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Narrator:
Today, on "How it's made"...
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Somewhere back in time,
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00:00:55,413 --> 00:00:58,206
Somebody was blowing on a fire
To get it started
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00:00:58,206 --> 00:01:00,000
And wondered if there
Were a way to do it
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00:01:00,000 --> 00:01:02,137
Without hyperventilating.
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A lot of people
Must have had this idea
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00:01:04,379 --> 00:01:06,000
Because different
Kinds of bellows
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00:01:06,000 --> 00:01:10,448
Can be found across the ancient
World from egypt to asia.
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00:01:13,586 --> 00:01:16,000
In the auvergne region
Of central france,
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This manufacturer
Has been building
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Classic fireplace bellows
Since 1895
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00:01:21,448 --> 00:01:26,000
Using high-quality beechwood
And leather sourced nearby.
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00:01:26,000 --> 00:01:28,137
An artisan starts
By selecting a template
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00:01:28,137 --> 00:01:30,724
From a range
Of sizes and shapes.
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00:01:30,724 --> 00:01:33,241
He traces an outline
On a piece of wood.
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00:01:35,379 --> 00:01:38,793
He uses a band saw to cut
The rough outline of the shape
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00:01:38,793 --> 00:01:40,655
To prepare for the next step.
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00:01:43,344 --> 00:01:46,862
A craftsman then places a stack
Of three rough-cut shapes
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00:01:46,862 --> 00:01:51,724
On top of a master prototype
And clamps the stack in place.
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00:01:51,724 --> 00:01:55,068
A large bearing slides up
Against the master prototype
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And, by following it,
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Guides a specialized
Cutting tool
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Around the perimeter
Of the stack.
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00:02:01,862 --> 00:02:03,172
The operation quickly
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00:02:03,172 --> 00:02:05,931
And precisely reduces
The three pieces of wood
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00:02:05,931 --> 00:02:08,413
To exactly the required
Dimensions.
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00:02:13,724 --> 00:02:15,689
This purpose-built mechanism
Undertakes
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00:02:15,689 --> 00:02:18,172
A three-step operation.
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00:02:18,172 --> 00:02:20,862
A drill pierces a hole
In the narrow end
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00:02:20,862 --> 00:02:25,241
While a second drill opens
Three holes underneath.
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A circular saw quickly
Slices partway
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Through the neck of the piece.
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A craftsman then uses
A rotary tool
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00:02:33,965 --> 00:02:36,896
To easily cut a decorative
Pattern of concentric circles
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00:02:36,896 --> 00:02:38,689
Into one side of the wood.
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00:02:41,655 --> 00:02:44,758
A cutting blade positioned
At precisely the right height
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Allows an artisan to slice
A beveled groove partway
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Around the perimeter of the wood
To the required depth.
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00:02:55,103 --> 00:02:57,827
A craftsman uses
A powerful band saw
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00:02:57,827 --> 00:03:00,689
To divide the wood in half
Along the groove line
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00:03:00,689 --> 00:03:03,448
All the way up to the cut
Across the neck.
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00:03:09,413 --> 00:03:13,034
The wooden components are now
Ready for the finished process.
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An artisan dunks the components
In a tub of stain
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And places them
On a shelf to dry.
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She keeps each pair
Of components together
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While separating them
Slightly to ensure
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They don't stick together.
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Once the stain has dried,
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The artisan buffs the outer
Surfaces of the components
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On a buffing wheel
To make the wood smooth.
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She then carefully positions
The components on a table
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And sprays them thoroughly with
A protective layer of varnish.
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Once the varnish has cured,
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A craftsperson
Can begin assembly
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00:03:57,655 --> 00:04:00,689
By creating the valve
That covers the intake hole.
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00:04:03,344 --> 00:04:05,758
She installs a rounded
Length of wire,
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00:04:05,758 --> 00:04:09,034
Stapling it in such a way
As to create enough tension
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For the wire to act as a spring.
