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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Crayons...
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...Wooden kayaks...
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...Lawn mowers...
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...And gold chains.
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Crayons are
A popular drawing tool
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00:00:55,206 --> 00:00:56,758
For today's young artists.
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00:00:56,758 --> 00:00:59,517
The average north american kid
Uses 730 of them
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By the age of 10.
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00:01:00,896 --> 00:01:04,000
An american chemical company
Invented crayons in 1903.
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00:01:04,000 --> 00:01:06,517
It took the basic wax crayon
It already made
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For marking crates and barrels
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And came up
With a nontoxic version
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In different colors.
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These crayons are made
From a combination of waxes --
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00:01:19,517 --> 00:01:22,482
Primarily paraffin, which is
Ideal for making crayons
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00:01:22,482 --> 00:01:25,275
Because it's inexpensive
And easy to melt.
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It also has what's called
A nice rub-off,
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Meaning it leaves enough wax
On the paper.
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They melt the wax
At 143 degrees fahrenheit.
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Then add a secret powder
To strengthen the crayon
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And act as a filler,
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Boosting the number of crayons
The wax will produce.
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They also add various
Synthetic chemicals --
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There's one to keep the wax
From sticking to the mold...
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And a fatty acid, called stearic
Acid, to improve the rub-off.
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Now they tint the wax --
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In this case, yellow and red
To produce orange crayons.
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This factory can produce
127 different colors.
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Every ingredient
In the crayons is nontoxic.
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After adding more wax,
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They blend the mixture
For about 45 minutes.
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00:02:22,482 --> 00:02:26,931
Now they pump the wax into this
Device called a rotary machine.
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00:02:29,137 --> 00:02:37,241
It first injects the wax
Into crayon-shaped molds.
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Then it envelops the molds
In cool water,
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Hardening the wax
Within roughly a minute.
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As the molds continue along
The circuit,
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A blade scrapes off the excess,
Which gets recycled.
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Just one rotary machine
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Molds more than 2,700 crayons
Per cycle.
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With several machines
Operating simultaneously,
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This factory churns out
30,000 crayons per hour.
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The machine ejects the crayons,
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And a conveyor transports them
To the labeling machine.
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One by one, they drop into
The grooves of a revolving drum.
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At the bottom left,
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A gluer coats the surface
In between the grooves
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00:03:44,827 --> 00:03:48,965
Just before the crayons go in.
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The machine then slaps a label
Onto each crayon.
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A roller presses the label
Against the adhesive,
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Then a little arm
Wraps it around the crayon.
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This machine labels
8,500 crayons per hour.
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The crayons exit the labeling
Machine and land in a bulk box.
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Workers sort the crayons
By color
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Into the appropriate hoppers
Of the packing machine.
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The packaging line
Is entirely automated.
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The factory programs the machine
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To collect a certain number
Of crayons in specific colors
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According to the type
Of pack in production.
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Their best sellers
Are packs of 16 and 24.
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The packing machine is designed
To handle the crayons gently.
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00:05:02,551 --> 00:05:04,482
Occasionally, though,
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A crayon does crack
Or a label comes loose.
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When that happens, a sensor
Automatically stops the machine
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00:05:10,275 --> 00:05:12,965
And a light goes on
Above the problem hopper.
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Workers clear the jam,
Then production resumes.
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00:05:22,896 --> 00:05:24,896
Once the count is complete,
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The crayon line
And the box line meet.
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00:05:28,793 --> 00:05:34,034
A pushing device slides
Each set of crayons into a box.
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A built-in scale
Weighs every box.
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Should one be underweight,
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The machine automatically blows
It off the conveyor belt.
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A worker then manually
Adds the missing crayon,
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Ensuring a full complement of
Colors for every budding artist.
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Narrator:
For thousands of years,
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Aboriginal people in the arctic
Have used kayaks to hunt
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And for good reason.
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These slender vessels
Glide swiftly in the water
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And are light enough to carry.
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High-tech materials
Make today's wooden kayaks
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00:06:12,620 --> 00:06:13,931
More durable than ever,
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But its shape
And performance in the water
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Are basically the same.
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It starts with plywood
Made from okoume --
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00:06:26,793 --> 00:06:28,827
A rugged type of mahogany.
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A computer-guided
Routing machine
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Cuts out the boat's
Various parts.
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One has finger joints that
Interlock with another piece
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To make one long strip.
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These panels will cover
The sides of the vessel
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And most of the top.
