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-- Captions by VITAC --
www.vitac.com
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00:00:05,304 --> 00:00:08,341
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
THE MOBILE CONCERT STAGE
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WAS INVENTED IN CANADA
IN THE 1980s.
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IT USES HYDRAULICS TO FOLD INTO
A TRAILER FOR TRANSPORT
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00:01:01,826 --> 00:01:05,595
AND THEN UNFOLDS UPON ARRIVAL
AT THE EVENT VENUE.
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00:01:05,596 --> 00:01:09,634
IT TAKES 45 MINUTES FOR A CREW
TO SET UP A MOBILE STAGE,
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00:01:09,635 --> 00:01:11,603
AND THEN IT'S SHOW TIME.
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00:01:15,441 --> 00:01:18,009
NO STAGE? NO PROBLEM.
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00:01:18,010 --> 00:01:20,845
JUST ORDER
A MOBILE HYDRAULIC STAGE,
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00:01:20,846 --> 00:01:24,383
AND IN LESS THAN AN HOUR,
YOU'RE READY TO ROCK 'N' ROLL.
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00:01:24,384 --> 00:01:26,116
THE CONVENIENCE MEANS
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00:01:26,117 --> 00:01:29,923
IT HAS PLENTY OF FANS IN
THE EVENT-PRODUCTION INDUSTRY.
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00:01:32,391 --> 00:01:35,527
A MOBILE STAGE STARTS
WITH THE TRAILER FRAMEWORK.
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00:01:35,528 --> 00:01:39,997
A WORKER SAWS ALUMINUM BEAMS
TO LENGTH.
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00:01:39,998 --> 00:01:42,467
AT THE SAME TIME,
ANOTHER MEMBER OF THE TEAM
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00:01:42,468 --> 00:01:45,702
PIECES TOGETHER ALUMINUM TUBING
FOR THE ROOF.
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00:01:45,703 --> 00:01:49,975
HE WELDS THE JOINTS TO COMPLETE
THE ROOF'S SKELETON.
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00:01:52,578 --> 00:01:56,648
HE THEN WELDS THE TRAILER
SUPPORT STRUCTURE TOGETHER.
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00:01:56,649 --> 00:01:59,283
WITH THE GIRDERS ASSEMBLED,
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00:01:59,284 --> 00:02:03,721
THE TRAILER'S SUBSTRUCTURE IS
READY FOR THE AXLES AND WHEELS.
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00:02:03,722 --> 00:02:07,326
EACH AXLE CAN SUPPORT
10,000 POUNDS OF WEIGHT.
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00:02:11,163 --> 00:02:15,333
THEY INSTALL HYDRAULIC CYLINDERS
ON EACH CORNER OF THE TRAILER.
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00:02:15,334 --> 00:02:18,736
THESE CYLINDERS ARE
THE EXTENDABLE LEGS
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00:02:18,737 --> 00:02:21,875
THAT WILL STABILIZE
THE STAGE TRAILER ON THE GROUND.
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00:02:29,681 --> 00:02:32,751
NEXT UP IS A PANEL WITH VALVES
TO CONTROL
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THE FLOW OF HYDRAULIC FLUID.
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THEY BOLT THE PANEL TO THE BACK
OF THE TRAILER
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00:02:42,328 --> 00:02:44,996
AND CONNECT HOSES TO THE VALVES.
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THIS NETWORK OF HOSES
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WILL CIRCULATE FLUID
FOR THE HYDRAULICS.
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00:02:52,371 --> 00:02:57,407
THEY COVER THE VALVES AND HOSES
WITH A METAL PLATE.
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00:02:57,408 --> 00:03:01,281
THE PLATE HAS SLOTS
FOR CONTROL LEVERS.
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00:03:03,716 --> 00:03:06,052
THEY SCREW THE LEVERS
TO THE VALVES.
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00:03:11,956 --> 00:03:17,027
HE THEN INSTALLS
A HYDRAULIC PRESSURE GAUGE.
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00:03:17,028 --> 00:03:20,065
THE TEAM NOW LOWERS THE TANK
FOR THE HYDRAULIC FLUID
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INTO THE BASE FRAME
AND SECURES IT.
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00:03:27,272 --> 00:03:29,806
THEY RUN THE HOSES
FOR THE HYDRAULIC FLUID
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00:03:29,807 --> 00:03:32,745
THROUGH A FILTER AT THE ENTRANCE
TO THE TANK.
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00:03:39,084 --> 00:03:43,488
THEY'RE READY FOR THE EXTENDABLE
SUPPORTS FOR THE STAGE MAST.
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00:03:43,489 --> 00:03:46,625
USING A FORKLIFT, THEY MANEUVER
THE PARTS INTO PLACE
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00:03:46,626 --> 00:03:48,992
AT THE ENDS OF THE TRAILER.