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00:04:11,413 --> 00:04:14,413
This step completes
The interior of the bellows.
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00:04:19,689 --> 00:04:24,655
An artisan can now bring the two
Halves of the bellows together.
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She starts by wrapping
A precut piece
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Of locally sourced sheep's
Leather around one handle
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And attaching the leather
In place with small nails.
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Carefully hammering a series of
Closely-spaced upholstery tacks
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At regular intervals
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Secures the leather
To the perimeter edge
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Of one half of the bellows.
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00:04:48,241 --> 00:04:50,896
The artisan can now
Attach the second half
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By repeating the operation on
The other side of the leather.
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00:04:55,379 --> 00:04:58,000
Adding a thin strip of leather
Along the tack line
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Will help prevent
Any ripping or tearing.
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The artisan uses a section of
Precut leather to form the hinge
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00:05:09,965 --> 00:05:13,862
Necessary for the proper
Functioning of the bellows.
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00:05:13,862 --> 00:05:17,724
The size, position, and tack
Pattern must all be precise
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00:05:17,724 --> 00:05:21,655
In order for the tool to open
And close smoothly and easily.
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The artisan trims off
Any excess lengths of leather.
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Finally,
She installs the nozzle.
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Making a dent with a tool
Called a punch prepares the site
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For a nail which secures
The nozzle in place.
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The completed bellows
Function perfectly.
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This simple, finely crafted tool
Is built to help start
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Warm fires for years to come.
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Narrator: calissons are
A traditional french candy
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Made of almonds, candied melon,
And orange peel
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Topped with a thin layer of
Hard, typically white, icing.
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Calissons are the specialty
Of the city of aix-en-provence
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In the provence region
Of southern france.
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The calisson was created in
France in the mid-15th century
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In honor of the wedding
Of king rene of anjou
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And queen jeanne of laval.
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The confection became
The specialty of provence,
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The region of southern france
Known for its almond orchards.
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Inside the greenish hull
Is a hard shell.
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Inside that shell is
The edible almond seed.
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The almonds arrive at the
Workshop dried for conservation
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And their brown skin removed.
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The first step in the production
Is to rehydrate the almonds
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With steam for about 10 minutes
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So that they can be
Worked into a paste.
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Once the almonds'
Moisture content
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Is increased by 2 to 4%,
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The almonds pass over
A vibrating screen
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To drain any water resulting
From steam condensation.
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Meanwhile, this cauldron
Heats up liquid beet sugar.
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France is one of the world's
Largest sugar beet producers,
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So high-quality beet sugar
Is readily available.
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Workers transfer the hydrated
Almonds to a grinder
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And add candied fruit --
95% melon and 5% orange peel.
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This flavor is the 500-year-old
Traditional recipe.
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Workers grind the ingredients
For about 10 minutes
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Until everything is thoroughly
Blended into a coarse paste.
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The paste drops
Onto a conveyor belt,
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Which transfers it
To a kneading machine
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Into which workers add
The hot liquid beet sugar
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And natural almond oil
Made from bitter almonds.
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Kneading blends the ingredients
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And smoothes the texture
Of the paste.
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A worker boxes
The calisson paste
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00:08:08,000 --> 00:08:10,241
And sets it aside for three days
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To let the sugar
Mature and stabilize.
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Calissons are topped with
An ever-so-thin layer
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Of royal icing.
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Unlike creamy icings,
Royal icing is as hard as a rock
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To make it, a worker
Combines icing sugar
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And whipped egg whites
Passed through a strainer.
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A mixer beats the ingredients
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Until the mixture
Is thick and smooth,
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Which typically takes
About 10 minutes.
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After 3 days of rest,
The paste is ready to be worked.
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00:08:52,413 --> 00:08:56,793
Shaping and decorating the
Calissons is a specialized task
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Entrusted to these
Experienced artisans
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Called "Calissonaires."