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The planks are so thin --
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Just a little over
An eighth of an inch --
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That the entire kayak
Will weigh only 37 1/2 pounds.
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Then there are bulkheads,
End panels, footrests,
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00:06:55,827 --> 00:06:59,448
And curved pieces
To support the deck and sides.
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After applying two coats
Of epoxy resin,
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A craftsman assembles the parts
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00:07:07,137 --> 00:07:11,344
And secures them in a jig for
Six hours until the glue sets.
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The side panels will span
The entire length of the boat,
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00:07:14,413 --> 00:07:16,724
At just over 16 1/2 feet.
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Assembling the kayak
Is pretty straightforward,
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00:07:19,241 --> 00:07:21,551
So if you want to save money
And do it yourself,
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00:07:21,551 --> 00:07:26,241
You can buy this kayak
Cheaper as a kit.
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He planes and sands the end
Panels to create a curved tip.
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00:07:37,965 --> 00:07:41,379
He drills small holes
Spaced 4 3/4 inches apart
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Along the edges
Of the bottom panels.
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00:07:45,103 --> 00:07:47,310
Then he threads copper wire
Through the holes.
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This stitches the panels
Together temporarily,
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Keeping them flexible
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And thereby easy to assemble
For gluing.
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He places wooden pegs
Between the side panels
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To pry them open...
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00:08:04,206 --> 00:08:05,896
Then joins those panels
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00:08:05,896 --> 00:08:10,413
With two screws in the front
And two in the back.
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00:08:10,413 --> 00:08:13,344
At this stage,
The kayak is upside down,
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00:08:13,344 --> 00:08:15,655
So they add the bottom panels.
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00:08:15,655 --> 00:08:17,413
He attaches them
With copper wire
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00:08:17,413 --> 00:08:19,724
Because it won't stick
To the resin he'll use
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00:08:19,724 --> 00:08:22,586
To glue these parts together.
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00:08:32,689 --> 00:08:34,103
After flipping the boat,
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00:08:34,103 --> 00:08:36,620
He attaches a bulkhead
With more wire.
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00:08:36,620 --> 00:08:40,586
It's one of two separators that
Create stowage compartments.
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00:08:40,586 --> 00:08:42,724
Using a putty knife as a gauge,
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00:08:42,724 --> 00:08:44,793
He ensures the gaps
At the seams are even,
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00:08:44,793 --> 00:08:47,413
Then he flips the boat
And coats the seams in resin.
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00:08:50,517 --> 00:08:52,724
He lets it dry for 6 hours,
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00:08:52,724 --> 00:08:56,517
Just part of the 40 hours
It takes to build the kayak.
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00:08:59,448 --> 00:09:00,793
Before the glue hardens,
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00:09:00,793 --> 00:09:03,275
He makes sure
The top of the boat is level.
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00:09:03,275 --> 00:09:07,965
This way, he can adjust
The pieces if he needs to.
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00:09:07,965 --> 00:09:10,344
After removing the wire
From the seams,
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00:09:10,344 --> 00:09:12,862
He applies more resin
To these areas.
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00:09:12,862 --> 00:09:17,137
Over this, strips of fiberglass
Cloth to form a watertight seal.
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00:09:17,137 --> 00:09:19,517
He'll also apply
Three more coats of resin
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00:09:19,517 --> 00:09:22,482
Throughout the inside
Of the kayak.
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00:09:27,482 --> 00:09:31,448
Once it dries, and he sands and
Varnishes the entire surface,
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00:09:31,448 --> 00:09:34,137
The craftsman
Adds the footrest assembly.
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00:09:34,137 --> 00:09:35,724
This one's got pivot pads
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00:09:35,724 --> 00:09:38,344
With cables that control
A rudder to help steer the boat.
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00:09:38,344 --> 00:09:40,620
This is an optional feature.
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00:09:40,620 --> 00:09:43,137
Otherwise,
There's a simple foot brace,
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00:09:43,137 --> 00:09:45,965
And you just use your paddle.
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00:09:51,310 --> 00:09:55,034
Next, craftsmen apply resin
Along the kayak's upper rim.
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00:09:55,034 --> 00:09:57,517
They add the top panel
To form the deck,
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00:09:57,517 --> 00:10:00,206
Then they wrap the entire boat
In packing tape,
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00:10:00,206 --> 00:10:05,413
Which compresses the panels
As the resin sets for 12 hours.
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00:10:05,413 --> 00:10:09,241
These pieces form a raised rim
Around where the kayaker sits.
