All language subtitles for S25E07 - Handcrafted Skis; Septic Tanks; Hydroformed Chassis Parts; Aquarium Windows (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:
You can buy mass-produced skis
From a large company,
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Or you could choose
To purchase a handcrafted set
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From a small independent.
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It's a matter of preference --
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Much like drinking beer
Produced by a major brewery
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Versus a microbrewery.
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In fact, many ski-buying guides
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Call small, independent brands
Microbrews.
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Handmade skis typically feature
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Exclusive designs
With high-end craftsmanship.
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They're produced
In limited quantities
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By small, independent companies.
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This maker
Builds the core of the ski
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From two types of wood --
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Colorado aspen
And colorado pine.
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They're harvested from trees
Killed by pine beetles.
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Workers glue together
8 to 10 pieces,
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Depending on
The width of the ski.
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The pieces form
A laminated block
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That's structurally stronger
Than a solid piece of wood.
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They clamp the block in a press
For two hours
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While the glue dries.
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After they remove the block
From the press,
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They use a band saw
To cut off strips.
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Each strip will be
The core of a ski.
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One block typically
Makes six ski cores.
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Next, they shape the ski cores
With a router,
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Using a template
Underneath the ski contour.
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They apply a blowtorch
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To strips of ultra-high
Molecular-weight plastic
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To make it bondable.
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00:02:25,793 --> 00:02:28,655
Then they coat the plastic
With epoxy
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And adhere a strip of it
To each side of the ski core.
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This forms a sturdy sidewall
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To protect the core
From side impact.
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After the epoxy sets,
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They saw 6 inches off
The front and back of the ski.
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With a hand planer, they taper
The thickness of the ends.
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Then they heat the sidewalls
Again to prep them for bonding.
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But first, workers glue a
Plastic core called a tipspacer
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To the front of the wood core.
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This holds the parts together
During construction.
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00:03:16,103 --> 00:03:18,068
Then they use
A hand-crank die machine
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To die-cut
The brand name and logo
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Into a strip of ultra-high
Molecular-weight plastic.
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They die-cut the same letters
In white,
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Then place them
In the black cutout strip.
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This is the ski's base.
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00:03:37,206 --> 00:03:40,551
Now they can begin
Constructing the skis.
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They take a left and right base
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And spread epoxy
Over the entire surface.
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They lay down a layer
Of epoxy-saturated fiberglass
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And position the ski core
On top.
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00:03:52,448 --> 00:03:56,827
Then they spread epoxy
On the core and tipspacers,
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As well as lay extra fiberglass
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Where the bindings
Will be installed.
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They position steel plates
For mounting the bindings,
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Then cover the entire ski with
Another layer of fiberglass.
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Finally,
They add a nylon top sheet
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Printed with a graphic design.
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They cover the assembly
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With a series of metal sheets
And silicone heating blankets,
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Then place everything
In a custom-design ski press.
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When workers activate the press,
Rubber air bladders inflate,
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Pressing the wood
Into a ski shape.
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35 minutes later,
The skis come out of the press.
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A worker separates them
With a band saw.
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Using a jigsaw,
They trim the tip and tail.
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The saw leaves a rough edge,
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So workers
Sand the entire perimeter.
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00:05:07,551 --> 00:05:10,896
Then they taper
And bevel the sidewall.
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00:05:10,896 --> 00:05:14,137
This gives the skis
A better edge grip on snow.
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The final step
Is to peel off the film
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That has been protecting
The nylon top
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Throughout construction.
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These handmade skis
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Come in several different
Styles, shapes, and sizes.
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All they need now are bindings.
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Then it's all downhill
From here.
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Narrator:
Septic tanks are the perfect
Sewage-treatment solution
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For houses that aren't
Connected to a sewage network.
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The tank collects and treats
Domestic wastewater
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Using a bacterial process
To decompose waste.
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It filters the dirty water
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Before recycling it
Back into the ground.
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Septic tanks
Are usually made of concrete
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00:06:26,724 --> 00:06:30,068
And have access covers on top.
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The waste-treatment process
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Takes place in separate chambers
Inside the tank.
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Steel bars called rebars
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Reinforce the concrete structure
Of the tank.
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A welder assembles the rods
To form a cage.
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Then he spot-welds the rebar
With a mig welding torch.
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The welded cage will maintain
The structural integrity
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Of the concrete septic tank.
