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00:00:01,793 --> 00:00:04,793
--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:53,241 --> 00:00:55,172
Narrator:
CYCLING SHOES HAVE CLEATS
4
00:00:55,172 --> 00:00:57,103
FOR BOLTING THE FOOT
TO THE PEDAL.
5
00:00:57,103 --> 00:01:00,724
THE CYCLIST IS CONNECTED
TO THE BICYCLE, BODY AND SOUL.
6
00:01:00,724 --> 00:01:04,793
BIKE SHOES WITH CLIP-IN CLEATS
ARE A FAIRLY RECENT INNOVATION.
7
00:01:04,793 --> 00:01:08,241
THE FIRST VERSIONS
APPEARED IN FRANCE IN THE 1980s
8
00:01:08,241 --> 00:01:11,586
AND WERE MODELED AFTER
ALPINE SKI BINDINGS.
9
00:01:15,448 --> 00:01:18,103
AVID CYCLISTS ARE VERY ATTACHED
TO THEIR BICYCLES
10
00:01:18,103 --> 00:01:20,448
THROUGH SPECIAL SHOES
THAT CLIP TO THE PEDALS.
11
00:01:23,413 --> 00:01:25,965
CYCLING SHOES TRANSFER POWER
FROM THE FOOT TO THE PEDAL
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00:01:25,965 --> 00:01:28,586
MORE EFFICIENTLY
THAN ORDINARY SHOES.
13
00:01:31,206 --> 00:01:33,379
TO START, AN OVERHEAD PRESS
14
00:01:33,379 --> 00:01:35,827
DRIVES COOKIE-CUTTER SHAPES
CALLED DYES
15
00:01:35,827 --> 00:01:40,310
THROUGH LAYERS OF FABRIC
TO PUNCH OUT SHOE PARTS.
16
00:01:40,310 --> 00:01:44,310
THEY USE BREATHABLE NYLON MESH
FOR THESE UPPER PIECES
17
00:01:44,310 --> 00:01:48,379
AND SYNTHETIC LEATHER
FOR PARTS LIKE THE SHOE TOE BOX.
18
00:01:48,379 --> 00:01:52,896
SYNTHETIC LEATHER IS RIGID,
WATERPROOF, AND LIGHTWEIGHT.
19
00:01:54,517 --> 00:01:58,344
IT TAKES 18 PIECES OF FABRIC
TO MAKE ONE CYCLING SHOE.
20
00:01:58,344 --> 00:02:02,068
THIS ASSEMBLER PIECES TOGETHER
THE UPPER MESH PARTS
21
00:02:02,068 --> 00:02:05,275
AND STITCHES ON
SYNTHETIC LEATHER TRIM.
22
00:02:08,413 --> 00:02:11,620
SHE ADDS A SYNTHETIC LEATHER
SIDE WITH VENT HOLES.
23
00:02:11,620 --> 00:02:14,034
IT GIVES THE CYCLING SHOE
STRUCTURE.
24
00:02:19,310 --> 00:02:22,034
WITH ONE HALF OF
THE CYCLING SHOE NOW COMPLETE,
25
00:02:22,034 --> 00:02:23,793
IT'S READY FOR THE OTHER HALF.
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00:02:23,793 --> 00:02:26,310
SHE JOINS IT TO THE OTHER HALF
AT THE TOE END
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00:02:26,310 --> 00:02:29,793
USING HIGH-DENSITY NYLON THREAD.
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00:02:33,379 --> 00:02:35,931
THE NEXT PART IS THE HEEL CUP.
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00:02:35,931 --> 00:02:37,862
IT'S A PIECE
OF MOLDED POLYURETHANE
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00:02:37,862 --> 00:02:41,758
THAT ADDS STRENGTH AND FORM
TO THE BACK OF THE CYCLING SHOE.
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00:02:41,758 --> 00:02:43,931
SHE STITCHES ON TRIM
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00:02:43,931 --> 00:02:47,551
AND JOINS THE HEEL CUP
TO THE REST OF THE CYCLING SHOE.
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00:02:51,448 --> 00:02:54,344
NEXT, USING SUPERSTRONG
KEVLAR THREAD,
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00:02:54,344 --> 00:02:58,620
SHE SEWS THE TOE BOX AND TONGUE
TO THE CYCLING-SHOE ASSEMBLY.
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00:02:58,620 --> 00:03:02,103
THE CONFIGURATION LEAVES
OPEN AREAS FOR MESH VENTS
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00:03:02,103 --> 00:03:03,758
AT THE FRONT OF THE SHOE.
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00:03:03,758 --> 00:03:07,551
THE SHOE UPPER IS NOW COMPLETE
AND READY FOR THE INNER SOLE.
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00:03:07,551 --> 00:03:11,689
IT'S MADE
OF HIGH-DENSITY PLASTIC.
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00:03:11,689 --> 00:03:16,103
THE EMPLOYEE TACKS IT TO
A FOOT MOLD USING SMALL NAILS.
40
00:03:17,793 --> 00:03:19,517
HE SETS IT ASIDE
41
00:03:19,517 --> 00:03:23,172
AND PLACES A PAIR OF SHOE UPPERS
IN HOT AND ROUNDED CLAMPS
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00:03:23,172 --> 00:03:26,517
TO WARM THEM TO A PLIABLE STATE.
43
00:03:26,517 --> 00:03:30,137
HE STRETCHES EACH UPPER
AROUND A FOOT MOLD
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00:03:30,137 --> 00:03:32,413
WITH A TACKED INNER SOLE.
