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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: its name can be a bit
Of a tongue-twister --
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"Wuss-te-shire" sauce,
"Woos-ter-sheer" sauce,
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00:00:56,689 --> 00:00:58,206
"Wuss-te-sure" sauce.
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All those pronunciations
Are acceptable,
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As are the endless ways
To use this condiment,
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From flavoring beef recipes
And salad dressings
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To joining tomato juice
And vodka in a bloody mary.
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In the early 1800s,
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An english nobleman
In the county of worcester
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Hired two local chemists,
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John lea and william perrins,
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To duplicate a sauce he had
Tasted while traveling in india.
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The resulting concoction
Was unpalatable,
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So they relegated it
To the cellar.
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Years later, they came across it
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During a cellar cleanup
And gave it another taste.
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Lo and behold, the sauce had
Matured and was now delicious.
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They christened their creation
"Worcestershire sauce"
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And went into business.
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Today,
More than 170 years later,
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That same company
Produces that very recipe,
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The specifics of which remain
A closely-guarded secret.
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The process begins
With onions and garlic
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Pickled in malt vinegar
For one to two years.
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Inside the pickling barrels,
The bulbs slowly liquefy,
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Their flavor
Infusing the liquid.
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Other barrels contain anchovies
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Cured in salt
For several months.
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Additional ingredients include
Salt, sugar, white vinegar...
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Malt vinegar...
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Tamarind concentrate...
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00:02:24,517 --> 00:02:26,724
Molasses...
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00:02:26,724 --> 00:02:31,655
And a top-secret blend
Of flavorings and spices.
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Starting with the two vinegars,
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Workers pour the ingredients
One at a time
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Into gigantic blending tanks.
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There goes
The tamarind concentrate.
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00:02:43,586 --> 00:02:46,241
Now the anchovies.
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The ingredient proportions
Are top secret,
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As is the prescribed mixing time
Between ingredients.
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Now the pickled onions
And garlic...
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...Sugar and salt...
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And that secret blend
Of flavorings and spices.
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Next, they pump the mixture
Into maturation tanks.
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There, over the course
Of several months,
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The ingredients age
And interact with each other,
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00:03:38,827 --> 00:03:42,000
Undergoing complex changes
In their natural chemistry
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Which produce the sauce's
Distinctive flavor.
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Agitators rotate intermittently
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To keep the ingredients
Well-blended.
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The sauce
Then goes through a sieve,
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Then through a press,
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Followed by another cycle
Of blending and straining.
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The sauce is a smooth liquid
By the time it progresses
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00:03:59,379 --> 00:04:02,068
To the next phase --
Pasteurization.
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00:04:02,068 --> 00:04:05,724
This process heats the sauce
To kill off organisms,
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00:04:05,724 --> 00:04:09,034
Ensuring optimal flavor
For at least 18 months.
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The sauce needs no artificial
Preservatives whatsoever
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Because the vinegars it contains
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Are natural
Antimicrobial agents.
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00:04:20,586 --> 00:04:23,965
The bottling process
Is entirely automated.
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The factory produces
Different formats.
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This one is modeled after the
Original bottle from the 1830s.
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The machinery closes each bottle
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With a one-piece,
Plastic flip-top cap.
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Inside, there's a small hole
To ensure the sauce
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Dispenses
At the right flow rate.
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This prevents accidentally
Pouring too much sauce.
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As each bottle
Enters the labeling machine,
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An arm descends onto the cap.
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The machine applies glue
To a label,
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00:05:04,827 --> 00:05:06,724
Slaps it on the bottle,
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00:05:06,724 --> 00:05:09,068
Then the arm spins the bottle
Against brushes
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00:05:09,068 --> 00:05:11,827
That push the edges
Of the label flat.
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Then, depending on the format
They're packaging,
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The equipment groups
6 or 12 bottles together
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And, from underneath,
Folds a carton around them.
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Then it shrink-wraps the carton,
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Which then joins others
On a pallet.
