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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: the instruments
In the violin family
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Have a distinct sound
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00:00:56,413 --> 00:00:59,448
Created in large part by
The type of strings they have.
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00:00:59,448 --> 00:01:00,724
While there are strings
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00:01:00,724 --> 00:01:03,413
Made of synthetic materials
Or metals on the market,
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00:01:03,413 --> 00:01:05,068
Traditional strings are made
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Of a specific part
Of a certain animal.
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Stay tuned for the details.
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Playing an instrument in
The violin family takes guts --
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Literally.
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That's because
The instrument's four strings
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00:01:23,620 --> 00:01:25,620
Are made of sheep intestines.
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00:01:25,620 --> 00:01:27,931
The two thinner,
Higher note strings
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00:01:27,931 --> 00:01:29,344
Are made of plain gut.
17
00:01:29,344 --> 00:01:31,689
The two thicker,
Lower note strings
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00:01:31,689 --> 00:01:34,241
Have a gut core
Wrapped in silver wire,
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00:01:34,241 --> 00:01:38,068
Then silk thread wound around
The extremities.
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00:01:38,068 --> 00:01:41,206
The intestines,
Each roughly 65 feet long,
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00:01:41,206 --> 00:01:43,724
Come from local slaughterhouses
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00:01:43,724 --> 00:01:46,689
And arrive already emptied,
Cleaned, and salted.
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00:01:46,689 --> 00:01:50,034
The first step
Is to soak them in cold water
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00:01:50,034 --> 00:01:51,655
For one to two days.
25
00:01:51,655 --> 00:01:54,482
This starts a controlled,
Very smelly decomposition
26
00:01:54,482 --> 00:01:57,482
Which helps loosen up
The intestines' components.
27
00:01:57,482 --> 00:02:00,103
Next, using a half piece
Of wood cane,
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00:02:00,103 --> 00:02:02,034
The string maker scrapes off
29
00:02:02,034 --> 00:02:05,241
The outer layers of fat
And mucosa membranes.
30
00:02:05,241 --> 00:02:08,413
Then, five times a day
For a week,
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00:02:08,413 --> 00:02:11,793
He softens the gut
In an alkaline potash bath
32
00:02:11,793 --> 00:02:15,000
And pulls it against
A handmade copper thimble.
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00:02:15,000 --> 00:02:17,896
This gently scrapes away
The waste remnants
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00:02:17,896 --> 00:02:21,275
Until the gut is a tube
Of pure, transparent muscle,
35
00:02:21,275 --> 00:02:24,931
At which point he slices it
With a splitting horn
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00:02:24,931 --> 00:02:27,827
Into two gut ribbons
Of differing widths.
37
00:02:27,827 --> 00:02:30,241
The thinner, right one
For making violin strings,
38
00:02:30,241 --> 00:02:31,344
The thicker, left one
39
00:02:31,344 --> 00:02:35,344
For making cello
And double bass strings.
40
00:02:35,344 --> 00:02:39,448
During the scraping phase,
Guts sometimes break apart.
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00:02:39,448 --> 00:02:41,241
Rather than discard
These pieces,
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00:02:41,241 --> 00:02:43,137
The string maker
Knots them together
43
00:02:43,137 --> 00:02:44,655
To produce full-length strands.
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00:02:48,172 --> 00:02:50,241
The string maker's assistants
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00:02:50,241 --> 00:02:53,241
Cut the gut ribbons
Into 23-foot lengths
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00:02:53,241 --> 00:02:55,379
And bleach them for four days.
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00:02:55,379 --> 00:02:58,862
This prevents the gut
From turning brown.
48
00:02:58,862 --> 00:03:02,206
Then they count out
The number of strands required
49
00:03:02,206 --> 00:03:04,827
To produce
The various size strings --
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00:03:04,827 --> 00:03:07,758
From six to make
The thinnest violin string
51
00:03:07,758 --> 00:03:13,551
All the way up to 120 to make
The thickest double bass string.
52
00:03:13,551 --> 00:03:15,413
They tie the ends in a loop
53
00:03:15,413 --> 00:03:18,172
And hook them up
To a twisting machine,
54
00:03:18,172 --> 00:03:19,827
Then turn the machine's crank
55
00:03:19,827 --> 00:03:22,206
And tightly twist
The gut ribbons together
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00:03:22,206 --> 00:03:26,586
To form one strong,
Single string.
