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--captions by vitac--
Www.Vitac.Com
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00:00:04,793 --> 00:00:07,758
Captions paid for by
Discovery communications
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Narrator:
Lace began as a fringe fabric.
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00:00:53,689 --> 00:00:55,241
Back in the middle ages,
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00:00:55,241 --> 00:00:58,793
It was handcrafted by european
Women to trim fashion finery.
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00:00:58,793 --> 00:01:00,827
The ladies' fingers got a break
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00:01:00,827 --> 00:01:04,724
With the advent of lace-making
Equipment in the 19th century.
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00:01:04,724 --> 00:01:06,551
With mass production,
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00:01:06,551 --> 00:01:09,724
Lace moved from the fringe
To the mainstream.
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00:01:12,689 --> 00:01:16,620
In the material world,
Lace used to be a luxury,
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00:01:16,620 --> 00:01:20,137
Handcrafted for decorative
Rather than practical reasons.
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00:01:20,137 --> 00:01:23,068
Machines
Now produce lace quickly,
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00:01:23,068 --> 00:01:25,862
And you don't have to be wealthy
To afford it.
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00:01:25,862 --> 00:01:28,206
To manufacture lace,
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00:01:28,206 --> 00:01:30,655
Hundreds of nylon
And polyester threads
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00:01:30,655 --> 00:01:33,758
Unwind simultaneously
Into a separator.
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00:01:33,758 --> 00:01:37,241
It arranges the threads in a
Configuration for manufacturing
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00:01:37,241 --> 00:01:40,379
And keeps them from tangling
As they move forward.
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00:01:40,379 --> 00:01:42,275
To maintain the formation,
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00:01:42,275 --> 00:01:46,827
The the threads pass through
A comb-like apparatus.
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00:01:46,827 --> 00:01:48,758
Still
In that neat configuration,
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00:01:48,758 --> 00:01:51,517
The threads
Wind around a large spool.
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00:01:51,517 --> 00:01:53,586
This spool is
Known as a ground beam
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00:01:53,586 --> 00:01:55,137
Because the threads on it
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00:01:55,137 --> 00:01:57,758
Will be used
For the lace's ground, or mesh.
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00:02:00,758 --> 00:02:04,000
These smaller spools supply
The threads for the pattern.
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00:02:04,000 --> 00:02:06,724
They all unwind
Into the lace-making machine,
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00:02:06,724 --> 00:02:10,413
Which will interweave them to
Create a pattern on the ground.
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00:02:13,586 --> 00:02:15,620
Here's how it happens.
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00:02:15,620 --> 00:02:18,241
A long thick card
With holes punched into it
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00:02:18,241 --> 00:02:19,448
Defines the pattern
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00:02:19,448 --> 00:02:22,655
And guides
A system of hooks and needles.
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00:02:22,655 --> 00:02:24,620
It's called a jacquard card,
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00:02:24,620 --> 00:02:27,517
And the technology has been
Around for two centuries
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00:02:27,517 --> 00:02:31,862
And was actually the inspiration
For computer technology.
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00:02:31,862 --> 00:02:34,793
Each hole on the card
Corresponds to one hook,
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00:02:34,793 --> 00:02:38,448
And the hooks are
Attached to these guide bars.
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00:02:41,482 --> 00:02:44,517
If the hook encounters
A hole in the jacquard card,
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00:02:44,517 --> 00:02:45,689
It loops a thread,
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00:02:45,689 --> 00:02:49,448
And if it encounters
The solid card, it stops.
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00:02:49,448 --> 00:02:51,482
The guide bars
Shuffle back and forth
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00:02:51,482 --> 00:02:53,827
To move the hooks
In concert with needles
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00:02:53,827 --> 00:02:56,310
And weave the design
On the ground.
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00:02:59,827 --> 00:03:03,413
This is the lace-weaving action
In slow motion.
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00:03:09,689 --> 00:03:12,103
The punch-card system
Allows for the same pattern
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00:03:12,103 --> 00:03:14,310
To be woven repeatedly
Without error.
