All language subtitles for S20E04 - Stagecoaches; Road Reflectors; Fire Baked Pottery; Custom Motorcycle Tanks (1080p AMZN WEB-DL x265 Garshasp)_track3_[eng]
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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:
Long before trains and buses,
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The stagecoach transported
Passengers and goods.
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The coach would travel
An established route in stages.
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But over time,
The word "Stage" was used
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To describe the coach itself.
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Drawn by two or four animals,
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It relied quite literally
On horsepower.
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Like a classic movie scene
Come alive,
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Seeing a stagecoach in action
Is a throwback to a bygone era.
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Even today,
Building a stagecoach,
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Horse-drawn carriage,
Or covered wagon
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Borrows techniques from a time
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When engineering and design
Were done by hand.
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The creation of the stagecoach
Begins with drawings
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Detailing both the look
Of the final product
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And its exact dimensions.
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They start with construction
Of the stagecoach body.
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A worker puts framing rails
For the back wall into place
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Using a mortise
And a tenon joint.
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The final panel
Slides into place,
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And another framing rail
Holds the end wall together.
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The end wall is added
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To other pieces
Of the stagecoach body
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That have already
Been assembled.
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The end wall has ribbing
For added strength.
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Although the floor
Is partially curved,
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Passengers will sit or stand
On the part that is flat.
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The coach maker inserts the door
Pillars into the mortise
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With a few taps of a hammer.
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He lowers the roof beam onto
The top part of the door pillars
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And fastens it
Firmly into place.
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Forging of stagecoach suspension
Components is done by hand.
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The blacksmith begins stretching
The heated bar of steel
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Into a component called a jack.
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He repeatedly heats and hammers
The steel bar
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Until it reaches
The desired shape.
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He hammers the tapered steel bar
Over an anvil
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To shape it into a curved hook.
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Once the hook becomes an eye,
He hammers a pin into it.
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The blacksmith wraps
The heated steel around the pin
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To form a snug joint.
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The transformation is done
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Without the help
Of presses or dies.
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It's the blacksmith
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Who essentially sculpts
The metal bar
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Into a piece that has
Both function and form.
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The blacksmith positions
The finished and cooled jack
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Onto the undercarriage
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And attaches it firmly
Into place.
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The assembly has to withstand
The stresses
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Of the leather suspension
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Used to make the stagecoach ride
More comfortable for passengers.
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Using a clip,
The blacksmith attaches the step
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Used to climb
Into the stagecoach
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To the jack assembly.
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He attaches a clevis
To the jack assembly.
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With four jacks
In opposing corners,
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The leather suspension
Will rest in the clevises.
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Now on to
The stagecoach interior.
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The trimmer inspects
The hide of leather.
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He positions patterns carefully,
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Choosing leather cuts
That match.
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Then he'll cut
The leather pieces
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With each pattern designated
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For a specific part
Of the stagecoach.
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He places the newly upholstered
Cushion on the seat bench
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00:04:16,206 --> 00:04:20,379
And buckles the retaining straps
That hold it securely in place.
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In the paint booth,
This particular undercarriage
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Is given coats
Of yellow and black stripes.
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A worker coats the running gear
And wheels with sealer
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To weatherproof
The undercarriage.
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00:04:39,172 --> 00:04:42,344
Workers gently lower the newly
Painted and upholstered wagon
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Onto the undercarriage.
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They connect the two
Using mounting bolts.
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They fix the name plate
To the center of the rear axle.
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00:05:01,310 --> 00:05:04,172
To help protect passengers
From the elements,
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This particular model
Comes with a roof.
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Workers lower the roof posts
Into receiver eyes
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And make sure
They're securely attached.
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Next, a worker positions
A brake pad
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Against one
Of the rear wagon wheels.
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00:05:22,586 --> 00:05:25,172
He then tests
The brake assembly.
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The face of the brake pad can be
Wood, steel, or rubber,
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Depending on the vocation
Of the wagon.
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Now for a suspension test.
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The process that began
With raw lumber and steel
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Ends up about 1,200 hours later
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With a stagecoach that's ready
To hit the dusty trail.
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Narrator:
Road reflectors originated
In britain in the 1930s.
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A cat's eyes reflected
In headlights on a foggy night,
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Alerting a driver to the fact
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That he was
About to veer off the road,
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Provided the flash
Of inspiration.
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The driver went on to invent
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A mechanical version
Of the cat's eyes --
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Reflective road studs.
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Today's reflective road studs
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Are shining examples
Of innovation.
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These versions are computerized
And solar-powered,
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So they're energy efficient
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And they'll function
In a power blackout.
