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Narrator:
Today on "How it's made"...
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Steel safes...
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False teeth...
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00:00:30,310 --> 00:00:32,482
Airplanes...
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00:00:32,482 --> 00:00:35,137
And maple syrup.
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00:00:38,793 --> 00:00:40,379
The first bank safes
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Were made of wood reinforced
With sheet iron.
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Thieves would just
Smash them open.
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00:00:45,827 --> 00:00:48,034
Then came safes
Made of solid iron.
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Thieves would just blow them up.
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00:00:50,172 --> 00:00:53,965
But then, to the crooks' dismay,
Came safes made of steel.
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00:00:58,482 --> 00:01:01,758
It all starts with sheets
Of solid steel
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00:01:01,758 --> 00:01:03,965
Up to 1 1/2 inches thick
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00:01:03,965 --> 00:01:08,862
And an automated machine with
An oxygen-and-gas-fueled flame.
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The flame slowly cuts
The plates
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That will form the walls
Of the safe.
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The cutting creates gases
That are doused with water.
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A welder with a manual version
Of the same flame
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Frees up the plates
With a few last cuts.
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Then, using a large magnet,
They stack the plates.
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Each one is labeled
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So the workers will know
In what order to assemble them.
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They're assembled by a welder
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Who uses a machine called
A mig welder.
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The welding wire is made
Of several different metals.
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It rolls off a spool as needed.
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Elsewhere in the factory,
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A semiautomatic saw cuts
Flat bars of steel.
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These bars will form the frame
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That will surround
The steel plates.
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Meanwhile, another machine,
Called a turret,
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Fashions steel bars
Into moving parts
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For the locking mechanism
And also into hinges.
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That milky liquid
Is a lubricant.
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Normally, you see raw material
Move on an assembly line
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From tool to tool.
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This is just the opposite.
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The steel bar stays on
The turret from start to finish.
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The tools come and go.
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Workers take pieces of sheet
Metal cut into shapes by laser
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And bend them in a press to make
Various parts and mechanisms.
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Meanwhile, the large steel
Plates they cut earlier
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Go into a hydraulic press
To make them perfectly flat.
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It's finally time to put
All the components together.
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They construct the frame
In an assembly jig,
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Then insert the plates
For the sides, top, and bottom.
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Using the mig welder again,
They fuse the pieces together.
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They measure the angles,
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Then use a giant clamp
To square the safe.
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Finally, they install the plate
For the back of the safe
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And weld the joints.
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They stand the safe upright
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And grind down the welding lines
Until they're smooth.
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This factory also produces
What's called a composite safe,
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Made of soft materials
Such as copper, aluminum,
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And low-grade steel.
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But it has a cement core,
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Making this safe
Harder to break in to.
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The finished safe gets
Three coats of paint.
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00:05:01,206 --> 00:05:02,965
Then, in the finishing
Department,
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They install the mechanical
Or electronic locks
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And locking mechanisms,
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As well as the internal
Time-lock mechanism.
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The time lock allows access
To the safe
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Only at certain times of day,
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Such as a bank's business hours.
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Even if someone picks
The outside combination locks,
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The door won't open
Outside those set hours.
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Narrator: the machines that
Sterilize medical instruments
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Use ethylene oxide,
A highly toxic gas.
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Now there's a new method
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That's safer, more effective,
And less expensive.
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This new machine uses ozone
As the sterilizing agent.
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00:05:48,586 --> 00:05:51,448
Ozone is a form of oxygen.
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00:05:56,379 --> 00:06:01,103
Until the 1800s, false teeth
Were made of animal bone, ivory,
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00:06:01,103 --> 00:06:03,172
Or actual human teeth.
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They came from poor people,
Who sold their teeth,
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And from dead bodies.
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Today's dentures
Are usually ceramic.
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They start by heating
A sheet of wax over a flame.
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They press it
Onto a rough plaster model
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Of the patient's mouth,
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Sent in by the dentist.
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The lab technicians use
This model
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To prepare what's called
An impression tray,
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What the dentist will use
To make a rubber mold
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To cast the dentures.