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First, they place slices
Of paste in a press
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And load a mold underneath.
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They cover the mold with a wafer
-thin sheet of unleavened bread.
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Then, the press piston descends,
Forcing the paste,
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With the bread layer underneath,
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Into the mold.
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They skim off the excess paste,
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Then fold the stencil
Over the mold
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And apply the layer
Of royal icing.
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They lift off the stencil
And push the buttons
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Which activate the mold pistons.
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Each piston pierces
The base of a calisson
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And lifts it out of the mold.
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Finally, they remove
The calissons with combs
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Designed to fit
Around the pistons.
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A 10-minute trip
Through a tunnel oven
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Set at low temperature
Bakes the royal icing
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To a hard and shiny state.
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Cameras record the position
Of the calissons
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As they exit the oven,
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00:10:04,793 --> 00:10:08,310
Guiding a robotic arm
To pick up 160 per minute
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00:10:08,310 --> 00:10:11,413
And place them in plastic trays.
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The next machine seals each tray
With plastic film
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To preserve freshness.
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There's also a gift box format
For which a worker hand-fills
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Plastic trays
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Designed to fit
Lozenge-shaped metal boxes.
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These traditional calissons
Contain a candied fruit content
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Of at least 30%,
The melon being a variety
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Cultivated
In the region of provence.
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However, if your taste buds are
The type that buck tradition,
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Today,
You can enjoy a wide selection
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Of other fashionable flavors
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Such as clementine
And cocoa bean
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Or raspberry
And matcha green tea.
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00:11:01,965 --> 00:11:04,827
Narrator: this new generation
Of personal watercraft
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Is something entirely different.
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It does more
Than skim the surface.
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This watercraft dives underwater
And can remain submerged
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At a depth of three feet
Or more for up to a minute.
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It also leaps into the air
And rolls with the waves.
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00:11:23,068 --> 00:11:27,172
This watercraft is painted to
Look like a vintage fighter jet,
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00:11:27,172 --> 00:11:31,103
And it rolls and dives
Like one in the water.
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A worker sprays a gel coat
Into a mold for the main body.
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This gel will become
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The shiny surface of
The completed fiberglass part.
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00:11:40,137 --> 00:11:42,103
Once the gel coat has hardened,
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A worker brushes a vinyl
Ester resin onto it.
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This resin is known
For its water resistance.
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He switches from a brush
To a roller
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As he generally
Applies the resin
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To the hardened gel coat.
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The crew then drapes
What's called chopped-strand mat
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Over the mold.
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This fabric is made of long
Strands of fiberglass.
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The binder in it dissolves
On contact with the resin,
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00:12:06,758 --> 00:12:10,379
Causing the fabric to soften
To the contours of the mold.
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00:12:10,379 --> 00:12:12,793
After trimming
The excess material,
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00:12:12,793 --> 00:12:16,931
The crew completely saturates
The strand mat with more resin.
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00:12:16,931 --> 00:12:20,965
Rolling it on firmly
Gets rid of air bubbles.
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00:12:20,965 --> 00:12:22,965
The top half of the main
Body mold
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Has been lined the same way.
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They now bolt a dorsal fin
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Mold to the back
On the top half of the mold.
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00:12:37,551 --> 00:12:40,655
The crew now joins
The two halves of the mold.
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As a crane lowers the top
To the bottom,
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00:12:46,827 --> 00:12:49,482
Workers ensure
They line up perfectly.
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00:12:49,482 --> 00:12:54,275
And they lock these two
Main molds together with bolts.
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A worker enters through
The cockpit
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Opening to roll on more resin.
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Meanwhile, another member
Of the crew
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00:13:06,344 --> 00:13:08,413
Pulls two sheets
Of fiberglass fabric
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00:13:08,413 --> 00:13:10,482
Onto a cutting machine.
