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Narrator:
Today, on "How it's made"...
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00:00:26,413 --> 00:00:28,413
Footballs...
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00:00:32,413 --> 00:00:36,000
...Electric-guitar amplifiers...
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00:00:37,965 --> 00:00:40,034
...Marbles...
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00:00:43,724 --> 00:00:45,724
...And airplane propellers.
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00:00:53,034 --> 00:00:57,413
In 1869, players in the first
Football game used a round ball,
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00:00:57,517 --> 00:00:58,793
Like in soccer.
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00:00:58,896 --> 00:01:01,448
It was tough to carry
And awkward to throw,
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00:01:01,551 --> 00:01:04,448
So they changed it
To look more like a watermelon.
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00:01:04,551 --> 00:01:06,482
The current shape
Enables a better grip
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00:01:06,586 --> 00:01:09,896
And passing on an arc
That's unique to football.
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00:01:18,896 --> 00:01:20,827
A lot of people
Handle a football
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00:01:20,931 --> 00:01:22,896
Before it ever gets
To the field.
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00:01:23,000 --> 00:01:24,310
They start with cowhide.
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00:01:24,413 --> 00:01:27,310
Footballs are traditionally
Made of this leather
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00:01:27,413 --> 00:01:29,275
Because it wears well over time.
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00:01:29,379 --> 00:01:32,241
With a die, a worker cuts out
The four sections
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00:01:32,344 --> 00:01:34,103
That make up the ball's skin.
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00:01:38,551 --> 00:01:42,310
A stamping machine then brands
The skin with the company logo.
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00:01:42,413 --> 00:01:44,724
They may put other markings
Elsewhere on the ball,
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00:01:44,827 --> 00:01:47,310
Depending on the design
Of the model they're making.
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00:01:53,241 --> 00:01:55,689
Each of the sections
Goes into a machine
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00:01:55,793 --> 00:01:58,586
That trims the pieces'
Combined weight down to spec.
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00:02:05,793 --> 00:02:07,103
To strengthen the skin,
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00:02:07,206 --> 00:02:09,586
A seamstress
Sews cotton and vinyl linings
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00:02:09,689 --> 00:02:11,068
Onto all four sections.
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00:02:16,379 --> 00:02:18,275
Then she places them in a die
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00:02:18,379 --> 00:02:22,551
That positions them
For another set of markings.
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00:02:22,655 --> 00:02:25,551
These four white lines
Will form two stripes
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00:02:25,655 --> 00:02:27,586
When the sections come together.
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00:02:27,689 --> 00:02:29,275
This is purely aesthetic
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00:02:29,379 --> 00:02:31,965
And varies according
To the football model.
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00:02:32,068 --> 00:02:34,793
Now it's time to sew
The top sections together
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00:02:34,896 --> 00:02:37,310
And then the bottom ones
To each other.
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00:02:37,413 --> 00:02:39,655
Exactly how many stitches
This takes
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00:02:39,758 --> 00:02:43,344
Is this company's
Closely guarded secret.
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00:02:43,448 --> 00:02:46,172
This press makes a hole
In one of the top sections
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00:02:46,275 --> 00:02:47,931
For the air valve.
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00:02:50,862 --> 00:02:52,965
They make eight holes
In the top sections
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00:02:53,068 --> 00:02:55,172
For laces that will hold
The skin tightly
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00:02:55,275 --> 00:03:00,172
Around an inflated bag
Called a bladder.
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00:03:00,275 --> 00:03:02,965
To join the ball's
Top and bottom sections,
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00:03:03,068 --> 00:03:04,793
The seamstress first cups them
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00:03:04,896 --> 00:03:07,068
And then joins
The edges together.
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00:03:07,172 --> 00:03:08,965
She sews the leather inside out
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00:03:09,068 --> 00:03:11,241
To make the stitches
Less visible.
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00:03:11,344 --> 00:03:13,827
Later, workers will turn
The skin right-side out
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00:03:13,931 --> 00:03:16,689
By reaching through the opening
Between the lace holes.