57
00:03:26,586 --> 00:03:29,310
Then, since the guts
Have begun to dry out a bit,
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00:03:29,310 --> 00:03:30,724
They rehydrate the string
59
00:03:30,724 --> 00:03:33,448
To restore a consistent level
Of moisture.
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00:03:33,448 --> 00:03:37,206
Then they twist it again
And transfer it,
61
00:03:37,206 --> 00:03:40,758
Along with additional strings,
To a drying frame.
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00:03:40,758 --> 00:03:43,034
There's no set drying time.
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00:03:43,034 --> 00:03:46,896
They monitor each string
Individually around the clock.
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00:03:46,896 --> 00:03:48,413
As a string dries,
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00:03:48,413 --> 00:03:51,793
It shrinks in diameter
But grows in length,
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00:03:51,793 --> 00:03:53,344
Creating slack.
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00:03:53,344 --> 00:03:56,275
So, they repeatedly remove
And retwist
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00:03:56,275 --> 00:03:57,793
Until it dries completely,
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00:03:57,793 --> 00:03:59,862
At which point it stabilizes.
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00:03:59,862 --> 00:04:02,482
This drying
And retwisting process
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00:04:02,482 --> 00:04:04,448
Can take up to seven days.
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00:04:04,448 --> 00:04:05,965
The string is ready
73
00:04:05,965 --> 00:04:09,689
When it's hard and stiff
And slightly yellowed.
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00:04:09,689 --> 00:04:12,620
At that stage,
They rub it with horsehair --
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00:04:12,620 --> 00:04:15,551
The traditional equivalent
Of coarse sandpaper.
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00:04:15,551 --> 00:04:19,620
It makes the string smooth
And even throughout.
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00:04:19,620 --> 00:04:21,827
Next, they fine-polish
The string
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00:04:21,827 --> 00:04:23,344
With abrasive, dried grass
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00:04:23,344 --> 00:04:26,137
In a cloth that's been moistened
With olive oil.
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00:04:26,137 --> 00:04:29,310
Some string makers
Use almond oil
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00:04:29,310 --> 00:04:32,379
And pumice or powdered glass
As the abrasive.
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00:04:37,068 --> 00:04:40,275
They sever the strings
From the drying frame
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And cut them
To standard lengths.
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00:04:42,517 --> 00:04:45,758
These strings will be
For a child-size violin,
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So they're 100 centimeters long.
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00:04:49,206 --> 00:04:51,862
To produce the correct sounds,
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00:04:51,862 --> 00:04:54,275
The instrument's
Two lower-note strings
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Must be considerably thicker
Than the others.
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The problem is
This thickness in gut alone
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00:04:59,689 --> 00:05:01,413
Would produce a dull sound,
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00:05:01,413 --> 00:05:04,655
So they wrap the string
In sterling silver wire --
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00:05:04,655 --> 00:05:07,103
Silver being
Seven times denser than gut.
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This gives the string
The right sound
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00:05:09,413 --> 00:05:14,586
And a loud, brilliant tone
With minimal thickness.
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00:05:14,586 --> 00:05:16,275
Next, for decoration,
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They wrap the top and bottom
Of these gut-core strings
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With silk thread.
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00:05:20,620 --> 00:05:22,068
On a violin string,
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00:05:22,068 --> 00:05:25,448
The silk runs about a centimeter
Long on each end.
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00:05:25,448 --> 00:05:27,482
On a longer cello string,
Like this one,
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00:05:27,482 --> 00:05:29,724
About 5 centimeters.
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00:05:29,724 --> 00:05:31,482
The finished string
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00:05:31,482 --> 00:05:34,344
Is ready to be inserted
Into its retail packaging.
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00:05:34,344 --> 00:05:37,517
There are less expensive
Synthetic strings on the market,
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00:05:37,517 --> 00:05:39,793
However,
Particularly for early music,
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Many musicians prefer
The sound and feel
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Of traditional gut strings --
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00:05:44,000 --> 00:05:47,965
Made by hand today
Just as they were centuries ago.