45
00:03:33,655 --> 00:03:36,482
THEN IT'S OVER TO A MACHINE
THAT OOZES EPOXY --
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00:03:36,482 --> 00:03:40,724
A HIGH-STRENGTH GLUE THAT IS
IMPERVIOUS TO WEATHER EXTREMES.
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00:03:40,724 --> 00:03:44,172
THE MACHINE GRIPS AND FOLDS
THE CYCLING-SHOE UPPER
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00:03:44,172 --> 00:03:45,344
TO THE SOLE
49
00:03:45,344 --> 00:03:48,655
AS IT APPLIES EPOXY
TO SEAL THEM TOGETHER.
50
00:03:48,655 --> 00:03:50,655
THE EPOXY HARDENS QUICKLY,
51
00:03:50,655 --> 00:03:54,241
AND A COMPUTER-CONTROLLED
GRINDER GETS RID OF THE EXCESS.
52
00:03:56,172 --> 00:03:59,724
NOW A SPINNING BRUSH APPLIES
A DIFFERENT EPOXY
53
00:03:59,724 --> 00:04:01,793
THAT WILL NEED HEAT
TO ACTIVATE IT.
54
00:04:03,413 --> 00:04:04,862
AT THE NEXT STATION,
55
00:04:04,862 --> 00:04:07,793
A WORKER APPLIES A RELEASE AGENT
TO A MOLD.
56
00:04:07,793 --> 00:04:10,448
HE INSERTS
A PIECE OF CARBON FIBER --
57
00:04:10,448 --> 00:04:12,448
A HIGH-TECH COMPOSITE MATERIAL.
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00:04:12,448 --> 00:04:14,655
HE ADDS NYLON FOR TEXTURE.
59
00:04:14,655 --> 00:04:16,758
HE FLIPS THE UPPER PART
OF THE MOLD,
60
00:04:16,758 --> 00:04:19,517
AND THE TWO PARTS COME TOGETHER
LIKE A WAFFLE IRON.
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00:04:19,517 --> 00:04:23,137
INSIDE, THE LAYERS MELT INTO ONE
AND THEN COOL,
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00:04:23,137 --> 00:04:26,551
CREATING A TOUGH AND LIGHTWEIGHT
OUTER SOLE.
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00:04:28,413 --> 00:04:32,965
THEY PUNCH OUT VENT HOLES
AND TRIM THE EDGES OF THE SOLE.
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00:04:32,965 --> 00:04:37,517
THEY PAINT DESIGNS ON TO IT
AND ADD A NONSLIP CLEAR COAT.
65
00:04:39,103 --> 00:04:42,000
HE GLUES TOUGH NYLON MESH
OVER THE VENT HOLES
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00:04:42,000 --> 00:04:43,896
TO KEEP THE DIRT OUT.
67
00:04:45,068 --> 00:04:47,310
HE TAPES THE CLEAT MOUNT
ONTO IT.
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00:04:47,310 --> 00:04:49,620
IT WILL BE
MORE SECURELY INSTALLED
69
00:04:49,620 --> 00:04:52,413
FOR THE INDIVIDUAL CYCLIST
AT THE BIKE SHOP.
70
00:04:52,413 --> 00:04:55,379
AND AFTER
AN APPLICATION OF EPOXY,
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00:04:55,379 --> 00:04:57,034
IT'S INTO THE OVEN.
72
00:04:57,034 --> 00:04:58,344
AT THE SAME TIME,
73
00:04:58,344 --> 00:05:01,379
HE HEATS THE GLUE-COVERED
OUTER SOLE IN ANOTHER OVEN.
74
00:05:01,379 --> 00:05:04,551
THE HEAT ACTIVATES THE EPOXY.
75
00:05:04,551 --> 00:05:09,551
IT'S TIME TO JOIN THE OUTER SOLE
AND THE SHOE UPPER.
76
00:05:09,551 --> 00:05:12,965
HE CAREFULLY ALIGNS THEM
AND PRESSES THEM TOGETHER.
77
00:05:15,275 --> 00:05:17,551
HE THEN SETS THE SHOE
ON A CRADLE,
78
00:05:17,551 --> 00:05:21,275
AND HYDRAULIC PUSHERS
APPLY PRESSURE AS THE GLUE SETS.
79
00:05:23,413 --> 00:05:26,482
HE PRESSES THE FOOT FORM
THAT'S STILL INSIDE THE SHOE
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00:05:26,482 --> 00:05:28,310
ONTO A SHARP POST,
81
00:05:28,310 --> 00:05:30,793
STABILIZING IT
TO PULL THE SHOE OFF.
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00:05:30,793 --> 00:05:34,000
THE NEXT EMPLOYEE INSTALLS
A CABLE-CLOSURE DEVICE
83
00:05:34,000 --> 00:05:37,931
THAT ACTS LIKE A SHOELACE
BUT DOESN'T BECOME TANGLED.
84
00:05:37,931 --> 00:05:41,517
SHE ADDS
A RATCHET-STYLE PLASTIC BUCKLE.
85
00:05:41,517 --> 00:05:45,241
CRAFTED BY HAND
USING HIGH-TECH MATERIALS,
86
00:05:45,241 --> 00:05:48,551
IT'S TAKEN ABOUT AN HOUR
TO MAKE THESE CYCLING SHOES.
87
00:05:48,551 --> 00:05:51,241
AND NOW THEY'RE READY
FOR A SPIN.
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00:06:01,517 --> 00:06:03,000
Narrator: FOR CENTURIES,
89
00:06:03,000 --> 00:06:06,103
YURTS HAVE BEEN HOME TO HERDERS
ON THE ASIAN PLATEAU.
