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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: on the battlegrounds
Of american history,
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Powder horns were everywhere.
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These modified cow horns
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Served as carrying cases
For gunpowder
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In 18th century colonial battles
And the american revolution.
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For soldiers engaged
In heated battle,
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The containers were a good way
To keep their powder dry.
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00:01:12,931 --> 00:01:17,206
With the invention of ammunition
Cartridges in the 19th century,
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Muzzle-loading firearms
And powder horns
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Became a thing of the past.
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But today, they're back.
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Powder horns are in demand
For historical re-enactments
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00:01:26,862 --> 00:01:29,896
And among some sportsmen
And collectors.
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The concept of using a cow horn
To make a gunpowder container
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Demonstrates the resourcefulness
Of people in an earlier time.
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Cow horns were accessible.
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They're naturally hollow,
Lightweight, and waterproof.
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To start, the craftsman
Selects the cow horn
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And evaluates it
For structural flaws.
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Finding no cracks
Or weaknesses in this one,
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He proceeds.
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He scrapes off the scale
To clean it
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And get a better look
At its condition.
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00:02:14,862 --> 00:02:18,103
Next, he identifies
The depth of the cavity
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With a thin wire.
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This tells him
Where the hollow section ends
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And the horn becomes solid.
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He marks the spot
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Then draws another line
1 1/2 inches down.
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These markings serve as guides
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As he now turns the tip
Of the horn into a spout.
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He cuts off the pointed end
Along the second line.
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He drills into the horn
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All the way through
To the horn cavity.
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He lays out the design
Of the spout with rubber rings.
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He traces around them
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And then scores the horn
At the pencil marks.
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00:03:03,413 --> 00:03:06,862
He files the horn
Around the score marks
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00:03:06,862 --> 00:03:09,379
To give the spout end
The desired contours
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And builds up a ringed ridge
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For the powder-horn strap
To rest against.
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Next, he gouges the horn
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00:03:16,724 --> 00:03:20,034
To create ornamental notches
Above the spout.
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This is known an engrailing.
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He pencils lettering onto
The side of the powder horn.
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00:03:33,896 --> 00:03:37,034
He scratches the horn
Along the penciled lines
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To engrave the letters into it.
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00:03:39,172 --> 00:03:42,517
Historically, powder horns
Were a soldier's canvas
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00:03:42,517 --> 00:03:45,000
Upon which
He etched maps, designs,
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And personal information.
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He rubs ink onto the lettering,
And it seeps into the fine cuts.
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When he wipes off the ink,
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It remains in the engravings
To make them really stand out.
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He slices the other end
Of the cow horn
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To create an even edge.
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00:04:04,172 --> 00:04:08,551
Then, he boils butternut hulls
And wood chips in water
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To make a dye.
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He immerses the powder horn
In the dye for about an hour
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00:04:15,793 --> 00:04:17,103
To give it a look
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That would take decades
To achieve naturally.
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It gives the powder horn
A yellowed, more aged patina.
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00:04:27,241 --> 00:04:32,103
He now carves a base plug
From pinewood.
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He trims the rough shape
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To the exact curvature
Of the horn.
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He inserts the plug
And ensures it's a snug fit.
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He drills six holes
Into the horn
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00:04:43,965 --> 00:04:45,241
And through to the plug.
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With a tack hammer,
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He drives wooden pegs
Into the holes,
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Securing the plug permanently.
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He slices off
The end of the wood
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To make it flush to the horn.
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He stains the wood plug
With shoe dye
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To make it blend in
With the color of the horn.
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Once the stain has dried,
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He creates a hook
For a shoulder strap.
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He drills holes
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That are a little smaller
Than the hook
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So that when he pounds it
Into the holes,
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The hook is firmly installed.
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He loops the strap
Through the hook
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And stitches it up.
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He inserts a wooden stopper
Into the spout,
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And this powder horn
Is now ready for containment.
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But mostly,
It will just hang around
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As a reminder of another time.
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Narrator:
Mass-produced glass items
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Are typically shaped
By automated machines,
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00:06:02,448 --> 00:06:06,206
Which insert molten glass
Into an assembly line of molds.
