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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:
A traffic intersection,
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00:00:53,827 --> 00:00:56,896
A hollywood movie set,
The outside of an airplane --
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It's hard to imagine
Any common ground among them
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00:00:59,965 --> 00:01:02,344
Until you flip a switch,
A light switch.
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00:01:02,344 --> 00:01:05,655
Traffic lights, movie lights,
And aircraft lights
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00:01:05,655 --> 00:01:08,827
Are all made of the same type
Of special glass.
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00:01:08,827 --> 00:01:10,724
It's called technical glass.
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00:01:15,206 --> 00:01:18,517
Borosilicate glass
Has a low thermal expansion
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00:01:18,517 --> 00:01:19,896
And is very durable.
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00:01:19,896 --> 00:01:22,448
It's used
In high-temperature applications
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00:01:22,448 --> 00:01:24,931
And when abrasion resistance
Is important.
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00:01:27,344 --> 00:01:32,103
It begins with a mix of silica
Sand and chemicals called batch.
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00:01:32,103 --> 00:01:33,344
Workers shovel the batch
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00:01:33,344 --> 00:01:35,344
And recycled glass,
Called cullet,
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00:01:35,344 --> 00:01:38,068
Into a pot furnace,
Where they melt for two days.
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00:01:38,068 --> 00:01:40,448
A variety of colorants are added
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To make hundreds
Of different colors.
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Next, it's on
To the molding process.
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Workers heat a ring
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00:01:50,379 --> 00:01:53,103
And transfer it
To the top of a mold.
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00:01:53,103 --> 00:01:56,172
Then they twist and turn
A stick called a punty
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00:01:56,172 --> 00:01:57,965
To gather some melted glass
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00:01:57,965 --> 00:02:00,482
And carefully string it
In the mold.
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00:02:02,689 --> 00:02:06,793
A plunger squeezes
The molten gob into shape.
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00:02:06,793 --> 00:02:11,862
The glass solidifies in seconds.
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00:02:11,862 --> 00:02:13,655
This glass lens is used
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00:02:13,655 --> 00:02:16,724
As a landing-light cover
On an aircraft.
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00:02:19,379 --> 00:02:23,000
They extract it from the mold
For a quick inspection.
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Any imperfections,
And it gets recycled.
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If the lens is acceptable,
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It's held in a forming device
To finalize the shape.
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00:02:47,172 --> 00:02:50,724
The burner maintains the proper
Temperature of the ring.
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00:02:53,241 --> 00:02:56,931
Once formed, the lenses
Are cooled in an annealing oven,
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Which relieves unwanted stress
In the glass.
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00:03:00,206 --> 00:03:01,482
This circular mold
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00:03:01,482 --> 00:03:04,103
Makes theatrical
And landscape lighting.
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00:03:04,103 --> 00:03:07,172
Again, a gob of molten glass
Is dropped in the mold,
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And the plunger is depressed,
Forming the lens.
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00:03:10,448 --> 00:03:11,931
Heat-resistant tongs
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00:03:11,931 --> 00:03:14,655
Enable workers
To handle the hot lenses.
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00:03:14,655 --> 00:03:17,689
Red and yellow lenses need
A high-temperature anneal
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For the color to appear.
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This is called striking.
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00:03:20,931 --> 00:03:22,793
Back on the molding line,
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Special tools are used
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To ensure this aircraft lens
Maintains its shape.
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00:03:27,758 --> 00:03:30,827
A quick spin on the light wheel
Illuminates any defects.
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00:03:34,275 --> 00:03:36,931
After a trip
Through the annealing lair,
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00:03:36,931 --> 00:03:39,793
The lenses are ready
For further processing.
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00:03:44,586 --> 00:03:48,310
The molding process for larger
Lenses can be more complicated.
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This large convex lens requires
Several gobs of molten glass
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Placed carefully
On top of one another.
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The plunger enters
Into the molten glass,
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Forming the lens.