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00:03:18,517 --> 00:03:21,068
It's all
Perfectly choreographed,
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00:03:21,068 --> 00:03:23,172
And this complex lace design
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00:03:23,172 --> 00:03:27,379
Comes together quickly
With no snarls.
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00:03:27,379 --> 00:03:29,931
The result
Is a thing of beauty --
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00:03:29,931 --> 00:03:33,551
An intricate floral pattern
On a mesh background.
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00:03:38,586 --> 00:03:40,551
The lace rolls by inspectors,
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00:03:40,551 --> 00:03:44,241
Who scrutinize the needlework
For flaws.
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00:03:44,241 --> 00:03:49,655
It then heads into a station
With high-speed knives.
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00:03:49,655 --> 00:03:53,275
They cut the loose threads that
Run between the floral patterns
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00:03:53,275 --> 00:03:54,827
On the front of the lace.
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00:03:54,827 --> 00:03:57,827
A worker finishes the job
By hand,
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00:03:57,827 --> 00:04:00,344
Removing what the knives miss.
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00:04:00,344 --> 00:04:03,551
Here you can see the difference
The trimming makes.
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00:04:03,551 --> 00:04:07,241
The mesh between the needlework
Is now completely transparent.
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00:04:07,241 --> 00:04:10,931
They mend the lace when needed,
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00:04:10,931 --> 00:04:14,241
And then it's into a dying
Machine to add some color.
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00:04:19,413 --> 00:04:22,172
After rinsing,
The now bright-yellow lace
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00:04:22,172 --> 00:04:26,344
Travels over bars under tension
To wring out the water.
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00:04:26,344 --> 00:04:31,413
The lace, still damp,
Lands and accumulates in a bin,
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00:04:31,413 --> 00:04:36,241
Which they wheel over
To a finishing machine.
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00:04:36,241 --> 00:04:38,586
The finishing machine
Is equipped with rollers.
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00:04:38,586 --> 00:04:42,206
The first ones
Remove the curl from the lace.
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00:04:42,206 --> 00:04:45,137
The others take it
Through a chemical bath
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00:04:45,137 --> 00:04:47,482
For a treatment
That both softens the lace
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00:04:47,482 --> 00:04:49,551
And prevents shrinkage.
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00:04:53,068 --> 00:04:56,689
A trip through a dryer removes
The water from the fabric
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00:04:56,689 --> 00:04:59,965
And cures
The finishing chemicals.
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00:04:59,965 --> 00:05:04,827
Now complete, the lace exits
Onto a network of rollers.
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00:05:04,827 --> 00:05:07,620
The final one
Swings the fabric to and fro
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00:05:07,620 --> 00:05:09,206
So that it lands neatly folded
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For transfer
To the packaging line.
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00:05:14,758 --> 00:05:17,827
Heavy industrial machinery
Has produced this delicate lace
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In a matter of minutes.
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They roll it and wrap it,
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00:05:24,551 --> 00:05:28,172
And it's on its way to the
Fabric store or another factory.
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00:05:28,172 --> 00:05:31,413
No ordinary textile,
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00:05:31,413 --> 00:05:34,413
The factory-made lace will add
Beauty to things of necessity
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00:05:34,413 --> 00:05:37,517
Like curtains,
A tablecloth, or a dress.
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00:05:37,517 --> 00:05:40,482
Its sheer good looks
Will add visual appeal
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To these ordinary items.
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Narrator: it's important
That the frame around a painting
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00:06:02,034 --> 00:06:03,689
Be stylistically consistent
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00:06:03,689 --> 00:06:06,896
With the period in which
The artist created the work.
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00:06:06,896 --> 00:06:09,517
When you're dealing with a
Centuries-old painting, however,
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00:06:09,517 --> 00:06:11,724
The original frame
Has often been replaced
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00:06:11,724 --> 00:06:12,896
With a newer one.
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The solution is commissioning
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00:06:14,586 --> 00:06:17,000
An historically accurate
Antique replica.
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00:06:19,724 --> 00:06:22,103
When a painting's original frame
Is lost,
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00:06:22,103 --> 00:06:24,862
A specialist can produce
An exact replica
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00:06:24,862 --> 00:06:27,793
Or a historically accurate
Alternative.
