All language subtitles for S25E01 - Grammy Awards; Bicycle Lights; Above-Ground Pools; Foldable Solar Panels (1080p AMZN WEB-DL x265 Garshasp)_track4_[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:
Today, on "How it's made"...
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In the music industry,
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Winning a grammy
Is the ultimate accolade.
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The national academy
Of recording arts and sciences
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Has been awarding grammys
For recording since 1958.
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Every year, the winners
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Are honored
With a golden gramophone trophy.
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The grammys are
To the music industry
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What the oscars are to movies.
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The coveted trophy
Is made of gold-plated grammium.
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But don't look for that metal
On the periodic table.
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It's a proprietary zinc alloy
Specially formulated
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And trademarked by the artisan
Who makes the grammys.
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To make the base of the trophy,
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They heat the grammium
To 644 degrees
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And pour it into a bronze mold.
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They immediately pour out
The excess molten metal.
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What remains quickly solidifies
In a thin layer
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Against the walls of the cavity,
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Creating a hollow cast.
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They also cast
The gramophone's cabinet
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And tone arm in grammium.
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They remove mold seams,
Excess metal,
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00:02:08,689 --> 00:02:11,206
And smooth out the surface
Of each cast component
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With a belt sander.
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Then, they file by hand
The areas the belt can't reach.
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00:02:29,655 --> 00:02:31,517
Finally, they polish the metal
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With an abrasive compound
On a buffing wheel.
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They make sure there are
No surface imperfections.
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Now, they work
On the gramophone's iconic horn.
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Using a metal shear,
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They cut a disc
Of malleable bronze.
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They mount the disc on a lathe.
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As the lathe spins,
They use a series of tools
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To transform the flat disc
Into a horn.
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Then, they spin the horn
On a different lathe,
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Pressing an abrasive cloth
Against the surface
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To remove any tool marks.
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Before they connect the tone arm
To the cabinet,
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They brush on some flux,
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A chemical that makes
The stationary solder flow
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Into the tiny gap
Between components.
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Now, they bolt the tone arm
To the cabinet, then solder.
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00:03:34,724 --> 00:03:36,758
They submerge this part
Of the trophy
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In a degreasing solution
For a few minutes,
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Then in water.
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Gold doesn't adhere to zinc,
So they plate it with copper.
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00:03:50,931 --> 00:03:54,241
They run a positive electric
Charge through the trophy
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And a negative charge
Through a piece of copper
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Also suspended
In the plating tank.
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This process
Dissolves the copper,
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Then draws the particles
Through the water
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And onto the trophy.
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They repeat the electroplating
Process in a different tank,
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This time with nickel.
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Nickel creates
A sufficiently hard base
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To support the gold plating.
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It also makes gold
Appear brighter.
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After another rinse,
It's back into a tank
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For the final plating
With 24-karat gold.
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To prepare the trophy's base
For painting,
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They smooth the surface
With a belt sander,
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Then fine-sand by hand.
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They spray on an epoxy primer,
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Let it dry for a day then
Wet sand it with fine sandpaper.
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They repeat these steps
With a black primer,
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Then paint the base
With high-gloss,
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Chip-resistant black paint.
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Once it dries, they can finish
Assembling the trophy.
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They bolt the polished
Gold-plated cabinet and tone arm
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To the painted base.
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00:05:12,068 --> 00:05:13,620
Then, they take the horn,
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Which has been gold-plated
And polished,
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And screw it into the tone arm.
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After 15 hours of craftsmanship,
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This grammy
Is ready to be awarded.
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But this trophy won't be handed
Out during the award show.
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The grammys handed out on stage
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Are actually props
That are used year after year.
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The winners
Receive a personalized trophy
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A few weeks after the show.
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The base has a brass plate
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Engraved with their name
And musical category.
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Narrator:
The first bicycle lights
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Were modified kerosene lamps
Fixed to the handlebars.
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The concept
Was truly trailblazing
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And made it possible
To cycle at night.
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A century later,
The technology has changed,
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But the concept
Remains the same.
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Bicycle lights
Are still showing us the way.
