Original subtitles

--Captions by VITAC-- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

Narrator: WHEN CHRISTOPHER COLUMBUS DISCOVERED THE AMERICAS,

HE ALSO DISCOVERED THE TOBACCO PIPE.

THE PIPE WAS AN IMPORTANT PART OF NATIVE CULTURE

TO BE SHARED DURING TIMES OF NEGOTIATION AND CELEBRATION.

COLUMBUS AND OTHER EXPLORERS BROUGHT THE CONCEPT HOME,

AND THE REST IS HISTORY.

SINCE THE 19th CENTURY, PIPES HAVE BEEN MADE FROM BRIAR,

A HARD, FIRE-RESISTANT WOOD

FROM THE ROOT OF A MEDITERRANEAN HEATHER SHRUB.

AFTER THE BRIAR HAS CURED FOR SEVERAL MONTHS,

THE PIPE-MAKER SAWS IT INTO A ROUGH PIPE SHAPE.

USING A LATHE AND CHISEL, HE ROUNDS THE LARGER BLOCK

TO APPROXIMATE THE SHAPE OF THE PIPE BOWL.

HE BORES THROUGH THE CENTER

TO CARVE OUT THE TOBACCO CHAMBER.

THEN HE SLIMS DOWN THE STEM,

MARKING THE CENTER FOR DRILLING LATER.

THE PIPE-MAKER FINALIZES THE SHAPE BY HAND.

HE NOW SANDS BOTH THE INSIDE OF THE TOBACCO CHAMBER...

...AND THE OUTSIDE OF THE PIPE BOWL.

NEXT, THE PIPE'S MOUTHPIECE TAKES SHAPE.

THE PIPE-MAKER PIERCES A PIECE OF HARDENED RUBBER

CALLED VULCANITE TO ESTABLISH THE CENTER

AND THEN DRILLS A CHANNEL THROUGH IT.

USING A GRINDSTONE, HE SCULPTS ONE END,

TAKING IT FROM ROUND TO OVAL,

A SHAPE THAT FITS MORE COMFORTABLY

BETWEEN THE LIPS.

HE CHECKS HIS WORK WITH A SIZING TEMPLATE...

THEN SHAVES THE EXTERIOR OF THE MOUTHPIECE,

REDUCING IT CONSIDERABLY.

HE SHAPES THE OTHER END TO FORM THE TENON,

WHICH FITS INTO THE PIPE STEM.

HE POLISHES THE TENON WITH A SPECIAL COMPOUND.

THE SMOOTHER SURFACE MAKES THIS PART EASIER

TO JOIN TO THE PIPE STEM.

USING A SERIES OF SANDING DISKS WITH PROGRESSIVELY FINER GRIT,

HE GIVES THE EXTERIOR OF THE MOUTHPIECE A SLEEK FINISH.

THEN HE STEADIES IT IN A CLAMP

AND WIDENS THE HOLE IN THE CENTER OF THE MOUTHPIECE

TO BROADEN IT INTO A FUNNEL-SHAPED CAVITY.

ATTENTION NOW TURNS TO THE SEAM

BETWEEN THE RUBBER AND WOOD PARTS.

HE SANDS IT TO MAKE THEM PERFECTLY FLUSH.

HAND-FILING REMOVES BLEMISHES

AND ADJUSTS THE THICKNESS FOR A MORE COMFORTABLE BITE.

THE THICKNESS CAN BE CUSTOMIZED FOR INDIVIDUAL PREFERENCES.

HE DRILLS A TINY HOLE INTO THE TOP OF THE MOUTHPIECE...

...THEN DIPS A THIN PLASTIC ROD IN GLUE

AND INSERTS IT IN THE HOLE.

HE SANDS IT DOWN, LEAVING A WHITE SPOT,

A MARKER THAT INDICATES THE MOUTHPIECE IS RIGHT-SIDE-UP.

FOR BENT OR CURVED PIPES,

THE MOUTHPIECES ARE HEATED IN AN OVEN AT 320 DEGREES FAHRENHEIT.

THIS MAKES THE VULCANITE FLEXIBLE ENOUGH

TO BE SHAPED BY HAND.

THE PIPE-MAKER BENDS THE MOUTHPIECE TO THE DESIRED SHAPE,

AND A QUICK COOL-DOWN IN WATER RE-HARDENS THE VULCANITE,

FIXING ITS CURVE.

NEXT, HE BUFFS THE WOODEN PART OF THE PIPE.

