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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:
The swiss army knife
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00:00:54,896 --> 00:00:58,310
Is an entire tool kit
In a pocket-sized package.
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00:00:58,413 --> 00:01:02,034
This little multitool
Actually dates back to 1891
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00:01:02,137 --> 00:01:04,310
With the original
Swiss soldier's knife.
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It wasn't long before
It morphed into other versions
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For sale to the general public,
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And a century later,
It continues to come in handy.
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Lost in the wilderness,
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00:01:18,793 --> 00:01:21,655
Or are you a serious
Multitasker?
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Either way, a swiss army knife
Has tools to help you cope.
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Production starts with this
Big coil of stainless steel.
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00:01:29,931 --> 00:01:35,000
Equipment pulls the steel
Between a press and a die.
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The press forces the steel
Against the die
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To punch out blade shapes.
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It also forms the finger groove
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For pulling the blade
Out of the handle.
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00:01:48,172 --> 00:01:51,724
They mass-produce parts
Like can openers and pliers
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Using the same technique.
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They load the blades
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Into a vibrating mix
Of ceramic stones and water.
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The friction polishes the steel.
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A little powder keeps the parts
From sticking together.
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00:02:05,689 --> 00:02:09,413
After several hours,
They activate a powerful magnet
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00:02:09,517 --> 00:02:13,862
To extract the parts
From the vibrating mass.
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00:02:13,965 --> 00:02:16,862
The process has smoothed
The blades significantly.
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00:02:16,965 --> 00:02:19,724
But the metal is weak and dull.
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00:02:19,827 --> 00:02:23,172
So a worker arranges the blades
On a mesh conveyor
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00:02:23,275 --> 00:02:27,586
Which goes into an oven that
Exposes them to intense heat.
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A quick cooldown follows,
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Which toughens the steel
Considerably.
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The hardened blades
Now ride a carousel
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Into a grinding station,
Which slims and trims them.
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That green liquid
Keeps them cool
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During this process.
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Afterwards, a computerized tool
Measures the blades.
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If the dimensions
Are even slightly off,
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They won't fit
Into the knife handle.
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A quick stamp gives the part
Its trademark name.
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00:03:07,931 --> 00:03:10,000
To build the swiss army knife,
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They slide everything
Onto brass rivets,
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00:03:12,655 --> 00:03:14,758
Beginning with
An aluminum spacer.
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A flat metal spring
Goes on next,
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Followed by a can opener,
A screwdriver,
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00:03:20,137 --> 00:03:24,724
And an awl, a punch
To make holes in leather.
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00:03:24,827 --> 00:03:28,689
They stack another spacer
And spring on top.
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They tamp it down
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00:03:30,275 --> 00:03:32,793
And then slide a multipurpose
Hook and a pair of scissors
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Onto the rivets.
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Another divider, another spring.
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And then they add a wood saw
To this multitool sandwich,
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Because you never know
When you might need one.
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They press-fit the main blade,
A corkscrew,
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And a smaller blade
Onto the assembly.
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00:03:56,689 --> 00:04:00,482
One final spacer,
And then they secure the rivets
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With attachments
Called bushings.
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00:04:03,896 --> 00:04:07,689
Incredibly, they've packed
Nine tools into a bundle
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00:04:07,793 --> 00:04:10,344
That's just under an inch thick.
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00:04:10,448 --> 00:04:12,103
They chop off
The tops of the rivets
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00:04:12,206 --> 00:04:15,068
To make them flush
With the bushings,
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And then this spinning tool
Flattens them.
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00:04:19,310 --> 00:04:21,448
The result
Is a multipronged tool
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That's virtually impossible
To pull apart.
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The blade on the
Swiss army knife is thin
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Compared to other pocket knives
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To allow it
To fit into the casing.
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00:04:32,758 --> 00:04:34,103
They grind the cutting edge
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To angle it
At just under 15 degrees.
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This makes it razor-sharp,
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Ensuring there won't be
Many dull moments
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In this blade's lifetime.
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They measure the angled edge
With a laser
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00:04:49,241 --> 00:04:51,827
To verify that it's on the mark.
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And now it's time
For the handle.
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It comes in two parts.
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They sandwich the tool bundle
Between them
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00:05:00,103 --> 00:05:03,172
And press everything together.
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This embeds the bushings
In the handle's holes
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For a tight installation.
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Amazingly, there's still space
In this swiss army knife
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For a set of tweezers
And a toothpick.
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Finally, they inspect every tool
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To confirm
That it's in perfect condition
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00:05:29,724 --> 00:05:33,103
And that it springs out of
The handle as it's designed to.
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Making a swiss army knife
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Is a job performed
With almost military precision.
