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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 --> 00:00:07,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:22,586 --> 00:00:25,034
Narrator:
TODAY, ON "HOW IT'S MADE"...
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00:00:51,620 --> 00:00:54,379
HISTORY SUGGESTS SLATE
MAY HAVE FIRST BEEN MINED
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00:00:54,379 --> 00:00:55,724
IN THE ROMAN ERA,
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00:00:55,724 --> 00:00:58,206
ALTHOUGH THE EARLIEST CONFIRMED
RECORDS DATE BACK TO
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00:00:58,206 --> 00:01:01,413
THE EARLY 1700s.
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00:01:01,413 --> 00:01:04,827
SLATE TILES WERE USED FOR
GENERAL BUILDING CONSTRUCTION
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00:01:04,827 --> 00:01:06,344
AND ARE STILL USED TODAY
10
00:01:06,344 --> 00:01:08,724
FOR PRACTICAL AND AESTHETIC
PURPOSES.
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00:01:12,758 --> 00:01:15,413
THESE PIECES OF FLOOR SLATE
APPEAR TO BE RIGHT
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00:01:15,413 --> 00:01:16,724
FROM THE QUARRY,
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00:01:16,724 --> 00:01:19,758
BUT THEY'RE PART
OF AN 18-PIECE
PUZZLE
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00:01:19,758 --> 00:01:22,344
THAT'S CUT THE SAME WAY
EVERY TIME.
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00:01:22,344 --> 00:01:23,896
THESE PIECES OF WALL SLATE
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00:01:23,896 --> 00:01:25,896
ARE MUCH THINNER
AND ARE USED FOR PANELING.
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00:01:29,103 --> 00:01:31,931
UNCUT SHEETS OF SLATE
IN A VARIETY OF THICKNESSES
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00:01:31,931 --> 00:01:33,517
COME STRAIGHT FROM THE QUARRY.
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00:01:37,137 --> 00:01:40,068
AFTER THE SLATE SHEETS
ARE STACKED ON A FORKLIFT,
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00:01:40,068 --> 00:01:41,793
A WORKER CAREFULLY
DRIVES THEM
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00:01:41,793 --> 00:01:43,758
TO ANOTHER PART
OF THE STORAGE YARD.
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00:01:47,000 --> 00:01:48,724
HE SETS THEM DOWN GENTLY.
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00:01:52,034 --> 00:01:54,344
ANOTHER WORKER SPLITS THE SHEETS
OF SLATE
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00:01:54,344 --> 00:01:55,793
USING A PNEUMATIC ZIP GUN.
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00:01:58,965 --> 00:02:01,758
IT'S A DELICATE PROCESS.
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00:02:01,758 --> 00:02:04,000
ONCE HE SPLITS THE SLATE SHEETS,
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00:02:04,000 --> 00:02:07,068
THE WORKER INSPECTS THE LINES
IN THE PIECES OF SLATE
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00:02:07,068 --> 00:02:08,413
AND LOOKS FOR CRACKS.
29
00:02:11,965 --> 00:02:15,275
THEN, HE CARRIES THE SHEET
TO A GAUGING MACHINE.
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00:02:15,275 --> 00:02:17,206
HE CHECKS THE THICKNESS
OF THE SHEET
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00:02:17,206 --> 00:02:20,034
TO MAKE SURE IT WON'T CAUSE JAMS
ON THE CUTTING TABLE.
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00:02:24,206 --> 00:02:27,482
THIS MULTIBLADE CUTTING TABLE
SLICES A SHEET OF SLATE
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00:02:27,482 --> 00:02:29,137
INTO A SERIES OF STRIPS.
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00:02:33,241 --> 00:02:35,586
IT'S COVERED
WITH RECYCLED WATER.
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00:02:35,586 --> 00:02:37,862
THIS LUBRICATES
THE CUTTING PROCESS,
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00:02:37,862 --> 00:02:39,862
COOLS THE SLATE
AND CUTTING BLADES,
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00:02:39,862 --> 00:02:42,793
AND REMOVES UNWANTED DUST
AND PARTICLES.
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00:02:42,793 --> 00:02:45,379
A CONVEYOR SLOWLY MOVES
THE SLATE SHEET FORWARD.
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00:02:49,068 --> 00:02:51,000
A TOTAL OF 18 DIAMOND BLADES
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00:02:51,000 --> 00:02:53,724
SLICE THE SHEET OF SLATE
INTO STRIPS.
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00:02:57,103 --> 00:02:59,689
THESE STRIPS OF SLATE
WILL BE USED FOR WALL PANELING.
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00:03:03,413 --> 00:03:06,103
THIS CUTTING TABLE
CAN CUT SEVERAL SHEETS OF SLATE
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00:03:06,103 --> 00:03:07,551
AT THE SAME TIME.
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00:03:10,793 --> 00:03:13,379
ONCE THE CUTTING PROCESS
IS COMPLETE,
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00:03:13,379 --> 00:03:16,241
A WORKER INSPECTS THE STRIPS
OF SLATE AND SORTS
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00:03:16,241 --> 00:03:20,551
THEM ACCORDING TO THICKNESS
AND WIDTH.
