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00:00:02,034 --> 00:00:05,034
--Captions by VITAC--
www.vitac.com
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00:00:05,034 --> 00:00:08,000
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator:
THINNING SHEARS ARE SCISSORS
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00:00:55,620 --> 00:00:57,620
WITH AT LEAST
ONE COMB-LIKE BLADE.
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00:00:57,620 --> 00:00:59,206
WHEN THE BLADES COME TOGETHER,
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00:00:59,206 --> 00:01:01,758
SOME HAIR FALLS BETWEEN
THE TEETH OF THE COMB,
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00:01:01,758 --> 00:01:03,172
AND THAT HAIR IS CUT
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00:01:03,172 --> 00:01:05,655
WHILE OTHER STRANDS
ARE LEFT INTACT.
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00:01:05,655 --> 00:01:06,896
A FEW QUICK SNIPS,
10
00:01:06,896 --> 00:01:09,827
AND THIS HANDY TOOL CAN DO A LOT
FOR YOUR STYLE.
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00:01:13,896 --> 00:01:17,137
IT'S OFTEN NECESSARY
TO GO MANY LENGTHS
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00:01:17,137 --> 00:01:18,931
TO ACHIEVE THE RIGHT LOOK.
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00:01:18,931 --> 00:01:22,310
STYLISTS USE THINNING SHEARS
TO LAYER A CUT FROM THE INSIDE.
14
00:01:22,310 --> 00:01:25,931
THIS REMOVES BULK
TO GIVE HAIR HEIGHT.
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00:01:25,931 --> 00:01:28,137
WHEN IT COMES
TO IMPROVING YOUR HAIRDO,
16
00:01:28,137 --> 00:01:31,034
THINNING SHEARS DEFINITELY HAVE
THE TEETH FOR THE JOB.
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00:01:31,034 --> 00:01:34,724
THEY START
WITH STAINLESS-STEEL RODS.
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00:01:34,724 --> 00:01:37,689
THE RODS RIDE
A MAGNETIZED CONVEYOR
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00:01:37,689 --> 00:01:40,724
UP TO AN INDUCTION HEATER.
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00:01:40,724 --> 00:01:42,758
IT HEATS EACH ROD FROM THE ENDS
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00:01:42,758 --> 00:01:46,931
UNTIL IT BECOMES
WHITE-HOT AND SOFT.
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00:01:46,931 --> 00:01:51,103
THE ROD IS NOW READY
FOR FORGING.
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00:01:51,103 --> 00:01:56,000
A WORKER MOVES THE HOT ROD
BACK AND FORTH OVER A DIE
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00:01:56,000 --> 00:01:58,241
AS A HAMMER SLAMS INTO IT.
25
00:02:01,448 --> 00:02:03,310
THIS FLATTENS AND FORMS IT
26
00:02:03,310 --> 00:02:06,137
INTO THE SHAPE
OF TWO SCISSOR BLADES.
27
00:02:06,137 --> 00:02:09,793
THE FORGING LEAVES A LOT OF
EXCESS STEEL AROUND THE BLADES.
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00:02:09,793 --> 00:02:12,931
THEY CUT AWAY THAT EXCESS.
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00:02:12,931 --> 00:02:14,172
REHEATED NOW,
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00:02:14,172 --> 00:02:17,896
A WORKER PLUNGES THE BLADES
INTO A LEAD BATH.
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00:02:19,586 --> 00:02:23,931
THEN HE DIPS THEM IN OIL,
STANDING BACK AS THEY FLAME UP.
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00:02:23,931 --> 00:02:26,551
THE LEAD BATH
AND THE QUICK COOLDOWN
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00:02:26,551 --> 00:02:27,896
HARDEN THE STEEL.
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00:02:27,896 --> 00:02:31,241
ANOTHER WORKER THEN CLAMPS
A BLADE INTO POSITION.
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00:02:31,241 --> 00:02:33,758
A CUTTING WHEEL
ROLLS INTO ACTION
36
00:02:33,758 --> 00:02:36,758
AND CARVES A COMB PROFILE
INTO THE BLADE.
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00:02:36,758 --> 00:02:40,655
A CONSTANT FLOW
OF WATER-BASED COOLANT
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00:02:40,655 --> 00:02:41,931
KEEPS THE TEMPERATURE
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00:02:41,931 --> 00:02:43,482
OF THE CUTTING WHEEL
AND THE SCISSOR PART DOWN,
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00:02:43,482 --> 00:02:44,965
OTHERWISE THE CUTTING PROCESS
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00:02:44,965 --> 00:02:46,793
COULD CAUSE THEM BOTH
TO OVERHEAT
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00:02:46,793 --> 00:02:51,517
AND COMPROMISE
THEIR STRENGTH AND INTEGRITY.
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00:02:54,103 --> 00:02:56,827
THIS IS THE THINNING SCISSOR
BLADE BEFORE CUTTING,
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00:02:56,827 --> 00:02:59,103
AND THIS IS THE BLADE
WITH ITS NEW TEETH.
45
00:03:01,862 --> 00:03:04,172
AT THE NEXT WORKSTATION,
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A ROBOT TRANSFERS A BLADE
47
00:03:05,689 --> 00:03:07,793
TO AN AUTOMATED
GRINDING MACHINE.
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00:03:07,793 --> 00:03:11,551
THE MACHINE GRINDS BOTH
THE FRONT AND SIDES OF THE TEETH
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TO SMOOTH THE ROUGH EDGES.
50
00:03:15,172 --> 00:03:17,413
THIS ROBOTIC SYSTEM PROCESSES
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00:03:17,413 --> 00:03:20,275
UP TO 150 SCISSOR BLADES
AN HOUR.
