All language subtitles for S31E13 - Leather Overnight Bags; Horse Exercisers; Air Hockey Tables; Copper Sculptures (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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Narrator:
Today on "How it's made"...
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...Leather overnight bags...
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...Horse exercisers...
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...Air hockey tables...
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...And copper sculptures.
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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Whether heading across
The country
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Or taking a weekend getaway,
People love to travel.
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00:00:59,344 --> 00:01:01,241
Regardless of the destination,
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It's impossible to leave home
Without luggage.
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00:01:04,413 --> 00:01:06,862
Luggage is made from all kinds
Of materials,
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00:01:06,862 --> 00:01:09,482
Including wood, metal, plastic,
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00:01:09,482 --> 00:01:12,172
Hi-tech polycarbonates,
And leather.
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Not all leather overnight bags
Are created equal.
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This dark brown bag
Was constructed
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With the capacity to hold water.
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The process starts
With full-grain hides,
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Chrome-tanned
By an outside facility.
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Chrome-tanning is an effective
Treatment
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Which allows the leather
To become more water resistant.
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00:01:37,965 --> 00:01:41,275
This bag is constructed
From a single piece of leather,
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Making it more durable
And water-tight.
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First, a leather worker
Uses a template
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To cut out the shape of the bag.
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00:02:00,206 --> 00:02:02,448
He uses the machine
To shave the edges
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00:02:02,448 --> 00:02:06,068
Off the piece of leather
In a process called sciving,
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Which prepares the leather
For folding and sewing.
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00:02:09,517 --> 00:02:10,896
Using a hole punch,
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00:02:10,896 --> 00:02:13,517
Another craftsman
Taps the series of openings
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For riveting on buckles
And other attachments.
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The holes will prevent
The opening from ripping.
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Next, a leather worker
Uses a template to mark
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00:02:29,586 --> 00:02:32,724
Where he'll apply
A strip of glue to the top edge.
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He attaches a polyester strip
To the bottom edge of the glue
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And spreads more glue
On top of the polyester.
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Then he folds and hammers
The top portion of the leather
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Over onto the polyester strip.
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00:02:56,655 --> 00:02:58,172
Once complete,
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00:02:58,172 --> 00:03:01,310
The leather worker trims
The edges of the polyester.
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00:03:03,482 --> 00:03:07,034
The leather is then placed into
A machine known as a clicker,
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00:03:07,034 --> 00:03:11,068
To stamp out the bag straps
And other leather components.
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The clicker works by applying
25 tons of pressure
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To custom-made dyes.
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The shoulder pad is one of
22 pieces of leather
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That will complete the bag.
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A craftsperson glues
A foam rectangle
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Between two layers of leather.
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00:03:35,655 --> 00:03:40,517
This type of glue won't bubble
In hot temperatures.
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00:03:40,517 --> 00:03:43,620
Chrome-tanned hide
Is tough stuff,
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So manufacturers use
A heated stamp
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To brand the leather
With their logo.
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A leather worker uses
A sewing machine
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To piece together
Multiple parts of the leather.
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The stitching perforations
Weakens the leather,
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So for added strength,
The craftsman uses a heavy gauge
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Continuous-filament
Polyester thread.
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00:04:07,689 --> 00:04:11,310
Next, a craftsman attaches
The buckles.
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He places one steel rivet
In each buckle piece
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00:04:14,344 --> 00:04:17,068
And secures it into place.
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00:04:17,068 --> 00:04:19,827
He leaves the remaining rivets
Out to accommodate
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The sewing machine,
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Which will reinforce
The attachment.
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The buckles are made of high
Strength 316 stainless steel.
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A craftsman attaches a piece of
Plastic to reinforce the handle
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And prevent the leather from
Becoming misshapen over time.
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Once he's glued in pieces of
Plastic to each handle opening,
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The leather worker
Finishes all the seams.
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This type of continuous-filament
Polyester thread
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Is the same kind that is used
To sew parachutes together.
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00:05:09,931 --> 00:05:13,206
Next, a craftswoman cleans
The completed bag
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And applies a generous amount
Of leather milk
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To condition the leather.
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The leather milk
Is made of all-natural,
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Non-toxic ingredients.
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The craftswoman uses a torch
To singe off any stray hairs
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Before the strap is attached to
A set of upper or lower d-rings.
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This first little bag
Can now be worn
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As a backpack or a shoulder bag.
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Stylish and durable,
This leather overnight bag
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Is built to hold your stuff
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While you travel
To any destination.
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Narrator:
Horses need regular exercise
To stay healthy and fit.