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00:03:16,793 --> 00:03:19,206
This is also where
They'll insert the bladder.
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00:03:22,379 --> 00:03:24,965
It's important
To flatten the four seams.
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00:03:25,068 --> 00:03:27,965
To do this, a worker places
Each one on a wheel,
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00:03:28,068 --> 00:03:30,137
As a roller
Passes over the top.
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00:03:30,241 --> 00:03:32,206
This keeps the ball
From being bumpy
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00:03:32,310 --> 00:03:34,758
When they stretch the skin
Over the bladder.
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00:03:39,000 --> 00:03:41,689
A 15-second steam
Softens the leather
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00:03:41,793 --> 00:03:44,344
And makes it easier
To manipulate.
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00:03:46,034 --> 00:03:49,103
A concave press
Flattens the seams at the tips.
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00:03:49,206 --> 00:03:52,758
This will also keep the ball
Smooth when they inflate it.
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00:03:52,862 --> 00:03:56,137
Time to turn the skin
Right-side out.
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00:03:56,241 --> 00:03:58,344
The worker places it
On a metal bar,
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00:03:58,448 --> 00:04:01,344
Then, reaching through the
Opening between the lace holes,
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00:04:01,448 --> 00:04:04,758
He grabs the other side of
The skin and pulls it through.
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00:04:04,862 --> 00:04:07,103
Then he runs the bar
Along the inside
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00:04:07,206 --> 00:04:08,758
To reshape the skin.
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00:04:12,896 --> 00:04:16,103
The bladder is made of
Polyurethane, a type of plastic,
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00:04:16,206 --> 00:04:19,896
With a vinyl patch
Reinforcing the lacing area.
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00:04:20,000 --> 00:04:22,586
After squeezing the bladder
Inside the skin,
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00:04:22,689 --> 00:04:25,241
A worker snips off
The end of the air valve
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00:04:25,344 --> 00:04:28,068
To keep it out of the way.
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00:04:28,172 --> 00:04:30,689
Then she inflates
The bladder a bit
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00:04:30,793 --> 00:04:33,344
To make it rigid enough
For lacing.
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00:04:35,137 --> 00:04:37,344
After steadying the ball
With clamps,
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00:04:37,448 --> 00:04:40,517
She uses an awl to thread
The lace through the holes --
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00:04:40,620 --> 00:04:45,000
Just one vinyl lace,
Measuring four feet.
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00:04:45,103 --> 00:04:47,896
It worms through both sides
And then down the center
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00:04:48,000 --> 00:04:50,206
And through all the holes
Once again.
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00:04:53,965 --> 00:04:56,448
The lacing is spaced
About a half inch apart --
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00:04:56,551 --> 00:04:58,137
Wide enough to comfortably grip
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For that magic pass
You've got in mind.
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00:05:04,586 --> 00:05:08,379
Next, workers temporarily
Overinflate the balls.
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00:05:08,482 --> 00:05:10,379
Steel molds surround them
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00:05:10,482 --> 00:05:12,724
To ensure they'll assume
The correct shape.
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00:05:12,827 --> 00:05:15,862
After 90 seconds,
The extra air seeps out.
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00:05:15,965 --> 00:05:18,862
Finally,
The factory inspects the balls
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00:05:18,965 --> 00:05:21,482
To ensure
They're up to standard.
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00:05:21,586 --> 00:05:26,103
Fully inflated, a ball must
Weigh no more than 15 ounces.
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00:05:28,068 --> 00:05:31,068
It should measure 21 1/2 inches
Through the middle
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00:05:31,172 --> 00:05:35,034
And 28 inches around both ends.
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00:05:39,620 --> 00:05:42,275
After a five-day
Manufacturing process,
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00:05:42,379 --> 00:05:44,931
These balls are ready
For the field.
