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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
Today on "How it's made"...
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Racing shells...
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...Stainless-steel sinks...
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00:00:38,689 --> 00:00:40,241
...Leather...
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...And pedal steel guitars.
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The racing shell is a high-tech
Rowboat that's built for speed.
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Long and exceptionally narrow,
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It's designed
To cut through wave drag
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00:01:04,793 --> 00:01:07,655
And leave the competition
In its wake.
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Racing shells are made for
Single rowers, called scullers,
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00:01:21,000 --> 00:01:23,827
For pairs, or entire crews.
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They're custom-made
To precise specifications.
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00:01:33,172 --> 00:01:35,862
Racers need to travel light
To maintain speed,
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00:01:35,862 --> 00:01:38,931
So these boats are made
From reinforced carbon fiber,
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00:01:38,931 --> 00:01:42,344
Which weighs a lot less
Than wood.
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First, several of these
Carbon-fiber sheets
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Are layered in a mold
And trimmed along the edge.
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Textured thermoplastic called
Honeycomb gets a spray of glue
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And is then pressed onto
The carbon-fiber plies.
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00:02:04,000 --> 00:02:06,793
Sandwiched between layers
Of carbon fiber,
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00:02:06,793 --> 00:02:10,517
The honeycomb will serve
As the shell's core,
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Lending some lightweight
Reinforcement
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00:02:12,586 --> 00:02:14,379
To the delicate hull.
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00:02:24,379 --> 00:02:27,482
Next, the entire boat
Is wrapped in breather cloth
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00:02:27,482 --> 00:02:28,931
And a plastic bag
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00:02:28,931 --> 00:02:32,793
So that the air can be vacuumed
From between the layers.
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00:02:32,793 --> 00:02:34,724
The breather cloth
Is a permeable layer
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That prevents the plastic
From sticking to the mold
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And creating air pockets.
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00:02:41,896 --> 00:02:44,137
Next, the shell goes
Into a long oven,
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Which melts the glue
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That's been impregnated
In the carbon material,
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Fusing the layers together.
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00:02:55,931 --> 00:02:59,724
The shell bakes at 210 degrees
For 8 hours.
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00:03:03,275 --> 00:03:06,586
Then the plastic and
Breather cloth are pulled away.
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00:03:10,379 --> 00:03:14,517
And the boat is pried out of
The mold using plastic wedges.
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The hull comes out
In one solid piece,
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And a primer paint sprayed
Into the mold earlier
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Has adhered
To the shell's surface.
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Workers check the weight,
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Which has to be exactly
What the customer ordered.
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00:03:35,793 --> 00:03:38,344
Next, they reinforce
The boat's cockpit
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With several
Carbon-fiber bulkheads.
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00:03:51,689 --> 00:03:54,551
Foam is glued on the inside rim
Of the racing shell,
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Using a piece of wood
As a guide.
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00:04:05,517 --> 00:04:08,758
Glue is applied
Around the bulkheads.
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00:04:08,758 --> 00:04:10,793
Then the cockpit panel
Is lowered
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00:04:10,793 --> 00:04:13,586
So that it adheres
To the glued areas
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00:04:13,586 --> 00:04:15,103
And rests on top of the foam
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That's been installed
Along the edges.
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00:04:23,586 --> 00:04:26,586
Next, a computerized tool
Drills holes
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For the hardware and riggers
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And workers trim the rim
From stern to bow.
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They smooth the holes' finish
With a grinding tool.
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And now it's over
To the paint station
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For some sanding and priming.
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Any flaws are marked for repair
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Because the slightest
Imperfection
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Could affect the boat's ability
To speed through the water.
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00:04:53,206 --> 00:04:55,034
Once the boat
Is perfectly smooth,
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It gets a high-gloss
Urethane coating.
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00:05:01,241 --> 00:05:05,931
Next, a fin is installed
For a little stability.
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00:05:05,931 --> 00:05:08,896
A laser guide helps align it
Into perfect position.
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00:05:13,862 --> 00:05:16,586
A rudder goes into the bottom
Of the boat.
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The system of ropes
That's attached next
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Will allow the rowers to steer.
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00:05:27,517 --> 00:05:31,034
This boat comes with special
Shoes and sliding seats
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That allow rowers to put a lot
Of leg power into their strokes.
