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Narrator: selecting furniture
Is a matter of scale,
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00:00:54,586 --> 00:00:56,965
Especially when
It's a dollhouse room.
3
00:00:56,965 --> 00:01:00,586
Miniature furniture is sized
For really small spaces.
4
00:01:00,586 --> 00:01:04,172
A popular scale is 1/12
Of full-sized furnishings.
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00:01:04,172 --> 00:01:06,551
But as far
As attention to detail,
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00:01:06,551 --> 00:01:10,206
There's no need to scale down
One's expectations.
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00:01:12,551 --> 00:01:15,689
These are replicas
Of full-sized antiques,
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Meticulously copied
In miniature.
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00:01:18,275 --> 00:01:21,896
This grandfather clock is
Modeled on an 18th-century one,
10
00:01:21,896 --> 00:01:25,448
And for the craftsman,
No detail is too small.
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00:01:25,448 --> 00:01:28,310
He first measures
And cuts numerous components
12
00:01:28,310 --> 00:01:29,827
From pear-tree wood.
13
00:01:29,827 --> 00:01:33,000
This wood's small grain
Scales down well
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00:01:33,000 --> 00:01:36,689
To make the miniature clock
Look more authentic.
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00:01:36,689 --> 00:01:39,931
The parts are too thin
And small to nail,
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00:01:39,931 --> 00:01:41,965
So he glues them together,
17
00:01:41,965 --> 00:01:44,620
Beginning with the front
Of the clock's trunk.
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00:01:44,620 --> 00:01:47,206
He applies the glue sparingly
With a tiny brass tool
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00:01:47,206 --> 00:01:51,275
To prevent messy overflow.
20
00:01:51,275 --> 00:01:57,034
He installs the sides
On the front of the clock trunk.
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00:01:57,034 --> 00:01:58,379
And he adds
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00:01:58,379 --> 00:02:01,068
A substantial-looking
Pearwood base.
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00:02:04,000 --> 00:02:06,896
He spiffs up the front of
The base with veneer paneling
24
00:02:06,896 --> 00:02:10,275
That's protected by a layer
Of tape for now.
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00:02:10,275 --> 00:02:12,137
He carves angles and trim
26
00:02:12,137 --> 00:02:17,034
To make it fit neatly
Around the paneling.
27
00:02:17,034 --> 00:02:18,586
He now peels away the tape
28
00:02:18,586 --> 00:02:21,275
To reveal the swirled burl
Of the veneer wood,
29
00:02:21,275 --> 00:02:24,517
Which has been cut from the root
Of a south-asian tree.
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00:02:24,517 --> 00:02:26,862
He rubs the paneling
Against sandpaper
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00:02:26,862 --> 00:02:31,310
To smooth its surface and expose
More of the wood grain.
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00:02:31,310 --> 00:02:34,034
Once the feet have
Been installed on the clock,
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00:02:34,034 --> 00:02:36,896
He applies a strip of molding
Above the trunk.
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00:02:36,896 --> 00:02:38,862
The crisp profile
Of this limewood trim
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00:02:38,862 --> 00:02:41,068
Is a classic touch.
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00:02:41,068 --> 00:02:43,758
Carving a mini gable
With the thin blade of a fretsaw
37
00:02:43,758 --> 00:02:47,000
Is tricky, especially
With this intricate design,
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00:02:47,000 --> 00:02:48,896
Called a swan neck.
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00:02:48,896 --> 00:02:52,034
He sands the edges
To finish off the job.
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00:02:52,034 --> 00:02:56,137
The swan-neck gable is one
Of numerous little parts that,
41
00:02:56,137 --> 00:02:59,034
When pieced together,
Form the hood of the clock,
42
00:02:59,034 --> 00:03:02,310
Which holds the face
And clockworks.
43
00:03:02,310 --> 00:03:04,137
He joins the hood to the trunk,
44
00:03:04,137 --> 00:03:06,758
And with the basic structure
Now complete,
45
00:03:06,758 --> 00:03:10,758
He glues a tiny wooden crest
To the center of the swan neck.
46
00:03:12,827 --> 00:03:16,448
He tapers it
With a surgical scalpel.
47
00:03:16,448 --> 00:03:19,965
After staining the clock
A deep antique mahogany,
48
00:03:19,965 --> 00:03:22,827
He sands it to make it look
More authentic.