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00:10:09,241 --> 00:10:11,413
A waterproof skirt
Fits under this rim,
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00:10:11,413 --> 00:10:14,965
Keeping the area dry
In the water.
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00:10:14,965 --> 00:10:17,379
The deck
Gets two coats of resin.
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00:10:17,379 --> 00:10:20,034
An hour later, they spread
Fiberglass over the bottom
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00:10:20,034 --> 00:10:22,344
To seal and protect the wood.
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00:10:22,344 --> 00:10:25,655
The bottom then gets
Three coats of resin.
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00:10:30,586 --> 00:10:33,068
Next, they spray on
Up to six coats of varnish,
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00:10:33,068 --> 00:10:36,172
Depending on the type of finish
The boat will have.
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00:10:36,172 --> 00:10:39,551
This protects the wood
From sun damage.
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00:10:39,551 --> 00:10:41,103
They add a foam backrest
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00:10:41,103 --> 00:10:43,965
And a seat
For your comfort on the trek.
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00:10:48,275 --> 00:10:51,379
And finally,
Flexible rubber straps --
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They're for securing your paddle
To the kayak.
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00:10:53,931 --> 00:10:56,931
Now it's off to the water.
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Narrator: gardeners' jobs
Got much easier in 1830
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With the invention of
The first mechanical lawn mower.
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00:11:14,034 --> 00:11:18,586
Nowadays, most lawn mowers have
Electric motors or gas engines.
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00:11:18,586 --> 00:11:21,965
They turn blades that are either
On a reel and cut like scissors
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00:11:21,965 --> 00:11:25,482
Or rotate like a propeller
To chop the grass.
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00:11:30,206 --> 00:11:32,517
These gas mowers
Have rotary blades
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That spin horizontally
On a vertical crankshaft.
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00:11:37,344 --> 00:11:40,551
To make the blade housing,
Which is called the deck,
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00:11:40,551 --> 00:11:43,206
A machine first applies
A lubricating chemical
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00:11:43,206 --> 00:11:46,620
To sheet steel, which was coiled
When it came to the factory.
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00:11:46,620 --> 00:11:49,655
The chemical helps flatten it
So it's easier to cut.
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00:11:51,241 --> 00:11:54,793
A press then perforates
The sheet every 2 feet.
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After the press
Separates the segments
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00:11:59,482 --> 00:12:01,172
And rounds off the corners,
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00:12:01,172 --> 00:12:06,379
A robotic arm
Moves each segment onto a die.
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00:12:06,379 --> 00:12:10,655
A 500-ton press bends the steel
Like tinfoil between two molds
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00:12:10,655 --> 00:12:14,000
To give the deck
Its basic shape.
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00:12:17,275 --> 00:12:21,448
A robot lifts the oily decks
With suction cups
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00:12:21,448 --> 00:12:24,482
And moves them to another press.
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00:12:30,586 --> 00:12:34,344
This machine trims away the
Excess around the deck's edges.
185
00:12:40,310 --> 00:12:43,862
Another machine bends
The sharp bottom lip inward
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To make the deck
Safer to handle.
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00:12:47,137 --> 00:12:50,413
The factory uses robots because
They work faster than humans,
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00:12:50,413 --> 00:12:52,620
Processing 500 decks an hour.
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00:12:56,310 --> 00:12:58,068
After a thorough cleaning,
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00:12:58,068 --> 00:13:00,896
The decks move into
An electrostatic-paint booth.
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00:13:00,896 --> 00:13:03,827
They lace the powder paint
With a negative electric charge,
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00:13:03,827 --> 00:13:05,965
The decks with a positive one.
193
00:13:05,965 --> 00:13:08,310
This draws the paint particles
Onto the decks,
194
00:13:08,310 --> 00:13:11,379
Creating a thorough
And even coat.
195
00:13:11,379 --> 00:13:14,103
The factory's six paint booths
Are on tracks
196
00:13:14,103 --> 00:13:15,862
So when it's time
To change color,
197
00:13:15,862 --> 00:13:20,862
Workers can easily switch the
Entire chamber for a clean one.
198
00:13:20,862 --> 00:13:26,241
The paint cures at 374 degrees
Fahrenheit for 15 minutes.
199
00:13:28,862 --> 00:13:31,103
This press bends
8-foot-long tubing
200
00:13:31,103 --> 00:13:33,482
To form the mower's
Upper handle.