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There's no room for error
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When it comes to packing
All these tools
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Into a pocket-sized unit.
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And once they do,
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This multitool is ready
To spring into action.
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Narrator: the first
Self-playing piano system
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Was invented around 1895.
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It sat in front
Of a regular piano,
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And the machine's wooden fingers
Would play the keys.
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Guiding those fingers
Was a roll of perforated paper.
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By the early 20th century,
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Piano companies incorporated
The roll mechanism
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Right into the piano itself.
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The player-piano rage
Petered out around 1930,
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But there are still plenty
Of old player pianos around,
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So there remains a market
For the music rolls they play.
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The original roll-making method
Used a recording piano.
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[ piano music playing ]
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As the musician played,
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Each key would trigger
A pneumatic valve
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Which pressed
The corresponding rod
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Against piano roll paper
Over carbon paper.
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Then they just perforate
The carbon marks.
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The modern method
Uses an electronic keyboard
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And a computer.
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As the musician plays,
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The computer
Converts the notes to data.
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The musician edits the data,
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Then loads it into a computer
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That's hooked up
To the roll perforator,
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A machine that produces
18 rolls simultaneously.
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Like the old recording machine,
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The roll perforator
Has a pneumatic valve
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For each note
Of the piano keyboard.
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As the computer
Activates each note,
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The corresponding valve
Triggers a steel punch
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To descend and pierce a hole
In the passing paper.
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00:07:45,172 --> 00:07:49,310
The longer the hole,
The longer the note.
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Most music consists
Of multi-note chords,
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So the machine vibrates
Like crazy,
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Punching many notes
Simultaneously.
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When the machine
Finishes perforating,
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The operator cuts off the paper
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And sticks on a temporary label
Bearing the song title.
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The paper then moves
On to another area,
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Where they permanently stamp on
The title and other information.
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00:08:25,172 --> 00:08:29,344
Here, they slice the front end
Of the paper into a point.
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00:08:35,827 --> 00:08:39,000
Meanwhile, this machine
Rivets brass eyelets
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Onto an adhesive-backed
Polyethylene strip.
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00:08:46,275 --> 00:08:51,103
Then around each eyelet,
A die stamps out a tab.
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They stick one eyelet tab
To the pointed tip of each roll.
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This tab end, as it's called,
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Hooks into the mechanism
Of the player piano.
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00:08:59,931 --> 00:09:03,482
A touch of cornstarch
Over any exposed adhesive
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Prevents the papers
From sticking to one another.
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When the music has lyrics,
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They print the words
Right on the rolls
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00:09:11,827 --> 00:09:14,448
So you can sing along
As the piano plays.
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00:09:14,551 --> 00:09:17,620
The first step
Is to make a lyric stencil,
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00:09:17,724 --> 00:09:21,965
Which requires cranking out
Each word, letter by letter.
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00:09:22,068 --> 00:09:25,172
The placement of words
On the stencil is tricky
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00:09:25,275 --> 00:09:27,862
Because they have to synchronize
With the notes.
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00:09:27,965 --> 00:09:30,413
The stencil goes into a printer
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00:09:30,517 --> 00:09:33,310
Which applies the lyrics
With an ink roller.
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00:09:39,137 --> 00:09:41,931
The last step
Is to roll up the rolls.
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They wind each one
Around a cardboard spool
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That has a plastic flange
On each end.
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When you load a roll
Into the piano,
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You mount its flanges
On holders,
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00:09:52,448 --> 00:09:54,551
Then hook the tab end
To a spool
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00:09:54,655 --> 00:09:56,965
That pulls the roll
Through the player mechanism.
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00:10:00,862 --> 00:10:03,551
A rubber band to keep the roll
From unraveling --
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00:10:03,655 --> 00:10:07,241
Then it's into a custom box.
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A machine shapes and hot-glues
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Sheets of ornately printed
Cardboard into the box tops.
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The finishing touch
Is a sticker
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With the title of the music.
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00:10:31,448 --> 00:10:33,655
When a roll
Moves through a player piano,
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Air flows
Through the perforations,
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Triggering the corresponding
Pneumatic valves.
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Each valve pushes down
The corresponding note.
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00:10:47,655 --> 00:10:51,724
This factory produces more than
4,500 different song titles
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On player-piano rolls,
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From classic favorites
To top-10 hits.
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Narrator: the first oil tanker
Was launched by the british
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In the latter part
Of the 19th century,
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And it fueled a revolution
In transportation.
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These enormous ships
Now dominate the world's oceans.
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They move millions of tons
Of oil daily.
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And without them,
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Most of the world's economies
Would be powerless.
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00:11:33,068 --> 00:11:34,724
The life-size version
Of this tanker ship
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00:11:34,827 --> 00:11:37,965
Will be bigger
Than two football fields.