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The production process
And recipe
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Have remained
Essentially the same
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Since worcestershire sauce
Was first bottled in 1835.
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Narrator: lawn bowling
Is a quiet, civilized game,
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Not something
You'd expect to be outlawed.
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But in 16th-century england,
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Henry viii banned lawn bowling
Among commoners
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Because it was a distraction
From work.
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It took a couple of centuries
Before his ban was lifted,
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And the game
Became completely legit.
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In lawn bowling, the path
To victory is not straight.
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The bowl is designed
To roll in a curve
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Towards the object ball --
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The smaller yellow one
Called the jack.
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For many years, lawn bowls
Were made of a tropical hardwood
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Called lignum vitae,
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But as this wood
Has become increasingly rare,
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Manufacturers
Have turned to melamine.
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And unlike wood,
Melamine doesn't change shape
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With temperature
And humidity fluctuations.
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Production begins
With melamine granules
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That have been pre-dyed
In a variety of colors
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To appeal
To individual preferences.
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00:06:48,689 --> 00:06:52,689
An employee scoops the granules
Into a tub and weighs them.
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00:06:52,689 --> 00:06:56,206
Lawn bowls come in a range
Of sizes to fit different hands,
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00:06:56,206 --> 00:06:59,655
So the weight varies
Accordingly.
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He drapes a cloth
Over the melamine granules
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00:07:05,586 --> 00:07:08,000
And holds it in place
With pieces of wood.
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Then it's into a machine
Called a pre-heater.
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00:07:11,103 --> 00:07:13,551
It uses high-frequency
Radio waves
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00:07:13,551 --> 00:07:15,793
To melt the plastic into putty.
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The cloth absorbs moisture
Generated in the process.
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All those melamine bits have now
Merged into a malleable mass.
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He squeezes it
To reshape it a bit
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So it can be inserted
Into a molding press.
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00:07:32,379 --> 00:07:37,862
This 150-ton press forces the
Plastic dough into a hot mold
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00:07:37,862 --> 00:07:40,413
To shape it into a lawn bowl.
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00:07:40,413 --> 00:07:44,724
This lawn bowl may look round,
But it's not a perfect sphere.
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00:07:44,724 --> 00:07:46,241
This slightly irregular shape
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00:07:46,241 --> 00:07:48,172
Will cause it
To roll into a curve.
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00:07:48,172 --> 00:07:50,896
He marks the size
And other information onto it,
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00:07:50,896 --> 00:07:55,068
And then it's over
To a computerized lathe.
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00:07:55,068 --> 00:07:58,344
It spins the lawn bowl
While the blade carves it
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00:07:58,344 --> 00:08:02,586
To perfect
That asymmetrical shape.
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00:08:02,586 --> 00:08:08,068
Other tools then etch two rows
Of half-moons onto the surface.
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00:08:08,068 --> 00:08:11,827
This engraved pattern makes
The lawn bowl easier to grip.
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00:08:14,000 --> 00:08:16,551
The next blade
Slices off the nubs
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00:08:16,551 --> 00:08:19,655
Used to spin the lawn bowl
In the lathe.
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00:08:19,655 --> 00:08:21,448
It also smoothes the surface
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00:08:21,448 --> 00:08:24,586
Until all evidence
Of the nubs disappears.
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00:08:24,586 --> 00:08:27,137
This receptacle
Uses suction power
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00:08:27,137 --> 00:08:29,413
To hold the lawn bowl steady
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00:08:29,413 --> 00:08:31,413
While a carousel
Moves it forward
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00:08:31,413 --> 00:08:33,689
To undergo a vigorous polishing.
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00:08:36,344 --> 00:08:39,241
The polisher rubs paste
Onto the surface
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00:08:39,241 --> 00:08:42,275
To buff the lawn bowl
To an even sheen.
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00:08:42,275 --> 00:08:45,931
A robot then turns
The lawn bowl upside down
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00:08:45,931 --> 00:08:50,103
To expose the unpolished side...
