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These are the user uploaded subtitles that are being translated: 1 00:00:22,758 --> 00:00:25,931 Narrator: Today on "How it's made"... 2 00:00:25,931 --> 00:00:28,344 Fiberglass insulation... 3 00:00:32,448 --> 00:00:34,275 ...Wooden ducks... 4 00:00:37,758 --> 00:00:39,862 ...Gumball machines... 5 00:00:43,310 --> 00:00:45,931 ...And exhaust systems. 6 00:00:52,310 --> 00:00:56,379 It's pink and fluffy, And it keeps us warm. 7 00:00:56,379 --> 00:00:58,965 Fiberglass insulation Is a great way 8 00:00:58,965 --> 00:01:01,172 To prevent heat loss From our buildings. 9 00:01:01,172 --> 00:01:04,551 It has a woolly texture, But it is, as the name suggests, 10 00:01:04,551 --> 00:01:07,689 Made of very fine threads Of glass. 11 00:01:07,689 --> 00:01:12,310 That's why it's sometimes Referred to as glass wool. 12 00:01:15,344 --> 00:01:18,965 Fiberglass insulation Will reduce energy consumption, 13 00:01:18,965 --> 00:01:20,758 But it also reduces waste 14 00:01:20,758 --> 00:01:24,241 Because it's made from at least 35% recycled glass. 15 00:01:24,241 --> 00:01:27,000 The recipe also includes What's called the batch -- 16 00:01:27,000 --> 00:01:29,793 A lot of sand and smaller Portions of soda ash, 17 00:01:29,793 --> 00:01:31,965 Limestone, and other minerals. 18 00:01:31,965 --> 00:01:37,034 The glass, called cullet, Used to be bottles and windows. 19 00:01:37,034 --> 00:01:41,344 This will be Its second recycling. 20 00:01:41,344 --> 00:01:43,137 The cullet and batch ingredients 21 00:01:43,137 --> 00:01:45,137 Spill onto A conveyer-belt system, 22 00:01:45,137 --> 00:01:48,379 Which transports it all To an electric furnace. 23 00:01:48,379 --> 00:01:50,517 The conveyer Moves back and forth 24 00:01:50,517 --> 00:01:53,724 To evenly distribute the cullet And batch ingredients. 25 00:01:53,724 --> 00:01:57,310 They seep down And melt into a previous mix, 26 00:01:57,310 --> 00:02:00,551 Which is now a pool of glass At the bottom of the furnace. 27 00:02:08,068 --> 00:02:10,827 The glass liquid Now flows out of the furnace 28 00:02:10,827 --> 00:02:12,310 And into sloped channels. 29 00:02:15,068 --> 00:02:16,620 Inside these channels, 30 00:02:16,620 --> 00:02:20,310 The temperature is kept red-hot By natural-gas burners. 31 00:02:20,310 --> 00:02:23,241 This keeps the glass mix In a liquid form, 32 00:02:23,241 --> 00:02:26,827 As it oozes out of the holes In the bottoms of the channels. 33 00:02:30,034 --> 00:02:33,103 The melted glass falls about 3 feet into a spinning bowl. 34 00:02:33,103 --> 00:02:35,482 It's called a fiberizer. 35 00:02:35,482 --> 00:02:37,103 The spinning action Flings the glass 36 00:02:37,103 --> 00:02:38,862 Through thousands of holes In the bowl, 37 00:02:38,862 --> 00:02:42,931 Creating thousands Of feathery glass fibers. 38 00:02:42,931 --> 00:02:45,827 Gas and compressed air pull the Fibers, stretching them thinner. 39 00:02:48,310 --> 00:02:51,413 The process is a lot like Making cotton candy, 40 00:02:51,413 --> 00:02:54,586 And the spun glass Even has a similar texture. 41 00:02:54,586 --> 00:02:59,172 But the fibers will soon become Even more like cotton candy. 