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00:11:38,068 --> 00:11:42,206
It's so big that they build it
In sections called grand blocks,
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Which they assemble by crane
In a dry dock.
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The process takes plenty
Of planning and engineering.
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They map out the job
On a computer
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And assign a number
To each of the 110,000 parts.
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00:12:02,034 --> 00:12:03,482
In a big job like this,
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Computer-coordinated labeling
Is the only way to go.
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00:12:07,689 --> 00:12:10,517
They weld steel sheets
To build the ship's hull.
189
00:12:10,620 --> 00:12:14,448
Sand, placed on the seam,
Melts during the welding
190
00:12:14,551 --> 00:12:19,862
To shield the seam from
Any contaminants in the air.
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00:12:19,965 --> 00:12:23,620
Workers ready
The structural steel beams.
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00:12:23,724 --> 00:12:26,482
A robot places them
At just the right spot
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00:12:26,586 --> 00:12:30,310
On the welded section
Of the hull.
194
00:12:30,413 --> 00:12:34,068
Then an operator verifies
That the placement is correct.
195
00:12:37,482 --> 00:12:41,482
More robots weld the beams
To the hull section.
196
00:12:41,586 --> 00:12:44,827
Next, they submerge
A steel plate in water.
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00:12:44,931 --> 00:12:48,482
The water suppresses the noise
And smoke from a plasma cutter
198
00:12:48,586 --> 00:12:51,103
As it carves holes in the steel.
199
00:12:51,206 --> 00:12:54,482
This steel plate will be part
Of the ballast tank.
200
00:12:54,586 --> 00:12:57,517
Some of the holes will allow
Water to flow through
201
00:12:57,620 --> 00:13:02,172
While others lighten up
The steel structure.
202
00:13:02,275 --> 00:13:04,896
The superheated plasma
Also cuts slits
203
00:13:05,000 --> 00:13:09,758
To interlock with the structural
Beams on the hull part.
204
00:13:09,862 --> 00:13:12,000
They then weld the assembly
205
00:13:12,103 --> 00:13:15,034
And install a top plate
For a double-layered hull.
206
00:13:15,137 --> 00:13:20,137
Double hulls provide extra
Protection against oil spillage.
207
00:13:22,551 --> 00:13:25,103
After a paint job,
208
00:13:25,206 --> 00:13:28,620
Powerful machinery transfers
The double-hull grand block
209
00:13:28,724 --> 00:13:32,172
To its final position
On the side of the tanker.
210
00:13:32,275 --> 00:13:34,551
When fully assembled,
211
00:13:34,655 --> 00:13:36,275
The hull
Will have 12 cargo tanks
212
00:13:36,379 --> 00:13:41,103
With a total capacity
Of 14 million gallons.
213
00:13:42,931 --> 00:13:46,689
The engine section is situated
At the stern of the tanker.
214
00:13:46,793 --> 00:13:48,965
It will take
Three diesel generators
215
00:13:49,068 --> 00:13:51,689
To power the ship's lighting,
Ventilation,
216
00:13:51,793 --> 00:13:53,448
And computer systems.
217
00:13:53,551 --> 00:13:57,000
They carefully lower each one
Onto the deck of the ship.
218
00:13:59,655 --> 00:14:02,206
A 10,000-horsepower
Diesel engine
219
00:14:02,310 --> 00:14:05,241
Will be the tanker's
Driving force.
220
00:14:05,344 --> 00:14:08,241
Installing it
Is a very precise business.
221
00:14:08,344 --> 00:14:10,551
It has to be
In just the right position
222
00:14:10,655 --> 00:14:13,275
To turn the massive propeller.
223
00:14:13,379 --> 00:14:16,206
Four months later,
The hull is complete
224
00:14:16,310 --> 00:14:20,344
And the massive propeller
Is in position.
225
00:14:23,275 --> 00:14:26,275
It's all hands on deck
To build the deckhouse,
226
00:14:26,379 --> 00:14:31,172
Where a crew will live
For months at a time.
227
00:14:31,275 --> 00:14:35,827
There will be an incredible
10 miles of piping on this ship.
228
00:14:35,931 --> 00:14:40,517
Here, workers weld and bolt them
To the deck grand blocks.
229
00:14:40,620 --> 00:14:45,172
It's an elaborate maze
With an impressive master plan.
230
00:14:45,275 --> 00:14:48,758
They connect these pipes to
The series of tanks in the hull
231
00:14:48,862 --> 00:14:53,448
So they can be used
To load and unload cargo.
232
00:14:56,965 --> 00:14:59,931
Meanwhile, inside the hull,
233
00:15:00,034 --> 00:15:02,965
Those cargo tanks
Are coming together.