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00:06:05,965 --> 00:06:08,137
This innovative mechanical
Exerciser
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Provides horses with a safe way
To stay active on their own,
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Especially if they spend long
Periods of time in their stalls.
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The rotating panels of this
Exerciser
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Give horses the push
They need to get moving.
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An operator regulates
The speed of the panel,
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Which controls the pace
Of the workout.
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Making this horse exerciser
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Starts with a
Computer-generated design.
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This one is for
A six-horse exerciser.
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Once designing is complete,
Production can begin.
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First, a sheet of mile-carbon
Steel uncoils
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Into a rolling slitting machine.
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Circular blades above
And below slice
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The steel sheet into strips.
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Most of the strips will be made
Into structural tubing.
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One of the strips enters
A 300-foot-long machine
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00:07:01,586 --> 00:07:03,827
With many rollers.
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00:07:03,827 --> 00:07:08,620
The rollers shape the strip
From flat to round.
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More rollers shape the material.
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00:07:11,551 --> 00:07:14,827
As an induction coil energized
By a radio-frequency
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00:07:14,827 --> 00:07:18,689
Electric current wields
It together.
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00:07:18,689 --> 00:07:23,655
A blade shaves the excess steel
From the wielded steam.
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00:07:23,655 --> 00:07:25,620
Meanwhile another tubing sheers
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The tubing against a set of guy
Clamping blocks,
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Cutting it to
The specified length.
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00:07:33,620 --> 00:07:37,655
Finally, the tubing exits
The cutting operation.
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A technician wields both plates
To the tubing
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00:07:40,344 --> 00:07:42,724
And adds
A cable-stabilizer bar.
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The completed part will serve
As one of the arms
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That link the center shaft
To the revolving panels.
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Another machinist builds
The panels
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For the exerciser's
Inner and outer walls.
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To do so, he arranges tubing
Horizontally and inserts
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A vertical support bar.
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00:08:04,655 --> 00:08:06,758
He wields a framework
To the tubing
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00:08:06,758 --> 00:08:09,758
To hold the panel
Structure together.
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He adds a steel shield
To the lower part.
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The shield will prevent sand
From being forced
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Out of the exerciser track
By the horses' hooves.
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00:08:20,724 --> 00:08:22,724
Once construction is complete,
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00:08:22,724 --> 00:08:25,862
The technician stacks
The assembled panels together.
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00:08:28,172 --> 00:08:30,206
Next, an overhead monorail
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00:08:30,206 --> 00:08:33,379
Transports the panels
To the powder-coating station.
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00:08:37,620 --> 00:08:39,137
Using an applicator,
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00:08:39,137 --> 00:08:42,724
A technician applies a powder
Coat to the revolving panels.
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00:08:42,724 --> 00:08:44,931
The powder coat provides
An anti-corrosive
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Protective finish.
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00:08:47,620 --> 00:08:50,965
A team clamps one of the
Structural panels in a machine
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With powerful mechanical arms.
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The arms bend the panel
To a specified curvature.
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00:08:57,724 --> 00:09:01,034
All the structural panels
Are bent to the same angle,
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So that when looked,
They'll form a round pen.
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00:09:09,620 --> 00:09:11,172
Using a press brake,
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A technician makes two strategic
Bends in a flat sheet of steel,
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00:09:16,931 --> 00:09:19,793
Which creates a flared
Three-walled part.
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00:09:23,689 --> 00:09:25,862
Another machinist fits two
Of these parts
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Together to create a structure
Known as the tree.
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00:09:29,448 --> 00:09:31,862
Then he wields connectors
To the tree
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For the cables and tubular arms.
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00:09:37,620 --> 00:09:42,172
A loop is wielded on top
For handling purposes.
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Then the tree is given
A powder-coat finish to match
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The rest
Of the horse-exerciser machine.
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Using a hoist, a technician
Lowers the drive shaft
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Onto the motor
And shakes the framework
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00:09:58,034 --> 00:10:00,344
To bring the connection
Into alignment.
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00:10:03,827 --> 00:10:06,655
Then the assembly is tested
To confirm the motor
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00:10:06,655 --> 00:10:08,379
Turns the shaft.
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Steel panels fit to the
Framework to enclose the motor
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And protect it
From the elements.
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00:10:17,655 --> 00:10:21,620
He attaches a door, so the motor
Can be accessed for maintenance.
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00:10:26,724 --> 00:10:29,931
Now complete, the parts
Are ready for shipping.
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On-site assembly takes about
Nine hours,
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But it's well worth the wait
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When the horses
Get to test it out.