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00:13:10,482 --> 00:13:14,034
The top fabric is a strong,
Tightly woven fiberglass,
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00:13:14,034 --> 00:13:17,931
And the bottom one
Is the chopped-strand mat.
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00:13:17,931 --> 00:13:20,931
Automated blades cut
The fiberglass to various shapes
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00:13:20,931 --> 00:13:22,172
And dimensions,
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Each one designed
For a different part
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00:13:24,034 --> 00:13:28,034
Of the diving vessel mold.
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These large rectangles
Will be used to mold
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00:13:30,206 --> 00:13:32,896
The sides of the watercraft.
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00:13:32,896 --> 00:13:34,689
After folding up the pieces,
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00:13:34,689 --> 00:13:38,034
The worker hands them over
To the fiberglass technician.
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00:13:40,103 --> 00:13:43,241
The technician has just an hour
To apply the fiberglass
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00:13:43,241 --> 00:13:46,655
Before the recently applied
Resin starts to harden.
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00:13:46,655 --> 00:13:48,344
He builds up eight layers
219
00:13:48,344 --> 00:13:53,068
And completely saturates
Each one with more resin.
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00:13:53,068 --> 00:13:56,862
While the thicker fiberglass
Material provides strength,
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00:13:56,862 --> 00:13:59,620
The thinner chopped-strand mat
Aids adhesion
222
00:13:59,620 --> 00:14:04,241
And helps the fabrics
Conform to the mold.
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00:14:04,241 --> 00:14:10,965
After a 3-hour cure, workers
Have a solid, seamless fuselage.
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00:14:10,965 --> 00:14:13,758
The crane lifts the fuselage
Out of the mold
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00:14:13,758 --> 00:14:16,241
And moves it onto a dolly
Where it will stay
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00:14:16,241 --> 00:14:19,172
While the team works on the
Other parts of the watercraft.
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00:14:23,379 --> 00:14:26,689
The cone-shaped front
Bumper is next.
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00:14:26,689 --> 00:14:30,103
The worker uses only three
Layers of fiberglass to make it
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00:14:30,103 --> 00:14:32,172
Because this bumper is meant
To collapse
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00:14:32,172 --> 00:14:34,965
In the event of a collision.
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00:14:34,965 --> 00:14:37,172
For that reason,
The part is also known
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00:14:37,172 --> 00:14:39,862
As the vessel's
Sacrificial nose.
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At another station,
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00:14:46,172 --> 00:14:49,517
Crew members line
Fin-shaped molds with fiberglass
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00:14:49,517 --> 00:14:52,655
And then pour liquefied
Plastic into the cavity.
236
00:14:52,655 --> 00:14:55,896
Once cured, the plastic will
Anchor the top of a steel
237
00:14:55,896 --> 00:14:57,758
Wing shaft in the fin.
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00:14:57,758 --> 00:15:00,034
A worker presses the shaft
Into the liquefied
239
00:15:00,034 --> 00:15:01,620
Plastic with the end
240
00:15:01,620 --> 00:15:04,448
Protruding from the fin.
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00:15:04,448 --> 00:15:07,137
A second mold,
Also lined with fiberglass
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00:15:07,137 --> 00:15:10,758
And filled with a plastic core,
Goes on top.
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00:15:10,758 --> 00:15:14,931
The team bolts it together
And leaves the part to cure.
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00:15:14,931 --> 00:15:17,275
The fins will ultimately
Be supported
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00:15:17,275 --> 00:15:18,896
By a triangular scaffold
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00:15:18,896 --> 00:15:21,241
Made of aluminum square tubing.
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00:15:21,241 --> 00:15:24,655
The worker clamps the scaffold
Framework to a worktable
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00:15:24,655 --> 00:15:28,000
To stabilize the framework
As he welds it together.
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00:15:28,000 --> 00:15:31,724
He then welds the scaffold
Tower to the base.
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00:15:31,724 --> 00:15:34,413
The worker drills holes for
The bushings that will be used
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00:15:34,413 --> 00:15:36,724
To attach the fins
To the scaffold.