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They apply an acrylic material
Over the wax lining,
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Forming a handle so they'll be
Able to remove it afterwards.
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Once the acrylic hardens,
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They pull it out of the model
And discard the wax.
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The dentist fills this
New acrylic tray with rubber
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To take a final impression.
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The lab uses the hardened rubber
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As a negative mold
Of the patient's mouth.
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They fill it with plaster
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00:07:01,620 --> 00:07:04,724
To make a new,
More precise plaster model.
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Then they use the new model
To make the part of the dentures
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That fits on top
Of the patient's gums.
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They take special
Orthodontic acrylic
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And press it into the model
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To form what's called
The baseplate.
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Then they heat a sheet of wax
To form a rim on the base.
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This new acrylic-and-wax model
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Now goes back for another
Fitting in the patient's mouth.
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The dentist takes a series
Of measurements
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To show the lab exactly
Where to place the teeth.
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00:07:35,896 --> 00:07:37,896
The model goes back to the lab,
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Where technicians select
The teeth
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That'll best suit the size
Of the patient's mouth.
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They install the teeth one by
One into the model's wax rim.
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Then they send the model
Back to the dentist
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For the final fitting.
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The dentist checks
That everything is centered
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And that the patient's bite
Is properly aligned.
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If the model fits well
And looks good,
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The lab can finally begin
To manufacture the dentures.
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They position the model in
A special holder called a flask,
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Then attach channels
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Through which acrylic
Will later be injected.
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This acrylic will replace the
Wax holding the teeth in place.
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But first,
To get rid of the wax,
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They have to cast a plaster mold
To hold the teeth in place.
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00:08:49,310 --> 00:08:50,620
Once the plaster dries,
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They submerge it in hot water
For five minutes
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To melt the wax inside.
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00:09:01,103 --> 00:09:04,137
They rinse the plaster mold
With warm water
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00:09:04,137 --> 00:09:06,034
To remove any wax residues.
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00:09:06,034 --> 00:09:08,655
Then they apply what's called
A separator,
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00:09:08,655 --> 00:09:10,758
A chemical
That will keep the acrylic
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From sticking
To the plaster mold --
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Just like greasing the pan
When you're baking.
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They position a cylinder of
Acrylic right over the flask.
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Using an air-pressure piston,
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They force the acrylic
Into the plaster mold.
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They submerge the mold in
Boiling water for 35 minutes
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To harden the acrylic.
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Once the flask has cooled down,
They break the plaster.
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The false teeth are now securely
Rooted in acrylic gums.
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00:09:48,931 --> 00:09:51,827
A bit of finishing,
And they'll be done.
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00:10:05,344 --> 00:10:09,793
An ultrasonic bath gets rid
Of any remaining plaster.
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00:10:13,137 --> 00:10:15,448
They polish the acrylic
With pumice,
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Then shine it up
With a polishing compound.
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The set of false teeth
Is finally ready.
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00:10:28,275 --> 00:10:31,000
When a patient doesn't need
A full set of dentures,
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00:10:31,000 --> 00:10:32,172
Just a few teeth,
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They get what's called
A partial --
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Made much the same way,
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But hooked on at either end
To the patient's natural teeth.
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Narrator: aviation was once
The exclusive domain
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Of commercial
And military pilots.
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Not anymore.
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Today many amateurs get
Their pilot's license
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And take to the skies
In light aircraft
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00:11:01,655 --> 00:11:05,206
Not for a job, but for the sheer
Pleasure of flying.
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To construct the body
Of these light aircraft,
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00:11:12,000 --> 00:11:14,344
They start
With two types of cloth,
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One woven from glass fibers --
Fiberglass --
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The other from carbon fibers.
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00:11:19,862 --> 00:11:23,586
Carbon is a chemical element
That's stronger than steel.
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Both materials go through
A laminating machine
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That coats them
With an epoxy resin.
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00:11:36,241 --> 00:11:40,275
To begin forming the various
Parts that make up the body,
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00:11:40,275 --> 00:11:44,068
Workers lay strips of
The laminated fabric into molds.
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The engineering plans dictate
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00:11:46,137 --> 00:11:49,000
The precise positioning
Of the strips,
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Which is critical
For strength and durability.
