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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
The drive in your computer
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Saves and stores your data --
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Everything from documents
To photos to software programs.
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The newer generation drives
Are solid state drives.
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They're gradually replacing
Traditional hard disk drives
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00:01:07,275 --> 00:01:10,000
Because they're compact,
More durable,
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And process information
Much faster.
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Just like portable usb drives
And camera memory cards,
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Solid state drives
Store information
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On several memory chips
Installed on a circuit board.
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Each chip contains
Highly complex circuitry
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Comprised of electrical pathways
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2,000 times narrower
Than a human hair.
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To make those memory chips,
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They begin with
A disk-shaped silicon wafer.
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Silicon is a non-metallic
Natural element
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That conducts electricity.
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It's highly susceptible
To contamination,
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So the production area
Is virtually sterile
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To the point of being
1,000 times cleaner
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Than the air
In a hospital operating room.
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An automated robotic system
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Moves the wafers through
More than 800 operations,
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00:01:58,448 --> 00:02:01,724
Which take more than a month
To complete.
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00:02:01,724 --> 00:02:05,172
Each wafer receives layer
After layer of materials --
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00:02:05,172 --> 00:02:07,241
Some conductive, such as copper,
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00:02:07,241 --> 00:02:10,620
Some nonconductive,
Such as silicon dioxide.
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After applying each layer,
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The machine coats the wafer
With a light-sensitive fluid
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Then flashes u.V. Light onto it
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Through a glass stencil of the
Electrical circuitry pattern.
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In the areas where the fluid
Is exposed to the light,
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The chemicals break down
And dissolve.
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Where the fluid was shielded
From light by the stencil,
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The materials remain intact,
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Effectively printing the
Circuitry pattern on the wafer.
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00:02:37,379 --> 00:02:41,689
Chemical baths then wash away
The exposed fluid and material.
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Each foot-wide wafer
Yields hundreds of microchips,
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Which now
Have to be sliced apart.
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The robotic cutting machine
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Covers the wafer
With an adhesive film
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To hold the chips in place
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While they're being cut loose
From each other.
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The next machine
Inserts each clip
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In a protective plastic housing.
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Meanwhile,
Six circuit boards at a time
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Enter a machine
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Which applies a thin layer
Of tin alloy solder paste
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Onto the areas
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Where the memory chips
And other components will go.
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As the boards exit the machine,
A robotic arm picks off
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The components required for
Each drive from feeder spools
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And deposits them
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At their respective locations
On the circuit board.
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This particular model
Has 8 microchips,
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Each able to store
64 gigabytes of data,
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Giving the drive a capacity
Of 5,012 gigs.
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The circuit boards now enter
A tunnel-shaped oven
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Which melts the solder paste,
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Fusing the components
To the board.
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The brain
Of the solid state drive
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Is now complete
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And ready for the first phase
Of quality-control testing.
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This machine
Performs an optical scan
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To verify that every component
On the board
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Is set in the right place.
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The next machine
X-rays the board
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To verify that each component
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Is securely soldered
In the correct location.
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A later phase
Of quality-control testing
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Will verify
The drive's performance.
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Until now, six circuit boards
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Have been attached
To each other.
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An automated router
Now cuts them apart,
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And workers insert each board
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Into a protective
Plastic housing.
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A slot on the outside
Of this housing
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Reveals the board's connector
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By which the drive links
To the computer.
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Solid state drives
Come in different sizes.
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This particular model
Is large enough
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To replace
A traditional hard disk drive.
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However,
Many models are smaller,
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Designed to fit
Where disk drives can't --
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For example,
In ultra-slim laptops.
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Every drive is labeled
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With its technical specs, model,
And serial numbers and so on,
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Along with a barcode
For production tracking.
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00:05:10,206 --> 00:05:13,896
Then they plug the drive's
Connector into a tester,
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Which, after verifying
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That everything
Functions electronically,
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Installs the drive's
Operating system.
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The drive moves
To the next station,
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Where it undergoes
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Up to 60 hours of
Extensive performance testing
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To ensure that it stores
And retrieves data
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Correctly and at target speed.
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Packaging is twofold.
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First, a foil shield
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To prevent static electricity
From damaging the drive,
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Then a carton,
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And finally into a shipping box
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Headed for a destination
Somewhere around the world.