THIS REMOVES FINE SCRATCHES AND BRINGS OUT THE WOOD GRAIN.

IT ALSO GIVES THE WOOD A GLOSSY FINISH.

BUT FOR A DIFFERENT FINISH,

A CRAFTSMAN SAND-BLASTS THE BRIAR WOOD,

GIVING IT A RIPPLE TEXTURE.

HE STAINS IT DARKER WITH AN ALCOHOL-BASED DYE,

WORKING THE STAIN INTO EVERY CREVICE.

AND NOW FOR A NEAT TRICK.

HE SETS IT ON FIRE,

AND THE ALCOHOL BURNS OFF TO SET THE STAIN.

THE PIPE DOESN'T GO UP IN FLAMES,

PROVING IT'S TRULY FIRE-RESISTANT.

HE BURNS UP TO 10 LAYERS OF STAIN INTO THE PIPE,

DEPENDING ON THE EFFECT HE'S TRYING TO ACHIEVE.

FINALLY, HE STAMPS THE COMPANY NAME

AND OTHER INFORMATION INTO THE PIPE.

AFTER A FINAL QUALITY INSPECTION,

THIS HANDCRAFTED BRIAR PIPE

IS ON ITS WAY TO MAKING A STATEMENT AT THE COUNTRY CLUB.

Narrator: ROCK-CLIMBING IS NO PASTIME FOR THE FAINT-HEARTED.

SCALING NATURAL ROCK FORMATIONS OR MANMADE ROCK WALLS

REQUIRES A CERTAIN FEARLESSNESS,

ALONG WITH GOOD PHYSICAL CONDITIONING,

BALANCE, AGILITY,

AND YOU MUST BE WELL-TRAINED IN CLIMBING TECHNIQUES

AND USE SPECIALIZED EQUIPMENT.

CLIMBERS USUALLY WORK IN PAIRS,

USING A SYSTEM OF ROPES AND OTHER DEVICES

TO CATCH THEM IF THEY FALL.

A KEY PIECE OF GEAR IS THE SPRING-LOADED CAMMING DEVICE.

THE CLIMBER PULLS THE TRIGGER TO CONTRACT THE CAMS

AND POSITION IT IN A CRACK

THEN RELEASES THE TRIGGER TO EXPAND THE CAMS,

WHICH SECURELY GRIP THE ROCK ON EITHER SIDE,

THEN ATTACHES A ROPE THROUGH A DEVICE CALLED A CARABINER.

CLIMBERS TYPICALLY CARRY SEVERAL TYPES AND SIZES OF CAMS,

CARABINERS, AND OTHER DEVICES.

THE EQUIPMENT MUST BE AS LIGHTWEIGHT AS POSSIBLE,

YET, AT THE SAME TIME,

STRONG ENOUGH TO SAVE A FALLING CLIMBER.

WHICH IS WHY THIS MANUFACTURER USES AIRCRAFT-GRADE ALUMINUM.

TO MAKE CARABINERS,

AUTOMATED SAWS CUT ALUMINUM BARS INTO PIECES THE REQUIRED LENGTH.

THEN A BENDING MACHINE FORCES EACH PIECE AROUND A FORM

IN THE BASIC SHAPE OF THE CARABINER.

CARABINERS COME IN VARIOUS SIZES AND SHAPES.

WORKERS SIMPLY MOUNT THE APPROPRIATE FORM ON THE MACHINE.

NEXT, THEY PLACE THE ROUGHLY FORMED CARABINER ONTO A HOT DIE.

ANOTHER DIE SLAMS DOWN ON IT WITH UP TO 800 TONS OF FORCE,

FORGING THE FINAL SHAPE.

THEN THE MOST CRITICAL PART OF THE MANUFACTURING PROCESS --

A MULTI-PHASE HEAT TREATMENT

TO HARDEN AND STRENGTHEN THE ALUMINUM.

NEXT, THEY USE A CLIPPING PRESS

TO SLICE OFF EXCESS METAL ALONG THE PERIMETER.

THIS LEAVES ROUGH EDGES,

WHICH THEY NOW SMOOTH OUT USING AN ABRASION PROCESS.

THE CARABINERS GO INTO A VIBRATING TUB,

WHERE THEY RUB AGAINST PORCELAIN CHIPS FOR THE NEXT 20 HOURS.

NEXT, WORKERS DRILL HOLES FOR THE RIVETS

ON WHICH THE SPRING-LOADED OPENING MECHANISM WILL HINGE.

