,985 --> 00:20:57,686
IT TAKES ABOUT 50 HOURS
330
00:20:57,687 --> 00:21:00,087
TO MANUFACTURE
AN EXCAVATION BUCKET,
331
00:21:00,088 --> 00:21:02,225
AND THEN
IT'S READY TO HIT THE GROUND.
332
00:21:13,002 --> 00:21:16,372
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
333
00:21:16,373 --> 00:21:19,575
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
334
00:21:19,576 --> 00:21:24,181
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