49
00:03:24,965 --> 00:03:27,896
He then brushes on coats
Of shellac sealer.
50
00:03:27,896 --> 00:03:29,724
It both protects the wood
51
00:03:29,724 --> 00:03:33,206
And provides a smooth surface
For the next finish.
52
00:03:35,068 --> 00:03:38,310
After the sealer dries,
He sands it a little
53
00:03:38,310 --> 00:03:42,034
And then applies two coats
Of traditional french polish.
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00:03:42,034 --> 00:03:43,793
This mix of alcohol and shellac
55
00:03:43,793 --> 00:03:47,413
Gives the cabinetry
A high-gloss finish.
56
00:03:47,413 --> 00:03:52,379
Once it dries, he buffs the wood
With wax to enhance the sheen.
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00:03:55,413 --> 00:03:57,862
The clock door
With its exotic veneer
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00:03:57,862 --> 00:04:00,758
Is also stained, polished,
And waxed.
59
00:04:03,620 --> 00:04:05,655
Then, using tweezers,
60
00:04:05,655 --> 00:04:09,137
He positions tiny brass hinges
On the door.
61
00:04:13,413 --> 00:04:16,586
He presses little brass pins
Into holes in the hinge
62
00:04:16,586 --> 00:04:18,758
To secure it to the door.
63
00:04:21,000 --> 00:04:24,310
He files the pinheads
Until their flush to the hinge.
64
00:04:24,310 --> 00:04:28,310
He now dips the pendulum
And its weights in acid,
65
00:04:28,310 --> 00:04:32,655
Which gives them
An antiqued finish.
66
00:04:32,655 --> 00:04:36,310
He installs them in their
Compartment in the cabinetry.
67
00:04:39,275 --> 00:04:41,827
He now sets the clock upright...
68
00:04:41,827 --> 00:04:45,344
And paints the back basic black.
69
00:04:47,620 --> 00:04:49,517
He inserts a piece
Of clear acrylic
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00:04:49,517 --> 00:04:51,758
Into the opening
Of the clock hood.
71
00:04:51,758 --> 00:04:54,862
Acrylic has a slight wave to it
That looks like old glass.
72
00:04:54,862 --> 00:04:56,310
This small watch movement
73
00:04:56,310 --> 00:04:59,310
Is what will make this miniature
Grandfather clock tick.
74
00:04:59,310 --> 00:05:03,000
Using double-sided tape,
He attaches it to the dial.
75
00:05:03,000 --> 00:05:05,931
He fastens the hands
To the clockwork shafts,
76
00:05:05,931 --> 00:05:07,793
And then he lowers the dial
And clockworks
77
00:05:07,793 --> 00:05:09,655
Into the hood compartment.
78
00:05:13,275 --> 00:05:15,758
He signs the back
With a paint-filled pen
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00:05:15,758 --> 00:05:17,793
Which makes his signature
Stand out
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00:05:17,793 --> 00:05:20,206
Against the black background.
81
00:05:20,206 --> 00:05:25,275
And finally, he glues a tiny
Tassel to the door handle.
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00:05:25,275 --> 00:05:28,482
Including drying time
For the various finishes,
83
00:05:28,482 --> 00:05:30,344
It has taken over three days
84
00:05:30,344 --> 00:05:33,827
To make this miniature
Grandfather clock.
85
00:05:33,827 --> 00:05:36,586
No small effort,
But it's the little details
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00:05:36,586 --> 00:05:39,896
That make a difference
In a small space.
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Narrator: it's out of the
Basement and into the backyard
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For the model train set.
89
00:05:55,000 --> 00:05:57,344
This trend
Is called garden railroading,
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00:05:57,344 --> 00:06:00,827
And it merges two hobbies --
Gardening and model trains.
91
00:06:00,827 --> 00:06:03,551
These outdoor train sets
Are often larger
92
00:06:03,551 --> 00:06:05,827
And more rugged
Than indoor ones,
93
00:06:05,827 --> 00:06:10,000
So people can hop aboard
For a tour of the perennials.
94
00:06:13,034 --> 00:06:14,965
These garden-variety train sets
95
00:06:14,965 --> 00:06:18,448
Have become the fastest-growing
Segment of model railroading.
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00:06:18,448 --> 00:06:21,482
People design gardens
To the scale of these trains
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00:06:21,482 --> 00:06:24,931
To provide the perfect backdrop.