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Narrator: absinthe
Is a strong alcoholic drink
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00:06:03,793 --> 00:06:05,275
With a colorful history.
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00:06:05,275 --> 00:06:07,896
During the late 1800s
And early 1900s,
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00:06:07,896 --> 00:06:10,310
Drinking
This anise-flavored spirit
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Was the rage
Among european bohemians.
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00:06:13,310 --> 00:06:16,310
Conservatives of the day
Saw it as dangerous and immoral
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00:06:16,310 --> 00:06:18,586
And succeeded
In getting absinthe banned
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00:06:18,586 --> 00:06:20,034
In several countries.
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The traditional way
To drink absinthe
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Is to pour one part
Into a glass,
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00:06:29,896 --> 00:06:32,896
Straddle a specially designed
Slotted spoon
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00:06:32,896 --> 00:06:35,586
Holding a sugar cube
Over the glass,
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00:06:35,586 --> 00:06:38,827
Then, very slowly, drip
Three to five parts ice water
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00:06:38,827 --> 00:06:40,689
Directly onto the cube,
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00:06:40,689 --> 00:06:45,862
Dissolving the sugar
Into the diluting spirit.
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00:06:45,862 --> 00:06:49,793
This transforms the drink
From clear to cloudy
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00:06:49,793 --> 00:06:52,482
And draws out
The subtle flavors and aromas
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00:06:52,482 --> 00:06:54,103
Of the herbal ingredients.
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00:06:54,103 --> 00:06:56,241
You can do this
With a single glass
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00:06:56,241 --> 00:06:59,103
Or several using a traditional
Absinthe fountain --
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00:06:59,103 --> 00:07:02,310
A large mounted glass vessel
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00:07:02,310 --> 00:07:05,896
Which dispenses the ice water
Through multiple spigots.
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This 180-year-old
French distillery
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00:07:09,344 --> 00:07:12,724
Makes both white and green
Versions of absinthe.
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00:07:12,724 --> 00:07:16,551
Each is made from a different
Combination aromatic plants.
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00:07:16,551 --> 00:07:18,310
However, for both,
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00:07:18,310 --> 00:07:22,931
The primary ingredients are
Green anise and grand wormwood.
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00:07:22,931 --> 00:07:24,931
Both also contain fennel.
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00:07:24,931 --> 00:07:27,448
The white absinthe
Has more of it.
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00:07:27,448 --> 00:07:30,655
And only green absinthe
Contains additional plants,
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00:07:30,655 --> 00:07:35,103
Such as petty wormwood,
Hyssop, mint, and chamomile.
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00:07:35,103 --> 00:07:38,724
The distillery workers
Pour the recipe ingredients
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00:07:38,724 --> 00:07:40,310
Into a copper still.
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00:07:40,310 --> 00:07:43,862
They pump in highly concentrated
Alcohol made from white grapes.
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00:07:43,862 --> 00:07:47,379
The plants soak
In this alcohol base overnight,
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00:07:47,379 --> 00:07:49,517
Gradually imbuing the alcohol
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00:07:49,517 --> 00:07:52,551
With their respective flavors
And aromas.
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00:07:52,551 --> 00:07:55,965
This process
Is called maceration.
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00:07:55,965 --> 00:07:59,172
The next day,
Distillation begins.
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00:07:59,172 --> 00:08:01,344
They heat the still
With pressurized steam.
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00:08:01,344 --> 00:08:04,586
After about 45 minutes,
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00:08:04,586 --> 00:08:06,862
The spirit reaches
The boiling point,
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00:08:06,862 --> 00:08:09,689
And a floating gauge
Monitoring its alcohol level
152
00:08:09,689 --> 00:08:11,034
Slowly rises
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00:08:11,034 --> 00:08:12,655
And flows out the neck
Of the still.
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00:08:15,965 --> 00:08:20,068
However, what comes out during
The first 10 minutes or so
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00:08:20,068 --> 00:08:21,862
Has to be discarded.
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00:08:21,862 --> 00:08:25,724
It's white, oily,
And has a 90% alcohol level.
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00:08:25,724 --> 00:08:28,275
What follows
Is the good stuff --
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00:08:28,275 --> 00:08:29,689
Crystal clear,
159
00:08:29,689 --> 00:08:33,344
With an average alcohol level
Of 78% to 80%.
