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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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Metal detectors...
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Rum...
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Tiffany reproductions...
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And aircraft engines.
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Airports use
Handheld metal detectors
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To safeguard flights.
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Treasure hunters use
Hobby metal detectors
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To find buried loot.
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Vastly different purposes.
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Yet the technology behind them
Is identical --
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A principle called
Magnetic induction.
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It all hinges
On tiny electrical currents
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Creating magnetic fields.
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A tiny electrical current
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Runs through a wire coil
Inside the detector,
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Creating a magnetic field.
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When the detector passes over
A metal object,
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The field is disturbed,
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Producing
A small voltage variation
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That triggers the alarm.
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To make the coil,
They use copper wire
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That's coated
With nylon insulation.
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They wind it around the two ends
Of a plastic bobbin
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A specific number of times.
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00:01:43,206 --> 00:01:46,482
Polyester tape
Keeps it from unraveling.
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00:01:46,482 --> 00:01:49,482
Security metal detectors
Need pure iron
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Glued into the bobbin
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To increase the magnetic-field
Strength the coil produces.
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Without it, the coil would have
To be several times larger
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And wouldn't fit inside
A handheld wand.
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00:02:01,517 --> 00:02:06,413
The next step is to solder the
Coil leads to a circuit board,
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00:02:06,413 --> 00:02:10,103
Then solder a vibrator motor to
Enable the detector to vibrate
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As well as beep
When it finds metal.
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The board contains
A microprocessor,
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The detector's alarm,
And other components
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That react to the signals
Coming from the coil.
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The coil and circuit board
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00:02:22,896 --> 00:02:25,103
Now go into the wand's
Plastic housing.
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A retaining clip holds
The vibrator motor in place.
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00:02:33,000 --> 00:02:36,103
They temporarily hook up
Power to the battery compartment
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00:02:36,103 --> 00:02:38,517
And push a button
On the circuit board.
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This calibrates the board
To the coil.
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They install a sliding cap
On the detector's on-off switch.
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Now they can close her up
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And stick on
The manufacturer's label.
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The last step is to install
The 9-volt battery.
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No metal detector
Leaves the factory
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Before undergoing extensive
Quality-control testing.
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Metal detectors for treasure
Hunting have larger coils
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00:03:16,275 --> 00:03:19,241
So they don't need iron inserts
To boost the magnetic field.
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00:03:19,241 --> 00:03:22,862
In fact, hobby detectors
Have two coils --
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One to transmit
And one to receive.
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This configuration
Lets you set the device
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To detect only the types
Of metal you want to find.
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00:03:30,724 --> 00:03:32,689
Like before,
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Polyester tape prevents
The wound wire from unraveling.
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00:03:39,275 --> 00:03:42,034
The leads go into a device
Called a stripper,
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Which bares the copper wire
Inside.
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00:03:45,827 --> 00:03:47,310
A testing machine
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Ensures the coil meet
The engineering specifications.
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Next, they place a circuit board
In the coil housing.
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A cable runs from this housing
To the detector head,
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Where components interpret
The coil's signals.
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After installing the coils,
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They solder the coil leads
To the board.
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They immobilize everything
With hot glue,
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Then seal the components inside
The housing with epoxy.
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00:04:18,275 --> 00:04:20,517
Next, they install
A circuit board
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Inside the metal detector's
Control pad.
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They plug the cable coming
From the coils into the board
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00:04:27,172 --> 00:04:29,103
And power up.
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This calibrates the coils
To the circuit board.
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00:04:36,206 --> 00:04:37,862
Now they test the calibration
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With three different types
Of material
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The metal detector might find
In the ground --
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Iron, silver, and nickel.
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If everything works perfectly,
Assembly continues.
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They install a small speaker
For the alarm.
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Then they attach the control pad
To the head
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And apply the decals.
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They attach a handle and
Arm support, then a long stem.
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The cable from the coil
Winds upward around the stem
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And plugs
Into the detector head.
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Signals from the coil
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Travel up the cable
To the electronics in the head.