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00:06:27,793 --> 00:06:29,931
Basswood is the wood of choice
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00:06:29,931 --> 00:06:33,241
Because it's relatively soft
And even-grained.
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00:06:33,241 --> 00:06:37,137
First, they saw the length
Required for the frame.
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00:06:40,000 --> 00:06:43,896
Then they plane the sides
To smooth the rough edges.
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00:06:47,206 --> 00:06:50,896
Next, they saw the piece
To the required dimensions.
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Once pieces for all four sides
Of the frame are cut,
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Workers set up a machine
Called a molding planer.
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00:06:57,379 --> 00:06:59,862
As its contoured steel blade
Spins,
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00:06:59,862 --> 00:07:02,034
They run each piece against it,
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00:07:02,034 --> 00:07:04,896
Carving the blade's profile
Into the wood.
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00:07:07,137 --> 00:07:09,758
The workshop
Has thousand of blades,
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Each with a different profile.
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00:07:11,965 --> 00:07:14,068
They all began
As a flat bar of steel,
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00:07:14,068 --> 00:07:17,482
Which the shop milled to shape
Following a profile drawing.
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00:07:17,482 --> 00:07:21,275
Once each side is contoured,
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Workers saw the ends
At 45-degree angles...
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00:07:26,827 --> 00:07:30,103
...Then cut a slot in each one.
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00:07:32,310 --> 00:07:35,724
They spread glue in the slot
And over the entire surface,
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00:07:35,724 --> 00:07:38,758
Then insert a beechwood biscuit.
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The biscuit goes in
Just halfway.
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They insert the other half
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Into the glued slot
Of the adjoining frame piece.
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00:07:47,310 --> 00:07:51,965
Once the glue dries,
The master carver gets to work.
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00:07:51,965 --> 00:07:53,758
With a pencil,
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00:07:53,758 --> 00:07:56,620
He draws the frame's design
Onto tracing paper,
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00:07:56,620 --> 00:07:59,413
Then lays the paper
Upside down on the replica
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00:07:59,413 --> 00:08:01,448
And retraces the design,
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00:08:01,448 --> 00:08:05,206
Which transfers it in graphite
Onto the frame surface.
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00:08:07,275 --> 00:08:10,620
Then he turns to his arsenal
Of 40-plus chisels
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00:08:10,620 --> 00:08:12,586
And begins carving out
The design.
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00:08:12,586 --> 00:08:16,241
Each chisel has
A different shape and sized tip
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00:08:16,241 --> 00:08:19,413
And therefore makes
A very specific type of cut.
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00:08:19,413 --> 00:08:22,000
He first cuts straight down
Along the outline
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00:08:22,000 --> 00:08:24,034
To sever the wood grain.
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00:08:24,034 --> 00:08:26,482
This prevents
The angled cuts, which follow,
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00:08:26,482 --> 00:08:29,448
From splitting the wood
Beyond the outline.
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00:08:29,448 --> 00:08:31,172
Interchanging chisels,
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00:08:31,172 --> 00:08:33,655
He repeatedly removes
Small chunks of wood
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Until the design emerges.
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00:08:35,827 --> 00:08:39,482
He clears away the wood chips
With a wire brush.
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00:08:39,482 --> 00:08:41,655
Now the master gilder
Takes over,
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00:08:41,655 --> 00:08:44,103
Brushing on
Up to 20 coats of gesso --
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00:08:44,103 --> 00:08:47,551
A traditional mixture of water,
Calcium carbonate,
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00:08:47,551 --> 00:08:50,620
And a very flexible glue
Made from rabbit skin.
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00:08:50,620 --> 00:08:52,620
Flexibility prevents cracking
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00:08:52,620 --> 00:08:55,413
When the wood
Expands and contracts.
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00:08:55,413 --> 00:08:57,000
He brushes on four coats
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00:08:57,000 --> 00:08:58,896
Of another traditional mixture
Called bole.