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00:08:50,103 --> 00:08:51,827
Then puts it back
In the receptacle
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00:08:51,827 --> 00:08:55,206
So the polisher can buff
This side of the lawn bowl.
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The entire lawn bowl now gleams,
143
00:09:02,413 --> 00:09:06,931
And an unpolished bowl next
To it looks dull by comparison.
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00:09:06,931 --> 00:09:09,586
But there's more polishing
To come.
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00:09:09,586 --> 00:09:12,965
The next machine spins the lawn
Bowl against another polisher.
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00:09:12,965 --> 00:09:16,482
This one applies a finer-grade
Compound to it.
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00:09:19,379 --> 00:09:22,448
Down the line,
Lasers move in unison
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00:09:22,448 --> 00:09:25,620
To engrave the same emblem
Onto four bowls.
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It's a scottish thistle,
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00:09:27,448 --> 00:09:30,310
One of over 4,000
Team insignias available
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00:09:30,310 --> 00:09:32,206
In this production facility.
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00:09:32,206 --> 00:09:35,172
Each lawn bowl then goes
For another spin,
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00:09:35,172 --> 00:09:38,413
And an employee paints over
All the detail work.
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He wipes the paint
From the surface,
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00:09:42,137 --> 00:09:45,655
But it remains in the engravings
To accentuate them.
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00:09:53,137 --> 00:09:56,241
Some lawn bowls
Get two-tone paint jobs.
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00:09:56,241 --> 00:09:59,241
The worker brushes red paint
Into a hawk engraving,
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00:09:59,241 --> 00:10:02,724
Which provides a nice contrast
To the yellow detail work.
159
00:10:08,862 --> 00:10:11,862
Then it's over
To the testing department,
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00:10:11,862 --> 00:10:16,000
Where they roll each bowl down
A chute and check its swerve.
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00:10:18,724 --> 00:10:20,758
They also verify that each bowl
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00:10:20,758 --> 00:10:24,448
Lands in approximately the same
Spot as the master bowl,
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00:10:24,448 --> 00:10:26,379
Which means they're all equal
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00:10:26,379 --> 00:10:28,965
And they conform
To world standards.
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00:10:28,965 --> 00:10:32,517
Including cooling time
Between processes,
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00:10:32,517 --> 00:10:35,275
It takes about two days
To make a lawn bowl.
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00:10:35,275 --> 00:10:39,482
But once the work is done,
It's all fun and games.
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Narrator:
Radio-controlled model jets
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First flew onto the radar
In the 1970s
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00:10:55,275 --> 00:10:58,931
And have since evolved into
Sophisticated flying machines.
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Many have turbine engines
And use real jet fuel.
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They allow people who would
Otherwise never pilot a jet
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To experience the thrill
Of flight
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With both feet on the ground.
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00:11:12,482 --> 00:11:18,000
Radio-controlled model jets can
Roll and dive like actual jets.
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00:11:20,241 --> 00:11:24,620
And they can reach speeds
Of up to 280 miles an hour.
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Operating one
Isn't child's play.
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It takes practice and skill
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00:11:29,034 --> 00:11:31,551
To pilot this kind
Of model aircraft.
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00:11:33,413 --> 00:11:38,310
It also takes money
Because they cost up to $20,000.
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Making a model jet
Begins with the paint job.
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They airbrush designs
Directly into the molds
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That will be used
To shape various parts.
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This particular mold
Will be used
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To make one half
Of a wing shell.
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00:12:00,827 --> 00:12:06,137
When the paint dries, they roll
Epoxy resin into the mold...
187
00:12:07,482 --> 00:12:10,482
...Then put down a layer
Of fiberglass.
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00:12:13,379 --> 00:12:17,827
They reinforce the fiberglass
With superstrong carbon fiber,
189
00:12:17,827 --> 00:12:21,068
Then brush on more epoxy resin.
190
00:12:21,068 --> 00:12:23,103
The next layer is balsa,
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00:12:23,103 --> 00:12:26,896
A lightweight wood
From south america.