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Narrator: in ancient egypt,
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Both men and women
Painted their eyes.
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It was thought that eye makeup
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Made one less vulnerable
To the evil eye,
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A gaze or stare
Meant to cause harm.
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Today, mostly women wear it.
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And of course, repelling evil
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Is no longer a reason
To wear eye shadow.
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With a palette of eye shadow,
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A woman can work
A certain kind of magic.
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Skillful shading can add depth
And drama to the eyes.
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This makeup
Can also create the illusion
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That the eyes are much larger
Than they really are.
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To make eye shadow,
They follow specific recipes.
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A technician
Weighs the ingredients,
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Beginning with mica,
A mineral that acts as filler.
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The next ingredient
Is zinc stearate.
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It's a binder.
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A combination of pigments
Provides the desired color.
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These particular pigments
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Are different shades
Of the mineral iron oxide.
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He transfers
The measured ingredients
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To a big blender jar.
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As he pours the ingredients,
They dust up,
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And a gas mask keeps him
From breathing in the particles.
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He places the jar
On the blender base,
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Covers the top,
And activates the blades.
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The blender mixes and grinds
The powdered ingredients
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To a very fine state.
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Then it's into
A very large mixer.
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He adds coconut oil --
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Just enough
For the powdered ingredients
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To eventually coagulate
Into a cake form.
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More mica is next --
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A lot more.
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Eye shadow is 80% mica.
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This mica is darker
To add intensity to the color.
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It also has a bit of shimmer.
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He latches the lid
To contain the ingredients
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00:08:01,896 --> 00:08:04,827
And powers up
This high-speed mixer.
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Inside, the mixing paddles
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Swivel around
For about 15 minutes
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To thoroughly mix
The ingredients.
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The eye shadow mixture
Flows into a plastic bag.
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A technician examines it
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00:08:19,965 --> 00:08:23,310
To confirm that the color
Has been evenly dispersed
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And that the powder
Is sufficiently moist.
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Another worker now pieces
Four eye shadow tins
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In pods on a metal platter.
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The platter rotates to deliver
The tins to a mixing dispenser
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That's been filled
With the eye shadow ingredients.
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The mixer pushes precise amounts
Through holes in the bottom
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And into the tins.
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A scraper levels off the tops.
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The next stop is a press
With four circular heads.
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00:08:58,758 --> 00:09:01,827
A ribbon of fabric
Keeps things hygienic
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00:09:01,827 --> 00:09:05,068
As the press compresses
The moist eye shadow powder
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And turns it
Into a cake-like form.
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Moving forward,
The pods eject the tins,
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00:09:12,379 --> 00:09:16,724
And an automated device
Pulls them off the machine.
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What a difference
The compression has made.
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No longer a loose powder,
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The eye shadow ingredients
Have caked up nicely.
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The tins now move into a lane
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And come up against
An abrasive belt
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That cleans the loose powder
From the sides.
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A blast of air also gets rid
Of some of the residual powder.
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For one out of every 100
Eye shadows produced,
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00:09:41,241 --> 00:09:46,241
A technician does a drop test
From a height of 18 inches.
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He checks
For chipping or damage.
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00:09:48,275 --> 00:09:52,517
And if he finds any,
He'll add power to the press.
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00:09:52,517 --> 00:09:54,482
For a color test,
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He brushes some eye shadow
Onto his arm,
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Beginning with
A laboratory standard.
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He then applies
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00:10:04,068 --> 00:10:06,620
Newly manufactured eye shadow
To his arm
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00:10:06,620 --> 00:10:08,206
And compares the two.
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00:10:08,206 --> 00:10:09,517
It's a match.
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00:10:09,517 --> 00:10:11,000
And with his approval,
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00:10:11,000 --> 00:10:13,448
The batch is almost ready
For retail.
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00:10:13,448 --> 00:10:15,827
Another worker inserts the tins
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00:10:15,827 --> 00:10:19,034
Into more substantial
Plastic containers
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With magnets on the bottom
To secure them.
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00:10:23,827 --> 00:10:26,517
She screws the clear caps
Onto the jars,
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00:10:26,517 --> 00:10:30,655
And the eye shadow is on its way
To the cosmetic counter.