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00:06:06,206 --> 00:06:09,620
Specialty items
Are usually cast individually
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With the artist manually
Planting the molten glass
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00:06:12,931 --> 00:06:16,034
In a mold crafted
By skilled mold-makers.
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00:06:17,448 --> 00:06:20,448
These molds for making
Specialty glass items
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Are entirely handcrafted.
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This one,
Comprised of three sections,
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Produces the ornate shade
Of a glass candle lamp.
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00:06:29,103 --> 00:06:31,896
This one,
Comprised of two sections,
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Produces the lamp's base.
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The glass manufacturer submits
The design sketch of the item
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To the mold shop.
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The shop,
Using computer software,
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Converts the sketch
Into technical drawings.
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Then following the drawings,
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Workers prepare a wooden pattern
Of the mold.
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00:06:53,172 --> 00:06:54,862
They first make
A cardboard template
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For each mold section,
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00:06:56,827 --> 00:07:00,137
Then trace the template
On a piece of wood,
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Saw along the pencil line,
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00:07:04,413 --> 00:07:08,000
Then finalize the shape
With a sander.
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00:07:10,827 --> 00:07:14,758
They send the patterns for
The mold sections to a foundry,
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Which casts copies in iron.
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00:07:20,827 --> 00:07:23,103
These iron castings are rough,
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So when they return
From the foundry,
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The mold-makers
Refine each section
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With a series
Of milling machines.
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This takes a tremendous degree
Of expertise,
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As these are not computer-guided
Automated machines.
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00:07:37,344 --> 00:07:40,965
These skilled tradesmen
Maneuver the mills manually,
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00:07:40,965 --> 00:07:44,000
Following
The technical drawings.
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00:07:56,344 --> 00:07:59,000
Once they finalize the shape,
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00:07:59,000 --> 00:08:02,793
They use a drill press to bore
Holes for the hefty pins
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00:08:02,793 --> 00:08:08,137
On which the mold sections
Will pivot open and closed.
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00:08:08,137 --> 00:08:10,758
Iron is the ideal material
For glass molds
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00:08:10,758 --> 00:08:13,034
Because it withstands
A temperature
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00:08:13,034 --> 00:08:17,172
Of over 2,000 degrees fahrenheit
For molten glass.
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00:08:17,172 --> 00:08:19,206
Iron does expand with such heat.
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00:08:19,206 --> 00:08:21,689
However, once cool, it contracts
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00:08:21,689 --> 00:08:26,275
And resumes its original shape
Without any distortion.
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00:08:26,275 --> 00:08:28,379
They mount
The mold section on a lathe
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00:08:28,379 --> 00:08:29,862
To begin forming the cavity.
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00:08:29,862 --> 00:08:32,586
Using a tool
Called a boring bar,
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00:08:32,586 --> 00:08:38,000
A mold-maker shapes the cavity
As per the technical drawings.
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00:08:38,000 --> 00:08:40,655
Then he takes the mold section
Off the lathe
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00:08:40,655 --> 00:08:42,275
And paints the cavity yellow
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00:08:42,275 --> 00:08:44,103
To give him a bright background
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Against which to sketch out
The fine details of the design.
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00:08:47,896 --> 00:08:50,413
This particular pattern
Features circles,
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Which he sketches
With compasses.
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00:08:53,137 --> 00:08:57,137
Using an arsenal of chisels with
Different size and shape tips,
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00:08:57,137 --> 00:09:00,379
He chips the metal
To carve out what he sketched.
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00:09:10,206 --> 00:09:13,689
Again, he follows the technical
Drawings meticulously,
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00:09:13,689 --> 00:09:17,620
Giving the carved lines
The specified depth and profile.
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00:09:21,310 --> 00:09:23,827
Once he finishes the pattern,
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00:09:23,827 --> 00:09:25,310
He mounts the mold section
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00:09:25,310 --> 00:09:27,793
On one side of
A mechanical copying machine
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Called a pantograph.
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00:09:30,000 --> 00:09:31,275
On the other side,
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00:09:31,275 --> 00:09:33,793
He mounts another section
Of the mold
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Which doesn't yet have
The carved pattern.
