All language subtitles for S12E13 - Motorcycle Engines; Glass Enamel Sculptures; Hand-Made Paper; Vaulting Poles (1080p AMZN WEB-DL x265 Garshasp)_track3_[eng]
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--captions by vitac--
Www.Vitac.Com
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00:00:05,103 --> 00:00:08,103
Captions paid for by
Discovery communications
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Narrator:
The v-twin motorcycle engine
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00:00:54,344 --> 00:00:56,724
Actually dates back
More than a century.
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00:00:56,724 --> 00:00:58,965
Talk about staying power.
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00:00:58,965 --> 00:01:01,517
Central to the design
Are two cylinders
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00:01:01,517 --> 00:01:04,000
That form a "V"
Around the crankshaft.
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00:01:04,000 --> 00:01:06,241
This configuration
Is more compact
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00:01:06,241 --> 00:01:10,517
Than a straight-line engine,
And its appeal is timeless.
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00:01:14,724 --> 00:01:16,517
With its throttle cranked,
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00:01:16,517 --> 00:01:19,448
The v-twin can take you
On an exciting ride
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00:01:19,448 --> 00:01:22,344
And leave sedans in its dust.
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00:01:24,586 --> 00:01:27,413
To make one,
A robot loads a cylinder
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00:01:27,413 --> 00:01:30,448
Into a machine
Equipped with cutting tools.
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00:01:30,448 --> 00:01:34,448
The tools mill the cylinder's
Metal slats to highlight them.
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00:01:34,448 --> 00:01:36,620
The slats
Are called cooling fins.
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00:01:36,620 --> 00:01:39,689
They allow the engine's heat
To dissipate.
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00:01:41,689 --> 00:01:44,862
This cutting tool bores
Into the center of the cylinder,
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00:01:44,862 --> 00:01:46,724
Carving it to precise dimensions
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00:01:46,724 --> 00:01:49,655
To allow engine components
A perfect fit.
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Next, an operator
Assembles the crankshaft.
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00:01:54,275 --> 00:01:58,344
He aligns connecting rods
And slides them over bearings.
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00:02:00,034 --> 00:02:04,241
He then assembles the rods
And bearings to the crankshaft.
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00:02:07,379 --> 00:02:10,724
A machine
Press-fits everything together.
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00:02:14,413 --> 00:02:17,655
Next, a lift scoops up
The crankshaft assembly
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00:02:17,655 --> 00:02:21,206
And transfers it to
The lower half of the crankcase.
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00:02:28,344 --> 00:02:29,655
At the next station,
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An automated dispenser
Precisely applies sealant
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00:02:32,586 --> 00:02:35,137
To the inner edge
Of the crankcase.
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00:02:37,241 --> 00:02:40,344
They then arrange
The upper half of the crankcase
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On the lower assembly
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00:02:41,724 --> 00:02:43,931
And bolt the two together.
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00:02:48,758 --> 00:02:51,586
It's now time to link
The crankcase and shaft assembly
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00:02:51,586 --> 00:02:53,758
To the transmission.
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00:02:56,586 --> 00:03:00,068
This chrome-plated cover
Is the finishing touch.
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00:03:04,034 --> 00:03:07,724
Next, they fit the camshaft
Into the crankcase.
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00:03:07,724 --> 00:03:10,724
Its job
Is to maintain valve timing.
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00:03:15,275 --> 00:03:17,034
They position the pistons
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00:03:17,034 --> 00:03:20,655
On the connecting rods
Now installed in the crankcase.
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00:03:22,862 --> 00:03:25,620
Remember those highlighted
Cylinders made earlier?
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00:03:25,620 --> 00:03:28,965
Workers now slide them
Over the pistons.
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These are
The cylinder-head castings.
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Technicians paint them
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00:03:36,034 --> 00:03:39,517
And then machine them
To fit on the cylinders.
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00:03:43,379 --> 00:03:47,724
A robot bolts them together with
Just the right amount of torque.
