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These are the user uploaded subtitles that are being translated: 1 00:00:01,896 --> 00:00:04,896 --captions by vitac-- Www.Vitac.Com 2 00:00:04,896 --> 00:00:07,896 Captions paid for by Discovery communications 3 00:00:52,689 --> 00:00:54,793 Narrator: The drive in your computer 4 00:00:54,793 --> 00:00:56,379 Saves and stores your data -- 5 00:00:56,379 --> 00:01:00,379 Everything from documents To photos to software programs. 6 00:01:00,379 --> 00:01:03,551 The newer generation drives Are solid state drives. 7 00:01:03,551 --> 00:01:07,275 They're gradually replacing Traditional hard disk drives 8 00:01:07,275 --> 00:01:10,000 Because they're compact, More durable, 9 00:01:10,000 --> 00:01:12,620 And process information Much faster. 10 00:01:12,620 --> 00:01:16,896 Just like portable usb drives And camera memory cards, 11 00:01:16,896 --> 00:01:19,965 Solid state drives Store information 12 00:01:19,965 --> 00:01:23,172 On several memory chips Installed on a circuit board. 13 00:01:23,172 --> 00:01:26,379 Each chip contains Highly complex circuitry 14 00:01:26,379 --> 00:01:28,655 Comprised of electrical pathways 15 00:01:28,655 --> 00:01:31,862 2,000 times narrower Than a human hair. 16 00:01:31,862 --> 00:01:34,241 To make those memory chips, 17 00:01:34,241 --> 00:01:37,275 They begin with A disk-shaped silicon wafer. 18 00:01:37,275 --> 00:01:40,413 Silicon is a non-metallic Natural element 19 00:01:40,413 --> 00:01:41,965 That conducts electricity. 20 00:01:41,965 --> 00:01:44,689 It's highly susceptible To contamination, 21 00:01:44,689 --> 00:01:47,517 So the production area Is virtually sterile 22 00:01:47,517 --> 00:01:50,413 To the point of being 1,000 times cleaner 23 00:01:50,413 --> 00:01:53,344 Than the air In a hospital operating room. 24 00:01:53,344 --> 00:01:55,137 An automated robotic system 25 00:01:55,137 --> 00:01:58,448 Moves the wafers through More than 800 operations, 26 00:01:58,448 --> 00:02:01,724 Which take more than a month To complete. 27 00:02:01,724 --> 00:02:05,172 Each wafer receives layer After layer of materials -- 28 00:02:05,172 --> 00:02:07,241 Some conductive, such as copper, 29 00:02:07,241 --> 00:02:10,620 Some nonconductive, Such as silicon dioxide. 30 00:02:10,620 --> 00:02:12,724 After applying each layer, 31 00:02:12,724 --> 00:02:16,482 The machine coats the wafer With a light-sensitive fluid 32 00:02:16,482 --> 00:02:18,724 Then flashes u.V. Light onto it 33 00:02:18,724 --> 00:02:22,758 Through a glass stencil of the Electrical circuitry pattern. 34 00:02:22,758 --> 00:02:26,137 In the areas where the fluid Is exposed to the light, 35 00:02:26,137 --> 00:02:28,448 The chemicals break down And dissolve. 36 00:02:28,448 --> 00:02:31,620 Where the fluid was shielded From light by the stencil, 37 00:02:31,620 --> 00:02:33,827 The materials remain intact, 38 00:02:33,827 --> 00:02:37,379 Effectively printing the Circuitry pattern on the wafer. 39 00:02:37,379 --> 00:02:41,689 Chemical baths then wash away The exposed fluid and material. 40 00:02:41,689 --> 00:02:45,000 Each foot-wide wafer Yields hundreds of microchips, 41 00:02:45,000 --> 00:02:47,620 Which now Have to be sliced apart. 42 00:02:47,620 --> 00:02:49,586 The robotic cutting machine 43 00:02:49,586 --> 00:02:52,448 Covers the wafer With an adhesive film 44 00:02:52,448 --> 00:02:54,068 To hold the chips in place 45 00:02:54,068 --> 00:02:56,896 While they're being cut loose From each other. 46 00:02:56,896 --> 00:02:59,551 The next machine Inserts each clip 47 00:02:59,551 --> 00:03:02,068 In a protective plastic housing. 48 00:03:03,931 --> 00:03:06,344 Meanwhile, Six circuit boards at a time 49 00:03:06,344 --> 00:03:07,758 Enter a machine 50 00:03:07,758 --> 00:03:10,827 Which applies a thin layer Of tin alloy solder paste 51 00:03:10,827 --> 00:03:12,206 Onto the areas 52 00:03:12,206 --> 00:03:15,586 Where the memory chips And other components will go. 53 00:03:15,586 --> 00:03:20,206 As the boards exit the machine, A robotic arm picks off 54 00:03:20,206 --> 00:03:24,103 The components required for Each drive from feeder spools 55 00:03:24,103 --> 00:03:25,586 And deposits them 56 00:03:25,586 --> 00:03:27,689 At their respective locations On the circuit board. 