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00:09:36,103 --> 00:09:39,724
The pantograph stylus traces the
Pattern on the carved section
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00:09:39,724 --> 00:09:42,344
And simultaneously moves
An engraving tool
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Through the identical motions
On the uncarved section,
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Transferring the pattern.
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00:09:51,793 --> 00:09:54,862
Because this is
A three-sectioned mold,
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They make two copies
On the pantograph.
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The carving tools leave marks
On the surface of the cavity,
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00:10:01,068 --> 00:10:04,586
So the next step is to polish
Them away with emery paper.
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00:10:13,034 --> 00:10:15,482
On the right,
You can see the marks.
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And on the left,
The smooth, polished surface.
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The sections are now ready
To be assembled with pins
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Into a complete mold.
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When it's time
To pour in the molten glass,
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The pins enable the sections
To close and interlock.
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00:10:34,655 --> 00:10:36,689
Once the glass cools
And solidifies,
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The pins make it easier to open
The mold to extract the casing.
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Glass artisans
And glass manufacturers alike
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Use handcrafted molds
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To produce a wide variety
Of glass items
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From functional to fancy.
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Narrator:
The perogi is a pillowy pastry
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Stuffed with mashed potato
Or other fillings.
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Popular for centuries
In eastern europe,
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00:11:13,000 --> 00:11:15,482
Perogies were
Initially peasant food.
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But today, their appeal crosses
Class and cultural boundaries,
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00:11:19,620 --> 00:11:23,551
And worldwide there's
A growing appetite for perogies.
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00:11:25,793 --> 00:11:27,862
Perogies are comfort food,
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00:11:27,862 --> 00:11:30,655
Traditionally made from scratch
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00:11:30,655 --> 00:11:33,275
By generations
Of polish grandmothers.
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00:11:33,275 --> 00:11:36,413
But today, few people
Have time for all that work,
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00:11:36,413 --> 00:11:38,310
And the job of making perogies
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00:11:38,310 --> 00:11:41,068
Has moved from the kitchen
To the factory.
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All you have to do is add
The sour cream and chives.
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Production starts with
The potato and cheese filling.
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They boil potatoes until tender.
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Then, still piping hot,
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They transfer the potatoes
To a mixer grinder.
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00:12:03,931 --> 00:12:07,517
They add a generous amount
Of shredded cheddar cheese
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00:12:07,517 --> 00:12:09,655
Along with some salt and spices.
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00:12:12,827 --> 00:12:16,827
A spiraling blade mashes
And mixes the ingredients.
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00:12:18,758 --> 00:12:21,448
The blade misses
A few chunks of potato,
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00:12:21,448 --> 00:12:24,103
So the machine
Forces the ingredients
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00:12:24,103 --> 00:12:26,000
Through
A perforated metal plate.
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00:12:26,000 --> 00:12:27,344
It gets rid of the chunks
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00:12:27,344 --> 00:12:30,482
And leaves the mix
Smooth and creamy.
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00:12:33,724 --> 00:12:35,689
With the filling done,
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00:12:35,689 --> 00:12:38,275
It's over
To the dough department.
199
00:12:38,275 --> 00:12:42,551
They pour measured amounts
Of flour into a mixer.
200
00:12:42,551 --> 00:12:46,551
They add oil
For texture and flavor
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00:12:46,551 --> 00:12:49,586
And some salt
To further enhance the taste.
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00:12:52,758 --> 00:12:55,206
They open an overhead tap,
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00:12:55,206 --> 00:12:59,586
And a measured amount of water
Flows directly into the mixer.
204
00:12:59,586 --> 00:13:03,344
The mixer's roller bars
Blend and knead the dough
205
00:13:03,344 --> 00:13:06,793
To a fairly thick consistency.
206
00:13:06,793 --> 00:13:10,482
After leaving the dough
To soften a bit,
207
00:13:10,482 --> 00:13:13,724
They feed it to a special
Perogi-making machine.
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00:13:17,827 --> 00:13:21,827
The potato and cheese filling
Flows into the same machine.
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00:13:24,000 --> 00:13:26,655
It forces both the filling
And the dough
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00:13:26,655 --> 00:13:28,137
Into a forming device.