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00:05:37,000 --> 00:05:40,724
Finally, the rigging equipment
For the oars goes in.
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Now this sleek racing shell
Is ready to hit the water.
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When we return,
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Turning stainless steel
Into a sparkling new sink.
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Narrator:
The stainless-steel sink
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Is an invention born
Of patriotism.
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It evolved during world war ii
When sinks were often made
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From copper-nickel material
Called monel.
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00:06:11,275 --> 00:06:13,724
When that material was needed
For the war effort,
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Stainless steel was drafted
For use on the home front,
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And it's still on kitchen duty
To this day.
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Stainless steel is lightweight
And heavy-duty,
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Which makes it great for sinks.
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The process begins with a large
Sheet of stainless steel,
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Uncoiled and sliced into pieces
Called blanks.
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Each blank goes under
A 1,000-ton press.
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As the press descends,
A punch rises from below,
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Stretching the steel
Into a rough sink shape.
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00:07:07,275 --> 00:07:10,896
This process also transforms
The steel on a molecular level,
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Hardening it.
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Workers brush lubricant in
And around the sink bowl
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To make it easier
To stretch it again.
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The bowl goes under the same
Punch press a second time
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For more precise shaping.
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This second working of the steel
Hardens it even more.
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Now the sink goes under
A different punch device
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That cuts out a drain hole
And forms a lip around it.
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As coolant flushes the sink,
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An abrasive belt
Grinds the surface
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To give it a brushed look.
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Next, a sink bowl slides
Into a welding machine.
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A second sink bowl is lined up
Against the first one.
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Inside, an electrode welds
The two sinks together.
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Using enormous force,
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A roller moves across the seam
To flatten it.
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A grinding belt behind
The roller sands it down.
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Now that the seam joining the
Two sinks is level and smooth...
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00:09:04,931 --> 00:09:07,724
...It's time to give
The sink's rim some shape.
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This die forms recesses
Along the sink's perimeter.
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These recesses give the sink
A sleek look
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And collect water runoff.
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Another press trims the rim
And gives it a bevel finish,
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Which softens those rough edges.
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Now, using a punch cutter,
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Workers pierce the back rim
Of the sink
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To make holes for faucets
And a soap dispenser.
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Then they grind and buff
The sink to a fine finish.
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It's a very intensive process
That takes about 25 minutes.
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The company's trademark
Is embossed on the sink.
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Then the sink's drains
Are plugged
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And a substance
Similar to latex paint
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Is sprayed onto the outside.
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The finish will muffle the sound
Of clattering dishes
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And protect the outside
Of the sink from condensation.
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It takes about 2 1/2 hours to
Make a stainless-steel sink --
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A functional and stylish
Addition to any kitchen.
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Coming up,
Turning hairy cowhides
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Into buttery-smooth leather.
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Narrator: leather production
Dates back to primitive times
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When humans rubbed fats into
Animal skins to preserve them.
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Times have changed,
But leather endures.
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From footwear to furniture,
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This tough material remains
An integral part of our lives.
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00:11:32,965 --> 00:11:37,000
This leather comes from the
Hides of cows killed for meat.
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00:11:37,000 --> 00:11:40,517
Without tanning, these cowhides
Would go to waste.
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00:11:40,517 --> 00:11:43,586
Converting them to leather
Is a kind of recycling.
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00:11:44,896 --> 00:11:48,344
The first step
Is to cut each hide in half.
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00:11:50,827 --> 00:11:53,620
The hides are draped
Over a sawhorse,
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Stamped with
An identification code...
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And sliced down the center.
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Two smaller pieces will be
Easier to handle and process
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Than one large hide.
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Hundreds of these hide halves
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Are loaded
Into a modified cement mixer
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For some serious hair removal.
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As the mixer fills with water,
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00:12:28,413 --> 00:12:33,172
A worker dumps in a combination
Of sodium sulfydrate and lime.
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A chemical reaction
Strips the hair from the hides.
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00:12:41,620 --> 00:12:44,000
The hairless hides
Now get an acid bath
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To prepare them
For the tanning process.
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00:12:53,931 --> 00:12:57,068
The tanning itself happens
Inside big wooden drums
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00:12:57,068 --> 00:13:01,103
With prongs to keep the skins
From getting tangled.
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00:13:01,103 --> 00:13:04,000
Chrome salts turn the hides
A robin's-egg blue
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As they bind to the
Collagen fibers of the skins.