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00:10:33,965 --> 00:10:37,793
They also manufacture
Entire palettes of eye shadow
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For a rainbow of choices.
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00:10:43,517 --> 00:10:47,586
It takes about a day
To manufacture eye shadow.
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And the result is truly
A thing of beauty.
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00:11:09,551 --> 00:11:10,862
Narrator:
The first stretch limousines,
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00:11:10,862 --> 00:11:12,344
Built around 1928,
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00:11:12,344 --> 00:11:16,310
Usually transported big bands
And their musical equipment.
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00:11:16,310 --> 00:11:19,793
Luxury sedans
With an extended chassis
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00:11:19,793 --> 00:11:22,689
Are typically associated
With special occasions
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00:11:22,689 --> 00:11:26,586
Such as weddings, proms,
Or a night on the town.
201
00:11:28,275 --> 00:11:33,275
It takes about 475 hours of work
And painstaking detail
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00:11:33,275 --> 00:11:38,206
To transform a luxury sedan
Into a stretch limo.
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00:11:38,206 --> 00:11:43,413
Workers cut an ordinary-size car
In half using cutting wheels.
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00:11:43,413 --> 00:11:44,827
Before cutting begins,
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00:11:44,827 --> 00:11:47,310
The inside of the car
Is stripped away,
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00:11:47,310 --> 00:11:48,965
Along with other components
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00:11:48,965 --> 00:11:51,344
Such as the gas tank
And drive shaft.
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00:11:51,344 --> 00:11:54,241
Workers cut away
The inner support structure
209
00:11:54,241 --> 00:11:56,655
And cut across
The floor of the car
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00:11:56,655 --> 00:11:59,000
With a reciprocating saw.
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00:12:02,137 --> 00:12:07,620
The car is now
Completely cut in half.
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00:12:07,620 --> 00:12:09,724
Workers wheel
The back half of the car
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00:12:09,724 --> 00:12:12,000
Away from the front half.
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00:12:14,689 --> 00:12:17,448
They place the back half
On the exact spot
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00:12:17,448 --> 00:12:22,275
Where the limousine
Will gradually be assembled.
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00:12:22,275 --> 00:12:24,724
The construction department
Employees
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00:12:24,724 --> 00:12:28,172
Insert steel frame rails
Into the front half of the car.
218
00:12:31,034 --> 00:12:34,517
They insert the rails
On both sides of the front half
219
00:12:34,517 --> 00:12:37,965
Before inserting the rails
Into the back half of the car.
220
00:12:41,482 --> 00:12:43,344
They measure the length
Of the frame rails
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00:12:43,344 --> 00:12:45,034
To make sure
That the frame is square
222
00:12:45,034 --> 00:12:48,689
And that the two halves
Are the correct distance apart
223
00:12:48,689 --> 00:12:53,137
To build the limousine.
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00:12:53,137 --> 00:12:55,793
A worker welds the rails
To the frames
225
00:12:55,793 --> 00:12:58,758
Of the front and back halves
Of the original car.
226
00:12:58,758 --> 00:13:01,103
They position
The drive shaft tunnel,
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00:13:01,103 --> 00:13:04,206
Which houses the steel
Drive shaft and exhaust pipes,
228
00:13:04,206 --> 00:13:08,827
And weld it
To the original vehicle tunnel.
229
00:13:08,827 --> 00:13:12,103
They position the floor,
230
00:13:12,103 --> 00:13:15,344
Which is made
Of galvanized steel,
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00:13:15,344 --> 00:13:19,448
And weld it to the frame rails
And tunnel.
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00:13:19,448 --> 00:13:24,206
They weld the steel roof rails
Into place.
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00:13:24,206 --> 00:13:26,517
They connect the new rails
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00:13:26,517 --> 00:13:29,034
To the roof rails
In the original vehicle.
235
00:13:33,206 --> 00:13:37,034
A worked welds a vertical
Side post into place.
236
00:13:37,034 --> 00:13:38,344
With a level,
237
00:13:38,344 --> 00:13:40,379
He checks that
The post of hardened steel
238
00:13:40,379 --> 00:13:41,448
Is perfectly vertical
239
00:13:41,448 --> 00:13:44,413
Before welding
The base of the post
240
00:13:44,413 --> 00:13:47,068
To the floor frame.