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00:03:26,655 --> 00:03:30,896
NEXT, IT'S INTO A TUMBLER
FILLED WITH SYNTHETIC PEBBLES.
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00:03:30,896 --> 00:03:33,172
AS THE THINNING BLADES
BOUNCE AROUND,
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FRICTION HAPPENS.
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00:03:35,517 --> 00:03:37,034
THIS SMOOTHES MORE ROUGH EDGES,
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00:03:37,034 --> 00:03:39,206
ESPECIALLY THE HANDLES
AND FINGER RINGS
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THAT DIDN'T UNDERGO GRINDING
AT THE ROBOT STATION.
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00:03:43,000 --> 00:03:45,241
AFTER ABOUT FOUR HOURS,
59
00:03:45,241 --> 00:03:47,586
A MAGNETIC CONVEYOR
RETRIEVES THEM.
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00:03:47,586 --> 00:03:48,965
THEN THE MIDSECTION,
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00:03:48,965 --> 00:03:51,517
WHERE THE TWO BLADES
ARE TO BE JOINED,
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00:03:51,517 --> 00:03:54,758
RECEIVES HANDS-ON ATTENTION
AS A WORKER SMOOTHES IT
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00:03:54,758 --> 00:03:57,448
USING A FINE
ABRASIVE SANDING BELT.
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00:03:57,448 --> 00:04:00,758
THEY MOVE ON
TO THE STRAIGHT SCISSOR BLADE.
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00:04:00,758 --> 00:04:04,172
AN EMPLOYEE HONES IT AGAINST
A HORIZONTAL GRINDING WHEEL.
66
00:04:04,172 --> 00:04:07,827
THIS ALIGNS THE CUTTING EDGE.
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00:04:10,896 --> 00:04:13,344
HE INSERTS THE THREADED SCREWS
IN HOLES
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00:04:13,344 --> 00:04:14,931
IN A STRAIGHT-EDGED BLADE
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00:04:14,931 --> 00:04:19,172
AND IN THE CORRESPONDING
COMB-LIKE BLADE.
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00:04:19,172 --> 00:04:24,068
HE BRINGS THE TWO TOGETHER
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00:04:24,068 --> 00:04:28,137
AND THEN TIGHTENS THE SCREWS
TO A SPECIFIC TORQUE.
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00:04:28,137 --> 00:04:29,862
TOO TIGHT OR TOO LOOSE,
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00:04:29,862 --> 00:04:33,206
AND THESE THINNING SHEARS
WON'T OPERATE SMOOTHLY.
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00:04:33,206 --> 00:04:37,206
WITH AN EMERY BOARD,
HE GENTLY FILES THE SHEARS
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00:04:37,206 --> 00:04:41,000
TO GET RIDE OF LINGERING DUST
FROM THE EXTENSIVE GRINDING.
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00:04:43,448 --> 00:04:46,275
HE NOW TESTS THEIR FUNCTION.
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00:04:46,275 --> 00:04:48,275
IT ISN'T ENTIRELY SMOOTH,
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00:04:48,275 --> 00:04:51,965
SO HAMMERS A SECTION
OF THE COMB BLADE TO LEVEL IT.
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00:04:54,793 --> 00:04:58,724
IT NOW MOVES MORE FREELY
AGAINST THE STRAIGHT BLADE.
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00:04:58,724 --> 00:05:02,137
AND NOW THE ULTIMATE TEST --
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00:05:02,137 --> 00:05:04,896
HE TRIES THEM OUT
ON A LOCK OF ARTIFICIAL HAIR,
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00:05:04,896 --> 00:05:07,379
AND HE CONFIRMS
THAT THESE THINNING SHEARS
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00:05:07,379 --> 00:05:08,931
ARE AS SHARP AS THEY LOOK.
84
00:05:08,931 --> 00:05:13,206
NEXT, THE BLADE COMES UP AGAINST
A SPINNING LEATHER BELT.
85
00:05:13,206 --> 00:05:16,689
THIS TAKES IT FROM MERELY SHARP
TO RAZOR-SHARP.
86
00:05:16,689 --> 00:05:20,068
IT ALSO POLISHES THE BLADE
TO A MIRROR FINISH.
87
00:05:23,862 --> 00:05:25,413
A COMPUTERIZED LASER
88
00:05:25,413 --> 00:05:29,586
BURNS THE BRAND NAME AND MODEL
INFORMATION INTO THE SHEARS.
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00:05:33,000 --> 00:05:37,103
THEY SCREW A BRASS NUB
TO THE FINGER RING
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00:05:37,103 --> 00:05:41,206
TO GIVE THE PINKIE FINGER
SOMETHING TO REST AGAINST.
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00:05:41,206 --> 00:05:44,482
THESE THINNING SHEARS
ARE NOW READY FOR SHIPMENT.
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00:05:44,482 --> 00:05:48,586
SOON, THEY'LL BE IN THE THICK
OF THINGS AT THE BEAUTY SALON.
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00:06:00,758 --> 00:06:02,517
Narrator: WOODEN WAGON WHEELS
94
00:06:02,517 --> 00:06:05,172
ROLL THROUGH THE TUMBLEWEEDS
OF ANOTHER TIME.
95
00:06:05,172 --> 00:06:06,689
FIXED TO COVERED WAGONS,
96
00:06:06,689 --> 00:06:09,482
THEY TRANSPORTED SETTLERS
TO THE AMERICAN WEST
97
00:06:09,482 --> 00:06:12,103
IN THE 18th AND 19th CENTURIES.
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00:06:12,103 --> 00:06:14,000
THERE ARE NOW CITIES
AND FREEWAYS
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00:06:14,000 --> 00:06:16,068
WHERE WAGON WHEELS
ONCE BLAZED TRAILS,
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00:06:16,068 --> 00:06:19,172
BUT MAKING THEM
IS NOT A LOST ART.