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00:06:00,344 --> 00:06:03,758
Narrator:
You have to plug an electrical
Guitar into an amplifier
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00:06:03,862 --> 00:06:06,206
If you want it to be more
Than barely audible.
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00:06:06,310 --> 00:06:08,689
A guitar amplifier
Is typically a boxed unit,
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00:06:08,793 --> 00:06:11,310
Containing an amp
To boost the electronic signal
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00:06:11,413 --> 00:06:12,620
And a loudspeaker.
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00:06:12,724 --> 00:06:13,965
Some amplifiers
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00:06:14,068 --> 00:06:16,689
Use state-of-the-art
Silicon-chip circuitry,
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00:06:16,793 --> 00:06:20,034
While others
Use traditional vacuum tubes.
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00:06:28,103 --> 00:06:30,896
The amp's electronics are housed
Inside a metal chassis.
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00:06:31,000 --> 00:06:33,517
This model's chassis is made
From a sheet of metal
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00:06:33,620 --> 00:06:35,724
That's less than
.04 inches thick.
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00:06:35,827 --> 00:06:38,517
A computer-guided machine
Called a turret punch
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00:06:38,620 --> 00:06:40,551
Cuts the contour
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00:06:40,655 --> 00:06:42,551
And pierces a series
Of holes and slots
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00:06:42,655 --> 00:06:43,931
For the controls.
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00:06:48,448 --> 00:06:50,689
A worker then uses
A computer-guided bender
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00:06:50,793 --> 00:06:52,965
To shape the chassis cutout.
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00:06:59,103 --> 00:07:00,482
Elsewhere in the factory,
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00:07:00,586 --> 00:07:02,758
The amp's circuit board
Takes shape.
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00:07:02,862 --> 00:07:04,793
It'll go inside the chassis.
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00:07:04,896 --> 00:07:07,172
A computer-guided drill
Makes tiny holes
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00:07:07,275 --> 00:07:10,275
In a laminate board
That's coated with copper.
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00:07:10,379 --> 00:07:14,275
The holes are for the board's
Various electronic components.
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00:07:14,379 --> 00:07:16,206
An automated silk-screen printer
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00:07:16,310 --> 00:07:19,275
Now applies a diagram
Of the electrical circuitry
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00:07:19,379 --> 00:07:21,103
In ammonia-resistant ink.
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00:07:21,206 --> 00:07:24,103
Then the board goes
Into a machine called an etcher,
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00:07:24,206 --> 00:07:27,655
Which uses ammonia
To dissolve the copper coating.
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00:07:27,758 --> 00:07:30,896
Copper shielded
By the ink diagram stays intact.
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00:07:31,000 --> 00:07:32,896
The machine
Then rinses the board
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00:07:33,000 --> 00:07:35,448
With sodium hydroxide
To dissolve the ink,
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00:07:35,551 --> 00:07:38,965
Leaving behind just the
Circuitry diagram and copper.
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00:07:39,068 --> 00:07:41,965
This copper configuration
Will conduct electricity
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00:07:42,068 --> 00:07:43,965
To the circuit-board components.
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00:07:54,758 --> 00:07:58,931
Automated machines
Insert the smaller components.
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00:07:59,034 --> 00:08:02,206
Here's what that looks like
In slow motion...
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00:08:04,275 --> 00:08:06,344
...And at actual speed.
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00:08:11,827 --> 00:08:14,137
As a worker provides
Counterpressure,
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00:08:14,241 --> 00:08:17,689
A machine folds over the leaves
Of some larger components
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00:08:17,793 --> 00:08:19,896
To secure them to the board
Until they're soldered.
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00:08:20,000 --> 00:08:23,310
Workers then install large,
Irregular parts by hand,
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00:08:23,413 --> 00:08:26,862
Among them --
The sockets that hold the tubes
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00:08:26,965 --> 00:08:28,413
Which power the amp...
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00:08:37,620 --> 00:08:39,000
...The ribbon connecters
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00:08:39,103 --> 00:08:41,931
That join different areas
Of the circuit board...
