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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Today on "How it's made"...
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The distinctive sound
Of the tin whistle
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Is characteristic of
The traditional music of
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00:00:58,344 --> 00:01:01,206
England, ireland, and scotland.
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00:01:01,206 --> 00:01:03,620
When this flute
Was first manufactured
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00:01:03,620 --> 00:01:05,241
In the mid-19th century,
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00:01:05,241 --> 00:01:08,172
It sold for just a penny,
Making it affordable
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00:01:08,172 --> 00:01:10,862
And earning its nickname
"The penny whistle."
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00:01:13,655 --> 00:01:18,137
This u.K. Company was the first
Factory to make tin whistles.
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00:01:18,137 --> 00:01:22,655
In 1843, the company produced
Whistles using tinplate --
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00:01:22,655 --> 00:01:26,827
That's tin-coated steel --
From british metal foundries.
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00:01:31,137 --> 00:01:34,827
A press strikes each sheet
With a dye 20 times,
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00:01:34,827 --> 00:01:40,344
Stamping out 20 flat shapes
Called blanks.
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00:01:40,344 --> 00:01:43,586
Each blank contains six
Finger holes toward the bottom
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00:01:43,586 --> 00:01:48,758
And a rectangular opening
Called a fipple near the top.
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00:01:48,758 --> 00:01:51,137
A technician inserts
One blank at a time
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00:01:51,137 --> 00:01:55,172
Into a custom-made mandrel,
Then turns the crank.
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00:01:55,172 --> 00:02:00,689
The mandrel rolls the flat blank
Into a tube.
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00:02:00,689 --> 00:02:03,137
While some tin whistles
Are straight,
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00:02:03,137 --> 00:02:05,724
This company's tin whistles
Are tapered.
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00:02:05,724 --> 00:02:11,172
The signature shape
Creates a distinctive sound.
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00:02:11,172 --> 00:02:15,000
Next, a technician slides
Four tubes into tapered slots
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00:02:15,000 --> 00:02:17,000
On a custom-built jig.
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00:02:17,000 --> 00:02:20,344
The slots align the tube's
Edges, creating a seam
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00:02:20,344 --> 00:02:25,068
That will prevent air blown into
The instrument from leaking out.
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00:02:25,068 --> 00:02:28,137
The seam is coated
In a chemical called flux.
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00:02:28,137 --> 00:02:33,000
Without it, solder wire
Won't adhere to the tinplate.
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00:02:33,000 --> 00:02:35,413
Using a custom-designed
Soldering gun,
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00:02:35,413 --> 00:02:39,310
The technician melts lead-free
Solder wire onto the edges,
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00:02:39,310 --> 00:02:41,551
Fusing them together.
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00:02:43,551 --> 00:02:46,379
The flux and solder
Are both nontoxic
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00:02:46,379 --> 00:02:48,586
Since they're being used
On an instrument
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00:02:48,586 --> 00:02:52,413
That goes into the mouth.
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00:02:52,413 --> 00:02:56,068
A worker washes the tin whistles
In mild soap and water
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00:02:56,068 --> 00:02:58,551
To remove any excess flux.
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00:03:00,275 --> 00:03:03,000
Another technician uses
A custom-made file
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00:03:03,000 --> 00:03:07,689
To scrape off any excess solder
And ensure the seam is smooth.
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00:03:07,689 --> 00:03:10,482
Then he shapes the top end
Of the tin whistle
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00:03:10,482 --> 00:03:13,344
With this custom-made
Squaring tool.
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00:03:13,344 --> 00:03:16,413
The round top of the instrument
Is now square.
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00:03:19,344 --> 00:03:22,620
The tin whistles are sent
To the factory's paint shop.
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00:03:22,620 --> 00:03:25,482
An operator hooks the whistles
Onto a track
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00:03:25,482 --> 00:03:28,172
That moves through
A paint chamber.
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00:03:28,172 --> 00:03:31,413
Inside, automated nozzles spray
The instruments
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00:03:31,413 --> 00:03:35,275
With powder paint.
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00:03:35,275 --> 00:03:37,413
Then the tin whistles
Head to an oven,
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00:03:37,413 --> 00:03:39,827
Which bakes the paint
For 20 minutes,
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00:03:39,827 --> 00:03:44,310
At a temperature
Of 255 degrees fahrenheit.