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They lay in carbon-fiber cloth
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Where they need to have
Extra strength
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Without additional weight,
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Areas such as this --
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The passenger compartment
Of the cockpit.
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To make the fuselage,
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They sandwich a foam core
Less than 1/2 inch thick
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00:12:07,793 --> 00:12:10,965
Between two layers
Of the fiberglass cloth.
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00:12:10,965 --> 00:12:15,482
The foam also insulates
Against heat, cold, and noise.
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00:12:17,379 --> 00:12:20,482
Workers coat the edges
And joints with resin,
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Filling any voids.
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00:12:25,000 --> 00:12:27,793
Once all the fabric
Is in the mold,
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00:12:27,793 --> 00:12:29,827
It's time to vacuum-bag it.
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00:12:29,827 --> 00:12:32,000
First, they cover everything
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With a layer
Of perforated plastic,
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00:12:34,827 --> 00:12:36,620
Then with a breather cloth,
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Which looks like
A white wool blanket.
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00:12:39,241 --> 00:12:42,103
Then comes another layer
Of plastic.
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They attach a vacuum
To suck out all the air.
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The excess resin exits through
The tiny holes in the plastic
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And soaks
Into the breather cloth.
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00:13:01,206 --> 00:13:05,310
Now that the mold is airtight,
It can begin to cure.
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00:13:05,310 --> 00:13:09,793
They put it into an oven at
40 degrees celsius for 8 hours.
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Once the molds come
Out of the oven,
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00:13:11,931 --> 00:13:14,793
Workers install
The internal structure.
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Then, using the same epoxy resin
They used earlier
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To laminate the fiberglass
And carbon-fiber fabrics,
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00:13:21,758 --> 00:13:25,275
They bond the tail's upper
And lower shells together.
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00:13:25,275 --> 00:13:27,413
They do the same
With the wings.
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00:13:27,413 --> 00:13:29,827
The parts are left to cure
Overnight.
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00:13:29,827 --> 00:13:33,275
The next day, they finally come
Out of the molds.
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00:13:33,275 --> 00:13:35,413
Next stop, the trim shop.
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00:13:35,413 --> 00:13:37,758
Workers remove
The excess fiberglass
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And cut out the windows.
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00:13:55,448 --> 00:13:58,827
The parts go back
For a final curing.
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00:13:58,827 --> 00:14:02,689
The oven is around 175 degrees.
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00:14:04,965 --> 00:14:08,482
18 hours later,
Out they come for painting.
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00:14:08,482 --> 00:14:12,862
Workers sand the parts and coat
Them with an epoxy primer.
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00:14:12,862 --> 00:14:14,965
The finish coat is polyurethane,
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00:14:14,965 --> 00:14:18,103
Which resists weathering.
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00:14:18,103 --> 00:14:20,344
Meanwhile,
Other workers assemble
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00:14:20,344 --> 00:14:22,103
And test various components,
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Such as the electrical system.
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00:14:25,344 --> 00:14:28,620
A computer guides a machine
To cut all the metal parts,
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00:14:28,620 --> 00:14:30,379
Such as the instrument panel.
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00:14:30,379 --> 00:14:32,206
The cutting machine
Doesn't have a blade,
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00:14:32,206 --> 00:14:34,758
But rather a sand-and-water jet
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00:14:34,758 --> 00:14:38,068
That's powerful enough
To cut through metal.
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00:14:46,758 --> 00:14:50,310
A certified aircraft welder
Prepares the engine mount,
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00:14:50,310 --> 00:14:52,896
The base that will hold
The engine in place.
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00:14:52,896 --> 00:14:55,793
It's made
Of high-grade carbon steel.
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00:14:57,137 --> 00:15:00,620
At the final assembly stage,
Workers install the engine
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00:15:00,620 --> 00:15:04,758
And other previously assembled
Components into the fuselage.
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00:15:04,758 --> 00:15:08,137
Workers position the wiring
And plumbing,
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00:15:08,137 --> 00:15:09,724
Then hook them up.