241
00:13:47,068 --> 00:13:50,413
A roof panel
Made of galvanized steel
242
00:13:50,413 --> 00:13:52,896
Is put in place.
243
00:13:52,896 --> 00:13:56,620
Workers install
The limousine's bar.
244
00:13:56,620 --> 00:14:01,448
They've already installed
The steel seat frames.
245
00:14:01,448 --> 00:14:04,724
Next, they install
An outer body panel
246
00:14:04,724 --> 00:14:08,379
Complete with
A hardened steel crash bar.
247
00:14:08,379 --> 00:14:10,724
They screw the panel into place.
248
00:14:10,724 --> 00:14:12,103
The screws will be removed
249
00:14:12,103 --> 00:14:17,586
Once the panel has bonded
Solidly to the limousine frame.
250
00:14:17,586 --> 00:14:21,448
A worker sprays on
Three coats of paint,
251
00:14:21,448 --> 00:14:25,965
Then applies two coats
Of protective clear coating.
252
00:14:25,965 --> 00:14:30,241
Once the painting process
Is complete,
253
00:14:30,241 --> 00:14:33,931
Workers install
The laminated safety side glass.
254
00:14:33,931 --> 00:14:37,793
Another worker
Sprays contact cement
255
00:14:37,793 --> 00:14:39,517
On the roof of the limousine
256
00:14:39,517 --> 00:14:42,103
In preparation
For the vinyl top.
257
00:14:42,103 --> 00:14:44,034
He stretches the vinyl
Across the roof
258
00:14:44,034 --> 00:14:48,517
And with his hand presses the
Fabric down into the crevices.
259
00:14:48,517 --> 00:14:52,862
Then he carefully trims off
The excess.
260
00:14:52,862 --> 00:14:56,379
He presses a strip
Of chrome molding into place
261
00:14:56,379 --> 00:15:00,379
On the top of the vinyl.
262
00:15:00,379 --> 00:15:03,482
Workers
In the interior department
263
00:15:03,482 --> 00:15:06,379
Install the back
Of a leather seat...
264
00:15:06,379 --> 00:15:09,206
And the leather bench seat.
265
00:15:11,689 --> 00:15:14,758
After reupholstering
The original rear seat to match,
266
00:15:14,758 --> 00:15:16,758
They return it
To its original spot
267
00:15:16,758 --> 00:15:20,896
In the back of the limousine.
268
00:15:20,896 --> 00:15:22,758
A systems installer
269
00:15:22,758 --> 00:15:25,620
Connects the electrical systems
For the control center,
270
00:15:25,620 --> 00:15:27,724
Located
Behind the driver's seat.
271
00:15:27,724 --> 00:15:31,551
A panel lists relays and fuses.
272
00:15:31,551 --> 00:15:34,827
The original center console
Is then reinstalled.
273
00:15:36,413 --> 00:15:39,517
A worker installs
A video monitor
274
00:15:39,517 --> 00:15:41,000
In the limousine.
275
00:15:43,724 --> 00:15:46,620
Next, he rolls out
The floor mats.
276
00:15:46,620 --> 00:15:51,206
The acrylic disco bar
Lighting system is tested.
277
00:15:53,034 --> 00:15:55,206
In just 21 days,
278
00:15:55,206 --> 00:15:59,827
The original car is transformed
Into a luxurious limousine.
279
00:15:59,827 --> 00:16:03,344
With test drives and
Quality-control checks complete,
280
00:16:03,344 --> 00:16:06,724
Enjoy a ride
In the lap of luxury.
281
00:16:16,586 --> 00:16:17,793
Narrator: a hammer
282
00:16:17,793 --> 00:16:19,551
Is one of the most useful tools
Out there.
283
00:16:19,551 --> 00:16:22,896
The only problem is
You have to control the rebound.
284
00:16:22,896 --> 00:16:26,034
That is, unless you have
A dead blow hammer.
285
00:16:26,034 --> 00:16:28,896
These tools are accurate
And easy to use
286
00:16:28,896 --> 00:16:32,137
Because this particular type
Absorbs the bounce.
287
00:16:35,482 --> 00:16:38,931
This facility makes a variety
Of dead blow hammers.