42 00:02:59,172 --> 00:03:03,103 Nozzles spray them With a polymer glue tinted pink. 43 00:03:06,586 --> 00:03:08,137 The now-pink and sticky fibers 44 00:03:08,137 --> 00:03:11,413 Drop into a hole In the ground and amass. 45 00:03:11,413 --> 00:03:12,896 Then a conveyer belt 46 00:03:12,896 --> 00:03:15,931 Takes the mounds of sticky glass To an oven. 47 00:03:18,724 --> 00:03:21,448 Steel plates compress the pack As it enters the oven 48 00:03:21,448 --> 00:03:24,137 That's heated To 500 degrees fahrenheit. 49 00:03:24,137 --> 00:03:27,000 Hot air blows through it, Setting the glue. 50 00:03:28,793 --> 00:03:33,310 As the pack exits the oven, Circular saws cut through it, 51 00:03:33,310 --> 00:03:35,862 Making 15- To 24-inch-wide strips 52 00:03:35,862 --> 00:03:37,551 That are called lanes. 53 00:03:37,551 --> 00:03:41,896 The lanes pass by a series Of poles that push them apart. 54 00:03:45,793 --> 00:03:49,482 Next, an ink jet Brands each lane with a number 55 00:03:49,482 --> 00:03:52,448 That conveys the "R" value. 56 00:03:52,448 --> 00:03:55,724 "R" stands for "Resistance to heat flow." 57 00:03:55,724 --> 00:03:58,482 It's a measure of how well The insulation will stop heat 58 00:03:58,482 --> 00:04:02,655 From going through the roof and Your energy bill along with it. 59 00:04:07,551 --> 00:04:11,724 A chopper with big steel teeth Now cuts the lanes, 60 00:04:11,724 --> 00:04:14,724 Making chunks That could easily be installed 61 00:04:14,724 --> 00:04:16,655 In an attic or wall. 62 00:04:21,827 --> 00:04:25,034 After chopping, The conveyer belt accelerates, 63 00:04:25,034 --> 00:04:29,172 Transporting the fiberglass Batts to the next station. 64 00:04:32,862 --> 00:04:36,000 A few at a time, The batts plunge down a chute, 65 00:04:36,000 --> 00:04:38,034 To a mechanical arm 66 00:04:38,034 --> 00:04:41,172 Which slides the batts Into a compression chamber. 67 00:04:41,172 --> 00:04:44,551 There, a hydraulic ram Squishes the batts down, 68 00:04:44,551 --> 00:04:47,137 Reducing their bulk 5 to 10 times. 69 00:04:47,137 --> 00:04:51,068 This compaction will make them Easier to transport. 70 00:04:58,689 --> 00:05:01,931 Now another ram Comes from the side 71 00:05:01,931 --> 00:05:04,517 And pushes the stack Of compressed batts forward 72 00:05:04,517 --> 00:05:06,103 Into a spout. 73 00:05:06,103 --> 00:05:09,000 The spout Is a hollow batt-shaped frame. 74 00:05:09,000 --> 00:05:12,551 A worker Pulls a plastic bag over it. 75 00:05:14,793 --> 00:05:18,034 Then the ram pushes The fiberglass-insulation batt 76 00:05:18,034 --> 00:05:20,000 Into the plastic bag, 77 00:05:20,000 --> 00:05:22,793 And the process begins again. 78 00:05:32,241 --> 00:05:34,724 A conveyer belt Transports the batt-filled bags 79 00:05:34,724 --> 00:05:37,206 To a machine That heat-seals them. 80 00:05:39,000 --> 00:05:43,137 Then they're sent off To be installed. 81 00:05:59,965 --> 00:06:02,931 Narrator: for centuries, Hunters have used wooden ducks 82 00:06:02,931 --> 00:06:05,517 To lure live ones To within shooting range. 83 00:06:05,517 --> 00:06:08,724 Stringing together decoys And floating them in the water, 84 00:06:08,724 --> 00:06:12,103 Hunters trick the birds down From the sky with duck calls. 