101
00:06:21,655 --> 00:06:23,655
A THRIVING NOSTALGIA INDUSTRY
102
00:06:23,655 --> 00:06:26,655
KEEPS THESE BIG WOODEN WHEELS
TURNING.
103
00:06:26,655 --> 00:06:30,137
WAGON WHEELS ARE IN DEMAND FOR
HISTORICAL RE-ENACTMENT EVENTS,
104
00:06:30,137 --> 00:06:32,689
MUSEUMS, AND THE MOVIES.
105
00:06:32,689 --> 00:06:34,793
THE WHEELWRIGHT CARVES THE HUB
106
00:06:34,793 --> 00:06:37,862
FROM A CHUNK OF STRONG,
ROT-RESISTANT OAK.
107
00:06:37,862 --> 00:06:41,068
AS IT SPINS ON A LATHE,
HE CUTS IT TO LENGTH.
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00:06:41,068 --> 00:06:42,413
HE STOPS THE LATHE
109
00:06:42,413 --> 00:06:45,689
AND MARKS MEASUREMENTS
FOR THE WAGON WHEEL'S PROFILE,
110
00:06:45,689 --> 00:06:48,862
SIZING IT
FOR REINFORCING METAL HOOPS.
111
00:06:48,862 --> 00:06:50,206
HE RESUMES CARVING,
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00:06:50,206 --> 00:06:52,758
USING THE PENCILED LINES
AS A GUIDE.
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00:06:52,758 --> 00:06:57,000
HE TRANSFORMS THE OAK BLANK
INTO A BARREL-SHAPED DESIGN,
114
00:06:57,000 --> 00:07:01,034
WHICH IS TRADITIONAL FOR
WAGON WHEEL HUBS OF THE 1870s.
115
00:07:03,172 --> 00:07:05,827
WITH THE HUB NOW CLAMPED
IN ANOTHER MACHINE,
116
00:07:05,827 --> 00:07:09,241
HE USES A MECHANIZED CHISEL
TO PUNCH OUT REGULAR SPOKE HOLES
117
00:07:09,241 --> 00:07:11,275
KNOWN AS MORTISES.
118
00:07:13,896 --> 00:07:16,000
HE ANGLES THE EDGE OF EACH HOLE
119
00:07:16,000 --> 00:07:18,655
TO RECEIVE THE TENON END
OF THE SPOKE.
120
00:07:22,862 --> 00:07:25,413
HE SLIDES STEEL HOOPS
ONTO THE HUB
121
00:07:25,413 --> 00:07:27,827
AT THE ENDS AND IN THE CENTER.
122
00:07:27,827 --> 00:07:32,206
IT'S A SNUG FIT,
BUT IT'S NOT QUITE TIGHT ENOUGH.
123
00:07:32,206 --> 00:07:36,034
A HYDRAULIC PRESS SQUEEZES
THE HOOPS AROUND THE HUB
124
00:07:36,034 --> 00:07:38,827
TO PROVIDE
JUST THE RIGHT TENSION.
125
00:07:38,827 --> 00:07:41,448
THE HOOPS WILL ACT
AS A CONSTRICTING FORCE
126
00:07:41,448 --> 00:07:43,344
TO KEEP THE WOOD FROM SPLITTING.
127
00:07:43,344 --> 00:07:45,482
FROM A CHUNK OF WOOD
128
00:07:45,482 --> 00:07:48,689
INTO A SUBSTANTIAL
WAGON WHEEL HUB.
129
00:07:48,689 --> 00:07:52,000
NOW USING TOOLS
CALLED SPOKESHAVES,
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00:07:52,000 --> 00:07:54,275
THE WHEELWRIGHT SHAPES
THE HICKORY WOOD SPOKES.
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00:07:54,275 --> 00:07:59,137
HE NARROWS THE THROAT
OF THE SPOKE TO ADD FLEXIBILITY,
132
00:07:59,137 --> 00:08:03,689
WHERE IT IS TO BE INSERTED
INTO THE HUB.
133
00:08:03,689 --> 00:08:08,758
HE COATS THE MORTISES
OF THE HUB WITH GLUE.
134
00:08:08,758 --> 00:08:12,034
HE INSERTS THE SPOKES
INTO THE GLUED HOLES.
135
00:08:12,034 --> 00:08:16,275
HE DRIVES THEM INTO PLACE
WITH A SLEDGEHAMMER.
136
00:08:16,275 --> 00:08:20,517
THERE ARE 12 SPOKES IN TOTAL
FOR THIS FRONT WAGON WHEEL.
137
00:08:20,517 --> 00:08:23,068
THE WHEELWRIGHT
THEN SPINS THE WHEEL
138
00:08:23,068 --> 00:08:24,862
AND EYEBALLS IT TO CONFIRM
139
00:08:24,862 --> 00:08:28,137
THAT THE SPOKES ROTATE
ON AN EVEN PLANE.
140
00:08:28,137 --> 00:08:32,896
THEN LIKE SHARPENING A PENCIL,
HE BRINGS THE ENDS TO A POINT.
141
00:08:32,896 --> 00:08:35,517
THIS PREPARES THEM
FOR THE TENON CUTTER
142
00:08:35,517 --> 00:08:37,620
THAT NOW CARVES THEM
INTO PEG SHAPES
143
00:08:37,620 --> 00:08:39,586
FOR INSERTION
INTO THE WHEEL RIM.
144
00:08:39,586 --> 00:08:43,896
HE INSTALLS THE STEAM-BENT
WOODEN RIM IN TWO SECTIONS.