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00:06:24,931 --> 00:06:26,689
This particular locomotive
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Is a quarter of the size
Of the 19th-century original.
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00:06:31,724 --> 00:06:34,862
It starts
With a sheet of copper,
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Cut to precise measurements
With a guillotine blade.
102
00:06:40,724 --> 00:06:43,724
An employee then turns
The crank of a machine
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00:06:43,724 --> 00:06:46,206
To curl the sheet
Into a cylinder shape.
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00:06:46,206 --> 00:06:48,172
This cylinder
Will serve as the barrel
105
00:06:48,172 --> 00:06:51,310
Or outer casing of the boiler.
106
00:06:51,310 --> 00:06:56,172
The next worker assembles the
Boiler's internal components.
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He groups together
Numerous copper tubes
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And welds them
To a firebox at one end
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00:07:01,000 --> 00:07:03,000
And a copper plate at the other.
110
00:07:03,000 --> 00:07:06,275
He's now ready
To enclose the firebox.
111
00:07:08,310 --> 00:07:09,931
He installs it on a base plate
112
00:07:09,931 --> 00:07:12,206
And then builds
A protective shell around it.
113
00:07:12,206 --> 00:07:16,310
He then encases the heat tubes
In the barrel.
114
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These boilers
Come in various sizes,
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Depending on the scale
Of the locomotive being made.
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00:07:23,896 --> 00:07:28,413
Next, a lathe spins as tools
Contour a bronze cylinder.
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00:07:28,413 --> 00:07:30,448
This sizes it to fit a piston
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That sets the steam engine's
Wheels in motion.
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00:07:33,310 --> 00:07:37,551
The cylinder on the right is the
One that's just been machined.
120
00:07:37,551 --> 00:07:42,275
More tools transform basic steel
Disks into the train wheels.
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They make four wheels
Per locomotive.
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The next worker inserts
A pre-cut sheet of steel
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00:07:51,413 --> 00:07:53,482
In a device that,
When activated,
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00:07:53,482 --> 00:07:55,827
Bends it in two places.
125
00:07:55,827 --> 00:07:59,310
The folding action
Shapes the sheet
126
00:07:59,310 --> 00:08:02,344
Into the locomotive cab.
127
00:08:02,344 --> 00:08:06,172
Then it's into the paint booth
For seven coats of epoxy paint.
128
00:08:06,172 --> 00:08:11,379
This gives this model train cab
A heavy-duty gloss.
129
00:08:11,379 --> 00:08:14,448
With a steady hand,
130
00:08:14,448 --> 00:08:16,620
A painter now applies
Plastic tape
131
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Around the perimeter of the cab
132
00:08:18,413 --> 00:08:20,551
To create
A kind of linear stencil.
133
00:08:20,551 --> 00:08:24,034
He arcs the tape at the corners
To soften the look.
134
00:08:24,034 --> 00:08:27,620
And then he brushes
Two coats of oil-based paint
135
00:08:27,620 --> 00:08:29,758
Into the tape stencil.
136
00:08:29,758 --> 00:08:33,793
He allows three days
For each coat to dry.
137
00:08:33,793 --> 00:08:35,965
Then he peels off the tape
138
00:08:35,965 --> 00:08:40,068
To reveal the crisp, clean lines
That now frame the cab.
139
00:08:40,068 --> 00:08:43,103
He adds black border
Next to the white
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00:08:43,103 --> 00:08:47,586
To give more depth
To this custom paint job.
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00:08:47,586 --> 00:08:50,758
They carve a piece of bronze
Into a valve
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00:08:50,758 --> 00:08:53,758
To control the flow of steam
To the piston.
143
00:08:55,620 --> 00:08:59,103
They assemble the locomotive
Chassis and paint it.
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00:08:59,103 --> 00:09:00,482
They install the wheels
145
00:09:00,482 --> 00:09:03,655
And the network of pipes
And parts that make them turn.
146
00:09:03,655 --> 00:09:06,068
They run compressed air
Through the system
147
00:09:06,068 --> 00:09:08,103
To confirm everything works.
148
00:09:08,103 --> 00:09:10,965
The worker adds a little oil
To lubricate the wheels
149
00:09:10,965 --> 00:09:13,310
And the rest of the parts.
150
00:09:13,310 --> 00:09:16,000
He then opens the steam chamber
151
00:09:16,000 --> 00:09:18,241
To check
The valve-and-piston action,
152
00:09:18,241 --> 00:09:21,758
Which is the driving force
Of this steam locomotive.