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00:12:28,275 --> 00:12:31,586
They apply carbon fiber
To sections of the wing
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Where parts are to be attached.
194
00:12:33,758 --> 00:12:39,689
Another sheet of fiberglass,
And epoxy is the final layer.
195
00:12:39,689 --> 00:12:42,310
Now they add a layer
Of absorbent material,
196
00:12:42,310 --> 00:12:47,172
Then sandwich the mold
In plastic film.
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00:12:47,172 --> 00:12:51,000
They install a connector for
A vacuum hose and hook it up.
198
00:12:54,620 --> 00:12:59,896
The vacuum pulls out the air,
Squeezing the layers together.
199
00:12:59,896 --> 00:13:03,586
Then they bake the unit,
Which activates the epoxy,
200
00:13:03,586 --> 00:13:05,931
Fusing the materials together.
201
00:13:05,931 --> 00:13:10,931
Next, they assemble the wooden
Framework for the wings.
202
00:13:10,931 --> 00:13:13,965
They reinforce it
With strips of carbon fiber
203
00:13:13,965 --> 00:13:17,034
And apply epoxy on the edges.
204
00:13:19,758 --> 00:13:22,586
The model makers carefully
Install the framework
205
00:13:22,586 --> 00:13:25,379
On the wing shell.
206
00:13:25,379 --> 00:13:29,000
They apply an extra rib
Along the wing tip...
207
00:13:31,724 --> 00:13:34,724
...Slide aluminum cylinders
Into tubes in the framework,
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00:13:34,724 --> 00:13:38,827
Then bead more epoxy along
The wing shell's perimeter.
209
00:13:40,310 --> 00:13:42,517
They use high-strength adhesive
210
00:13:42,517 --> 00:13:44,413
In strategic parts
Of the framework
211
00:13:44,413 --> 00:13:47,620
To attach the other half
Of the molded wing.
212
00:13:51,310 --> 00:13:53,413
They bolt the molds together
213
00:13:53,413 --> 00:13:56,793
And set the assembly aside
To allow the epoxy to cure.
214
00:13:56,793 --> 00:13:59,620
After a few hours,
They extract the wing,
215
00:13:59,620 --> 00:14:01,689
Its artwork nicely transferred
216
00:14:01,689 --> 00:14:04,206
From the inside surface
Of the mold.
217
00:14:04,206 --> 00:14:06,655
Machinery then cuts holes
In the wing
218
00:14:06,655 --> 00:14:11,655
For installing landing gear
And motors called servos.
219
00:14:11,655 --> 00:14:14,517
This router
Is computer programmed
220
00:14:14,517 --> 00:14:17,793
To make perfect cuts without
Damaging the internal framework.
221
00:14:17,793 --> 00:14:21,620
This is critical because
Just a fraction of an inch off,
222
00:14:21,620 --> 00:14:25,482
And the router would destroy
The carefully crafted wing.
223
00:14:30,000 --> 00:14:33,862
The modeler now perforates the
Fiberglass layer of the wing.
224
00:14:33,862 --> 00:14:37,103
He's creating a hinged section
Called an aileron.
225
00:14:37,103 --> 00:14:41,413
It's a control surface that will
Cause the plane to turn or roll.
226
00:14:46,551 --> 00:14:49,310
The ailerons
And other control surfaces
227
00:14:49,310 --> 00:14:51,206
Will be powered by servomotors.
228
00:14:55,758 --> 00:14:58,724
The front fuselage shell
Has been molded
229
00:14:58,724 --> 00:15:01,241
And is now ready to be revealed.
230
00:15:07,758 --> 00:15:10,275
Like the wings,
The body of this model jet
231
00:15:10,275 --> 00:15:12,103
Needs a supporting framework
232
00:15:12,103 --> 00:15:16,689
Along with brackets
For attachments.
233
00:15:16,689 --> 00:15:18,379
Another computerized router
234
00:15:18,379 --> 00:15:21,862
Carves them out of multilayered
Carbon-fiber board.