145
00:08:43,896 --> 00:08:46,172
IT'S DRILLED
TO MATCH UP WITH THE SPOKES.
146
00:08:47,931 --> 00:08:51,379
AT FIRST, IT'S EASY,
BUT AS THE TENSION BUILDS,
147
00:08:51,379 --> 00:08:54,517
IT BECOMES TOUGHER TO INSERT
THE REMAINING SPOKES,
148
00:08:54,517 --> 00:08:56,896
SO HE STRETCHES THE RIM WIDER
WITH A CLAMP.
149
00:08:56,896 --> 00:08:59,310
THIS GIVES HIM
MORE ROOM TO MANEUVER
150
00:08:59,310 --> 00:09:02,000
AS HE FITS THE OTHERS
INTO THE RIM HALF.
151
00:09:02,000 --> 00:09:03,724
IN THE PROCESS,
152
00:09:03,724 --> 00:09:06,413
HE CREATES A SLIGHT BOW
IN THE PLANE OF THE WHEEL.
153
00:09:06,413 --> 00:09:08,000
IT'S A TRUSS-LIKE STATE
154
00:09:08,000 --> 00:09:10,620
THAT ADDS STRENGTH
TO THE WAGON WHEEL.
155
00:09:10,620 --> 00:09:13,724
NOW USING
AN ELECTRIC ROLLER MACHINE,
156
00:09:13,724 --> 00:09:17,689
HE BENDS A STRIP OF STEEL
INTO A ROUND WAGON-WHEEL TIRE.
157
00:09:20,965 --> 00:09:23,241
IT TAKES JUST ONE PASS
THROUGH THE ROLLERS
158
00:09:23,241 --> 00:09:27,206
TO ACHIEVE THE DESIRED BEND.
159
00:09:27,206 --> 00:09:30,206
THE LENGTH WILL NEED TO BE
PRECISELY MEASURED.
160
00:09:32,275 --> 00:09:34,344
HE MEASURES
THE INNER CIRCUMFERENCE
161
00:09:34,344 --> 00:09:37,000
WITH AN OLD WHEELWRIGHT TOOL
CALLED A TRAVELER,
162
00:09:37,000 --> 00:09:41,172
TO DETERMINE JUST
HOW MUCH TWEAKING IT NEEDS.
163
00:09:41,172 --> 00:09:43,655
THEN USING A TORCH,
164
00:09:43,655 --> 00:09:46,586
HE CUTS THE TIRE
TO THE EXACT LENGTH REQUIRED.
165
00:09:46,586 --> 00:09:50,103
HE MAKES THE TIRE SLIGHTLY
SMALLER THAN THE WHEEL ITSELF
166
00:09:50,103 --> 00:09:52,793
BECAUSE IT MUST SERVE
AS A HEAVY-DUTY ELASTIC BAND
167
00:09:52,793 --> 00:09:56,344
TO HOLD THE ASSEMBLED
WAGON WHEEL TOGETHER.
168
00:09:56,344 --> 00:09:59,206
HE WELDS IT WHERE THE ENDS MEET,
169
00:09:59,206 --> 00:10:03,344
AND THIS COMPLETES
THE WAGON-WHEEL TIRE.
170
00:10:03,344 --> 00:10:06,793
HE NOW BAKES THE TIRE BRIEFLY
IN AN OPEN FIRE.
171
00:10:06,793 --> 00:10:09,551
THE METAL EXPANDS
AND AT A STRATEGIC MOMENT,
172
00:10:09,551 --> 00:10:12,172
THEY PULL IT OUT OF THE FLAMES.
173
00:10:12,172 --> 00:10:13,931
THE TIRE HAS STRETCHED
TO THE POINT
174
00:10:13,931 --> 00:10:15,793
WHERE IT CAN BE INSTALLED
ON THE WHEEL,
175
00:10:15,793 --> 00:10:17,551
BUT IT'S NOT QUITE HOT ENOUGH
176
00:10:17,551 --> 00:10:20,068
TO CAUSE THE WOODEN WHEEL
TO CATCH FIRE.
177
00:10:20,068 --> 00:10:21,827
THEY POUR WATER ONTO THE TIRE
178
00:10:21,827 --> 00:10:24,344
TO BRING IT BACK
TO A COOLER TEMPERATURE.
179
00:10:24,344 --> 00:10:27,620
AS IT COOLS,
IT SHRINKS TO THE WAGON WHEEL,
180
00:10:27,620 --> 00:10:31,793
CREATING
THAT ELASTIC BAND EFFECT.
181
00:10:31,793 --> 00:10:34,827
NEXT, THEY PRIME AND PAINT
A MATCHING SET OF WHEELS
182
00:10:34,827 --> 00:10:38,241
IN THE COLOR
OF THE CLIENT'S CHOICE.
183
00:10:40,172 --> 00:10:42,103
AND WITH
THOSE FINISHING TOUCHES,
184
00:10:42,103 --> 00:10:45,241
THESE WAGON WHEELS
ARE EN ROUTE TO THE PAST.
185
00:10:47,034 --> 00:10:49,517
FOR FANS OF AMERICAN HISTORY,
186
00:10:49,517 --> 00:10:52,137
IT'S SURE TO BE
A SENTIMENTAL JOURNEY.
187
00:11:08,827 --> 00:11:10,827
Narrator:
FOR PEOPLE WHO NEED TO GRAB
188
00:11:10,827 --> 00:11:12,275
A QUICK BITE FOR BREAKFAST,
189
00:11:12,275 --> 00:11:15,068
THE INVENTION OF
THE TOASTER PASTRY IN THE 1960s
190
00:11:15,068 --> 00:11:17,517
WAS THE GREATEST THING
SINCE SLICED BREAD.
