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Narrator: the folding kayak
Is a seaworthy vessel
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That can be disassembled
And stuffed into a duffel bag.
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This boat-in-a-bag concept
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00:00:59,000 --> 00:01:01,655
Was developed in germany
A century ago.
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00:01:01,655 --> 00:01:04,379
It's a good fit for
The modern traveler's lifestyle
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00:01:04,379 --> 00:01:06,551
Because it can be stowed
In a car trunk,
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Checked on to a plane,
Or stashed in the condo closet.
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History has shown
That when going gets rough,
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The folding kayak
Doesn't fall apart.
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Adventurers have crossed oceans
In them,
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And today its story
Continues to unfold.
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The kayak frame
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Starts with parts cut from
Solid ash and laminated birch.
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For waterproofing,
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They dip them in marine-grade
Varnish three times,
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Drying them for 24 hours
Between dips.
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A worker then rivets
Metal fittings
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To a varnished section
Of the keel board.
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It's these fittings
That enable the folding kayak
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To move with the sea
Instead of against it.
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That's because they're made
Of an aluminum-copper alloy,
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A metal with
A certain amount of give.
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He fastens more aluminum-alloy
Fittings on the cross ribs.
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There will be a total
Of seven cross ribs
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In this two-seater
Folding kayak.
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The center three
Will carry most of the load,
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So they're made of nine layers
Of laminated birch.
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It's super strong
Because unlike solid wood,
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It has few knots
Or imperfections.
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He applies a label with
The production's serial number
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To a boomerang-shaped piece
Of the frame.
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This is how the kayak owner
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Would actually assemble the boat
On-site.
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He locks two sections
Of the keel board together
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With the flexible fitting
We saw installed earlier.
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He snaps the bow piece
To the front
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And hooks rods into fittings
Installed on the bow.
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He fastens a couple of ribs
To the keel board.
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The gunnels, which are the top
Sides of the boat, are next.
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He attaches one end to the bow
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And the other
To one of the ribs.
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The bow and stern parts
Are color-coded
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With red-painted fittings
For the bow
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And blue ones for the stern.
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All the parts fit together
Like a toy model.
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With both gunnels now attached,
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00:03:05,172 --> 00:03:07,413
He's ready to install
More ribs --
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The laminated birch ones
That form the cockpit.
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00:03:14,000 --> 00:03:16,758
He completes
The assembly of rods.
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00:03:16,758 --> 00:03:20,758
All these rods will give
The kayak directional stability.
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00:03:20,758 --> 00:03:23,758
He unfolds part
Of the kayak deck assembly,
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Known as the coaming,
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And arranges it to surround
The cockpit.
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He attaches it to the gunnels
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Using metal clamps and fittings.
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00:03:34,655 --> 00:03:39,862
He slides the two seats
Into place on the keel board.
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00:03:39,862 --> 00:03:42,965
And he attaches the back rest
To the gunnels.
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The frame of this folding kayak
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Is now complete and ready
For its custom-made skin.
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00:03:52,448 --> 00:03:54,655
Over in the sewing department,
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The seamstress traces
The patterns for the kayak deck
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Onto cotton-hemp material and
Cuts along the penciled lines.
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00:04:02,103 --> 00:04:05,241
This natural fabric will allow
The deck to breathe
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And yet keep it water-tight.
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00:04:09,655 --> 00:04:12,655
It's now time to piece together
All of the parts,
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Including two long sleeves
For inserting inflatable tubes.
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Deflated, the tubes
Will create slack,
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Making it easier to fit
The frame into the skin.
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Inflated, they make the kayak
Virtually unsinkable.
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00:04:26,172 --> 00:04:28,965
Once the thick layers
Have been stitched together,
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00:04:28,965 --> 00:04:31,620
She's ready to insert
The inflatable tubes.
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They were pumped full of air
To be examined for holes,
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So she deflates them.
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She uses a long pole
To extend her reach
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And push the inflatable tube
Into the sleeve.
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With a synthetic rubber hull
Now stitched to the deck fabric,
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The skin is complete and ready
For the kayak's wooden frame.
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This particular model
Has been painted black.
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If the fit is even slightly off,
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The kayak won't perform
Properly.
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The skin fits like a glove.