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00:15:09,724 --> 00:15:11,482
They screw on the wing tips,
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00:15:11,482 --> 00:15:14,379
Which already have
Their navigational lights.
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00:15:14,379 --> 00:15:19,103
An avionics technician powers up
The airplane for the first time
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00:15:19,103 --> 00:15:21,827
To function-test everything.
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00:15:25,000 --> 00:15:28,551
The final inspection takes place
Where it really counts --
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00:15:28,551 --> 00:15:30,448
In flight.
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Narrator:
How do maple trees make sap?
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00:15:45,310 --> 00:15:48,482
They accumulate starch
During their growing season.
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00:15:48,482 --> 00:15:52,241
With the spring thaw, enzymes
Transform the starch into sugar.
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00:15:52,241 --> 00:15:54,620
When the trees absorb water
Through their roots,
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00:15:54,620 --> 00:15:57,379
It mixes with that sugar
To make sap.
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00:16:04,172 --> 00:16:07,241
Long before the white man
Came to north america,
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00:16:07,241 --> 00:16:10,793
The native indians revered
The maple tree.
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00:16:10,793 --> 00:16:14,448
In early spring, they'd pierce
Its trunk with a tomahawk,
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00:16:14,448 --> 00:16:17,000
Then place a wood chip
Under the hole
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00:16:17,000 --> 00:16:19,758
To channel the sap
Into a bark container.
239
00:16:19,758 --> 00:16:24,862
Then they boiled the sap
Over a fire in clay pots.
240
00:16:24,862 --> 00:16:29,620
The indians introduced maple
Syrup to the european settlers.
241
00:16:29,620 --> 00:16:33,275
Today most producers use tubing
Instead of sap buckets --
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00:16:33,275 --> 00:16:37,517
No more trudging through
The snow from tree to tree.
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00:16:46,482 --> 00:16:49,793
The time to collect sap
Is in the early spring,
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00:16:49,793 --> 00:16:51,724
When the maple trees
Are still dormant
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00:16:51,724 --> 00:16:55,620
And when the temperature hits
3 or 4 degrees above freezing.
246
00:16:55,620 --> 00:16:59,310
The freeze-and-thaw cycle alters
The pressure inside the tree
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00:16:59,310 --> 00:17:01,724
And starts the sap flowing.
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00:17:01,724 --> 00:17:04,448
The first step
Is to tap the trees.
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00:17:04,448 --> 00:17:07,517
They drill a hole 1/2 inch
In diameter,
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2 inches deep,
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00:17:09,172 --> 00:17:13,068
Then gently insert a spout
Made of metal or plastic.
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00:17:13,068 --> 00:17:16,517
It's important not to damage
The bark.
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That not only harms the tree
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But also lets air in the sap,
Which ruins the flavor.
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You don't see too many
Sap buckets around anymore.
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00:17:26,310 --> 00:17:29,344
Today sap is pumped
Through polyethylene tubes
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To larger collector tubes...
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Then into the pumping station.
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00:17:34,793 --> 00:17:40,448
Sap is 97.5% water
And only 2.5% sugar.
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00:17:40,448 --> 00:17:42,827
To transform the sap to syrup,
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00:17:42,827 --> 00:17:45,413
They have to boil it down.
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00:17:45,413 --> 00:17:47,517
It takes 35 gallons of sap
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00:17:47,517 --> 00:17:50,379
To make just one gallon
Of syrup.
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00:17:53,310 --> 00:17:55,413
When the tank fills up,
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00:17:55,413 --> 00:17:58,517
The sap is automatically pumped
To the sugar house
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00:17:58,517 --> 00:18:00,896
Into a stainless-steel tank.
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00:18:00,896 --> 00:18:05,379
The more advanced producers use
A specialized machine
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That partially concentrates
The sap by reverse osmosis.
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00:18:09,448 --> 00:18:12,758
This more than triples
The sap's natural sugar level
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00:18:12,758 --> 00:18:16,896
And means they'll have
Less boiling to do.
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00:18:16,896 --> 00:18:19,965
From there, the sap flows
To the evaporator.