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00:03:47,724 --> 00:03:52,241
The operator then installs
Tubing that will house pushrods.
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00:03:55,965 --> 00:04:00,034
He snaps them
Into the cylinder heads.
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00:04:00,034 --> 00:04:04,517
Then he clips on metal covers
To secure them.
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00:04:04,517 --> 00:04:08,551
He now inserts the pushrods
In the tubing.
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00:04:08,551 --> 00:04:11,931
Up next is the electronic
Fuel-injection system,
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00:04:11,931 --> 00:04:15,793
Which controls
The flow of fuel to the engine.
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00:04:15,793 --> 00:04:19,000
They install it
Between the two cylinders.
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00:04:22,586 --> 00:04:27,000
A special bracket holds
The injection system in place.
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He bolts the rocker boxes
To the cylinder heads,
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Then tops off the assembly with
More gleaming chrome covers.
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00:04:40,758 --> 00:04:44,758
The operator now screws the
Oil filter onto the engine case
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00:04:44,758 --> 00:04:47,862
And secures it
With a special wrench.
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00:04:47,862 --> 00:04:51,068
This is the electrical
Charging system.
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It goes on the crankshaft.
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00:04:57,793 --> 00:05:00,517
Now it's time to pump oil
Into this v-twin engine
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00:05:00,517 --> 00:05:03,000
And put it through its paces.
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Computerized testing equipment
Moves in
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And mates to the engine.
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00:05:10,172 --> 00:05:11,827
The engine rotates,
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00:05:11,827 --> 00:05:13,862
And they shift the transmission
Through all the gears.
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00:05:13,862 --> 00:05:16,827
This allows
The testing equipment
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00:05:16,827 --> 00:05:20,034
To analyze every aspect
Of its performance.
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00:05:26,241 --> 00:05:31,275
Next, they insert spark plugs
Into the cylinder heads.
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And these
1584cc motorcycle engines
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Are now revved and ready
For their wheels.
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Narrator:
Enameling is the process
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Of fusing colored glass to metal
With intense heat.
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00:05:56,827 --> 00:06:00,172
This decorative art developed
More than 3,000 years ago.
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00:06:00,172 --> 00:06:03,482
The earliest enameled objects
Archeologists have found
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00:06:03,482 --> 00:06:06,275
Are pieces of jewelry
Made in ancient greece.
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Today, artisans most often
Produce glass enamel on copper.
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Artisans handcraft
These magnificent sculptures
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By fusing vibrant colors
Of finely ground glass
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To solid copper.
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First, the artist
Draws the design,
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Then chooses the glass colors
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From a palette
Of hundreds of shades.
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She takes one element at a time
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And makes multiple copies of it
On a sheet of paper.
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She has a lab
Produce a film negative,
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Which she lays
In an exposure machine.
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On top, she lays a silk screen
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Coated with
A light-sensitive chemical.
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Then it exposes them
To halogen light for 90 seconds.
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The film negative
Works like a stencil.
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Its dark parts block the light
From hitting the screen
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While its clear parts
Allow light through.
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Where light penetrates,
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The light-sensitive chemical
Reacts and hardens.
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00:07:07,103 --> 00:07:09,931
The unhardened chemical
Rinses away,
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00:07:09,931 --> 00:07:12,793
Leaving just the image behind.
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In the next department,
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They lay the screen
In a silk-screen printer,
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Apply chemical-resistant ink,
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Then load
A sheet of solid copper
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About half a millimeter thick.
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The machine automatically prints
The images onto the copper.
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They cure the ink in an oven
For 20 minutes,
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Then repeat
The entire exposure process
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For the back side of the sheet.
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Next, they feed the sheet
Into a two-step milling machine.
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It applies chemicals
That eat away any copper
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That isn't coated
With the chemical-resistant ink.
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This cuts out the shapes.
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Then it strips off the ink,
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Which, by this point,
Has served its purpose.