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The hides have now been
Preserved into leather.
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Next, the pieces
Are fed grain-side up
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Into a machine that slices the
Leather to an even thickness.
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The cutoffs won't be wasted.
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00:13:33,655 --> 00:13:36,724
They'll be recycled into suede.
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00:13:38,862 --> 00:13:41,379
Workers check each piece
Of leather with a gauge
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To confirm that the thickness
Is uniform.
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Now it's back into the wooden
Drums for a second tanning,
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This time using a solution
Of vegetable extract,
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Tree bark, and water.
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Dye is added
Along with a chemical
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That will make the leather
Water-resistant.
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00:14:02,586 --> 00:14:04,551
The solution
Binds to the leather,
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00:14:04,551 --> 00:14:06,724
Giving it a brownish tone.
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00:14:06,724 --> 00:14:09,379
It's a gentler process
Than the first tanning,
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And it softens the leather.
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00:14:15,965 --> 00:14:18,241
Now a mixture
Of starch and water
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Is brushed
Onto the tanned hides.
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This paste-like solution
Allows the hides
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To be pressed
Onto big glass frames,
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Which also have been moistened
With the same starchy mixture.
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This process allows the leather
To dry flat...
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...Prevents it from shrinking...
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...And stops the edges
From curling up.
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After four hours in a dryer,
It's time to remove the leather.
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It easily peels away
From the glass.
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00:15:17,896 --> 00:15:22,344
A revolving paint-gun system
Dyes the leather.
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And now it's time
For the finishing touches.
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A glazing jack pulls a glass
Cylinder over the leather,
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00:15:35,379 --> 00:15:38,931
And the abrasive action
Polishes it.
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00:15:38,931 --> 00:15:40,862
This glass is very strong,
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00:15:40,862 --> 00:15:45,620
So it can do this vigorous work
Without shattering.
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00:15:45,620 --> 00:15:50,758
Finally, huge heated rollers
Smooth out any wrinkles.
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It's the end
Of the production line
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For this big pile of leather
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00:15:54,241 --> 00:15:57,896
But just the beginning
For so many other products.
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Fashionable and tough, it's
No wonder this ancient material
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00:16:01,862 --> 00:16:06,413
Continues to be one
Of our favorite products today.
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00:16:06,413 --> 00:16:07,965
Up next, an instrument
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That's almost as tricky to build
As it is to play.
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Narrator:
Playing the pedal steel guitar
Takes quite a lot of skill.
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00:16:19,206 --> 00:16:21,310
You slide a steel bar
Up and down the strings
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00:16:21,310 --> 00:16:22,724
As you pluck them,
198
00:16:22,724 --> 00:16:26,448
All the while operating a system
Of pedals and knee levers below.
199
00:16:26,448 --> 00:16:30,172
This means using both hands,
Both feet, and both knees.
200
00:16:30,172 --> 00:16:32,137
But a pedal steel guitar's
Unique sound
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00:16:32,137 --> 00:16:35,586
And impressive range
Are worth all the effort.
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00:16:53,586 --> 00:16:55,344
To make one, a guitar maker
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00:16:55,344 --> 00:16:58,827
First carves the neck
Of the instrument from hardwood.
204
00:17:02,448 --> 00:17:04,655
He beads glue
Around the edges of the neck
205
00:17:04,655 --> 00:17:07,310
And applies strips
Of intricate wooden inlay.
206
00:17:13,586 --> 00:17:16,896
Once the fretboard design
Is silk-screened onto the top,
207
00:17:16,896 --> 00:17:19,310
The guitar neck is complete.
208
00:17:19,310 --> 00:17:21,793
The guitar maker
Then outlines a design
209
00:17:21,793 --> 00:17:24,379
Onto aircraft-grade aluminum
And cuts it out
210
00:17:24,379 --> 00:17:26,827
To make an end plate
For the guitar frame.
211
00:17:26,827 --> 00:17:29,517
He pops the end plate
Out of the holding device.
212
00:17:29,517 --> 00:17:32,172
Then he welds it
To the rest of the framework
213
00:17:32,172 --> 00:17:35,137
And polishes everything
To a mirror finish.
214
00:17:42,482 --> 00:17:46,379
Next, the part of the guitar
Called the steps is machined.