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00:03:44,310 --> 00:03:46,862
As each instrument exits
The oven,
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00:03:46,862 --> 00:03:49,344
The operator inspects
The paint job.
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00:03:53,206 --> 00:03:55,275
A pad printer spreads gold ink
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00:03:55,275 --> 00:03:58,655
Into the engraved company logo
And design.
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00:03:58,655 --> 00:04:00,586
The pad picks up the ink,
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00:04:00,586 --> 00:04:06,482
And stamps the logo and design
On the instrument.
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00:04:06,482 --> 00:04:09,827
To create the narrow air channel
That produces sound,
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00:04:09,827 --> 00:04:11,689
A wooden plug is created
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00:04:11,689 --> 00:04:15,034
And placed above the mouthpiece,
Or fipple.
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00:04:15,034 --> 00:04:18,068
The plug is made from cedar
Or beechwood.
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00:04:18,068 --> 00:04:20,827
This type of wood
Contains closed grains
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00:04:20,827 --> 00:04:24,758
That prevent swelling.
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00:04:24,758 --> 00:04:28,103
After pieces of wood
Are cut to the required shape,
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00:04:28,103 --> 00:04:30,965
A tin whistle tuner
Applies a water-based,
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00:04:30,965 --> 00:04:36,379
Nontoxic adhesive inside
The top of the instrument.
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00:04:36,379 --> 00:04:38,896
Then he takes a plug,
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00:04:38,896 --> 00:04:43,241
Sands the cut edge,
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00:04:43,241 --> 00:04:45,413
And glues it into the top.
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00:04:52,241 --> 00:04:54,344
Once he's completed sanding,
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00:04:54,344 --> 00:04:57,137
The whistle specialist
Tunes the tin whistle
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00:04:57,137 --> 00:04:59,482
By inserting a sizing tool
In the gap
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00:04:59,482 --> 00:05:02,034
Between the tinplate
And the plug.
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00:05:02,034 --> 00:05:06,103
He gently hammers the tinplate
Against the plug and tool.
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00:05:06,103 --> 00:05:09,482
This step adjusts the air
Channel to the required width,
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00:05:09,482 --> 00:05:11,965
Perfectly tuning the instrument.
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00:05:11,965 --> 00:05:14,862
After tuning
50 or so tin whistles,
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00:05:14,862 --> 00:05:17,034
He performs a musical
Spot-check.
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00:05:19,655 --> 00:05:22,482
Once the adhesive has cured
For 24 hours,
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The tin whistle is ready
For packaging.
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00:05:25,344 --> 00:05:27,620
After the instrument
Has been cleaned,
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00:05:27,620 --> 00:05:29,862
A technician includes
A fingering chart
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And a sheet of tunes
In the package
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00:05:31,896 --> 00:05:35,413
So that beginners can
Teach themselves how to play.
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00:05:37,206 --> 00:05:40,689
The tin whistle comes
In the key of c and d.
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00:05:40,689 --> 00:05:45,034
The musical landscapes of jigs,
Reels, highland flings,
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00:05:45,034 --> 00:05:48,206
And other traditional melodies
Of the british isles.
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00:06:08,206 --> 00:06:11,448
Narrator: animal horns are made
From meat-industry by-products.
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00:06:11,448 --> 00:06:13,586
They can be shaped
And cut easily,
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00:06:13,586 --> 00:06:16,344
While remaining
Incredibly durable.
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00:06:16,344 --> 00:06:20,758
In the 20th century, synthetic
Plastics largely replaced horn,
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00:06:20,758 --> 00:06:23,068
But today,
It's making a comeback
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As an all-natural
Biodegradable material.
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00:06:28,137 --> 00:06:33,482
In 1749, this manufacturer
Made inexpensive utensils
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00:06:33,482 --> 00:06:35,379
For people on a tight budget.
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00:06:35,379 --> 00:06:37,310
Two and a half centuries later,
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00:06:37,310 --> 00:06:40,655
Horn products
Are desirable luxury items.