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It takes more than 20 parts
To make one road reflector.
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The assembler
First solders two wires
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To the back
Of a solar circuitry board,
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Establishing a connection.
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She flips the solar
Circuitry board around
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And applies double-sided tape.
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She places two strips of copper
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On conductive pads
In the corners above the tape.
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She removes the backing
From the double-sided tape.
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Using a vacuum tool,
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She transfers the solar cell
To the tape.
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Once in place,
She turns off the vacuum
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And smoothes the cell
To the tape.
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She solders the copper strips
To the conductive pads,
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Creating the circuitry.
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She connects the solar panel
To the board
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With short, little wires
Called jumpers.
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She slides rubber protectors
Onto the board.
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Each road reflector will have
Two of these solar units.
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Next, she assembles
The flashing l.E.D. Lights.
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She solders wires
To the back panels
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To link the lights
To the main computer board.
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She then applies adhesive
To the panel
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And presses the framework
For the l.E.D. Lens to it.
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00:08:09,034 --> 00:08:12,724
She inserts the polycarbonate
Lens into the framework,
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00:08:12,724 --> 00:08:14,896
And it clicks in.
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00:08:14,896 --> 00:08:19,206
There are two l.E.D. Lights
Per road reflector.
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She now assembles the reflector.
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She angles shiny aluminum flaps
To bounce light.
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She tucks the lights
Into the reflector,
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And they adhere
To the double-sided tape
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Applied to the base.
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She powers up
The flashing lights
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And checks the intensity
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And the effect
Of the reflective flaps.
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Things are looking good,
So now she inserts foam
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In a slot at the center
Of the aluminum casing.
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She places the reflective
Light unit on it.
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She installs a foam-wrapped
Rechargeable battery
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In a compartment
On one side of the lights.
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00:09:07,517 --> 00:09:10,896
She places the main
Computer board and solar cells
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In the compartment
On the other side.
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And then a computer technician
Programs the road reflector
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To interface with a control
System on the street pole.
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The reflector is now ready
To stop traffic
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00:09:28,724 --> 00:09:31,482
Or at least slow it down.
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A crew carves a slot in the road
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Sized precisely
For the reflector.
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To keep the pavement clean
During installation,
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One of them tapes
The perimeter of the hole.
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He then pumps
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Industrial-strength epoxy
Into it.
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He inserts a cast-iron framework
Into the epoxy-filled hole.
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He wipes up the epoxy overflow
And removes the tape.
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Entrenched in the pavement,
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This cast-iron framework
Will encase the road reflector,
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Allowing it to hold up
To heavy traffic.
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00:10:13,551 --> 00:10:17,931
He screws a protective crossbar
Over the lights
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00:10:17,931 --> 00:10:20,551
And then secures
The road reflector
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To the support structure.
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00:10:22,344 --> 00:10:25,172
They install the wireless
Communication system
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Atop a pole.
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This positions it
To activate the road reflectors
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When the curbside crosswalk
Button has been pressed.
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00:10:37,965 --> 00:10:40,586
Modern communications technology
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Has improved
On this 1930s invention.
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00:10:43,965 --> 00:10:49,103
Today's road reflector systems
Are flashier than ever,
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00:10:49,103 --> 00:10:52,413
Designed to attract
A driver's attention
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And keep it on the road.
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Narrator: in tribal communities
In the american southwest,
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Pottery takes shape
Much as it has for 2,000 years.
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In the hands of native artisans,
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Mud becomes a cooking pot
Or a storage vessel.
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No pottery wheel necessary,
No kiln required --
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Just a roaring campfire.
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00:11:30,103 --> 00:11:33,724
Times may change,
But in the southwest,
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00:11:33,724 --> 00:11:36,103
Tribal culture
Is true to its roots,
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Creating pots that look like
Ancient artifacts,
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Except they're new.
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Crafted from local clay,
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The pots are both lightweight
And durable,
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And their appeal
Is truly timeless.
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The potter gathers her own clay.
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This is micaceous clay from
Volcanic deposits in new mexico.
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She also mines minerals
Like iron oxide
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To paint the pottery.
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00:12:00,827 --> 00:12:05,000
In its raw form, micaceous clay
Sparkles in the sunlight.
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Its natural glitter will make
The finished pottery shimmer.
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She picks out leaves
And tree roots
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Because anything organic
Will outgas
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And cause the pottery to crack.
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00:12:16,241 --> 00:12:19,724
She transfers the clay
To a bucket of water.
