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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 cinecamera
Is the type of camera they use
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00:00:54,103 --> 00:00:55,655
For making motion pictures.
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It captures what it shoots
On 16- or 35-millimeter film.
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00:00:59,551 --> 00:01:02,241
Running like
A well-oiled machine,
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00:01:02,241 --> 00:01:05,482
Its intricate components
Work with ultimate precision,
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All inside a powerful marvel
Of technology and craftsmanship.
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00:01:13,103 --> 00:01:16,586
The internal mechanics
And electronics of a cinecamera
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Perform an impressive
Choreography to capture images.
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To make the main housing,
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00:01:22,551 --> 00:01:24,758
A computer-controlled
Milling machine
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00:01:24,758 --> 00:01:28,241
Cuts precise spaces
In a block of aluminum.
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00:01:28,241 --> 00:01:31,620
Then a probe scans it
So a computer can verify
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The shape meets
Engineering specifications.
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00:01:35,413 --> 00:01:38,172
Next, a variety
Of computer-guided drills
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00:01:38,172 --> 00:01:40,586
And cutters
Shape the film gate --
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00:01:40,586 --> 00:01:44,068
The component that holds
The film for exposure.
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00:01:48,000 --> 00:01:51,862
A grinding wheel completes
This highly precise task.
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They buff the film gate
On a rotating drum,
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Infused with diamond powder
And a polishing compound.
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00:01:57,793 --> 00:02:01,310
Next, workers apply glue
To the film guide,
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00:02:01,310 --> 00:02:05,206
Which pushes the film
Into the film gate.
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00:02:05,206 --> 00:02:07,724
Then they put glue
On the film movement,
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00:02:07,724 --> 00:02:10,000
Mate the guide and movement,
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00:02:10,000 --> 00:02:13,137
Then drive in screws
To secure the bond.
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00:02:13,137 --> 00:02:16,241
These two registration pins
Hold the film in place.
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00:02:16,241 --> 00:02:19,034
Now for the pulldown claws.
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00:02:19,034 --> 00:02:21,551
Workers mount
These aluminum devices
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Inside the film movement --
One on each side.
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They move forward and downward
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As the registration pins
Retract,
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00:02:29,103 --> 00:02:31,724
Dragging the film
Along the guide.
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00:02:33,551 --> 00:02:37,379
As the claws pull the film down,
The pins enter.
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00:02:37,379 --> 00:02:43,034
This exposure repeats at a rate
Of 150 frames per second.
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00:02:43,034 --> 00:02:45,103
Next, workers screw on a cover
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To protect
The movement's fragile parts.
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00:02:47,827 --> 00:02:51,000
Another cover
Fits on the other side.
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00:02:57,724 --> 00:03:02,517
Workers then test
Each of the buttons.
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00:03:02,517 --> 00:03:05,344
Now they attach
The camera's drive shaft.
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00:03:05,344 --> 00:03:08,620
The motor drives the movement
Using a toothed belt.
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00:03:08,620 --> 00:03:10,862
A mechanics test comes next
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To ensure the claws and pins
Perform with precision.
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00:03:19,172 --> 00:03:21,793
This part of the camera
Is the shutter.
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00:03:21,793 --> 00:03:24,379
It sits between
The film and lens.
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00:03:26,137 --> 00:03:29,034
Workers mount a mirror
Over half the shutter.
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00:03:29,034 --> 00:03:32,275
The mirror reflects the image
Into the viewfinder
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00:03:32,275 --> 00:03:36,068
When it rotates in
Behind the lens.
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00:03:36,068 --> 00:03:40,758
A dab of special cleaning fluid
Yields a pristine surface.
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00:03:40,758 --> 00:03:44,965
Any dirt on the mirror
Would create a fuzzy image.
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00:03:44,965 --> 00:03:50,172
The protective cover plates
Will shield existing openings.
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00:03:50,172 --> 00:03:54,172
Here the shutter and mirror
Spin in unison.
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In this model,
The shutter is electronic,
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So it requires a tiny microchip
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And electrical wires
With plugs on the ends.
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Technicians scrutinize the parts
And connections.
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00:04:05,551 --> 00:04:08,103
Then they test
The electronics again
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00:04:08,103 --> 00:04:10,965
To ensure everything is working,
Starting with the shutter.