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Deep ridges located
In the plunger of the mold
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Create the circular prisms
On the glass lens.
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Within seconds,
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The lens is ready for extraction
And inspection.
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00:04:19,413 --> 00:04:21,275
Using heat-resistant mitts,
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00:04:21,275 --> 00:04:24,517
Workers scrutinize the glass
From every angle,
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Checking for small fractures
Or imperfections in the glass.
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00:04:34,344 --> 00:04:36,413
Next, they inspect for flatness
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Using a paper-thin
Plastic feeler.
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If it slides underneath,
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The lens is warped
And unacceptable.
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They check the glass thickness
In many locations,
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Using a calibrated
Thickness gauge.
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Any major defects,
And they discard the lens.
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00:04:56,000 --> 00:04:58,551
In the factory's finishing shop,
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They use a diamond saw
To slice away excess glass
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00:05:01,689 --> 00:05:03,103
Around the periphery.
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00:05:03,103 --> 00:05:05,000
A special sanding belt is used
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00:05:05,000 --> 00:05:07,379
To smooth the surface
To perfection.
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00:05:13,724 --> 00:05:16,068
Then,
With a cloth buffing wheel,
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They polish the glass
To a shine.
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00:05:18,482 --> 00:05:20,655
At last, the final inspection.
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Using calipers, they measure
The lens's ridged edges,
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Called the flange,
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To make sure the dimensions
Are correct.
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Producing such a colorful
Assortment of technical glass
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Takes a lot of work,
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But at least there's light
At the end of the tunnel.
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Narrator:
In the days before electricity,
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Doing laundry
Was just plain hard work.
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The first electric
Washing machines
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Were little more than a bucket
With a motor attached.
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00:06:00,379 --> 00:06:02,931
Fully automatic machines
Came about in the 1960s.
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00:06:02,931 --> 00:06:05,000
But with rising concern
For the environment,
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00:06:05,000 --> 00:06:08,137
There are new designs that need
Less water and electricity
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00:06:08,137 --> 00:06:10,482
To get the dirty job done.
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Most washing machines
Contain a circular tub
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To hold the laundry.
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But this model
Has a unique feature --
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A hexagon-shaped tub
Made from panels
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Of laser-cut,
Perforated stainless steel.
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00:06:33,689 --> 00:06:36,413
The operator
Separates the cut panels
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00:06:36,413 --> 00:06:40,206
And places one on a bending
Machine called a press brake.
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It forces the panel
Against a die,
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Bending the edge.
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The operator repositions
The panel for the next bend,
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Repeating this until
The six-sided shape is complete.
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Then an assembler attaches
A hinged door
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To the tub's opening.
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That's where the laundry
Goes in.
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This inner tub is contained
By another outer tub.
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00:07:10,965 --> 00:07:12,068
To assemble it,
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A welder sets
A stainless steel plate
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Onto a welding fixture.
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Then he places
The tub's main frame
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And slides in another
Steel plate to close it up.
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He clamps the tub
Firmly in place
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Then spot-welds it on each side
So the pieces hold together.
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00:07:38,896 --> 00:07:43,137
Next, he takes the tub over to
A machine called a seam welder.
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There,
An electrode wheel travels
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All along the tub's edge,
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Welding together
The front and back panels
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To the main frame.
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00:07:58,103 --> 00:07:59,793
There's still more welding to do
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00:07:59,793 --> 00:08:01,689
With the use
Of a robotic welding arm
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00:08:01,689 --> 00:08:05,896
To build the machine's
24x27-inch steel base.
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00:08:09,793 --> 00:08:13,137
A concrete counterweight
Mounted on the outer tub's side
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00:08:13,137 --> 00:08:15,758
Prevents the machine
From shaking too much
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00:08:15,758 --> 00:08:17,275
When it's in operation.
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00:08:17,275 --> 00:08:21,655
Next, an assembler attaches
A pressure tube and a sump hose
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To draw the used water
Out of the machine.