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Now they have a blank shape,
But it's completely flat.
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To give it dimension, they
Stamp it with a forming dye.
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Now the enameling process
Can finally begin.
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For each color grouping
Of the design,
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There's an aluminum stencil.
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They lay down the first one
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And sprinkle glass powder
In the first base-coat color,
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Which looks white now,
But comes out clear.
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Then a second stencil
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00:08:36,172 --> 00:08:39,000
For the second
Base-coat color -- white.
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00:08:43,172 --> 00:08:46,482
The shape then goes into a kiln
For about a minute
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To liquefy the glass powder
And fuse it to the copper.
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Once the base coat cools,
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They create the detail work with
Additional stencils and colors.
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This is where
The true artistry comes in.
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Each shake of powdered glass
Is like a painter's brushstroke.
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00:09:07,896 --> 00:09:10,793
Too much, and the color
Will come out too dark.
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00:09:10,793 --> 00:09:13,379
Too little,
And it'll come out too light.
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00:09:13,379 --> 00:09:17,551
It takes an experienced enameler
To get it just right.
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They craft dimension
By blending colors
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And by combining different types
Of glass in the design --
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Some transparent, some opaque,
Some opalescent.
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00:09:38,689 --> 00:09:41,103
After every few
Powder applications,
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They return the piece
To the kiln,
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Where the intense heat --
1,600 degrees fahrenheit --
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00:09:46,862 --> 00:09:50,586
Liquefies and fuses the glass
To the copper.
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Slowly but surely, they turn
What was a blank copper shape
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Into a vibrant work of art.
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00:09:57,137 --> 00:09:59,448
Meanwhile, an artistic welder
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Skillfully creates the
Sculpture's metal framework --
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In this case, branches on which
Copper-enamel birds will perch.
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He's using steel,
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00:10:08,655 --> 00:10:12,586
But frameworks can also be made
Of copper, bronze, or brass.
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Besides birds, this sculpture
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Features copper-enameled leaves
And flowers.
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00:10:17,724 --> 00:10:21,793
Their stems are bronze because
Bronze fuses easily to steel.
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00:10:21,793 --> 00:10:25,793
With the framework and
Background elements in place,
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It's just a matter of attaching
The main design elements.
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00:10:29,379 --> 00:10:32,965
Some industrial-strength
Hot glue does the trick.
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00:10:32,965 --> 00:10:35,655
A modern twist
On an ancient craft,
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These glass-enamel sculptures
Make a glistening impression.
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Narrator: today,
Most commercially made paper
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00:10:53,931 --> 00:10:55,275
Is made from wood pulp
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00:10:55,275 --> 00:10:57,965
Treated with chemicals
And mechanically processed.
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Making paper by hand
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Is a craft that involves
Techniques and materials
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That go back
Over 2,000 years in china.
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00:11:04,310 --> 00:11:06,793
These techniques
Have evolved over time,
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00:11:06,793 --> 00:11:10,586
But the main ingredient
Remains the same -- imagination.
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Handmade paper is a distinctive
Choice for a variety of uses,
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From fine stationery
To limited-edition prints.
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Natural fibers, like linen
Or these cotton remnants,
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00:11:26,068 --> 00:11:28,896
Are the raw materials
For handmade paper.
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Workers place the cotton rag
And put it on a conveyer,
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00:11:35,068 --> 00:11:39,137
Which leads into a machine that
Chops it up into small pieces.
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00:11:45,655 --> 00:11:48,137
It collects in a bin,
Ready for the next step,
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Called beating the rag.
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00:11:52,793 --> 00:11:55,241
Workers pour out
The chopped-up rag
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Into a tub called a hollander
That is filling with water.
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This machine
Beats the material into a pulp.
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Its only moving part --
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A large roll
Weighing several tons,
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00:12:08,068 --> 00:12:11,034
Equipped with metal blades.