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00:03:48,993 --> 00:03:50,929
THEY RETURN TO THE FLOOR
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00:03:50,930 --> 00:03:54,931
AND BOLT SIX HYDRAULIC CYLINDERS
INTO THE FRAMEWORK.
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00:03:54,932 --> 00:03:58,304
THEY'LL BE USED TO LIFT
AND LOWER THE FLOORS.
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THE ROOF STRUCTURE IS NEXT.
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00:04:09,647 --> 00:04:11,948
A CRANE DOES THE LIFTING,
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00:04:11,949 --> 00:04:15,486
AND A WORKER GUIDES THE PANELS
ONTO THE BEAMS.
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00:04:15,487 --> 00:04:20,459
THEY SECURE THE PANELS WITH
HINGES, TORQUING THEM TIGHTLY.
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00:04:23,661 --> 00:04:25,996
THE TEAM TRANSFERS
THE FLOOR PANELS
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TO BOTH SIDES
OF THE MAIN CHASSIS.
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THE INSTALL LEG JACKS
TO SUPPORT THEM.
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THERE ARE EIGHT JACKS
FOR EACH FLOOR PANEL.
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00:04:44,016 --> 00:04:46,184
THEY INSTALL
MORE HYDRAULIC CYLINDERS
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00:04:46,185 --> 00:04:48,221
FOR RAISING AND LOWERING
THE FLOOR.
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00:04:51,757 --> 00:04:55,228
THIS MOBILE CONCERT STAGE
IS READY FOR THE OUTER SKIN.
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00:04:57,463 --> 00:05:01,633
AN EMPLOYEE GLUES FIBERGLASS
SHEETING TO THE SIDES.
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00:05:01,634 --> 00:05:05,838
A TEAM THEN LAYS THE PLYWOOD
FLOORS SHEET BY SHEET.
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00:05:12,478 --> 00:05:14,879
THE PLYWOOD IS MARINE-GRADE.
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00:05:14,880 --> 00:05:18,415
IT HAS
A LAMINATE COMPOSITE SURFACE.
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00:05:18,416 --> 00:05:21,586
THE LAMINATE IS TEXTURED
FOR SKID RESISTANCE.
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00:05:24,589 --> 00:05:28,126
IT'S ALSO WATERPROOF
FOR OUTDOOR EVENTS.
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00:05:32,798 --> 00:05:35,299
ONCE ALL THE PANELING
IS IN PLACE,
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THIS MOBILE STAGE IS
READY TO GO ON TOUR.
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EIGHT WEEKS IN THE MAKING,
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IT WILL BE A TIME-SAVER
ON THE ROAD.
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Narrator:
ONE WAY TO ENHANCE EYELASHES
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IS TO COAT THEM WITH MASCARA.
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EARLY MASCARAS WERE MADE
OF PETROLEUM JELLY AND COAL
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00:06:06,873 --> 00:06:10,444
OR SOAP CAKE
TINTED WITH BLACK DYE.
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00:06:10,445 --> 00:06:13,014
TODAY'S LIQUID MASCARA
COMES IN A TUBE
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00:06:13,015 --> 00:06:15,883
WITH AN APPLICATOR BRUSH
BUILT RIGHT INTO THE CAP.
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MASCARA FORMULATIONS VARY.
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00:06:23,691 --> 00:06:28,927
THE BASIC INGREDIENTS ARE WAX,
WATER, PIGMENT, AND BINDERS.
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ADDITIONAL INGREDIENTS
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PRODUCE FEATURES
SUCH AS WATER RESISTANCE.
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00:06:38,171 --> 00:06:40,206
EVERY FORMULATION IS
COMPRISED OF
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AN OIL-SOLUBLE PHASE
AND A WATER-SOLUBLE PHASE.
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TO PREPARE
THIS MASCARA'S OIL PHASE,
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00:06:46,380 --> 00:06:49,382
A TECHNICIAN COMBINES
FOUR TYPES OF WAX --
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00:06:49,383 --> 00:06:52,485
CARNAUBA,
FROM A BRAZILIAN PALM TREE;
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00:06:52,486 --> 00:06:54,553
CANDELILLA,
FROM A PLANT THAT GROWS
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00:06:54,554 --> 00:06:56,689
IN PARTS OF MEXICO AND TEXAS;
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00:06:56,690 --> 00:06:59,559
BEESWAX; AND GLYCERYL STEARATE,
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00:06:59,560 --> 00:07:03,297
AN EMULSIFIER WHICH HELPS
INGREDIENTS BLEND WELL.