85 00:06:12,103 --> 00:06:15,862 Nowadays, hunters generally Prefer cheaper, plastic decoys. 86 00:06:15,862 --> 00:06:19,310 Wooden ducks are mostly Decorative items for the home. 87 00:06:20,724 --> 00:06:24,896 This company's flock Includes males, females, 88 00:06:24,896 --> 00:06:26,896 And androgynous models Like this one. 89 00:06:26,896 --> 00:06:28,827 This more elaborate male Is inspired 90 00:06:28,827 --> 00:06:32,344 By another aquatic bird, The loon. 91 00:06:32,344 --> 00:06:35,448 To make them, these craftsmen Use eastern white pine 92 00:06:35,448 --> 00:06:37,758 Because it's easy to carve And has a nice grain. 93 00:06:37,758 --> 00:06:41,896 First, a machine shapes A 2-inch-thick slab. 94 00:06:41,896 --> 00:06:44,172 They cut the slab lengthwise. 95 00:06:44,172 --> 00:06:46,896 They'll use four to six Of these smaller pieces 96 00:06:46,896 --> 00:06:48,965 To make most of the duck's body. 97 00:06:48,965 --> 00:06:53,448 The birds range in size from Baby ducks just 4 inches long 98 00:06:53,448 --> 00:06:56,551 To geese at more than 19 inches long. 99 00:06:56,551 --> 00:06:58,206 A craftsman now applies 100 00:06:58,206 --> 00:07:01,034 A generous amount Of carpenter's glue 101 00:07:01,034 --> 00:07:02,586 To one side of the wood. 102 00:07:02,586 --> 00:07:04,793 Using a lot Ensures a strong bond 103 00:07:04,793 --> 00:07:06,793 And prevents splitting later on. 104 00:07:09,275 --> 00:07:12,758 The pieces then go Into what's called a wood clamp. 105 00:07:12,758 --> 00:07:15,793 He tightens a vice, Squeezing them together. 106 00:07:15,793 --> 00:07:18,862 It takes about two hours For the pieces to bond properly. 107 00:07:18,862 --> 00:07:24,620 Then he'll shave away the excess Glue and even up the surfaces. 108 00:07:24,620 --> 00:07:26,000 Once that's done, 109 00:07:26,000 --> 00:07:29,000 They run the block Over what's called a joiner. 110 00:07:29,000 --> 00:07:31,965 A roller with 3 blades Shaves about 3/4 of an inch 111 00:07:31,965 --> 00:07:36,379 From what will become The top and bottom of the duck. 112 00:07:36,379 --> 00:07:38,793 Each model Has three wooden patterns 113 00:07:38,793 --> 00:07:42,000 For the top, the bottom, And the profile. 114 00:07:42,000 --> 00:07:45,000 Here, a worker traces the Outline of the bird's profile 115 00:07:45,000 --> 00:07:46,413 In pencil on the wood. 116 00:07:46,413 --> 00:07:48,137 Since this is a small model, 117 00:07:48,137 --> 00:07:50,482 He'll make two birds With one block. 118 00:07:52,965 --> 00:07:55,965 Using a band saw, He trims along the trace line. 119 00:07:55,965 --> 00:07:58,241 This company Recycles the cutoffs 120 00:07:58,241 --> 00:08:02,551 Into fireplace kindling And shavings for farm stables. 121 00:08:02,551 --> 00:08:05,793 Next, he uses another pattern To create the top of the bird. 122 00:08:05,793 --> 00:08:08,310 These patterns provide Only the general shape 123 00:08:08,310 --> 00:08:09,586 Of a particular model. 124 00:08:09,586 --> 00:08:12,000 The craftsman Will later carve the details 125 00:08:12,000 --> 00:08:14,620 Using smaller electric tools And by hand. 126 00:08:17,172 --> 00:08:19,965 Now he sands the wood With a pneumatic drum sander -- 127 00:08:19,965 --> 00:08:23,827 A tube of pressurized air with Sandpaper stretched over it. 128 00:08:23,827 --> 00:08:26,758 He uses higher pressure For sharper curves, 129 00:08:26,758 --> 00:08:28,793 Lower pressure for softer edges. 