153
00:09:21,758 --> 00:09:24,068
He pulls the forward
And reverse lever
154
00:09:24,068 --> 00:09:26,689
To confirm that the wheels
Run in both directions.
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00:09:26,689 --> 00:09:32,379
He applies the brakes,
And the wheels grind to a halt.
156
00:09:32,379 --> 00:09:35,413
Now that everything
On the chassis is checked out,
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This steam locomotive is ready
For the chimney and boiler.
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00:09:38,896 --> 00:09:42,517
The steam dome
And a safety valve go on next,
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00:09:42,517 --> 00:09:45,620
Followed by the cab and roof.
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00:09:45,620 --> 00:09:51,103
And this garden steam locomotive
Is now complete.
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00:09:53,827 --> 00:09:57,068
A worker now shines a light
Through the boiler tubes
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00:09:57,068 --> 00:10:00,103
To examine them
For any obstructions.
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00:10:00,103 --> 00:10:03,758
He pokes a brush through them
To be certain
164
00:10:03,758 --> 00:10:06,275
And then gives them
The all-clear.
165
00:10:09,793 --> 00:10:13,793
It's time to fire up the boiler
Using real coal.
166
00:10:13,793 --> 00:10:18,965
Hot gases flow through the tubes
To heat the water in the boiler.
167
00:10:18,965 --> 00:10:22,379
Like a big kettle,
This locomotive builds up steam.
168
00:10:22,379 --> 00:10:27,379
The pressure increases
Until it's ready to roll.
169
00:10:30,172 --> 00:10:33,000
Aboard one of these
Garden locomotive replicas,
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One can relive the heady days
Of steam engines.
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Narrator: a hovercraft rides
On a cushion of air
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Created by powerful fans.
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This enables the craft to travel
Over both land and sea.
174
00:10:59,344 --> 00:11:02,448
The concept
Actually dates back to 1870,
175
00:11:02,448 --> 00:11:05,448
But it wasn't until
The middle of the 20th century
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That a british inventor
Perfected it
177
00:11:07,758 --> 00:11:10,068
And the idea got off the ground.
178
00:11:12,965 --> 00:11:16,241
This model of hovercraft
Is equipped with a single fan.
179
00:11:16,241 --> 00:11:17,896
It both inflates the skirt,
180
00:11:17,896 --> 00:11:20,137
Lifting the vessel
About 10 inches,
181
00:11:20,137 --> 00:11:23,103
And creates thrust
To propel the hovercraft
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00:11:23,103 --> 00:11:25,448
Over virtually any surface.
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00:11:32,241 --> 00:11:34,344
Production begins with a hull
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00:11:34,344 --> 00:11:36,931
Made of lightweight
Polyethylene.
185
00:11:36,931 --> 00:11:40,413
The fabricator installs aluminum
Skids on the bottom
186
00:11:40,413 --> 00:11:43,413
To protect the hull during
Landings on rough surfaces.
187
00:11:48,827 --> 00:11:51,931
He screws plastic attachments
For the hovercraft skirt
188
00:11:51,931 --> 00:11:54,517
Into pre-marked positions
On the hull.
189
00:11:57,137 --> 00:12:00,103
The technician drills
65 holes around the hull.
190
00:12:00,103 --> 00:12:02,862
The fan's air
Will pass through these holes
191
00:12:02,862 --> 00:12:06,551
To fill the hovercraft skirt.
192
00:12:06,551 --> 00:12:10,034
The hull consists of a thick,
Hard outer layer
193
00:12:10,034 --> 00:12:14,344
And a low-density inner layer
That makes the material buoyant.
194
00:12:14,344 --> 00:12:18,310
It's what keeps the hovercraft
Afloat during stops on water.
195
00:12:22,275 --> 00:12:25,379
The crew now fastens
The seat base and console
196
00:12:25,379 --> 00:12:27,379
In the front of the hull.
197
00:12:29,689 --> 00:12:34,000
Once it's secure, they fit
The gauge panel in its slot.
198
00:12:38,896 --> 00:12:41,137
The team then moves
To the back of the hull
199
00:12:41,137 --> 00:12:43,206
To install the drive belt,
Pulley,
200
00:12:43,206 --> 00:12:45,241
And the main drive frame.