201
00:13:37,724 --> 00:13:40,344
Another press bends
6-foot-long tubes
202
00:13:40,344 --> 00:13:42,620
To make a shorter, lower handle.
203
00:13:42,620 --> 00:13:45,172
Workers will later attach
The two handles
204
00:13:45,172 --> 00:13:46,862
To form one folding handle.
205
00:13:46,862 --> 00:13:49,620
By folding, it takes up
Less space in the shipping box
206
00:13:49,620 --> 00:13:54,655
And, later, in your garage.
207
00:13:58,517 --> 00:14:01,241
Here's the mower's
5-horsepower engine.
208
00:14:01,241 --> 00:14:05,517
A worker attaches it to the deck
With three bolts.
209
00:14:05,517 --> 00:14:06,965
He uses a powerful torque gun
210
00:14:06,965 --> 00:14:09,344
So the bolts won't loosen
Because of vibrations.
211
00:14:09,344 --> 00:14:11,655
Later, workers
Will mount the blades
212
00:14:11,655 --> 00:14:13,655
To the engine's crankshaft
213
00:14:13,655 --> 00:14:16,724
That protrudes
Through an opening in the deck.
214
00:14:19,862 --> 00:14:22,793
Next, workers install
A plastic rear door,
215
00:14:22,793 --> 00:14:25,724
Through which
The grass clippings eject.
216
00:14:25,724 --> 00:14:27,275
This door attaches to brackets,
217
00:14:27,275 --> 00:14:29,344
Which have levers
That adjust the mower
218
00:14:29,344 --> 00:14:31,758
To nine different
Height positions.
219
00:14:40,896 --> 00:14:45,551
It's time to mount
The plastic rear wheels.
220
00:14:45,551 --> 00:14:48,965
Next an adaptor to stabilize
The blade on the crankshaft,
221
00:14:48,965 --> 00:14:50,103
Then the blade.
222
00:14:50,103 --> 00:14:51,551
It's wider at each end
223
00:14:51,551 --> 00:14:55,241
To create the proper airflow
Inside the deck.
224
00:14:59,379 --> 00:15:02,448
They secure the blade tightly
With a powerful wrench
225
00:15:02,448 --> 00:15:06,965
Because it's going to spin
At 3,300 rpm.
226
00:15:06,965 --> 00:15:09,965
The front wheels are 1/3 smaller
Than the back ones.
227
00:15:09,965 --> 00:15:15,000
This makes the mower easier
To maneuver over uneven terrain.
228
00:15:15,000 --> 00:15:17,586
They put rubber covers
On the height-adjustment levers
229
00:15:17,586 --> 00:15:19,448
So they're softer
On the fingers.
230
00:15:19,448 --> 00:15:21,862
The mower adjusts from 1 inch
231
00:15:21,862 --> 00:15:25,448
To nearly 3 1/2 inches
Off the ground.
232
00:15:25,448 --> 00:15:27,586
They secure the lower handle,
233
00:15:27,586 --> 00:15:30,310
Then loosely attach the upper
Handle to the lower one.
234
00:15:30,310 --> 00:15:33,068
The consumer can tighten this
After shipping.
235
00:15:35,931 --> 00:15:38,724
They add a safety handle
That turns the engine off
236
00:15:38,724 --> 00:15:41,275
If you're not squeezing it
Against the upper handle.
237
00:15:41,275 --> 00:15:43,000
It attaches to a caliper system,
238
00:15:43,000 --> 00:15:46,172
Much like what you'd find
On a bicycle.
239
00:15:52,827 --> 00:15:55,551
Finally, workers apply labels
240
00:15:55,551 --> 00:15:58,103
To indicate the mower's
Horsepower and width.
241
00:15:58,103 --> 00:16:02,793
Fill it up with gas, and it's
Ready to give your lawn a trim.
242
00:16:14,448 --> 00:16:17,137
Narrator:
Some of the first gold chains
243
00:16:17,137 --> 00:16:19,862
Date back to the ancient
Cultures of iraq and greece.
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They were symbols of wealth,
Royalty, and the divine.
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Lucky for us, jewelers now
Make these personal treasures
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More affordable
And more durable than ever.
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But you may be surprised to
Learn what they put in the gold
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To make it better.
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Pure gold is fairly soft
And bright yellow,
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So it's common to create
An alloy to strengthen it
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And alter its color.
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Copper lends a reddish hue.
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And brass helps the alloy
Melt more quickly than gold
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And copper would alone.