288
00:16:38,931 --> 00:16:40,965
Some are soft-faced
289
00:16:40,965 --> 00:16:44,620
And some are ball-peens,
Which are used by machinists.
290
00:16:44,620 --> 00:16:46,344
All in all, they come in handy
291
00:16:46,344 --> 00:16:48,862
Everywhere
From nascar racetracks
292
00:16:48,862 --> 00:16:51,655
To operating rooms.
293
00:16:51,655 --> 00:16:55,827
To first create the internal
Structure of the hammer,
294
00:16:55,827 --> 00:16:59,034
They drill through a short
Length of welded steel tubing
295
00:16:59,034 --> 00:17:00,586
With a drill press.
296
00:17:00,586 --> 00:17:02,724
The worker drills
Straight through the tube,
297
00:17:02,724 --> 00:17:05,344
Creating a hole on both sides.
298
00:17:05,344 --> 00:17:08,862
This tube will become
The internal head of the hammer.
299
00:17:10,862 --> 00:17:12,896
The head needs a handle.
300
00:17:12,896 --> 00:17:16,310
A worker places the tube
On a jig
301
00:17:16,310 --> 00:17:18,344
And then positions a rod
On the hole.
302
00:17:18,344 --> 00:17:22,758
A press forces the rod
Through the tube.
303
00:17:22,758 --> 00:17:24,034
At the next station,
304
00:17:24,034 --> 00:17:26,241
A worker places
The internal hammer assemblage
305
00:17:26,241 --> 00:17:30,448
Behind a pane of tinted glass
To protect her eyes
306
00:17:30,448 --> 00:17:33,689
As she welds
The head and handle together.
307
00:17:33,689 --> 00:17:35,655
She only welds
The top of the tube
308
00:17:35,655 --> 00:17:37,172
So as not to alter the metal.
309
00:17:39,724 --> 00:17:44,413
A machine drills a set of small
Conical indents in the handle.
310
00:17:44,413 --> 00:17:46,965
Fitting a set of pins
Inside the mold,
311
00:17:46,965 --> 00:17:50,896
These indents will be crucial
To the process.
312
00:17:50,896 --> 00:17:54,000
Because the internal handle
Is round,
313
00:17:54,000 --> 00:17:56,413
The urethane exterior
Could twist on it
314
00:17:56,413 --> 00:17:58,172
When the hammer is being used.
315
00:17:58,172 --> 00:18:02,482
To prevent this,
A worker welds on a flat tab.
316
00:18:02,482 --> 00:18:06,206
The urethane will lock in place
Around the tab.
317
00:18:06,206 --> 00:18:09,448
Next, a worker crimps
A metal cap
318
00:18:09,448 --> 00:18:13,241
On one end of the tube.
319
00:18:13,241 --> 00:18:16,344
This creates an open canister,
320
00:18:16,344 --> 00:18:19,344
Which the worker partially fills
With a crucial ingredient --
321
00:18:19,344 --> 00:18:21,793
Hardened steel shot.
322
00:18:21,793 --> 00:18:24,379
He then crimps a cap
On the open end,
323
00:18:24,379 --> 00:18:26,379
Sealing in the shot.
324
00:18:26,379 --> 00:18:28,241
With the head canister done,
325
00:18:28,241 --> 00:18:31,896
The core of the dead blow hammer
Is now complete.
326
00:18:31,896 --> 00:18:34,275
While the basic components
Are simple,
327
00:18:34,275 --> 00:18:38,827
Workers must assemble
Every element with precision.
328
00:18:38,827 --> 00:18:41,655
The mold has
A set of pins inside it.
329
00:18:41,655 --> 00:18:43,896
A worker aligns the indents
On the metal handle
330
00:18:43,896 --> 00:18:45,103
With these pins.
331
00:18:45,103 --> 00:18:49,172
The pins ensure that
The internal hammer hangs
332
00:18:49,172 --> 00:18:52,931
In a perfectly centered position
Inside the mold.
333
00:18:52,931 --> 00:18:54,896
Workers secure the mold
In a support frame
334
00:18:54,896 --> 00:18:58,103
Before placing it on a conveyor
335
00:18:58,103 --> 00:19:01,551
That will take it through
A preheating oven.
336
00:19:02,896 --> 00:19:05,827
Ball-peen hammers
Are assembled differently.