234
00:15:03,068 --> 00:15:04,517
On the very bottom,
235
00:15:04,620 --> 00:15:07,482
The crew builds a network
Of heating coils.
236
00:15:07,586 --> 00:15:08,965
They'll be used
To heat crude oil
237
00:15:09,068 --> 00:15:10,482
To a more fluid form
238
00:15:10,586 --> 00:15:13,827
So it can be pumped
Out of the tanks.
239
00:15:18,275 --> 00:15:22,137
Other workers grind welded seams
On the ship's outer skin.
240
00:15:22,241 --> 00:15:26,103
This evens the surface
For painting.
241
00:15:26,206 --> 00:15:28,172
The paint is an epoxy blend
242
00:15:28,275 --> 00:15:30,896
That resists corrosion
In salt water.
243
00:15:31,000 --> 00:15:33,172
They apply it
In three or four layers
244
00:15:33,275 --> 00:15:37,758
And measure its thickness
With a special ultrasonic gauge.
245
00:15:37,862 --> 00:15:42,068
In total, they spray more
Than 38,000 gallons of paint
246
00:15:42,172 --> 00:15:44,620
On this tanker.
247
00:15:47,413 --> 00:15:49,137
In this time-lapse video,
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Our tanker comes together
Like toy building blocks
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In a matter of seconds.
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But as you've just learned,
This is a complex job.
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It actually takes 16 months.
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A couple more months of testing,
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And this tanker should be good
For the long haul.
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Narrator: at first glance,
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A racing wheel doesn't look much
Different than a standard wheel.
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But look a little closer.
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There are subtle differences
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In the angles and contours
That set it apart.
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They give it the strength
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To handle the extreme forces
Of racing
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And to corner well
At high speed,
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Which should have them cheering
In the stands.
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The driver will get the trophy
And the credit,
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But a good set of wheels
Is behind every win.
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They start with high-strength,
Low-alloy steel,
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Which is a very stable material.
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The first
Of a series of die presses
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Gives the center disc
A concave profile
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And forms lug holes.
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The next press punches a hole
For the hub
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And others called windows.
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Windows help cool the brakes
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While maintaining strength
Where needed.
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They stamp rings
Around the windows.
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This is called coining.
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The rings give the windows
A nicer look,
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And the action
Compresses the steel
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To further strengthen the part.
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The next press is critical.
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It forces the disc
Into a bowl shape
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And gives it precise dimensions
To accommodate brakes.
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The specific angles
Also reinforce the part.
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It has taken a lot
Of punching and pressing,
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But the center disc
Of this racing wheel
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Has really taken shape.
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A smaller press
Now punches out the lug holes
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That were outlined earlier.
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These holes will allow the wheel
To be mounted to a vehicle.
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Then the center disc
Goes for a spin
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As a series of tools trim it.
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The part is now complete.
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To make the rim,
A machine unwinds coiled steel,
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And rollers iron out the curl.
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A mechanical arm maintains slack
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As the flattened steel
Goes under the knife.
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The blade, called a shearer,
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Cuts the steel to length
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And stamps product information
Onto it in one swoop.
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An operator now winds the steel
Between three rollers
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To twist it into a band.
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He then places the band
Into the jaws of a welder,
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Which fuses
The two ends together.
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He then slides the band
Into a machine
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That scrapes off excess material
From the well.
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It's still warm,
So it can be easily removed.
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Now the band comes under
Some serious pressure
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As a machine forces it
Around dies at both ends
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To create flares.
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This rack transfers the rim
To a series of rollers
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Which shape its inner ledge.
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This part of the rim
Is called the bead seed,
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And it will be attached
To the bead wall of the tire.
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They trim the rim
To make the edges neater.
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This finishes off the part.
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They nestled the center disc
Loosely in the rim.
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As the rim spins, they heat
The outside with a torch.
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This causes the steel to expand,
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And the center disc
Drops further into the rim.
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As the rim cools, it contracts,
Shrinking to the center part.
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The two parts
Are now interconnected,
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And a welding job
Makes the bond permanent.
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A worker drills
Threaded holes onto the wheel
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To attach valve stems.
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As it exits,
The drill turns in reverse
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So it doesn't wreck the threads.
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After a fresh coat of paint,
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They apply a thread-locking
Adhesive to the valve stems
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And screw them into the holes.
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The valves will be used
To add air to the tires.
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The wheel rotates
As a small roller
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Paints a stripe onto the rim
For accent.
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Then a press stamps
A number onto it
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To identify this wheel
In the event of a problem.
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And now this wheel is on
A fast track to the finish line.
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If you have any comments
About the show,
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Or if you'd like to suggest
Topics for future shows,
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Drop us a line at...
27035
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