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00:07:03,298 --> 00:07:07,468
NEXT COMES VITAMIN "E,"
WHICH CONDITIONS LASHES
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AND GIVES THE MASCARA
A SMOOTH TEXTURE.
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00:07:09,871 --> 00:07:15,041
AFTER THAT IS A CHEMICAL
COMPOUND CALLED PELEMOL D-2000,
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00:07:15,042 --> 00:07:17,377
WHICH MAKES THE MASCARA
WATER-RESISTANT.
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00:07:17,378 --> 00:07:21,380
THE TECHNICIAN HEATS THIS
OIL PHASE OF THE FORMULATION.
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00:07:21,381 --> 00:07:26,053
ONCE THE WAXES BEGIN MELTING,
BLENDS THE INGREDIENTS.
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WAX IS A THICKENER.
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00:07:32,592 --> 00:07:37,564
THIS CALCULATED COMBINATION
OF FOUR DIFFERENT WAXES PRODUCES
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00:07:37,565 --> 00:07:41,403
A SEMILIQUID GEL THAT
COATS LASHES WITH A SHINY FILM.
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00:07:44,873 --> 00:07:46,574
THE TECHNICIAN NOW PREPARES
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00:07:46,575 --> 00:07:49,908
THE WATER-SOLUBLE PHASE
OF THE FORMULATION SEPARATELY,
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00:07:49,909 --> 00:07:55,148
FIRST, HEATING UP COLD WATER,
THEN ADDING AN EMULSIFIER.
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00:07:55,149 --> 00:07:57,850
THIS WILL BIND
THE WATER AND OIL PHASES
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00:07:57,851 --> 00:07:59,886
WHEN THEY'RE COMBINED LATER ON.
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00:07:59,887 --> 00:08:01,588
WITHOUT AN EMULSIFIER,
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00:08:01,589 --> 00:08:04,624
OIL AND WATER SOLUBLES
WOULD NATURALLY SEPARATE.
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00:08:04,625 --> 00:08:06,425
THE NEXT INGREDIENT IS
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00:08:06,426 --> 00:08:09,295
A COSMETIC-GRADE
IRON OXIDE PIGMENT.
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THE COLOR IS BLACK BECAUSE
SHE'S MAKING BLACK MASCARA.
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SHE BLENDS THE MIXTURE
UNTIL THE COLOR IS UNIFORM.
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00:08:22,275 --> 00:08:24,644
THEN SHE ADDS T.E.A.
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00:08:24,645 --> 00:08:28,081
THIS ORGANIC COMPOUND BALANCES
THE MASCARA'S pH LEVEL
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SO THAT IT ISN'T TOO ACIDIC
OR ALKALINE.
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00:08:31,951 --> 00:08:36,989
NEXT, SHE ADDS A COSMETIC POWDER
TO MAKE THE MASCARA SILKY
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00:08:36,990 --> 00:08:40,392
AND A CHEMICAL TO PROVIDE
ADDITIONAL WATER RESISTANCE.
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00:08:40,393 --> 00:08:43,729
FINALLY, SHE COMPLETES
THE FORMULATION
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00:08:43,730 --> 00:08:46,366
BY ADDING THE OIL PHASE
TO THIS WATER PHASE.
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00:08:46,367 --> 00:08:48,768
HEATING THE MIXTURE
WHILE BLENDING
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00:08:48,769 --> 00:08:51,739
PREVENTS THE WAXES
FROM SOLIDIFYING.
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00:08:54,008 --> 00:08:55,508
BEFORE PACKAGING,
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00:08:55,509 --> 00:08:59,313
THE FACTORY'S CHEMIST RUNS
QUALITY-CONTROL TESTS.
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00:09:03,050 --> 00:09:05,852
USING A VISCOMETER TO MEASURE
THICKNESS,
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00:09:05,853 --> 00:09:09,589
HE MAKES SURE THE MASCARA
ISN'T RUNNY OR GOOEY.
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00:09:09,590 --> 00:09:12,693
HE ALSO TESTS THE pH LEVEL.
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00:09:14,729 --> 00:09:17,296
IF THE SAMPLE MEETS
SPECIFICATIONS,
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00:09:17,297 --> 00:09:20,599
THE LAB GIVES THE GO-AHEAD
TO PACKAGE THE MASCARA,
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00:09:20,600 --> 00:09:25,671
AND A WORKER POURS THE BATCH
INTO A FILLING MACHINE.
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00:09:25,672 --> 00:09:29,508
THE MACHINE CONTINUOUSLY MIXES
THE MASCARA
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00:09:29,509 --> 00:09:33,146
AND KEEPS IT HOT
SO THAT IT REMAINS LIQUID.