337
00:19:05,827 --> 00:19:08,068
Instead of crimping a cap on,
338
00:19:08,068 --> 00:19:11,344
They screw the face of
The hammer onto a threaded tube.
339
00:19:11,344 --> 00:19:14,103
The metal core of the ball-peen
Is placed in a mold
340
00:19:14,103 --> 00:19:17,137
That leaves the metal face
And ball exposed.
341
00:19:19,448 --> 00:19:22,103
After the molds
Go through the preheater,
342
00:19:22,103 --> 00:19:24,551
They arrive
At the filling station.
343
00:19:24,551 --> 00:19:25,827
A high-speed mix head
344
00:19:25,827 --> 00:19:28,931
Blends urethane
With hardeners and catalysts
345
00:19:28,931 --> 00:19:32,034
And pumps the mix
Through a flexible hose.
346
00:19:32,034 --> 00:19:34,655
A worker uses the hose
347
00:19:34,655 --> 00:19:37,965
To fill the molds to the brim
With the orange fluid.
348
00:19:37,965 --> 00:19:39,758
She then sends them
Into the oven,
349
00:19:39,758 --> 00:19:42,586
Where they'll spend
30 minutes curing
350
00:19:42,586 --> 00:19:46,655
At about 300 degrees fahrenheit.
351
00:19:46,655 --> 00:19:48,793
On the other side of the oven,
352
00:19:48,793 --> 00:19:51,965
A worker removes the molds
From their frames
353
00:19:51,965 --> 00:19:54,931
And then releases
The newly formed hammers.
354
00:19:54,931 --> 00:19:56,827
Thanks
To a special release agent
355
00:19:56,827 --> 00:19:59,344
That was sprayed
Inside the mold,
356
00:19:59,344 --> 00:20:03,551
The hammers come out easily.
357
00:20:03,551 --> 00:20:05,551
At the finishing station,
358
00:20:05,551 --> 00:20:08,068
Workers use
A high-speed circular brush
359
00:20:08,068 --> 00:20:11,172
To remove the excess material,
Or flash,
360
00:20:11,172 --> 00:20:13,655
Produced by the molding process.
361
00:20:13,655 --> 00:20:15,689
This is
The most difficult operation
362
00:20:15,689 --> 00:20:17,689
In the making
Of dead blow hammers,
363
00:20:17,689 --> 00:20:20,965
And these workers
Are highly skilled.
364
00:20:23,482 --> 00:20:25,896
When molding ball-peen hammers,
365
00:20:25,896 --> 00:20:29,413
The front and back of the head
Are left exposed.
366
00:20:29,413 --> 00:20:33,482
For performance reasons,
This steel is not stainless.
367
00:20:33,482 --> 00:20:37,620
Workers dip the exposed steel
In hot wax.
368
00:20:37,620 --> 00:20:40,310
The wax coating will protect
The hammer from rust
369
00:20:40,310 --> 00:20:44,379
Until it's taken off
The store shelf and put to use.
370
00:20:44,379 --> 00:20:46,793
Soft-faced ball-peens
And sledges
371
00:20:46,793 --> 00:20:49,103
Are among the 20 models
Of dead blow hammers
372
00:20:49,103 --> 00:20:50,620
Manufactured here.
373
00:20:52,655 --> 00:20:54,655
A worker attaches a label
374
00:20:54,655 --> 00:20:58,379
Which includes all the relevant
Information and warnings.
375
00:20:58,379 --> 00:21:02,827
The labeled hammers then go
In a box ready for shipping.
376
00:21:02,827 --> 00:21:05,482
Dead blow hammers
Have many applications,
377
00:21:05,482 --> 00:21:07,793
From food processing plants
378
00:21:07,793 --> 00:21:10,482
To woodworking shops
To the oil industry.
379
00:21:10,482 --> 00:21:12,000
Some surgeons even use them
380
00:21:12,000 --> 00:21:14,655
To drive artificial hips
Into place.
381
00:21:20,551 --> 00:21:23,068
If you have any comments
About the show,
382
00:21:23,068 --> 00:21:25,517
Or you'd like to suggest
Topics for future shows,
383
00:21:25,517 --> 00:21:28,000
Drop us a line at...
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