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Workers fill the hollander
With up to 800 pounds of rag.
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Once all the rag is in,
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00:12:16,586 --> 00:12:19,758
The giant roll descends
To begin the beating.
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00:12:19,758 --> 00:12:22,379
Water pours down
To soak the fabric,
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As workers
Push it toward the roll.
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00:12:28,965 --> 00:12:31,965
They sometimes take paper
From previous batches,
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Known as broke,
And add it to the mix.
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00:12:43,724 --> 00:12:47,068
They may also add a little dye
To adjust the color,
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Depending on the desired effect.
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After eight hours of beating,
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00:12:53,206 --> 00:12:56,344
Workers feel
The pulp's consistency.
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00:12:56,344 --> 00:12:59,275
They will then take samples
From this batch
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00:12:59,275 --> 00:13:03,068
To make sure it doesn't contain
Any unbeaten rag or knots.
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00:13:03,068 --> 00:13:06,413
Next, they add colorful
Scraps of paper to the pulp
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00:13:06,413 --> 00:13:09,068
To create a decorative pattern.
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To make a sheet of paper,
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00:13:16,586 --> 00:13:19,931
The vat man plunges
A wooden mold into the pulp.
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00:13:19,931 --> 00:13:21,724
As he lifts out the mold,
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00:13:21,724 --> 00:13:24,206
He shakes it
To even out the pulp.
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00:13:24,206 --> 00:13:25,517
Water pours out,
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00:13:25,517 --> 00:13:29,724
Leaving only fibers
Caught on the mold's surface.
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00:13:29,724 --> 00:13:32,586
He removes the mold's frame,
Known as the deckle,
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00:13:32,586 --> 00:13:34,241
And lowers
The corner of the mold
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00:13:34,241 --> 00:13:36,275
To drain away more water.
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00:13:42,206 --> 00:13:44,517
He places the mold facedown
On a wet felt,
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00:13:44,517 --> 00:13:47,655
Then carefully lifts it away.
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00:13:47,655 --> 00:13:50,137
A sheet of paper
Now lies on the felt,
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00:13:50,137 --> 00:13:53,551
Which he then covers
With another wet felt.
203
00:13:53,551 --> 00:13:56,482
When pulp pours
Through the mold's metal screen,
204
00:13:56,482 --> 00:14:00,068
It traps the fiber
And lets the water through.
205
00:14:00,068 --> 00:14:03,551
The vat man plunges the mold
Once again into the pulp
206
00:14:03,551 --> 00:14:08,034
And couches another sheet
Of this distinctive paper.
207
00:14:08,034 --> 00:14:13,551
At this point,
The paper is 99% water.
208
00:14:13,551 --> 00:14:16,379
Workers bring a stack
Over to a hydraulic press
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00:14:16,379 --> 00:14:20,689
To draw the water from the paper
And link the fibers together.
210
00:14:20,689 --> 00:14:22,689
They press the papers with care
211
00:14:22,689 --> 00:14:25,551
So they don't burst
Right out of the felts.
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00:14:29,448 --> 00:14:32,172
They brush any leftover pulp
From the felts,
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00:14:32,172 --> 00:14:36,034
Leaving them clean and ready
For the next batch of sheets.
214
00:14:38,241 --> 00:14:41,586
Now workers can handle the paper
Without it falling apart.
215
00:14:41,586 --> 00:14:43,862
They take the sheets
From the felts
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00:14:43,862 --> 00:14:47,000
And hang them to dry
On plastic tubes.
217
00:14:50,931 --> 00:14:54,862
Once dry, they collect
The sheets according to type
218
00:14:54,862 --> 00:14:57,586
And stack them
For a final finishing press
219
00:14:57,586 --> 00:15:02,896
Before they go on for shipment
To customers around the world.
220
00:15:02,896 --> 00:15:05,896
The mold's frame
Leaves a feathery edge --
221
00:15:05,896 --> 00:15:08,896
A distinctive feature
Of handmade paper.