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00:08:46,689 --> 00:08:49,068
...And the wires
That connect external components
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00:08:49,172 --> 00:08:50,413
To the board.
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00:08:52,620 --> 00:08:55,827
The factory permanently affixes
Everything in one shot,
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00:08:55,931 --> 00:08:58,310
Using a process
Called wave soldering.
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00:08:58,413 --> 00:09:02,068
The circuit board runs through
A bath of molten tin and lead.
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00:09:02,172 --> 00:09:05,206
In just a couple of seconds,
The liquefied metal hardens,
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00:09:05,310 --> 00:09:08,068
Bonding the components securely.
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00:09:08,172 --> 00:09:09,482
Back to that steel chassis
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00:09:09,586 --> 00:09:11,551
We saw them bend
Into shape earlier.
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00:09:11,655 --> 00:09:13,620
Since then,
They've painted it black.
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00:09:13,724 --> 00:09:15,137
With a silk screen printer,
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00:09:15,241 --> 00:09:19,034
They apply the control markings,
Logos, and other information.
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00:09:26,137 --> 00:09:28,068
They begin the final assembly.
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00:09:28,172 --> 00:09:30,965
First, they screw the
Circuit board into the chassis.
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00:09:31,068 --> 00:09:33,103
Then they plug the preamp tube
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00:09:33,206 --> 00:09:36,241
Into the appropriate socket
On the board.
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00:09:36,344 --> 00:09:39,241
This tube boosts the electrical
Signal coming from the guitar
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00:09:39,344 --> 00:09:41,655
And feeds it
To the output tubes,
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00:09:41,758 --> 00:09:43,517
Which up the voltage level,
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00:09:43,620 --> 00:09:46,206
Making the signal
Stronger and louder.
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00:09:46,310 --> 00:09:47,965
After installing control knobs
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00:09:48,068 --> 00:09:50,413
And covering the bottom
Of the chassis,
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00:09:50,517 --> 00:09:53,000
Workers insert
And clamp the output tubes,
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00:09:53,103 --> 00:09:55,172
The number of which
Usually varies
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00:09:55,275 --> 00:09:57,482
According to
How many watts of power
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00:09:57,586 --> 00:09:59,758
The amp is designed to produce.
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00:09:59,862 --> 00:10:03,620
The chassis housing
The electronics goes into a box.
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00:10:03,724 --> 00:10:05,758
This factory builds its boxes
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00:10:05,862 --> 00:10:08,655
From high-grade
Baltic birch plywood,
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00:10:08,758 --> 00:10:12,482
But other companies
Often use domestic plywood, mdf,
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00:10:12,586 --> 00:10:15,241
Or even plastic.
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00:10:15,344 --> 00:10:17,379
After covering the box
In leatherette
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00:10:17,482 --> 00:10:19,137
And adding
Corner reinforcements,
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00:10:19,241 --> 00:10:21,275
They install
The two remaining components --
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00:10:21,379 --> 00:10:23,000
The spring reverb...
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00:10:25,275 --> 00:10:28,379
...And the speaker.
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00:10:28,482 --> 00:10:31,586
As the guitar's electrical
Signals run through the amp,
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00:10:31,689 --> 00:10:33,275
Part of the electrical signal
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00:10:33,379 --> 00:10:36,034
Diverts to one end
Of the spring, vibrating it.
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00:10:36,137 --> 00:10:38,827
The spring's other end
Picks up this vibration
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00:10:38,931 --> 00:10:42,241
And sends it back through
The amp as a delayed signal.
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00:10:42,344 --> 00:10:45,551
That reverberation combines
With the original signal
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00:10:45,655 --> 00:10:47,517
To produce a bigger sound.
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00:11:07,517 --> 00:11:09,310
Narrator:
People have been playing
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00:11:09,413 --> 00:11:11,551
With small balls
Of stone, clay, or marble
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00:11:11,655 --> 00:11:14,206
Since ancient egyptian
And roman times.