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00:08:24,103 --> 00:08:26,793
He seals both tubes
With a watertight adhesive.
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00:08:30,379 --> 00:08:33,000
Now he can install
The suspension struts
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00:08:33,000 --> 00:08:36,206
That support the outer tub,
One at each corner of the base.
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00:08:41,413 --> 00:08:44,862
A single electric motor
Powers the whole machine.
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It's set
On the machine's underside
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On an adjustable pivot shaft.
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With the motor in place,
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Assemblers now turn over
The completed outer tub
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00:08:58,068 --> 00:09:00,034
And lower it into position
On its base.
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00:09:00,034 --> 00:09:02,448
They connect the support struts
On all four sides
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00:09:02,448 --> 00:09:03,758
And then push the tub
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00:09:03,758 --> 00:09:06,068
To make sure the struts
Align properly
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00:09:06,068 --> 00:09:07,586
And keep the machine balanced.
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00:09:12,862 --> 00:09:17,206
Next, the inner tub
Is set into the outer tub.
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00:09:17,206 --> 00:09:19,931
Workers insert
A stainless steel shaft
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Right through both tubs.
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A strip of watertight foam
Is set
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00:09:26,172 --> 00:09:28,344
Along the outer tub's perimeter
To seal it
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00:09:28,344 --> 00:09:31,000
Before workers
Install a plastic bezel
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00:09:31,000 --> 00:09:34,344
That keeps water from splashing
Out of the machine.
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00:09:39,896 --> 00:09:42,586
Next, assemblers
Install the drive pulley
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00:09:42,586 --> 00:09:45,655
Onto the shaft that supports
The inner tub.
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00:09:47,620 --> 00:09:50,448
A drive belt connects the motor
To the pulley,
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00:09:50,448 --> 00:09:51,896
Which rotates the shaft
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00:09:51,896 --> 00:09:54,137
And the inner tub
That it supports.
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Now they slide
A stainless steel outer cabinet
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00:09:56,931 --> 00:09:59,034
Onto the base
That covers the tubs.
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It contains a control board,
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00:10:00,517 --> 00:10:02,724
The brain
Of the washing machine.
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00:10:02,724 --> 00:10:06,034
The assembler
Sets the lid into place,
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00:10:06,034 --> 00:10:08,241
And the machine is complete.
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00:10:08,241 --> 00:10:09,586
The control-board wiring
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Is located on the underside
Of the lid.
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That's also where the valves
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That dispense detergent, bleach,
And softener are.
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Before it leaves the plant,
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00:10:17,689 --> 00:10:20,655
A member of the quality-control
Team tests it out
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With a load of soiled laundry.
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00:10:22,413 --> 00:10:24,344
According to the manufacturers,
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00:10:24,344 --> 00:10:27,034
The unique shape
Of the inner tub is the key
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To making this a lean, green
Washing machine
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00:10:29,724 --> 00:10:32,206
That requires less water,
Less detergent,
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00:10:32,206 --> 00:10:34,551
And less energy
To get the job done.
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There's been a lot of water
Under the bridge
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Since the days
Of those first machines.
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They've sure come a long way.
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00:10:53,172 --> 00:10:55,413
Narrator: the playing card
Traces its roots
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00:10:55,413 --> 00:10:58,586
Back more than 1,100 years
To 9th century china.
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Since then,
Generations young and old
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Lay down their true colors
In a variety of games,
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Each as unique
As the traditional 52-card deck
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00:11:07,034 --> 00:11:09,896
And as timeless
As the four famous suits.
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00:11:15,034 --> 00:11:16,344
Whatever the hand,
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A winning combination
Of technical features
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00:11:19,310 --> 00:11:22,758
Makes these playing cards
Durable and cheater-proof.
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00:11:22,758 --> 00:11:25,551
Industrial humidifiers
Control the moisture level
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Of the card stock.
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00:11:27,137 --> 00:11:31,379
This prevents the cardboard
From drying out and warping.