90
00:06:06,103 --> 00:06:09,724
THEY CONTINUE NOW FOR
PRACTICALITY AND PORTABILITY.
91
00:06:09,724 --> 00:06:13,206
TODAY YURTS USED AS SECOND HOMES
OR STUDIO SPACES
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00:06:13,206 --> 00:06:15,310
OFFER DURABILITY, COMFORT,
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00:06:15,310 --> 00:06:18,172
AND A BARELY DETECTABLE
FOOTPRINT.
94
00:06:21,172 --> 00:06:23,724
THIS IS THE ENGINEERED,
MODERN VERSION
95
00:06:23,724 --> 00:06:25,965
OF THE ANCIENT
NOMADIC STRUCTURE.
96
00:06:25,965 --> 00:06:29,551
COMPRESSION AND TENSION TOGETHER
FORM FREESTANDING YURTS
97
00:06:29,551 --> 00:06:32,620
THAT TODAY FEATURE
ALL THE MODERN CONVENIENCES,
98
00:06:32,620 --> 00:06:36,482
INCLUDING KITCHENS,
DINING AREAS, AND LOFTS.
99
00:06:36,482 --> 00:06:41,103
THE VINYL POLYMER ROOF
IS GRADUALLY SHAPED INTO A CONE.
100
00:06:41,103 --> 00:06:43,896
A WORKER FOLDS THE POLYMER,
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00:06:43,896 --> 00:06:48,275
LAYING TWO EDGES BESIDE EACH
OTHER ON TOP OF A FORMICA BOARD.
102
00:06:48,275 --> 00:06:53,103
USING A HOT-AIR WELDER,
HE MELTS THE TWO EDGES TOGETHER.
103
00:06:56,103 --> 00:06:58,551
A VINYL LAMINATE VALANCE
IS HEAT-WELDED
104
00:06:58,551 --> 00:07:00,827
TO THE BOTTOM PERIMETER
OF THE ROOF,
105
00:07:00,827 --> 00:07:02,896
CREATING
A WATERTIGHT CONNECTION.
106
00:07:04,034 --> 00:07:07,551
TOGETHER, THE WORKERS PULL
THE ENTIRE BOTTOM PERIMETER
107
00:07:07,551 --> 00:07:10,137
OF THE ROOF
THROUGH THE HEAT WELDER.
108
00:07:11,965 --> 00:07:14,275
IN THE WOODWORKING AREA,
109
00:07:14,275 --> 00:07:17,827
A WORKER DRILLS A HOLE
IN A ROOF RAFTER.
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00:07:17,827 --> 00:07:20,379
WITH A ROUTER, HE CUTS A NOTCH
111
00:07:20,379 --> 00:07:23,931
THAT WILL EVENTUALLY FIT
OVER A SUPPORT CABLE.
112
00:07:23,931 --> 00:07:27,827
WORKERS SPRAY AN OIL FINISH
ONTO THE TOOLED RAFTERS
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00:07:27,827 --> 00:07:31,000
FOR AESTHETICS
AND ADDED WEATHERPROOFING.
114
00:07:34,241 --> 00:07:37,068
TO KEEP THE RAFTER
FROM SLIPPING OFF ITS CABLE,
115
00:07:37,068 --> 00:07:41,965
A WORKER SCREWS A KEEPER BOLT
INTO A BRASS THREAD IN THE HOLE.
116
00:07:41,965 --> 00:07:43,793
HE ASSEMBLES
THE COMPRESSION RING,
117
00:07:43,793 --> 00:07:45,586
WHICH SITS
AT THE TOP OF THE YURT.
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00:07:45,586 --> 00:07:49,793
HE SCREWS IN RAFTER BRACKETS
MADE OF GALVANIZED STEEL.
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00:07:49,793 --> 00:07:53,965
A WORKER USES SILICONE GLUE
TO ATTACH A RUBBER GASKET
120
00:07:53,965 --> 00:07:56,758
TO THE BOTTOM EDGE
OF THE ROOF'S ACRYLIC DOME.
121
00:07:56,758 --> 00:07:59,413
THE WORKERS REST IT
ON THE COMPRESSION RING,
122
00:07:59,413 --> 00:08:00,551
WHERE IT'LL BE HELD IN PLACE
123
00:08:00,551 --> 00:08:04,517
BY CABLES
AND STAINLESS-STEEL SPRINGS.
124
00:08:04,517 --> 00:08:08,275
THEY BEGIN PREPARING
THE YURT'S LATTICE WALL.
125
00:08:08,275 --> 00:08:11,310
THE VERTICAL-GRAIN PIECES
OF DOUGLAS FIR
126
00:08:11,310 --> 00:08:15,000
ARE DIPPED IN WATER-BASED
NONTOXIC PENETRATING OIL.
127
00:08:17,448 --> 00:08:19,379
THE PIECES FOR THE LATTICE WALL
128
00:08:19,379 --> 00:08:22,241
ARE PLACED IN
A MULTIPLE-HEAD BORING MACHINE.
129
00:08:22,241 --> 00:08:26,655
IN ONE SHOT, IT PRECISION DRILLS
200 IDENTICAL HOLES
130
00:08:26,655 --> 00:08:29,551
THROUGH SEVERAL PIECES OF WOOD.
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00:08:29,551 --> 00:08:32,758
A WORKER BEGINS ASSEMBLING
THE LATTICE WALL.
132
00:08:32,758 --> 00:08:35,310
AS HE LINES UP
THE PIECES OF WOOD,
133
00:08:35,310 --> 00:08:38,137
HE FLEXES THEM
TO TEST THEIR STRENGTH.