125
00:09:33,147 --> 00:09:36,782
OTHERWISE, THE MASCARA WOULD
BEGIN TO COOL AND JELLIFY
126
00:09:36,783 --> 00:09:39,820
AND CLOG THE FILLING NOZZLE.
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00:09:43,290 --> 00:09:45,458
A MASCARA BOTTLE
TYPICALLY CONTAINS
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00:09:45,459 --> 00:09:48,026
ABOUT 2 OUNCES OF MASCARA.
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00:09:48,027 --> 00:09:49,429
AS IT COOLS IN THE BOTTLE,
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00:09:49,430 --> 00:09:52,967
IT TRANSFORMS
INTO A SEMILIQUID GEL.
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00:09:55,101 --> 00:09:56,703
SHE SEALS THE BOTTLE
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00:09:56,704 --> 00:10:00,041
BY PRESSING IN
A PLUNGER-STYLE PLASTIC STOPPER.
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00:10:03,777 --> 00:10:06,411
THE STOPPER HAS A HOLE
IN THE MIDDLE FOR INSERTING
134
00:10:06,412 --> 00:10:10,618
THE BRUSH APPLICATOR THAT'S
BUILT INTO THE BOTTLE'S CAP.
135
00:10:13,987 --> 00:10:17,324
THE LIP OF THE STOPPER HOLE
IS DESIGNED TO WIPE OFF
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00:10:17,325 --> 00:10:21,527
EXCESS MASCARA AS YOU PULL
THE BRUSH OUT OF THE BOTTLE.
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00:10:21,528 --> 00:10:26,500
THIS HELPS PREVENT THE MASCARA
FROM CLUMPING.
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00:10:29,302 --> 00:10:32,738
THIS MANUFACTURER FILLS
SMALL ORDERS MANUALLY,
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00:10:32,739 --> 00:10:35,040
LIKE THIS ONE
FOR A PRIVATE-LABEL BRAND.
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00:10:35,041 --> 00:10:39,478
ITS AUTOMATED PRODUCTION LINE
IS RESERVED FOR LARGE ORDERS.
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00:10:39,479 --> 00:10:41,781
REGARDLESS OF QUANTITY,
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00:10:41,782 --> 00:10:44,251
CLIENTS SPECIFY
THE CHARACTERISTICS THEY WANT
143
00:10:44,252 --> 00:10:45,917
IN THEIR BRAND OF MASCARA,
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00:10:45,918 --> 00:10:48,988
SUCH AS LENGTHENING
OR WATER RESISTANCE,
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00:10:48,989 --> 00:10:52,993
AND THE MANUFACTURER TAILORS
THE FORMULATION ACCORDINGLY.
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00:11:05,605 --> 00:11:09,374
Narrator: THE CONTINUOUS MINER
IS ALWAYS ON THE JOB.
147
00:11:09,375 --> 00:11:12,744
THIS MACHINE CONSTANTLY
BORES INTO DEPOSITS OF COAL,
148
00:11:12,745 --> 00:11:16,616
SALT, OR POT ASH TO BREAK THEM
INTO LITTLE PIECES.
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00:11:16,617 --> 00:11:19,453
ITS INVENTION IN AMERICA
IN THE 1940s
150
00:11:19,454 --> 00:11:21,656
WAS AN EARTH-SHATTERING
DEVELOPMENT.
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00:11:26,125 --> 00:11:30,230
THE CONTINUOUS MINER IS A FORCE
TO BE RECKONED WITH UNDERGROUND.
152
00:11:32,532 --> 00:11:35,635
A SPINNING DRUM IS SPIKED
WITH TUNGSTEN CARBIDE TEETH.
153
00:11:35,636 --> 00:11:37,771
IT TEARS INTO THE ROCK FACE
154
00:11:37,772 --> 00:11:41,940
AND SPITS THE PIECES OUT
ONTO A CONVEYOR.
155
00:11:44,579 --> 00:11:49,214
THE CONTINUOUS MINER CAN REMOVE
24 TONS OF MINERALS PER MINUTE.
156
00:11:49,215 --> 00:11:54,421
THAT'S MORE THAN A HUMAN MINER
CAN DIG IN AN ENTIRE DAY.
157
00:11:57,291 --> 00:11:59,525
THE WORK IS HARD
ON THE EQUIPMENT,
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00:11:59,526 --> 00:12:01,761
AND, SO, EVENTUALLY,
THE CONTINUOUS MINER
159
00:12:01,762 --> 00:12:04,031
UNDERGOES A COMPLETE REBUILD.
160
00:12:04,032 --> 00:12:07,499
IT STARTS WITH
AN EXTENSIVE CLEANING.
161
00:12:07,500 --> 00:12:09,268
AFTER A STEAM WASH,
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00:12:09,269 --> 00:12:12,539
A WORKER AIMS A TORCH
AT THE BOLTS OF THE DRUM.