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00:12:21,896 --> 00:12:24,551
After three or four days,
It dissolves,
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00:12:24,551 --> 00:12:28,000
And she filters it
To remove smaller contaminants.
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00:12:28,000 --> 00:12:31,448
Once the clay thickens
To a gravy-like consistency,
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00:12:31,448 --> 00:12:34,241
She transfers it
To a fabric-lined mold.
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00:12:34,241 --> 00:12:36,034
She leaves it to set
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00:12:36,034 --> 00:12:38,758
And coagulate
To a dough-like consistency.
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00:12:41,517 --> 00:12:45,172
She kneads a chunk of it
To remove air bubbles.
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00:12:47,517 --> 00:12:50,344
She then shapes it into a bowl.
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00:12:50,344 --> 00:12:54,793
It will serve as the base
Of a traditional storage pot.
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00:12:54,793 --> 00:12:58,482
She scrapes the pot base
Inside and out
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00:12:58,482 --> 00:13:00,620
To thin it as it dries.
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00:13:00,620 --> 00:13:04,137
The thinning process also works
The clay into a harder state.
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00:13:07,241 --> 00:13:11,137
She moistens the tip of the bowl
To make it malleable
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00:13:11,137 --> 00:13:12,862
And flattens the edge,
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00:13:12,862 --> 00:13:16,724
Creating a foundation
To build up the pot.
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00:13:16,724 --> 00:13:19,689
She now rolls
Another piece of clay
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00:13:19,689 --> 00:13:21,137
Into a long, thin strand
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00:13:21,137 --> 00:13:24,000
And coils it around the pot.
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00:13:24,000 --> 00:13:26,758
She blends the strand
Into the pot base
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00:13:26,758 --> 00:13:29,793
And then shapes it
To extend the pot upward.
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00:13:31,896 --> 00:13:36,000
The process is called coiling.
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00:13:36,000 --> 00:13:39,413
She continues
To build up the coils,
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00:13:39,413 --> 00:13:41,965
Blending them until they become
Completely enmeshed
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00:13:41,965 --> 00:13:44,862
And seamless
To the rest of the pot.
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00:13:44,862 --> 00:13:48,482
As she coils and blends,
She turns the pot inward,
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00:13:48,482 --> 00:13:52,034
Creating a shoulder
Near the top.
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00:13:52,034 --> 00:13:54,689
She smoothes the lip
And thins the extensions
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00:13:54,689 --> 00:13:57,034
To ensure the thickness
Is consistent.
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00:13:57,034 --> 00:13:59,655
This will prevent
Structural weakness.
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00:14:01,793 --> 00:14:06,758
In the hands a skilled artisan,
A lump of clay has become a pot,
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00:14:06,758 --> 00:14:09,620
But there's more work
To be done.
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00:14:09,620 --> 00:14:11,689
She narrows the opening.
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00:14:14,862 --> 00:14:19,068
She cuts the lip
In six symbolic orientations,
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00:14:19,068 --> 00:14:21,931
Representing north,
South, east, and west,
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The sky, and the earth.
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00:14:25,137 --> 00:14:27,344
She scallops the edge
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00:14:27,344 --> 00:14:30,517
In the direction of the cuts
To accentuate them.
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00:14:32,862 --> 00:14:36,620
She smoothes the pot
With a wet sponge.
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00:14:36,620 --> 00:14:39,551
Before dawn,
When the wind is low,
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00:14:39,551 --> 00:14:43,896
She lights a fire and places
The pots directly into it.
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00:14:43,896 --> 00:14:47,655
She stacks wood around the pots,
And flames engulf them.
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00:14:47,655 --> 00:14:50,586
This changes the clay's
Molecular structure
238
00:14:50,586 --> 00:14:53,758
So that it can never turn back
Into sticky mud.
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00:14:53,758 --> 00:14:56,310
She covers the fire
With a metal tub.
240
00:14:56,310 --> 00:15:00,310
The flames subside,
And the pots cool.
241
00:15:00,310 --> 00:15:04,068
Curing clay over an open fire
Isn't an exact science.
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00:15:04,068 --> 00:15:07,482
Heat is uneven,
And this causes fracturing.
243
00:15:07,482 --> 00:15:10,965
20% of these clay pots
Will be damaged.
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00:15:10,965 --> 00:15:12,758
She examines them carefully
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00:15:12,758 --> 00:15:15,448
And rejects anything
That is not intact.
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00:15:15,448 --> 00:15:18,896
In addition
To the micaceous clay pots,
247
00:15:18,896 --> 00:15:21,862
She also fires
Some red clay ones.