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00:11:31,379 --> 00:11:33,068
Technicians regularly monitor
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00:11:33,068 --> 00:11:35,448
The cardboard's temperature
And humidity
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00:11:35,448 --> 00:11:36,758
By inserting a flat probe
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00:11:36,758 --> 00:11:39,896
4 inches from the top
Of the 3,000-sheet stack.
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00:11:42,758 --> 00:11:45,275
Card stock arrives from
The paper mill ready-made --
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00:11:45,275 --> 00:11:49,172
Two layers of cardboard
Bonded with colored glue.
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00:11:49,172 --> 00:11:51,448
This construction
Makes the playing cards
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00:11:51,448 --> 00:11:53,241
Impossible to see through.
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00:11:53,241 --> 00:11:55,275
Before making printing plates,
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00:11:55,275 --> 00:11:58,379
A technician checks the artwork
For the deck,
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00:11:58,379 --> 00:12:01,034
Then prints out
A low-resolution sample
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00:12:01,034 --> 00:12:04,448
To confirm the sequence
And layout are correct.
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00:12:04,448 --> 00:12:06,896
There's absolutely no room
For error,
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00:12:06,896 --> 00:12:09,206
So she carefully double-checks
Every card
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For suit, sequence, color,
And layout.
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00:12:14,620 --> 00:12:16,896
A signature on this sticker
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00:12:16,896 --> 00:12:20,000
Confirms these cards
Are good for print.
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00:12:20,000 --> 00:12:23,206
The next step is to make
A digital proof.
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00:12:23,206 --> 00:12:25,655
This printer's internal laser
205
00:12:25,655 --> 00:12:29,275
Heat-transfers dots of colored
Foils onto a clear film.
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00:12:29,275 --> 00:12:31,965
These dots perfectly reproduce
The content and color
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00:12:31,965 --> 00:12:34,172
Of each card.
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00:12:34,172 --> 00:12:38,275
Next, a laminating machine
Bonds the exposed films
209
00:12:38,275 --> 00:12:40,620
Onto a sheet
Of the same cardboard
210
00:12:40,620 --> 00:12:42,586
Used to make the cards.
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00:12:42,586 --> 00:12:44,379
This produces a printed proof
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00:12:44,379 --> 00:12:46,586
Showing exactly what
The finished playing cards
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00:12:46,586 --> 00:12:48,413
Will look like.
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00:12:51,379 --> 00:12:55,034
Here, graphic artists adapt
Hand drawings of the face cards,
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00:12:55,034 --> 00:12:58,068
Adding color and a touch
Of regal class wherever needed.
216
00:13:01,034 --> 00:13:03,827
The next step is
To make the printing plates.
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00:13:03,827 --> 00:13:05,310
A computer-guided laser
218
00:13:05,310 --> 00:13:07,724
Etches the design
Into the polymer surface
219
00:13:07,724 --> 00:13:08,965
Of the printing plate.
220
00:13:08,965 --> 00:13:11,137
Entirely automated,
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00:13:11,137 --> 00:13:14,931
This machine produces
30 plates an hour.
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00:13:23,793 --> 00:13:25,586
To set up for a print run,
223
00:13:25,586 --> 00:13:28,172
Workers pour several cans
Of thick cyan ink
224
00:13:28,172 --> 00:13:31,103
Into the ink duct.
225
00:13:31,103 --> 00:13:34,034
The three other colors --
Same setup.
226
00:13:34,034 --> 00:13:36,000
When the printing press
Gets rolling,
227
00:13:36,000 --> 00:13:37,862
Each fountain
Will disperse ink evenly
228
00:13:37,862 --> 00:13:41,172
Via 16 rollers.
229
00:13:41,172 --> 00:13:44,206
Feeders transport
The cardboard sheets one by one
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00:13:44,206 --> 00:13:46,413
Into the press.
231
00:13:49,241 --> 00:13:52,551
Each printing plate
Is mounted on a rotating drum.