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Halfway through the test,
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The operator reverses
The direction of the machine
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To ensure all of
The horses' muscles
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Are being exercised accordingly,
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Proving that running around
In circles can be a good thing.
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Narrator:
Air hockey was developed
In the late '60s and early '70s
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By a group
Of american billiard engineers.
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When in play, the puck floats
On a thin cushion of air,
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Propelled by players
On each end.
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00:11:25,827 --> 00:11:28,965
With no friction,
The puck moves fast,
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00:11:28,965 --> 00:11:33,068
Making air hockey
A high-speed game.
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In a game of air hockey,
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The puck levitates
Ever so slightly,
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Made possible
By a constant flow of air
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Flowing through perforations
In the playfield.
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00:11:43,344 --> 00:11:46,724
The playfield is made from a
Laminated composite material
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That's been printed
With air hockey graphics.
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A computerized drill cuts
Into three playfields at once
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In the same consistent pattern.
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00:12:00,448 --> 00:12:03,793
The size of the holes are
A little larger than pin holes,
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00:12:03,793 --> 00:12:09,344
Creating over 4,600 perforations
In each air hockey playfield.
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00:12:13,379 --> 00:12:15,517
An automated tool carves grooves
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In a sheet of medium
Density fiber board.
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The board will serve as a base
For the playfield.
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Air will circulate
In the grooves and exit
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Through the playfield holes.
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Next, sawdust is blasted
Out of the grooves.
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00:12:34,310 --> 00:12:38,551
The grooves' fiberboard moves
Through a glue applicator.
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00:12:38,551 --> 00:12:40,793
The rubber roller coats
The top of the board
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With a small amount of glue,
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So it doesn't seep
Into the grooves.
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00:12:47,379 --> 00:12:51,551
As the board exits, technicians
Move the board onto a stack.
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00:12:54,275 --> 00:12:56,724
Once the board is in the correct
Position,
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The laminate is applied
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00:12:59,034 --> 00:13:01,793
And aligned with the grooves
In the fiber board.
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00:13:05,413 --> 00:13:08,965
A cardboard cover is placed
On the laminate for protection
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00:13:08,965 --> 00:13:12,793
As the stack
Moves through a press.
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00:13:12,793 --> 00:13:15,724
The weight of the press
Squeezes the stack together,
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00:13:15,724 --> 00:13:18,586
Ensuring adhesion
As the glue cures.
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00:13:21,379 --> 00:13:24,620
Meanwhile, a craftswoman applies
Stick-on graphics
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00:13:24,620 --> 00:13:26,758
Onto the side apron boards.
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00:13:30,241 --> 00:13:33,344
She opens a pre-cut slot
For a coin door
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00:13:33,344 --> 00:13:35,655
And exposes a hole for a bolt.
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00:13:38,241 --> 00:13:41,103
She cuts open a slot
For maintenance access
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00:13:41,103 --> 00:13:43,896
And removes the panel
That will serve as a door.
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00:13:46,448 --> 00:13:49,137
She numbers the door
And the side apron piece,
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00:13:49,137 --> 00:13:52,379
So she can match them up later
During installation.
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00:13:55,275 --> 00:13:58,034
After applying art work
To the end panels,
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00:13:58,034 --> 00:14:01,310
Another technician assembles
Curved corner parts
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00:14:03,379 --> 00:14:06,724
And links mental brackets
To the side apron parts.
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00:14:09,241 --> 00:14:11,793
He installs a bracket
For a puck deflector
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00:14:11,793 --> 00:14:17,413
In the center
Of the end panel
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00:14:17,413 --> 00:14:19,965
And screws down
The corner connectors.
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00:14:22,344 --> 00:14:25,172
He sets the end panels
In an upside-down possession
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00:14:25,172 --> 00:14:28,310
On the work surface
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00:14:28,310 --> 00:14:31,758
And attaches the side boards
To the corner connectors.
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00:14:34,241 --> 00:14:36,517
This completes the table apron.
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00:14:39,413 --> 00:14:42,931
A locked door is installed
In the plywood floor.
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00:14:42,931 --> 00:14:46,068
This will serve as an interior
Storage compartment.
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00:14:50,241 --> 00:14:53,172
Next, a craftsman installs
The coin door
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00:14:53,172 --> 00:14:55,172
And secures it into place.
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00:14:57,482 --> 00:15:00,689
He mounts wire speakers
That projects sound effects
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00:15:00,689 --> 00:15:02,931
To a computerized optical system
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00:15:02,931 --> 00:15:06,206
That tracks
The puck's movements.