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00:04:14,000 --> 00:04:16,758
With all the internal components
Complete,
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It's time to install them
In the camera's housing.
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The film gate we saw earlier
Snaps into position.
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00:04:24,000 --> 00:04:27,034
Next, technicians
Carefully mount the film guide
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Behind the film,
Then fasten it tightly.
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Last but not least, the shutter
Gently slides into position.
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They close up one side
Of the housing with the cover
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To protect
The circuit board inside.
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00:04:46,724 --> 00:04:49,275
Workers then lay
An accessory controller
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Gently into
The camera's side cover.
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It takes tweezers
And a steady hand
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To insert this focusing screen
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Through the lens mount
At the front of the housing.
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00:05:03,689 --> 00:05:07,344
Finally, the lens takes
Its place front and center.
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With the camera structure
Now complete,
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Workers attach a magazine
Containing the film.
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A little nudge here and there
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Leads the film
Down the right path.
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The movement swings forward
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To allow the film
To run its course.
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With the touch of a button,
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The film successfully
Races through a mechanical maze.
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This camera excels at high-speed
And special effects.
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All it needs now is some action.
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Narrator:
It's hard to beat
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The glitter and glow
Of glass christmas ornaments.
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For many people,
The christmas tree
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Just wouldn't be the same
Without them.
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They were invented
In the 19th century
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By a german glassmaker
Who decided to improvise
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Because he couldn't afford
To decorate his tree
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With the usual nuts and candy.
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They're christmas eye candy.
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Today's glass ornaments
Are a visual treat.
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To make some of the ornaments,
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They start with a sketch
And make a plaster model of it.
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They use it
To create a two-part metal mold.
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They take a glass cylinder
And fire its wider end
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So it softens.
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The glassmaker
Blows into the pipe end
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To stretch the supple glass
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Into the basic shape
Of a bauble ornament.
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Other glass tubes
Are more bulbous at the center,
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And that's the section
That's fired
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As the glassmaker blows it
Into a more elongated bubble.
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He places that bubble in
The mold and blows extra hard.
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The glass expands
Into its crevices
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And takes its shape --
A snowman.
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He burns off
One of the blowpipe ends
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And then aims the torch at the
Snowman's nose to pull it out.
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A quick cooldown
Could shatter this ornament,
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So he gradually
Lowers its temperature
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With a less-intense flame.
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Blowing and molding
Glass figurines is quick work.
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The glassmaker has just a few
Seconds to complete the job
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Before the glass becomes
Too cool and stiff to shape.
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The ornaments now head
Down the line to get some shine.
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This will be an inside job.
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The glassmaker
Pours silvering solution
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Into the baubles
Through the stem.
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She then dips the bauble
In warm water.
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This activates
The silvering chemicals,
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00:08:10,413 --> 00:08:15,379
And shaking the ornament
Accelerates this process.
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00:08:15,379 --> 00:08:18,241
She swirls
The silvering liquid around
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To completely coat
The inside of the ornament.
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00:08:20,344 --> 00:08:23,344
A final dip gives this bauble
A mirror finish
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From the inside out.
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She empties
The silvering solution
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Into another tank
For recycling.
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00:08:37,034 --> 00:08:39,896
They also use this technique
On the figurines,
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Like the snowman.
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A quick shake gives this guy
An inner beauty.
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Next, they submerge
The glass ornament in lacquer
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To give it some color.
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The mirror finish inside
Shines through the lacquer.
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Now the snowman ornament
Gets an artist's touch.
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She airbrushes white lacquer
Onto the figurine
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For a frosty finish.
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00:09:18,310 --> 00:09:22,068
It makes the snowman
Look more like old frosty.
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00:09:24,551 --> 00:09:27,586
The artist paints
Some of the details by hand,
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Like the trim on the hat
And robe of this santa ornament.
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This gives it more visual depth.
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Once the paint dries,
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She brushes glue onto sections
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Where she wants glitter dust
To stick.
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The glue dries quickly,
So the artist applies more.
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When it comes
To christmas sparkle,
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You just can't get enough.
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Next, she makes an incision
In the stem and snaps it off.
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00:10:10,655 --> 00:10:14,103
A metal cap
Fits on the ornament stub.