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00:07:04,275 --> 00:07:06,827
The welder
Measures the cage's diagonals
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00:07:06,827 --> 00:07:10,137
To make sure it's straight.
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Next, the worker
Places rebar spacers
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To keep the cage centered
In the mold
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And leveled on the floor.
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A crane lowers the cage
Into a custom formwork
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Made of
High-strength steel plates.
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Workers close the walls
Around the form
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And secure them in place
With heavy-duty locks.
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The crane lowers
Machined steel cores
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To form the interior walls
Of the tank chambers.
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A rigid plastic tube is inserted
Inside a rubber sleeve
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00:07:49,241 --> 00:07:53,724
To create a flow hole
Between chambers.
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Using an acetylene torch,
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A worker cuts holes in the rebar
For access openings.
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The mold allows concrete
To flow over the rebar
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And embed the access-opening
Covers in the septic-tank lid.
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Workers pour over 1,300 gallons
Of wet concrete into the mold.
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They use a stick vibrator
To eliminate air pockets
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And level the walls
With a putty knife.
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Next, they mix more concrete
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And pour it over
The top-slab rebar.
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Concrete blocks are used
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To keep the plastic covers from
Floating in the wet concrete.
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00:08:57,034 --> 00:09:00,068
While one worker
Pours the concrete in the mold,
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The other consolidates the
Mixture with a vibrating stick.
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00:09:04,137 --> 00:09:08,034
Then a worker levels the top
Of the slab with a trowel.
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00:09:11,137 --> 00:09:15,413
Once the concrete tank is cured,
Workers strip the forms.
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They remove the concrete tank
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00:09:21,000 --> 00:09:24,275
Using an overhead crane
And a compressed-air system,
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Which forces the mold
Away from the concrete tank.
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The crane takes the stripped
Core away for cleanup.
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A worker brushes
The top of the walls
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And sweeps the floor
Inside the tank.
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Then he applies
A butyl-rubber tape
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Around the top
Of the exterior wall.
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This forms a watertight seal
Between the tank and the lid.
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00:09:58,931 --> 00:10:02,034
An overhead crane lifts
The lid out of the formwork
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00:10:02,034 --> 00:10:06,000
And brings it to the tank mold.
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00:10:06,000 --> 00:10:09,448
The crane slowly
Lowers the lid onto the tank.
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Workers keep it aligned
To make sure it seals properly.
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00:10:16,586 --> 00:10:19,758
Then they label the tank
To indicate its capacity.
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00:10:22,448 --> 00:10:24,482
Next, the mold is opened,
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Revealing
A finished septic tank.
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The rubber sleeve
Molded into the wall
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Ensures a watertight connection
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00:10:31,241 --> 00:10:36,000
Between the pipe carrying waste
From the home and the tank.
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00:10:36,000 --> 00:10:38,896
This tank is now ready
For delivery.
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00:10:42,620 --> 00:10:45,379
They set the tank in the ground
At the client's home
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00:10:45,379 --> 00:10:48,827
Using a radio-remote-controlled
Knuckle-boom crane.
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A septic tank like this will
Provide a three-bedroom house
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With a fully independent
Sewage system.
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Narrator: building a vehicle
Begins with the chassis.
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Chassis used to be
Made out of welded-steel parts
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That were very heavy
And lowered fuel efficiency.
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00:11:21,241 --> 00:11:25,310
But thanks to a manufacturing
Process called hydroforming,
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00:11:25,310 --> 00:11:28,551
Steel chassis parts are
Now much lighter and stronger.
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00:11:30,482 --> 00:11:33,275
Years ago,
This suspension-system component
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Would have been made
By stamping a number of parts
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Out of heavy steel,
Then welding them together.
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00:11:41,379 --> 00:11:43,517
But today, the same component
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00:11:43,517 --> 00:11:47,137
Is made out of a single steel
Tube at a hydroforming plant.
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A solid tube is stronger
Than welded parts,
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Allowing the component
To be made out of lighter steel.
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The first step
Is to insert the steel tube
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00:11:57,068 --> 00:12:00,965
In a computer-guided machine
Called a rotary draw bender.
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The machine inserts a mandrel
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To prevent the tube walls
From collapsing.
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00:12:08,586 --> 00:12:12,034
Then it bends the tube into
A starting shape for the part.