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00:15:06,206 --> 00:15:09,206
Once the structure is fitted
With wooden panels,
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00:15:09,206 --> 00:15:14,310
The game's flashing lights and
Sensor activators are installed.
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00:15:14,310 --> 00:15:15,758
At another station,
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00:15:15,758 --> 00:15:20,379
A team flips a playfield
Over to work on the back.
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00:15:20,379 --> 00:15:23,655
One technician attaches a board
Above the open grooves,
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00:15:23,655 --> 00:15:25,862
Creating a chamber for airflow.
229
00:15:28,655 --> 00:15:32,172
The motor and fan are installed
Over the small opening.
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00:15:32,172 --> 00:15:34,551
This system will blow air
Into the grooves
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00:15:34,551 --> 00:15:38,310
And the playfield perforations.
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00:15:38,310 --> 00:15:40,137
The playfield is turned over
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00:15:40,137 --> 00:15:43,724
And lowered onto
The table structure.
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00:15:43,724 --> 00:15:46,551
Next, aluminum bumpers
Are attached to the table's
235
00:15:46,551 --> 00:15:51,206
Border as a barrier
For the puck during play.
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00:15:51,206 --> 00:15:54,862
A technician installs goal puck
Deflectors on the ends
237
00:15:57,068 --> 00:16:02,344
And screws in metal plates
Over the deflector cups.
238
00:16:02,344 --> 00:16:04,793
He installs a lock
On each goal compartment
239
00:16:04,793 --> 00:16:06,827
So no one can steal the puck.
240
00:16:10,206 --> 00:16:14,137
Finally, the air hockey
Table assembly is complete.
241
00:16:14,137 --> 00:16:16,000
Let the games begin.
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00:16:27,448 --> 00:16:30,620
Narrator: artisans have
Worked with copper for years.
243
00:16:30,620 --> 00:16:35,034
The metal is soft enough to
Easily cut, shape, and emboss.
244
00:16:35,034 --> 00:16:37,931
Unless sealed, copper's bright,
Shiny surface
245
00:16:37,931 --> 00:16:40,310
Naturally tarnishes over time,
246
00:16:40,310 --> 00:16:44,551
Producing a warm, aged finish,
Referred to as patina.
247
00:16:48,206 --> 00:16:49,896
These intricate copper
Sculptures
248
00:16:49,896 --> 00:16:54,413
Are the work of an artist
With a quirky imagination.
249
00:16:54,413 --> 00:16:58,793
This style of work is designed
To rotate on rods as lawn art
250
00:16:58,793 --> 00:17:01,275
Or weather vanes.
251
00:17:01,275 --> 00:17:03,517
When a customer commissions
A sculpture,
252
00:17:03,517 --> 00:17:06,448
The artist draws the sculpture
On cardstock,
253
00:17:06,448 --> 00:17:08,137
A thick type of paper.
254
00:17:12,275 --> 00:17:15,379
When planning a spinning
Sculpture like this griffin,
255
00:17:15,379 --> 00:17:17,689
The artist sketches
The side view.
256
00:17:20,206 --> 00:17:21,827
Using a pair of scissors,
257
00:17:21,827 --> 00:17:24,206
He cuts off
The excess cardstock.
258
00:17:30,206 --> 00:17:32,172
Then he uses smaller scissors
259
00:17:32,172 --> 00:17:35,310
To cut precisely along
The lines of his drawing.
260
00:17:42,275 --> 00:17:44,931
Now the artist
Has a pattern to work with.
261
00:17:48,172 --> 00:17:50,896
He lays the pattern
On a sheet of copper,
262
00:17:53,689 --> 00:17:55,172
Tapes it down,
263
00:17:57,413 --> 00:17:59,620
And traces it
With a fine-point pen
264
00:17:59,620 --> 00:18:01,793
To get a crisp line.
265
00:18:01,793 --> 00:18:04,724
The tracing must be precise
For the sculpture's components
266
00:18:04,724 --> 00:18:07,275
To line up properly.
267
00:18:07,275 --> 00:18:10,172
He repeats this step
On a second sheet of copper,
268
00:18:10,172 --> 00:18:13,517
Since the sculpture
Will be two-sided.
269
00:18:13,517 --> 00:18:17,827
He cuts along the line
With metal sheers.
270
00:18:17,827 --> 00:18:20,413
First, he cuts away
The excess copper
271
00:18:20,413 --> 00:18:23,310
And then does
The detailed cutting.
272
00:18:23,310 --> 00:18:28,241
He cuts out pieces for the left
And right side of the sculpture.
