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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 first armored car
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Was developed
In the late 19th century.
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First used
As scouting vehicles,
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00:00:59,551 --> 00:01:03,620
They quickly became a source
Of protection in modern warfare.
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Today, private armored vehicles
Are made for celebrities,
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00:01:07,137 --> 00:01:10,655
C.E.O.S,
And government officials.
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00:01:14,310 --> 00:01:18,241
This armored s.U.V.
Looks like an ordinary car,
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But it's reinforced
With bulletproof steel
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00:01:21,172 --> 00:01:25,896
And has
Transparent armor windows.
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A designer
Integrates armored parts
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Into the original design of
The car using a 3d cad system.
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00:01:34,689 --> 00:01:36,896
A c.N.C. Precision
Laser cutter
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Shapes the armored parts
Out of a ballistic steel sheet.
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00:01:49,655 --> 00:01:52,896
A mechanic tests the steel's
Ballistic resistance
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Using a high-power rifle.
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He makes sure the armor
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Meets international
Ballistic impact standards.
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A mechanic starts
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By removing the inside covers
And liners of the car,
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Stripping it down
To the chassis frame.
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00:02:10,206 --> 00:02:13,620
Now the mechanics
Can install the armor.
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00:02:13,620 --> 00:02:17,724
They weld bulletproof steel
Sheets to the chassis frame.
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00:02:20,517 --> 00:02:22,689
They reinforce
The car floor
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With blast-absorbent
Steel sheets
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And install
Ballistic armored steel
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To cover
The interior cabin walls.
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00:02:31,206 --> 00:02:34,275
A mechanic now uses
An electric grinder
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To remove the standard-steel
Panels from the door.
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Armored steel plates
Designed to fit to the chassis
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Are welded in place.
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At the end
Of the process,
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The vehicle is armored
From top to bottom.
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00:02:55,103 --> 00:02:58,103
The armor adds around two tons
Of weight to the vehicle,
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00:02:58,103 --> 00:02:59,896
Depending on the model,
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So each vehicle is equipped with
An adapted suspension system.
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00:03:06,206 --> 00:03:10,551
A welder assembles a fuel-tank
Casing using ballistic steel.
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00:03:10,551 --> 00:03:15,034
He arranges the metal to form a
Protective shell around the tank
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00:03:15,034 --> 00:03:17,862
Then welds
The pieces together.
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00:03:24,206 --> 00:03:27,310
Another worker applies
Electrostatic, anti-rust,
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00:03:27,310 --> 00:03:29,206
And flame-retardant paint,
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Designed to prevent
The tank from exploding
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If exposed to open flames.
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00:03:37,137 --> 00:03:42,172
A welder attaches the fuel pan
To the bulletproof casing.
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He uses a mig torch to tack-weld
The pan onto the armored steel.
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The c.N.C.-designed casing
Fits perfectly around the tank.
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00:03:59,068 --> 00:04:02,034
Mechanics now reassemble
The interior fitting,
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00:04:02,034 --> 00:04:03,241
Air-conditioning system,
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00:04:03,241 --> 00:04:07,689
And electrical wiring
Running through the roof.
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00:04:07,689 --> 00:04:10,827
Another worker reattaches
The original panels
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To the armored door frame
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And puts the door-lock and
Window controls back in place.
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They cover the blast-absorbent
Steel with floor mats,
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Then they bring in
The rear bulkhead door,
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Which is upholstered
To match the original interior.
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00:04:31,448 --> 00:04:35,827
The bulletproof door can be used
As an emergency escape hatch.
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It opens horizontally
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00:04:37,758 --> 00:04:45,137
Because the door is too heavy
For hatch lifts to support.
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00:04:45,137 --> 00:04:48,275
Now they install
The windshield.
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It's made
Of transparent armored glass.
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The thickness of the glass
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Depends on the ballistic
Standard the car needs to meet.
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00:04:56,551 --> 00:05:00,344
He installs runflat devices
Made of composite plastic
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Inside the wheels.
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This allows the car
To keep rolling on a flat tire
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00:05:05,034 --> 00:05:06,517
For 40 to 50 miles
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00:05:06,517 --> 00:05:10,206
At a speed of
Up to 50 miles per hour.
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00:05:13,344 --> 00:05:15,827
A mechanic tightens
The device around the rim
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Before a robotic arm
Attaches the tire to the wheel.
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He labels
The reinforced wheel
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With the specifications
Of the runflat device
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And mounts it
Back on the car.