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00:08:33,344 --> 00:08:35,275
This streams steadily
Out of the still
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00:08:35,275 --> 00:08:37,655
For about three to five hours,
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Followed by a weak tail-end flow
163
00:08:39,517 --> 00:08:41,862
That they discard
Like the first flow.
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00:08:41,862 --> 00:08:45,827
Then they dilute
This distilled spirit with water
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00:08:45,827 --> 00:08:49,034
To reduce the final alcohol
Level of this white absinthe
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00:08:49,034 --> 00:08:50,724
To 60%.
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00:08:50,724 --> 00:08:54,724
To make green absinthe,
Before that final dilution,
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00:08:54,724 --> 00:08:57,793
They pump the white absinthe
Through a burlap bag
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00:08:57,793 --> 00:08:59,689
Containing a specific plant --
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00:08:59,689 --> 00:09:04,137
The identity of which
The distillery won't divulge.
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00:09:04,137 --> 00:09:06,310
They let the plant soak
In the absinthe
172
00:09:06,310 --> 00:09:07,931
For a specific length of time.
173
00:09:07,931 --> 00:09:11,344
This draws out
The plant's chlorophyll,
174
00:09:11,344 --> 00:09:14,344
Which colors the spirit
Bright green.
175
00:09:14,344 --> 00:09:16,241
Then they dilute with water
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00:09:16,241 --> 00:09:19,310
To obtain the target
Alcohol level of 62%,
177
00:09:19,310 --> 00:09:21,896
Slightly higher
Than white absinthe.
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00:09:21,896 --> 00:09:25,000
That extra bit of alcohol
Helps preserve the chlorophyll.
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00:09:25,000 --> 00:09:28,413
In the distillery's
In-house laboratory,
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00:09:28,413 --> 00:09:32,517
Quality-control technicians test
A sample from each batch
181
00:09:32,517 --> 00:09:34,689
To verify the alcohol content.
182
00:09:34,689 --> 00:09:38,896
Absinthe contains about 20%
More alcohol than most spirits.
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00:09:43,310 --> 00:09:46,103
The lab monitors
The level of thujone,
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00:09:46,103 --> 00:09:48,344
A chemical compound in wormwood,
185
00:09:48,344 --> 00:09:51,034
The drink's
Second key ingredient.
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00:09:51,034 --> 00:09:53,448
Thujone content is regulated
187
00:09:53,448 --> 00:09:55,206
To varying degrees
In many countries.
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00:09:55,206 --> 00:09:56,862
The european union permits
189
00:09:56,862 --> 00:09:59,413
Up to 35 parts per million,
For example,
190
00:09:59,413 --> 00:10:03,620
While canada, no more
Than 7 parts per million.
191
00:10:03,620 --> 00:10:05,448
The distillery, therefore,
192
00:10:05,448 --> 00:10:08,034
Bottles several versions
Of absinthe,
193
00:10:08,034 --> 00:10:09,965
Tailoring the wormwood portion
Of the recipe
194
00:10:09,965 --> 00:10:12,758
To the export destination.
195
00:10:12,758 --> 00:10:17,586
White absinthe
Has a strong anise taste,
196
00:10:17,586 --> 00:10:19,620
Well balanced with wormwood,
197
00:10:19,620 --> 00:10:21,965
Whereas green absinthe,
Containing more plants,
198
00:10:21,965 --> 00:10:25,689
Has a more complex flavor.
199
00:10:25,689 --> 00:10:28,344
While white is typically bottled
In clear glass,
200
00:10:28,344 --> 00:10:30,758
Green is always bottled
In dark-colored glass.
201
00:10:30,758 --> 00:10:33,758
That's because chlorophyll,
202
00:10:33,758 --> 00:10:36,000
The plant pigment
That produces the green color,
203
00:10:36,000 --> 00:10:38,551
Is highly sensitive to light.
204
00:10:38,551 --> 00:10:41,724
Without dark glass
Shielding it from exposure,
205
00:10:41,724 --> 00:10:43,931
The green absinthe inside
Would turn yellow
206
00:10:43,931 --> 00:10:45,137
And eventually brown.