THAT MECHANISM, CALLED THE GATE,

HAS CHANNELS WHICH ALIGN WITH THESE HOLES.

ASSEMBLERS SLIDE A SPRING AND SPRING-PUSHER INTO THE GATE,

THEN INSERT THE RIVETS THROUGH THE ALIGNED HOLES AND CHANNELS.

A RIVETING MACHINE LOCKS EACH RIVET IN PLACE

BY ROUNDING AND WIDENING THE HEAD.

THEN THEY ADJUST THE CARABINER'S FRAME

UNTIL THE ALIGNMENT IS PERFECT.

AFTER A THOROUGH INSPECTION,

A LASER ETCHING MACHINE INSCRIBES PRODUCT INFORMATION

AND A UNIQUE SERIAL NUMBER.

RANDOM SAMPLES UNDERGO STRENGTH AND OTHER QUALITY-CONTROL TESTS.

ELSEWHERE IN THE FACTORY,

CAMMING DEVICE PRODUCTION IS UNDER WAY.

COMPUTER-GUIDED EQUIPMENT MACHINES THE SAME ALUMINUM ALLOY

TO A PRELIMINARY SHAPE,

SAWS OFF SLICES,

THEN MACHINES EACH SLICE TO THE FINAL SHAPE OF A CAM.

AN ASSEMBLER ATTACHES A WIRE TO EACH CAM...

THEN TAKES FOUR CAMS AND JOINS THEIR WIRES

TO THE TRIGGER WIRES WITH A METAL CRIMP.

THE CAMS, BY THIS POINT, ARE DIFFERENT COLORS.

THAT'S BECAUSE THEY'VE UNDERGONE CHEMICAL TREATMENT

TO MAKE THEM CORROSION-RESISTANT.

THIS PROCESS CAN, IN FACT, PRODUCE VARIOUS COLORS.

SO, AT THE SAME TIME,

THE COMPANY CAN COLOR-CODE THE DIFFERENT MODELS.

AS ASSEMBLY CONTINUES, THEY THREAD THE CAMS

ONTO AN AXLE-LIKE COMPONENT CALLED THE SPINDLE,

POSITIONING A SPRING IN BETWEEN EACH CAM.

THE SPRINGS PROVIDE THE RESISTANCE REQUIRED

TO EXPAND AND RETRACT THE DEVICE.

A CONE-SHAPED WASHER ON EACH END OF THE SPINDLE

HOLDS EVERYTHING TOGETHER.

THIS TIME, THE RIVETING MACHINE LOCKS IN THE COMPONENTS

BY FLATTENING AND WIDENING THE END OF THE SPINDLE

TO FILL THE HOLE IN THE WASHER.

WITH THAT, THE CAMMING DEVICE IS FINISHED.

THIS IS HOW CAMMING DEVICES, CARABINERS,

AND OTHER CLIMBING GEAR ALL WORK TOGETHER

TO CATCH CLIMBERS WHO LOSE THEIR FOOTHOLD.

NOT ONLY DO THEY KEEP THE CLIMBER SAFE,

THEY ALSO PROTECT NATURE,

BECAUSE THEY ATTACH TO THE ROCK FACE

WITHOUT DAMAGING IT IN ANY WAY.

Narrator: LEATHER BIKE SADDLES

FEATURE A LEATHER TOP SUSPENDED ON A METAL FRAME.

WITH TIME AND USE, THE LEATHER MOLDS ITSELF

TO PERFECTLY SUIT THE RIDER'S ANATOMY

AND THEIR CYCLING STYLE.

AND JUST LIKE A PAIR OF LEATHER SHOES,

THE SADDLE BECOMES VERY COMFORTABLE.

LEATHER BIKE SADDLES LOOK ALMOST THE SAME

AS THEY DID 100 YEARS AGO.

THEY ARE STILL MADE BY HAND

AND BY SOME MACHINERY THAT IS SOMETIMES OVER 60 YEARS OLD.

SADDLES ARE MADE EXCLUSIVELY OF METAL AND LEATHER,

TRADITIONAL MATERIALS THAT RETAIN

THE STYLE AND QUALITY OF THE EARLY DAYS.

THE FIRST STEP IS MAKING THE STEEL WIRE SPRINGS

FOR SADDLES THAT HAVE A SUSPENSION.

THE MACHINE COILS AND CUTS THE WIRE TO THE PROPER LENGTH.