191
00:11:17,517 --> 00:11:19,379
FINALLY,
THE TOASTER COULD BE USED
192
00:11:19,379 --> 00:11:20,896
FOR MORE THAN TOASTING BREAD,
193
00:11:20,896 --> 00:11:25,241
AND THE TOASTER PASTRY WAS
DEFINITELY A SWEET ALTERNATIVE.
194
00:11:29,724 --> 00:11:32,896
THE TOASTER PASTRY RETAINS
ITS SWEETNESS DURING TOASTING.
195
00:11:32,896 --> 00:11:35,551
THE SYRUPY FILLING AND FROSTING
DON'T MELT OUT
196
00:11:35,551 --> 00:11:36,931
AND INTO THE TOASTER.
197
00:11:36,931 --> 00:11:39,206
IT'S ALL BECAUSE
OF THE INGREDIENTS
198
00:11:39,206 --> 00:11:41,310
AND HOW THEY COME TOGETHER.
199
00:11:42,793 --> 00:11:43,931
AT THIS FACTORY,
200
00:11:43,931 --> 00:11:45,965
THEY START BY MAKING
AN ORGANIC PASTRY.
201
00:11:45,965 --> 00:11:47,172
THE BLENDER OPERATOR
202
00:11:47,172 --> 00:11:49,413
LOADS DRY INGREDIENTS,
LIKE RICE BRAN,
203
00:11:49,413 --> 00:11:50,896
INTO THE BLENDER,
204
00:11:50,896 --> 00:11:54,068
FOLLOWED BY A SUGAR SYRUP
AND MOLASSES.
205
00:11:54,068 --> 00:11:57,758
IT'S THE MOLASSES THAT GIVES
THE PASTRY A BROWNISH COLOR.
206
00:11:57,758 --> 00:12:02,655
HE ADDS ORGANIC PALM SHORTENING
AND ORGANIC GRANULATED SUGAR.
207
00:12:02,655 --> 00:12:05,896
THE FLOUR AND WATER ARE PIPED
INTO THE BLENDER BARREL.
208
00:12:05,896 --> 00:12:08,482
SPIRALING MIXERS BLEND
AND KNEAD THE DOUGH
209
00:12:08,482 --> 00:12:12,620
TO THE DESIRED CONSISTENCY.
210
00:12:12,620 --> 00:12:14,586
NEXT, IT'S INTO A HOPPER
211
00:12:14,586 --> 00:12:17,931
THAT FEEDS THE DOUGH
BETWEEN TWO ROLLERS.
212
00:12:17,931 --> 00:12:20,000
THEY SQUEEZE
AND FLATTEN THE DOUGH
213
00:12:20,000 --> 00:12:24,068
INTO A SHEET THAT'S ABOUT
8/10 OF AN INCH THICK.
214
00:12:24,068 --> 00:12:27,482
A CONVEYOR MOVES
THE TOASTER-PASTRY DOUGH FORWARD
215
00:12:27,482 --> 00:12:30,793
TO SETS OF LARGER ROLLERS.
216
00:12:30,793 --> 00:12:34,068
THEY APPLY SERIOUS PRESSURE
TO ROLL THE DOUGH MUCH THINNER.
217
00:12:34,068 --> 00:12:37,655
WHEELS AT THE SIDES
FOLD BACK THE DOUGH
218
00:12:37,655 --> 00:12:40,413
AS THE WIDTH EXPANDS.
219
00:12:40,413 --> 00:12:41,896
A DUSTING OF FLOUR
TO THE ROLLERS
220
00:12:41,896 --> 00:12:43,482
KEEPS THINGS FROM GETTING
TOO STICKY.
221
00:12:43,482 --> 00:12:47,000
COMING OFF THE FINAL ROLLERS,
222
00:12:47,000 --> 00:12:51,137
THE THICKNESS OF THE DOUGH HAS
BEEN REDUCED TO 2/10 OF A INCH.
223
00:12:51,137 --> 00:12:53,413
AT ANOTHER STATION,
224
00:12:53,413 --> 00:12:56,448
THEY WHIPPED UP A BATCH
OF CHERRY POMEGRANATE JAM.
225
00:12:56,448 --> 00:12:58,241
THE JAM IS HEARTY AND THICK,
226
00:12:58,241 --> 00:13:00,896
SO IT WON'T RUN
AS NOZZLES PUMP THE JAM
227
00:13:00,896 --> 00:13:04,586
ONTO THE ROLLED PASTRY SHEET.
228
00:13:04,586 --> 00:13:09,000
EACH TOASTER PASTRY RECEIVES
THREE STRINGS OF JAM.
229
00:13:09,000 --> 00:13:12,482
THIS DEPOSITOR SYSTEM
FILLS 10 TARTS AT A TIME.
230
00:13:12,482 --> 00:13:15,241
IT WORKS OUT
TO 390 TARTS A MINUTE.
231
00:13:15,241 --> 00:13:20,517
A SECOND SHEET OF DOUGH HEADS
TOWARDS THE JAM-FILLED ONE.
232
00:13:20,517 --> 00:13:23,586
EN ROUTE,
A SPIKED ROLLER PUNCHES HOLES
233
00:13:23,586 --> 00:13:25,965
FOR VENTING STEAM DURING BAKING.
234
00:13:25,965 --> 00:13:28,724
WITHOUT THESE HOLES,
THE PRESSURE WOULD BUILD
235
00:13:28,724 --> 00:13:31,206
AND THE TOASTER PASTRIES
WOULD EXPLODE.
236
00:13:31,206 --> 00:13:35,206
THE TOP SHEET OF PASTRY
NOW MERGES WITH THE BOTTOM ONE.