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These bicycle lights
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Are battery-powered with
Energy-efficient l.E.D. Lights.
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Mounted to handlebars
Or a helmet,
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They make it possible
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For a cyclist
To see and be seen at night.
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A bicycle light starts
With a design for the canister.
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In this case, it's for
A handlebar-mounted trail light.
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Following that plan,
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Computerized tools
Carve blocks of aluminum
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Into a two-part mold
For the bicycle light reflector.
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They secure the mold
In an injection molding machine.
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Then,
They load white acrylic pellets
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00:07:07,586 --> 00:07:10,827
Into the machine's hopper.
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The machine grinds
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00:07:12,379 --> 00:07:15,586
And melts the acrylic pellets
Into a thick liquid.
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00:07:15,586 --> 00:07:19,103
Then, it pushes the liquid
Into the crevices of the mold.
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The acrylic quickly solidifies
Into the shape of a reflector.
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An aluminum finish makes the
Acrylic shiny and reflective.
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Then, it's over to a different
Injection-molding machine.
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This one uses molten rubber
To form four on/off buttons.
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A worker sets an l.E.D.-studded
Circuit board on a switch
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Cradled in a fixture.
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She trims wires
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From the switch that protrudes
Through the board.
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She solders those wires
To copper pads on the board,
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Securing the switch and making
An electrical connection.
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She removes the assembly
From the fixture
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00:08:05,931 --> 00:08:08,862
And threads the battery cord
Through the board.
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She attaches the board
To a vented heat sink,
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Which will draw heat
Away from the lights,
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Allowing them to run
More efficiently.
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00:08:23,931 --> 00:08:27,827
She installs the reflector
Over the tiny l.E.D. Lights.
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The reflector
Will focus the light forward,
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Creating narrow beams.
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Another member of the team
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Places a tray of reflector
Covers in a laser etcher.
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00:08:43,689 --> 00:08:48,275
He closes the lid
And activates the laser.
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It etches through tape that's
Been applied to the metal.
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The tape has a blackening agent
On it.
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The laser transfers
That blackening agent
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To the etched number,
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Making it stand out.
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The number indicates
The lumen power of the light.
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Lumen is a measure of the total
Amount of visible light
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Emitted by a source.
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00:09:07,724 --> 00:09:09,275
Back on the assembly line,
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A worker snaps the cover
Onto the bike light.
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00:09:13,620 --> 00:09:17,000
Then, she attaches an open guard
To the heat sink
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To protect the cyclist
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From the heat generated
By the l.E.D.S.
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This bicycle light
Is ready to be put to the test.
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A technician turns it on
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00:09:27,310 --> 00:09:31,034
And inserts it in a device
Called a lumen sphere.
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00:09:31,034 --> 00:09:33,000
A computer analyzes the light
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And finds
That it meets standards.
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Next, an employee builds
A smaller bike light
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For a cyclist helmet.
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She inserts the l.E.D. Assembly
In a canister,
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00:09:46,103 --> 00:09:48,413
Then attaches the on/off button.
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She attaches the light
To a circuit board
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With three l.E.D.S.
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She tucks the circuit board
Into the housing
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00:09:59,793 --> 00:10:04,000
And inserts
A rechargeable lithium battery.
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00:10:04,000 --> 00:10:05,827
She puts the assembly aside
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00:10:05,827 --> 00:10:08,275
And attaches
A red reflective panel
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To an aluminized reflector.
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00:10:11,137 --> 00:10:14,206
She snaps the assembly
Into a clear plastic case,
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00:10:14,206 --> 00:10:16,517
Completing the rear light lens.
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00:10:18,827 --> 00:10:21,137
She returns
For the front helmet light
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And installs the reflector
Over the light.
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She screws on a glass cover
That's framed by a metal bezel.
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00:10:30,793 --> 00:10:32,310
She joins the rear lens
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And the l.E.D. Assembly,
Encasing the electronics
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Of this bike light.
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She switches on both lights
To confirm
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That they're fully operational.
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These bicycle lights are ready
To illuminate a rider's path,
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Whether it's
A shadowy mountain trail
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Or a dark city street.