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00:18:19,965 --> 00:18:22,689
They heat the sap
To the boiling point
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00:18:22,689 --> 00:18:25,931
And keep it boiling
However long it takes
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00:18:25,931 --> 00:18:28,241
To evaporate 66% of the water.
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00:18:28,241 --> 00:18:31,862
If the water evaporates
Too slowly or too quickly,
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00:18:31,862 --> 00:18:35,379
That'll adversely affect
The color, flavor, and texture
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00:18:35,379 --> 00:18:36,758
Of the syrup.
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00:18:36,758 --> 00:18:40,793
However -- and here's where
Expertise is everything --
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There's no set cooking time.
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00:18:43,344 --> 00:18:45,758
Experienced
Maple-sugar producers
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00:18:45,758 --> 00:18:48,965
Can tell when it's ready
Just by looking at it.
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00:18:52,068 --> 00:18:56,310
They test the sugar level using
A device called a hydrotherm.
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00:19:06,000 --> 00:19:07,793
When the syrup is just right,
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00:19:07,793 --> 00:19:10,103
They run it through
A pressure filter
285
00:19:10,103 --> 00:19:13,586
To remove calcium residues
And other impurities.
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00:19:16,931 --> 00:19:20,344
They store the syrup
In steam-cleaned barrels.
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00:19:20,344 --> 00:19:24,965
The lab at the central warehouse
Tests a sample from each drum.
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00:19:24,965 --> 00:19:27,172
Using sophisticated instruments,
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00:19:27,172 --> 00:19:30,931
Technicians classify the color
From dark to extra light.
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00:19:30,931 --> 00:19:33,655
They also assess the quality.
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00:19:33,655 --> 00:19:36,068
Lower-grade syrup
Is for industrial use,
292
00:19:36,068 --> 00:19:38,827
Higher-grade
For the retail market.
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00:19:38,827 --> 00:19:41,310
They pasteurize the syrup,
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00:19:41,310 --> 00:19:45,137
Then put it into huge
Stainless-steel storage tanks.
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00:19:45,137 --> 00:19:48,137
The tanks are vacuum-sealed
With a nitrogen barrier
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00:19:48,137 --> 00:19:52,551
To preserve the flavor and color
And to prevent fermentation.
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00:19:52,551 --> 00:19:55,862
It also keeps the syrup
From crystallizing.
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00:19:55,862 --> 00:19:58,034
The lab then uses an instrument
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00:19:58,034 --> 00:20:01,172
Called an atomic absorption
Spectrophotometer
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00:20:01,172 --> 00:20:03,896
To analyze the syrup's
Mineral content,
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00:20:03,896 --> 00:20:07,172
Making sure it meets
Market standards.
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00:20:11,000 --> 00:20:15,586
Next, they warm the syrup
In stainless-steel heaters...
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00:20:22,068 --> 00:20:26,068
...And run it through
Industrial-sized filters.
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00:20:26,068 --> 00:20:30,275
This step ensures the syrup
Will be perfectly clear.
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00:20:32,862 --> 00:20:36,103
Then, just before bottling,
They heat the syrup again,
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00:20:36,103 --> 00:20:39,068
This time to 180 degrees.
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00:20:39,068 --> 00:20:41,517
This not only sterilizes
The bottles
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00:20:41,517 --> 00:20:46,172
But also guarantees the syrup
Will have a 4-year shelf life.
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00:20:53,413 --> 00:20:55,793
Maple syrup is high in sugar
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00:20:55,793 --> 00:20:59,310
But has somewhat fewer calories
Than honey or brown sugar.
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00:20:59,310 --> 00:21:02,241
It's 100% pure and natural,
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00:21:02,241 --> 00:21:05,344
And it's a good source
Of three essential nutrients --
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00:21:05,344 --> 00:21:10,379
Calcium, potassium,
And magnesium.
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00:21:10,379 --> 00:21:13,379
--captions by vitac--
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00:21:13,379 --> 00:21:16,413
Captions paid for by
Discovery communications, inc.
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00:21:17,000 --> 00:21:19,241
If you have any comments
About the show,
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00:21:19,241 --> 00:21:21,896
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318
00:21:21,896 --> 00:21:23,896
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