232
00:13:52,551 --> 00:13:55,275
Rollers transfer the ink
Onto the plate,
233
00:13:55,275 --> 00:13:58,172
Which then transfer
Onto a rubber blanket,
234
00:13:58,172 --> 00:14:00,965
Which presses
Against the passing cardboard
235
00:14:00,965 --> 00:14:02,827
As it moves through the press.
236
00:14:02,827 --> 00:14:05,034
At the end of the machine,
237
00:14:05,034 --> 00:14:08,310
The printed sheet
Is flattened and stacked.
238
00:14:08,310 --> 00:14:11,241
They feed the same sheets
Back through the press,
239
00:14:11,241 --> 00:14:14,172
This time upside-down.
240
00:14:16,517 --> 00:14:17,724
The sheets now move
241
00:14:17,724 --> 00:14:20,379
Through a cutting machine
Called the combi,
242
00:14:20,379 --> 00:14:22,758
Where rotating blades divide
The sheet into columns,
243
00:14:22,758 --> 00:14:26,000
Then into individual cards.
244
00:14:33,206 --> 00:14:35,448
The cards get grouped
Into decks.
245
00:14:35,448 --> 00:14:38,862
Then the deck heads into what
They call the cornering station.
246
00:14:42,586 --> 00:14:45,344
A die descends
And, in one fell swoop,
247
00:14:45,344 --> 00:14:47,137
Cuts off all four corners.
248
00:14:47,137 --> 00:14:49,586
Next, a robotic arm
Nudges each deck
249
00:14:49,586 --> 00:14:52,275
Onto a conveyor destined
For the cello wrapper.
250
00:14:55,344 --> 00:14:57,724
Grippers pull
A cellophane reel downwards
251
00:14:57,724 --> 00:14:59,551
While a knife
Then cuts the film.
252
00:14:59,551 --> 00:15:03,034
A heated bar descends
And seals the film,
253
00:15:03,034 --> 00:15:04,896
Which forms an envelope.
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With a simple pull,
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The red tear strip
Removes the wrapper.
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The traditional english deck
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Is the international standard
For games such as poker.
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But there are many more types
Of playing cards.
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This set of spanish cards,
For example,
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Has no numbers, just symbols.
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Whether at the casino
Blackjack table
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Or the kitchen table,
Playing cards are the real deal.
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Narrator: a crossbow
Is a modern bow and arrow
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That you shoot like a rifle.
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It's popular for both
Target shooting and hunting.
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With a rifle, you can shoot
From 200 yards away.
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But using a crossbow
Is more of a challenge.
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You have to be at least four
Times closer to your target.
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A crossbow consists
Of the bow and the stock.
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The bow shoots the arrow,
While the stock
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Houses the trigger
And the aiming scope.
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A plate of fiberglass
Is the starting point
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For the bow's limbs,
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The two curved arms
That pull back
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And release to shoot the arrow.
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A vacuum holds the plate steady
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As a computer-guided grinder
Does some initial shaping.
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Workers measure the plate
With micrometers
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To ensure it meets
Strict specifications.
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This is a special type
Of fiberglass.
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The fibers all run
In the same direction,
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Meaning they can bend repeatedly
Without weakening over time.
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Workers mount the plate
On a computer-guided cutter.
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It carves out the limbs with
A high-pressure water jet --
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The most precise way
To slice fiberglass.
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Each plate yields four limbs --
Two bows' worth.
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The severed fibers
Make their surface rough,
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So a little polishing
Is in order.
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00:17:21,931 --> 00:17:23,965
The limbs go
Into a vibrating tub
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Filled with ceramic stones
That rub against the limbs,
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Wearing down the coarse fibers.
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Now the limbs are ready
For decoration.
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The design is printed
On plastic film.
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This machine uses heat
And pressure
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To transfer the design.
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00:17:40,137 --> 00:17:42,931
The next bow component
Is called the riser.