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00:15:11,241 --> 00:15:14,068
These papers are available
In more than 30 colors
223
00:15:14,068 --> 00:15:17,827
In various finishes,
From smooth to rugged.
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00:15:28,344 --> 00:15:31,206
There's a paper
For every project,
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00:15:31,206 --> 00:15:33,310
Whether it's etching...
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00:15:33,310 --> 00:15:35,413
Watercolor...
227
00:15:35,413 --> 00:15:37,172
Drawing...
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Or even folding.
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00:15:52,655 --> 00:15:56,034
Narrator: pole-vaulting began
As a mode of transportation,
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00:15:56,034 --> 00:15:57,379
Not a sport.
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00:15:57,379 --> 00:15:59,137
In europe, men would use poles
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00:15:59,137 --> 00:16:01,931
To propel themselves
Across bridgeless canals.
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00:16:01,931 --> 00:16:06,000
In the late 1800s, pole-vaulting
Caught on as a college sport.
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00:16:06,000 --> 00:16:08,068
The athletes used bamboo poles
235
00:16:08,068 --> 00:16:11,000
To vault themselves
Over a horizontal bar.
236
00:16:19,275 --> 00:16:21,517
Today's poles
Are incredibly lightweight,
237
00:16:21,517 --> 00:16:24,137
Yet strong enough
To absorb the vaulter's energy,
238
00:16:24,137 --> 00:16:26,758
Then throw it back
To propel him over the bar.
239
00:16:26,758 --> 00:16:28,931
Some poles
Are made of carbon fiber,
240
00:16:28,931 --> 00:16:33,793
Others out of thismaterial --
Resin-impregnated fiberglass.
241
00:16:33,793 --> 00:16:37,068
The first step
Is to spread out the material
242
00:16:37,068 --> 00:16:39,206
And cut out the pole pattern.
243
00:16:39,206 --> 00:16:41,137
Meanwhile, a slitter machine
244
00:16:41,137 --> 00:16:44,862
Cuts the same material
Into strips of a specific width.
245
00:16:44,862 --> 00:16:48,103
Then it winds each strip
Into its own roll.
246
00:16:50,137 --> 00:16:54,413
This spiral-wrap machine
Automatically unravels the strip
247
00:16:54,413 --> 00:16:58,931
And wraps it around a hollow
Steel tube called a mandrel.
248
00:17:02,379 --> 00:17:08,206
This first layer of fiberglass
Gives the pole its flexibility.
249
00:17:08,206 --> 00:17:11,482
They wrap a second layer
In the opposite direction,
250
00:17:11,482 --> 00:17:14,827
Employing a crisscross pattern
To increase durability.
251
00:17:14,827 --> 00:17:18,000
The second layer fortifies
The pole's circumference.
252
00:17:22,758 --> 00:17:24,793
For the next layers,
253
00:17:24,793 --> 00:17:27,793
They remove the mandrel
And lay it on the table.
254
00:17:27,793 --> 00:17:30,517
Now it's time
For those fiberglass patterns
255
00:17:30,517 --> 00:17:33,103
They cut earlier.
256
00:17:33,103 --> 00:17:35,655
They heat the edge
Of the first one with an iron,
257
00:17:35,655 --> 00:17:39,413
Melting the resin in
The fiberglass until it's tacky.
258
00:17:39,413 --> 00:17:42,275
They stick this edge
To the mandrel,
259
00:17:42,275 --> 00:17:45,172
Then slide the other end
Between heated rollers.
260
00:17:47,103 --> 00:17:51,103
The rollers wrap the rest of
The material around the mandrel,
261
00:17:51,103 --> 00:17:54,172
The heat activating the resin
In the process.
262
00:17:54,172 --> 00:17:57,413
The same procedure,
Now with the second pattern.
263
00:17:57,413 --> 00:17:59,034
This piece is critical,
264
00:17:59,034 --> 00:18:03,931
Because the way it's cut
Controls the way the pole bends.