163
00:12:12,540 --> 00:12:15,308
THE HEAT CAUSES THE BOLTS
TO EXPAND
164
00:12:15,309 --> 00:12:17,111
AND MOVE AWAY FROM THE HOLE.
165
00:12:17,112 --> 00:12:19,246
THIS MAKES IT EASIER
TO PULL THEM OUT,
166
00:12:19,247 --> 00:12:21,516
USING A PNEUMATIC IMPACT WRENCH.
167
00:12:24,652 --> 00:12:26,786
ONCE ALL THE BOLTS
HAVE BEEN REMOVED,
168
00:12:26,787 --> 00:12:30,458
THE DRUM CAN BE PRIED
FROM THE SHAFT.
169
00:12:32,658 --> 00:12:35,962
ONCE FREE,
A CRANE LIFTS THE HEAVY DRUM,
170
00:12:35,963 --> 00:12:39,132
AND WORKERS GUIDE IT
TO THE NEXT STATION.
171
00:12:39,133 --> 00:12:41,767
HERE, A WORKER
IN PROTECTIVE GEAR
172
00:12:41,768 --> 00:12:45,305
BLASTS THE DRUM
WITH TINY STEEL SHOT.
173
00:12:45,306 --> 00:12:47,841
THIS REMOVES
ANY REMAINING DIRT AND GRIME.
174
00:12:52,780 --> 00:12:55,283
SOME PARTS, LIKE THESE
CENTRIFUGAL LOADING ARMS,
175
00:12:55,284 --> 00:12:59,752
ARE BEYOND REPAIR,
SO THEY BUILD NEW ONES.
176
00:12:59,753 --> 00:13:01,420
CONNECTED TO A HUB,
177
00:13:01,421 --> 00:13:03,622
THESE ARMS WILL MOVE
MINED MATERIAL
178
00:13:03,623 --> 00:13:05,824
ONTO THE MACHINE'S CONVEYOR.
179
00:13:05,825 --> 00:13:09,529
A WORKER REINFORCES EACH ONE
WITH A WEAR PLATE.
180
00:13:11,764 --> 00:13:14,300
HE THEN HEATS THE WEAR PLATE
AND LOADING ARM
181
00:13:14,301 --> 00:13:16,803
BEFORE WELDING THEM TOGETHER.
182
00:13:16,804 --> 00:13:18,204
PREHEATING REDUCES
183
00:13:18,205 --> 00:13:21,075
THE POSSIBILITY
OF THE WELD CRACKING.
184
00:13:24,311 --> 00:13:26,146
THEY LOWER
THE LOADING-ARM ASSEMBLY
185
00:13:26,147 --> 00:13:27,949
INTO THE MACHINE FRAMEWORK.
186
00:13:33,186 --> 00:13:36,989
THEN A COMPUTERIZED CUTTER
CARVES A SHEET OF STEEL
187
00:13:36,990 --> 00:13:40,627
TO MAKE NEW ACCESS PANELS
FOR THE CONTINUOUS MINER.
188
00:13:44,965 --> 00:13:47,800
THE SLICING FORCE
COMES FROM A PRESSURIZED MIXTURE
189
00:13:47,801 --> 00:13:50,335
OF WATER AND GARNET GRANULES.
190
00:13:50,336 --> 00:13:52,572
NO BLADE IS NECESSARY.
191
00:13:56,176 --> 00:13:59,280
THE OPERATOR OF THE MACHINE
HOSES OFF THE FILINGS.
192
00:14:01,983 --> 00:14:04,751
HE RETRIEVES THE CUT PART
WITH A MAGNET.
193
00:14:04,752 --> 00:14:09,088
OVER TO THE CONVEYOR PART
OF THE CONTINUOUS MINER NOW.
194
00:14:09,089 --> 00:14:12,290
THEY HAD BUILT UP THE HOLE
FOR THE PIVOT PIN
195
00:14:12,291 --> 00:14:14,661
BECAUSE IT HAD STRETCHED
FROM WEAR.
196
00:14:14,662 --> 00:14:17,430
A TOOL MILLS THE BUILT-UP HOLE
197
00:14:17,431 --> 00:14:20,100
TO RETURN IT
TO THE CORRECT DIAMETER.
198
00:14:25,506 --> 00:14:27,540
THE TEAM THEN FOCUSES ON
199
00:14:27,541 --> 00:14:30,477
THE MAIN FRAMES
OF THE CONTINUOUS MINER.
200
00:14:30,478 --> 00:14:33,046
THEY WELD THE CRACKS
AND GRIND THEM SMOOTH.