248
00:15:21,862 --> 00:15:24,931
She paints geometric motifs
Onto those,
249
00:15:24,931 --> 00:15:28,000
Using the mineral paints
She's prepared herself.
250
00:15:28,000 --> 00:15:30,586
Each pot is one of a kind.
251
00:15:30,586 --> 00:15:32,862
Quality varies depending
On the nature of the clay
252
00:15:32,862 --> 00:15:37,724
And smoke patterns
Created during firing.
253
00:15:37,724 --> 00:15:41,034
She leaves the pots made
Of micaceous clay unpainted
254
00:15:41,034 --> 00:15:43,206
For traditional reasons.
255
00:15:43,206 --> 00:15:45,241
She signs the vase
256
00:15:45,241 --> 00:15:47,689
And includes
The name of her tribe.
257
00:15:47,689 --> 00:15:50,793
She tucks her biographical
Information into it.
258
00:15:50,793 --> 00:15:54,310
She's been making pottery
Since childhood.
259
00:15:54,310 --> 00:15:55,862
From a handful of mud
260
00:15:55,862 --> 00:15:58,482
To a storage vessel
Or cooking pot,
261
00:15:58,482 --> 00:16:00,344
Southwest native pottery
262
00:16:00,344 --> 00:16:03,344
Continues to be
A triumph of ingenuity.
263
00:16:16,965 --> 00:16:18,344
Narrator: as a group,
264
00:16:18,344 --> 00:16:21,103
Motorcycle riders
Aren't big on convention.
265
00:16:21,103 --> 00:16:23,517
So when it comes to the look
Of their ride,
266
00:16:23,517 --> 00:16:25,103
They often go their own way.
267
00:16:25,103 --> 00:16:28,103
The gas tank presents
The greatest opportunity
268
00:16:28,103 --> 00:16:30,793
When customizing
The facade of the bike.
269
00:16:30,793 --> 00:16:32,379
Prominent and up-front,
270
00:16:32,379 --> 00:16:35,344
The tank both fuels the ride
And defines it.
271
00:16:38,551 --> 00:16:40,413
On a car or truck,
272
00:16:40,413 --> 00:16:43,000
The gas tank is tucked away
Out of sight.
273
00:16:43,000 --> 00:16:45,758
But on a motorbike,
There's no place to hide it,
274
00:16:45,758 --> 00:16:49,379
So you may as well
Just show it off.
275
00:16:49,379 --> 00:16:52,034
To make a custom gas tank,
276
00:16:52,034 --> 00:16:54,068
The metalworker
Starts with a sheet
277
00:16:54,068 --> 00:16:56,413
Of sturdy cold-rolled steel.
278
00:16:56,413 --> 00:16:58,965
He traces around paper patterns
279
00:16:58,965 --> 00:17:01,827
To transfer their outline
To the steel.
280
00:17:01,827 --> 00:17:03,758
There are seven pattern pieces.
281
00:17:03,758 --> 00:17:08,620
The design
Is a tapered classic one.
282
00:17:08,620 --> 00:17:11,896
He follows the lines
With an electric metal shear.
283
00:17:11,896 --> 00:17:15,068
With it, he can produce
A rough cut quickly.
284
00:17:20,551 --> 00:17:23,344
He switches
To a lever-operated shear
285
00:17:23,344 --> 00:17:26,275
To trim the parts cleanly
And precisely.
286
00:17:29,586 --> 00:17:32,241
He physically bends
One piece around a tube
287
00:17:32,241 --> 00:17:34,344
To create the tunnel.
288
00:17:34,344 --> 00:17:36,724
The tunnel is
The lower section of the tank
289
00:17:36,724 --> 00:17:39,620
That fits around the backbone
Portion of the bike frame.
290
00:17:41,586 --> 00:17:46,620
He cuts the tunnel to size
Along marked lines.
291
00:17:50,275 --> 00:17:54,172
He drills holes in the tunnel
For the mounting tubes.
292
00:17:58,862 --> 00:18:00,965
Using threaded bolts
As guides now,
293
00:18:00,965 --> 00:18:04,482
He positions the two
Mounting tubes on the holes
294
00:18:04,482 --> 00:18:08,586
And welds them to the tunnel,
Creating leak-proof seams.
295
00:18:13,758 --> 00:18:17,482
With rods attached as a mockup
Of the rest of the tank,
296
00:18:17,482 --> 00:18:19,482
He tests the fit to the bike.
297
00:18:19,482 --> 00:18:21,896
He confirms
The handlebars move freely
298
00:18:21,896 --> 00:18:24,862
And that there's no interference
With the engine.