237
00:13:35,206 --> 00:13:38,586
THE CONVEYOR BELTS MOVE IT
EXACTLY THE SAME SPEED,
238
00:13:38,586 --> 00:13:41,620
SO THE TOP PASTRY LANDS
IN PERFECT ALIGNMENT
239
00:13:41,620 --> 00:13:43,172
ON THE JAM-FILLED ONE.
240
00:13:43,172 --> 00:13:46,000
A CYLINDER
WITH A BRASS GRID PATTERN
241
00:13:46,000 --> 00:13:47,827
BEARS DOWN ON THE PASTRY
242
00:13:47,827 --> 00:13:51,103
TO COMPRESS IT
BETWEEN THE JAM FILLINGS.
243
00:13:51,103 --> 00:13:54,517
THIS FORMS POCKETS OF JAM.
244
00:13:54,517 --> 00:13:57,931
A CYLINDRICAL BLADE
SLICES THE PASTRY
245
00:13:57,931 --> 00:14:01,896
INTO INDIVIDUAL TARTS.
246
00:14:01,896 --> 00:14:05,758
A DEVICE PULLS OFF
THE SIDE TRIMMINGS.
247
00:14:09,413 --> 00:14:10,724
THE TOASTER PASTRIES
248
00:14:10,724 --> 00:14:13,620
TRAVEL THROUGH
A 150-FOOT-LONG CONVECTION OVEN
249
00:14:13,620 --> 00:14:17,758
HEATED TO
300 DEGREES FAHRENHEIT.
250
00:14:17,758 --> 00:14:20,689
THE OPERATOR KEEPS A CLOSE WATCH
FOR LEAKING JAM.
251
00:14:20,689 --> 00:14:22,000
THAT WOULD BE A SIGN
252
00:14:22,000 --> 00:14:24,310
OF BAD SEALS
IN THE PASTRY POCKETS.
253
00:14:24,310 --> 00:14:25,965
HE REJECTS ANY WITH LEAKS.
254
00:14:25,965 --> 00:14:28,620
HE ALSO KEEPS AN EYE
ON THE COLOR
255
00:14:28,620 --> 00:14:30,275
AS THE PASTRIES BROWN.
256
00:14:30,275 --> 00:14:33,655
THEY SHOULDN'T BE TOO DARK
OR TOO LIGHT.
257
00:14:37,689 --> 00:14:39,103
FRESH OUT OF THE MIXER,
258
00:14:39,103 --> 00:14:41,931
THE PINK FROSTING NOW FLOWS
ONTO A REVOLVING BELT
259
00:14:41,931 --> 00:14:44,379
THAT SPREADS IT
ONTO THE TOASTER PASTRIES
260
00:14:44,379 --> 00:14:45,965
AT JUST THE RIGHT THICKNESS.
261
00:14:48,344 --> 00:14:51,034
THEY'VE ADDED A BIT OF STARCH
TO THE ICING,
262
00:14:51,034 --> 00:14:54,551
AND IT'S THIS STARCH THAT ALLOWS
THE ICING TO HARDEN AND SET
263
00:14:54,551 --> 00:14:57,793
SO IT WON'T MELT AND DRIP INTO
THE TOASTER DURING TOASTING.
264
00:15:02,000 --> 00:15:05,172
THEY SPRINKLE
GRANULATED COLORED SUGAR
265
00:15:05,172 --> 00:15:07,275
ONTO THE TOASTER PASTRIES.
266
00:15:07,275 --> 00:15:09,931
THEY CALL THIS TOPPING
THE CRUNCHLETS.
267
00:15:09,931 --> 00:15:14,137
THE CRUNCHLETS ADD BOTH FLAVOR
AND TEXTURE TO THE PASTRY.
268
00:15:14,137 --> 00:15:17,724
ONCE COOLED,
THE TOASTER PASTRIES TRANSFER
269
00:15:17,724 --> 00:15:20,310
FROM ONE CONVEYOR TO ANOTHER.
270
00:15:20,310 --> 00:15:22,724
A BREAKER ROLLER SNAPS THEM
AT THE CRIMP LINE
271
00:15:22,724 --> 00:15:24,689
TO SEPARATE THEM
INTO GROUPS OF TWO.
272
00:15:27,000 --> 00:15:30,965
THE COMPLETED TARTS
HEAD TOWARDS THE PACKAGING LINE.
273
00:15:30,965 --> 00:15:34,758
AN OPERATOR DOES A VISUAL
INSPECTION AS THEY PASS BY.
274
00:15:34,758 --> 00:15:38,310
MECHANICAL ARMS PUSH THE TARTS
INTO ALUMINUM WRAPPING.
275
00:15:38,310 --> 00:15:42,103
HOT ROLLERS SEAL AND CUT
THE WRAP AT THE ENDS.
276
00:15:42,103 --> 00:15:45,448
THIS WRAPPING PRESERVES
THE TARTS FOR EIGHT MONTHS,
277
00:15:45,448 --> 00:15:48,137
NO PRESERVATIVES NEEDED.
278
00:15:48,137 --> 00:15:50,724
SUCTIONING ARMS
GRAB AND OPEN CARTONS
279
00:15:50,724 --> 00:15:53,344
TO ACCEPT THE FOIL-WRAPPED
TOASTER PASTRIES.
280
00:15:55,758 --> 00:15:57,413
IT TAKES ABOUT AN HOUR
281
00:15:57,413 --> 00:16:00,448
TO MANUFACTURE
A BOX OF TOASTER PASTRIES,
282
00:16:00,448 --> 00:16:03,758
AND NOW IT'S TIME FOR A TOAST.