130 00:08:28,793 --> 00:08:30,655 To sculpt the bird's plumage, 131 00:08:30,655 --> 00:08:33,137 The craftsman Uses this band sander 132 00:08:33,137 --> 00:08:36,413 Whose rounded edge Presses sandpaper into the wood. 133 00:08:36,413 --> 00:08:38,896 Here, he makes Three long grooves -- 134 00:08:38,896 --> 00:08:41,862 One on top, and one On each side of the duck. 135 00:08:43,965 --> 00:08:47,068 The head's made from a different Piece of wood than the body. 136 00:08:47,068 --> 00:08:49,896 Here, he sands down the piece To smooth out the curves. 137 00:08:52,482 --> 00:08:55,172 Using various shaping tools And the band sander, 138 00:08:55,172 --> 00:08:57,793 He sculpts the bird's Head and bill area, 139 00:08:57,793 --> 00:09:01,034 Then the underside and rear end Of this waddling duck. 140 00:09:01,034 --> 00:09:04,517 He also carves depressions For eye sockets to come later. 141 00:09:09,034 --> 00:09:10,862 Here, he puts glue on the neck 142 00:09:10,862 --> 00:09:13,206 To attach it To the rest of the body. 143 00:09:15,275 --> 00:09:16,620 Using a nail gun, 144 00:09:16,620 --> 00:09:19,793 He reinforces the area With two nails on each side. 145 00:09:19,793 --> 00:09:22,482 To hide the nails And smooth out the neck, 146 00:09:22,482 --> 00:09:24,482 The craftsman uses wood putty. 147 00:09:24,482 --> 00:09:27,000 Once it dries, He'll sand it smooth. 148 00:09:29,551 --> 00:09:33,275 Next, he tints the duck bill Using an orange wood stain... 149 00:09:35,310 --> 00:09:39,103 ...Then a forest-green stain To tint the head and neck areas. 150 00:09:39,103 --> 00:09:42,413 Males have colorful feathers To better attract mates. 151 00:09:42,413 --> 00:09:44,655 Females Have more neutral colors 152 00:09:44,655 --> 00:09:48,068 To blend into their surroundings And protect their ducklings. 153 00:09:48,068 --> 00:09:50,551 The craftsman Covers the duck's lower body 154 00:09:50,551 --> 00:09:52,137 With a clear wood stain. 155 00:09:52,137 --> 00:09:55,482 This way, the natural grain Of the wood shows through. 156 00:09:55,482 --> 00:09:59,137 The front gets a clear but Darker stain to mark the chest. 157 00:09:59,137 --> 00:10:03,068 And darker stain also highlights The plumage in the long grooves. 158 00:10:03,068 --> 00:10:05,758 Then, some green accents For the feathers 159 00:10:05,758 --> 00:10:07,379 On the sides in the back. 160 00:10:10,379 --> 00:10:15,724 Next, two coats of white paint To mark the duck's collar. 161 00:10:15,724 --> 00:10:19,206 Then he glues plastic eyes In the eye sockets. 162 00:10:19,206 --> 00:10:23,517 The irises are black, brown, Or red, depending on the model. 163 00:10:23,517 --> 00:10:26,689 He then sprays on a protective, Water-based varnish, 164 00:10:26,689 --> 00:10:28,620 And elevates the duck on nails 165 00:10:28,620 --> 00:10:31,793 So that the underside will dry Along with the rest. 166 00:10:31,793 --> 00:10:35,379 Finally, the craftsman rubs The entire carving in wood wax. 167 00:10:35,379 --> 00:10:38,344 This makes the varnish Appear uneven in places, 168 00:10:38,344 --> 00:10:41,000 Giving the duck A worn, antique finish, 169 00:10:41,000 --> 00:10:43,758 Like he's been Around the pond a few times. 