LIQUID LUBRICANT KEEPS EVERYTHING RUNNING SMOOTHLY.

DEPENDING ON THE SADDLE'S MODEL, SOME SPRINGS ARE THEN CHROMED.

THIS MACHINE FOLDS AND CURLS STEEL OR TITANIUM WIRE

TO FORM BRACKETS.

IT'S ADJUSTABLE,

SO IT CAN MAKE BRACKETS OF DIFFERENT SIZES AND SHAPES,

DEPENDING ON THE MODEL BEING PRODUCED.

A TECHNICIAN ASSEMBLES THE SPRINGS AND BRACKETS

TO FORM THE SADDLE'S FRAME.

HE ATTACHES THE CLAMP SO THAT THE SADDLE

CAN BE ATTACHED TO THE BICYCLE'S SEAT POST.

SADDLES COME IN DIFFERENT SIZES AND SHAPES,

WITH OR WITHOUT SUSPENSION SPRINGS

TO ACCOMMODATE VARIOUS RIDING STYLES --

RACING, MOUNTAIN BIKING, OR CITY COMMUTING.

NOW FOR THE SADDLE'S LEATHER TOP.

USING A HYDRAULIC CLICKING PRESS,

THE WORKER CUTS THE LEATHER WITH A SHARP BLADE.

THE BLADE CUTS VENTILATION HOLES AT THE SAME TIME.

TANNERIES PROVIDE LEATHER IN ANY COLOR REQUIRED BY THE FACTORY.

AFTER THE TOPS ARE CUT,

THEY SOAK IN TEPID WATER FOR 20 MINUTES TO AN HOUR,

UNTIL THE LEATHER IS COMPLETELY SATURATED.

THE WET LEATHER TOP THEN GOES TO A PRESS,

WHICH APPLIES 2,000 POUNDS OF PRESSURE PER SQUARE INCH.

USING A LEATHER CUSHION,

THE TECHNICIAN PADS THE LEATHER PIECE

TO HELP REINFORCE THE SHAPE,

ESPECIALLY IN THE NARROW FRONT END.

BECAUSE THE TOP IS WET,

IT RETAINS THE SHAPE AND DOES NOT BOUNCE BACK.

THEY CAREFULLY SAND THE LEATHER TO GET A SMOOTH EDGE.

THE TOPS NOW GO INTO THE OVEN FOR THREE HOURS

AT A MAXIMUM TEMPERATURE OF 130 DEGREES FAHRENHEIT.

NOW THEY'RE READY FOR THE FINISHING PROCESS.

A WORKER RIVETS A NAME PLATE TO THE REAR OF THE SADDLE...

...THEN STAMPS A TRADEMARK ON EACH SIDE.

EACH SADDLE MODEL HAS ITS OWN TRADEMARK.

THEY ATTACH THE NOSE TO THE FRONT OF THE SADDLE

USING SOLID COPPER RIVETS.

THEY HAMMER EACH ONE DOWN CAREFULLY

TO FOLLOW THE CONTOURS OF THE LEATHER WITHOUT SCRATCHING IT.

THIS MACHINE NOW RIVETS THE FRAME TO THE BACK OF THE SADDLE.

THEY INSERT A TENSION PIN BETWEEN THE FRAME AND THE NOSE.

THIS PIN WILL ALLOW THE RIDER TO ADJUST HIS SADDLE

IF THE LEATHER STARTS SAGGING AFTER A FEW YEARS.

IT TAKES ABOUT THREE DAYS TO MAKE A LEATHER BIKE SADDLE.

AND WITH CAREFUL CARE,

IT CAN BE USED FOR YEARS TO COME.

Narrator: LUXURY SPORTS CARS

ARE COVETED BY PEOPLE AROUND THE WORLD,

AND WITH GOOD REASON.

THE EXTRAORDINARY SKILLS AND MATERIALS

THAT GO INTO MAKING THEM

WERE DEVELOPED FROM A LONG RACING HERITAGE.

EACH ONE OF THESE AUTOMOBILES

IS BORN FROM EXPERT CRAFTSMANSHIP

AND A PASSION FOR RACING.

UNDERNEATH THE BEAUTIFUL EXTERIOR OF THESE CARS

LIE A CHASSIS AND POWER TRAIN

CAPABLE OF DELIVERING REMARKABLE PERFORMANCE.