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00:06:40,655 --> 00:06:44,034
This facility sources its horns
From nigeria
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00:06:44,034 --> 00:06:46,655
Where ankole cattle are known
For their long,
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00:06:46,655 --> 00:06:48,724
Magnificent horns.
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00:06:48,724 --> 00:06:51,758
A craftsman cuts the horns
On a band saw.
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00:06:51,758 --> 00:06:54,275
Horn is formed from keratin,
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00:06:54,275 --> 00:06:57,068
The same material
In hair and nails.
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00:06:57,068 --> 00:06:59,482
Even though it's hard,
Woodworking tools
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00:06:59,482 --> 00:07:02,241
Can easily cut and shape
The horn.
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00:07:02,241 --> 00:07:05,586
The horn is also biodegradable.
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00:07:05,586 --> 00:07:09,379
The craftsman uses a sanding
Disk to shape the edges.
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00:07:09,379 --> 00:07:13,103
This particular horn will become
A drinking mug.
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00:07:13,103 --> 00:07:15,172
Horn is thermoplastic.
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It can be shaped when heated
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00:07:17,103 --> 00:07:20,241
And will retain its new shape
When cooled.
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00:07:20,241 --> 00:07:25,137
An artisan heats a thin section
And bends the tip.
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00:07:25,137 --> 00:07:29,000
He heats the base of the thin
Section over an open flame
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00:07:29,000 --> 00:07:31,172
And then carefully folds it over
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00:07:31,172 --> 00:07:32,827
To form a perfect handle
For the mug.
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00:07:35,206 --> 00:07:37,689
The craftsman puts the mug
Into a vice
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00:07:37,689 --> 00:07:40,793
To ensures that the handle
Will retain its new shape
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00:07:40,793 --> 00:07:42,482
Once cooled.
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00:07:42,482 --> 00:07:45,413
In just a few steps,
This cattle horn
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00:07:45,413 --> 00:07:51,000
Has been transformed
Into a unique mug-shaped object.
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00:07:51,000 --> 00:07:53,586
Now the mug needs a bottom.
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00:07:53,586 --> 00:07:57,275
A technician glues a set of mugs
To wooden planks
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00:07:57,275 --> 00:08:01,689
And then pours in a food-safe
Resin to form a watertight seal.
123
00:08:04,068 --> 00:08:07,793
It takes 24 hours
For the resin to cure.
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00:08:07,793 --> 00:08:12,689
Once cured, a craftsman uses
A band saw to separate the mugs.
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00:08:12,689 --> 00:08:14,310
Then he trims the wood
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00:08:14,310 --> 00:08:17,310
Until there's only a small
Amount left around the edges.
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00:08:24,586 --> 00:08:28,034
The sanding disk easily removes
The excess
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00:08:28,034 --> 00:08:30,448
Until the wood
Is even with the horn.
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00:08:35,724 --> 00:08:38,448
A specialized wheel
With sandpaper edges
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00:08:38,448 --> 00:08:42,896
Smoothes hard-to-reach areas
Of the mug.
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00:08:42,896 --> 00:08:46,172
A craftsman sands
And polishes each mug thoroughly
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00:08:46,172 --> 00:08:49,137
Until they shine.
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00:08:49,137 --> 00:08:51,551
For constructing
Other types of products,
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00:08:51,551 --> 00:08:53,793
This facility uses
A deep fryer
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00:08:53,793 --> 00:08:58,862
To heat sections of horn
In 392-degree cooking oil.
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00:08:58,862 --> 00:09:01,931
A hydraulic press flattens
The heated material
137
00:09:01,931 --> 00:09:05,551
By applying pressure,
Then it's set aside to cool.
138
00:09:05,551 --> 00:09:09,379
After 10 minutes, the horn
Will retain its new shape,
139
00:09:09,379 --> 00:09:11,310
Which is called a plate.
140
00:09:11,310 --> 00:09:15,034
Flat horn plate is used
To make a variety of products.
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00:09:15,034 --> 00:09:18,862
Here, a cutting form stamps
Out spoons.
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00:09:18,862 --> 00:09:23,103
Artisans use a sanding disk
To refine the spoon's shape.
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00:09:23,103 --> 00:09:26,655
Another press hollows out
The end of the spoon.