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00:10:16,758 --> 00:10:21,137
Time to pack up these
Fragile beauties very carefully.
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00:10:21,137 --> 00:10:24,689
They put them in boxes that
Cradle each one individually
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00:10:24,689 --> 00:10:27,034
To ensure they arrive safely.
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00:10:27,034 --> 00:10:30,206
Now these glass ornaments
Are ready to go "Out on a limb"
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To add beauty to the holidays.
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Narrator: tires for construction
And mining equipment
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Are truly giant-sized.
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They can be twice the height
Of a human being
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And weigh thousands of pounds.
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These giant tires also come
With a hefty price tag.
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00:11:05,620 --> 00:11:09,724
Just one can cost more
Than an average family sedan.
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Giant tires are made
To carry heavy loads
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In conditions
That are seriously off-road,
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Like mining
And construction sites.
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To make giant tires,
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They feed rubber
Into a powerful mixer.
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They add sulfur
And antioxidants
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To boost
The rubber's durability,
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00:11:39,482 --> 00:11:43,000
As well as recycle
Pieces of used tires.
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00:11:43,000 --> 00:11:44,586
At the top of the mixer,
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They add carbon black
In measured amounts.
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It's an oil by-product that
Helps bind everything together.
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00:11:54,068 --> 00:11:57,689
The mixing generates heat,
Which softens the rubber,
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Making it doughy.
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The rubber dough
Then falls between rollers
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That squeeze it into a sheet.
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00:12:06,689 --> 00:12:09,068
The process is called milling.
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They slice the sheeted rubber
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And feed it back
Into the machine several times.
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00:12:14,137 --> 00:12:17,241
This repeated milling
Essentially kneads the rubber
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To give it
The right consistency.
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00:12:22,689 --> 00:12:25,241
Once the rubber
Has been sufficiently processed,
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They feed it to a conveyor.
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A wheel rolls over the rubber
To impress the date
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And identification number
Onto it.
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00:12:34,413 --> 00:12:38,931
The rubber then winds through
A tank of soapy water.
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00:12:38,931 --> 00:12:40,655
As it exits,
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It falls over hangers
That move it through a dryer.
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A soapy residue remains,
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Keeping the layers
From sticking together
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As they await more processing.
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00:12:51,034 --> 00:12:54,517
They write the I.D. Number
On a sample of the rubber
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00:12:54,517 --> 00:12:57,482
And tag the production run
With the same number.
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This signifies
That testing is under way.
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00:13:07,275 --> 00:13:10,034
They tuck the test sample
In a canister
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00:13:10,034 --> 00:13:12,241
And send it up a chute
To the lab.
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00:13:12,241 --> 00:13:15,551
Once it's confirmed the rubber
Has the right characteristics,
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00:13:15,551 --> 00:13:18,241
It's ready to be made
Into the various components
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Of a giant tire.
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00:13:24,482 --> 00:13:26,172
At the next station,
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00:13:26,172 --> 00:13:30,931
Dozens of steel cords
Unwind into a machine.
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00:13:30,931 --> 00:13:34,655
Each cord is made
Of numerous steel threads,
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00:13:34,655 --> 00:13:37,275
And each thread is brass-plated.
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00:13:37,275 --> 00:13:42,862
These steel cords will be used
To fortify the processed rubber.
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00:13:45,275 --> 00:13:48,241
The cords enter a machine
Called an extruder.
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00:13:48,241 --> 00:13:51,206
It grinds and heats
Some of the processed rubber
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00:13:51,206 --> 00:13:54,827
And then forces it around
The steel cords to encase them.
206
00:13:56,793 --> 00:13:59,482
The result is what's known
As steel-belted rubber.
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00:14:04,137 --> 00:14:07,413
They cut several of the
Steel-belted strips on an angle
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00:14:07,413 --> 00:14:10,758
And fuse them together.
209
00:14:10,758 --> 00:14:13,862
This exposes steel cord
Around the edges,
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00:14:13,862 --> 00:14:16,689
So hot rollers
Seal them with rubber.
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00:14:22,758 --> 00:14:24,655
The steel-belted rubber
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00:14:24,655 --> 00:14:28,413
Will make the tires
More resistant to punctures.