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00:08:58,896 --> 00:09:01,034
The ingredients --
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00:09:01,034 --> 00:09:06,655
Ultra-fine particle clay, water,
And, again, rabbit-skin glue.
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00:09:06,655 --> 00:09:08,896
Bole provides background colors.
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00:09:08,896 --> 00:09:10,758
It also provides a cushion
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00:09:10,758 --> 00:09:13,689
Between the gesso layer
And the gold leaf.
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00:09:13,689 --> 00:09:16,931
Next, a coat of what's called
Gilder's liquor --
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00:09:16,931 --> 00:09:19,620
A combination of water, alcohol,
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00:09:19,620 --> 00:09:22,413
And either gelatin
Or rabbit-skin glue.
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00:09:22,413 --> 00:09:24,896
Then he cuts
A piece of gold leaf --
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00:09:24,896 --> 00:09:30,275
A sheet of genuine gold a mere
1/10,000 of a millimeter thick.
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00:09:30,275 --> 00:09:33,344
He applies it with a fine brush
Made of squirrel hair,
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00:09:33,344 --> 00:09:35,793
Which he has lightly oiled.
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00:09:35,793 --> 00:09:38,482
As soon as he taps the frame,
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00:09:38,482 --> 00:09:42,000
The water in the gilder's liquor
Grabs the gold leaf,
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00:09:42,000 --> 00:09:45,310
Pulling it away from the oil,
Adhering it to the bristles.
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00:09:45,310 --> 00:09:47,344
This is the tricky part,
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00:09:47,344 --> 00:09:49,448
Because too much oil
On the brush
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Or too little water
In the gilder's liquor
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00:09:51,586 --> 00:09:54,448
Can hinder
This delicate transfer.
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00:09:54,448 --> 00:09:57,827
Next, the master gilder rubs
Select areas
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00:09:57,827 --> 00:10:00,862
With a polished agate,
A natural stone.
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00:10:00,862 --> 00:10:04,310
This burnishing process
Compresses the gold leaf,
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00:10:04,310 --> 00:10:06,965
Making it smooth and shiny.
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00:10:06,965 --> 00:10:10,724
Now he'll make the frame
Look old.
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00:10:10,724 --> 00:10:13,275
He removes some gold
From the high points
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00:10:13,275 --> 00:10:15,448
To create
The appearance of wear.
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00:10:15,448 --> 00:10:19,655
Then he applies a tinted glaze
To simulate patina --
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00:10:19,655 --> 00:10:22,344
Natural darkening
That develops over time
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00:10:22,344 --> 00:10:26,379
Due to the accumulation
Of airborne dust and dirt.
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00:10:26,379 --> 00:10:29,724
He works in the glaze
With a brush
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00:10:29,724 --> 00:10:31,689
To distribute it strategically
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00:10:31,689 --> 00:10:36,620
So that the fake patina
Looks perfectly natural.
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00:10:36,620 --> 00:10:40,137
For this frame,
He uses 23-karat gold leaf.
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00:10:40,137 --> 00:10:44,965
Gilders will also use 6-, 12-,
14, 18-, and 22-karat leaf
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00:10:44,965 --> 00:10:47,379
To achieve
Different shades of gold.
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00:10:47,379 --> 00:10:50,206
The higher the karat,
The yellower the color,
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00:10:50,206 --> 00:10:53,000
Due to the greater proportion
Of gold in the composition
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00:10:53,000 --> 00:10:57,344
And lesser proportion
Of copper and silver alloys.
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Narrator:
Orchids are a standout.
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00:11:09,379 --> 00:11:10,827
Their exquisite beauty
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00:11:10,827 --> 00:11:13,655
Even caused a frenzy
In the mid-19th century
187
00:11:13,655 --> 00:11:16,137
When wealthy british collectors
Hired orchid hunters
188
00:11:16,137 --> 00:11:18,482
To search the world
For new species.
189
00:11:18,482 --> 00:11:22,620
Today, the fascination
With orchids continues,
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00:11:22,620 --> 00:11:25,310
And cultivating them
Is a growing industry.
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00:11:28,965 --> 00:11:31,655
In thailand, orchids grow wild,
192
00:11:31,655 --> 00:11:33,724
But the wild orchids
Have been tamed.