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00:13:28,137 --> 00:13:30,896
It's enclosed
For safety reasons,
212
00:13:30,896 --> 00:13:32,931
So you can't see it here.
213
00:13:32,931 --> 00:13:36,344
Inside, the machine shapes
The filling
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00:13:36,344 --> 00:13:38,379
Into a cylindrical form
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00:13:38,379 --> 00:13:41,172
And the dough around it
Into a sleeve.
216
00:13:48,896 --> 00:13:52,586
Here, the machine pumps out
A roll of potato filling,
217
00:13:52,586 --> 00:13:56,137
The dough surrounds it,
Creating sausage-like form.
218
00:14:00,068 --> 00:14:02,000
As the filled dough exits,
219
00:14:02,000 --> 00:14:06,517
A roller shapes it
Into individual perogies.
220
00:14:06,517 --> 00:14:08,931
It also cuts
And crimps the edges.
221
00:14:12,034 --> 00:14:14,862
This produces
Uniformly plump perogies
222
00:14:14,862 --> 00:14:17,103
At an incredible speed.
223
00:14:17,103 --> 00:14:21,068
This machinery churns out
50,000 perogies an hour.
224
00:14:25,620 --> 00:14:29,206
The freshly formed perogies
Ride by a divider mechanism
225
00:14:29,206 --> 00:14:30,896
That separates them,
226
00:14:30,896 --> 00:14:34,413
Preventing clumping as they
Transfer to another conveyor.
227
00:14:36,620 --> 00:14:39,482
An inspector rejects
Any defective dumplings
228
00:14:39,482 --> 00:14:42,620
So that only perfect perogies
Head into a freezer.
229
00:14:45,413 --> 00:14:51,241
The temperature inside
Is an icy negative-50 degrees.
230
00:14:51,241 --> 00:14:54,689
It's a winding journey
On spiraling tiers,
231
00:14:54,689 --> 00:14:59,000
Where they chill
For about 14 minutes.
232
00:14:59,000 --> 00:15:00,931
When they exit,
233
00:15:00,931 --> 00:15:04,310
They're frozen solid
And ready for packaging.
234
00:15:04,310 --> 00:15:06,586
The dumplings
Ride a series of conveyors
235
00:15:06,586 --> 00:15:08,068
Towards the packaging line.
236
00:15:08,068 --> 00:15:11,344
It's a quick journey,
Giving them no time to thaw.
237
00:15:14,413 --> 00:15:17,413
The perogies funnel
Into weigh stations.
238
00:15:17,413 --> 00:15:22,000
Below, mechanical fingers
Open bags.
239
00:15:22,000 --> 00:15:27,344
The scale releases 22 ounces
Of perogies into each bag.
240
00:15:27,344 --> 00:15:31,379
That's about 23 perogies
Per bag.
241
00:15:33,965 --> 00:15:38,310
Hot jaws seal the plastic.
242
00:15:38,310 --> 00:15:41,068
The bags of perogies travel
Through an x-ray station
243
00:15:41,068 --> 00:15:43,103
On their way
To the warehouse freezer.
244
00:15:43,103 --> 00:15:46,068
It scans them
For bits of metal or glass
245
00:15:46,068 --> 00:15:50,068
That may have contaminated
The perogies during production.
246
00:15:50,068 --> 00:15:54,344
Today, perogies have
Many different fillings.
247
00:15:54,344 --> 00:15:57,103
There are even fruit-filled ones
For dessert,
248
00:15:57,103 --> 00:16:01,724
The recipe may be centuries old,
But there are a few new tricks.
249
00:16:12,517 --> 00:16:14,241
Narrator: the earliest tires
250
00:16:14,241 --> 00:16:17,034
Were bands of steel
Fitted to wooden wheels,
251
00:16:17,034 --> 00:16:18,689
Hardly a comfortable ride.
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00:16:18,689 --> 00:16:20,172
Air-filled inner tubes
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00:16:20,172 --> 00:16:23,241
Were part of the first
Successful car tire in 1911,
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00:16:23,241 --> 00:16:25,551
And inner tubes
Are still used today
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00:16:25,551 --> 00:16:29,448
In most bicycle tires
And many motorcycle tires.