273
00:18:28,241 --> 00:18:32,586
The artist draws an eye on the
Back of the right-side head.
274
00:18:32,586 --> 00:18:35,172
With a round-head hammer,
He taps a piece of
275
00:18:35,172 --> 00:18:38,758
Stainless-steel wire
On the line to create an eyelid.
276
00:18:41,344 --> 00:18:45,344
He uses tools designed
For stamping leather.
277
00:18:45,344 --> 00:18:48,758
He recesses the head,
So that on the reverse side,
278
00:18:48,758 --> 00:18:52,379
The front of the sculpture,
The head will appear raised.
279
00:18:55,206 --> 00:18:57,827
This technique brings dimension
And texture
280
00:18:57,827 --> 00:19:01,206
To what was originally
A flat piece of copper.
281
00:19:01,206 --> 00:19:03,344
The artist hammers the back
Of the wing
282
00:19:03,344 --> 00:19:06,448
To gradually contour
And texture the feathers.
283
00:19:09,758 --> 00:19:12,827
He uses different tools
To create finer effects
284
00:19:12,827 --> 00:19:14,896
Such as veining.
285
00:19:14,896 --> 00:19:17,931
This age-old technique
Of hammering a malleable metal
286
00:19:17,931 --> 00:19:20,965
From the reverse side
To create a design in relief
287
00:19:20,965 --> 00:19:26,310
Is called repoussé,
French for "Pushed back".
288
00:19:26,310 --> 00:19:28,793
The artist heats a part
With a torch
289
00:19:28,793 --> 00:19:32,448
And applies zinc chloride flux
To the parameter.
290
00:19:32,448 --> 00:19:35,068
This caustic solution cleans
The copper,
291
00:19:35,068 --> 00:19:38,655
Removing impurities that would
Prevent solder from adhering.
292
00:19:42,137 --> 00:19:45,586
Then he uses a blowtorch
To melt silver-based solder
293
00:19:45,586 --> 00:19:46,793
Onto the copper,
294
00:19:46,793 --> 00:19:48,862
Around
The parameter of the part.
295
00:19:53,758 --> 00:19:56,206
This step is called
Pre-soldering,
296
00:19:56,206 --> 00:19:59,137
As the sculpture
Will be fully soldered later.
297
00:20:07,241 --> 00:20:09,517
He pre-solders the back
Of the pieces
298
00:20:09,517 --> 00:20:12,551
That will be attached
To matching pieces.
299
00:20:12,551 --> 00:20:14,689
Then he heats the front surface
300
00:20:14,689 --> 00:20:18,172
To bring out
A rainbow of colors.
301
00:20:18,172 --> 00:20:20,586
Next, he aligns
The matching parts
302
00:20:20,586 --> 00:20:22,586
And heats them with a torch.
303
00:20:22,586 --> 00:20:25,034
This melts the solder along the
Parameter,
304
00:20:25,034 --> 00:20:27,827
Fusing the pieces together.
305
00:20:27,827 --> 00:20:31,448
In areas where the sides are too
Far apart to be fused,
306
00:20:31,448 --> 00:20:36,034
He solders a small copper patch
To fit over the gap.
307
00:20:36,034 --> 00:20:39,586
He flattens all the seams
With fine grinding tools
308
00:20:39,586 --> 00:20:42,586
Until they appear seamless.
309
00:20:42,586 --> 00:20:47,275
He repeats this process for
Each section of the sculpture.
310
00:20:47,275 --> 00:20:49,586
Once all the sections
Are assembled,
311
00:20:49,586 --> 00:20:51,655
He solders them to each other.
312
00:20:55,241 --> 00:20:57,379
The wing fits into
A thin channel
313
00:20:57,379 --> 00:20:59,862
He hammered into the body
Of the sculpture.
314
00:20:59,862 --> 00:21:01,827
He melts the solder
In the channel
315
00:21:01,827 --> 00:21:04,137
To produce a neat and even seam.
316
00:21:11,103 --> 00:21:15,034
To display the copper sculpture
Or use it as a weather vane,
317
00:21:15,034 --> 00:21:17,000
The artist solders
A ball bearing
318
00:21:17,000 --> 00:21:19,000
Inside a copper tube,
319
00:21:19,000 --> 00:21:24,000
Then attaches the tube
To the bottom of the sculpture.
320
00:21:24,000 --> 00:21:25,827
The tube slides over a rod,
321
00:21:25,827 --> 00:21:29,310
So it can be set in the ground
Or mounted on the roof.
26288
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