57 00:03:27,689 --> 00:03:31,586 This particular model Has 8 microchips, 58 00:03:31,586 --> 00:03:35,137 Each able to store 64 gigabytes of data, 59 00:03:35,137 --> 00:03:39,689 Giving the drive a capacity Of 5,012 gigs. 60 00:03:39,689 --> 00:03:42,620 The circuit boards now enter A tunnel-shaped oven 61 00:03:42,620 --> 00:03:44,344 Which melts the solder paste, 62 00:03:44,344 --> 00:03:46,758 Fusing the components To the board. 63 00:03:50,275 --> 00:03:52,068 The brain Of the solid state drive 64 00:03:52,068 --> 00:03:53,517 Is now complete 65 00:03:53,517 --> 00:03:56,965 And ready for the first phase Of quality-control testing. 66 00:03:56,965 --> 00:03:59,482 This machine Performs an optical scan 67 00:03:59,482 --> 00:04:02,379 To verify that every component On the board 68 00:04:02,379 --> 00:04:04,482 Is set in the right place. 69 00:04:10,137 --> 00:04:12,620 The next machine X-rays the board 70 00:04:12,620 --> 00:04:14,586 To verify that each component 71 00:04:14,586 --> 00:04:17,724 Is securely soldered In the correct location. 72 00:04:17,724 --> 00:04:19,896 A later phase Of quality-control testing 73 00:04:19,896 --> 00:04:22,344 Will verify The drive's performance. 74 00:04:22,344 --> 00:04:25,586 Until now, six circuit boards 75 00:04:25,586 --> 00:04:27,344 Have been attached To each other. 76 00:04:27,344 --> 00:04:30,034 An automated router Now cuts them apart, 77 00:04:30,034 --> 00:04:31,965 And workers insert each board 78 00:04:31,965 --> 00:04:34,586 Into a protective Plastic housing. 79 00:04:34,586 --> 00:04:36,655 A slot on the outside Of this housing 80 00:04:36,655 --> 00:04:38,172 Reveals the board's connector 81 00:04:38,172 --> 00:04:41,931 By which the drive links To the computer. 82 00:04:41,931 --> 00:04:45,931 Solid state drives Come in different sizes. 83 00:04:45,931 --> 00:04:48,000 This particular model Is large enough 84 00:04:48,000 --> 00:04:50,206 To replace A traditional hard disk drive. 85 00:04:50,206 --> 00:04:52,413 However, Many models are smaller, 86 00:04:52,413 --> 00:04:55,758 Designed to fit Where disk drives can't -- 87 00:04:55,758 --> 00:04:58,931 For example, In ultra-slim laptops. 88 00:04:58,931 --> 00:05:02,034 Every drive is labeled 89 00:05:02,034 --> 00:05:05,655 With its technical specs, model, And serial numbers and so on, 90 00:05:05,655 --> 00:05:08,344 Along with a barcode For production tracking. 91 00:05:10,206 --> 00:05:13,896 Then they plug the drive's Connector into a tester, 92 00:05:13,896 --> 00:05:15,172 Which, after verifying 93 00:05:15,172 --> 00:05:17,551 That everything Functions electronically, 94 00:05:17,551 --> 00:05:20,275 Installs the drive's Operating system. 95 00:05:20,275 --> 00:05:22,517 The drive moves To the next station, 96 00:05:22,517 --> 00:05:23,724 Where it undergoes 97 00:05:23,724 --> 00:05:26,724 Up to 60 hours of Extensive performance testing 98 00:05:26,724 --> 00:05:29,068 To ensure that it stores And retrieves data 99 00:05:29,068 --> 00:05:32,000 Correctly and at target speed. 100 00:05:33,862 --> 00:05:35,689 Packaging is twofold. 101 00:05:35,689 --> 00:05:37,103 First, a foil shield 102 00:05:37,103 --> 00:05:40,517 To prevent static electricity From damaging the drive, 103 00:05:40,517 --> 00:05:42,620 Then a carton, 104 00:05:42,620 --> 00:05:44,862 And finally into a shipping box 105 00:05:44,862 --> 00:05:48,724 Headed for a destination Somewhere around the world. 106 00:06:01,827 --> 00:06:03,241 Narrator: in ancient egypt, 107 00:06:03,241 --> 00:06:05,310 Both men and women Painted their eyes. 108 00:06:05,310 --> 00:06:07,137 It was thought that eye makeup 109 00:06:07,137 --> 00:06:09,758 Made one less vulnerable To the evil eye, 110 00:06:09,758 --> 00:06:12,655 A gaze or stare Meant to cause harm. 111 00:06:12,655 --> 00:06:15,068 Today, mostly women wear it. 112 00:06:15,068 --> 00:06:16,931 And of course, repelling evil 113 00:06:16,931 --> 00:06:19,586 Is no longer a reason To wear eye shadow. 