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00:05:35,413 --> 00:05:37,413
A keen observer
May see the overlap
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00:05:37,413 --> 00:05:40,793
Between the edge of the
Doorframe and the main chassis
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Or notice the unusual thickness
Of the windows,
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But the design
Of these cars
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Makes them look
Perfectly normal to most people,
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Even though they are
As protected as armored tanks.
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Narrator:
A tension fabric building
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Combines the benefits
Of a tent and a building
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Into a single structure.
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It has a strong,
Load-resistant roof
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And a sturdy steel structure
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But can be quickly
Dismantled and reconstructed
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At a new location.
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You often see
Tension fabric buildings
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On farms
Or at public works yards.
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They're often used
To store equipment
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And bulk materials
Like gravel or road salt.
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Tension fabric buildings
Can also house small factories.
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The fabric cover
Is high-density polyethylene,
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A material known
For its exceptional strength.
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It can withstand strong winds
And heavy snow accumulation.
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Following
The engineer's plan,
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Workers cut
The required sheets of fabric.
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Then, the assembly
Process begins.
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They flatten and tape down
The first sheet to immobilize it
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00:07:03,655 --> 00:07:07,862
Then overlap the second sheet
By two inches.
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They tape down that sheet
To keep it in position.
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00:07:13,172 --> 00:07:18,448
Then, with a hot-air welder,
They melt the overlapping edges
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And press them together
With heavy wheels.
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This fuses the edges
Into a strong seam.
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00:07:30,896 --> 00:07:34,896
Workers use this same process
To weld on tension pockets
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Two feet in
From the bottom and sides.
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00:07:37,827 --> 00:07:40,965
Each pocket will contain
A steel or pvc tube
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00:07:40,965 --> 00:07:42,931
Holding nylon straps.
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The straps are spaced
2 to 10 feet apart,
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Depending on
The building size.
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They apply tension
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To fasten the fabric down
Over the steel structure.
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The assembled sheets
Form a single cover
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That goes over the sides
And roof of the building.
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Separate covers are made
For the front and back walls.
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The covers of larger buildings
Are made differently.
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Workers connect multiple covers
With a keter system.
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Keter is an ultra-strong
Pvc or nylon rope.
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00:08:18,724 --> 00:08:22,275
An automated
Hot-air welder
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Folds the edges of each cover
Over the keter.
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The fabric-sealed rope edge
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Will slide snugly
Into an aluminum channel
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00:08:33,310 --> 00:08:35,517
In the building's
Roof structure.
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00:08:39,827 --> 00:08:42,068
When the cover is finished,
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Workers fan-fold it...
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...Then roll it up for transport
To the installation site.
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For the building's
Steel structure,
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The factory
Orders steel tubing
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00:08:58,758 --> 00:09:01,724
And cuts pieces
To the required lengths.
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00:09:01,724 --> 00:09:05,482
The steel is coated with zinc
To prevent corrosion.
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00:09:11,931 --> 00:09:14,517
Works put the tubes
Into a press
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To flatten the ends
Into connectable surfaces.
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00:09:18,206 --> 00:09:23,310
At the same time, the press
Punches holes for bolts.
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00:09:25,793 --> 00:09:27,827
For buildings
With a rounded top,
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00:09:27,827 --> 00:09:29,965
Works bend tubes
For the trusses,
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00:09:29,965 --> 00:09:33,758
A main component
Of the roof framing.
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The operator
Programs in the required radius,
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00:09:37,827 --> 00:09:40,655
And the machine
Automatically adjusts the dies
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00:09:40,655 --> 00:09:43,137
To curve the tube
Accordingly.
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00:09:46,931 --> 00:09:49,931
Workers then place the parts
For each truss segment
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00:09:49,931 --> 00:09:53,034
In an assembly jig
To prepare for welding.
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They tack-weld
The parts together
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So they come off the jig
As a single unit.
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At the next station,
Workers finish the welding.
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00:10:08,482 --> 00:10:11,482
This truss segment
Will connect with six others,
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00:10:11,482 --> 00:10:16,241
Forming a 200-foot truss running
The full width of the building.
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00:10:16,241 --> 00:10:20,172
To keep up with the high demand,
Robots do all the welding
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For this factory's
Most-popular models.
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00:10:24,965 --> 00:10:27,034
Welding removes
The galvanization,
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Which keeps the steel
Corrosion-resistant,
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00:10:29,620 --> 00:10:33,793
So the last step is to spray
Zinc-rich paint on the welds
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00:10:33,793 --> 00:10:36,344
To restore
That protection.
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A tension fabric building
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Typically takes a team of four
Just a few days to set up.