299
00:18:24,862 --> 00:18:29,793
Next, he uses an english wheel
On the two top panels.
300
00:18:29,793 --> 00:18:32,448
He rolls each panel
Between two wheels
301
00:18:32,448 --> 00:18:35,931
To take the profile
From flat to curved.
302
00:18:35,931 --> 00:18:39,068
He tests the curvature
Against the mockup rods.
303
00:18:39,068 --> 00:18:41,137
It needs tweaking.
304
00:18:41,137 --> 00:18:43,000
He continues to shape it
305
00:18:43,000 --> 00:18:47,344
Until the custom gas-tank part
Matches the mockup perfectly.
306
00:18:47,344 --> 00:18:50,103
Using another machine now,
307
00:18:50,103 --> 00:18:53,000
He forms a stylish curl
Onto the edges.
308
00:18:53,000 --> 00:18:55,103
This will also allow
The two parts
309
00:18:55,103 --> 00:18:57,000
To be joined neatly at the peak.
310
00:18:57,000 --> 00:19:00,172
After marking the location
Of the fuel cap,
311
00:19:00,172 --> 00:19:03,620
He punches small holes
For mounting screws.
312
00:19:03,620 --> 00:19:07,965
He cuts out the hole
For the gas cap.
313
00:19:07,965 --> 00:19:11,862
He joins the two top sections
Of the custom gas tank
314
00:19:11,862 --> 00:19:13,758
With tack welds.
315
00:19:13,758 --> 00:19:16,482
A more permanent weld
Will come later.
316
00:19:16,482 --> 00:19:18,000
He drills holes for mounting
317
00:19:18,000 --> 00:19:20,172
The top panel assembly to
The tunnel,
318
00:19:20,172 --> 00:19:23,586
Spacing them to correspond
With the mounting tubes.
319
00:19:25,931 --> 00:19:28,827
With the mockup rods
Removed from the tunnel,
320
00:19:28,827 --> 00:19:32,103
He joins the top
Panel assembly to it.
321
00:19:32,103 --> 00:19:34,448
He then tack-welds the sides
322
00:19:34,448 --> 00:19:37,034
To this custom
Gas-tank assembly.
323
00:19:40,206 --> 00:19:43,103
He hammers the tank's front cap
Against a form
324
00:19:43,103 --> 00:19:46,379
To give the outer edges
A rounded profile.
325
00:19:50,241 --> 00:19:53,241
He sands the part
Around the edges
326
00:19:53,241 --> 00:19:57,379
To fine-tune the contours
And ensure a perfect fit.
327
00:19:59,793 --> 00:20:01,620
He tack-welds the front cap
328
00:20:01,620 --> 00:20:04,827
To the rest
Of the motorcycle tank.
329
00:20:04,827 --> 00:20:07,413
And with the tank structure
Complete,
330
00:20:07,413 --> 00:20:10,724
It's time to make it leak-proof.
331
00:20:10,724 --> 00:20:15,206
He does a full penetration weld
On every seam.
332
00:20:15,206 --> 00:20:18,724
Using a pneumatic tool,
333
00:20:18,724 --> 00:20:21,965
He sands the seam smooth
And flat.
334
00:20:24,620 --> 00:20:27,689
He then sands the rest
Of the tank by hand
335
00:20:27,689 --> 00:20:30,310
To make the entire surface
Uniform.
336
00:20:34,758 --> 00:20:38,586
He positions
The tank on the bike.
337
00:20:38,586 --> 00:20:41,896
After equipping the gas cap
With a gasket,
338
00:20:41,896 --> 00:20:43,862
He screws it tightly
To the custom tank.
339
00:20:49,517 --> 00:20:52,931
Using mounting screws
And wing nuts,
340
00:20:52,931 --> 00:20:56,413
He secures the tank
To the bike frame.
341
00:20:56,413 --> 00:20:59,724
This custom gas tank
Now becomes a canvas.
342
00:20:59,724 --> 00:21:02,517
He paints it
And applies silver borders
343
00:21:02,517 --> 00:21:05,689
And graphics requested
By the customer.
344
00:21:05,689 --> 00:21:09,310
He connects the tank
To the carburetor,
345
00:21:09,310 --> 00:21:12,310
And this bike is ready
To show off its new custom look.
346
00:21:21,482 --> 00:21:24,344
If you have any comments
About the show,
347
00:21:24,344 --> 00:21:27,517
Or if you'd like to suggest
Topics for future shows,
348
00:21:27,517 --> 00:21:29,655
Drop us a line at...
27816
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