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00:08:38,137 --> 00:08:42,206
THE ALLOY RIVETS HE PLACES
IN THE HOLES WILL ACT AS HINGES.
135
00:08:42,206 --> 00:08:46,275
HE USES A PNEUMATIC RIVETING
MACHINE TO ASSEMBLE THE WALL.
136
00:08:46,275 --> 00:08:49,896
ITS LOAD-BEARING CAPABILITY,
ONCE FULLY ASSEMBLED,
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00:08:49,896 --> 00:08:53,551
IS EXTREMELY HIGH.
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00:08:53,551 --> 00:08:57,137
LARGER YURTS WILL HAVE WALLS
WITH AS MANY AS 200 PIECES,
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00:08:57,137 --> 00:09:00,896
WHILE SMALLER YURTS
WILL HAVE CLOSER TO 100.
140
00:09:00,896 --> 00:09:03,137
ONCE RIVETING IS COMPLETE,
141
00:09:03,137 --> 00:09:07,137
THE WORKER MAKES SURE
THE WALL SPREADS PROPERLY.
142
00:09:07,137 --> 00:09:10,896
ON-SITE,
WORKERS SPREAD THE LATTICE WALL.
143
00:09:13,275 --> 00:09:16,724
THEY BOLT BOTH ENDS
OF THE LATTICE TO THE DOORJAMBS.
144
00:09:16,724 --> 00:09:19,758
A WORKER PLACES
THE GALVANIZED AIRCRAFT CABLE
145
00:09:19,758 --> 00:09:22,724
IN THE UPPER NOTCH
OF THE LATTICE WALL.
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00:09:22,724 --> 00:09:26,517
WORKERS ATTACH ROOF RAFTERS
TO THE COMPRESSION RING.
147
00:09:26,517 --> 00:09:29,137
THE RING END OF THE RAFTER
IS ATTACHED TO THE BRACKETS
148
00:09:29,137 --> 00:09:30,448
WITH A THROUGH BOLT,
149
00:09:30,448 --> 00:09:33,482
WHILE THE WALL END OF THE RAFTER
ATTACHES TO THE CABLE.
150
00:09:33,482 --> 00:09:37,689
THE RAFTERS ARE MADE
OF MACHINED STRESS-RATED WOOD,
151
00:09:37,689 --> 00:09:41,034
WHICH CAN WITHSTAND
THE WEIGHT OF SNOW.
152
00:09:41,034 --> 00:09:43,620
THEY LEVEL THE COMPRESSION RING.
153
00:09:45,172 --> 00:09:47,413
THEY DRAPE
A POLYESTER INSULATION LINING
154
00:09:47,413 --> 00:09:48,758
OVER THE RAFTERS
155
00:09:48,758 --> 00:09:51,034
AND FASTEN IT SECURELY IN PLACE.
156
00:09:53,965 --> 00:09:56,103
THEY COVER THE INSULATION LINING
157
00:09:56,103 --> 00:09:59,103
WITH A HIGHLY-EFFICIENT
REFLECTIVE INSULATION.
158
00:10:05,896 --> 00:10:09,000
USING FIBERGLASS-REINFORCED
ALUMINUM TAPE,
159
00:10:09,000 --> 00:10:10,448
THEY SEAL THE SEAM.
160
00:10:13,172 --> 00:10:15,275
THE FOIL INSULATION RESTS
161
00:10:15,275 --> 00:10:18,344
BETWEEN THE LINING UNDERNEATH
AND THE EXTERIOR ROOF.
162
00:10:20,241 --> 00:10:23,896
THE WORKERS NOW ROLL
THE VINYL LAMINATE EXTERIOR WALL
163
00:10:23,896 --> 00:10:26,241
AROUND THE SIDES OF THE YURT.
164
00:10:26,241 --> 00:10:30,827
THE EXTERIOR WALL
IS SECURELY LACED INTO GROMMETS
165
00:10:30,827 --> 00:10:33,275
ALONG THE BOTTOM EDGE
OF THE ROOF VALANCE.
166
00:10:39,448 --> 00:10:42,103
A WORKER STANDING
IN THE COMPRESSION RING
167
00:10:42,103 --> 00:10:45,000
HOISTS THE ACRYLIC DOME
UP TO THE TOP OF THE ROOF
168
00:10:45,000 --> 00:10:48,068
AND POSITIONS IT
ON THE COMPRESSION-RING FRAME.
169
00:10:48,068 --> 00:10:51,551
YURT WINDOWS ARE SEWN IN
WITH MOSQUITO NETTING
170
00:10:51,551 --> 00:10:53,896
AND HAVE A CLEAR VINYL COVERING.
171
00:10:53,896 --> 00:10:59,000
ALL IN ALL, YURT LIVING MEANS
NEVER PULLING UP STAKES.
172
00:11:08,896 --> 00:11:10,655
Narrator: MARINE PLYWOOD IS USED
173
00:11:10,655 --> 00:11:12,931
IN THE CONSTRUCTION
OF DOCKS AND BOATS.
174
00:11:12,931 --> 00:11:16,413
YOU CAN'T USE STANDARD PLYWOOD
IN SUCH WET ENVIRONMENTS.
175
00:11:16,413 --> 00:11:19,103
MARINE PLYWOOD ISN'T AFFECTED
BY MOISTURE
176
00:11:19,103 --> 00:11:21,896
BECAUSE IT'S MADE FROM SHEETS
OF A TROPICAL HARDWOOD
177
00:11:21,896 --> 00:11:23,931
THAT'S NATURALLY WATER-RESISTANT
178
00:11:23,931 --> 00:11:26,517
AND BONDED
WITH WATER-RESISTANT GLUE.