207
00:10:45,137 --> 00:10:49,103
This would have no effect
Whatsoever on the taste,
208
00:10:49,103 --> 00:10:50,689
However, the potent drink
209
00:10:50,689 --> 00:10:52,413
Known in 19th-century france
210
00:10:52,413 --> 00:10:54,620
As la fée verte,
The green fairy,
211
00:10:54,620 --> 00:10:57,275
Would lose some of its magic.
212
00:11:08,379 --> 00:11:10,068
Narrator: there are reports
213
00:11:10,068 --> 00:11:13,379
Of archaeologists finding
Evidence of belts and buckles
214
00:11:13,379 --> 00:11:16,482
Dating back to the 6th
And 7th centuries in britain.
215
00:11:16,482 --> 00:11:17,758
Decorative belt buckles
216
00:11:17,758 --> 00:11:20,068
Appear to have been worn
For the first time
217
00:11:20,068 --> 00:11:22,517
As symbols of status
In the 1500s
218
00:11:22,517 --> 00:11:24,551
Throughout regional spain.
219
00:11:28,724 --> 00:11:30,931
Today,
Hand-engraved belt buckles
220
00:11:30,931 --> 00:11:33,758
Are prized not only
As fashion accessories
221
00:11:33,758 --> 00:11:37,137
But as inspired examples
Of workmanship and art.
222
00:11:37,137 --> 00:11:41,586
The buckle maker welds small
Stainless steel rods together
223
00:11:41,586 --> 00:11:43,724
To form the back of the buckle.
224
00:11:43,724 --> 00:11:45,793
After placing them
In a welding fixture,
225
00:11:45,793 --> 00:11:49,310
He precision-welds them.
226
00:11:49,310 --> 00:11:50,862
Using another fixture,
227
00:11:50,862 --> 00:11:54,000
The buckle maker adds a center
Pin to the back of the buckle.
228
00:11:56,724 --> 00:11:59,068
After precision-welding it
Into place,
229
00:11:59,068 --> 00:12:01,689
He melts the tip
Of the stainless steel pin
230
00:12:01,689 --> 00:12:04,206
Into a smooth ball.
231
00:12:04,206 --> 00:12:08,206
This locating pin
Centers the belt in the buckle.
232
00:12:08,206 --> 00:12:10,103
The buckle maker
Uses a jeweler's saw
233
00:12:10,103 --> 00:12:11,551
To cut the shape of the buckle
234
00:12:11,551 --> 00:12:14,275
From heavy gauge
Solid sterling silver.
235
00:12:19,172 --> 00:12:23,551
He stamps the company logo
Into the back of the buckle.
236
00:12:23,551 --> 00:12:25,000
Using pure silver,
237
00:12:25,000 --> 00:12:28,965
He solders the welded rods
Onto the back of the buckle,
238
00:12:28,965 --> 00:12:32,275
Along with a stainless steel
Keeper tongue.
239
00:12:32,275 --> 00:12:36,172
He uses a jeweler's saw
To cut out initials,
240
00:12:36,172 --> 00:12:38,655
Using the font,
Material, and size
241
00:12:38,655 --> 00:12:40,689
Selected by the customer.
242
00:12:40,689 --> 00:12:43,241
The buckle maker
Uses a soldering gun
243
00:12:43,241 --> 00:12:45,758
To apply solder
To the back of the letters,
244
00:12:45,758 --> 00:12:47,344
Which are made of gold fill,
245
00:12:47,344 --> 00:12:50,931
A thin layer of gold
On top of brass.
246
00:12:50,931 --> 00:12:52,965
He carefully positions
The initials
247
00:12:52,965 --> 00:12:54,655
On the sterling silver buckle,
248
00:12:54,655 --> 00:12:58,310
Which has been covered with flux
For the soldering phase to come.
249
00:12:58,310 --> 00:13:00,620
Too much solder
On the back of the letters,
250
00:13:00,620 --> 00:13:03,724
And it could flow out
Onto the buckle surface.
251
00:13:03,724 --> 00:13:05,068
Heating the belt buckle
252
00:13:05,068 --> 00:13:07,482
Causes the solder
On the back of the letters
253
00:13:07,482 --> 00:13:10,793
To attach firmly
To the sterling silver surface.