201
00:12:45,241 --> 00:12:49,379
This pulley will transfer power
From the engine to the fan.
202
00:12:49,379 --> 00:12:53,275
Once they confirm
Everything moves freely,
203
00:12:53,275 --> 00:12:55,758
They assemble the fan
To the main drive frame
204
00:12:55,758 --> 00:12:58,793
With high-tension bolts.
205
00:13:04,103 --> 00:13:07,862
This duct will divide the fan's
Air into two streams.
206
00:13:07,862 --> 00:13:11,482
One stream will be directed
Under the craft to provide lift.
207
00:13:11,482 --> 00:13:16,655
The other will be routed
Out the back to generate thrust.
208
00:13:16,655 --> 00:13:18,931
They now return to the cockpit
209
00:13:18,931 --> 00:13:22,379
To attach handlebars
To a steering mechanism.
210
00:13:27,103 --> 00:13:30,482
The engine can be either
A two-stroke or four-stroke,
211
00:13:30,482 --> 00:13:33,965
Depending on
The amount of power desired.
212
00:13:33,965 --> 00:13:36,310
They connect it
To the drive assembly
213
00:13:36,310 --> 00:13:39,655
And protect that connection
With metal casing.
214
00:13:39,655 --> 00:13:43,310
Once the engine
Has been bolted into place,
215
00:13:43,310 --> 00:13:46,172
They equip it with a radiator...
216
00:13:46,172 --> 00:13:48,758
An air filter...
217
00:13:48,758 --> 00:13:51,103
An exhaust system...
218
00:13:51,103 --> 00:13:54,620
And a waterproof box containing
The electrical components.
219
00:13:54,620 --> 00:13:56,896
Then they connect the fuel tank
To the engine
220
00:13:56,896 --> 00:13:59,379
And cover the engine
With a polyethylene hood
221
00:13:59,379 --> 00:14:01,793
To keep it dry.
222
00:14:01,793 --> 00:14:04,310
They install seating,
Including a rear bench,
223
00:14:04,310 --> 00:14:08,413
That accommodates three.
224
00:14:08,413 --> 00:14:12,586
Then the installer attaches
Two rudders to the fan duct.
225
00:14:15,862 --> 00:14:19,896
He links them with a bar
So they'll move in tandem.
226
00:14:21,931 --> 00:14:25,103
These steering parts
Are made of marine-grade steel
227
00:14:25,103 --> 00:14:28,137
To prevent rusting.
228
00:14:28,137 --> 00:14:31,206
A quick check confirms
The rudders are operational.
229
00:14:35,758 --> 00:14:38,965
The hovercraft's skirt
Is made of the same material
230
00:14:38,965 --> 00:14:43,310
Used on shoe soles --
Sturdy polyurethane nylon.
231
00:14:43,310 --> 00:14:48,413
They assemble the skirt to
The hull in 65 different pieces.
232
00:14:48,413 --> 00:14:50,655
The worker loops each segment
Over a side bumper
233
00:14:50,655 --> 00:14:53,379
And secures it
With a steel clip.
234
00:14:53,379 --> 00:14:56,310
He then attaches
The bottom of each skirt piece
235
00:14:56,310 --> 00:14:59,448
To the little hooks on the hull.
236
00:14:59,448 --> 00:15:02,137
He uses plastic cable ties
For this job,
237
00:15:02,137 --> 00:15:03,689
And there's a good reason.
238
00:15:03,689 --> 00:15:06,275
If the skirt
Becomes snagged on something,
239
00:15:06,275 --> 00:15:09,034
These ties will break
And free that section.
240
00:15:09,034 --> 00:15:11,517
Then other parts of the skirt
Will balloon out
241
00:15:11,517 --> 00:15:14,241
To fill the breach
And maintain the air cushion.
242
00:15:17,241 --> 00:15:20,586
And they also won't have to
Replace the whole skirt,
243
00:15:20,586 --> 00:15:23,413
Just the section
That's been damaged.
244
00:15:25,620 --> 00:15:27,620
After a final inspection,
245
00:15:27,620 --> 00:15:30,793
They take this hovercraft
For a test spin.
246
00:15:30,793 --> 00:15:33,620
They check the steering
And overall performance
247
00:15:33,620 --> 00:15:36,689
And enjoy gliding on air.
248
00:15:49,758 --> 00:15:53,275
Narrator: a folding bicycle
Is a compact set of wheels.