170 00:10:47,034 --> 00:10:50,931 The prices of wooden ducks vary According to size and detail. 171 00:10:50,931 --> 00:10:54,068 $500 will buy you This magnificent canada goose 172 00:10:54,068 --> 00:10:57,620 With wings stretched and ready For a graceful landing. 173 00:11:07,758 --> 00:11:09,310 Narrator: For a century, 174 00:11:09,310 --> 00:11:11,758 There have been machines To give us gumballs. 175 00:11:11,758 --> 00:11:16,241 Vending machines that dispensed Gumballs were introduced in 1907 176 00:11:16,241 --> 00:11:19,000 On a new york city Subway platform. 177 00:11:19,000 --> 00:11:22,586 Today's machines are more modern Versions of the originals, 178 00:11:22,586 --> 00:11:25,896 But they still perform, Basically, the same function. 179 00:11:30,310 --> 00:11:34,172 The gumball machine is all about Instant gratification. 180 00:11:34,172 --> 00:11:38,241 Insert a coin, turn a handle, And out comes the merchandise. 181 00:11:40,758 --> 00:11:42,551 To make a gumball machine, 182 00:11:42,551 --> 00:11:46,000 A designer first sketches out The exact proportions. 183 00:11:48,689 --> 00:11:51,965 Then, a worker ladles molten Zinc into a holding furnace, 184 00:11:51,965 --> 00:11:54,206 Where a steel plunger Pushes the metal 185 00:11:54,206 --> 00:11:58,310 Through a die that forms A gumball machine base. 186 00:11:58,310 --> 00:12:02,448 A mechanical claw removes the Newly shaped base from the die 187 00:12:02,448 --> 00:12:05,827 And places it On a conveyor belt to cool. 188 00:12:08,241 --> 00:12:09,827 A similar die shapes 189 00:12:09,827 --> 00:12:13,034 The coin mechanism handle And drive gears. 190 00:12:16,448 --> 00:12:19,586 A worker places a braided hose With a natural-gas flame 191 00:12:19,586 --> 00:12:23,413 Under a mold that will shape The gumball-dispensing chute. 192 00:12:26,206 --> 00:12:29,275 He pours piping-hot Liquid aluminum into the mold. 193 00:12:29,275 --> 00:12:32,586 The flame below warms the mold Enough to prevent condensation, 194 00:12:32,586 --> 00:12:34,068 Which would ruin the shape. 195 00:12:34,068 --> 00:12:36,689 But the mold is still cooler Than the aluminum, 196 00:12:36,689 --> 00:12:40,586 And that allows it to solidify Into a chute shape in seconds. 197 00:12:42,724 --> 00:12:46,068 Now, using a punch press, A worker trims the waste away 198 00:12:46,068 --> 00:12:48,758 From the lid For the gumball machine. 199 00:12:51,620 --> 00:12:54,689 They also trim the front plate Of the coin mechanism, 200 00:12:54,689 --> 00:12:57,000 Using a similar press. 201 00:13:01,551 --> 00:13:05,103 A computerized cutter mills out A hole in the top of the globe 202 00:13:05,103 --> 00:13:06,793 That will hold the gumballs. 203 00:13:06,793 --> 00:13:09,344 The globe is made Of shatterproof plastic. 204 00:13:16,275 --> 00:13:17,620 At another station, 205 00:13:17,620 --> 00:13:19,620 They press the base Of the gumball machine 206 00:13:19,620 --> 00:13:21,758 Against A cloth-covered buffing wheel 207 00:13:21,758 --> 00:13:25,034 To give it a shine. 