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00:16:31,827 --> 00:16:35,379
These motorcycle inner tubes
Are made with a combination
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00:16:35,379 --> 00:16:38,000
Of synthetic
And pure, natural rubber.
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00:16:38,000 --> 00:16:42,241
They come in a variety of sizes
And offer superior quality
259
00:16:42,241 --> 00:16:45,517
Because no recycled
Or reclaimed rubber is used
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00:16:45,517 --> 00:16:48,000
During
The manufacturing process.
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00:16:48,000 --> 00:16:50,551
A worker selects
A slab of synthetic rubber,
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00:16:50,551 --> 00:16:52,344
A package
Of chemically enhanced rubber,
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00:16:52,344 --> 00:16:55,172
Chemicals used as antioxidants,
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00:16:55,172 --> 00:16:58,103
Accelerators and curing agents,
265
00:16:58,103 --> 00:17:03,310
And finally a package
Of pure, natural rubber.
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00:17:05,034 --> 00:17:09,310
A worker pulls the materials
From an internal mixer
267
00:17:09,310 --> 00:17:11,586
And guides them
Into a two-roll mill,
268
00:17:11,586 --> 00:17:13,379
Where they're squeezed together.
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00:17:13,379 --> 00:17:16,275
He trims off the rubber sheet.
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00:17:16,275 --> 00:17:20,896
Ideally, the texture
Of the rubber sheet is smooth.
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00:17:20,896 --> 00:17:24,517
Carbon black provides
Pigmentation to the process
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00:17:24,517 --> 00:17:26,448
And reinforces the rubber.
273
00:17:26,448 --> 00:17:30,068
The rubber is now sent
For cooling.
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00:17:30,068 --> 00:17:32,586
It soaks in a mixture
Of calcium carbonate,
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00:17:32,586 --> 00:17:33,965
Which, once dry,
276
00:17:33,965 --> 00:17:37,413
Will prevent the rubber
From sticking to itself.
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00:17:37,413 --> 00:17:41,758
Workers carefully fold
The continuous sheet of rubber
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00:17:41,758 --> 00:17:43,344
In a stack to dry.
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00:17:45,689 --> 00:17:49,551
The next day,
The rubber is cool and hard,
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00:17:49,551 --> 00:17:53,103
And the calcium carbonate
Has dried into a powder.
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00:17:53,103 --> 00:17:56,827
A worker places the small strip
Coming out of the two-roll mill
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00:17:56,827 --> 00:17:58,724
Onto an overhead conveyor belt,
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00:17:58,724 --> 00:18:01,137
Which takes it
To the next phase of production.
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00:18:01,137 --> 00:18:04,275
The strip falls
Into a extruding machine,
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00:18:04,275 --> 00:18:07,206
Where a turning screw
Forces the raw rubber
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00:18:07,206 --> 00:18:08,551
Through a strainer.
287
00:18:08,551 --> 00:18:11,758
A worker uses a wire
288
00:18:11,758 --> 00:18:14,517
To cut the rubber strands
As they emerge.
289
00:18:14,517 --> 00:18:18,379
He places the rubber wad
In the two-roll mill once again.
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00:18:21,103 --> 00:18:23,172
The rubber
Will gradually be shaped
291
00:18:23,172 --> 00:18:27,275
In preparation for
The next phase of extrusion.
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00:18:27,275 --> 00:18:29,137
Squeezed into a strip,
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00:18:29,137 --> 00:18:32,310
The rubber falls
Into a tube extruder machine.
294
00:18:32,310 --> 00:18:34,206
As it passes through the die,
295
00:18:34,206 --> 00:18:37,275
It emerges
In a cylindrical shape.
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00:18:37,275 --> 00:18:40,241
The rubber tube is hot.
297
00:18:40,241 --> 00:18:41,379
Water cools it down
298
00:18:41,379 --> 00:18:43,586
And cleans away
Any remaining residue.
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00:18:46,620 --> 00:18:50,689
The rubber tube
Now enters a cutting machine.