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00:09:26,655 --> 00:09:29,379
Horn is a naturally
Non-stick material
145
00:09:29,379 --> 00:09:33,689
That won't absorb odor
Or color from food.
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00:09:33,689 --> 00:09:36,241
Beside their many
Other products,
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00:09:36,241 --> 00:09:40,689
This facility also
Manufactures shoehorns.
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00:09:40,689 --> 00:09:44,000
Shoehorns get their name
From the horn material
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00:09:44,000 --> 00:09:46,275
Used to make them.
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00:09:46,275 --> 00:09:50,241
A sanding disk is used
To shape the horn.
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00:09:50,241 --> 00:09:51,896
It takes artisans years
152
00:09:51,896 --> 00:09:56,137
To develop
This particular set of skills.
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00:09:56,137 --> 00:09:57,862
The horn, which has been
Straightened
154
00:09:57,862 --> 00:09:59,758
In a specialized press
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00:09:59,758 --> 00:10:03,137
Is now ready
For the final phase.
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00:10:03,137 --> 00:10:05,758
A craftsman refines
The shape of the horn
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00:10:05,758 --> 00:10:07,862
By using a specialized tool,
158
00:10:07,862 --> 00:10:11,793
Equipped with a narrow belt
Of sandpaper
159
00:10:11,793 --> 00:10:14,482
He smoothes the inner curve
Of the shoehorn
160
00:10:14,482 --> 00:10:18,344
By pressing on
The sandpaper belt.
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00:10:18,344 --> 00:10:21,655
This operation requires a high
Degree of concentration
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00:10:21,655 --> 00:10:23,172
And skill.
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00:10:23,172 --> 00:10:26,172
Too much pressure will remove
More of the horn material
164
00:10:26,172 --> 00:10:30,241
Than necessary.
165
00:10:30,241 --> 00:10:34,275
Polishing wheels give
The shoehorn its final sheen.
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00:10:34,275 --> 00:10:40,310
Once polishing is complete,
The horn's color is revealed.
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00:10:40,310 --> 00:10:43,103
The colors of a horn
Are near the surface,
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00:10:43,103 --> 00:10:50,000
So the sander must be careful
Not to remove too much material.
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00:10:50,000 --> 00:10:53,310
Skilled craftsmanship
Has transformed a raw horn
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00:10:53,310 --> 00:10:57,586
Into a shoe horn
In just a few steps.
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00:10:57,586 --> 00:11:01,034
A laser engraving machine
Brands the shoehorn
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00:11:01,034 --> 00:11:07,068
With the manufacturer's mark.
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00:11:07,068 --> 00:11:09,448
Horns may be
An ancient material,
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00:11:09,448 --> 00:11:13,000
But they still make relevant
Instruments for modern life.
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00:11:22,758 --> 00:11:25,689
Narrator: many professional
Race-car drivers got their start
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00:11:25,689 --> 00:11:28,862
In a formula f car,
An entry-level racing car
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00:11:28,862 --> 00:11:31,793
Developed in britain
In the 1960s.
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00:11:31,793 --> 00:11:34,000
Initially called "Formula ford,"
179
00:11:34,000 --> 00:11:36,482
The name was changed
To formula f
180
00:11:36,482 --> 00:11:39,448
When a motor
Other than a ford was permitted.
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00:11:44,862 --> 00:11:48,827
A formula f racecar is driven by
Both aspiring professionals
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00:11:48,827 --> 00:11:50,896
And amateurs.
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00:11:50,896 --> 00:11:53,827
This car can give drivers
A start in the sport
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00:11:53,827 --> 00:11:56,862
And hopefully a strong finish.
185
00:11:56,862 --> 00:11:59,896
Productions starts
With a steel tube skeleton
186
00:11:59,896 --> 00:12:01,862
Known as a space frame.
187
00:12:01,862 --> 00:12:05,896
The frame is designed
To be lightweight yet rigid.
188
00:12:05,896 --> 00:12:10,862
The technician measures
A piece of steel to be trimmed.
189
00:12:10,862 --> 00:12:15,896
Using a band saw, he cuts the
Steel to its specified length.
190
00:12:15,896 --> 00:12:18,310
This piece will be used
For the roll hoop,
191
00:12:18,310 --> 00:12:23,000
Which protects the driver's head
In the event the car rolls.