208 00:13:25,034 --> 00:13:28,034 A worker now assembles The coin mechanism, 209 00:13:28,034 --> 00:13:31,103 Layering the front plate, The coin carrier, 210 00:13:31,103 --> 00:13:34,655 The back plate, And ending with a cam, 211 00:13:34,655 --> 00:13:39,586 The part that ensures the Coin mechanism moves clockwise. 212 00:13:39,586 --> 00:13:41,413 She screws it tightly together, 213 00:13:41,413 --> 00:13:44,172 Then inserts the handle On the front plate. 214 00:13:44,172 --> 00:13:47,620 The handle will turn the coins That pay for the gumballs. 215 00:13:50,206 --> 00:13:53,620 She places a little spacer and Drive gear on the handle stem 216 00:13:53,620 --> 00:13:56,379 That protrudes through the back Of the assembly 217 00:13:56,379 --> 00:13:59,413 And then screws the drive gear Onto the handle stem. 218 00:14:01,965 --> 00:14:04,413 Now it's time To put the money up front. 219 00:14:04,413 --> 00:14:06,206 They insert a coin in the slot 220 00:14:06,206 --> 00:14:09,206 And turn the handle To make sure the system works. 221 00:14:13,310 --> 00:14:15,724 People in many countries Like gumballs, 222 00:14:15,724 --> 00:14:19,241 And so these coin mechanisms Can be made to accept currencies 223 00:14:19,241 --> 00:14:20,724 From around the world. 224 00:14:20,724 --> 00:14:24,275 They can also be used in other Types of vending machines. 225 00:14:29,000 --> 00:14:31,655 Now they spray powder paint Onto the lids, 226 00:14:31,655 --> 00:14:35,000 Giving them a coating that's Almost 1/16 of an inch thick. 227 00:14:35,000 --> 00:14:37,068 They bake the paint Onto the lids 228 00:14:37,068 --> 00:14:41,413 At 400 degrees fahrenheit For 25 minutes. 229 00:14:41,413 --> 00:14:44,172 Now it's time To put all the pieces together. 230 00:14:44,172 --> 00:14:46,931 They place the dispensing wheels In hoppers, 231 00:14:46,931 --> 00:14:50,034 Then cover them with a part That stops free gumballs 232 00:14:50,034 --> 00:14:51,655 From spilling out. 233 00:14:51,655 --> 00:14:54,620 The next part Is the adaptor ring, 234 00:14:54,620 --> 00:14:58,137 And the plastic globes Fit on top of them. 235 00:15:01,241 --> 00:15:04,965 They place aluminum rings On top of the globes. 236 00:15:04,965 --> 00:15:08,206 Then they slide two side rods Through the top rings, 237 00:15:08,206 --> 00:15:10,586 Down into the bottom Of the globes. 238 00:15:12,586 --> 00:15:14,482 They screw them down Very tightly, 239 00:15:14,482 --> 00:15:16,551 And then they set The assembly aside. 240 00:15:18,827 --> 00:15:21,241 Now they place Plastic bodies on bases 241 00:15:21,241 --> 00:15:23,862 And install the chute doors On the front. 242 00:15:29,275 --> 00:15:32,275 They place the chute covers In the plastic body... 243 00:15:34,965 --> 00:15:38,310 ...And mount the coin mechanism Just above the chute. 244 00:15:40,310 --> 00:15:43,206 Next, they slide The globe assemblies 245 00:15:43,206 --> 00:15:48,068 Over center rods and Onto the plastic foundations. 246 00:15:48,068 --> 00:15:51,655 They put a lid on every globe... 247 00:15:51,655 --> 00:15:53,689 And then lock them on. 248 00:16:00,068 --> 00:16:03,793 And now we're at The vending part of the story. 249 00:16:03,793 --> 00:16:05,655 Gumball, anyone? 250 00:16:14,586 --> 00:16:16,793 Narrator: The job it does is exhausting. 