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It can be customized
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To attach to different types
Of foundations
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And be designed
With windows and garage doors.
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Narrator: rowing machines
Were invented in the late 1800s.
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These early versions
Were rudimentary
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But helped competitive rowers
Train in the off-season.
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00:11:17,241 --> 00:11:19,758
As technology improved,
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00:11:19,758 --> 00:11:22,206
Rowing machines
Gained a much wider appeal.
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Today's machines offer
A realistic rowing experience
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Without putting
An oar in the water.
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00:11:33,448 --> 00:11:34,793
When the weather is bad,
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A rowing machine
Can bring the workout indoors.
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To make a rower,
A computerized tool
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00:11:42,241 --> 00:11:45,206
Punches assembly holes
In high-carbon steel.
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Then, a laser carves out
The parts around the holes.
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These parts will be used
To create the housing
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00:11:52,034 --> 00:11:55,068
For the rower's
Flywheel and brakes.
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00:11:55,068 --> 00:12:00,827
They fold the edges using a
Bench press, making neat flaps.
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Next up is the main tube
For the rower.
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All the other components
Will attach to this part.
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A punch cuts assembly holes
Into the steel tube.
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00:12:17,206 --> 00:12:23,172
Then, an employee places
The tube in a welding fixture.
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00:12:23,172 --> 00:12:27,793
He positions the stand
Of the seat frame at one end.
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A robot welds
The stand to the tube
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00:12:30,586 --> 00:12:34,413
And welds mounts
For the seat rail.
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They apply a powder-coat finish
To the assembly,
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Making it corrosion-resistant.
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00:12:41,344 --> 00:12:46,379
An employee places the flywheel
Housing parts in a fixture
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00:12:46,379 --> 00:12:49,137
And activates
An automated welder,
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00:12:49,137 --> 00:12:52,206
Which fuses them together
At the seams.
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00:12:53,034 --> 00:12:56,862
They powder-coat
This assembly, too.
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00:12:56,862 --> 00:12:59,275
Plastic wheels
With metal bearings
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00:12:59,275 --> 00:13:02,482
Allow the seat
To slide on the rails.
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00:13:02,482 --> 00:13:04,379
A worker
Screws four wheels
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00:13:04,379 --> 00:13:08,931
To the carrier plate
Under the rower seat.
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00:13:08,931 --> 00:13:12,275
Now an employee applies
A decal with the company name
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00:13:12,275 --> 00:13:15,379
To the main tube.
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00:13:15,379 --> 00:13:19,068
He inserts a pulley in a notch
At the end of the tube.
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00:13:19,068 --> 00:13:24,758
Next, he sets the chrome
Seat rail on the mounts
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00:13:24,758 --> 00:13:27,620
And secures it with screws.
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00:13:27,620 --> 00:13:30,241
He attaches the ends
Of the chrome rail
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00:13:30,241 --> 00:13:32,137
To eyelets on the stand.
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00:13:34,448 --> 00:13:38,586
He screws plastic feet
To the bottom of the stand.
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00:13:38,586 --> 00:13:40,241
At another station,
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00:13:40,241 --> 00:13:43,620
A worker places a bearing
In the center of the flywheel
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00:13:43,620 --> 00:13:46,827
And uses a press
To secure it.
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00:13:46,827 --> 00:13:49,310
Next, he pulls a black,
Plastic cord through a spool
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00:13:49,310 --> 00:13:51,517
And knots it at the end.
202
00:13:56,620 --> 00:13:59,310
He also pulls a white,
Rubberized cord through,
203
00:13:59,310 --> 00:14:04,724
Then mounts the spool
To a shaft in the flywheel.
204
00:14:04,724 --> 00:14:09,000
He locks the spool to the shaft
With a special steel ring
205
00:14:09,000 --> 00:14:14,206
And winds the black cord
Around the spool.
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00:14:14,206 --> 00:14:16,379
He puts the flywheel
In the steel housing
207
00:14:16,379 --> 00:14:21,068
And screws it in place.
208
00:14:21,068 --> 00:14:23,103
Using a hooked tool,
209
00:14:23,103 --> 00:14:26,482
He grabs a spring linked
To the magnetic braking system.
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00:14:29,896 --> 00:14:31,862
He fastens
This end of the spring
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00:14:31,862 --> 00:14:34,965
To a hole
In the flywheel housing.
212
00:14:38,206 --> 00:14:41,827
A team now threads the white
Pull cord through the main tube
213
00:14:41,827 --> 00:14:46,241
And uses the pulley at the end
To loop it back.
