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Narrator:
Today on "How it's made"...
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Fishing reels...
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...Miniature houses...
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...And kitchen mixers.
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The chinese in the 12th century
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Were first to wind excess
Fishing line on their rods
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Before unreeling it
Back into the water.
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Today's reels have gears
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To quickly deploy
And retrieve the line.
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They're made with lightweight,
High-strength materials
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So you can catch bigger,
Stronger fish --
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Or at least try to.
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Antique reels are heavy
And have just one speed.
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Modern reels have
Two speeds and fewer parts.
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To make a reel's frame,
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A computer-guided router
Cuts four openings
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In a cylinder made of aluminum.
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They let the angler --
The person fishing --
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Access the spool
Inside the frame
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To undo any knots in the line.
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Another cutting machine shapes
A stainless-steel blank
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Into a spindle,
The inner part of the reel
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Around which
The fishing line winds.
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It also carves
Two pinion gears into the piece.
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The high gear
Retrieves line faster.
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The low gear gives more power
To fight big fish.
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The machine's cutters
Are made of carbide,
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An extremely durable material.
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Even so,
Workers change them weekly.
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Another cutter carves
The reel's main gears --
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A high-speed and a low-speed.
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These main gears
Interact with the pinion gears
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To make the spool revolve.
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This lets the angler
Wind line back onto the reel.
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This cutter
Drills small indentations,
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Part of the reel's drag system,
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Which lets the angler
Adjust line tension
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To fight large fish.
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The next cutter
Engraves the company name
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Into one of the reel's
Two side plates.
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Yet another cutter engraves
The drag settings --
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"1" through "4"
And then "Strike."
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Strike lets the angler
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Fight fish
Weighing up to 2,000 pounds.
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Next,
A process called anodizing.
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The side plates are dipped
In a series of chemical baths
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That bind a gold-colored dye
To their surface.
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Now time
To assemble the fishing reel.
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First, they apply
Waterproof grease and lubricant
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00:03:18,000 --> 00:03:20,275
To two safety catches
That prevent an angler
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From applying too little
Or too much line tension.
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A worker then adds a bearing
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To support the spindle
In the spool.
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He also installs
What's called a click plate
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That makes clicking sounds
When a fish takes the line.
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He adds a stainless-steel
Spindle sleeve and drag plate...
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...And a sturdy
Synthetic washer.
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He then adds the spindle
And pinion gears to the spool.
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The spool is now ready
To go into the frame.
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00:04:06,413 --> 00:04:08,793
Using a rotating clamp
To steady the reel,
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Another worker installs
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A stainless-steel fixture that
Attaches the reel to the rod...
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And installs the left-side plate
With six screws.
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This metal spring and plunger
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Enable the angler to
Change speeds from high to low
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With just the push of a button.
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A metal clip
Locks the mechanism in place.
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A little grease to the gearing,
Then a plastic cover,
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And the spool
Is fully assembled.
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He inserts it in the frame
And installs a harness lug,
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Used to attach the reel
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To what's called
A fighting harness,
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Worn to prevent a fish
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From yanking the rod
Out of your hands.
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Now the worker
Mounts the right-side plate.
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00:05:00,137 --> 00:05:03,482
He adds a lever and a knob
To adjust the drag settings.
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You turn the knob clockwise
For more tension,
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Counterclockwise for less.
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Next, he installs the
Stainless-steel-and-plastic knob
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You use to reel in the line.
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And finally,
The button for switching speeds.
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He tests the drag lever
And gears
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To check
If they engage properly.
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He puts it
Into high speed to see
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If the safety catch prevents
What's called free spooling,
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A glitch that could send
A 1/2 mile of line
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Flying wildly out of control
And leave you "Reeling."
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Narrator:
For hundreds of years,
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Dollhouses
Have been hot property.
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At first,
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They were built to entertain
The children of the wealthy,
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But eventually,
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Mass production made these
Mini mansions widely available.
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And today, they continue to be
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Great places for childhood
Fantasies to reside.
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Any home-building project
Is all about the details,
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But the details don't get
Much smaller than this.
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These dollhouses are miniature
Versions of actual homes,
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Made to scale.
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They take a big sheet of plywood
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And slice it
Into smaller pieces.
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For a consistently accurate job,
They use a saw guide,
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Which positions the wood
For a specific cut.
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There's a different guide
For each dollhouse part.
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Using a hot iron,
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They brand the company name
Onto a foundation part.
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This dollhouse
Will be sold as a kit,
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And here, they demonstrate
How to put it together.