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00:11:33,724 --> 00:11:36,137
They've been
Hybridized and domesticated
194
00:11:36,137 --> 00:11:39,586
To satisfy a global demand
For this fantastic flower.
195
00:11:42,068 --> 00:11:45,413
At this farm, cultivation
Starts with bud cuttings,
196
00:11:45,413 --> 00:11:48,827
Mixed with nutrients and water
In glass bottle.
197
00:11:48,827 --> 00:11:51,965
The bottle provides
A germ-free growing environment,
198
00:11:51,965 --> 00:11:53,862
Keeping the cuttings
Disease-free
199
00:11:53,862 --> 00:11:56,655
As they grow into baby orchids.
200
00:11:56,655 --> 00:11:59,310
This takes a year or more.
201
00:11:59,310 --> 00:12:02,000
When the plants have developed
A strong root system,
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00:12:02,000 --> 00:12:04,068
They're ready to come out
Into the world.
203
00:12:06,206 --> 00:12:09,931
The worker deposits the baby
Orchids in a tub of clean water
204
00:12:09,931 --> 00:12:13,862
And swishes each one around to
Give their roots a good rinse.
205
00:12:17,241 --> 00:12:21,586
She transfers the baby orchids
To a perforated plastic basket.
206
00:12:24,965 --> 00:12:27,551
A wad of coconut fiber
Soaked in water
207
00:12:27,551 --> 00:12:30,103
Provides
The next growing environment.
208
00:12:32,241 --> 00:12:35,000
The worker places
The roots of each baby plant
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00:12:35,000 --> 00:12:36,482
In one of the wads.
210
00:12:36,482 --> 00:12:40,413
She wraps the fiber snuggly
And ties the wad.
211
00:12:43,034 --> 00:12:46,827
She places the fiber-wrapped
Orchids in growing cells.
212
00:12:46,827 --> 00:12:51,862
The team waters and fertilizes
Them for four to six months.
213
00:12:51,862 --> 00:12:55,724
The orchids grow to midsize,
214
00:12:55,724 --> 00:12:59,000
And the plant's root system
Flourishes.
215
00:12:59,000 --> 00:13:03,034
The plants are now ready
For the next phase of growth.
216
00:13:03,034 --> 00:13:07,517
They transfer the mid-sized
Orchids to coconut husks.
217
00:13:10,965 --> 00:13:16,172
The husks act as a kind of plant
Pot and growing media in one.
218
00:13:16,172 --> 00:13:20,482
They absorb water to provide
A constant supply to the plants.
219
00:13:20,482 --> 00:13:22,275
The plants grow on the husks.
220
00:13:22,275 --> 00:13:26,448
No soil is needed.
221
00:13:26,448 --> 00:13:30,758
In nature, orchids flourish
On tree bark or cracks in rocks,
222
00:13:30,758 --> 00:13:34,172
And coconut husks
Are the next best thing.
223
00:13:34,172 --> 00:13:38,758
Overhead, a nylon-fabric roof
Diffuses sunlight
224
00:13:38,758 --> 00:13:41,827
To simulate conditions
Found in a shady rainforest.
225
00:13:41,827 --> 00:13:45,379
Too much light and
The heat would harm the plants.
226
00:13:49,206 --> 00:13:52,586
Gardeners regularly observe
The growth of the orchids.
227
00:13:52,586 --> 00:13:55,793
They're on the lookout
For disease or other problems.
228
00:13:55,793 --> 00:13:58,344
Not all of the plants
Will thrive.
229
00:13:58,344 --> 00:14:01,241
They'll lose
About 10% of the crop.
230
00:14:04,172 --> 00:14:05,896
They fertilize and water
The orchids
231
00:14:05,896 --> 00:14:08,310
Over a period of several months.
232
00:14:08,310 --> 00:14:11,793
Many of the plants are hybrids,
233
00:14:11,793 --> 00:14:16,206
Created by crossing species to
Achieve a certain color or shape
234
00:14:16,206 --> 00:14:19,172
Or to improve the plant's vigor.