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He brushes glue onto the tips
Of the bow and stern
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And then presses molded rubber
Bumpers onto those areas.
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The bumpers will protect
The ends of the hull casing,
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Which takes
A lot of hard knocks.
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In total, it takes
About 50 person-hours
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To make a folding kayak.
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It should take the owner
About 15 minutes
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To disassemble or assemble one.
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For some, it will become
A traveling essential,
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Part of the luggage on any trip.
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Narrator: the piñata is
A colorful paper-mache object
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Typically filled
With candy or small toys,
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Then suspended high
From a string.
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Blindfolded partiers take turns
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Trying to hit the piñata
With a stick to break it open
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And release a shower of goodies.
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00:06:11,793 --> 00:06:15,517
From popular cartoon characters
To colorful, glittery shapes,
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Today's piñatas are a big hit
At kid's parties
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Where children eagerly await
The decisive blow
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That breaks open the piñata,
Releasing the treats inside.
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00:06:27,206 --> 00:06:29,000
The traditional way to build one
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00:06:29,000 --> 00:06:33,586
Starts with a clay pot
Suspended from a string.
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00:06:33,586 --> 00:06:36,172
The piñata-maker glues
Cardboard shapes to it
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And secures them by gluing
On pieces of newspaper.
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Then she covers
The rest of the pot.
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When the glue dries,
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She decorates the surface
With colorful paper.
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00:06:56,275 --> 00:07:00,620
The modern method is to use
A balloon instead of a clay pot.
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After inflating the balloon,
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She pastes pieces of newspaper
All over it.
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This technique is known
As paper-mache.
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The trick is to completely
Saturate the newspaper
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With a thick paste
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And make sure no part of
The balloon is left uncovered.
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She continues this process
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Until she's built up two or
Three even layers of newspaper
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All over the balloon.
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00:07:41,620 --> 00:07:44,862
Then she suspends it
From a clothespin to dry.
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00:07:50,724 --> 00:07:52,827
Hours later, the paper-mache
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00:07:52,827 --> 00:07:55,241
Is hardened into a shell
Around the balloon,
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Which she now breaks
And removes.
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00:08:01,482 --> 00:08:04,379
Next, she cuts an opening
At the top of the shell.
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This is the hole
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00:08:05,793 --> 00:08:08,586
Through which the buyer will
Fill the piñata with treats.
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00:08:08,586 --> 00:08:14,137
She'll later reattach the cut
Piece to make a trap door.
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00:08:14,137 --> 00:08:17,137
But first, with the sharp tips
Of her scissors,
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She pierces a row of holes
Along the circumference
129
00:08:20,655 --> 00:08:23,793
And threads twine through them.
130
00:08:29,551 --> 00:08:31,965
She leaves long ends at the top
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00:08:31,965 --> 00:08:35,551
With which to suspend
The piñata.
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This piñata will be star-shaped.
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To make each point,
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She rolls thin cardboard
Into a cone, taping it closed.
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She trims it
To the required size,
136
00:08:59,413 --> 00:09:03,034
Then cuts tabs at the base
And bends them back.
137
00:09:05,931 --> 00:09:09,448
She makes seven
Of these cardboard points,
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Then tapes them onto the shell
One by one.
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00:09:20,793 --> 00:09:23,724
Once all seven are positioned,
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00:09:23,724 --> 00:09:26,758
The decorating with colorful,
Glittery foil wrapping paper
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Can begin.
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She tapes a sheet around
Each point of the star.
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Then she applies glue
In between the points
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And adheres pieces of wrapping
Paper to those areas.
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00:09:49,724 --> 00:09:52,482
She folds other pieces
Into flower shapes
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And glues them on, as well.
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00:10:02,344 --> 00:10:05,137
Once the entire piñata
Is covered,
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She tapes matching streamers
To the end of each point.
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00:10:08,827 --> 00:10:11,000
Historians believe
Spanish missionaries
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00:10:11,000 --> 00:10:12,517
Used star piñatas like this one
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To convert the native peoples
In the americas to christianity.
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The star symbolized satan,
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00:10:19,689 --> 00:10:22,275
Its seven points,
The seven deadly sins,
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00:10:22,275 --> 00:10:24,586
Its beautiful colors,
Temptation.