254
00:13:10,793 --> 00:13:15,241
The attachment process
Happens very quickly.
255
00:13:15,241 --> 00:13:18,931
With a polishing compound
And cloth polishing wheel,
256
00:13:18,931 --> 00:13:23,482
He gives the buckle
A brilliant shine.
257
00:13:23,482 --> 00:13:26,241
The buckle maker
Hand-engraves the buckle
258
00:13:26,241 --> 00:13:28,793
Using assorted engraving tools.
259
00:13:30,758 --> 00:13:34,620
He uses a shading tool
To add depth to lines.
260
00:13:34,620 --> 00:13:37,482
He follows guidelines
Drawn in felt pen.
261
00:13:37,482 --> 00:13:40,517
The pattern engraved
Is chosen by the customer.
262
00:13:43,137 --> 00:13:48,137
The belt maker rolls out
A piece of tan strap leather.
263
00:13:48,137 --> 00:13:49,275
Using a gauge knife,
264
00:13:49,275 --> 00:13:51,241
He cuts the width
Of leather needed
265
00:13:51,241 --> 00:13:54,827
To make the belt chosen
By the customer.
266
00:13:56,827 --> 00:13:59,931
The belt maker
Uses a variety of tools
267
00:13:59,931 --> 00:14:02,034
To cut and shape the leather.
268
00:14:02,034 --> 00:14:04,000
He cuts the tip of the belt.
269
00:14:06,896 --> 00:14:09,758
He places the leather
In room-temperature water
270
00:14:09,758 --> 00:14:11,241
For about five minutes.
271
00:14:11,241 --> 00:14:15,206
When bubbles stop rising,
The leather is saturated.
272
00:14:15,206 --> 00:14:18,000
After the leather has dried,
273
00:14:18,000 --> 00:14:22,793
He transfers a pattern from
The design strip to the leather.
274
00:14:25,000 --> 00:14:28,758
Stamping tools allow him
To stamp intricate designs.
275
00:14:28,758 --> 00:14:32,620
Using a swivel knife,
He cuts to a depth
276
00:14:32,620 --> 00:14:37,068
Of between a quarter to a third
Of the way through the leather.
277
00:14:37,068 --> 00:14:40,724
The initial pattern
Has been carved.
278
00:14:40,724 --> 00:14:44,758
With a beveler, he deepens
And shapes the carved lines.
279
00:14:47,379 --> 00:14:49,793
He chooses a bar backgrounder
280
00:14:49,793 --> 00:14:53,862
To create leaf
In the background.
281
00:14:53,862 --> 00:14:55,448
With a swivel knife,
282
00:14:55,448 --> 00:14:57,586
He makes
The final decorative cuts.
283
00:14:57,586 --> 00:14:59,241
The belt maker applies dye
284
00:14:59,241 --> 00:15:02,310
To the background sections
Of the carved leather,
285
00:15:02,310 --> 00:15:06,862
Completing the most intricate
Part of his work.
286
00:15:06,862 --> 00:15:09,000
He stamps in the maker's mark.
287
00:15:12,068 --> 00:15:14,068
Using a piece of sheepskin,
288
00:15:14,068 --> 00:15:18,137
He applies an oil finish
To the belt.
289
00:15:18,137 --> 00:15:20,689
A thin paste highlights the cuts
290
00:15:20,689 --> 00:15:24,551
And gives the belt
An antique finish.
291
00:15:24,551 --> 00:15:27,413
A final tanned coat
Waterproofs the belt
292
00:15:27,413 --> 00:15:28,896
And helps protect it.
293
00:15:28,896 --> 00:15:31,965
He makes holes in the belt.
294
00:15:38,310 --> 00:15:39,862
The belt has a bend in it
295
00:15:39,862 --> 00:15:42,103
Where the buckle
Will be attached.
296
00:15:46,517 --> 00:15:48,689
With chicago screws,
297
00:15:48,689 --> 00:15:51,586
He attaches the buckle firmly
To the belt.
298
00:15:51,586 --> 00:15:56,517
Ideally, the belt and buckle
Complement each other.