179
00:11:28,620 --> 00:11:31,551
MARINE PLYWOOD
IS TYPICALLY USED IN BOATS
180
00:11:31,551 --> 00:11:34,413
FOR FLOORING, BULKHEADS,
AND FURNITURE.
181
00:11:34,413 --> 00:11:38,068
THE SURFACE IS TYPICALLY A
DECORATIVE TYPE OF WOOD VENEER,
182
00:11:38,068 --> 00:11:41,379
SUCH AS OAK, MAPLE,
TEAK, OR MAHOGANY.
183
00:11:41,379 --> 00:11:44,965
THE CORE, HOWEVER, IS MADE
OF BONDED LAYERS OF OKOUME,
184
00:11:44,965 --> 00:11:46,448
A WATER-RESISTANT SPECIES
185
00:11:46,448 --> 00:11:49,724
THAT GROWS IN THE HOT AND HUMID
EQUATORIAL FOREST OF GABON
186
00:11:49,724 --> 00:11:51,413
IN AFRICA.
187
00:11:51,413 --> 00:11:54,000
WHEN THE OKOUME LOGS
ARRIVE AT THE FACTORY,
188
00:11:54,000 --> 00:11:57,724
AN AUTOMATED CHAINSAW CUTS
HALF THE SHIPMENT INTO PIECES,
189
00:11:57,724 --> 00:12:01,241
MEASURING THE LENGTH
OF A FINISHED PANEL OF PLYWOOD,
190
00:12:01,241 --> 00:12:02,827
AND THE OTHER HALF INTO PIECES
191
00:12:02,827 --> 00:12:05,034
MEASURING THE WIDTH
OF A FINISHED PANEL.
192
00:12:05,034 --> 00:12:08,482
THIS PRODUCES LOGS WITH THE
GRAIN RUNNING IN ONE DIRECTION,
193
00:12:08,482 --> 00:12:09,758
AS WELL AS LOGS
194
00:12:09,758 --> 00:12:12,172
WITH THE GRAIN RUNNING
IN THE OPPOSITE DIRECTION.
195
00:12:12,172 --> 00:12:15,931
THIS IS CRITICAL BECAUSE
WHEN THEY CONSTRUCT THE PLYWOOD,
196
00:12:15,931 --> 00:12:19,379
THEY'LL CRISSCROSS GRAIN
DIRECTIONS TO ADD STRENGTH.
197
00:12:19,379 --> 00:12:23,310
NEXT THE LOGS GO THROUGH
A SERIES OF ROTARY BLADES
198
00:12:23,310 --> 00:12:25,551
THAT PROGRESSIVELY
SHAVE OFF THE BARK.
199
00:12:28,655 --> 00:12:32,068
THE NOW-BARKLESS LOGS ENTER
THE ROTARY PEELING MACHINE.
200
00:12:32,068 --> 00:12:34,655
IT WORKS LIKE
A GIANT PENCIL SHARPENER,
201
00:12:34,655 --> 00:12:37,689
SHAVING OFF A CONTINUOUS
THIN SHEET CALLED A PLY,
202
00:12:37,689 --> 00:12:39,586
HENCE THE TERM PLYWOOD.
203
00:12:39,586 --> 00:12:43,931
THE PLY IS BETWEEN 1/100
AND 1/10 OF AN INCH THICK,
204
00:12:43,931 --> 00:12:46,931
DEPENDING ON ITS POSITION
IN THE FINISHED PANEL.
205
00:12:46,931 --> 00:12:49,172
BLADES ON BOTH SIDES
TRIM THE PLY,
206
00:12:49,172 --> 00:12:52,206
PRODUCING NEAT, STRAIGHT EDGES.
207
00:12:52,206 --> 00:12:55,448
THEN THE MACHINE
ROLLS UP THE PLY.
208
00:12:59,275 --> 00:13:02,068
THE NEXT MACHINE
UNWINDS THE CONTINUOUS PLY
209
00:13:02,068 --> 00:13:04,965
AND SLICES IT
INTO SEPARATE PLIES.
210
00:13:04,965 --> 00:13:06,689
IF THE LOG
THAT PRODUCED THIS ROLL
211
00:13:06,689 --> 00:13:08,172
WAS ONE OF THOSE CUT
212
00:13:08,172 --> 00:13:10,758
TO THE EIGHT-FOOT LENGTH
OF A FINISHED PLYWOOD PANEL,
213
00:13:10,758 --> 00:13:13,896
THEN THIS MACHINE
MAKES A CUT EVERY FOUR FEET --
214
00:13:13,896 --> 00:13:16,344
THE WIDTH
OF THE FINISHED PANEL...
215
00:13:16,344 --> 00:13:18,413
AND VICE-VERSA.
216
00:13:18,413 --> 00:13:22,206
THIS THICKNESS OF PLYWOOD
HAS A FIVE-PLY CORE.
217
00:13:22,206 --> 00:13:23,862
THREE OF THE PLIES REMAIN DRY,
218
00:13:23,862 --> 00:13:25,862
WHILE TWO
GO THROUGH THIS MACHINE,
219
00:13:25,862 --> 00:13:27,862
WHICH ROLLS STRONG,
WATER-RESISTANT GLUE
220
00:13:27,862 --> 00:13:30,586
SIMULTANEOUSLY ON BOTH SIDES.
221
00:13:30,586 --> 00:13:33,586
NOW ASSEMBLY BEGINS.
222
00:13:33,586 --> 00:13:37,482
ALTERNATING GRAIN DIRECTIONS,
THE FIRST PLY IS A DRY ONE,
223
00:13:37,482 --> 00:13:38,931
THE SECOND A GLUED ONE.