192
00:12:23,000 --> 00:12:25,793
He measures the tubing
One last time.
193
00:12:25,793 --> 00:12:27,896
When satisfied
With its placement,
194
00:12:27,896 --> 00:12:33,000
He lowers the saw
And cuts off any excess steel.
195
00:12:33,000 --> 00:12:36,413
He clamps the tubing
In a hydraulic bending device.
196
00:12:38,724 --> 00:12:42,827
Once activated, the device wraps
The tubing around a dye
197
00:12:42,827 --> 00:12:45,793
Forming it
To the desired curvature.
198
00:12:45,793 --> 00:12:48,965
Next, he builds
The car's front bulkhead.
199
00:12:48,965 --> 00:12:52,551
He arranges steel tubing in
The desired configuration
200
00:12:52,551 --> 00:12:57,103
And clamps them to the work
Bench to hold them steady.
201
00:12:57,103 --> 00:12:59,310
Using angle-measuring tools,
202
00:12:59,310 --> 00:13:00,724
The craftsman verifies
That the corners
203
00:13:00,724 --> 00:13:05,206
Of the bulkhead structure
Measure 90 degrees.
204
00:13:05,206 --> 00:13:09,241
This confirms that the bulkhead
Is perfectly square.
205
00:13:09,241 --> 00:13:14,482
Next, the bulkhead structure
Is welded at the joints.
206
00:13:14,482 --> 00:13:18,206
The space-frame tubing is made
Up of varying thicknesses.
207
00:13:18,206 --> 00:13:21,896
This ensures the bulkhead steel
Is strong and protected
208
00:13:21,896 --> 00:13:24,724
In the event
There's a frontal collision.
209
00:13:24,724 --> 00:13:29,689
He compares the newly fabricated
Bulkhead to the standard.
210
00:13:29,689 --> 00:13:33,103
Once the frame is complete,
The builder applies epoxy
211
00:13:33,103 --> 00:13:36,689
To the base in preparation
For floor installation.
212
00:13:36,689 --> 00:13:38,620
Since the steel floor
Is substantial
213
00:13:38,620 --> 00:13:41,551
In thickness and weight,
It takes two technicians
214
00:13:41,551 --> 00:13:45,586
To lift it onto the epoxied
Section of the space frame.
215
00:13:45,586 --> 00:13:49,172
In addition to the epoxy,
A craftsman uses rivets
216
00:13:49,172 --> 00:13:51,517
To fasten the floor
To the frame.
217
00:13:51,517 --> 00:13:53,517
The floor will be
The only barrier
218
00:13:53,517 --> 00:13:57,620
Between the driver
And the track.
219
00:13:57,620 --> 00:14:00,310
With the space frame
And floor secured,
220
00:14:00,310 --> 00:14:05,689
The racecar is ready for
Mechanical-component assembly.
221
00:14:05,689 --> 00:14:08,620
After installing adapter plates
To the engine,
222
00:14:08,620 --> 00:14:12,344
The engine is hoisted into
The back of the space frame.
223
00:14:12,344 --> 00:14:15,379
Then the adapter plates
Are bolted to the frame,
224
00:14:15,379 --> 00:14:18,379
Securing the engine in place.
225
00:14:18,379 --> 00:14:19,965
The technician uses a hoist
226
00:14:19,965 --> 00:14:23,586
To carry the transmission system
To the motor.
227
00:14:23,586 --> 00:14:27,551
Once in position, he connects
The input shaft to the engine.
228
00:14:30,620 --> 00:14:33,551
He straps a fire extinguisher
To the cockpit floor
229
00:14:33,551 --> 00:14:37,689
Using metal bands.
230
00:14:37,689 --> 00:14:40,517
Then he runs wires from
The instrument panel
231
00:14:40,517 --> 00:14:45,620
To the extinguisher
For easy activation.
232
00:14:45,620 --> 00:14:50,620
He screws the panel to the cowl.
233
00:14:50,620 --> 00:14:52,000
Moving to the front,
234
00:14:52,000 --> 00:14:54,862
The technician bolts
The foot pedals to the floor.
235
00:14:59,103 --> 00:15:02,931
Next, he works on the
Rack-and-pinion steering system.