283
00:16:16,068 --> 00:16:18,241
Narrator:
THE TYPE OF BOW USED TODAY
284
00:16:18,241 --> 00:16:20,379
FOR INSTRUMENTS
IN THE VIOLIN FAMILY
285
00:16:20,379 --> 00:16:22,448
ORIGINATED IN FRANCE
IN THE 1800s.
286
00:16:22,448 --> 00:16:26,551
THE MASTER BOW MAKERS
OF THE DAY USED PERNAMBUCO,
287
00:16:26,551 --> 00:16:29,931
A WOOD BEING IMPORTED
FROM BRAZIL TO MAKE TEXTILE DYE.
288
00:16:29,931 --> 00:16:31,931
THEY CONSIDERED THIS WOOD IDEAL
289
00:16:31,931 --> 00:16:35,275
DUE TO ITS STRENGTH,
DURABILITY, AND BEAUTY.
290
00:16:36,827 --> 00:16:39,413
[ PLAYS CLASSICAL MUSIC PLAYS ]
291
00:16:42,482 --> 00:16:45,172
TODAY, JUST LIKE
HUNDREDS OF YEARS AGO,
292
00:16:45,172 --> 00:16:48,551
QUALITY BOWS ARE MADE
OF PERNAMBUCO WOOD FROM BRAZIL
293
00:16:48,551 --> 00:16:50,758
AND HORSE HAIR.
294
00:16:50,758 --> 00:16:54,275
TO MAKE THE WOODEN PART,
CALLED THE STICK,
295
00:16:54,275 --> 00:16:56,034
THE BOW MAKER LAYS A TEMPLATE
296
00:16:56,034 --> 00:16:58,793
ONTO A .4 TO .5-INCH-THICK BLOCK
OF PERNAMBUCO
297
00:16:58,793 --> 00:17:02,103
AND MARKS WHERE
HE'LL MAKE HIS CUTS.
298
00:17:05,034 --> 00:17:08,034
HE FOLLOWS HIS MARKINGS
WITH A BAND SAW,
299
00:17:08,034 --> 00:17:11,275
CUTTING OUT
THE STICK'S BASIC SHAPE.
300
00:17:16,482 --> 00:17:20,379
THEN HE PLANES THE STICK,
THINNING IT OUT,
301
00:17:20,379 --> 00:17:22,172
TAPERING IT
TO NARROW TOWARD THE FRONT,
302
00:17:22,172 --> 00:17:24,206
AND ANGLING THE CORNERS
303
00:17:24,206 --> 00:17:26,724
TO MAKE THE SQUARE CONTOUR
OCTAGONAL.
304
00:17:29,310 --> 00:17:33,689
NEXT, HE REPEATEDLY HEATS
THE STICK WITH A GAS FLAME
305
00:17:33,689 --> 00:17:34,965
TO SOFTEN IT
306
00:17:34,965 --> 00:17:37,206
AND GENTLY BENDS IT
AGAINST HIS KNEE.
307
00:17:37,206 --> 00:17:40,655
THEN, AFTERWARD,
AGAINST A WOODEN FORM
308
00:17:40,655 --> 00:17:44,103
TO GIVE THE STICK
A VERY PRECISE CURVE.
309
00:17:46,655 --> 00:17:50,482
THIS IS REFERRED TO
AS THE CAMBER OF THE BOW.
310
00:17:50,482 --> 00:17:53,137
NEXT, USING A HANDSAW
AND TEMPLATE,
311
00:17:53,137 --> 00:17:55,137
HE CUTS OUT
A PIECE OF PERNAMBUCO
312
00:17:55,137 --> 00:17:57,551
FOR THE BOW'S FRONT TIP,
CALLED THE HEAD.
313
00:17:57,551 --> 00:18:00,827
HE REFINES THE SHAPE,
FIRST WITH A RASP,
314
00:18:00,827 --> 00:18:04,965
THEN WITH A FILE,
THEN WITH SANDPAPER.
315
00:18:04,965 --> 00:18:09,103
THEN HE GLUES ON A BONE PLATE
TO PROTECT THE HEAD FROM DAMAGE.
316
00:18:11,068 --> 00:18:13,827
HE WRAPS STRING
TIGHTLY AROUND IT
317
00:18:13,827 --> 00:18:17,517
TO APPLY CONTINUAL PRESSURE
WHILE THE GLUE SETS OVERNIGHT.
318
00:18:17,517 --> 00:18:20,034
THE NEXT DAY,
HE FILES DOWN THE SIDES
319
00:18:20,034 --> 00:18:22,241
TO MAKE THE PLATE FLUSH
WITH THE WOOD.
320
00:18:22,241 --> 00:18:24,551
USING A TRADITIONAL DRILL,
321
00:18:24,551 --> 00:18:29,413
HE BORES A HOLE ABOUT 4/10
OF AN INCH DEEP INTO THE HEAD
322
00:18:29,413 --> 00:18:32,241
AND CHISELS THE HOLE
INTO A TRAPEZOID SHAPE.
323
00:18:32,241 --> 00:18:33,896
THIS FORMS THE HAIR BLOCK
324
00:18:33,896 --> 00:18:36,517
INTO WHICH HE'LL LATER
INSERT THE HAIR.
325
00:18:36,517 --> 00:18:40,137
NEXT, HE MEASURES AND MARKS
A BLOCK OF EBONY WOOD
326
00:18:40,137 --> 00:18:42,413
TO BEGIN MAKING THE BOW'S FROG,
327
00:18:42,413 --> 00:18:43,827
THE PIECE AT THE BOTTOM
328
00:18:43,827 --> 00:18:46,034
BY WHICH THE MUSICIAN
HOLDS THE BOW
329
00:18:46,034 --> 00:18:48,275
AND ADJUSTS THE TENSION
OF THE HAIR.