214
00:14:46,241 --> 00:14:51,551
A piece of metal cable attached
The end of the pull cord
215
00:14:51,551 --> 00:14:55,586
Makes it easier to snake
The cord through the tube.
216
00:14:57,448 --> 00:15:01,758
Now a worker unwinds
Some of the black cord.
217
00:15:01,758 --> 00:15:04,724
He threads it through a guide
On the flywheel housing
218
00:15:04,724 --> 00:15:06,551
And attaches it
To the handlebar,
219
00:15:06,551 --> 00:15:10,000
Also known as the oar.
220
00:15:10,000 --> 00:15:13,586
He pushes caps
Into the ends of the handlebar,
221
00:15:13,586 --> 00:15:18,827
Then rests it on top
Of the flywheel housing.
222
00:15:18,827 --> 00:15:22,000
Another employee builds
A protective outer structure
223
00:15:22,000 --> 00:15:23,896
Around the flywheel
Steel housing
224
00:15:23,896 --> 00:15:26,000
Using molded
Plastic parts.
225
00:15:28,862 --> 00:15:31,827
He installs a port
For the electrical system
226
00:15:31,827 --> 00:15:34,379
That powers
The workout computer.
227
00:15:34,379 --> 00:15:38,620
The top part of the casing
Contains the computer.
228
00:15:38,620 --> 00:15:43,620
The computer measures
Row strokes and calories burned.
229
00:15:43,620 --> 00:15:45,793
After making
All the necessary connections,
230
00:15:45,793 --> 00:15:48,965
He screws it in place.
231
00:15:48,965 --> 00:15:51,896
A plastic cradle
Supports the assembly.
232
00:15:51,896 --> 00:15:53,965
It snaps into place.
233
00:15:56,896 --> 00:15:58,862
Once the seat
Is attached,
234
00:15:58,862 --> 00:16:03,551
This rowing machine
Is ready for a workout.
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00:16:13,551 --> 00:16:18,103
Narrator:
Until recently, if a sculptor
Wanted to create a large statue,
236
00:16:18,103 --> 00:16:20,379
They had to make
Their model by hand,
237
00:16:20,379 --> 00:16:21,620
But now an artist
238
00:16:21,620 --> 00:16:24,275
Can make a small-scale replica
Of their statue
239
00:16:24,275 --> 00:16:25,862
And have a large copy
Made in foam.
240
00:16:25,862 --> 00:16:28,000
The artist
Can then use this model
241
00:16:28,000 --> 00:16:30,413
To make their full-size
Sculpture,
242
00:16:30,413 --> 00:16:33,965
Saving them
A lot of time and money.
243
00:16:33,965 --> 00:16:37,758
A full-size sculpture starts out
As a small clay model.
244
00:16:37,758 --> 00:16:39,896
The artist
Uses the clay model
245
00:16:39,896 --> 00:16:43,137
To make a mold
Out of wax, plaster, or resin.
246
00:16:43,137 --> 00:16:46,172
The artist then sends
The copy, called a maquette
247
00:16:46,172 --> 00:16:49,068
To a specialist,
Who produces a foam enlargement
248
00:16:49,068 --> 00:16:54,793
To be used as a model
To cast the full-size sculpture.
249
00:16:54,793 --> 00:16:58,896
The specialist places
The maquette on a turntable.
250
00:16:58,896 --> 00:17:03,068
He spins it at an event pace
While scanning it.
251
00:17:03,068 --> 00:17:04,931
The scanner's five cameras
252
00:17:04,931 --> 00:17:07,620
Take continuous
High-resolution photos
253
00:17:07,620 --> 00:17:09,655
And upload them
To a computer.
254
00:17:09,655 --> 00:17:13,241
The computer then converts
These photos into a 3d image.
255
00:17:13,241 --> 00:17:15,517
He scans
The maquette several times
256
00:17:15,517 --> 00:17:18,413
To make sure he captures
Every detail.
257
00:17:18,413 --> 00:17:20,413
Then, he combines
The pictures together
258
00:17:20,413 --> 00:17:25,172
And divides the sculpture
Into sections.
259
00:17:25,172 --> 00:17:26,448
He uses another program
260
00:17:26,448 --> 00:17:29,379
To calculate
The scale of enlargement.
261
00:17:29,379 --> 00:17:30,724
This helps him determine
262
00:17:30,724 --> 00:17:33,482
How many and what size
Blocks of foam he needs
263
00:17:33,482 --> 00:17:36,413
To produce
Each section.