249
00:15:53,275 --> 00:15:56,448
In seconds, it folds up
Into a neat little bundle,
250
00:15:56,448 --> 00:15:58,862
Less than a third
Of its full size.
251
00:15:58,862 --> 00:16:01,586
The concept has been around
For well over a century,
252
00:16:01,586 --> 00:16:04,068
And in recent years,
It's on the comeback trail
253
00:16:04,068 --> 00:16:06,275
As urban commuters
Discover the advantages
254
00:16:06,275 --> 00:16:09,310
Of downsizing
This mode of transportation.
255
00:16:11,896 --> 00:16:16,241
A few quick folds and this bike
No longer carries the rider.
256
00:16:16,241 --> 00:16:17,517
He carries it.
257
00:16:17,517 --> 00:16:20,172
The bike can then be carted
Onto public transit
258
00:16:20,172 --> 00:16:21,551
Or into the office,
259
00:16:21,551 --> 00:16:24,896
And that makes it a handy way
To get around town.
260
00:16:28,724 --> 00:16:31,275
They lubricate
The rim of tubing,
261
00:16:31,275 --> 00:16:35,068
Which makes it easier
For machinery to pinch that end.
262
00:16:35,068 --> 00:16:39,068
The next machine
Uses several blades
263
00:16:39,068 --> 00:16:42,241
To trim the pinched end
And cut a small groove.
264
00:16:42,241 --> 00:16:44,862
These exact cuts
Will enable the team
265
00:16:44,862 --> 00:16:47,724
To precisely install
A hinge to the tube.
266
00:16:47,724 --> 00:16:50,448
Hinges are now gripped
By a moving clamp
267
00:16:50,448 --> 00:16:52,379
That angles them for contouring
268
00:16:52,379 --> 00:16:54,793
And the drilling of holes
For bolts.
269
00:16:54,793 --> 00:16:56,965
It's computer choreographed
270
00:16:56,965 --> 00:17:02,689
To produce a hinge that will
Attach snugly to the main tube.
271
00:17:02,689 --> 00:17:05,413
Once the hinge has been bonded
To the main tube,
272
00:17:05,413 --> 00:17:06,896
A technician checks the job
273
00:17:06,896 --> 00:17:10,241
By exposing it
To a magnetic field.
274
00:17:10,241 --> 00:17:12,448
Variations in the field
Would indicate a flaw,
275
00:17:12,448 --> 00:17:14,448
But he finds none.
276
00:17:14,448 --> 00:17:17,586
So next, he secures the tube
On a work table
277
00:17:17,586 --> 00:17:20,310
So a tool can make scoops
In the other end.
278
00:17:20,310 --> 00:17:22,551
Scooping this end will enable it
279
00:17:22,551 --> 00:17:26,241
To interconnect with another
Part of the bike frame.
280
00:17:26,241 --> 00:17:29,275
A hydraulic tool
Then bends the main tube
281
00:17:29,275 --> 00:17:31,103
To give it a slight curve
282
00:17:31,103 --> 00:17:34,103
So it will arch
Around a bicycle wheel.
283
00:17:37,206 --> 00:17:41,827
You can see the difference
In this before-and-after shot.
284
00:17:41,827 --> 00:17:43,793
The main tube of the bike frame
285
00:17:43,793 --> 00:17:46,655
Now undergoes a process
Called shot blasting.
286
00:17:46,655 --> 00:17:48,379
An operator turns a crank
287
00:17:48,379 --> 00:17:51,586
To make the tube revolve
In an enclosed chamber
288
00:17:51,586 --> 00:17:54,931
As nozzles blow fine grit
At the hinge point.
289
00:17:56,482 --> 00:18:01,034
This cleans up
Some of the rough patches.
290
00:18:01,034 --> 00:18:05,310
A little manual filing smoothes
The area around the hinge.
291
00:18:05,310 --> 00:18:07,655
Smaller parts
Of the bicycle frame
292
00:18:07,655 --> 00:18:09,344
Take a tumble with ceramic bits,
293
00:18:09,344 --> 00:18:11,000
And this agitation action
294
00:18:11,000 --> 00:18:13,931
Improves the finish
On these parts.
295
00:18:18,862 --> 00:18:20,827
Further down
The production line,
296
00:18:20,827 --> 00:18:23,068
A worker locks the main tube
In a jig.