251 00:16:16,793 --> 00:16:19,620 The exhaust system On your vehicle 252 00:16:19,620 --> 00:16:22,724 Gets rid of harmful gases That could damage the engine. 253 00:16:22,724 --> 00:16:24,482 It also cleans up The gases a bit 254 00:16:24,482 --> 00:16:26,758 Before venting them Into the air. 255 00:16:26,758 --> 00:16:30,379 A properly functioning exhaust System does another big job -- 256 00:16:30,379 --> 00:16:33,000 Muffling the airborne noise Of the engine. 257 00:16:38,586 --> 00:16:40,896 It's a system Of metal tubes and plates 258 00:16:40,896 --> 00:16:43,379 We only seem to notice When it breaks down. 259 00:16:43,379 --> 00:16:45,689 And when it does, Everyone can hear it. 260 00:16:48,344 --> 00:16:49,689 To make an exhaust system, 261 00:16:49,689 --> 00:16:52,793 A mechanical puller draws A stainless-steel strip 262 00:16:52,793 --> 00:16:54,310 Up into a punch press, 263 00:16:54,310 --> 00:16:57,655 Shuffling it back and forth To allow for a precise cut 264 00:16:57,655 --> 00:16:59,241 With little waste. 265 00:17:04,931 --> 00:17:07,448 The press brings 60 tons Of force to bear 266 00:17:07,448 --> 00:17:09,689 As it pushes the steel Into a die. 267 00:17:09,689 --> 00:17:12,344 It punches out a baffle shape With holes in it, 268 00:17:12,344 --> 00:17:17,310 Which will form the skeleton For the muffler box. 269 00:17:17,310 --> 00:17:19,517 The finished baffles Fall onto a conveyor 270 00:17:19,517 --> 00:17:21,862 And go into a storage cage. 271 00:17:24,137 --> 00:17:27,034 Now a long steel tube Tumbles to automated blades 272 00:17:27,034 --> 00:17:30,379 Which score the tube crosswise To prevent denting 273 00:17:30,379 --> 00:17:32,379 And then cut it To produce smaller tubes 274 00:17:32,379 --> 00:17:34,034 That go inside a muffler. 275 00:17:34,034 --> 00:17:36,620 A circular saw descends On another tube 276 00:17:36,620 --> 00:17:39,068 To make a tail pipe. 277 00:17:39,068 --> 00:17:44,206 Its length depends on The type of muffler being made. 278 00:17:44,206 --> 00:17:46,724 A louver machine Spins and punctures 279 00:17:46,724 --> 00:17:48,379 One of the inside tubes. 280 00:17:48,379 --> 00:17:51,551 The holes will regulate airflow In the muffler. 281 00:17:53,655 --> 00:17:55,103 A cnc bending machine 282 00:17:55,103 --> 00:17:57,655 Grips and bends a pipe In several spots. 283 00:17:57,655 --> 00:18:01,517 This is how they make inlet, Intermediate, and outlet tubes. 284 00:18:01,517 --> 00:18:04,724 These tubes run the length Of the exhaust system. 285 00:18:11,551 --> 00:18:14,620 Then they place a tube In a circular hydraulic vice, 286 00:18:14,620 --> 00:18:17,620 Which pinches the end down To a prescribed diameter 287 00:18:17,620 --> 00:18:19,551 To allow For further assembly. 288 00:18:21,206 --> 00:18:24,758 A worker now places two baffles In a jig. 289 00:18:24,758 --> 00:18:27,551 He fits the tubes Through the holes in the baffles 290 00:18:27,551 --> 00:18:29,793 So that the tubes Connect the baffles. 291 00:18:31,172 --> 00:18:34,068 Three mandrels Slide into the tubes. 292 00:18:34,068 --> 00:18:37,793 The mandrels expand, locking The tubes to the baffles. 293 00:18:37,793 --> 00:18:40,241 Then they contract And slide out. 294 00:18:40,241 --> 00:18:43,137 Now the baffles and tubes Are one piece. 