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00:11:14,310 --> 00:11:17,034
Today's marbles
Are actually made of glass
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00:11:17,137 --> 00:11:20,206
And used for industrial tasks
As well as games.
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00:11:20,310 --> 00:11:22,517
Glass is not only
Inexpensive and durable,
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00:11:22,620 --> 00:11:24,793
But also quite beautiful.
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00:11:32,034 --> 00:11:33,448
To make marbles,
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00:11:33,551 --> 00:11:36,965
This company melts recycled
Glass with marbles made earlier
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00:11:37,068 --> 00:11:39,517
But rejected
For being the wrong size.
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00:11:42,413 --> 00:11:44,448
All this goes into a kiln
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00:11:44,551 --> 00:11:47,413
Heated to 2,200 degrees
Fahrenheit.
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00:11:49,344 --> 00:11:52,793
After 16 hours, they open a door
At the bottom of the kiln,
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00:11:52,896 --> 00:11:54,896
And the molten glass flows out.
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00:11:58,310 --> 00:12:01,137
A shearing device cuts
The stream every half a second,
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00:12:01,241 --> 00:12:05,620
Forming segments called slugs
That become marbles.
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00:12:05,724 --> 00:12:07,655
To make different-sized marbles,
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00:12:07,758 --> 00:12:11,896
They adjust the device to cut
At shorter or longer intervals.
197
00:12:13,413 --> 00:12:15,310
The slugs slide down chutes,
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00:12:15,413 --> 00:12:18,931
Landing between grooves
On spinning cast-iron rolls.
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00:12:19,034 --> 00:12:22,586
The spinning keeps the slugs
From sticking.
200
00:12:22,689 --> 00:12:26,068
They'll need 72 hours
To cool completely,
201
00:12:26,172 --> 00:12:28,413
But their final appearance
Is already set.
202
00:12:28,517 --> 00:12:30,655
That was determined
Back in the kiln,
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00:12:30,758 --> 00:12:32,689
When the airflow
Drove the heat
204
00:12:32,793 --> 00:12:34,896
To melt the glass
And mix the colors.
205
00:12:37,793 --> 00:12:40,551
These channels separate
The good from the bad.
206
00:12:40,655 --> 00:12:42,275
Openings along the way
207
00:12:42,379 --> 00:12:45,172
Weed out the ones
That are too big or too small
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00:12:45,275 --> 00:12:47,793
And collect the ones
That are just right.
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00:12:53,275 --> 00:12:55,896
More intricate marbles
Are handmade.
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00:12:58,448 --> 00:13:00,862
This craftsman first preheats
Some clear glass
211
00:13:00,965 --> 00:13:02,551
In a small oven.
212
00:13:04,517 --> 00:13:09,000
Then he breaks off a piece
Of colored glass.
213
00:13:09,103 --> 00:13:11,862
After the clear glass has melted
In the furnace overnight,
214
00:13:11,965 --> 00:13:13,793
He gathers some on a steel rod
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00:13:13,896 --> 00:13:17,413
Then picks up a chunk of
Preheated colored glass with it.
216
00:13:17,517 --> 00:13:20,827
He forms a knob and works
The mass into a long string
217
00:13:20,931 --> 00:13:24,137
That's up to 16 1/2 feet long
And thin as a noodle.
218
00:13:28,655 --> 00:13:30,758
He'll use them in various colors
219
00:13:30,862 --> 00:13:34,172
To decorate the clear glass
Cores of the marbles.
220
00:13:34,275 --> 00:13:37,758
He gathers a clump
Of melted clear glass on the rod
221
00:13:37,862 --> 00:13:40,241
And shapes it
With wet newspaper,
222
00:13:40,344 --> 00:13:42,379
Which won't stick to hot glass.
223
00:13:42,482 --> 00:13:44,000
After shaping the end,
224
00:13:44,103 --> 00:13:48,241
He rolls the clump on several
Preheated colored glass strings.