235
00:14:19,172 --> 00:14:21,896
With thousands of species
Available in nature,
236
00:14:21,896 --> 00:14:24,551
The potential combinations
Are never-ending,
237
00:14:24,551 --> 00:14:27,517
And the results
Are always stunning.
238
00:14:30,896 --> 00:14:34,482
With the orchids in full bloom,
It's time for the harvest.
239
00:14:37,000 --> 00:14:39,862
Workers cut the orchids
At the base of the stems,
240
00:14:39,862 --> 00:14:43,310
With an eye to making them
Approximately the same length.
241
00:14:46,931 --> 00:14:50,000
In the packing room, they tweak
The length of the stems
242
00:14:50,000 --> 00:14:53,620
Until each bunch
Is perfectly uniform.
243
00:14:53,620 --> 00:14:56,034
They make this final cut
On an angle.
244
00:14:56,034 --> 00:14:59,034
This creates a larger surface
For absorbing water
245
00:14:59,034 --> 00:15:02,482
So the orchid
Will stay fresh longer.
246
00:15:02,482 --> 00:15:06,172
They sort the flowers
By the size of the bloom.
247
00:15:09,206 --> 00:15:11,620
They insert the stems
In plastic capsules
248
00:15:11,620 --> 00:15:15,275
That contain
A flower-food and water mixture.
249
00:15:15,275 --> 00:15:17,413
This should maintain
The orchids' freshness
250
00:15:17,413 --> 00:15:19,310
During shipping.
251
00:15:22,275 --> 00:15:25,655
It's time to wrap up
Each stunning display.
252
00:15:25,655 --> 00:15:30,310
The plastic sleeve will preserve
Them on the journey ahead.
253
00:15:33,172 --> 00:15:37,620
This particular orchid is a
Hybrid species known as mokara.
254
00:15:37,620 --> 00:15:39,206
Extremely desirable,
255
00:15:39,206 --> 00:15:42,862
Cut mokara orchids should bloom
For up to three weeks.
256
00:15:42,862 --> 00:15:47,000
En route to the airport
In a climate-controlled truck,
257
00:15:47,000 --> 00:15:49,896
They'll soon be
On an international flight.
258
00:15:49,896 --> 00:15:52,931
Thai orchids
Are sold around the world.
259
00:15:52,931 --> 00:15:54,551
Chances are they'll end up
260
00:15:54,551 --> 00:15:57,482
At the center of a big event
In someone's life,
261
00:15:57,482 --> 00:16:00,000
And whether
It's a wedding or a birthday,
262
00:16:00,000 --> 00:16:03,931
These stunning orchids will add
Something special to the party.
263
00:16:14,793 --> 00:16:17,241
Narrator: the key part
Of a wheel is its hub,
264
00:16:17,241 --> 00:16:20,137
The central point to which
All the spokes attach.
265
00:16:20,137 --> 00:16:23,034
It's comprised of a body
Which receives the spokes
266
00:16:23,034 --> 00:16:26,137
And houses an axle and bearings.
267
00:16:26,137 --> 00:16:27,724
If the wheel has a gear system,
268
00:16:27,724 --> 00:16:29,172
Then those gears and a clutch
269
00:16:29,172 --> 00:16:31,275
Are also integrated
Into the hub.
270
00:16:33,689 --> 00:16:36,344
This is the only
Commercially available unicycle
271
00:16:36,344 --> 00:16:37,862
With a gearing system.
272
00:16:37,862 --> 00:16:39,655
Located on the wheel hub,
273
00:16:39,655 --> 00:16:41,551
It enables the rider
To push a button
274
00:16:41,551 --> 00:16:44,344
To shift from regular gear
Into high gear
275
00:16:44,344 --> 00:16:46,551
And reach 25 miles per hour --
276
00:16:46,551 --> 00:16:50,344
Twice the speed
Of a regular unicycle.
277
00:16:50,344 --> 00:16:53,793
The geared wheel hub contains
Six identical small gears,
278
00:16:53,793 --> 00:16:56,517
Rotating
Around a large central gear.