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Back on the production line,
They're milling the siding.
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This machine cuts furrows
In wood panels
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To mimic a clapboard finish.
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Next, using a router,
They cut window and door holes.
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And now the walls go up.
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Because this is a kit, each
Piece has to be a perfect fit,
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Because, unlike
A real construction project,
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They can't do recuts on-site.
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They install the second floor
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And tape it
With ordinary masking tape
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While the glue dries.
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And now for the second story.
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It can take up to 100 hours
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To paint and assemble all
The parts in a dollhouse kit,
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Depending on
How elaborate the design is.
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Next, they raise the roof.
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This victorian design
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Has a two-part roof
With a tower in the middle.
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They add weight to apply
Pressure while the glue dries.
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This machine's protective cover
Has been temporarily removed
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To show its inner workings.
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They carefully feed in
A piece of pine.
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It cuts the board
Into little shingles,
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Which fall into a bin below.
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Once the shingles are stained,
They hot-glue them to the roof,
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Following a grid
That was penciled on in advance.
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They wrap the roof with tape
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To stabilize it
While the glue dries.
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Back in the factory,
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Four cutting wheels
Shape a piece of pine
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Into moldings that will be used
For trim on various models.
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The door now goes on.
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It's been trimmed
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With some of the molding
We just saw being made.
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The windows also have
Some molding details.
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All this trim has been made
On the same machine,
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Using different cutters
For the different profiles.
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This railing is a nice touch
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And will also provide support
For the structure.
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00:10:21,724 --> 00:10:24,827
All that's left
Is the interior decorating.
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Some people spend
A small fortune on this stuff --
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Tiny toilets...
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Chairs...
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Even full kitchens in miniature.
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And in this model
Of president lincoln's home,
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The details
Are historically accurate.
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Now they carefully pack up
All the pieces.
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Soon, they'll make
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00:10:51,241 --> 00:10:54,000
Some child's dream
Of home ownership come true,
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But first, somebody had better
Read the instructions.
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Narrator:
Whipping up a dessert
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Used to take
A fair bit of muscle power,
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Until they invented
A mixer with a motor
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In the early part
Of the 20th century.
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The first ones were
Very industrial-looking
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And not much like
Today's sleek models.
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But with this invention,
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The job of pastry-making
Has become a piece of cake.
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Today's mixers
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Can whisk you into
A world of the culinary arts.
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To make one,
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A machine straightens wire
Between a row of wheels.
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Computer-programmed
Forming tools
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Make a total of a dozen bends
To produce arc shapes,
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Which will be used to build
A whip attachment for the mixer.
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00:12:08,620 --> 00:12:10,172
To assemble a whip,
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A technician fits the wire arcs
Into an aluminum hub,
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Starting with the largest one
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And graduating
Down to the smallest.
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Underneath, a punch mechanism
Dimples the hub
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To fasten each wire to it.
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Here, they drop
Some dough hooks and beaters
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Into a vibrating bowl
Full of metal nuggets.
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The friction polishes
These zinc mixer attachments
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And gets rid of the sharp edges.
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Next,
They thread a band of aluminum
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Into a machine that bends
It to the contour of the mixer.
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It's a piece of trim
That carries the brand name.
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A bowl feeder now funnels
Hollow iron weights
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Toward a system that threads
Wire through each of them.
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00:13:24,965 --> 00:13:27,758
Mechanical arms
Pinch and bend the wire,
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Making little hooks on the ends.
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00:13:29,896 --> 00:13:32,620
Two of these weights will be
Used in each speed governor,
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A device that keeps
The mixer's speed constant,
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Despite changes in the load.
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00:13:39,103 --> 00:13:41,275
To assemble the speed governor,
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00:13:41,275 --> 00:13:43,827
They arrange a brass hub,
Spring, and a washer
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00:13:43,827 --> 00:13:46,517
In a holding device...
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00:13:46,517 --> 00:13:48,965
And then
Press-fit them together.
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00:13:51,655 --> 00:13:54,862
They attach the two weights
To the spring assembly,
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00:13:54,862 --> 00:13:57,034
Using the protruding wires.
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00:13:57,034 --> 00:14:00,310
The speed-governor system
Is now complete.
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00:14:02,724 --> 00:14:04,862
Here's how
The governor weights fly out
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00:14:04,862 --> 00:14:06,827
To regulate the mixer's speed.
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00:14:10,862 --> 00:14:13,965
And now it's time
To prepare the motor shaft.
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00:14:13,965 --> 00:14:17,965
They lower this spinning steel
Cylinder to a revolving cutter.