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00:17:42,931 --> 00:17:44,965
They machine it out of aluminum,
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Then jazz it up
With an ink transfer.
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To assemble the bow,
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They bolt a limb
To each side of the riser.
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It acts as a spacer,
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Separating the limbs so that
The arrow can pass between them
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When you shoot.
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The riser and limbs
Go into a press,
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Which applies more than
660 pounds of pressure,
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Bending the limbs into an arc.
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Next, workers mount a set
Of aluminum pulleys
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On each limb tip.
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These are called compound cams.
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00:18:20,758 --> 00:18:22,862
Next, the yoke.
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A yoke is a string
With a loop on each end.
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They anchor one loop
To one side of the limb tip,
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00:18:28,758 --> 00:18:31,862
Pass the other end
Through a loop on a steel cable,
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Then anchor it
To the other side.
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00:18:34,551 --> 00:18:36,137
This forms "Y" shape
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That distributes pressure
On the limb evenly.
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They repeat the same process
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With a second yoke
On the other limb.
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00:18:44,241 --> 00:18:46,206
Now for the bowstring.
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On each limb,
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They attach the bowstring end
To one side of the cam.
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Then they anchor the cable
Coming from the yoke
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To the other side.
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00:19:01,034 --> 00:19:04,586
Next, two rubber silencers
Go onto the bowstring.
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00:19:04,586 --> 00:19:05,862
When you shoot,
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00:19:05,862 --> 00:19:09,172
These silencers absorb
The string's vibration,
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Reducing the sound.
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00:19:10,655 --> 00:19:14,000
These components make up
What's known as a compound bow.
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00:19:14,000 --> 00:19:16,206
This design enables
The bowstring
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00:19:16,206 --> 00:19:17,965
To propel the arrow farther.
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00:19:17,965 --> 00:19:21,206
Now the bow is finished
And ready for testing.
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00:19:21,206 --> 00:19:23,965
This scale measures
How much strength it takes
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00:19:23,965 --> 00:19:26,103
To draw the bow.
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00:19:28,689 --> 00:19:31,965
Elsewhere,
The stock is coming together.
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00:19:31,965 --> 00:19:33,931
First, the trigger mechanism.
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00:19:33,931 --> 00:19:37,896
It undergoes extensive testing
In a specially designed device
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00:19:37,896 --> 00:19:41,827
That applies air pressure to
Simulate the bowstring tension.
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00:19:41,827 --> 00:19:46,137
They pull the trigger six times
To ensure it fires properly.
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Then they apply
The safety catch.
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00:19:48,448 --> 00:19:51,172
And with a strap
To get maximum strength,
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They pull some more.
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This makes absolutely sure
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00:19:54,241 --> 00:19:56,310
The trigger
Won't fire accidentally
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In the safety position.
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After attaching a connecting rod
That fits in the bow's riser,
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00:20:03,344 --> 00:20:06,137
They install the trigger
In the barrel.
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00:20:06,137 --> 00:20:10,551
Then they bolt these components
Into the stock housing.
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00:20:10,551 --> 00:20:14,793
They attach a bridge and rail
On which the scope will mount.
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00:20:14,793 --> 00:20:18,965
Now they test the trigger again
To check the installation.
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00:20:24,000 --> 00:20:27,103
Connecting the crossbow's
Two sections is simple.
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00:20:27,103 --> 00:20:30,413
You insert the stock's rod
Into a slot in the riser
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And tighten the mounting bolt.
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00:20:32,206 --> 00:20:34,103
Then you attach a foot stirrup.
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To cock the bow, you stand
The crossbow on the ground,
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Put your foot in the stirrup,
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And pull the bowstring upward
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Until it locks
Into the trigger mechanism.
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Then you pick up the crossbow,
Aim, and fire.
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If you have any comments
About the show,
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00:20:55,448 --> 00:20:58,379
Or if you'd like to suggest
Topics for future shows,
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00:20:58,379 --> 00:21:00,551
Drop us a line at...
28432
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