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A small computer analyzes
These signals
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To determine whether
The detector has found metal.
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If it has, the computer
Activates a circuit
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To set off the alarm
And display a message.
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But the ground's
By no means the limit.
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There are even metal detectors
Designed for scuba diving
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That are completely submersible.
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Narrator:
Rum comes from by-products
Of the sugar industry,
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Like molasses.
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The caribbean and latin america
Produce much of the world's rum.
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Light rums are the base for
Cocktails like the minty mojito.
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Amber rums are medium-bodied
And aged for flavor.
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They're often drunk straight,
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As is dark rum,
The strongest-tasting of all.
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This fine amber rum
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Is the product
Of a long and complex process
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That begins with the harvest
Of mature sugarcane plants.
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The cut cane goes to
A sugar mill where they wash it
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Then crush it
To extract its sweet juice.
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They boil it down.
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This produces a kind of molasses
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That then goes on
To a centrifuge machine
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That draws out excess moisture.
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Rum making really beings here
In these distillation towers.
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This is where ferment made from
Molasses distills into raw rum.
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To make ferment, molasses
Mixed with water and yeast
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Heats in open tanks
For about 30 hours.
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This converts sugar
Into alcohol.
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Here's a sample straight
From one of these tanks.
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Notice that foamy top layer?
That's fermentation in action.
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Before distilling the contents
Of the tank,
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Technicians first test a sample.
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In this glass still,
Steam heats the ferment
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And releases alcohol vapors
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That condense
At the top of the column.
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00:07:29,724 --> 00:07:32,827
As they travel down
The still's spiral,
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The vapors cool
And condense even more.
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The liquid that collects
In the beaker is 80% alcohol.
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It's the same process
Inside the distillation towers
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On a much larger scale.
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The ferment must reach
176 degrees fahrenheit
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To distill into raw rum.
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Then it's stored in these
13,000-gallon containers
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Until they test it for quality.
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These gas-powered boilers
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00:08:03,655 --> 00:08:07,172
Provide the steam heat
For the distillation towers.
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00:08:10,034 --> 00:08:13,275
Workers monitor the distilling
Towers day and night.
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This facility can produce
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00:08:14,896 --> 00:08:18,034
More than 10,000 gallons
Of raw rum a day,
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All stored
In these gigantic silos.
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From there, the raw rum
Goes into charred oak barrels.
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It's mixed with water
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And left to age
Anywhere from 1 to 12 years.
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The charred wood produces asters
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That give the rum
Color, flavor, and aroma.
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The longer it ages,
The more intense the flavor.
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Technicians perform tests
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On a sample
At the distillery's laboratory,
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Closely monitoring
The aging process.
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00:08:51,655 --> 00:08:53,965
First, using a hydrometer,
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00:08:53,965 --> 00:08:56,310
They measure the amount
Of alcohol in the samples
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To make sure
It's in the standard 50% range.
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Next, they smell each sample
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00:09:04,620 --> 00:09:07,724
To make sure
The aromas are in balance.
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They keep a journal
Of all their observations.
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00:09:11,068 --> 00:09:12,413
Quality control
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Is the key to producing
A consistent, flavorful product.
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Once it has aged,
The rum is bottled.
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It's a fully automated process.
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First, they sterilize
New bottles
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In a sodium-carbonate solution.
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00:09:26,310 --> 00:09:29,137
Then a conveyer moves them
To a filling station
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That can process 150 bottles
A minute.
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Rotating wheels deliver
The bottles to a lever system
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That raises them up to
The nozzles on pneumatic pumps.
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They fill up with rum -- more
Than 72,000 of them each day.
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Next, aluminum bottle caps
Come down a chute
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Right onto the bottle tops.
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A piston valve pushes down
On the caps
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And tightly seals each bottle.
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Next stop -- labeling.
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00:10:00,965 --> 00:10:03,482
First, a spinning roller
Applies glue
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00:10:03,482 --> 00:10:07,068
To panels
Set on a rotating wheel.
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The panels pass a dispenser,
And a label glues onto them.