114 00:06:22,931 --> 00:06:24,931 With a palette of eye shadow, 115 00:06:24,931 --> 00:06:27,931 A woman can work A certain kind of magic. 116 00:06:27,931 --> 00:06:31,034 Skillful shading can add depth And drama to the eyes. 117 00:06:31,034 --> 00:06:33,758 This makeup Can also create the illusion 118 00:06:33,758 --> 00:06:38,896 That the eyes are much larger Than they really are. 119 00:06:38,896 --> 00:06:43,793 To make eye shadow, They follow specific recipes. 120 00:06:43,793 --> 00:06:46,551 A technician Weighs the ingredients, 121 00:06:46,551 --> 00:06:50,586 Beginning with mica, A mineral that acts as filler. 122 00:06:50,586 --> 00:06:53,724 The next ingredient Is zinc stearate. 123 00:06:53,724 --> 00:06:55,068 It's a binder. 124 00:06:55,068 --> 00:06:59,275 A combination of pigments Provides the desired color. 125 00:06:59,275 --> 00:07:01,551 These particular pigments 126 00:07:01,551 --> 00:07:04,862 Are different shades Of the mineral iron oxide. 127 00:07:07,551 --> 00:07:10,448 He transfers The measured ingredients 128 00:07:10,448 --> 00:07:12,103 To a big blender jar. 129 00:07:12,103 --> 00:07:15,448 As he pours the ingredients, They dust up, 130 00:07:15,448 --> 00:07:18,206 And a gas mask keeps him From breathing in the particles. 131 00:07:18,206 --> 00:07:22,827 He places the jar On the blender base, 132 00:07:22,827 --> 00:07:27,586 Covers the top, And activates the blades. 133 00:07:29,275 --> 00:07:32,517 The blender mixes and grinds The powdered ingredients 134 00:07:32,517 --> 00:07:35,103 To a very fine state. 135 00:07:35,103 --> 00:07:38,586 Then it's into A very large mixer. 136 00:07:38,586 --> 00:07:40,551 He adds coconut oil -- 137 00:07:40,551 --> 00:07:42,862 Just enough For the powdered ingredients 138 00:07:42,862 --> 00:07:46,172 To eventually coagulate Into a cake form. 139 00:07:46,172 --> 00:07:48,586 More mica is next -- 140 00:07:48,586 --> 00:07:50,172 A lot more. 141 00:07:50,172 --> 00:07:52,931 Eye shadow is 80% mica. 142 00:07:52,931 --> 00:07:56,517 This mica is darker To add intensity to the color. 143 00:07:56,517 --> 00:07:58,620 It also has a bit of shimmer. 144 00:07:58,620 --> 00:08:01,896 He latches the lid To contain the ingredients 145 00:08:01,896 --> 00:08:04,827 And powers up This high-speed mixer. 146 00:08:04,827 --> 00:08:07,689 Inside, the mixing paddles 147 00:08:07,689 --> 00:08:09,758 Swivel around For about 15 minutes 148 00:08:09,758 --> 00:08:13,862 To thoroughly mix The ingredients. 149 00:08:13,862 --> 00:08:17,862 The eye shadow mixture Flows into a plastic bag. 150 00:08:17,862 --> 00:08:19,965 A technician examines it 151 00:08:19,965 --> 00:08:23,310 To confirm that the color Has been evenly dispersed 152 00:08:23,310 --> 00:08:25,379 And that the powder Is sufficiently moist. 153 00:08:25,379 --> 00:08:29,206 Another worker now pieces Four eye shadow tins 154 00:08:29,206 --> 00:08:32,965 In pods on a metal platter. 155 00:08:32,965 --> 00:08:36,793 The platter rotates to deliver The tins to a mixing dispenser 156 00:08:36,793 --> 00:08:39,620 That's been filled With the eye shadow ingredients. 157 00:08:39,620 --> 00:08:43,655 The mixer pushes precise amounts Through holes in the bottom 158 00:08:43,655 --> 00:08:45,103 And into the tins. 159 00:08:46,965 --> 00:08:49,551 A scraper levels off the tops. 160 00:08:54,758 --> 00:08:58,758 The next stop is a press With four circular heads. 161 00:08:58,758 --> 00:09:01,827 A ribbon of fabric Keeps things hygienic 162 00:09:01,827 --> 00:09:05,068 As the press compresses The moist eye shadow powder 163 00:09:05,068 --> 00:09:06,896 And turns it Into a cake-like form. 164 00:09:08,896 --> 00:09:12,379 Moving forward, The pods eject the tins, 165 00:09:12,379 --> 00:09:16,724 And an automated device Pulls them off the machine. 