201
00:14:36,749 --> 00:14:39,018
NOW BEGINNING
WITH THE CONVEYOR TAIL,
202
00:14:39,019 --> 00:14:41,753
A WORKER SPRAY PAINTS
THE CONTINUOUS MINER
203
00:14:41,754 --> 00:14:43,758
ONE PIECE AT A TIME.
204
00:14:47,460 --> 00:14:49,627
ANOTHER MEMBER OF THE TEAM
205
00:14:49,628 --> 00:14:53,334
INSERTS NEW PLUGS
INTO AN ELECTRICAL CONTROL BOX.
206
00:14:57,137 --> 00:14:59,005
HE BOLTS THE PANEL,
207
00:14:59,006 --> 00:15:02,243
HOLDING ELECTRICAL CONTROLS
TO THE MACHINE CASING.
208
00:15:07,046 --> 00:15:09,582
HE THEN INSTALLS HEAVY DOORS
THAT SWING OPEN
209
00:15:09,583 --> 00:15:12,887
SO THE ELECTRICAL CAN BE
EASILY ACCESSED.
210
00:15:16,022 --> 00:15:19,090
THERE ARE A TOTAL
OF 25 COVERS AND DOORS
211
00:15:19,091 --> 00:15:21,460
ON THE CONTINUOUS MINER.
212
00:15:21,461 --> 00:15:25,430
SOME PROTECT HYDRAULIC HOSES.
213
00:15:25,431 --> 00:15:29,135
OTHERS ENCASE THE WIRING
OR GEAR BOXES.
214
00:15:29,136 --> 00:15:30,637
THEY CAN ALL BE REMOVED
215
00:15:30,638 --> 00:15:33,173
IF MAINTENANCE
NEEDS TO BE PERFORMED.
216
00:15:36,942 --> 00:15:40,079
IT'S TAKEN SEVERAL MONTHS
FOR THIS MASSIVE OVERHAUL,
217
00:15:40,080 --> 00:15:42,815
AND THEY'RE READY TO PUT
THIS REBUILT CONTINUOUS MINER
218
00:15:42,816 --> 00:15:45,517
TO THE TEST.
219
00:15:45,518 --> 00:15:48,188
USING THE MACHINE'S
REMOTE CONTROL,
220
00:15:48,189 --> 00:15:52,025
A TECHNICIAN CHECKS THE FUNCTION
OF EVERY COMPONENT.
221
00:15:52,026 --> 00:15:54,526
WITH HIS APPROVAL,
222
00:15:54,527 --> 00:15:56,795
THE CONTINUOUS MINER
GOES BACK UNDERGROUND
223
00:15:56,796 --> 00:15:59,734
TO PICK UP WHERE IT LEFT OFF.
224
00:16:09,000 --> 00:16:10,368
Narrator: A PRODUCT PRESENTED
IN A BEAUTIFUL,
225
00:16:10,369 --> 00:16:13,738
HIGH-QUALITY, WOODEN BOX
IS SURE TO STAND OUT.
226
00:16:13,739 --> 00:16:17,542
COMPANIES USE THEM
AS SPECIAL-EVENT DISPLAYS
227
00:16:17,543 --> 00:16:19,676
OR AS CORPORATE GIFT BOXES.
228
00:16:19,677 --> 00:16:21,780
BECAUSE THEY'RE HANDMADE,
229
00:16:21,781 --> 00:16:25,251
THE BOXES CAN BE CUSTOMIZED
TO SHOWCASE EACH PRODUCT.
230
00:16:28,152 --> 00:16:31,922
WOOD GIFT BOXES MAKE WONDERFUL
CASES FOR SPIRIT BOTTLES,
231
00:16:31,923 --> 00:16:35,727
COLLECTIBLE COINS, WATCHES,
OR CHRISTMAS ORNAMENTS.
232
00:16:35,728 --> 00:16:38,630
NOT ONLY DO THEY DISPLAY
THE PRODUCT BEAUTIFULLY,
233
00:16:38,631 --> 00:16:41,332
THEY ALSO PROTECT
THE CONTENTS INSIDE.
234
00:16:41,333 --> 00:16:44,736
TODAY, THEY'RE MAKING A BOX
WITH MAPLE BOARDS,
235
00:16:44,737 --> 00:16:48,873
WHICH ARE CUT
ON AN AUTOMATED SAW.
236
00:16:48,874 --> 00:16:50,874
A MORTISER'S PARALLEL BLADES
237
00:16:50,875 --> 00:16:54,345
CUT SQUARE-SHAPED NOTCHES
AT THE END OF EACH PLANK.
238
00:16:54,346 --> 00:16:58,249
THESE WILL SERVE TO FINGER JOINT
THE SIDES OF THE BOX LATER ON.