264
00:17:36,413 --> 00:17:39,517
He uses a dense foam
With a fine grain
265
00:17:39,517 --> 00:17:45,275
Called extruded polystyrene.
266
00:17:45,275 --> 00:17:47,551
He secures
The foam with tape,
267
00:17:47,551 --> 00:17:50,551
Then uses
A computer-guided router
268
00:17:50,551 --> 00:17:53,896
To carve the enlarged sections
Of the sculpture.
269
00:18:00,000 --> 00:18:02,172
The larger
And more detailed the part,
270
00:18:02,172 --> 00:18:05,344
The longer
This process takes.
271
00:18:05,344 --> 00:18:10,172
For example, this half of
The dog's head took 45 minutes,
272
00:18:10,172 --> 00:18:16,103
While carving half a leg
Would take just eight minutes.
273
00:18:16,103 --> 00:18:18,551
He uses a hot-wire machine
274
00:18:18,551 --> 00:18:22,586
To slice through the block
And free the carved part.
275
00:18:29,241 --> 00:18:33,551
The specialist removes excess
Foam with a sanding block.
276
00:18:44,034 --> 00:18:47,275
He makes sure adjacent sections
Line up properly,
277
00:18:47,275 --> 00:18:49,482
Then tapes them together.
278
00:18:54,482 --> 00:19:00,482
He scrapes off the seam
With a horse-grooming comb,
279
00:19:00,482 --> 00:19:05,000
Then sands it down.
280
00:19:07,689 --> 00:19:09,793
Next, he measures
The sections
281
00:19:09,793 --> 00:19:13,551
So he can cut a steel pipe
To the correct length.
282
00:19:13,551 --> 00:19:17,724
The steel pipe is used
As a stiffener
283
00:19:17,724 --> 00:19:21,241
To make the sections
More rigid.
284
00:19:21,241 --> 00:19:25,517
It also connects
Adjacent sections together.
285
00:19:29,206 --> 00:19:31,241
He uses
A standard pipe bender
286
00:19:31,241 --> 00:19:36,620
To match the stiffeners to
The sections they're going into.
287
00:19:36,620 --> 00:19:39,551
To embed the stiffener
In the dog's leg,
288
00:19:39,551 --> 00:19:42,655
He first traces it
On one side of the leg,
289
00:19:42,655 --> 00:19:44,413
Then he carves out
A trough
290
00:19:44,413 --> 00:19:46,448
To the depth of
The stiffener's diameter.
291
00:19:53,482 --> 00:19:56,827
He cleans out the loose foam
With a narrow brush.
292
00:19:56,827 --> 00:20:00,000
He checks to make sure
The stiffener will fit.
293
00:20:05,310 --> 00:20:12,758
Then, he applies an adhesive
Designed especially for foam
294
00:20:12,758 --> 00:20:15,379
And inserts the stiffener.
295
00:20:20,758 --> 00:20:23,206
He places the other half
Of the leg on top,
296
00:20:23,206 --> 00:20:27,551
Encasing the stiffener.
297
00:20:27,551 --> 00:20:30,724
He leaves about six inches
Sticking out of the leg.
298
00:20:30,724 --> 00:20:32,862
He inserts
The protruding steel rod
299
00:20:32,862 --> 00:20:37,344
Into a hole drilled
In the enlargement.
300
00:20:39,551 --> 00:20:42,241
Once he has assembled
All the sections,
301
00:20:42,241 --> 00:20:46,068
He tapes them together
To check their alignment.
302
00:20:46,068 --> 00:20:48,310
The completed
Sculpture enlargement
303
00:20:48,310 --> 00:20:51,517
Is about four times bigger
Than the original maquette.
304
00:20:51,517 --> 00:20:54,413
It's now ready
To be sent back to the sculptor,
305
00:20:54,413 --> 00:20:56,758
Where he or she
Will cover it with clay
306
00:20:56,758 --> 00:21:01,275
And add fine details that
Can't be reproduced in foam.
307
00:21:01,275 --> 00:21:02,931
Once this is done,
308
00:21:02,931 --> 00:21:06,275
The sculptor sends
The clay model to a mold maker,
309
00:21:06,275 --> 00:21:09,655
Who casts a mold
And sends it to a metal foundry
310
00:21:09,655 --> 00:21:13,034
To create
The final sculpture.
311
00:21:19,034 --> 00:21:21,379
If you have any comments
About the show,
312
00:21:21,379 --> 00:21:24,620
Or if you'd like to suggest
Topics for future shows,
313
00:21:24,620 --> 00:21:26,862
Drop us a line at...
25455
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