330
00:18:48,275 --> 00:18:50,758
HE SHAPES THE BLOCK
USING FIRST A SAW,
331
00:18:50,758 --> 00:18:52,068
THEN A CHISEL,
332
00:18:52,068 --> 00:18:56,724
AND RASPS, FILES, AND SANDS
ALL THE SURFACES SMOOTH.
333
00:18:56,724 --> 00:19:00,000
THE FROG HAS A SPACE ON TOP
CALLED THE MORTIS,
334
00:19:00,000 --> 00:19:03,000
INTO WHICH HE'LL LATER
INSERT THE HAIR.
335
00:19:03,000 --> 00:19:06,448
THE BOW MAKER GLUES A DECORATIVE
MOTHER-OF-PEARL ACCENT
336
00:19:06,448 --> 00:19:07,586
ONTO THE SIDE,
337
00:19:07,586 --> 00:19:10,275
THEN CUTS TWO SMALL PLUGS
OUT OF MAPLE WOOD.
338
00:19:10,275 --> 00:19:13,206
THESE WILL ANCHOR THE HAIR
AT EACH END OF THE BOW.
339
00:19:13,206 --> 00:19:17,103
HE INSERTS ONE
INTO THE FROG'S MORTIS...
340
00:19:20,689 --> 00:19:24,000
...AND THE OTHER INTO
THE HAIR BLOCK IN THE HEAD.
341
00:19:25,379 --> 00:19:28,758
A BOW THIS SIZE REQUIRES
A TENTH OF AN OUNCE OF HAIR.
342
00:19:28,758 --> 00:19:32,965
THAT'S APPROXIMATELY
180 HORSE HAIRS.
343
00:19:32,965 --> 00:19:35,793
THE BOW MAKER
BONDS THEM AT ONE END
344
00:19:35,793 --> 00:19:39,275
WITH SOME MELTED ROSIN,
A STICKY PLANT RESIN,
345
00:19:39,275 --> 00:19:43,034
THEN INSERTS
THIS END INTO THE FROG
346
00:19:43,034 --> 00:19:45,344
AND ANCHORS IT WITH A PLUG.
347
00:19:50,413 --> 00:19:52,206
THEN HE BENDS THE HAIRS
348
00:19:52,206 --> 00:19:55,655
AND SLIDES ON A NICKEL-SILVER
RING CALLED A FERRULE
349
00:19:55,655 --> 00:19:58,379
TO HOLD THEM TOGETHER.
350
00:19:58,379 --> 00:20:01,620
MORE EXPENSIVE BOWS
OFTEN HAVE A GOLD FERRULE.
351
00:20:01,620 --> 00:20:04,000
TO MOUNT THE FROG,
352
00:20:04,000 --> 00:20:06,965
HE INSERTS A LONG METAL SCREW
WITH AN ADJUSTER HEAD
353
00:20:06,965 --> 00:20:09,655
INTO A HOLE DRILLED
INTO THE BACK OF THE BOW.
354
00:20:09,655 --> 00:20:13,482
THE SCREW OPERATES AN EYELET
CONNECTED TO THE FROG.
355
00:20:13,482 --> 00:20:16,310
NOW HE COMBS THE HAIR STRAIGHT.
356
00:20:16,310 --> 00:20:19,310
THE INDIVIDUAL HAIRS MUST BE
PARALLEL TO EACH OTHER
357
00:20:19,310 --> 00:20:21,137
FOR THE BOW TO PERFORM PROPERLY.
358
00:20:21,137 --> 00:20:25,758
HE TIES THE LOOSE ENDS
TOGETHER WITH THREAD
359
00:20:25,758 --> 00:20:27,448
AND BONDS THEM WITH ROSIN.
360
00:20:27,448 --> 00:20:32,896
THEN HE INSERTS THE SEALED END
INTO THE TIP
361
00:20:32,896 --> 00:20:35,103
AND ANCHORS IT
WITH THAT SECOND PLUG.
362
00:20:41,758 --> 00:20:43,241
BACK TO THE FROG NOW,
363
00:20:43,241 --> 00:20:45,827
HE MOVES THE FERRULE
OUT OF POSITION,
364
00:20:45,827 --> 00:20:48,413
SEALS THE MORTIS WITH
A MOTHER-OF-PEARL SLIDE,
365
00:20:48,413 --> 00:20:50,827
THEN PUTS THE FERRULE BACK.
366
00:20:50,827 --> 00:20:53,827
HE WRAPS THE PARTS OF THE STICK
THE MUSICIAN HOLDS
367
00:20:53,827 --> 00:20:55,896
IN SILVER OR GOLD WIRE
AND LEATHER
368
00:20:55,896 --> 00:20:57,758
TO PROTECT THE WOOD FROM WEAR
369
00:20:57,758 --> 00:21:00,172
AND BRANDS THE MAKER'S NAME.
370
00:21:00,172 --> 00:21:02,689
TURNING THE ADJUSTER AT THE BACK
371
00:21:02,689 --> 00:21:05,310
MOVES THE FROG
FORWARD AND BACKWARD
372
00:21:05,310 --> 00:21:07,689
TO ALTER THE TENSION
OF THE HAIR.
373
00:21:07,689 --> 00:21:10,241
THE VIOLINIST TIGHTENS THE HAIR
BEFORE PLAYING
374
00:21:10,241 --> 00:21:12,827
AND LOOSENS IT WHEN PUTTING
THE INSTRUMENT AWAY.
375
00:21:21,034 --> 00:21:24,068
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
376
00:21:24,068 --> 00:21:26,344
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
377
00:21:26,344 --> 00:21:28,655
DROP US A LINE AT...
29700
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