279
00:16:56,517 --> 00:16:58,551
The central one
Is called the sun wheel
280
00:16:58,551 --> 00:17:01,310
And the small ones,
Planetary gears,
281
00:17:01,310 --> 00:17:03,689
Because they revolve
Around the central gear
282
00:17:03,689 --> 00:17:05,827
The way planets
Revolve around the sun.
283
00:17:05,827 --> 00:17:10,758
Each of the small gears begins
As a disk-shaped steel blank.
284
00:17:10,758 --> 00:17:14,000
A conventional,
1950s-era gear-cutting machine
285
00:17:14,000 --> 00:17:15,724
Cuts teeth into it
286
00:17:15,724 --> 00:17:19,379
As a shower of oil washes away
The shards of metal.
287
00:17:19,379 --> 00:17:22,241
The oil also cools
And lubricates the tool
288
00:17:22,241 --> 00:17:25,586
So that it doesn't
Overheat or jam.
289
00:17:25,586 --> 00:17:28,137
After about 30 seconds
Of machining,
290
00:17:28,137 --> 00:17:31,310
The blank is
A fully shaped gear.
291
00:17:31,310 --> 00:17:33,965
An even older machine,
Circa 1930,
292
00:17:33,965 --> 00:17:36,758
Mills a larger blank
Into the central gear.
293
00:17:36,758 --> 00:17:39,344
However,
Because this gear is bigger,
294
00:17:39,344 --> 00:17:40,793
Cutting the teeth into it
295
00:17:40,793 --> 00:17:44,206
Takes much longer --
About two minutes.
296
00:17:44,206 --> 00:17:46,862
Once all the gears are machined,
297
00:17:46,862 --> 00:17:49,827
They, along with the hub's
Other steel components,
298
00:17:49,827 --> 00:17:54,758
Undergo a complex heat-treatment
Process to strengthen the steel.
299
00:17:54,758 --> 00:17:57,137
Elsewhere in the factory,
300
00:17:57,137 --> 00:17:59,793
Workers assemble
The two halves of the clutch,
301
00:17:59,793 --> 00:18:02,517
The component which locks
Into regular or high gear
302
00:18:02,517 --> 00:18:04,965
When the rider shifts.
303
00:18:04,965 --> 00:18:07,965
Using a cylindrical tool
Called a broach,
304
00:18:07,965 --> 00:18:11,068
The machine grooves
In the center of the clutch.
305
00:18:11,068 --> 00:18:14,379
Slots on the axle
Will fit into these grooves.
306
00:18:18,862 --> 00:18:21,448
Next, they unscrew
The two halves of the clutch
307
00:18:21,448 --> 00:18:24,793
And mount eight hollow pins
In each one.
308
00:18:24,793 --> 00:18:28,758
In one half, they also install
Three longer alignment pins
309
00:18:28,758 --> 00:18:32,827
And a greased spring
Inside each hollow pin.
310
00:18:32,827 --> 00:18:36,241
Then they thread the two halves
Of the clutch onto the axle,
311
00:18:36,241 --> 00:18:38,931
Aligning the axle slots
In the clutch's grooves
312
00:18:38,931 --> 00:18:41,000
And the pins on one half
313
00:18:41,000 --> 00:18:45,172
With corresponding pins
And holes on the other.
314
00:18:45,172 --> 00:18:47,827
After fastening the halves
Together once again,
315
00:18:47,827 --> 00:18:50,137
They mount
The six planetary gears
316
00:18:50,137 --> 00:18:51,827
On a ring called
The planet carrier,
317
00:18:51,827 --> 00:18:54,793
Then install it on the axle.
318
00:18:54,793 --> 00:18:56,896
The spring-loaded pins
On the clutch
319
00:18:56,896 --> 00:18:59,931
Click into corresponding slots
On the planet carrier.
320
00:18:59,931 --> 00:19:02,758
These slots are engineered
To fit the pins
321
00:19:02,758 --> 00:19:08,068
With no more than
.01 millimeters of clearance.