239
00:16:58,250 --> 00:17:01,218
THE PIECES OF WOOD ARE
PRESSED AGAINST THE CORNER
240
00:17:01,219 --> 00:17:04,521
SO THAT THE RESULTING FINGERS
ARE PERFECTLY ALIGNED.
241
00:17:04,522 --> 00:17:06,358
THE FACTORY
USUALLY MAKES FINGERS
242
00:17:06,359 --> 00:17:08,225
THAT ARE 6 MILLIMETERS WIDE.
243
00:17:08,226 --> 00:17:10,094
WIDER FINGERS
WOULD BE UNSIGHTLY,
244
00:17:10,095 --> 00:17:13,132
AND THINNER ONES WOULD BE
TOO FRAGILE.
245
00:17:15,134 --> 00:17:17,702
THEY NOW PREPARE
THE TOP OF THE WOOD BOX.
246
00:17:17,703 --> 00:17:19,870
A PRESS USES HEAT AND PRESSURE
247
00:17:19,871 --> 00:17:23,508
TO STAMP THE COMPANY'S LOGO
ON THE SURFACE OF THE WOOD.
248
00:17:23,509 --> 00:17:26,344
THEY BRAND THE WOOD
WITH A MAGNESIUM PLATE,
249
00:17:26,345 --> 00:17:28,847
HEATING TO 840 DEGREES
FAHRENHEIT.
250
00:17:28,848 --> 00:17:32,684
THE PROCESS TAKES
JUST TWO SECONDS.
251
00:17:32,685 --> 00:17:35,986
NEXT, THEY ASSEMBLE THE SIDES,
252
00:17:35,987 --> 00:17:38,223
INTERLOCKING THE PIECES
MANUALLY.
253
00:17:38,224 --> 00:17:39,991
THEY USE A RUBBER MALLET
254
00:17:39,992 --> 00:17:42,994
TO AVOID DAMAGING OR DENTING
THE WOOD.
255
00:17:42,995 --> 00:17:46,630
WHEN THE FOUR SIDES ARE
END TO END,
256
00:17:46,631 --> 00:17:48,733
THEY APPLY A SMALL AMOUNT
OF WOOD GLUE
257
00:17:48,734 --> 00:17:51,735
ON THE INSIDE OF EACH JOINT.
258
00:17:51,736 --> 00:17:56,473
THEY FORM THE CORNERS
AT A 90-DEGREE ANGLE.
259
00:17:56,474 --> 00:17:59,042
ONCE THE BOX IS ASSEMBLED,
260
00:17:59,043 --> 00:18:02,314
A PRESS WILL FINISH PUSHING IN
THE FINGERS ON EACH JOINT.
261
00:18:04,850 --> 00:18:06,983
WHEN THE BOX COMES OUT
OF THE PRESS,
262
00:18:06,984 --> 00:18:09,020
THEY CHECK THE SQUARE.
263
00:18:09,021 --> 00:18:14,192
THEY APPLY WOOD GLUE
FOR THE BOTTOM OF THE BOX.
264
00:18:14,193 --> 00:18:16,860
SINCE THE BOTTOM IS
LESS VISIBLE,
265
00:18:16,861 --> 00:18:19,798
CLIENTS SOMETIMES CHOOSE PLYWOOD
INSTEAD OF SOLID WOOD
266
00:18:19,799 --> 00:18:21,734
TO SAVE ON COSTS.
267
00:18:25,972 --> 00:18:28,473
THEY GLUE A SOLID MAPLE TOP,
268
00:18:28,474 --> 00:18:31,210
AND THE BOXES GO INTO PRESS
FOR 35 MINUTES
269
00:18:31,211 --> 00:18:33,344
UNTIL THE GLUE DRIES.
270
00:18:33,345 --> 00:18:39,751
AFTER SANDING, A ROUTER SHAPES
THE EDGE OF THE BOX'S TOP.
271
00:18:39,752 --> 00:18:41,953
BY CHANGING THE ROUTER-BIT,
272
00:18:41,954 --> 00:18:46,157
THEY CAN CREATE ALL KINDS
OF DECORATIVE PROFILES.
273
00:18:46,158 --> 00:18:49,860
THIS ONE IS SIMPLY ROUNDED.
274
00:18:49,861 --> 00:18:55,599
THEY SAND THE WHOLE BOX AGAIN
WITH 120-GRIT SANDPAPER,
275
00:18:55,600 --> 00:18:58,537
AND FINISH
WITH 180-GRIT SANDPAPER.
276
00:19:01,205 --> 00:19:04,675
NOW THEY CAN CUT THE BOX OPEN,
STARTING AT THE BACK.
277
00:19:04,676 --> 00:19:06,476
THEY CREATE A WIDE ANGLE
278
00:19:06,477 --> 00:19:10,248
SO THE LID CAN OPEN FREELY
ON ITS HINGES.