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Stay tuned for more
As the team prepares
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This personal diving watercraft
For its maiden voyage.
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Narrator:
This personal watercraft leaps,
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00:16:04,344 --> 00:16:06,965
Dives, and barrel-rolls
With the waves.
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00:16:06,965 --> 00:16:09,241
But it doesn't capsize.
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00:16:09,241 --> 00:16:10,758
It's been engineered to return
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00:16:10,758 --> 00:16:13,137
To an upright
Position in the water.
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00:16:13,137 --> 00:16:16,379
And when it comes to the fun
Factor, this diving watercraft
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00:16:16,379 --> 00:16:19,000
Leaves other recreational boats
In its wake.
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00:16:23,000 --> 00:16:25,793
To make the diving watercraft's
Passenger cabin,
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00:16:25,793 --> 00:16:28,103
A worker sprays a gel coat
Onto a form
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00:16:28,103 --> 00:16:30,758
And covers it with fiberglass.
264
00:16:30,758 --> 00:16:34,827
A computer-driven router then
Carves into marine-grade plywood
265
00:16:34,827 --> 00:16:38,206
To produce structural backing
For the sides of the cockpit.
266
00:16:41,172 --> 00:16:44,379
A worker slathers adhesive putty
Onto the plywood part
267
00:16:44,379 --> 00:16:47,482
And applies more adhesive
To the fiberglass cockpit.
268
00:16:50,241 --> 00:16:54,034
He presses the plywood to
The glued areas of the cockpit
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00:16:54,034 --> 00:16:56,793
And brushes resin onto
The front of the plywood.
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00:16:59,724 --> 00:17:02,379
After cutting the cockpit
Section in two,
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00:17:02,379 --> 00:17:06,103
The crew glues the parts
To the inside of the fuselage.
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00:17:08,275 --> 00:17:11,137
The fabricating team
Applies adhesive putty
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00:17:11,137 --> 00:17:14,482
To the cone-shaped bumper
Known as the sacrificial nose.
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00:17:17,137 --> 00:17:20,344
They slide it onto the front
Of the fuselage
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00:17:20,344 --> 00:17:22,931
And the screw the bumper
In place temporarily
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00:17:22,931 --> 00:17:24,724
While the adhesive sets.
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00:17:27,896 --> 00:17:30,206
Another worker sands
All the fiberglass parts
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00:17:30,206 --> 00:17:33,827
Of the watercraft
To remove bumps and blemishes.
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00:17:33,827 --> 00:17:36,000
This piece is the engine hatch.
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00:17:38,034 --> 00:17:39,931
The team bolts
The aluminum scaffold
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00:17:39,931 --> 00:17:41,793
To the floor of the fuselage.
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00:17:41,793 --> 00:17:43,793
This is a test fit to confirm
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00:17:43,793 --> 00:17:46,137
That the dimensions
Are exactly right.
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00:17:50,137 --> 00:17:53,379
As they installed the scaffold,
The used dummy wing shafts
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00:17:53,379 --> 00:17:56,758
To correctly position it
Within the vessel.
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00:17:56,758 --> 00:17:58,827
They confirm that the
Dimensions are right
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00:17:58,827 --> 00:18:03,758
And that the scaffold sits plumb
To the base of the watercraft.
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00:18:03,758 --> 00:18:05,620
The next team inserts
The hatch frame
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00:18:05,620 --> 00:18:08,103
And the rim around the cockpit.
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00:18:08,103 --> 00:18:11,275
They'll bond the frame in place
Later with a liquid plastic
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00:18:11,275 --> 00:18:14,034
And adhesive putty.
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00:18:14,034 --> 00:18:17,103
After priming the sanded
Surface of the watercraft,
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00:18:17,103 --> 00:18:19,689
Team members lower
The 300-horsepower engine
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00:18:19,689 --> 00:18:21,172
Into the hatch.