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00:14:17,965 --> 00:14:20,172
Lubricant keeps the cutter cool
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00:14:20,172 --> 00:14:22,931
As it carves spirals
Into the end of the shaft.
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00:14:27,241 --> 00:14:29,758
The spiraling grooves
Will allow the shaft
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00:14:29,758 --> 00:14:32,482
To drive
The mixer's internal gears.
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00:14:35,965 --> 00:14:37,551
They install the shaft,
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00:14:37,551 --> 00:14:39,724
With motor windings
And bearings attached,
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Into the mixer body.
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00:14:44,275 --> 00:14:46,965
Next,
They rivet electrical contacts
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00:14:46,965 --> 00:14:49,413
To plastic control boards.
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00:14:49,413 --> 00:14:53,068
These contacts will convey
Electricity to drive the motor.
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00:15:05,413 --> 00:15:08,172
They deliver an electrical
Charge to the contacts
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00:15:08,172 --> 00:15:10,310
To make sure they're working.
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00:15:11,793 --> 00:15:14,482
Then they
Attach screws, nuts, and springs
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00:15:14,482 --> 00:15:16,620
To complete
The control-board assembly.
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00:15:16,620 --> 00:15:18,241
The control board will work
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00:15:18,241 --> 00:15:20,206
In concert
With the governor weights
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00:15:20,206 --> 00:15:23,862
To control the mixer's speed.
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00:15:29,965 --> 00:15:31,965
For these mixers
To really shine,
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00:15:31,965 --> 00:15:34,275
They'll need a good paint job.
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00:15:34,275 --> 00:15:36,551
To prepare the mixer parts
For painting,
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00:15:36,551 --> 00:15:39,310
They polish them
On an abrasive belt.
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00:15:41,586 --> 00:15:44,068
Then it's into the paint booth.
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00:15:44,068 --> 00:15:46,310
This is
A highly charged process.
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The paint has
A positive electrical charge
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00:15:49,344 --> 00:15:51,655
And is attracted
To the zinc mixer parts,
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00:15:51,655 --> 00:15:53,551
Which are negatively charged.
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Now all the parts
Are in the mix.
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00:15:59,034 --> 00:16:00,241
Coming up next...
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00:16:00,241 --> 00:16:03,103
We'll show you
How they all come together.
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00:16:14,965 --> 00:16:17,206
Narrator:
Behind many a successful cook
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00:16:17,206 --> 00:16:19,965
Is a well-oiled machine
That's made for speed,
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00:16:19,965 --> 00:16:22,586
And that's the electric mixer.
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00:16:22,586 --> 00:16:26,068
It produces the best results
When the blades turn rapidly.
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00:16:26,068 --> 00:16:29,655
If they turn too slowly, they
Won't mix the batter thoroughly,
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00:16:29,655 --> 00:16:32,689
And that means
Your pastry could be a flop.
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00:16:36,862 --> 00:16:39,241
To assemble
This tilt-head mixer,
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00:16:39,241 --> 00:16:41,655
They install
A gear to drive the attachments.
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00:16:41,655 --> 00:16:43,551
Next comes the stator,
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00:16:43,551 --> 00:16:46,137
Which creates the electrical
Field for the motor.
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00:16:46,137 --> 00:16:47,620
A dab of oil,
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00:16:47,620 --> 00:16:50,275
And then they mount
The shaft and motor windings
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00:16:50,275 --> 00:16:51,827
Inside the unit.
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00:16:55,896 --> 00:16:59,413
They slide two motor brushes
Into predrilled holes.
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00:16:59,413 --> 00:17:01,586
The motor brush
Will supply electricity
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00:17:01,586 --> 00:17:04,034
To the internal components.
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00:17:08,413 --> 00:17:11,034
This bearing bracket
Holds the motor in place.
251
00:17:13,758 --> 00:17:15,758
They lubricate the front of it
252
00:17:15,758 --> 00:17:18,448
Before installing
The electrical control board.
253
00:17:24,275 --> 00:17:27,344
They wrap a trim band
With the brand name on it
254
00:17:27,344 --> 00:17:28,655
Around the outside.
255
00:17:33,448 --> 00:17:35,586
Next, they pour gobs of grease
256
00:17:35,586 --> 00:17:39,103
Into the section of the mixer
That will hold the gears.
257
00:17:39,103 --> 00:17:44,206
The gear section will be sealed
So the grease can't leak out.
258
00:17:46,137 --> 00:17:48,413
They attach
The other half of the unit
259
00:17:48,413 --> 00:17:51,655
That has some gears
Already fixed to it.