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00:10:24,586 --> 00:10:28,103
Wearing a blindfold represented
Blind faith in god.
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00:10:28,103 --> 00:10:30,413
Striking the piñata
With a stick meant goodness
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00:10:30,413 --> 00:10:32,241
And virtue battling evil.
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00:10:32,241 --> 00:10:36,206
Breaking the piñata, releasing
A shower of treats or trinkets,
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00:10:36,206 --> 00:10:38,344
Symbolized heavenly rewards.
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00:10:50,724 --> 00:10:53,586
Narrator: human beings
Have always generated garbage.
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In the battle
To keep the streets clean,
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The mechanized garbage truck
Is a combat vehicle.
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It crushes tons of trash
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00:11:00,793 --> 00:11:02,758
En route to deliver it
To landfills,
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Incinerators,
And recycling facilities.
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00:11:05,517 --> 00:11:09,413
Without it, we'd all be
Knee-deep in garbage.
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00:11:12,758 --> 00:11:16,034
Garbage trucks have different
Approaches to handling garbage.
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00:11:16,034 --> 00:11:20,379
Some load from the front,
Other from the rear or side.
169
00:11:20,379 --> 00:11:24,517
And some are entirely mechanized
Like this side-loader truck.
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The operator inside the cab
Barely needs to lift a finger
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00:11:28,310 --> 00:11:31,724
As the hydraulic lift-arm
Does all the heavy work.
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00:11:31,724 --> 00:11:33,448
The garbage truck
Has come a long way
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Since it hit the street
In 1952.
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00:11:36,689 --> 00:11:38,965
Production
On a modern side-loader truck
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00:11:38,965 --> 00:11:41,172
Begins with a welding robot.
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The robot fuses
Numerous steel supports
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To the truck body floor.
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These supports
Will allow the truck
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To hold up to the force of tons
Of trash being compacted inside.
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00:11:52,172 --> 00:11:55,965
Meanwhile, down the line, other
Parts like the roof and sides
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Take shape
In separate assemblies.
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00:11:58,310 --> 00:11:59,724
Once they're complete,
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00:11:59,724 --> 00:12:02,413
They hoist the large steel parts
Into place
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00:12:02,413 --> 00:12:04,241
And assemble them
Within a metal framework.
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00:12:04,241 --> 00:12:06,689
The framework serves as a guide
186
00:12:06,689 --> 00:12:09,724
To piece together
All the parts of the truck box.
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00:12:09,724 --> 00:12:13,206
Once assembled, the workers
Clamp the parts together
188
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To secure the assembly
As they weld the seams.
189
00:12:16,655 --> 00:12:20,000
The garbage truck body is then
Ready for the mechanized parts,
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00:12:20,000 --> 00:12:22,103
Beginning with a hopper.
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00:12:22,103 --> 00:12:24,793
It's equipped with
A powerful, hydraulic compactor
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00:12:24,793 --> 00:12:28,310
To squeeze as much trash
As possible into the truck.
193
00:12:28,310 --> 00:12:31,586
They fit the hopper snugly
To the front of the truck body
194
00:12:31,586 --> 00:12:34,413
And weld it to it.
195
00:12:34,413 --> 00:12:36,655
Then they lift the tailgate
Into position
196
00:12:36,655 --> 00:12:39,517
At the rear of the truck box.
197
00:12:39,517 --> 00:12:42,689
They hinge it to the truck
198
00:12:42,689 --> 00:12:45,344
By sliding heavy-duty steel pins
Through brackets.
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00:12:48,275 --> 00:12:51,862
Once hinged, the tailgate can
Swing up and out of the way
200
00:12:51,862 --> 00:12:54,896
To allow garbage
To be discharged.
201
00:12:54,896 --> 00:12:56,620
The driving force for this
202
00:12:56,620 --> 00:13:00,310
Is a pair of hydraulic cylinders
Attached by brackets,
203
00:13:00,310 --> 00:13:02,137
Welded to the tailgate
At one end
204
00:13:02,137 --> 00:13:04,344
And the truck body at the other.
205
00:13:06,241 --> 00:13:08,931
With that job done,
These cylinders
206
00:13:08,931 --> 00:13:10,896
Can now extend
To lift the tailgate
207
00:13:10,896 --> 00:13:13,275
And retract to close it.