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00:14:28,413 --> 00:14:31,310
But they make
The tires' basic structure
214
00:14:31,310 --> 00:14:33,793
From rubber-coated nylon cord.
215
00:14:33,793 --> 00:14:37,758
They cut the nylon-rubber ply
To a specific length.
216
00:14:40,620 --> 00:14:43,379
Workers then piece
Several of these sheets together
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00:14:43,379 --> 00:14:44,448
To form a loop.
218
00:14:44,448 --> 00:14:47,862
The pieces adhere
Because uncured rubber
219
00:14:47,862 --> 00:14:49,586
Is naturally tacky.
220
00:14:49,586 --> 00:14:53,586
And a machine rolls the loop
To the correct size.
221
00:14:55,517 --> 00:14:58,551
They layer more
Of the nylon-rubber ply
222
00:14:58,551 --> 00:15:01,689
In a crisscross fashion
To add strength.
223
00:15:05,103 --> 00:15:07,448
The machine
That helps size the loop
224
00:15:07,448 --> 00:15:10,206
Also applies
A thin layer of ordinary rubber
225
00:15:10,206 --> 00:15:13,034
Between each crisscrossed layer.
226
00:15:13,034 --> 00:15:15,103
This thickens the rubber loop.
227
00:15:16,827 --> 00:15:20,310
The finished loop
Is called the band.
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00:15:20,310 --> 00:15:23,034
It's the skeleton
Of the giant tire.
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00:15:25,827 --> 00:15:27,827
They hoist it onto a cart
230
00:15:27,827 --> 00:15:30,482
And move it
To the next station.
231
00:15:33,241 --> 00:15:37,413
Stay tuned, as they shape
And inflate this band of rubber
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00:15:37,413 --> 00:15:40,172
To turn it into a giant tire.
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00:15:53,551 --> 00:15:56,241
Narrator:
When it comes to tires,
It takes time to supersize.
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00:15:56,241 --> 00:15:59,310
Making a giant tire
Can take 24 hours or more,
235
00:15:59,310 --> 00:16:02,551
Mainly because the rubber
Needs a lot of curing.
236
00:16:02,551 --> 00:16:05,793
It's not mass production.
It's massiveproduction.
237
00:16:05,793 --> 00:16:07,137
As a result,
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00:16:07,137 --> 00:16:10,758
Factories only produce
A few of the largest ones a day.
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00:16:15,827 --> 00:16:19,413
This machine is about to stretch
The big band of rubber
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00:16:19,413 --> 00:16:20,931
Like an elastic.
241
00:16:26,310 --> 00:16:27,793
The machine pivots,
242
00:16:27,793 --> 00:16:30,551
And its many rollers
Expand and turn
243
00:16:30,551 --> 00:16:33,241
To transfer the band
To a spinning drum.
244
00:16:33,241 --> 00:16:36,448
The machine pumps air
Around the protruding rollers
245
00:16:36,448 --> 00:16:38,206
To make the transfer easier,
246
00:16:38,206 --> 00:16:40,517
While the drum turns
At a constant speed
247
00:16:40,517 --> 00:16:41,965
To aid the process.
248
00:16:46,724 --> 00:16:49,034
Once the transfer is complete,
249
00:16:49,034 --> 00:16:52,379
The rollers retract,
And the air escapes.
250
00:16:52,379 --> 00:16:56,689
This causes the rubber to shrink
To the drum and take its shape.
251
00:17:02,551 --> 00:17:06,034
They fold the overlap
Into the center of the drum.
252
00:17:07,862 --> 00:17:13,689
The giant rubber band now has
The basic contour of a tire.
253
00:17:13,689 --> 00:17:15,206
Next, another machine
254
00:17:15,206 --> 00:17:17,965
Coats numerous steel wires
With rubber,
255
00:17:17,965 --> 00:17:20,551
Creating strips
Of rubberized steel.
256
00:17:20,551 --> 00:17:23,137
This will be used
To make the bead --
257
00:17:23,137 --> 00:17:26,275
The part of the tire
That sits on the wheel rim.
258
00:17:29,448 --> 00:17:32,896
They wind the rubberized steel
Around a metal wheel
259
00:17:32,896 --> 00:17:35,931
Up to 20 times to form the bead.