236
00:15:02,931 --> 00:15:04,413
This assembly will convert
237
00:15:04,413 --> 00:15:06,931
The rotational motion
Of the steering wheel
238
00:15:06,931 --> 00:15:10,689
To the lateral motion
Of the rack.
239
00:15:10,689 --> 00:15:15,413
Tie rods link the tires
To the system.
240
00:15:15,413 --> 00:15:17,758
The technician tests
The movement of the rack
241
00:15:17,758 --> 00:15:22,655
To confirm
That it's operating smoothly.
242
00:15:22,655 --> 00:15:25,827
At another station,
Computerized tools drill holes
243
00:15:25,827 --> 00:15:28,551
In a solid piece of aluminum.
244
00:15:28,551 --> 00:15:30,965
This step transforms
The aluminum
245
00:15:30,965 --> 00:15:33,344
Into a part called
The bell crank.
246
00:15:33,344 --> 00:15:35,413
The bell crank
Will provide a link
247
00:15:35,413 --> 00:15:41,620
Between the car's suspension
Rods and the shock absorbers.
248
00:15:41,620 --> 00:15:44,827
It takes about 10 minutes
For these computerized tools
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00:15:44,827 --> 00:15:46,931
To turn a piece of aluminum
250
00:15:46,931 --> 00:15:49,206
Into a precision-crafted
Bell crank.
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00:15:53,655 --> 00:15:57,275
The technician installs the
Bell crank onto the car frame.
252
00:16:01,103 --> 00:16:03,551
With that, they've turned
A production corner,
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00:16:03,551 --> 00:16:07,000
And it's full speed ahead to
The next phase, coming up.
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00:16:17,793 --> 00:16:19,758
Narrator:
A formula f car is designed
255
00:16:19,758 --> 00:16:23,827
To make semi-professional
Racing accessible to amateurs.
256
00:16:23,827 --> 00:16:28,137
This vehicle's steel space frame
Is inexpensive to produce
257
00:16:28,137 --> 00:16:30,965
And easier to repair
In comparison to frames
258
00:16:30,965 --> 00:16:33,068
Made of carbon fiber.
259
00:16:37,275 --> 00:16:39,206
With the steel frame complete
260
00:16:39,206 --> 00:16:41,620
And the engine
And transmission installed,
261
00:16:41,620 --> 00:16:44,931
The technician bolts shock
Absorbers to the chassis,
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00:16:44,931 --> 00:16:48,586
One for each wheel's
Suspension system.
263
00:16:48,586 --> 00:16:52,137
A technician connects the shock
Absorbers to the bell crank,
264
00:16:52,137 --> 00:16:56,172
Linking it to the rest
Of the suspension system.
265
00:16:56,172 --> 00:17:01,241
He bolts suspension arms
To mounts on the frame.
266
00:17:01,241 --> 00:17:04,172
A push rod links the arms
To the bell crank.
267
00:17:08,586 --> 00:17:11,620
He bolts the wheel hub assembly
To the suspension arms.
268
00:17:14,379 --> 00:17:17,034
He assembles a brake rotor
To the hub.
269
00:17:22,655 --> 00:17:26,241
Then he installs
The drive shaft assembly.
270
00:17:26,241 --> 00:17:28,517
This assembly connects
The transmission
271
00:17:28,517 --> 00:17:32,413
To the wheel hub.
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00:17:32,413 --> 00:17:36,172
That completes the push-rod
Suspension system for one wheel.
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00:17:39,448 --> 00:17:41,206
This sheet of aluminum
Will be used
274
00:17:41,206 --> 00:17:44,586
For the back of
The fuel-cell compartment.
275
00:17:44,586 --> 00:17:47,724
He measures and marks the sheet
Accordingly.
276
00:17:47,724 --> 00:17:51,482
He clamps the sheet in a press
Brake along the measured line
277
00:17:51,482 --> 00:17:53,931
And activates the press brake.
278
00:17:53,931 --> 00:17:55,517
The bend forms a flap
279
00:17:55,517 --> 00:17:59,586
That will be used to attach
The sheet to the car frame.