235
00:15:26,275 --> 00:15:29,172
The modeler glues these parts
Inside the fuselage
236
00:15:29,172 --> 00:15:32,103
And the tail of the jet.
237
00:15:32,103 --> 00:15:33,896
Coming up next,
238
00:15:33,896 --> 00:15:38,000
This model jet gets its wings
And prepares for takeoff.
239
00:15:50,827 --> 00:15:53,758
Narrator: controlling one
Of these jets is challenging
240
00:15:53,758 --> 00:15:55,862
And requires concentration.
241
00:15:55,862 --> 00:15:59,413
These are expensive toys,
And the learning curve is steep.
242
00:15:59,413 --> 00:16:00,758
One bad landing,
243
00:16:00,758 --> 00:16:03,827
And this model jet could end up
In a crumpled heap.
244
00:16:03,827 --> 00:16:06,827
It's why flyers hone
Their skills at airfields
245
00:16:06,827 --> 00:16:09,862
And test them
In international competitions.
246
00:16:12,551 --> 00:16:14,689
Back at the factory,
247
00:16:14,689 --> 00:16:18,758
The molded pieces of this
Model jet are coming together.
248
00:16:18,758 --> 00:16:21,517
They attach the wings
To the fuselage
249
00:16:21,517 --> 00:16:24,379
Using the cylinders
Installed earlier.
250
00:16:24,379 --> 00:16:27,241
Then the modeler
Moves to the aircraft's tail
251
00:16:27,241 --> 00:16:30,655
And attaches the stabilizers...
252
00:16:30,655 --> 00:16:33,896
The rudder...
253
00:16:33,896 --> 00:16:36,620
And the vertical fin.
254
00:16:36,620 --> 00:16:41,103
Super-strength glue
Cements the assembly.
255
00:16:41,103 --> 00:16:43,551
Next, they build the motor.
256
00:16:43,551 --> 00:16:46,482
This one is a ducted-fan
Electric system,
257
00:16:46,482 --> 00:16:48,965
A type used in smaller jets.
258
00:16:48,965 --> 00:16:51,448
The modeler first assembles
The casing
259
00:16:51,448 --> 00:16:53,931
That will hold the fan
And its motor.
260
00:16:53,931 --> 00:16:56,275
He slides airfoils
Into the casing
261
00:16:56,275 --> 00:16:57,724
To create four ducts,
262
00:16:57,724 --> 00:17:01,586
Which will properly channel
The flow of air.
263
00:17:01,586 --> 00:17:05,482
He slides the electric motor
Into the aluminum hub...
264
00:17:09,000 --> 00:17:10,931
...Then anchors the assembly
265
00:17:10,931 --> 00:17:13,172
With a screw
From the other side.
266
00:17:16,551 --> 00:17:19,344
The next part
Is a speed-control mechanism.
267
00:17:19,344 --> 00:17:23,000
He solders its wires to those
Protruding from the motor.
268
00:17:24,620 --> 00:17:28,379
He encloses the mechanism
In a vented tube,
269
00:17:28,379 --> 00:17:33,137
Then sets the assembly aside
Temporarily.
270
00:17:33,137 --> 00:17:35,655
Now focus turns to the fan,
271
00:17:35,655 --> 00:17:38,413
Which he hooks up
To a testing device.
272
00:17:38,413 --> 00:17:39,620
As the fan spins,
273
00:17:39,620 --> 00:17:42,206
The machine analyzes it
For vibrations
274
00:17:42,206 --> 00:17:45,379
That would indicate the blades
Are out of balance.
275
00:17:45,379 --> 00:17:48,068
The gauge shows
It's vibrating slightly,
276
00:17:48,068 --> 00:17:51,586
So he makes adjustments,
And then it's ready to install.
277
00:17:51,586 --> 00:17:54,137
He attaches the fan
To the motor shaft
278
00:17:54,137 --> 00:17:56,896
And secures it with a bolt
In the center.