208
00:13:13,275 --> 00:13:15,241
Across the factory floor,
209
00:13:15,241 --> 00:13:18,448
Another team assembles
A pair of steel lift-arms.
210
00:13:18,448 --> 00:13:21,551
These lift-arms are designed
For another kind of truck,
211
00:13:21,551 --> 00:13:22,931
The front-end loader.
212
00:13:22,931 --> 00:13:24,620
It's mainly used to collect
213
00:13:24,620 --> 00:13:28,862
Hefty commercial
Garbage containers.
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00:13:28,862 --> 00:13:33,034
In action, these arms pivot
Around the truck cab
215
00:13:33,034 --> 00:13:35,931
And extend to the front to fork
Up the trash container
216
00:13:35,931 --> 00:13:38,172
And deposit the contents
In the hopper.
217
00:13:38,172 --> 00:13:42,000
Hydraulic cylinders
Also power these lift-arms.
218
00:13:42,000 --> 00:13:44,896
When the task is complete,
The forks at the end of the arms
219
00:13:44,896 --> 00:13:47,965
Fold back out of the way.
220
00:13:47,965 --> 00:13:52,448
Nearby, workers test
This rear-loader garbage truck.
221
00:13:52,448 --> 00:13:55,034
Its tailgate is split
Into two hoppers --
222
00:13:55,034 --> 00:13:57,655
One for recyclables
And the other for trash.
223
00:13:57,655 --> 00:14:03,034
Hydraulic systems lift them
One at a time or simultaneously.
224
00:14:03,034 --> 00:14:05,206
Collecting garbage
And disposing of it
225
00:14:05,206 --> 00:14:07,206
Can be tough
On a truck's paint job,
226
00:14:07,206 --> 00:14:11,103
So they apply
An extra-durable finish.
227
00:14:11,103 --> 00:14:14,310
They spray sealer
On the sanded outer surface,
228
00:14:14,310 --> 00:14:17,206
Followed by two coats
Of epoxy paint.
229
00:14:17,206 --> 00:14:20,620
After that,
They bake on the layers.
230
00:14:20,620 --> 00:14:24,172
Meanwhile, the truck chassis has
Arrived from another factory.
231
00:14:24,172 --> 00:14:25,793
It's a standard size,
232
00:14:25,793 --> 00:14:29,137
So they chop a piece off to size
It for the garbage-truck body.
233
00:14:29,137 --> 00:14:32,137
They install bracket plates
At the back
234
00:14:32,137 --> 00:14:34,517
And slide thick pins
Through the holes
235
00:14:34,517 --> 00:14:36,689
To join the truck body
To the chassis.
236
00:14:39,344 --> 00:14:43,034
Using a crane, they lift the
Automated side-loader truck body
237
00:14:43,034 --> 00:14:45,000
Onto the modified chassis.
238
00:14:52,172 --> 00:14:55,275
Once it's installed,
They test the compactor.
239
00:14:55,275 --> 00:14:56,482
Dual hydraulic cylinders
240
00:14:56,482 --> 00:14:59,965
Push the ejector blade
To the back of the truck.
241
00:15:01,862 --> 00:15:05,344
They test the tailgate --
Which has by now been equipped
242
00:15:05,344 --> 00:15:08,000
With signal lights, mud flaps,
And other parts --
243
00:15:08,000 --> 00:15:13,758
And verify that everything
Functions properly.
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00:15:13,758 --> 00:15:15,965
Once a truck passes muster,
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00:15:15,965 --> 00:15:17,137
It's ready to handle
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00:15:17,137 --> 00:15:20,448
Whatever garbage
Society throws its way.
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00:15:25,206 --> 00:15:27,586
And with these automated
Garbage trucks,
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00:15:27,586 --> 00:15:30,517
There's no need for anyone
To strain their back
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Or get their hands dirty,
250
00:15:32,137 --> 00:15:36,068
Because these robot arms
Can handle it.
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00:15:48,965 --> 00:15:51,000
Narrator:
High-performance cars
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00:15:51,000 --> 00:15:53,379
Typically have ceramic composite
Brake disks
253
00:15:53,379 --> 00:15:56,034
Rather than
Regular cast-iron ones.