224
00:13:38,931 --> 00:13:41,862
THE BOTTOM OF IT
STICKS TO THE PLY UNDERNEATH --
225
00:13:41,862 --> 00:13:45,517
THE TOP TO THE DRY THIRD PLY
THAT GOES OVER IT.
226
00:13:45,517 --> 00:13:48,034
THE NEXT PLY -- THE FOURTH --
IS A GLUED ONE.
227
00:13:48,034 --> 00:13:50,310
THE BOTTOM STICKS TO
THE PLY UNDERNEATH,
228
00:13:50,310 --> 00:13:54,482
AND THE TOP TO THE FIFTH
AND FINAL PLY A DRY ONE ABOVE.
229
00:13:54,482 --> 00:13:57,275
WORKERS USE
A POWERFUL PNEUMATIC STAPLE GUN
230
00:13:57,275 --> 00:14:00,448
TO ATTACH THIS ASSEMBLED CORE
ALONG THE FRONT EDGE
231
00:14:00,448 --> 00:14:04,241
SO THAT IT DOESN'T COME APART
AS IT ENTERS THE PRESS.
232
00:14:06,551 --> 00:14:09,793
THE PRESS HOLDS
10 CORE ASSEMBLIES AT A TIME.
233
00:14:09,793 --> 00:14:11,931
THE CURRENT THICKNESS OF A CORE
234
00:14:11,931 --> 00:14:14,655
IS THE SUM OF THE PILES
PLUS GLUE.
235
00:14:14,655 --> 00:14:18,034
THE PRESS WILL REDUCE THAT
BY 10%.
236
00:14:18,034 --> 00:14:22,275
IT APPLIES ABOUT 170 POUNDS
PER SQUARE INCH OF PRESSURE,
237
00:14:22,275 --> 00:14:24,103
WHILE AT THE SAME TIME
238
00:14:24,103 --> 00:14:27,344
HEATING THE CORE
TO 250 DEGREES FAHRENHEIT
239
00:14:27,344 --> 00:14:29,931
TO LITERALLY COOK THE ADHESIVE.
240
00:14:31,931 --> 00:14:35,103
THE CORE EXITS THE PRESS
AFTER SEVEN MINUTES,
241
00:14:35,103 --> 00:14:39,482
THE PLIES NOW PERFECTLY FLAT
AND SOLIDLY BONDED.
242
00:14:39,482 --> 00:14:42,793
THE WOOD VENEER FOR THE CORE'S
DECORATIVE FACING IS VERY THIN,
243
00:14:42,793 --> 00:14:45,793
BARELY MORE THAN
1/100 OF AN INCH.
244
00:14:45,793 --> 00:14:48,965
TO CREATE A PATTERN
RESEMBLING A HARDWOOD FLOOR,
245
00:14:48,965 --> 00:14:54,068
THEY JOIN TWO STRIPS AT A TIME
WITH A WAVY THREAD OF GLUE.
246
00:14:57,482 --> 00:15:00,275
NEXT THEY JOIN THE
TWO MATED STRIPS TO TWO OTHERS,
247
00:15:00,275 --> 00:15:01,482
AND SO ON,
248
00:15:01,482 --> 00:15:03,172
UNTIL THE ASSEMBLED VENEER
249
00:15:03,172 --> 00:15:06,172
ARE THE LENGTH AND WIDTH
OF THE PLYWOOD CORE.
250
00:15:06,172 --> 00:15:09,965
THE CORE, MEANWHILE,
GOES THROUGH THE GLUE MACHINE,
251
00:15:09,965 --> 00:15:12,344
WHICH COATS BOTH TOP AND BOTTOM
WITH ADHESIVE.
252
00:15:12,344 --> 00:15:16,517
THE VENEER SHEET IS ALSO GLUED,
BUT ON ONE SIDE ONLY.
253
00:15:16,517 --> 00:15:19,551
WORKERS LAY THE VENEER
GLUED-SIDE UP
254
00:15:19,551 --> 00:15:22,655
THEN CAREFULLY PLACE THE CORE
ONTO IT.
255
00:15:25,000 --> 00:15:28,344
A SECOND VENEER,
GLUED-SIDE DOWN, GOES ON TOP.
256
00:15:28,344 --> 00:15:30,931
THE OKOUME CORE
IS NOW SANDWICHED
257
00:15:30,931 --> 00:15:33,793
BETWEEN
TWO DECORATIVE WOOD VENEERS.
258
00:15:33,793 --> 00:15:36,379
THE PRESS APPLIES
THE SAME HEAT AND PRESSURE
259
00:15:36,379 --> 00:15:38,137
AS IT DID TO THE CORE ASSEMBLY,
260
00:15:38,137 --> 00:15:39,862
BUT FOR JUST ONE MINUTE.
261
00:15:39,862 --> 00:15:42,137
THE RESULT --
A FINISHED SHEET OF,
262
00:15:42,137 --> 00:15:45,758
IN THIS CASE,
CHERRY VENEERED MARINE PLYWOOD.
263
00:15:46,965 --> 00:15:50,517
MARINE PLYWOOD COMES NOT JUST
IN A VARIETY OF VENEER CHOICES,
264
00:15:50,517 --> 00:15:52,793
BUT ALSO
IN A RANGE OF THICKNESSES.
265
00:15:52,793 --> 00:15:56,206
TYPICALLY COMPRISED
OF THREE TO 13 PLIES --
266
00:15:56,206 --> 00:15:57,896
ALWAYS AN ODD NUMBER
267
00:15:57,896 --> 00:16:01,482
IN ORDER TO HAVE EQUAL WEIGHT ON
EITHER SIDE OF THE CENTRAL PLY
268
00:16:01,482 --> 00:16:03,517
FOR BALANCE.