279
00:17:59,275 --> 00:18:02,965
It's now time to power up
This motor at a test station.
280
00:18:02,965 --> 00:18:05,344
[ whirring ]
281
00:18:05,344 --> 00:18:08,586
[ whirring intensifies ]
282
00:18:08,586 --> 00:18:11,793
He brings it up to full throttle
283
00:18:11,793 --> 00:18:13,896
And measures the thrust
It generates.
284
00:18:16,862 --> 00:18:18,758
It passes the test,
285
00:18:18,758 --> 00:18:22,655
So he installs it
In the model jet's fuselage.
286
00:18:22,655 --> 00:18:24,413
Later, this ducted fan motor
287
00:18:24,413 --> 00:18:27,758
Will be connected
To a battery pack.
288
00:18:27,758 --> 00:18:30,172
Now he moves on
To the landing gear
289
00:18:30,172 --> 00:18:33,689
And attaches air cylinders
To the front and rear wheels.
290
00:18:33,689 --> 00:18:35,689
Pumping air into these cylinders
291
00:18:35,689 --> 00:18:38,793
Will cause the wheels to retract
After takeoff.
292
00:18:41,517 --> 00:18:46,448
This system will also cause the
Wheels to engage for landing.
293
00:18:50,172 --> 00:18:54,034
Next, a sheet of clear
Thermoplastic is transformed
294
00:18:54,034 --> 00:18:56,586
Into cockpit-canopy parts.
295
00:18:58,655 --> 00:19:00,724
A machine heats the plastic,
296
00:19:00,724 --> 00:19:03,620
Then vacuum-shrinks it
To two molds.
297
00:19:03,620 --> 00:19:06,482
The plastic hardens in seconds
298
00:19:06,482 --> 00:19:09,965
To create two clear plastic
Bubbles for the jet canopy.
299
00:19:12,517 --> 00:19:15,206
They mold the cockpit shell
In two sections
300
00:19:15,206 --> 00:19:17,310
Using the same technique.
301
00:19:26,689 --> 00:19:31,137
With the cockpit now installed
And a doll for a pilot,
302
00:19:31,137 --> 00:19:35,551
This '50s-era korean war jet
Replica is in fighting form.
303
00:19:35,551 --> 00:19:39,724
All that's left is to install
The radio-control system,
304
00:19:39,724 --> 00:19:42,586
Which will be done
By the operator after purchase.
305
00:19:42,586 --> 00:19:48,379
From nose to tail, the attention
To detail isimpressive.
306
00:19:48,379 --> 00:19:52,310
Some of these model jets
Even have gas-turbine engines
307
00:19:52,310 --> 00:19:56,206
For added authenticity.
308
00:19:56,206 --> 00:19:58,586
With radio controls installed,
309
00:19:58,586 --> 00:20:02,793
This turbine model jet is ready
To taxi down the runway.
310
00:20:02,793 --> 00:20:06,862
The operator does one last check
Of the control surfaces,
311
00:20:06,862 --> 00:20:09,275
Then it's time for takeoff.
312
00:20:14,586 --> 00:20:16,448
Miniature turbine engines
313
00:20:16,448 --> 00:20:19,724
Sound and work like those
Of a big jet.
314
00:20:19,724 --> 00:20:21,793
These jets rumble and soar
315
00:20:21,793 --> 00:20:25,655
And can be made to perform
Many aerobatic stunts.
316
00:20:25,655 --> 00:20:29,655
Of course, it all hinges on both
The skill of the operator
317
00:20:29,655 --> 00:20:32,655
And a job well done
At the factory.
318
00:20:36,379 --> 00:20:39,310
But this looks like
Another successful landing.
319
00:20:52,655 --> 00:20:54,862
If you have any comments
About the show,
320
00:20:54,862 --> 00:20:57,724
Or if you'd like to suggest
Topics for future shows,
321
00:20:57,724 --> 00:20:59,862
Drop us a line at...
26080
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