166 00:09:16,724 --> 00:09:19,620 What a difference The compression has made. 167 00:09:19,620 --> 00:09:21,517 No longer a loose powder, 168 00:09:21,517 --> 00:09:26,310 The eye shadow ingredients Have caked up nicely. 169 00:09:26,310 --> 00:09:28,241 The tins now move into a lane 170 00:09:28,241 --> 00:09:30,793 And come up against An abrasive belt 171 00:09:30,793 --> 00:09:33,448 That cleans the loose powder From the sides. 172 00:09:33,448 --> 00:09:37,413 A blast of air also gets rid Of some of the residual powder. 173 00:09:37,413 --> 00:09:41,241 For one out of every 100 Eye shadows produced, 174 00:09:41,241 --> 00:09:46,241 A technician does a drop test From a height of 18 inches. 175 00:09:46,241 --> 00:09:48,275 He checks For chipping or damage. 176 00:09:48,275 --> 00:09:52,517 And if he finds any, He'll add power to the press. 177 00:09:52,517 --> 00:09:54,482 For a color test, 178 00:09:54,482 --> 00:09:57,034 He brushes some eye shadow Onto his arm, 179 00:09:57,034 --> 00:09:59,482 Beginning with A laboratory standard. 180 00:10:02,896 --> 00:10:04,068 He then applies 181 00:10:04,068 --> 00:10:06,620 Newly manufactured eye shadow To his arm 182 00:10:06,620 --> 00:10:08,206 And compares the two. 183 00:10:08,206 --> 00:10:09,517 It's a match. 184 00:10:09,517 --> 00:10:11,000 And with his approval, 185 00:10:11,000 --> 00:10:13,448 The batch is almost ready For retail. 186 00:10:13,448 --> 00:10:15,827 Another worker inserts the tins 187 00:10:15,827 --> 00:10:19,034 Into more substantial Plastic containers 188 00:10:19,034 --> 00:10:22,000 With magnets on the bottom To secure them. 189 00:10:23,827 --> 00:10:26,517 She screws the clear caps Onto the jars, 190 00:10:26,517 --> 00:10:30,655 And the eye shadow is on its way To the cosmetic counter. 191 00:10:33,965 --> 00:10:37,793 They also manufacture Entire palettes of eye shadow 192 00:10:37,793 --> 00:10:39,551 For a rainbow of choices. 193 00:10:43,517 --> 00:10:47,586 It takes about a day To manufacture eye shadow. 194 00:10:49,655 --> 00:10:53,413 And the result is truly A thing of beauty. 195 00:11:09,551 --> 00:11:10,862 Narrator: The first stretch limousines, 196 00:11:10,862 --> 00:11:12,344 Built around 1928, 197 00:11:12,344 --> 00:11:16,310 Usually transported big bands And their musical equipment. 198 00:11:16,310 --> 00:11:19,793 Luxury sedans With an extended chassis 199 00:11:19,793 --> 00:11:22,689 Are typically associated With special occasions 200 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 202 00:11:33,275 --> 00:11:38,206 To transform a luxury sedan Into a stretch limo. 203 00:11:38,206 --> 00:11:43,413 Workers cut an ordinary-size car In half using cutting wheels. 204 00:11:43,413 --> 00:11:44,827 Before cutting begins, 205 00:11:44,827 --> 00:11:47,310 The inside of the car Is stripped away, 206 00:11:47,310 --> 00:11:48,965 Along with other components 207 00:11:48,965 --> 00:11:51,344 Such as the gas tank And drive shaft. 208 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 210 00:11:56,655 --> 00:11:59,000 With a reciprocating saw. 211 00:12:02,137 --> 00:12:07,620 The car is now Completely cut in half. 212 00:12:07,620 --> 00:12:09,724 Workers wheel The back half of the car 213 00:12:09,724 --> 00:12:12,000 Away from the front half. 214 00:12:14,689 --> 00:12:17,448 They place the back half On the exact spot 215 00:12:17,448 --> 00:12:22,275 Where the limousine Will gradually be assembled. 216 00:12:22,275 --> 00:12:24,724 The construction department Employees 217 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 221 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. 224 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, 227 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, 231 00:13:15,344 --> 00:13:19,448 And weld it to the frame rails And tunnel. 232 00:13:19,448 --> 00:13:24,206 They weld the steel roof rails Into place. 233 00:13:24,206 --> 00:13:26,517 They connect the new rails 234 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... 30161

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