215
00:17:52,586 --> 00:17:56,620
The holes in the steps will
Be used to attach tuning pegs.
216
00:17:56,620 --> 00:17:59,344
There's one for every string.
217
00:17:59,344 --> 00:18:04,517
The steps are attached to the
Neck just above the fretboard.
218
00:18:04,517 --> 00:18:06,206
This is the pickup plate.
219
00:18:06,206 --> 00:18:09,482
It will hold the device that
Transfers sound to the amplifier
220
00:18:09,482 --> 00:18:12,103
As well as a series
Of metal fingers.
221
00:18:16,758 --> 00:18:19,206
The fingers are made
From several aluminum pieces
222
00:18:19,206 --> 00:18:23,482
That are machined
And assembled together.
223
00:18:23,482 --> 00:18:27,310
The fingers pivot to raise and
Lower the pitch of the strings.
224
00:18:28,896 --> 00:18:31,482
All of the fingers are fitted
Into the pickup plate
225
00:18:31,482 --> 00:18:35,068
And secured with screws.
226
00:18:35,068 --> 00:18:37,827
The guitar maker double-checks
The fingers' movement,
227
00:18:37,827 --> 00:18:40,172
Then he hooks springs
To the end of each one
228
00:18:40,172 --> 00:18:42,655
To maintain the proper tension.
229
00:18:48,965 --> 00:18:52,655
A little grease ensures that
This next step goes smoothly --
230
00:18:52,655 --> 00:18:55,482
The production
Of the guitar's cross-shafts.
231
00:18:57,724 --> 00:19:00,758
Then it's on
To the guitar's undercarriage
232
00:19:00,758 --> 00:19:03,310
And the system of foot pedals
And knee levers
233
00:19:03,310 --> 00:19:06,689
That will move the fingers.
234
00:19:06,689 --> 00:19:09,137
The guitar maker
Screws several cross-shafts,
235
00:19:09,137 --> 00:19:12,241
One for each pedal,
Into the undercarriage.
236
00:19:15,310 --> 00:19:18,379
He attaches bell cranks
To the cross-shafts...
237
00:19:20,310 --> 00:19:22,034
...Then connects thin steel rods
238
00:19:22,034 --> 00:19:25,517
From the fingers
To the bell cranks.
239
00:19:29,931 --> 00:19:31,551
This system
Will allow the performer
240
00:19:31,551 --> 00:19:34,896
To tighten or relax strings
While playing,
241
00:19:34,896 --> 00:19:37,896
Which gives the instrument
Its characteristic sound.
242
00:19:53,758 --> 00:19:56,551
The guitar maker
Tests the knee lever.
243
00:20:03,827 --> 00:20:06,310
Here he's winding
Copper-coated wire
244
00:20:06,310 --> 00:20:08,206
Around a cartridge
Thousands of times
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00:20:08,206 --> 00:20:09,931
To make the guitar's pickup,
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00:20:09,931 --> 00:20:13,413
Which transfers sound from
The guitar to the amplifier.
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00:20:20,689 --> 00:20:23,103
He takes two
Of the wire-bound cartridges
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00:20:23,103 --> 00:20:26,586
And places a magnet between them
To complete the pickup.
249
00:20:26,586 --> 00:20:29,724
Then he fits it into the other
Slot in the pickup plate
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00:20:29,724 --> 00:20:32,413
Just above the fingers.
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00:20:32,413 --> 00:20:36,724
Now, using a gauge and a level,
He adjusts the pickup.
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00:20:36,724 --> 00:20:38,758
It has to sit low enough
In the slot
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00:20:38,758 --> 00:20:41,551
That it won't interfere
With the strings.
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00:20:41,551 --> 00:20:43,758
There's no room for error here.
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00:20:43,758 --> 00:20:47,586
The positioning must be exact
Or the guitar won't sound right.
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00:20:52,620 --> 00:20:55,827
10 to 12 strings are attached
To the guitar neck.
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00:20:55,827 --> 00:20:57,655
Some instruments have two necks
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00:20:57,655 --> 00:21:00,655
To add even more dimension
To the sound.
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00:21:13,034 --> 00:21:15,137
If you have any comments
About the show,
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00:21:15,137 --> 00:21:18,103
Or if you'd like to suggest
Topics for future shows,
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00:21:18,103 --> 00:21:22,517
Drop us a line at...
21521
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