THE ALUMINUM FRAME IS ENGINEERED TO BE LIGHTWEIGHT, YET RIGID,

AND PROVIDE CRUMPLE ZONES

THAT CAN EVENLY DISTRIBUTE FORCE IN THE EVENT OF AN IMPACT.

IT TAKES HIGHLY SKILLED TECHNICIANS

TO PERFORM THESE COMPLEX WELDS.

ON THE FACTORY FLOOR, ROBOTS TRANSPORT THE BODY PANELS

THAT WILL LATER BE FITTED ONTO THE CHASSIS.

ONCE THE FRAME IS COMPLETED,

TECHNICIANS USE A PNEUMATIC HOIST

TO POSITION AND ATTACH EXTERIOR PANELS AND DOORS.

DOOR PANEL CUTOUTS REDUCE THE CAR'S WEIGHT

WHILE RETAINING A HIGH DEGREE OF STRUCTURAL INTEGRITY.

THE ELONGATED CUTOUTS ON THIS MODEL

WILL HOUSE ITS STYLIZED HEADLIGHTS.

NEXT, THEY COAT THE CAR IN A COMPOUND

WHICH FLUORESCES UNDER A SPECIAL LIGHTING SYSTEM.

THIS HELPS TECHNICIANS DETECT ANY MINUTE IMPERFECTIONS.

THESE IMPERFECTIONS ARE THEN FILED DOWN BY HAND.

HERE, A ROBOT FULLY IMMERSES AND ROTATES THE CHASSIS

IN A GALVANIZING SOLUTION THAT PREVENTS CORROSION.

ONCE THE BODY HAS BEEN PRIMED,

IT PASSES THROUGH A DEVICE THAT DUSTS OFF THE ENTIRE BODY

WITH OSTRICH-FEATHER BRUSHES.

NEXT STOP, THE PAINT ROOM, WHERE ROBOTS SPRAY THE CAR BODY

WITH A SMOOTH, EVEN COAT OF PAINT.

ONCE THE PAINT DRIES AND CURES,

THE ROBOTS APPLY SEVERAL COATS OF VARNISH.

THE FINAL STEP IN BODY PREP IS A METICULOUS WAXING BY HAND

TO REMOVE ANY REMAINING BLEMISHES.

MOVING ON TO THE CHASSIS, A TECHNICIAN USES A HOIST

TO POSITION AND FASTEN THE ENGINE AND GEARBOX IN PLACE.

HERE, ROBOTS TRANSPORT THE COMPLETED POWER TRAIN

TO THE ASSEMBLY AREA...

WHERE AN AUTOMATIC CRANE

GENTLY LOWERS THE CAR BODY ONTO THE CHASSIS,

WHICH INCLUDES THE FULLY ASSEMBLED SUSPENSION,

GEARBOX, AND ENGINE.

THIS STEP IS KNOWN AS THE MARRIAGE.

NEXT, A WORKER INSTALLS THE WHEELS

WITH SOME HELP FROM A HYDRAULIC LIFTING SYSTEM.

AT THE NEXT STATION,

TECHNICIANS TEST ALL THE DASHBOARD COMPONENTS.

THIS VEHICLE FEATURES A COMBINATION

OF ANALOG AND DIGITAL DISPLAYS.

A MASTER COMPUTER

RUNS THE ELECTRONICS AND INFORMATION SYSTEMS.

AGAIN WITH THE HELP OF THE CRANE,

TECHNICIANS INSTALL THE FINISHED DASHBOARD.

THE NEXT STEP IS THE STEERING WHEEL.

ASSISTED BY A SPECIAL ASSEMBLY JIG,

A TECHNICIAN POSITIONS

AND TIGHTENS IT ONTO THE STEERING COLUMN.

WORKERS LOWER THE TRUNK COVER

AND CONVERTIBLE HARDTOP INTO POSITION,

WHICH IS PARTICULAR TO THIS MODEL OF CAR.

A WORKER DOUBLE-CHECKS THE INSTALLATION

OF THE HYDRAULIC MECHANISM.

THIS BEAUTIFUL ROAD MACHINE

IS THE CULMINATION OF YEARS OF RACING HISTORY,

MODERN ENGINEERING, AND DEDICATED CRAFTSMANSHIP.

NOW WATCH THIS.

THIS IS ONE OF THE FEW CARS

THAT FEATURES A FULLY AUTOMATED CONVERTIBLE HARDTOP.

THIS BEAUTY IS NOW READY FOR THE SUN, WIND,

AND THE OPEN ROAD.

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