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Depending on the ratio,
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Adding these metals produces
14- or 18-karat gold.
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They melt the mix in a crucible
At 1,850 degrees fahrenheit.
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Just three of these scoops
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Are enough to make about 5,000
14-karat-gold chains.
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A worker pours the molten alloy
Into a casting machine.
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Water cools the metal to
Around 700 degrees fahrenheit,
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Solidifying it.
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The metal passes through
A round die
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Which shapes it
Into a golden rod
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That's nearly 6 1/2 feet long.
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After cutting the rod in half,
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Workers pass it through
What's called a breakdown mill.
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The machine reshapes the rod
From round to square
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So it will be easier to stretch.
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Next stop -- a tandem mill.
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It's got 12 rollers
That stretch the rod
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Until it's about as thin
As a piece of spaghetti.
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As it emerges, rollers shape
The rod into a coil
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That's nearly 78 feet long.
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Workers soften the coiled metal
In an oven.
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Then they uncoil and continue
Stretching what's now a wire
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By passing it through a die
Lined with industrial diamonds.
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To prevent overheating,
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The machine sprays lubricant
To cool the wire
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While reducing it
To the width of a human hair --
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Its final size.
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The wire then winds into a spool
That's over 1 1/2 miles long.
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Next, they unwind 32
Of the spools
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00:18:42,379 --> 00:18:45,034
And run the wires
Through another oven
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To soften them even more.
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Just in case you're thinking
About walking off
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With some of them,
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You should know that security
Is very tight.
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Employees must pass through
Metal detectors
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Before going home,
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And wearing jewelry to work
Is strictly forbidden.
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00:19:00,103 --> 00:19:03,310
This machine makes
What's called cable chain.
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It passes wire
Through a link and closes it
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To make another link.
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00:19:06,689 --> 00:19:09,827
The machine makes 600 links
Per minute.
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00:19:14,206 --> 00:19:17,000
Here, a worker
Does a random quality check.
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00:19:20,758 --> 00:19:24,724
This machine makes a chain in
What's called a venetian style.
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00:19:24,724 --> 00:19:26,482
The wire passes through
A channel
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Where mechanical jaws
Bend it over a die
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00:19:28,517 --> 00:19:31,103
To make a link
With the preceding segment.
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00:19:35,965 --> 00:19:38,206
To make what's called
A spider style,
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00:19:38,206 --> 00:19:41,000
This machine passes a wire
Through up to five loops
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Before closing the link.
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For a figaro-style chain,
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00:19:52,034 --> 00:19:54,034
This machine
Makes three short links
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Before a mechanical arm moves
The chain to another area
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00:19:57,241 --> 00:20:01,172
To add one longer link.
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00:20:01,172 --> 00:20:04,827
The arm then moves it back
To add three more short links.
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00:20:11,068 --> 00:20:13,655
The simplest style
Is what's called a rope chain.
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00:20:13,655 --> 00:20:15,793
To make it,
This machine threads a wire
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Through as many as two loops
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Then closes it
To make another loop.
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00:20:24,896 --> 00:20:28,034
They coat the finished chains
With a lubricating powder
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00:20:28,034 --> 00:20:30,413
That prevents the links
From sticking to each other
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00:20:30,413 --> 00:20:31,724
During the next step,
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00:20:31,724 --> 00:20:36,241
When they heat the chains
To 1,500 degrees fahrenheit.
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00:20:36,241 --> 00:20:40,000
This activates a soldering agent
Added to the metals earlier.
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00:20:40,000 --> 00:20:43,172
It fuses the ends of the links
To each other.
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00:20:46,689 --> 00:20:50,551
This machine welds a link
To a clasp on the chain.
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00:20:50,551 --> 00:20:53,931
A tag indicating the gold
Quality goes onto the clasp.
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00:20:53,931 --> 00:20:57,000
Finally, the chains
Go through four chemical baths,
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Which thoroughly clean them,
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00:20:58,896 --> 00:21:02,931
Then workers plate them with
A layer of 14- or 18-karat gold.
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Plating gold with gold
Creates a more vibrant finish.
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00:21:06,689 --> 00:21:08,689
After one last quality check,
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00:21:08,689 --> 00:21:11,172
These chains are ready
To dazzle their way
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To a neckline near you.
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If you have any comments
About the show,
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00:21:20,379 --> 00:21:23,068
Or if you'd like to suggest
Topics for future shows,
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00:21:23,068 --> 00:21:24,896
Drop us a line at...
26903
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