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Narrator:
Installing a pool above ground
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Costs much less
Than installing one in ground.
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This is because there's
No excavation required.
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You can build an elevated deck
Around the top
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To give it
An in-ground appearance,
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Or you can simply climb
Up a ladder and jump right in.
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No hole to dig,
No underground pipes to install.
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00:11:32,137 --> 00:11:35,137
Just a day or so
Of on-site prep and assembly,
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And you can take
To your above-ground pool
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Like a duck to water.
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At the factory,
A computer-guided machine
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Cuts vinyl panels for the pool's
Water-retaining inside surface.
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00:11:47,931 --> 00:11:51,103
The vinyl comes in a wide choice
Of printed designs.
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It's tear-resistant,
U.V.-resistant,
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And is treated
With an antifungal coating.
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The wall panel is rectangular,
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00:11:59,448 --> 00:12:04,275
And the floor panels are curved
To fit the pool's perimeter.
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The wall panels go through
A welder that fuses a bead
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00:12:07,206 --> 00:12:10,172
To the top edge.
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00:12:10,172 --> 00:12:13,482
A bead is a flexible,
"U'-shaped, thermoplastic strip
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00:12:13,482 --> 00:12:16,827
That is used to attach
The pool wall to the liner.
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00:12:19,758 --> 00:12:22,448
A hot welding tool
Slightly melts both the bead
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00:12:22,448 --> 00:12:25,413
And the liner edge,
So when they cool and solidify,
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00:12:25,413 --> 00:12:27,137
They're bonded.
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00:12:29,413 --> 00:12:31,793
The liner is ready
To be assembled.
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00:12:31,793 --> 00:12:34,137
Workers use
A manual welding machine
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00:12:34,137 --> 00:12:38,310
That generates heat
With radio frequencies.
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00:12:38,310 --> 00:12:40,862
They overlap the edges
Of adjoining panels,
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00:12:40,862 --> 00:12:44,413
Then fuse them together.
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00:12:44,413 --> 00:12:46,793
After connecting
The floor panels to each other,
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00:12:46,793 --> 00:12:52,413
Workers complete the liner by
Joining the wall to the floor.
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00:12:52,413 --> 00:12:55,689
A quality-control inspector
Checks every soldered seam
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00:12:55,689 --> 00:12:57,551
To make sure they're solid.
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00:13:00,482 --> 00:13:02,724
Meanwhile, workers manufacture
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00:13:02,724 --> 00:13:05,931
The pool's
Structural components.
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00:13:05,931 --> 00:13:09,068
They feed a continuous strip
Of painted, galvanized steel
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00:13:09,068 --> 00:13:11,551
Through a roll former.
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00:13:11,551 --> 00:13:14,551
The strip is shaped
To a specific profile.
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00:13:17,068 --> 00:13:18,965
A punch press
Cuts the components
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00:13:18,965 --> 00:13:21,517
To the required length
And shape.
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00:13:21,517 --> 00:13:25,068
Four different structural
Components are made this way --
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00:13:25,068 --> 00:13:28,482
The pieces that form the top
And bottom tracks of the pool,
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00:13:28,482 --> 00:13:31,448
The vertical posts
That support the pool wall,
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00:13:31,448 --> 00:13:36,206
And the ledges running
Along the top of the wall.
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00:13:36,206 --> 00:13:40,068
The wall is also made
Of painted galvanized steel.
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00:13:40,068 --> 00:13:43,241
A roller impresses a corrugated
Pattern to give the wall
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00:13:43,241 --> 00:13:45,724
More vertical strength.
219
00:13:45,724 --> 00:13:47,586
Then, a press
Punches out openings
220
00:13:47,586 --> 00:13:51,517
For the pool's water inlet
And filter.
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00:13:51,517 --> 00:13:54,068
After folding each end
Of the wall over itself
222
00:13:54,068 --> 00:13:55,724
To form a strong edge,
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00:13:55,724 --> 00:13:59,275
They punch holes for the bolts
That will join the edges.