225
00:13:51,275 --> 00:13:52,965
Then it's back in the furnace.
226
00:13:53,068 --> 00:13:55,517
He repeats these steps
Up to three times
227
00:13:55,620 --> 00:13:57,827
And rolls the clump
On a metal table
228
00:13:57,931 --> 00:14:01,275
To even out the surface between
Each trip to the furnace.
229
00:14:01,379 --> 00:14:04,931
Then he adds a layer
Of clear glass on top.
230
00:14:08,206 --> 00:14:09,620
With another tool now,
231
00:14:09,724 --> 00:14:12,586
He stretches the clump
To about 1 1/2 feet long.
232
00:14:12,689 --> 00:14:15,103
He'll use this
To make several cores.
233
00:14:15,206 --> 00:14:17,655
To make the second layer
Of the core,
234
00:14:17,758 --> 00:14:19,620
He rolls a 2-inch-long segment
235
00:14:19,724 --> 00:14:22,482
Onto colored glass slivers
Called ribbons.
236
00:14:24,689 --> 00:14:27,517
After rolling them
In the furnace to melt them,
237
00:14:27,620 --> 00:14:29,827
He flattens the ribbons
With pliers
238
00:14:29,931 --> 00:14:32,310
And snips off the excess
At the ends.
239
00:14:39,827 --> 00:14:42,034
He wraps the core
And the ribbons
240
00:14:42,137 --> 00:14:45,896
In a layer of clear glass,
Then hand-shapes it.
241
00:14:49,137 --> 00:14:52,103
Now he rolls the core
On more glass strings.
242
00:14:52,206 --> 00:14:55,206
Then it's back in the furnace
To meld them.
243
00:14:57,896 --> 00:15:00,344
He adds one more
Clear glass layer,
244
00:15:00,448 --> 00:15:02,275
And the inside is finished.
245
00:15:02,379 --> 00:15:05,379
That's a total of six layers
For this marble.
246
00:15:05,482 --> 00:15:08,862
Other models have fewer or more.
247
00:15:08,965 --> 00:15:11,344
The craftsman shapes the glass
248
00:15:11,448 --> 00:15:13,931
With several metal
And wooden tools.
249
00:15:18,241 --> 00:15:21,241
He measures the diameter
With metal calipers
250
00:15:21,344 --> 00:15:23,241
And gradually sculpts a sphere.
251
00:15:23,344 --> 00:15:26,379
He'll make up to five marbles
From this segment,
252
00:15:26,482 --> 00:15:29,034
Ranging up to the size
Of a golf ball.
253
00:15:31,931 --> 00:15:34,206
After scoring the glass
With a knife,
254
00:15:34,310 --> 00:15:38,344
He places it in the open end
Of a pipe to hold it.
255
00:15:38,448 --> 00:15:40,758
Then he gently taps the rod,
256
00:15:40,862 --> 00:15:43,413
Which breaks the glass
And releases the sphere.
257
00:15:43,517 --> 00:15:47,758
He melts away the bump left at
The spot where the glass broke.
258
00:15:47,862 --> 00:15:50,344
Next, the marble goes
Into an oven
259
00:15:50,448 --> 00:15:53,103
At 986 degrees fahrenheit.
260
00:15:53,206 --> 00:15:57,758
The oven slowly cools overnight
To strengthen the glass.
261
00:15:57,862 --> 00:15:59,448
Clearly a cut above,
262
00:15:59,551 --> 00:16:02,000
This eye-catching,
Handcrafted marble
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00:16:02,103 --> 00:16:04,344
Is already an object of art.
264
00:16:15,034 --> 00:16:17,758
Narrator:
An airplane propeller usually
Has two, three, or four blades,
265
00:16:17,862 --> 00:16:19,965
The angles of which
The pilot can adjust
266
00:16:20,068 --> 00:16:22,379
In response to airspeed
And flight conditions.