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00:12:17,448 --> 00:12:19,965
This operation
May look effortless,
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00:12:19,965 --> 00:12:22,275
But the machine's hydraulics
Must generate
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00:12:22,275 --> 00:12:26,000
Nearly 9 tons of pressure
To bend the steel.
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00:12:28,517 --> 00:12:33,517
After several bends,
The part has its starting shape.
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The hydroforming process begins
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00:12:48,068 --> 00:12:51,034
When a robot
Places the tube in a press
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For preliminary shaping.
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This is called preforming.
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The press forces the tube
Against a die
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00:12:58,034 --> 00:13:00,689
To prepare it
For the hydroforming mold.
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Here's the tube
Before preforming...
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00:13:08,206 --> 00:13:10,379
And after.
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Next, a robot places
The steel tube in a part mold
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That's already mounted
On the hydroforming press.
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The machine
Fills the tube with water
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00:13:19,103 --> 00:13:22,586
And seals the ends
To trap the liquid inside.
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00:13:22,586 --> 00:13:24,689
Then the machine closes the mold
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00:13:24,689 --> 00:13:28,448
And raises the water pressure
To 20,000 p.S.I. --
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00:13:28,448 --> 00:13:32,448
More than 600 times
The air pressure in a car tire.
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00:13:32,448 --> 00:13:35,241
The high pressure
Softens the steel tube,
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00:13:35,241 --> 00:13:40,000
Allowing it to conform
To the shape of the mold cavity.
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00:13:40,000 --> 00:13:42,586
When the press opens,
A robot removes
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00:13:42,586 --> 00:13:45,379
The now-fully-formed part
From the mold.
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00:13:45,379 --> 00:13:47,931
The hydroforming press
Even punched holes in it
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00:13:47,931 --> 00:13:51,000
For screws and bolts.
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00:13:51,000 --> 00:13:54,724
Next, a robot transfers the part
To a circular saw,
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00:13:54,724 --> 00:13:56,551
Which cuts the component
In half.
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00:13:56,551 --> 00:14:01,724
This creates mirror-image
Right and left suspension parts.
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00:14:05,482 --> 00:14:08,724
The saw left sharp edges
On the ends of the part,
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00:14:08,724 --> 00:14:13,241
So a worker smoothes them out
With a handheld grinder.
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00:14:13,241 --> 00:14:16,206
Then they inspect the parts
By putting them
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00:14:16,206 --> 00:14:19,793
In a specially designed
Dimension-verification fixture.
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00:14:19,793 --> 00:14:23,103
They use tools
Called precise-diameter spheres
200
00:14:23,103 --> 00:14:25,586
To make sure
The clearances between each part
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00:14:25,586 --> 00:14:27,310
Meet specifications.
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00:14:29,482 --> 00:14:31,379
If the parts pass inspection,
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00:14:31,379 --> 00:14:33,137
They're shipped
To the assembly plant.
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00:14:36,206 --> 00:14:38,862
There, workers position
These parts
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00:14:38,862 --> 00:14:43,172
And adjacent suspension parts
In an assembly jig.
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00:14:43,172 --> 00:14:46,000
An automated machine
Welds them together.
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00:14:52,448 --> 00:14:54,724
Then a worker
Positions the next part
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00:14:54,724 --> 00:14:57,482
And welds it
To the rear-suspension unit.
209
00:14:57,482 --> 00:15:01,758
He repeats this process until
The entire assembly is complete.
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00:15:05,310 --> 00:15:08,275
To make the suspension unit
Corrosion-resistant,
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00:15:08,275 --> 00:15:10,206
They apply a chemical coating
212
00:15:10,206 --> 00:15:13,482
Which is bonded to the steel
With an electrical charge.
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00:15:15,517 --> 00:15:17,448
Once the coating dries,
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00:15:17,448 --> 00:15:19,620
Automated machines
Insert bushings
215
00:15:19,620 --> 00:15:22,620
For parts that will be installed
On the suspension later.
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00:15:22,620 --> 00:15:25,931
Bushings are
Rubber or polyurethane pieces
217
00:15:25,931 --> 00:15:28,413
That go in between
Two metal components
218
00:15:28,413 --> 00:15:31,896
To absorb shock
And reduce noise.
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00:15:31,896 --> 00:15:34,689
Workers put
The finished rear suspension
220
00:15:34,689 --> 00:15:39,103
Into a shipping cradle
For delivery to the auto plant.