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00:14:01,689 --> 00:14:04,172
A stamping die
Progressively shapes strips
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00:14:04,172 --> 00:14:06,896
Of galvanized steel
Into connectors.
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00:14:06,896 --> 00:14:09,000
The connectors
Join the vertical posts
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00:14:09,000 --> 00:14:13,482
To the structure's bottom track
And top rail.
228
00:14:13,482 --> 00:14:14,758
An injection molder
229
00:14:14,758 --> 00:14:19,793
Makes the plastic covers
That will hide those connectors.
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00:14:19,793 --> 00:14:21,620
Workers then box the liner
231
00:14:21,620 --> 00:14:23,655
And structural components
For transport
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00:14:23,655 --> 00:14:25,482
To the installation site.
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00:14:28,965 --> 00:14:31,931
On-site, they lay crushed stone
Around the perimeter
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00:14:31,931 --> 00:14:35,034
To support the bottom track
Under the weight of the water.
235
00:14:42,206 --> 00:14:44,275
Next, they unroll the pool wall
236
00:14:44,275 --> 00:14:46,275
And place it
In the bottom track.
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00:14:56,206 --> 00:14:59,206
They place a vertical post
Over each bottom connector
238
00:14:59,206 --> 00:15:01,344
And secure it with screws.
239
00:15:03,379 --> 00:15:04,793
Inside the pool wall,
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00:15:04,793 --> 00:15:08,896
They lay down a base of sand
And compact it.
241
00:15:08,896 --> 00:15:13,310
Then, they
Lay down landscaping fabric.
242
00:15:13,310 --> 00:15:16,275
They cut a hole
For a central bottom drain.
243
00:15:19,310 --> 00:15:22,000
Then, they begin spreading
Out the liner.
244
00:15:25,827 --> 00:15:29,758
They hook the bead
Over the top edge of the wall,
245
00:15:29,758 --> 00:15:33,965
Then lock it in place
With the top rail.
246
00:15:33,965 --> 00:15:35,965
Once the liner
Is fully attached,
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00:15:35,965 --> 00:15:40,413
They suction out the air to draw
It tight against the wall.
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They seal the liner
To the bottom drain.
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They hide the top rail
Under the ledge
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And the connections
Under plastic caps.
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They run pipes to connect the
Filtration system and skimmer.
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Then, with an ordinary
Garden hose,
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They fill the pool with water.
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Narrator: foldable solar panels
Were invented in the 1990s
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For american soldiers
In the field.
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They use them
To recharge electronic devices.
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The panels have environmental
And tactical advantages,
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Conserving both electricity
And physical energy.
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00:16:36,068 --> 00:16:39,931
Today, foldable solar panels
Are not just for the military.
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These lightweight panels
Can be folded up
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And tucked into a backpack,
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Allowing anyone
To escape to the wilderness
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But stay plugged in.
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00:16:51,689 --> 00:16:55,000
Production starts with a roll
Of thin plastic film.
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It's the same material
Used to make flat-screen tvs.
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A worker loads it into machines
That distribute thin layers
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00:17:03,034 --> 00:17:05,793
Of aluminum and silicon onto it.
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00:17:08,034 --> 00:17:11,137
The aluminum acts
As an electrical contact.
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The silicon produces electricity
When exposed to the sun's rays.
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Next, lasers carve vertical and
Horizontal lines into the film.
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00:17:23,689 --> 00:17:26,724
These lines
Define the solar cells.
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An automated squeegee applies
Black ink through a screen
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And into the lines.
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The ink will act
As an electrical insulator.
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It also makes it possible
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To cut through the film
Without damaging it.
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00:17:43,965 --> 00:17:48,586
Uv light cures
The insulator ink.
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00:17:48,586 --> 00:17:52,068
An employee pours a generous
Amount of metallic silver ink
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Onto a pattern.
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00:17:53,689 --> 00:17:57,344
A squeegee forces the ink
Through to the solar film.
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This creates a conductive grid
On the film.
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A camera magnifies the grid
For inspection.
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The solar film travels
Through a chamber
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Where heat cures the silver ink.