267
00:16:22,482 --> 00:16:24,758
A propeller's main parts
Are made of aluminum
268
00:16:24,862 --> 00:16:27,793
Because it's critical to keep it
As lightweight as possible.
269
00:16:27,896 --> 00:16:30,586
The blades and hub are made
Of aerospace-grade aluminum
270
00:16:30,689 --> 00:16:32,793
That resist corrosion
And metal fatigue.
271
00:16:39,827 --> 00:16:42,034
The propeller's blades
Attach to a hub.
272
00:16:42,137 --> 00:16:45,241
This piece of aluminum is
On its way to becoming that hub.
273
00:16:45,344 --> 00:16:47,517
Like the starting pieces
For all parts,
274
00:16:47,620 --> 00:16:49,344
It was forged beforehand
275
00:16:49,448 --> 00:16:51,965
Into a rough version
Of the final shape.
276
00:16:52,068 --> 00:16:54,586
This sophisticated,
Computer-guided mill
277
00:16:54,689 --> 00:16:56,275
Now machines the piece.
278
00:16:56,379 --> 00:16:57,793
40 minutes later,
279
00:16:57,896 --> 00:17:00,862
The hub is finished and ready
For assembly to the engine.
280
00:17:00,965 --> 00:17:03,310
This roughly shaped piece
281
00:17:03,413 --> 00:17:07,241
Is about to become
One of the propeller's blades.
282
00:17:07,344 --> 00:17:12,068
A computer-guided lathe
Machines it to the final shape.
283
00:17:12,172 --> 00:17:14,827
Liquid lubricant washes away
The metal shavings
284
00:17:14,931 --> 00:17:17,172
And cools
The friction-generated heat.
285
00:17:17,275 --> 00:17:19,275
The lathe first forms
The shank --
286
00:17:19,379 --> 00:17:22,000
The end of the blade
That fits into the hub.
287
00:17:26,655 --> 00:17:29,689
The next milling machine
Cuts the blade's shape.
288
00:17:46,586 --> 00:17:48,103
Now the finishing steps --
289
00:17:48,206 --> 00:17:52,000
Done manually
Because they require a keen eye.
290
00:17:52,103 --> 00:17:54,689
Workers use a rotary sander,
291
00:17:54,793 --> 00:17:56,448
Then a belt sander
To grind away the marks
292
00:17:56,551 --> 00:17:59,137
The machining process
Left behind.
293
00:17:59,241 --> 00:18:02,689
They buff the metal
With a polishing wheel...
294
00:18:06,758 --> 00:18:08,137
...Then clean the blades
295
00:18:08,241 --> 00:18:10,482
By dipping them
In a strong detergent.
296
00:18:10,586 --> 00:18:13,655
This acidic solution eats away
Any dirt, oil, or grease
297
00:18:13,758 --> 00:18:15,413
On the surface of the metal.
298
00:18:20,137 --> 00:18:21,896
After that, they dip the blades
299
00:18:22,000 --> 00:18:24,241
In a bath of water
And chromic acid.
300
00:18:24,344 --> 00:18:26,482
This seals the pores
In the metal,
301
00:18:26,586 --> 00:18:27,965
Fending off corrosion.
302
00:18:40,448 --> 00:18:43,965
The factory tests all critical
Parts for surface defects
303
00:18:44,068 --> 00:18:46,758
By dipping them
In a fluorescent solution
304
00:18:46,862 --> 00:18:49,896
That leaches
Into any imperfections.
305
00:18:50,000 --> 00:18:53,827
After rinsing,
An inspection under black light.
306
00:18:53,931 --> 00:18:56,413
A blue glow means
The parts are a-okay.
307
00:18:56,517 --> 00:18:59,862
Any imperfections show up
As bright, fluorescent green.
308
00:18:59,965 --> 00:19:02,448
The defective part
Is either repaired
309
00:19:02,551 --> 00:19:04,965
Or rejected
From the production line.