279
00:19:10,249 --> 00:19:11,918
NEXT, THEY MAKE A STRAIGHT CUT
280
00:19:11,919 --> 00:19:14,319
THROUGH EACH
OF THE THREE REMAINING SIDES,
281
00:19:14,320 --> 00:19:16,253
SAWING THE BOX IN HALF.
282
00:19:16,254 --> 00:19:19,022
THEY SEPARATE THE BODY
FROM THE LID,
283
00:19:19,023 --> 00:19:21,125
AND THE TWO MATCH UP PERFECTLY.
284
00:19:21,126 --> 00:19:23,560
EACH HALF OF THE BOX
285
00:19:23,561 --> 00:19:27,197
GOES ON AN AUTOMATED MILLING
MACHINE CALLED A SLOTTER.
286
00:19:27,198 --> 00:19:30,469
IT CUTS THE SLOTS IN THE WOOD
ON THE BACK OF THE BOX.
287
00:19:32,705 --> 00:19:35,706
THESE SLOTS WILL RECEIVE
THE HINGES.
288
00:19:35,707 --> 00:19:39,609
THE BOTTOM OF EACH SLOT
IS ROUNDED
289
00:19:39,610 --> 00:19:42,579
TO CRADLE THE ROUNDED ENDS
OF THE HINGES.
290
00:19:42,580 --> 00:19:45,249
THESE HINGES ARE MADE
OF NICKEL-PLATED METAL.
291
00:19:45,250 --> 00:19:47,185
THEY'RE DESIGNED
TO BE PRESSURE FITTED,
292
00:19:47,186 --> 00:19:50,021
SO THEY WON'T NEED ANY SCREWS
TO STAY IN PLACE.
293
00:19:50,022 --> 00:19:52,290
THE WORKER USES A RUBBER MALLET
294
00:19:52,291 --> 00:19:55,427
TO INSERT THE HINGES IN THE BODY
OF THE BOX.
295
00:19:59,665 --> 00:20:02,133
ONCE THE HINGES ARE ALIGNED
WITH THE LID,
296
00:20:02,134 --> 00:20:03,801
HE SQUEEZES THEM TIGHT,
297
00:20:03,802 --> 00:20:07,437
USING THE HAMMER AGAIN
IF NECESSARY.
298
00:20:07,438 --> 00:20:11,041
THE ANGLED CUT CREATES
ENOUGH SPACE FOR THE HINGES
299
00:20:11,042 --> 00:20:13,612
AND HELPS TO OPEN THE LID.
300
00:20:15,915 --> 00:20:19,483
THEY APPLY A COAT OF SEALER,
LIGHTLY SAND THE WOOD,
301
00:20:19,484 --> 00:20:23,320
AND FINISH
WITH A COAT OF LACQUER.
302
00:20:23,321 --> 00:20:25,623
WHEN THE LACQUER IS DRY,
303
00:20:25,624 --> 00:20:29,094
THEY INSTALL THE MAGNETIC
CLOSURE IN A PRE-DRILLED HOLE.
304
00:20:29,095 --> 00:20:31,529
ANOTHER MAGNET
GOES INTO THE LID,
305
00:20:31,530 --> 00:20:34,099
AND THAT MAKES
FOR A NICE-CLOSING BOX.
306
00:20:35,399 --> 00:20:38,269
THEY STICK A PIECE
OF SELF-ADHESIVE FELT
307
00:20:38,270 --> 00:20:41,606
TO THE BOTTOM OF THE BOX
AND TRIM THE EXCESS.
308
00:20:41,607 --> 00:20:44,541
NEXT, THEY LINE THE BOX
WITH FOAM
309
00:20:44,542 --> 00:20:47,712
IN ORDER TO PROTECT
ITS CONTENTS.
310
00:20:47,713 --> 00:20:50,883
SOME CLIENTS PREFER
THERMOFORMED PLASTIC TRAYS
311
00:20:50,884 --> 00:20:55,619
MOLDED TO THEIR PRODUCT'S
SPECIFIC SHAPE.
312
00:20:55,620 --> 00:20:57,687
YOU CAN CHOOSE THE SIZE, SHAPE,
313
00:20:57,688 --> 00:21:01,692
TYPE OF WOOD, COLOR,
AND HARDWARE OF THE BOX.
314
00:21:01,693 --> 00:21:05,397
THE ONLY LIMIT IS YOUR BUDGET
AND YOUR IMAGINATION.
315
00:21:13,004 --> 00:21:15,139
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
316
00:21:15,140 --> 00:21:18,142
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
317
00:21:18,143 --> 00:21:21,447
DROP US A LINE AT...
25431
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