299
00:15:56,517 --> 00:15:58,344
Strong and stylish,
300
00:15:58,344 --> 00:16:01,344
Meticulously handcrafted
Belt buckles and belts
301
00:16:01,344 --> 00:16:04,172
Have managed to make
A clear fashion statement
302
00:16:04,172 --> 00:16:05,965
Out of belt-tightening.
303
00:16:16,517 --> 00:16:17,689
Narrator: the lever lock
304
00:16:17,689 --> 00:16:19,517
Was invented
In the late 18th century
305
00:16:19,517 --> 00:16:21,103
By an englishman.
306
00:16:21,103 --> 00:16:22,724
At the time, the ward lock,
307
00:16:22,724 --> 00:16:25,344
With its simple,
Concentric plate mechanism,
308
00:16:25,344 --> 00:16:27,689
Was the main kind of lock
In use.
309
00:16:27,689 --> 00:16:31,448
It was medieval technology
And fairly easy to pick.
310
00:16:31,448 --> 00:16:34,758
The lever lock took security
To a whole new level.
311
00:16:37,206 --> 00:16:40,103
More than two centuries
After their invention,
312
00:16:40,103 --> 00:16:42,758
Lever locks are still
On security duty.
313
00:16:42,758 --> 00:16:45,896
The mechanism
Hasn't changed much,
314
00:16:45,896 --> 00:16:49,655
Except instead of two levers,
There can be many inside.
315
00:16:49,655 --> 00:16:51,172
They fall into slots,
316
00:16:51,172 --> 00:16:54,655
Locking the bolt
Until a key lifts the levers.
317
00:16:54,655 --> 00:16:57,034
This lever mechanism
Is very rugged.
318
00:16:57,034 --> 00:16:58,793
It will continue to function
319
00:16:58,793 --> 00:17:01,862
Even if dirt or moisture
Infiltrates the lock.
320
00:17:01,862 --> 00:17:05,620
It's why many armed forces
Will only use this kind of lock.
321
00:17:05,620 --> 00:17:07,931
To make the two halves
Of the lock body,
322
00:17:07,931 --> 00:17:10,241
They uncoil
A narrow band of heavy steel.
323
00:17:10,241 --> 00:17:12,931
Rollers straighten it.
324
00:17:12,931 --> 00:17:16,655
Then a punch press shapes
And cuts out the part.
325
00:17:16,655 --> 00:17:20,896
Four punches produce
A fully formed part.
326
00:17:20,896 --> 00:17:23,137
The front half
Includes the side flange,
327
00:17:23,137 --> 00:17:26,206
The keyhole, a post,
And rivet holes.
328
00:17:30,758 --> 00:17:33,827
The parts tumble
With wood chips,
329
00:17:33,827 --> 00:17:36,551
And the friction removes
Unwanted bits called burrs.
330
00:17:36,551 --> 00:17:40,241
The chips also absorb residual
Oil from punch pressing.
331
00:17:40,241 --> 00:17:43,310
They punch out the lock levers
And other parts.
332
00:17:43,310 --> 00:17:46,862
They plate all 23 parts
With yellow zinc.
333
00:17:46,862 --> 00:17:51,758
Next, rivets funnel
Into a network of tubing.
334
00:17:51,758 --> 00:17:57,275
They tumble four at a time
Into an assembly device.
335
00:17:57,275 --> 00:18:01,517
There are different-sized rivets
To fit different-sized holes.
336
00:18:01,517 --> 00:18:04,103
The delivery system
Pushes the rivets
337
00:18:04,103 --> 00:18:06,586
Up through holes
In the assembly device.
338
00:18:06,586 --> 00:18:10,000
A factory worker places the back
Of a lock body on the rivets,
339
00:18:10,000 --> 00:18:14,000
And a hydraulic press
Squeezes them into place.
340
00:18:14,000 --> 00:18:16,344
He keeps a stash of rivets
At the workbench
341
00:18:16,344 --> 00:18:19,551
In the event that the tubing
Doesn't deliver.
342
00:18:19,551 --> 00:18:21,275
The back of the lock body
343
00:18:21,275 --> 00:18:24,275
Is now ready to receive
The lock mechanism.
344
00:18:24,275 --> 00:18:27,275
There are 240 different
Lever combinations.
345
00:18:27,275 --> 00:18:30,517
The next worker
Determines which one to use.