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00:15:39,103 --> 00:15:41,655
At the plant,
Assembly-line workers
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00:15:41,655 --> 00:15:44,172
Install springs
And shock absorbers.
223
00:15:44,172 --> 00:15:47,793
They also mount struts,
Wheels, and brakes.
224
00:15:47,793 --> 00:15:51,586
Then they install
The entire unit on the vehicle.
225
00:15:51,586 --> 00:15:55,103
Hydroforming allows
Auto manufacturers
226
00:15:55,103 --> 00:15:57,482
The ability
To produce chassis parts
227
00:15:57,482 --> 00:15:59,344
In shapes impossible to achieve
228
00:15:59,344 --> 00:16:01,827
By the older method
Of stamping steel
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00:16:01,827 --> 00:16:04,551
And reduces
The weight of the car.
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00:16:18,482 --> 00:16:22,793
Narrator:
Acrylic aquarium windows
Are designed to be transparent.
231
00:16:22,793 --> 00:16:25,103
But they also need to be
Virtually indestructible
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00:16:25,103 --> 00:16:29,172
And able to hold back several
Hundred gallons of water.
233
00:16:29,172 --> 00:16:32,344
Some of the largest ones are
Built to withstand repeated hits
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00:16:32,344 --> 00:16:34,551
From sharks or other big fish
235
00:16:34,551 --> 00:16:37,137
That are swimming around
Inside the tank.
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00:16:40,724 --> 00:16:42,344
Acrylic aquarium windows
237
00:16:42,344 --> 00:16:45,379
Can be molded into
Different shapes and sizes.
238
00:16:45,379 --> 00:16:48,413
They can also be made
To various thicknesses.
239
00:16:48,413 --> 00:16:50,896
Round, flat,
Or just slightly curved,
240
00:16:50,896 --> 00:16:53,655
These windows
Are worth looking into,
241
00:16:53,655 --> 00:16:57,965
Because they offer close-up
Views of aquatic ecosystems.
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00:17:01,620 --> 00:17:05,689
Each acrylic window starts
With an engineer's design.
243
00:17:05,689 --> 00:17:09,068
He takes into account
The anticipated water volume
244
00:17:09,068 --> 00:17:12,448
And the type of marine life
To be housed in the tank.
245
00:17:12,448 --> 00:17:16,068
Next, a technician measures
Specific amounts of chemicals
246
00:17:16,068 --> 00:17:17,862
To be added to the acrylic.
247
00:17:17,862 --> 00:17:19,655
Two are strengthening agents
248
00:17:19,655 --> 00:17:22,206
And another
Is a u.V.-light stabilizer
249
00:17:22,206 --> 00:17:25,482
To counteract the damaging
Effects of the sun's rays.
250
00:17:27,965 --> 00:17:30,724
After the chemicals have been
Mixed with the binding agent,
251
00:17:30,724 --> 00:17:33,827
They add them
To a small amount of acrylic.
252
00:17:33,827 --> 00:17:35,275
This premix will be added
253
00:17:35,275 --> 00:17:38,620
To a much larger amount
Of acrylic later.
254
00:17:38,620 --> 00:17:39,965
They blend in some dye
255
00:17:39,965 --> 00:17:43,413
To offset the yellowish tone
That's common in acrylic.
256
00:17:43,413 --> 00:17:46,103
The result
Is a homogenous mixture
257
00:17:46,103 --> 00:17:48,379
With a syrupy consistency.
258
00:17:50,827 --> 00:17:52,034
Using a crane,
259
00:17:52,034 --> 00:17:54,965
They bring two halves
Of a steel mold together
260
00:17:54,965 --> 00:17:56,758
And place them on supports.
261
00:17:59,862 --> 00:18:02,206
Once the walls of the mold
Are in place,
262
00:18:02,206 --> 00:18:05,620
They lock them together
With bolts.
263
00:18:05,620 --> 00:18:08,241
The final acrylic mixture
Is ready.
264
00:18:08,241 --> 00:18:11,482
It now flows
Into the mold cavity.
265
00:18:11,482 --> 00:18:14,379
A thermostat for heat coils
Located in the walls
266
00:18:14,379 --> 00:18:15,931
Is activated.
267
00:18:15,931 --> 00:18:19,241
They roll the mold
Into an autoclave.