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00:10:11,655 --> 00:10:14,931
Another rotating wheel grabs
The labels from the panel
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00:10:14,931 --> 00:10:16,931
And transfers them
Onto the bottles.
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Sponges press them
Neatly into place.
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As the bottles convey
Out of the labeling station,
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00:10:24,931 --> 00:10:27,758
Brushes smooth out each label.
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00:10:29,827 --> 00:10:34,758
Finally, the bottles lower
Into boxes 12 at a time
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To ship to customers
All over the world.
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Narrator: tiffany lamps
Were invented and produced
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00:10:54,275 --> 00:10:55,965
By designer
Louis comfort tiffany
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00:10:55,965 --> 00:10:57,758
Starting
In the late 19th century.
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They were renowned for their
Elaborate stained-glass shades,
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Crafted entirely by hand.
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00:11:01,862 --> 00:11:05,034
The term tiffany has come
To be used as a generic term
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For any lamp
Or hanging light fixture
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With a stained-glass shade.
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00:11:14,482 --> 00:11:18,103
This lighting company produces
Original stained-glass lamps,
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00:11:18,103 --> 00:11:22,448
As well as reproductions
Of renown tiffany designs.
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00:11:22,448 --> 00:11:24,379
There's nothing
Machine-made here.
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00:11:24,379 --> 00:11:29,758
Each and every creation
Is meticulously handcrafted.
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00:11:29,758 --> 00:11:33,172
The lamp designer first draws
A pencil sketch of the shade,
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00:11:33,172 --> 00:11:35,862
Then prepares a color rendition.
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00:11:37,413 --> 00:11:40,275
He produces a pattern
In the lamp's actual size
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00:11:40,275 --> 00:11:42,482
And assigns a number
To each pattern piece,
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00:11:42,482 --> 00:11:44,344
Then records by code number
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00:11:44,344 --> 00:11:48,000
The specific glass they'll use
For each piece.
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00:11:53,931 --> 00:11:56,965
Next, they cut out
The numbered pattern pieces,
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00:11:56,965 --> 00:11:59,172
Lay them
On the corresponding glass,
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00:11:59,172 --> 00:12:01,137
And trace them with a marker.
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00:12:01,137 --> 00:12:05,793
Using a glass cutter, they score
The trace lines and snap them.
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00:12:06,689 --> 00:12:10,310
When a piece is too small
To get enough snapping leverage,
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00:12:10,310 --> 00:12:14,275
They grip the glass with special
Pliers called groziers.
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00:12:19,620 --> 00:12:23,241
Next, they sand-smooth the rough
Edges of the cut pieces
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00:12:23,241 --> 00:12:24,620
So they won't puncture
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00:12:24,620 --> 00:12:28,000
The adhesive copper foil
That goes on next.
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00:12:31,137 --> 00:12:34,413
After wrapping each piece,
They crimp the foil tightly,
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00:12:34,413 --> 00:12:38,000
First with their fingers,
Then with a flat object.
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00:12:44,206 --> 00:12:48,689
This design, like many,
Incorporates glass jewels.
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00:12:48,689 --> 00:12:52,241
These come from glass suppliers
Ready-made.
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00:12:59,034 --> 00:13:01,413
The next step
Is to coat the foil with flux,
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00:13:01,413 --> 00:13:04,724
A chemical
That enables solder to stick.
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00:13:06,758 --> 00:13:08,448
Now with a soldering iron,
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00:13:08,448 --> 00:13:11,965
They melt tin and lead solder
Onto the copper foil.
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00:13:11,965 --> 00:13:15,241
Initially, they just tack
All the pieces together,
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00:13:15,241 --> 00:13:17,827
Completing one section
Of the shade at a time.
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00:13:17,827 --> 00:13:20,172
Then they lay the sections
Side by side
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00:13:20,172 --> 00:13:22,000
In a curved plaster mold.
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00:13:22,000 --> 00:13:25,206
This bends them
To the correct shape.
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00:13:28,206 --> 00:13:29,758
More flux.