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00:18:13,551 --> 00:18:16,137
A laser now
Connects the solar cells,
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00:18:16,137 --> 00:18:18,862
Linking the bottom aluminum
Layer of one cell
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00:18:18,862 --> 00:18:21,862
To the top silicon layer
Of the next.
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00:18:24,793 --> 00:18:27,137
The laser ties them together
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00:18:27,137 --> 00:18:30,448
Similar to
How a soldering tool would.
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This establishes
Electrical connections
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00:18:32,896 --> 00:18:37,413
And increases the voltage
Significantly.
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00:18:37,413 --> 00:18:39,793
A different camera
Magnifies the connections
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To check the alignment.
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00:18:42,620 --> 00:18:46,310
Now, a worker loads
The solar film into a machine.
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It deposits a transparent oxide
Onto the film
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That will increase conductivity.
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00:18:52,655 --> 00:18:55,551
These solar cells
Are now fully functional.
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The next machine tests each one.
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00:18:59,379 --> 00:19:04,965
It also applies a conductive
Foil tape at certain points.
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00:19:04,965 --> 00:19:07,482
Another machine
Rolls a clear sheet of plastic
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00:19:07,482 --> 00:19:10,827
Onto the solar cells.
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00:19:10,827 --> 00:19:13,068
The plastic adheres
To the cells,
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00:19:13,068 --> 00:19:16,793
Waterproofing
And encapsulating them.
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00:19:16,793 --> 00:19:18,862
A die press cuts
Out solar panels
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00:19:18,862 --> 00:19:22,241
Along the black insulator lines.
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00:19:22,241 --> 00:19:26,241
The press uses computerized
Cameras for accurate cuts.
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00:19:28,793 --> 00:19:31,689
A robot transfers each panel
To the next station
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00:19:31,689 --> 00:19:33,827
Using suctioning heads.
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00:19:33,827 --> 00:19:35,241
A computerized camera
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Scrutinizes the panels
For defects.
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After more testing,
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00:19:44,275 --> 00:19:48,862
They deposit the panels
On a piece of fabric.
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00:19:48,862 --> 00:19:53,206
A laser cuts the fabric
Around the panels.
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00:19:53,206 --> 00:19:56,758
Heated rollers bond the plastic
Panels to the fabric.
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00:20:00,724 --> 00:20:04,000
Now, an employee
Burns through clear plastic film
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00:20:04,000 --> 00:20:06,655
To reach the conductive foil.
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00:20:06,655 --> 00:20:08,344
He solders wire to the foil
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00:20:08,344 --> 00:20:12,000
At these points to connect
The positive and negative leads.
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00:20:14,758 --> 00:20:17,827
The wire is flexible
And will bend with the fabric
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00:20:17,827 --> 00:20:19,586
When it's folded.
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00:20:22,172 --> 00:20:24,655
A seamstress now
Stitches strips of fabric
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Over the wires, enclosing them
In a protective pocket.
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00:20:33,379 --> 00:20:35,689
Another member of the team
Solders a connector
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00:20:35,689 --> 00:20:41,379
To a circuit board that's been
Attached to protruding wires.
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00:20:41,379 --> 00:20:44,137
He squeezes silicone
Into a plastic cover
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00:20:44,137 --> 00:20:46,517
And places it on the assembly.
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00:20:46,517 --> 00:20:50,000
The silicone solidifies
Around the components to protect
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00:20:50,000 --> 00:20:52,620
Them from water damage.
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00:20:52,620 --> 00:20:57,344
Finally, he rivets the cover
To the fabric.
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00:20:57,344 --> 00:21:00,413
This foldable solar charger
Is ready to be bundled up
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00:21:00,413 --> 00:21:02,827
And placed in a backpack.
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00:21:02,827 --> 00:21:05,758
It can power a laptop
Or a smartphone,
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Keeping the user
Connected anywhere in the world.
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If you have any comments
About the show,
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00:21:21,827 --> 00:21:24,517
Or if you'd like to suggest
Topics for future shows,
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00:21:24,517 --> 00:21:26,413
Drop us a line at...
27019
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