297
00:18:23,068 --> 00:18:28,172
He butts a bracing tube to it
At just the right angle...
298
00:18:28,172 --> 00:18:30,103
And then melts metal
Into the joint
299
00:18:30,103 --> 00:18:31,586
In a process called brazing.
300
00:18:31,586 --> 00:18:35,000
As the metal cools
And solidifies,
301
00:18:35,000 --> 00:18:36,517
It seals the two parts.
302
00:18:36,517 --> 00:18:38,413
He now fits the bottom bracket
303
00:18:38,413 --> 00:18:40,862
Onto the scooped end
Of the main tube
304
00:18:40,862 --> 00:18:43,482
And brazes them together.
305
00:18:43,482 --> 00:18:46,827
The frame of a folding bicycle
Is much more complex
306
00:18:46,827 --> 00:18:50,034
Than that of a conventional
One-piece a-frame bike.
307
00:18:50,034 --> 00:18:53,206
There are six parts to assemble
In tight alignment,
308
00:18:53,206 --> 00:18:57,517
And that means there's
Absolutely no room for error.
309
00:18:57,517 --> 00:19:00,344
Once the main frame assembly
Has been painted,
310
00:19:00,344 --> 00:19:04,206
It's ready to be joined
To the rear frame.
311
00:19:04,206 --> 00:19:06,827
He attaches it
By bolting the hinge.
312
00:19:06,827 --> 00:19:09,931
He twists the bolts
To just the right torque.
313
00:19:09,931 --> 00:19:12,793
He tests the folding
And unfolding action
314
00:19:12,793 --> 00:19:14,241
Of the rear assembly
315
00:19:14,241 --> 00:19:15,931
And then checks the lock
316
00:19:15,931 --> 00:19:17,827
To confirm
That it functions properly.
317
00:19:20,793 --> 00:19:23,103
He installs
The steering mechanism
318
00:19:23,103 --> 00:19:26,586
And wheel fork
In the front of the frame...
319
00:19:26,586 --> 00:19:29,551
And bolts the front wheel
To the fork.
320
00:19:32,241 --> 00:19:34,758
He verifies that
The assembled steering column
321
00:19:34,758 --> 00:19:37,241
And handlebars
Are in working order...
322
00:19:37,241 --> 00:19:41,931
And then slides them into place
At the front of the bicycle.
323
00:19:41,931 --> 00:19:44,275
He adjusts the position
Of the column
324
00:19:44,275 --> 00:19:46,965
So it folds
At just the right angle.
325
00:19:53,034 --> 00:19:54,931
He then attaches the rear wheel,
326
00:19:54,931 --> 00:19:57,310
Along with the gear hub,
To the frame.
327
00:19:59,827 --> 00:20:03,448
He secures the chain wheel
And pedals to the bicycle
328
00:20:03,448 --> 00:20:06,137
And fits the chain
Into the sprockets,
329
00:20:06,137 --> 00:20:07,586
Joining the two ends
330
00:20:07,586 --> 00:20:10,655
So the chain will travel
In a perpetual loop.
331
00:20:10,655 --> 00:20:13,896
He flips the bicycle around
To install the seat,
332
00:20:13,896 --> 00:20:15,413
And it's time to fold.
333
00:20:15,413 --> 00:20:18,793
The rear frame flips neatly
Under the main tube assembly.
334
00:20:18,793 --> 00:20:21,482
The front wheel locks on
To the rear frame.
335
00:20:21,482 --> 00:20:24,413
Sliding the seat pillar down
Locks the fold,
336
00:20:24,413 --> 00:20:26,793
And he lowers
The steering column.
337
00:20:28,689 --> 00:20:30,724
After a final inspection,
338
00:20:30,724 --> 00:20:34,241
This folding bicycle
Is ready for the big city.
339
00:20:34,241 --> 00:20:37,551
And when dodging traffic
Becomes too much of a hassle,
340
00:20:37,551 --> 00:20:41,655
Its owner can always fold it
And take public transit.
341
00:20:41,655 --> 00:20:44,655
--captions by vitac--
Www.Vitac.Com
342
00:20:44,655 --> 00:20:47,655
Captions paid for by
Discovery communications
343
00:20:51,793 --> 00:20:54,172
If you have any comments
About the show,
344
00:20:54,172 --> 00:20:57,103
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345
00:20:57,103 --> 00:20:59,068
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