310
00:19:05,068 --> 00:19:07,896
Blades that make the cut
Move onto the paint shop --
311
00:19:08,000 --> 00:19:09,931
A coat of black on the back side
312
00:19:10,034 --> 00:19:12,551
To prevent sun reflection
Into the pilot's eyes
313
00:19:12,655 --> 00:19:14,517
And stripes for safety,
314
00:19:14,620 --> 00:19:17,620
To make
The spinning blades visible.
315
00:19:17,724 --> 00:19:19,586
Next comes a de-icing boot --
316
00:19:19,689 --> 00:19:22,413
A rubber-encased
Electric heating element
317
00:19:22,517 --> 00:19:24,172
That prevents ice buildup.
318
00:19:24,275 --> 00:19:26,103
The rubber is highly durable,
319
00:19:26,206 --> 00:19:29,758
Yet flexible enough to mold
To the curve of the blade.
320
00:19:32,517 --> 00:19:36,103
Next, they lubricate a part
Of the blade shank with grease,
321
00:19:36,206 --> 00:19:39,241
Then install a strong
Steel-ball-bearing system.
322
00:19:39,344 --> 00:19:42,172
This will hold the blade
Securely in the hub,
323
00:19:42,275 --> 00:19:45,413
Yet still enable it to pivot
To change its angle.
324
00:19:50,896 --> 00:19:52,551
The shanks of the three blades
325
00:19:52,655 --> 00:19:55,310
Fit right into this steel part
Called the fork.
326
00:19:55,413 --> 00:19:57,896
It keeps all the blades
At the same angle.
327
00:20:00,931 --> 00:20:04,275
Now for what's called
The pitch change rod.
328
00:20:04,379 --> 00:20:07,482
The term "Pitch" refers
To the angle of the blades.
329
00:20:07,586 --> 00:20:09,724
Engine oil will exert
Hydraulic pressure
330
00:20:09,827 --> 00:20:12,034
On a piston that moves
The pitch rod,
331
00:20:12,137 --> 00:20:13,689
Which advances the fork,
332
00:20:13,793 --> 00:20:16,551
Rotating the blades
To the required angle.
333
00:20:16,655 --> 00:20:19,793
After removing the
Pitch change rod temporarily,
334
00:20:19,896 --> 00:20:21,724
They apply sealant
To the top half of the hub
335
00:20:21,827 --> 00:20:24,068
And place it
Over the bottom half
336
00:20:24,172 --> 00:20:26,517
That contains
The ball-bearing set.
337
00:20:28,896 --> 00:20:31,655
A rubber o-ring seal,
338
00:20:31,758 --> 00:20:36,000
Then a sturdy spring to provide
The required counterpressure.
339
00:20:40,517 --> 00:20:43,448
Workers thread and torque the
Piston and pitch change rod --
340
00:20:43,551 --> 00:20:46,551
Now attached to each other --
To the fork.
341
00:20:49,896 --> 00:20:51,862
Another rubber o-ring --
342
00:20:51,965 --> 00:20:54,517
This one to prevent leaks
Out of the top of the cylinder
343
00:20:54,620 --> 00:20:56,862
That will contain
The engine oil.
344
00:20:56,965 --> 00:20:58,482
They use a special tool
345
00:20:58,586 --> 00:21:01,965
To tightly torque the cylinder
Down against the hub.
346
00:21:02,068 --> 00:21:04,137
With assembly complete,
347
00:21:04,241 --> 00:21:08,448
This propeller is ready to be
Installed on today's airplanes.
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00:21:08,551 --> 00:21:11,448
--captions by vitac--
Www.Vitac.Com
349
00:21:11,551 --> 00:21:14,517
Captions paid for by
Discovery communications, inc.
350
00:21:17,620 --> 00:21:20,206
If you have any comments
About the show,
351
00:21:20,310 --> 00:21:22,896
Or if you'd like to suggest
Topics for future shows,
352
00:21:23,000 --> 00:21:25,724
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