221
00:13:29,758 --> 00:13:33,689
Then with a soldering iron, they
Tack the sections to each other,
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00:13:33,689 --> 00:13:36,965
Then solder the whole interior.
223
00:13:45,379 --> 00:13:48,413
Once that's done, they remove
The shape from the mold
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00:13:48,413 --> 00:13:51,379
And solder the whole exterior.
225
00:13:56,000 --> 00:14:00,586
Now they top the shade with
A brass cap and solder that on.
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00:14:06,172 --> 00:14:07,413
This lampshade design
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00:14:07,413 --> 00:14:10,241
Features dragonflies
With brass filigree wings.
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00:14:10,241 --> 00:14:13,172
After soldering the wings
In place,
229
00:14:13,172 --> 00:14:16,310
It's time for what's called
The final beading --
230
00:14:16,310 --> 00:14:19,275
A final soldering
Over the existing solder lines
231
00:14:19,275 --> 00:14:22,241
To make them even and rounded.
232
00:14:22,241 --> 00:14:25,620
Now they wash the shade
In an antiquing solution,
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00:14:25,620 --> 00:14:28,793
Which dulls the shine of both
The solder and the brass cap,
234
00:14:28,793 --> 00:14:31,551
Giving the lampshade
An aged look.
235
00:14:33,620 --> 00:14:34,965
In another department,
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00:14:34,965 --> 00:14:37,689
They install what's called
The light cluster,
237
00:14:37,689 --> 00:14:40,206
A rod with light sockets
And a pull chain,
238
00:14:40,206 --> 00:14:42,275
Into a lamp base.
239
00:14:46,137 --> 00:14:49,896
They fish the power cord
Up the base and out the top,
240
00:14:49,896 --> 00:14:54,000
Then connect the cord to the
Wires coming from the sockets.
241
00:14:58,724 --> 00:15:01,379
They tuck in the wiring...
242
00:15:01,379 --> 00:15:03,724
Apply thread-locking solution...
243
00:15:03,724 --> 00:15:08,137
Then screw the base closed.
244
00:15:08,137 --> 00:15:10,068
For the time being,
245
00:15:10,068 --> 00:15:13,620
They attach the finial
That goes on top of the shade.
246
00:15:16,137 --> 00:15:19,379
And now a light-bulb moment.
247
00:15:19,379 --> 00:15:21,068
If everything works perfectly,
248
00:15:21,068 --> 00:15:25,655
The tags go on
And the base gets its shade.
249
00:15:25,655 --> 00:15:29,655
The bases of the original
Tiffanies were made of bronze.
250
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These, both for tabletop lamps
And hanging fixtures,
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Are cast from zinc -- the same
Look at a fraction of the price.
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Narrator:
For safety reasons,
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Aircraft engines have
Built-in redundancy features,
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Like dual spark plugs
And dual ignition systems
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So that vital components
Have a backup.
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Rising gas prices
And eco awareness
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Are compelling manufacturers
To build aircraft engines
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That are more efficient
And less polluting.
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00:16:12,551 --> 00:16:17,413
Aircraft engines are remarkable
Pieces of engineering.
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00:16:17,413 --> 00:16:21,827
To build a four-cylinder engine,
A worker wraps abrasive tape
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00:16:21,827 --> 00:16:25,517
Around what's called a bearing
Journal on a crankshaft.
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Using a polishing jack,
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00:16:31,827 --> 00:16:35,241
He polishes the journal
To the correct diameter,
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Which he verifies
With a digital snap gage.
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An operator
Then oils the journal
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And attaches a connecting rod.
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These link the pistons
To the crankshaft,
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Which turns to generate power.
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Then he applies gasket sealant
On the edge of the crankcase
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And silk thread
That acts like a gasket
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So when the two halves
Of the crankcase are joined,
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The engine won't leak oil.
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He places a camshaft
Into one side of the crankcase
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And measures the clearance
To make sure it's a tight fit.
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Then he oils it
To ensure there is no friction.
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00:17:22,862 --> 00:17:26,517
They place the crankshaft and
Rod assembly into the crankcase,
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Then join the two halves
Together.