254
00:15:56,034 --> 00:15:58,931
That kind of power on wheels
Requires being lightweight,
255
00:15:58,931 --> 00:16:01,206
And cast iron is very heavy.
256
00:16:01,206 --> 00:16:03,068
It would also wear out
Too quickly
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00:16:03,068 --> 00:16:05,793
Due to the intense heat
Friction generates
258
00:16:05,793 --> 00:16:09,448
When you brake a car
With such a powerful engine.
259
00:16:09,448 --> 00:16:14,482
Ceramic is heat-resistant
Up to 1,830 degrees fahrenheit.
260
00:16:14,482 --> 00:16:17,275
Therefore, these ceramic
Composite brake disks
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00:16:17,275 --> 00:16:20,896
Last about 60 times longer
Than standard cast-iron disks.
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00:16:20,896 --> 00:16:24,068
Ceramic composite means
The ceramic material silicon
263
00:16:24,068 --> 00:16:27,724
Is combined
With carbon fiber for strength.
264
00:16:27,724 --> 00:16:29,965
The disk factory
Prepares the carbon fiber
265
00:16:29,965 --> 00:16:31,517
By mixing two ingredients --
266
00:16:31,517 --> 00:16:35,482
A heat-molded resin and chopped
Pieces of raw carbon fiber,
267
00:16:35,482 --> 00:16:37,655
The strength of which
Lies in the interweaving
268
00:16:37,655 --> 00:16:41,827
Of its miniscule
Carbon filaments.
269
00:16:41,827 --> 00:16:45,482
Automated machines pour the
Carbon fiber into aluminum molds
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00:16:45,482 --> 00:16:47,517
In the shape of the disk ring.
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00:16:47,517 --> 00:16:51,793
The first filling station fills
The mold cavity only halfway.
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00:16:55,931 --> 00:16:59,034
Workers then fit a slotted belt
Around the mold
273
00:16:59,034 --> 00:17:02,310
And insert aluminum cores
Into the slots.
274
00:17:02,310 --> 00:17:04,931
These cores will form
A ventilation channel
275
00:17:04,931 --> 00:17:08,413
In the disk ring to keep
The disk from overheating.
276
00:17:19,137 --> 00:17:22,551
Now the mold moves on
To the next filling station.
277
00:17:22,551 --> 00:17:26,413
It fills the remainder
Of the cavity with carbon fiber.
278
00:17:29,413 --> 00:17:31,620
A roller levels the top.
279
00:17:35,172 --> 00:17:37,620
Then workers close up the mold,
280
00:17:37,620 --> 00:17:40,206
And a small press
Pushes down the cover
281
00:17:40,206 --> 00:17:42,758
To lightly compact the contents.
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00:17:42,758 --> 00:17:44,931
The mold enters a large press
283
00:17:44,931 --> 00:17:47,586
Which applies 20 tons
Of pressure
284
00:17:47,586 --> 00:17:51,172
While heating to almost
400 degrees fahrenheit.
285
00:17:51,172 --> 00:17:53,862
This compacts the carbon fiber
286
00:17:53,862 --> 00:17:57,275
And transforms the resin powder
Into plastic.
287
00:17:57,275 --> 00:18:00,103
Once the mold has cooled down
Enough to be handled,
288
00:18:00,103 --> 00:18:03,793
Workers submerge it in cold
Water for five to eight minutes.
289
00:18:03,793 --> 00:18:06,068
This cools the disk ring
Completely,
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00:18:06,068 --> 00:18:08,724
Enabling them
To pull out the cores.
291
00:18:08,724 --> 00:18:12,448
A computer-guided laser
Then examines the mold
292
00:18:12,448 --> 00:18:16,068
To make sure every last core
Has been removed.
293
00:18:16,068 --> 00:18:17,724
When they get the all-clear,
294
00:18:17,724 --> 00:18:20,413
They open the top and bottom
Sections of the mold
295
00:18:20,413 --> 00:18:22,344
And extract the disk ring.
296
00:18:24,965 --> 00:18:28,172
Computer-guided machines
Then smooth out the rough areas
297
00:18:28,172 --> 00:18:30,275
And drill
Tiny ventilation holes.