268
00:18:19,241 --> 00:18:21,724
The acrylic
Slowly bakes under pressure
269
00:18:21,724 --> 00:18:24,103
To ensure a consistent cure.
270
00:18:27,793 --> 00:18:29,172
It takes five days
271
00:18:29,172 --> 00:18:32,275
For the acrylic
To turn into a solid slab.
272
00:18:32,275 --> 00:18:36,344
An employee monitors
The temperature readings daily.
273
00:18:36,344 --> 00:18:38,379
Once the acrylic cures,
274
00:18:38,379 --> 00:18:40,172
They slice a piece off
And bend it
275
00:18:40,172 --> 00:18:42,724
With a hydraulic tool
Until it breaks.
276
00:18:42,724 --> 00:18:44,379
If the piece can withstand
277
00:18:44,379 --> 00:18:47,689
14,000 pounds per square inch
Without breaking,
278
00:18:47,689 --> 00:18:50,379
It passes the test.
279
00:18:50,379 --> 00:18:54,793
At another station, they test
The elasticity of the acrylic.
280
00:18:54,793 --> 00:18:56,482
They do
A few more compression tests
281
00:18:56,482 --> 00:19:00,000
To prove that the acrylic holds
Strong under heavy pressure.
282
00:19:04,620 --> 00:19:09,172
After testing, they're ready
To cut the acrylic slab.
283
00:19:09,172 --> 00:19:12,689
Acrylic shrinks unevenly
During the curing process,
284
00:19:12,689 --> 00:19:13,896
So they need to cut it
285
00:19:13,896 --> 00:19:16,724
To the desired size and shape
Afterwards.
286
00:19:19,172 --> 00:19:21,448
As you can see, aquarium windows
287
00:19:21,448 --> 00:19:24,068
Are a lot thicker
Than normal windows.
288
00:19:26,000 --> 00:19:28,344
To make
A contoured aquarium window,
289
00:19:28,344 --> 00:19:32,275
They lower a flat acrylic slab
Onto a curved molding bed.
290
00:19:32,275 --> 00:19:35,517
Then they heat it in an oven
For up to a month.
291
00:19:35,517 --> 00:19:37,862
This causes the acrylic
To soften
292
00:19:37,862 --> 00:19:41,275
And conform to the rounded shape
Of the molding bed.
293
00:19:50,448 --> 00:19:53,586
Once again,
They've made the slab oversized
294
00:19:53,586 --> 00:19:55,724
To account for the distortion
And shrinkage
295
00:19:55,724 --> 00:19:59,241
That can occur
During the curing process.
296
00:19:59,241 --> 00:20:04,310
A worker cuts the curved slab to
The engineer's specifications.
297
00:20:08,793 --> 00:20:11,137
He cuts off big chunks.
298
00:20:11,137 --> 00:20:15,965
They're so heavy that it takes
Three people to carry them away.
299
00:20:18,206 --> 00:20:21,724
They test the optical clarity
Of each window.
300
00:20:21,724 --> 00:20:25,827
To do this, a worker
On one side of the window
301
00:20:25,827 --> 00:20:27,827
Moves a grid pattern around
302
00:20:27,827 --> 00:20:29,793
While a worker on the other side
303
00:20:29,793 --> 00:20:32,620
Scrutinizes the grid lines
For distortion.
304
00:20:34,655 --> 00:20:38,862
Satisfied that the aquarium
Window offers a clear view,
305
00:20:38,862 --> 00:20:41,482
They clean and polish it
Thoroughly.
306
00:20:44,103 --> 00:20:47,931
They'll do a final clean after
The window is installed on-site.
307
00:20:56,827 --> 00:21:00,137
The time it takes to manufacture
An aquarium window
308
00:21:00,137 --> 00:21:02,862
Depends on
The complexity of its design
309
00:21:02,862 --> 00:21:04,655
And the window's thickness.
310
00:21:04,655 --> 00:21:08,068
Some can be produced
In as little as four weeks.
311
00:21:08,068 --> 00:21:09,931
No matter how long it takes,
312
00:21:09,931 --> 00:21:13,482
There's no doubt that the views
Will be well worth the wait.
313
00:21:23,689 --> 00:21:26,206
If you have any comments
About the show,
314
00:21:26,206 --> 00:21:28,896
Or if you'd like to suggest
Topics for future shows,
315
00:21:28,896 --> 00:21:30,965
Drop us a line at...
25742
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