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To prevent the connecting rods
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From hitting the sides
Of the housing,
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They put on what are called
Torque plates.
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00:17:42,586 --> 00:17:45,862
He adds a little sealant
To hold a gasket in place
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00:17:45,862 --> 00:17:48,172
Then attaches
An accessory housing,
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Which holds all the gears
And hoses
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That are mounted
On the back of the engine.
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00:17:57,103 --> 00:18:00,586
He installs the sump
That holds the oil supply,
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00:18:00,586 --> 00:18:04,137
Then attaches a piston
To each connecting rod.
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Now he mounts a cylinder
Onto a piston
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And connects the parts
To the engine.
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00:18:14,551 --> 00:18:18,000
He'll mount and secure
All four cylinders this way.
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00:18:20,620 --> 00:18:26,103
He inserts hydraulic tappets
And then shroud tubes.
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00:18:27,655 --> 00:18:32,862
He attaches them to the cylinder
Using a retainer.
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00:18:32,862 --> 00:18:36,482
He inserts a pushrod
Into each tube
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00:18:36,482 --> 00:18:39,827
And fits a rocker arm
Onto each rod, completing
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00:18:39,827 --> 00:18:42,689
The cylinder-and-valve-action
Assembly.
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00:18:46,758 --> 00:18:49,862
He steam-cleans the engine.
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00:18:49,862 --> 00:18:54,137
Then he paints it
With rustproofing enamel paint.
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00:18:54,137 --> 00:18:56,275
Next come the spark plugs --
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00:18:56,275 --> 00:18:59,896
One on the top and one
On the bottom of each cylinder.
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00:19:03,896 --> 00:19:07,344
He grounds and then installs
Two magnetos.
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00:19:07,344 --> 00:19:10,827
These devices generate the
Electricity for the spark plugs,
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00:19:10,827 --> 00:19:13,275
Which ignite the fuel
In the cylinder.
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00:19:18,551 --> 00:19:20,517
He attaches the spark-plug wires
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00:19:20,517 --> 00:19:23,034
From the magneto
To the spark plugs,
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00:19:23,034 --> 00:19:25,896
Then verifies the engine timing.
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00:19:28,137 --> 00:19:30,689
Next come the heat shields...
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00:19:30,689 --> 00:19:33,310
The intake pipes...
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00:19:33,310 --> 00:19:36,482
All the spark-plug connections
And drain tubes,
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00:19:36,482 --> 00:19:39,137
And finally, a fuel injector.
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00:19:42,827 --> 00:19:45,517
An operator then attaches
A testing propeller
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00:19:45,517 --> 00:19:48,413
To the engine to keep it cool
During testing.
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00:19:51,965 --> 00:19:55,827
He runs the engine using
Controls like a pilot would use
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00:19:55,827 --> 00:19:59,379
And certifies everything from
Engine speed and temperature
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00:19:59,379 --> 00:20:01,965
To fuel pressure and airflow.
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00:20:04,344 --> 00:20:07,172
Hours later,
He checks the oil filter
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00:20:07,172 --> 00:20:10,206
For signs of foreign material
Or contamination.
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00:20:10,206 --> 00:20:13,172
And this engine passes the test.
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00:20:15,655 --> 00:20:20,034
A worker then puts preservative
Oil into the cylinders.
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00:20:20,034 --> 00:20:23,896
This special oil safeguards the
Engine en route to the customer,
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00:20:23,896 --> 00:20:26,827
Whether they be
General aviation manufacturers
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00:20:26,827 --> 00:20:29,689
Or individual owners.
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00:20:31,206 --> 00:20:33,379
Once installed in the airplane
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And after the standard
Preflight checks are done,
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The four-cylinder engine
Allows the pilot
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To take to the clear-blue skies
In total confidence.
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00:20:50,413 --> 00:20:53,034
If you have any comments
About the show,
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00:20:53,034 --> 00:20:55,724
Or if you'd like to suggest
Topics for future shows,
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00:20:55,724 --> 00:20:57,793
Drop us a line at...
26550
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