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00:18:32,689 --> 00:18:34,827
They put the disk ring
Into an oven
299
00:18:34,827 --> 00:18:36,896
Which, over the course
Of two days,
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00:18:36,896 --> 00:18:40,965
Gradually heats it to just over
1,800 degrees fahrenheit.
301
00:18:40,965 --> 00:18:43,034
This causes a chemical change
302
00:18:43,034 --> 00:18:46,827
Which transforms the plastic
Into carbon.
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00:18:46,827 --> 00:18:48,931
Next, they take a crucible --
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00:18:48,931 --> 00:18:51,103
A high-heat resistant
Container --
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00:18:51,103 --> 00:18:53,586
And position five mounts inside.
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00:18:56,965 --> 00:19:00,551
They place the disk ring
On the mounts.
307
00:19:00,551 --> 00:19:02,758
Then in the middle, a funnel,
308
00:19:02,758 --> 00:19:08,172
Into which they pour a ceramic
Material, a fine silicon powder.
309
00:19:08,172 --> 00:19:11,586
Then they load the crucible
Into an oven for 24 hours.
310
00:19:11,586 --> 00:19:13,758
It gradually heats the disk ring
311
00:19:13,758 --> 00:19:17,620
To more than 3,000 degrees
Fahrenheit, melting the silicon.
312
00:19:17,620 --> 00:19:19,758
Then it applies
Low-level suction,
313
00:19:19,758 --> 00:19:22,896
Drawing the now-liquid silicon
Into the disk ring.
314
00:19:22,896 --> 00:19:25,724
This creates an exceptionally
Hard new material
315
00:19:25,724 --> 00:19:29,103
Called silicon carbide.
316
00:19:29,103 --> 00:19:32,551
After a computer-guided drill
Bores mounting holes,
317
00:19:32,551 --> 00:19:34,482
The disk ring
Goes into a chamber
318
00:19:34,482 --> 00:19:37,000
Where it receives
A coat of protective paint.
319
00:19:37,000 --> 00:19:40,689
The paint shields the carbon
In this disk ring from oxygen,
320
00:19:40,689 --> 00:19:45,379
Which is critical because at
High heat, oxygen burns carbon.
321
00:19:45,379 --> 00:19:47,206
This anti-oxidation treatment
322
00:19:47,206 --> 00:19:50,965
Significantly extends the life
Of the brake disk.
323
00:19:50,965 --> 00:19:56,586
The paint is cured in an oven,
Leaving behind a white residue.
324
00:19:56,586 --> 00:19:58,724
A robot sands it off,
325
00:19:58,724 --> 00:20:01,931
Then polishes
The entire disk-ring surface.
326
00:20:07,931 --> 00:20:09,655
Here's what
The finished disk ring
327
00:20:09,655 --> 00:20:12,000
Looks like before it's cleaned
And polished...
328
00:20:14,068 --> 00:20:17,448
...And after.
329
00:20:17,448 --> 00:20:18,620
Every single brake disk ring
330
00:20:18,620 --> 00:20:21,068
Undergoes
A meticulous inspection.
331
00:20:21,068 --> 00:20:23,655
This sophisticated machine
Takes thousands
332
00:20:23,655 --> 00:20:26,448
Of high-definition photographs
Of the surface,
333
00:20:26,448 --> 00:20:30,551
Which a computer then analyzes
In micron-level detail.
334
00:20:30,551 --> 00:20:33,206
To complete the brake disk,
They affix the bell,
335
00:20:33,206 --> 00:20:35,758
A circular component
In the middle
336
00:20:35,758 --> 00:20:38,793
Which connects the brake disk
To the vehicle.
337
00:20:38,793 --> 00:20:42,034
The bell is made of either
Aluminum or stainless steel
338
00:20:42,034 --> 00:20:45,206
And bolted into the mounting
Holes in the disk ring.
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00:20:45,206 --> 00:20:48,172
--captions by vitac--
Www.Vitac.Com
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00:20:48,172 --> 00:20:51,827
Captions paid for by
Discovery communications
341
00:20:51,827 --> 00:20:54,206
If you have any comments
About the show,
342
00:20:54,206 --> 00:20:56,793
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343
00:20:56,793 --> 00:20:58,827
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