265
00:18:09,172 --> 00:18:12,275
The mandrel and
Its multilayer fiberglass coat
266
00:18:12,275 --> 00:18:13,896
Now go into an oven.
267
00:18:13,896 --> 00:18:16,103
The heat, generated by steam,
268
00:18:16,103 --> 00:18:19,551
Starts at
175 degrees fahrenheit.
269
00:18:19,551 --> 00:18:24,413
This liquefies the resin so that
It re-saturates the fiberglass.
270
00:18:24,413 --> 00:18:28,931
Then the temperature gradually
Rises to nearly 300 degrees,
271
00:18:28,931 --> 00:18:32,103
Solidifying the resin again,
Curing it.
272
00:18:34,000 --> 00:18:38,827
This entire process takes about
45 minutes from start to finish.
273
00:18:43,827 --> 00:18:46,586
And when it finishes,
A pole extractor
274
00:18:46,586 --> 00:18:50,758
Slides the mandrel out of
What's now a fiberglass pole.
275
00:19:04,655 --> 00:19:07,551
The pole
Moves onto a flex machine.
276
00:19:07,551 --> 00:19:09,965
In part, this is a stress test.
277
00:19:09,965 --> 00:19:14,655
If there's any type of defect,
The pole will crack or break.
278
00:19:14,655 --> 00:19:16,103
But the flexor
279
00:19:16,103 --> 00:19:19,206
Also permanently puts a specific
Degree of curve in the pole,
280
00:19:19,206 --> 00:19:23,965
Which helps the athlete
Vault higher.
281
00:19:23,965 --> 00:19:27,137
Now they make what's called
The soft-side mark.
282
00:19:27,137 --> 00:19:30,172
This helps the pole vaulter
Locate the bend,
283
00:19:30,172 --> 00:19:32,448
In order to know
Where to grip the pole.
284
00:19:38,620 --> 00:19:41,689
Next, they apply
A maximum-weight label,
285
00:19:41,689 --> 00:19:45,103
Indicating how heavy
The vaulter can be.
286
00:19:47,103 --> 00:19:48,724
To finish the surface now,
287
00:19:48,724 --> 00:19:50,862
They mount the pole
On a spindle,
288
00:19:50,862 --> 00:19:53,862
Then run a polishing pad
Over it.
289
00:19:53,862 --> 00:19:57,517
Then, using a solvent,
They clean off the debris.
290
00:20:01,206 --> 00:20:04,172
Now that the surface
Is pristine,
291
00:20:04,172 --> 00:20:06,724
They wrap it
In thin, lightweight tape.
292
00:20:06,724 --> 00:20:10,827
Different-colored tapes
Designate different pole styles.
293
00:20:12,896 --> 00:20:15,482
They cap the top of the pole
With plastic,
294
00:20:15,482 --> 00:20:17,137
Then, at the bottom,
295
00:20:17,137 --> 00:20:20,655
Mallet on a molded tip
Made of hard rubber.
296
00:20:22,310 --> 00:20:26,000
The finishing touch
Is the manufacturer's decal.
297
00:20:29,724 --> 00:20:34,344
Vaulting poles come in various
Lengths, between 10 and 16 feet.
298
00:20:34,344 --> 00:20:36,517
A pole designed
For a heavier vaulter
299
00:20:36,517 --> 00:20:39,655
Has to be stiffer than one
Designed for a lighter vaulter
300
00:20:39,655 --> 00:20:42,068
Because the pole
Has to propel more weight
301
00:20:42,068 --> 00:20:44,482
With the same degree of bending.
302
00:20:53,000 --> 00:20:55,379
If you have any comments
About the show,
303
00:20:55,379 --> 00:20:58,344
Of if you'd like to suggest
Topics for future shows,
304
00:20:58,344 --> 00:21:00,482
Drop us a line at...
24999
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