280
00:17:59,586 --> 00:18:02,655
He measures and marks spots
For mounting holes
281
00:18:02,655 --> 00:18:05,310
So they'll be evenly spaced
When drilled.
282
00:18:07,379 --> 00:18:10,931
The panel is placed in the space
Frame behind the cockpit
283
00:18:10,931 --> 00:18:14,413
With the flap resting
On lateral tubing.
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00:18:14,413 --> 00:18:18,172
The fuel cell is made of
A flexible rubber-like material
285
00:18:18,172 --> 00:18:22,137
That's unlikely to rupture
If in an accident.
286
00:18:22,137 --> 00:18:25,206
He assembles the sides
And front panels to the back,
287
00:18:25,206 --> 00:18:28,344
Creating a compartment
That encloses the fuel cell.
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00:18:28,344 --> 00:18:30,275
Next, the technician wires
289
00:18:30,275 --> 00:18:33,310
The racecar's electrical systems
Together.
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00:18:33,310 --> 00:18:34,931
He crimps connectors
To the ends of the wires
291
00:18:34,931 --> 00:18:37,275
And plugs them into
292
00:18:37,275 --> 00:18:40,448
Their corresponding
Electrical components.
293
00:18:40,448 --> 00:18:48,206
He routes wiring through the car
And plugs in the alternator.
294
00:18:48,206 --> 00:18:51,724
He installs fiberglass
Support parts to the radiators,
295
00:18:51,724 --> 00:18:54,482
Attaching one to each side
Of the car.
296
00:18:56,586 --> 00:18:59,482
He runs hoses from
The radiators to the engine.
297
00:19:01,103 --> 00:19:03,620
With the radiators now
On the supports,
298
00:19:03,620 --> 00:19:05,724
The packing material
Is removed.
299
00:19:07,620 --> 00:19:11,517
A cone-shaped air filter located
On the engine's throttle body
300
00:19:11,517 --> 00:19:14,517
Will keep dirt
Out of the engine.
301
00:19:14,517 --> 00:19:17,172
After installing
Front shock absorbers,
302
00:19:17,172 --> 00:19:20,413
He assembles the steering column
And shaft to the car.
303
00:19:22,655 --> 00:19:27,689
He slides the steering wheel
Onto the column.
304
00:19:27,689 --> 00:19:31,448
He tucks a special safety seat
Into the cockpit.
305
00:19:31,448 --> 00:19:35,448
The seat has been custom-made
For the driver.
306
00:19:35,448 --> 00:19:39,689
The harness has six straps
For upper-body protection.
307
00:19:42,482 --> 00:19:45,413
Then he connects an exhaust pipe
To the engine
308
00:19:45,413 --> 00:19:48,310
And hangs it to the car
With metal bands.
309
00:19:52,655 --> 00:19:55,379
After the fiberglass body parts
Are molded,
310
00:19:55,379 --> 00:19:58,000
He maps out holes
For components.
311
00:20:01,586 --> 00:20:04,896
He cuts out the holes
With a rotary sanding tool.
312
00:20:06,551 --> 00:20:09,862
The cockpit's side panels
Are fitted to the space frame
313
00:20:09,862 --> 00:20:11,448
And screwed into place.
314
00:20:14,172 --> 00:20:17,275
The nose of the car
Is made of carbon fiber.
315
00:20:17,275 --> 00:20:19,482
The strength
Of the carbon fiber
316
00:20:19,482 --> 00:20:21,965
Provides additional
Crash protection.
317
00:20:25,310 --> 00:20:28,137
The body panels are attached
With fasteners
318
00:20:28,137 --> 00:20:30,965
That can be quickly
During a race.
319
00:20:34,310 --> 00:20:36,517
With the front suspension
Installed,
320
00:20:36,517 --> 00:20:39,448
This racecar
Is ready for wheels.
321
00:20:39,448 --> 00:20:41,620
The technician
Torques the locknut
322
00:20:41,620 --> 00:20:45,896
That holds the wheel in place
And slides a pin onto the axle.
323
00:20:49,241 --> 00:20:51,103
It takes about
Two to three months
324
00:20:51,103 --> 00:20:53,655
To build
This formula f racecar.
325
00:20:57,275 --> 00:21:01,896
Now that it's left the shop,
Things are sure to accelerate.
26744
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