269
00:16:16,931 --> 00:16:20,241
Narrator:
THERE ARE MANY TYPES OF PAINTS
AT AN ARTIST'S DISPOSAL,
270
00:16:20,241 --> 00:16:22,724
EACH PRODUCING
A VERY DIFFERENT EFFECT.
271
00:16:22,724 --> 00:16:24,758
OIL PAINT IS OPAQUE AND RICH.
272
00:16:24,758 --> 00:16:27,275
ENCAUSTIC PAINT,
BEING WAX-BASED,
273
00:16:27,275 --> 00:16:30,068
HAS A UNIQUE TEXTURE
THAT THE ARTIST CAN SHAPE,
274
00:16:30,068 --> 00:16:34,034
THEN REHEAT, AND RESHAPE
IN COUNTLESS CREATIVE WAYS.
275
00:16:37,448 --> 00:16:40,241
OIL PAINT COMES IN LIQUID FORM
AND STICK FORM.
276
00:16:40,241 --> 00:16:43,586
WITH EITHER, THE ARTIST CAN
COMBINE IT WITH OTHER PRODUCTS
277
00:16:43,586 --> 00:16:45,586
TO MODIFY THE CONSISTENCY.
278
00:16:45,586 --> 00:16:49,862
BEING OIL-BASED, THE PAINT
TAKES A COUPLE OF DAYS TO DRY,
279
00:16:49,862 --> 00:16:51,517
SO THERE'S LOTS OF TIMES
TO WORK WITH IT.
280
00:16:51,517 --> 00:16:55,758
HOWEVER, ONCE THE COAT IS DRY,
IT CAN'T BE REWORKED.
281
00:16:55,758 --> 00:16:59,379
ENCAUSTIC PAINT, BY CONTRAST,
IS WAX-BASED,
282
00:16:59,379 --> 00:17:02,379
SO THE ARTIST MUST MELT IT
WHILE APPLYING IT.
283
00:17:02,379 --> 00:17:05,068
BECAUSE WAX COOLS AND HARDENS
SO QUICKLY,
284
00:17:05,068 --> 00:17:07,758
ENCAUSTIC PAINT
HAS A SHORT WORKING TIME.
285
00:17:07,758 --> 00:17:11,172
HOWEVER, THE ARTIST CAN
REHEAT IT AND WORK IT SOME MORE.
286
00:17:13,068 --> 00:17:15,241
THE MAIN INGREDIENT
IN ENCAUSTIC PAINT
287
00:17:15,241 --> 00:17:16,896
IS WHITE BEESWAX.
288
00:17:16,896 --> 00:17:18,896
TO THAT, THEY ADD CARNAUBA WAX,
289
00:17:18,896 --> 00:17:22,275
WHICH COMES FROM THE LEAVES
OF THE CARNAUBA PALM TREE.
290
00:17:22,275 --> 00:17:24,620
CARNAUBA WAX IS QUITE FRAGILE,
291
00:17:24,620 --> 00:17:28,655
WHICH IS WHY THEY STRENGTHEN IT
WITH BEESWAX.
292
00:17:28,655 --> 00:17:30,620
THEY MELT THEM
IN A MICROWAVE OVEN
293
00:17:30,620 --> 00:17:31,758
ON CONVECTION MODE.
294
00:17:33,758 --> 00:17:36,137
NEXT THEY ADD DAMMAR RESIN,
295
00:17:36,137 --> 00:17:39,551
WHICH COMES FROM TREES
NATIVE TO SOUTHEAST ASIA.
296
00:17:39,551 --> 00:17:43,241
THEY GRIND THE CHUNKS OF RESIN
INTO OF POWDER
297
00:17:43,241 --> 00:17:44,689
IN A COFFEE GRINDER,
298
00:17:44,689 --> 00:17:47,172
THEN MIX IT INTO
THE MOLTEN WAXES.
299
00:17:47,172 --> 00:17:49,827
THE RESIN WILL ACT
AS A SOLIDIFYING AGENT,
300
00:17:49,827 --> 00:17:52,724
AS WELL AS
MAKE THE PAINT GLOSSY.
301
00:17:52,724 --> 00:17:55,965
ONCE THE INGREDIENTS
ARE EVENLY BLENDED,
302
00:17:55,965 --> 00:17:58,068
THEY POUR THE MIX
THROUGH CHEESECLOTH
303
00:17:58,068 --> 00:18:00,931
TO FILTER OUT
MINUTE PLANT PARTICLES,
304
00:18:00,931 --> 00:18:03,137
WHICH THE RESIN CONTAINED.
305
00:18:03,137 --> 00:18:06,448
THEY WEIGH OUT A QUANTITY
OF SYNTHETIC PIGMENT
306
00:18:06,448 --> 00:18:09,172
AND ADD IT
TO THE WAX-RESIN MIXTURE.
307
00:18:09,172 --> 00:18:12,620
THE RATIO OF PIGMENT TO MIXTURE
VARIES BY COLOR.
308
00:18:12,620 --> 00:18:15,275
SOME HAVE MORE WAX
AND LESS PIGMENT
309
00:18:15,275 --> 00:18:17,275
AND OTHERS VICE-VERSA.
310
00:18:17,275 --> 00:18:20,172
THIS MANUFACTURER
WON'T REVEAL ANY SPECIFICS
311
00:18:20,172 --> 00:18:22,310
ABOUT INGREDIENT PROPORTIONS.
312
00:18:22,310 --> 00:18:25,310
ITS PAINT RECIPES
ARE TOP-SECRET.