300
00:18:50,689 --> 00:18:54,413
Calcium carbonate powder
Helps prevent sticking.
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00:18:54,413 --> 00:18:56,137
After being cut,
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00:18:56,137 --> 00:18:59,103
A hole is punched in the tube
And a valve inserted.
303
00:18:59,103 --> 00:19:01,379
The first cone punches the hole.
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00:19:01,379 --> 00:19:04,551
The second inserts the valve.
305
00:19:04,551 --> 00:19:06,620
A worker replaces each valve
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00:19:06,620 --> 00:19:10,103
After it's been inserted
Into the rubber tube.
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00:19:10,103 --> 00:19:14,275
This machine can process
22 tubes per minute.
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00:19:18,724 --> 00:19:22,275
Here is the rubber tube
With the hole punched
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00:19:22,275 --> 00:19:25,103
And with the incomplete
Valve inserted.
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00:19:25,103 --> 00:19:29,586
A worker now connects
The two ends of the cut tube.
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00:19:29,586 --> 00:19:32,379
He places both ends
Into the machine,
312
00:19:32,379 --> 00:19:36,448
Which, using different steps,
Cuts and fuses them together.
313
00:19:36,448 --> 00:19:39,448
By the time the machine
Completes the process,
314
00:19:39,448 --> 00:19:41,965
The worker has
Two more loose ends in place.
315
00:19:41,965 --> 00:19:45,448
First, the knife cuts
Both ends of the tube.
316
00:19:45,448 --> 00:19:49,068
By clearing away
The calcium carbonate powder,
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00:19:49,068 --> 00:19:52,758
The two heated ends
Can stick together.
318
00:19:52,758 --> 00:19:54,965
No glue is needed.
319
00:19:54,965 --> 00:19:56,793
The cut is clean and straight.
320
00:19:56,793 --> 00:20:00,379
Heat, combined with
The rubber's natural stickiness,
321
00:20:00,379 --> 00:20:03,172
Firmly holds the seam together.
322
00:20:03,172 --> 00:20:07,655
A worker now pumps air
Into the circular tube.
323
00:20:07,655 --> 00:20:10,586
He hammers wax
Into the incomplete valve
324
00:20:10,586 --> 00:20:14,413
In order to temporarily
Seal the air inside.
325
00:20:17,172 --> 00:20:19,620
Another worker places the tube
In a mold.
326
00:20:19,620 --> 00:20:21,827
It will be heated
For a few minutes,
327
00:20:21,827 --> 00:20:24,172
Part of
The vulcanization process.
328
00:20:24,172 --> 00:20:26,689
The wax that held the air inside
Has melted,
329
00:20:26,689 --> 00:20:28,931
But after being vulcanized
In the mold,
330
00:20:28,931 --> 00:20:32,379
The tube retains
Its cylindrical shape.
331
00:20:32,379 --> 00:20:34,620
To flatten the shaped tube,
332
00:20:34,620 --> 00:20:38,827
Any air remaining inside
Is removed using a vacuum.
333
00:20:38,827 --> 00:20:40,896
These workers
Give the inner tube
334
00:20:40,896 --> 00:20:42,241
Its finishing touches.
335
00:20:42,241 --> 00:20:46,551
They complete the valve
By adding a core,
336
00:20:46,551 --> 00:20:51,517
Followed by a ring, a nut,
And a valve cap.
337
00:20:51,517 --> 00:20:53,379
They fold
The finished inner tube
338
00:20:53,379 --> 00:20:57,241
And circle it
With two elastic bands.
339
00:20:57,241 --> 00:21:00,413
The folded inner tubes
Are inserted in packaging
340
00:21:00,413 --> 00:21:03,620
That is then heat sealed.
341
00:21:03,620 --> 00:21:05,413
Ready to hit the open road,
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00:21:05,413 --> 00:21:09,655
These motorcycle inner tubes
Are sure to get riders pumped.
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00:21:16,310 --> 00:21:18,344
If you have any comments
About the show,
344
00:21:18,344 --> 00:21:21,206
Or if you'd like to suggest
Topics for future shows,
345
00:21:21,206 --> 00:21:23,551
Drop us a line at...
27480
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