322
00:19:08,068 --> 00:19:10,413
After securing
The planet carrier to the axle
323
00:19:10,413 --> 00:19:11,793
With a retaining clip,
324
00:19:11,793 --> 00:19:14,103
They insert ball bearings
With a spring
325
00:19:14,103 --> 00:19:16,724
In two holes
On opposite sides of the axle.
326
00:19:16,724 --> 00:19:20,724
A retaining ring holds these
Spring-loaded bearings in place.
327
00:19:20,724 --> 00:19:24,206
Meanwhile, a laser engraver
Etches the company logo
328
00:19:24,206 --> 00:19:26,896
And product identification
On the wheel-hub body.
329
00:19:26,896 --> 00:19:29,551
The body is made
Of high-strength aluminum
330
00:19:29,551 --> 00:19:31,586
That's undergone
An electrochemical treatment
331
00:19:31,586 --> 00:19:34,620
To make it corrosion-resistant.
332
00:19:34,620 --> 00:19:37,620
They mount the hub body
On a hydraulic press
333
00:19:37,620 --> 00:19:39,344
And insert the sun wheel,
334
00:19:39,344 --> 00:19:41,896
Surrounded
By a large ball bearing.
335
00:19:41,896 --> 00:19:43,862
Then they activate the press,
336
00:19:43,862 --> 00:19:46,310
Which forces the sun wheel
Into the body.
337
00:19:46,310 --> 00:19:48,517
They install the body
On the axle,
338
00:19:48,517 --> 00:19:50,068
Positioning the sun wheel
339
00:19:50,068 --> 00:19:52,758
Right in the center
Of the planetary gears.
340
00:19:52,758 --> 00:19:57,344
A cover protects the gears from
Dust, dirt, and precipitation.
341
00:19:57,344 --> 00:19:59,586
On the opposite end of the body,
342
00:19:59,586 --> 00:20:01,655
They install additional bearings
343
00:20:01,655 --> 00:20:04,965
And affix a cover
With nine screws.
344
00:20:04,965 --> 00:20:07,241
Now the shift buttons --
345
00:20:07,241 --> 00:20:09,896
A chrome-plated one
For shifting down,
346
00:20:09,896 --> 00:20:12,379
A gold-plated one
For shifting up.
347
00:20:12,379 --> 00:20:16,620
Both screw into a shaft running
Through the center of the axle.
348
00:20:16,620 --> 00:20:18,034
The two spring-loaded bearings
349
00:20:18,034 --> 00:20:20,206
Workers inserted in the axle
Earlier
350
00:20:20,206 --> 00:20:22,172
Hold that shaft in place.
351
00:20:22,172 --> 00:20:26,586
This cross-section model shows
How everything comes together.
352
00:20:26,586 --> 00:20:28,793
The shift button
Moves the shaft,
353
00:20:28,793 --> 00:20:32,517
Which moves the clutch
To lock into the selected gear.
354
00:20:32,517 --> 00:20:34,103
In regular gear,
355
00:20:34,103 --> 00:20:38,068
Pedaling one revolution makes
The wheel turn one revolution.
356
00:20:38,068 --> 00:20:40,379
When the rider shifts
To high gear,
357
00:20:40,379 --> 00:20:42,275
Pedaling one revolution
358
00:20:42,275 --> 00:20:45,551
Makes the wheel turn
1 1/2 revolutions.
359
00:20:45,551 --> 00:20:50,896
The unicycle moves 50% further
As a result of the same action.
360
00:20:50,896 --> 00:20:54,068
Riders use the regular gear
For climbing
361
00:20:54,068 --> 00:20:56,689
And the higher gear
For flat or downhill terrain.
362
00:20:56,689 --> 00:20:58,689
They hit the shift button
363
00:20:58,689 --> 00:21:01,103
With their heel or ankle
While pedaling --
364
00:21:01,103 --> 00:21:05,827
A quick, slight movement that
Won't throw them off balance.
365
00:21:16,551 --> 00:21:19,620
If you have any comments
About the show,
366
00:21:19,620 --> 00:21:22,275
Or if you'd like to suggest
Topics for future shows,
367
00:21:22,275 --> 00:21:25,413
Drop us a line at...
29960
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