346
00:18:30,517 --> 00:18:34,137
She places the bolt lever
In the casing
347
00:18:34,137 --> 00:18:37,379
And slides all the other levers
Onto a rivet.
348
00:18:37,379 --> 00:18:41,000
There are a total of six levers
In this particular padlock.
349
00:18:41,000 --> 00:18:43,896
Some locks have more,
Some have fewer.
350
00:18:43,896 --> 00:18:47,379
The more levers there are,
The tougher the lock is to pick.
351
00:18:49,413 --> 00:18:52,620
She wraps a metal spring
Around a rivet...
352
00:18:55,068 --> 00:18:58,517
...And then hinges the shackle
To a third post.
353
00:18:58,517 --> 00:19:00,655
She sets the back half aside
354
00:19:00,655 --> 00:19:05,689
And assembles the keyhole cover
To the front part of the lock.
355
00:19:05,689 --> 00:19:10,551
She winds a spring around a post
And places the cover over it.
356
00:19:10,551 --> 00:19:15,172
The spring will allow the cover
To be swung open and shut.
357
00:19:15,172 --> 00:19:17,551
A rivet secures
The keyhole cover.
358
00:19:20,586 --> 00:19:24,034
She now brings the two
Lock body halves together,
359
00:19:24,034 --> 00:19:27,000
So the rivets from the back
Protrude through the front.
360
00:19:27,000 --> 00:19:30,241
She flattens the rivets
To hold the parts together.
361
00:19:32,655 --> 00:19:35,000
The next part is the clevis.
362
00:19:35,000 --> 00:19:37,689
It's a u-shaped attachment
For a chain
363
00:19:37,689 --> 00:19:41,827
To make the lock easier to hang
Onto when not in lockdown mode.
364
00:19:43,620 --> 00:19:47,724
Another worker now categorizes
The locks in separate boxes,
365
00:19:47,724 --> 00:19:49,655
According to the key code.
366
00:19:49,655 --> 00:19:53,896
He leaves a key code I.D. Card
In each box.
367
00:19:53,896 --> 00:19:56,482
When transferring a lock
For painting,
368
00:19:56,482 --> 00:19:58,275
That I.D. Card goes with it.
369
00:19:58,275 --> 00:20:00,241
This system prevents mix-ups,
370
00:20:00,241 --> 00:20:03,517
So that later they'll be able
To make keys to match.
371
00:20:09,344 --> 00:20:11,448
They spray the locks
Military green
372
00:20:11,448 --> 00:20:14,344
And give them four coats
For corrosion resistance.
373
00:20:17,586 --> 00:20:20,724
It's time to rev up
The key cutter.
374
00:20:20,724 --> 00:20:22,931
There are 240 key profiles
375
00:20:22,931 --> 00:20:26,000
To match the 240 lever lock
Combinations.
376
00:20:26,000 --> 00:20:28,482
The operator sets the blades
In the desired sequence
377
00:20:28,482 --> 00:20:32,517
And carves the keys to give them
The right geometry.
378
00:20:35,551 --> 00:20:37,275
With the correct profile,
379
00:20:37,275 --> 00:20:40,517
The key lifts and lowers
The levers in the lock
380
00:20:40,517 --> 00:20:42,724
To open and close it.
381
00:20:47,448 --> 00:20:51,241
A standard padlock
Comes with two keys.
382
00:20:51,241 --> 00:20:52,724
If the owner loses them both,
383
00:20:52,724 --> 00:20:55,241
The lock will usually
Need to be replaced.
384
00:20:55,241 --> 00:20:58,655
That's because the keycode is
Never written on the lock body
385
00:20:58,655 --> 00:21:00,172
To avoid tipping off thieves.
386
00:21:02,931 --> 00:21:05,827
The technician confirms
That both keys work,
387
00:21:05,827 --> 00:21:09,344
And this lever padlock is now
Ready to thwart criminals
388
00:21:09,344 --> 00:21:11,620
And safeguard possessions.
389
00:21:21,689 --> 00:21:24,379
If you have any comments
About the show,
390
00:21:24,379 --> 00:21:27,068
Or if you'd like to suggest
Topics for future shows,
391
00:21:27,068 --> 00:21:30,275
Drop us a line at...
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