260
00:17:51,655 --> 00:17:53,344
They insert a drive pin
261
00:17:53,344 --> 00:17:56,448
In the shaft that moves
The whisk and other attachments
262
00:17:56,448 --> 00:18:00,068
And screw
The two halves together.
263
00:18:00,068 --> 00:18:02,758
They apply more grease
To this section
264
00:18:02,758 --> 00:18:05,379
And then install
The planetary gear.
265
00:18:05,379 --> 00:18:09,413
This gear will rotate the mixer
Attachments around the bowl.
266
00:18:09,413 --> 00:18:11,413
With a mallet,
267
00:18:11,413 --> 00:18:15,068
The worker hammers a pin
To attach the planetary gear.
268
00:18:15,068 --> 00:18:18,689
He taps a decorative ring
Onto the outside.
269
00:18:23,793 --> 00:18:27,931
He mounts the motor unit
To the base...
270
00:18:27,931 --> 00:18:32,241
And marks an identification
Number onto the bottom.
271
00:18:35,965 --> 00:18:38,620
Now they take
The tilt-head mixer for a spin.
272
00:18:47,413 --> 00:18:50,827
And the next step
Is to adjust the speed.
273
00:18:50,827 --> 00:18:53,379
The technician
Installs a speed-setting tool
274
00:18:53,379 --> 00:18:55,310
In the hub of the mixer.
275
00:18:55,310 --> 00:18:59,586
While the gears turn, he checks
The readout and tunes it up.
276
00:18:59,586 --> 00:19:00,793
Each mixer has to be able
277
00:19:00,793 --> 00:19:05,310
To make a dizzying
200 rotations per minute.
278
00:19:10,689 --> 00:19:13,620
They cap the hub.
279
00:19:13,620 --> 00:19:16,413
The final step
Is testing the beater.
280
00:19:18,551 --> 00:19:22,793
They check that it's correctly
Positioned above the bowl.
281
00:19:22,793 --> 00:19:25,241
One last polish, and it's ready.
282
00:19:27,931 --> 00:19:29,448
Over at another station,
283
00:19:29,448 --> 00:19:31,965
They're making
A more commercial type of mixer,
284
00:19:31,965 --> 00:19:33,931
One with a bowl
That lifts to the beater
285
00:19:33,931 --> 00:19:36,551
Instead of a tilt-head
That lowers to the bowl.
286
00:19:40,000 --> 00:19:42,758
They screw a base
To a bowl-support piece.
287
00:19:50,379 --> 00:19:53,965
Then they attach the lower
Housing for the beater motor.
288
00:19:59,275 --> 00:20:01,275
As the mixer moves
On a conveyor,
289
00:20:01,275 --> 00:20:04,517
They install
The motor and gears.
290
00:20:04,517 --> 00:20:06,586
They add
A generous squirt of grease
291
00:20:06,586 --> 00:20:08,275
To lubricate the transmission
292
00:20:08,275 --> 00:20:11,344
And then encase the top
Of the motor with more housing.
293
00:20:13,655 --> 00:20:15,206
Continuing down the line,
294
00:20:15,206 --> 00:20:17,965
They install
The electrical speed controls,
295
00:20:17,965 --> 00:20:21,689
Topping it off
With more housing.
296
00:20:23,206 --> 00:20:26,103
They wrap the signature
Piece of trim around it.
297
00:20:36,000 --> 00:20:40,827
Using a probe, they check
The wattage and speed.
298
00:20:43,137 --> 00:20:46,310
It passes inspection,
And it's ready for packing.
299
00:20:50,517 --> 00:20:52,620
It's taken
Approximately 10 minutes
300
00:20:52,620 --> 00:20:54,965
To assemble
This bowl-lift mixer,
301
00:20:54,965 --> 00:20:57,517
But it's been made
To last a lifetime.
302
00:20:57,517 --> 00:21:00,448
And with such a range
Of attachments for these mixers,
303
00:21:00,448 --> 00:21:02,896
You can really go "Stir" crazy.
304
00:21:02,896 --> 00:21:05,896
--captions by vitac--
Www.Vitac.Com
305
00:21:05,896 --> 00:21:08,896
Captions paid for by
Discovery communications, inc.
306
00:21:18,034 --> 00:21:20,172
If you have any comments
About the show,
307
00:21:20,172 --> 00:21:22,793
Or if you'd like to suggest
Topics for future shows,
308
00:21:22,793 --> 00:21:24,517
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