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00:18:21,172 --> 00:18:25,206
This is a dry fit to confirm
Everything lines up correctly.
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00:18:25,206 --> 00:18:27,034
They'll eventually
Remove the engine
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00:18:27,034 --> 00:18:31,344
For the final paint
And artwork.
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00:18:31,344 --> 00:18:34,448
As the dry fit continues,
They connect the air tubes
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00:18:34,448 --> 00:18:37,551
To the snorkel fins
That deliver air to the engine.
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00:18:44,862 --> 00:18:47,862
The engine hatch has, by now,
Also been primed,
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00:18:47,862 --> 00:18:51,137
And they fit it to the diving
Watercraft's main body.
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00:18:51,137 --> 00:18:53,931
The crew verifies that
The hatch sits flush
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00:18:53,931 --> 00:18:55,965
With the rest of the fuselage.
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00:18:58,034 --> 00:19:00,620
A worker installs the exhaust
Outlet into the hole
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00:19:00,620 --> 00:19:04,137
At the rear of the watercraft.
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00:19:04,137 --> 00:19:07,896
Crew members slide elevator
Fins into bushings at the back.
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00:19:07,896 --> 00:19:12,896
These fins will control the
Pitch axis of the watercraft.
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00:19:12,896 --> 00:19:15,862
Next, they install
The jet propulsion system.
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00:19:18,862 --> 00:19:20,241
Back to the cockpit,
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00:19:20,241 --> 00:19:23,241
The crew bolts the control
Pedals to the floor
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00:19:23,241 --> 00:19:25,620
And run cables
To the jet propulsion unit,
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00:19:25,620 --> 00:19:28,000
The elevator fins,
And the steering system.
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00:19:31,482 --> 00:19:33,551
They reinstall
The dive fin scaffold,
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00:19:33,551 --> 00:19:36,034
Which has been powder coated
In a yellow color.
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00:19:38,758 --> 00:19:41,724
The crew connects
The dive fins to the scaffold.
316
00:19:41,724 --> 00:19:45,482
They situate the control panel
Just above the control pedals.
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00:19:47,896 --> 00:19:49,965
They run a metal linkage
From the dive fins
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00:19:49,965 --> 00:19:52,482
To a control stick.
319
00:19:55,724 --> 00:19:58,724
They then test the control stick
And confirm it moves
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00:19:58,724 --> 00:20:01,448
The dive planes easily
And correctly.
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00:20:04,137 --> 00:20:07,034
Bucket seats made
Of lightweight carbon fiber
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00:20:07,034 --> 00:20:09,241
Minimize the load
For added speed.
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00:20:12,034 --> 00:20:14,344
They tuck a rubber gasket
Into the framework
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00:20:14,344 --> 00:20:19,137
For the clear canopy that will
Surround the occupants.
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00:20:19,137 --> 00:20:20,379
They add a bead of sealant
326
00:20:20,379 --> 00:20:22,793
Where the gasket mates
To the window frame.
327
00:20:25,034 --> 00:20:29,344
The vessel canopy is made
Of thick aircraft-grade acrylic.
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00:20:29,344 --> 00:20:31,827
It's been tinted
To repel the sun's rays
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00:20:31,827 --> 00:20:35,931
And keep the temperature cooler
In the cockpit.
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00:20:35,931 --> 00:20:41,068
The back canopy serves as a
Hatch for accessing the cockpit.
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00:20:41,068 --> 00:20:43,896
Finally, an artist
Does a custom paint job
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00:20:43,896 --> 00:20:46,275
And makes the fuselage
Look fierce.
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00:20:50,000 --> 00:20:52,448
With the mechanical
Components reinstalled,
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00:20:52,448 --> 00:20:57,241
This diving watercraft
Is ready to hit the water.
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00:20:57,241 --> 00:21:00,862
Fasten your seatbelt.
It should be quite a ride.
27733
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