260
00:17:42,068 --> 00:17:45,068
They remove the bead
And inspect it.
261
00:17:47,103 --> 00:17:50,068
Then they pack
A thick layer of rubber onto it
262
00:17:50,068 --> 00:17:54,758
So it will be easier
To shape to the tire.
263
00:17:54,758 --> 00:17:56,931
Using a special
Applicator wheel,
264
00:17:56,931 --> 00:18:00,448
They push the bead against the
Lip of the rubber tire shape.
265
00:18:00,448 --> 00:18:05,172
The bead adheres, but it needs
To be more solidly attached.
266
00:18:07,137 --> 00:18:10,310
A spinning disk forces the bead
More firmly
267
00:18:10,310 --> 00:18:12,172
To the rubber tire shape.
268
00:18:15,689 --> 00:18:18,689
Then the tire assembler
Folds back the extra rubber
269
00:18:18,689 --> 00:18:20,206
From the tire
270
00:18:20,206 --> 00:18:24,896
And wraps it around the bead,
Using sheer physical strength.
271
00:18:26,758 --> 00:18:30,689
They install two or three beads
On each side of the tire.
272
00:18:30,689 --> 00:18:34,275
The multiroller device
Takes over from the assembler
273
00:18:34,275 --> 00:18:38,000
And folds back extra rubber
To lock the beads in place.
274
00:18:40,068 --> 00:18:41,655
Next, the tire turns
275
00:18:41,655 --> 00:18:44,896
As they wind steel-belted rubber
Around it,
276
00:18:44,896 --> 00:18:48,137
Followed by a continuous strip
Of ordinary rubber.
277
00:18:48,137 --> 00:18:50,896
That strip builds up contours
For tread.
278
00:18:58,931 --> 00:19:02,379
The assembler then wraps
A thick piece of ordinary rubber
279
00:19:02,379 --> 00:19:04,206
Around the outer edge.
280
00:19:04,206 --> 00:19:07,172
This is the tire's sidewall.
281
00:19:07,172 --> 00:19:09,689
The spinning-disc device
282
00:19:09,689 --> 00:19:12,689
Presses the sidewall
To the tire.
283
00:19:14,827 --> 00:19:17,827
This tire is now ready
To move on.
284
00:19:20,379 --> 00:19:23,827
Here, a huge rubber bladder
Inflates and deflates
285
00:19:23,827 --> 00:19:26,793
As they spray it
With a nonstick coating.
286
00:19:26,793 --> 00:19:30,586
This bladder will act
As the inner part of a mold.
287
00:19:37,344 --> 00:19:41,931
They lift the tire
Onto the deflated bladder.
288
00:19:41,931 --> 00:19:46,586
They then pump steam into it,
Expanding the tire.
289
00:19:50,103 --> 00:19:53,413
A metal mold with
A tread pattern engraved in it
290
00:19:53,413 --> 00:19:57,241
Closes around the swelling tire.
291
00:19:57,241 --> 00:20:01,068
The tire cooks in this mold
For up to 18 hours,
292
00:20:01,068 --> 00:20:03,275
Causing the rubber to cure.
293
00:20:06,344 --> 00:20:10,862
The giant tire
Pops out of the mold with tread.
294
00:20:18,551 --> 00:20:20,965
The brand name
And identification numbers
295
00:20:20,965 --> 00:20:23,241
Have all been molded
Into the rubber.
296
00:20:26,655 --> 00:20:28,137
After cooling,
297
00:20:28,137 --> 00:20:33,034
An inspection team examines
The giant tire inside and out.
298
00:20:33,034 --> 00:20:37,103
And once it gets the okay,
It's ready to roll.
299
00:20:37,103 --> 00:20:39,172
And with all that deep tread,
300
00:20:39,172 --> 00:20:42,862
Each giant tire is guaranteed
To make a big impression
301
00:20:42,862 --> 00:20:45,034
On the jobsite.
302
00:20:52,517 --> 00:20:54,965
If you have any comments
About the show,
303
00:20:54,965 --> 00:20:57,931
Or if you'd like to suggest
Topics for future shows,
304
00:20:57,931 --> 00:21:00,689
Drop us a line at...
24586
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