295 00:18:45,793 --> 00:18:48,620 Next, a robotic arm Picks up metal sheets, 296 00:18:48,620 --> 00:18:51,448 Which will become the outer skin Of the muffler box. 297 00:18:51,448 --> 00:18:54,310 It pushes them Under an oval mold. 298 00:18:54,310 --> 00:18:57,413 Another arm With numerous rollers on it 299 00:18:57,413 --> 00:19:01,310 Moves up and wraps the steel Around the oval form. 300 00:19:01,310 --> 00:19:03,344 Then a metal block Moves over the ends, 301 00:19:03,344 --> 00:19:04,758 Double-folding them. 302 00:19:04,758 --> 00:19:06,413 This locks them together, 303 00:19:06,413 --> 00:19:09,517 And it completes the assembly Of the muffler's outside skin. 304 00:19:17,862 --> 00:19:20,620 Magnets pick up the new skin, And, sliding on rails, 305 00:19:20,620 --> 00:19:23,206 They relay it To a mechanical claw 306 00:19:23,206 --> 00:19:25,413 Which, in turn, Feeds it to a flanger. 307 00:19:28,068 --> 00:19:30,103 The flanger bends the edges, 308 00:19:30,103 --> 00:19:33,310 Creating a lip on either end Of the muffler skin. 309 00:19:33,310 --> 00:19:34,965 A carousel turns, 310 00:19:34,965 --> 00:19:38,482 And a mechanical claw transfers The newly flanged muffler skin 311 00:19:38,482 --> 00:19:40,000 To the stuffing position. 312 00:19:45,000 --> 00:19:48,448 Hydraulic pushers press the Pre-assembled baffles and tubes 313 00:19:48,448 --> 00:19:50,896 Inside the skin. 314 00:19:50,896 --> 00:19:52,931 After the muffler is stuffed, 315 00:19:52,931 --> 00:19:56,586 The robotic claw transfers it To a conveyor belt. 316 00:19:59,862 --> 00:20:03,068 Next, a worker presses each end Of the muffler 317 00:20:03,068 --> 00:20:06,034 Against a set Of steel expansion fingers. 318 00:20:06,034 --> 00:20:09,103 The fingers move forward Into holes in the muffler. 319 00:20:09,103 --> 00:20:11,862 They expand and lock The baffles and tubes inside 320 00:20:11,862 --> 00:20:15,517 To form one solid, Internal unit. 321 00:20:15,517 --> 00:20:17,241 Grippers place the muffler 322 00:20:17,241 --> 00:20:20,551 On a spinning machine That will fasten the caps on. 323 00:20:24,758 --> 00:20:28,448 Rollers press against the flared Edges of the revolving muffler, 324 00:20:28,448 --> 00:20:31,517 Tightly locking the end cap To the rest of the body. 325 00:20:37,862 --> 00:20:40,931 Here, you see the rolling In slow motion. 326 00:20:40,931 --> 00:20:44,275 It takes only a few revolutions To do the job. 327 00:20:56,793 --> 00:20:59,000 Then the roller backs away, 328 00:20:59,000 --> 00:21:01,586 And a mechanical arm Grabs the muffler 329 00:21:01,586 --> 00:21:03,965 And transfers it To a conveyor belt. 330 00:21:07,137 --> 00:21:08,862 Now these mufflers are ready 331 00:21:08,862 --> 00:21:11,586 To help keep the traffic noise At a minimum. 332 00:21:18,034 --> 00:21:20,310 If you have any comments About the show, 333 00:21:20,310 --> 00:21:23,172 Or if you'd like to suggest Topics for future shows, 334 00:21:23,172 --> 00:21:24,931 Drop us a line at... 335 00:21:24,931 --> 00:21:26,965 --captions by vitac-- Www.Vitac.Com 336 00:21:26,965 --> 00:21:28,965 Captions paid for by Discovery communications, inc. 27778

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