313
00:18:25,310 --> 00:18:27,724
AFTER MIXING
FOR ABOUT 15 MINUTES,
314
00:18:27,724 --> 00:18:30,206
THE PAINT IS READY.
315
00:18:30,206 --> 00:18:32,965
THEY CAREFULLY POUR IT
INTO A MOLD.
316
00:18:32,965 --> 00:18:36,482
THIS TYPE OF MOLD
PRODUCES STICKS.
317
00:18:43,620 --> 00:18:46,413
THE PAINT HARDENS
IN JUST A FEW MINUTES.
318
00:18:46,413 --> 00:18:49,931
THEY SCRAPE OFF THE EXCESS
AND MELT IT BACK TO LIQUID
319
00:18:49,931 --> 00:18:52,275
TO CAST THE NEXT BATCH
OF STICKS.
320
00:18:53,482 --> 00:18:57,344
THEN THEY UNSCREW THE MOLD
AND PRY IT APART.
321
00:19:03,137 --> 00:19:05,551
ONCE THE MOLD IS SAFELY OPENED,
322
00:19:05,551 --> 00:19:09,482
THEY GENTLY EXTRACT
THE FINISHED ENCAUSTIC STICKS.
323
00:19:16,827 --> 00:19:19,103
THEY WEAR GLOVES
324
00:19:19,103 --> 00:19:21,103
BECAUSE THE STICKS
ARE STILL A BIT HOT
325
00:19:21,103 --> 00:19:23,275
AND CAN STAIN THEIR HANDS.
326
00:19:25,517 --> 00:19:27,206
FOR THOSE SAME REASONS,
327
00:19:27,206 --> 00:19:30,586
THEY WRAP THE STICKS,
ONCE LABELED, IN PLASTIC.
328
00:19:33,551 --> 00:19:37,448
THIS MANUFACTURER ALSO PRODUCES
HANDMADE ENCAUSTIC PAINT
329
00:19:37,448 --> 00:19:40,379
IN ANOTHER FORMAT --
RECTANGULAR BLOCKS.
330
00:19:40,379 --> 00:19:42,827
THE PROCESS IS IDENTICAL.
331
00:19:46,448 --> 00:19:48,862
THE MOLD IS MADE
OF FLEXIBLE RUBBER.
332
00:19:48,862 --> 00:19:51,758
THE PAINT HARDENS SOONER
THAN IN A METAL MOLD
333
00:19:51,758 --> 00:19:55,689
BECAUSE RUBBER DISSIPATES HEAT
FAR FASTER THAN METAL DOES.
334
00:20:04,172 --> 00:20:06,275
WORKERS
DON'T NEED TO WEAR GLOVES
335
00:20:06,275 --> 00:20:07,827
WHEN EXTRACTING THE BLOCKS
336
00:20:07,827 --> 00:20:09,965
BECAUSE THE PAINT
IS ALREADY COOL
337
00:20:09,965 --> 00:20:12,275
AND THEREFORE
WON'T STAIN THEIR HANDS.
338
00:20:16,482 --> 00:20:18,586
TO MAKE OIL-PAINT STICKS,
339
00:20:18,586 --> 00:20:22,379
THEY FIRST MAKE A LARGE BATCH
OF OIL PAINT OUT OF WALNUT OIL,
340
00:20:22,379 --> 00:20:25,103
PIGMENT, A DRYING AGENT,
AND A BIT OF WAX.
341
00:20:25,103 --> 00:20:27,655
THEN THEY WEIGH OUT
A SPECIFIC QUANTITY
342
00:20:27,655 --> 00:20:29,827
AND ADD MORE WALNUT OIL.
343
00:20:33,620 --> 00:20:36,758
NEXT THEY ADD COMBINED
CARNAUBA WAX AND BEESWAX,
344
00:20:36,758 --> 00:20:39,689
WHICH ARE NECESSARY
TO FORM THE STICK SHAPE,
345
00:20:39,689 --> 00:20:42,655
HOWEVER LESS WAX
THAN FOR ENCAUSTIC STICKS.
346
00:20:42,655 --> 00:20:46,241
THEY BLEND ALL THESE INGREDIENTS
FOR ABOUT 15 MINUTES,
347
00:20:46,241 --> 00:20:50,103
THEN POUR THE PAINT INTO
A METAL MOLD TO CAST STICKS.
348
00:20:50,103 --> 00:20:53,655
EVERY BATCH OF OIL STICKS
UNDERGOES DRYING TESTS
349
00:20:53,655 --> 00:20:56,344
TO ENSURE THE PAINT DRIES
WITHIN TWO DAYS
350
00:20:56,344 --> 00:20:58,655
AFTER BEING APPLIED TO PAPER.
351
00:20:58,655 --> 00:21:02,241
ENCAUSTIC IS THE MORE DURABLE
OF THESE TWO TYPES OF PAINTS
352
00:21:02,241 --> 00:21:05,344
BECAUSE IT CONTAINS
A LARGER PERCENTAGE OF BEESWAX,
353
00:21:05,344 --> 00:21:07,137
WHICH IS RESISTANT TO MOISTURE.
354
00:21:07,137 --> 00:21:09,275
AND ENCAUSTIC PAINTING,
THEREFORE,
355
00:21:09,275 --> 00:21:12,758
DOESN'T HAVE TO BE VARNISHED
OR PUT BEHIND GLASS.
356
00:21:21,586 --> 00:21:24,172
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
357
00:21:24,172 --> 00:21:27,310
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
358
00:21:27,310 --> 00:21:29,241
DROP US A LINE AT...
29082
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