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00:03:20,551 --> 00:03:23,896
NEXT, HE PILES SOME OF THEM
IN PREPARATION FOR SPLITTING.
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00:03:26,000 --> 00:03:29,103
HE CRACKS THICKER STRIPS
OF SLATE USING A STONE SPLITTER
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00:03:29,103 --> 00:03:30,862
WITH A HARDENED STEEL BLADE.
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00:03:34,000 --> 00:03:35,413
HE MAKES SURE
THEY'RE THIN ENOUGH
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00:03:35,413 --> 00:03:37,689
TO BE USED FOR WALL PANELING.
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00:03:37,689 --> 00:03:43,310
ONCE THE PIECES OF SLATE
REACH THEIR FINAL THICKNESS,
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00:03:43,310 --> 00:03:47,103
A WORKER PLACES THEM IN BOXES,
READY FOR INSTALLATION.
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00:03:50,172 --> 00:03:51,965
A WORKER INSPECTS A SHEET
OF SLATE
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00:03:51,965 --> 00:03:54,241
THAT WILL BE USED FOR FLOORING.
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00:03:54,241 --> 00:03:56,862
THE THICKNESS OF SLATE FLOORING
MUST BE CONSTANT.
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00:04:01,137 --> 00:04:03,379
HE PLACES A SHEET ON A CONVEYOR.
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00:04:03,379 --> 00:04:05,827
IT TAKES THE SLATE
THROUGH A GAUGING MACHINE,
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00:04:05,827 --> 00:04:08,000
WHERE ITS SURFACE
WILL BE MADE PERFECTLY EVEN.
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00:04:12,103 --> 00:04:15,482
USING TWO DIAMOND GRINDING
WHEELS, THE GAUGING MACHINE
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00:04:15,482 --> 00:04:19,517
SHAVES OFF ANY PIECES OF STONE
THAT EXCEED A PRESET THICKNESS.
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00:04:22,137 --> 00:04:23,965
AFTER SEVERAL MINUTES
OF SHAVING,
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00:04:23,965 --> 00:04:27,793
THE SLATE SHEET EMERGES
FROM THE GAUGING MACHINE.
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00:04:27,793 --> 00:04:31,724
AN EMPLOYEE CHECKS THE SHEET
TO MAKE SURE IT'S SMOOTH.
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00:04:31,724 --> 00:04:36,896
FIRST, HE CHECKS THE UNDERSIDE
OF THE EVENTUAL FLOOR TILES.
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00:04:36,896 --> 00:04:38,896
THEN, HE CHECKS THE TOP SIDE,
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00:04:38,896 --> 00:04:40,931
THE STONE FACE
THAT WILL BE DISPLAYED.
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00:04:43,965 --> 00:04:46,758
THE WORKER PLACES THE SMOOTH,
FLAT PIECE OF SLATE
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00:04:46,758 --> 00:04:48,620
ON A CUTTING FRAME.
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00:04:48,620 --> 00:04:50,310
THE COMPUTERIZED CUTTING MACHINE
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00:04:50,310 --> 00:04:55,034
CUTS 18 PIECES OF SLATE
ACCORDING TO A PRESET PATTERN.
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00:04:55,034 --> 00:04:58,206
A HIGH-VELOCITY WATER JET
CUTS THE STONE AT THREE TIMES
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00:04:58,206 --> 00:05:00,620
THE SPEED OF SOUND.
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00:05:00,620 --> 00:05:04,275
THE WATER IS PURE,
FILTERED SEVERAL TIMES.
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00:05:04,275 --> 00:05:07,000
THE FIRST TIME THE SLABS
MOVE THROUGH THE MACHINE,
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00:05:07,000 --> 00:05:09,448
IT CUTS PIECES 1 TO 9,
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00:05:09,448 --> 00:05:11,344
AND THE SECOND TIME THROUGH,
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00:05:11,344 --> 00:05:13,206
IT CUTS PIECES 10 TO 18.
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00:05:17,068 --> 00:05:20,172
THE WORKER SNAPS OFF EXCESS TRIM
AND STACKS
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00:05:20,172 --> 00:05:24,172
THE CUT PIECES OF SLATE
ACCORDING TO THEIR NUMBERS.
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00:05:24,172 --> 00:05:27,379
ALL THE NUMBER ONES
ARE IDENTICAL TO EACH OTHER,
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00:05:27,379 --> 00:05:30,344
AS ARE EACH OF THE OTHER NUMBERS
IN THE 18-PIECE PATTERN.
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00:05:35,275 --> 00:05:36,724
REPEATED ON A FLOOR,
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00:05:36,724 --> 00:05:40,000
THE 18-PIECE PATTERN
APPEARS NATURAL.
85
00:05:40,000 --> 00:05:43,758
THIS NONPOROUS SLATE COMES IN
DIFFERENT TEXTURES AND COLORS,
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00:05:43,758 --> 00:05:46,758
AND CAN ALSO BE USED
IN BATHROOMS OR ROOFING.
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00:06:00,724 --> 00:06:03,034
Narrator:
THE FIRST HOT DOG CARTS
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00:06:03,034 --> 00:06:06,551
WERE ROLLED OUT IN NEW YORK CITY
IN THE MID-19th CENTURY.
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00:06:06,551 --> 00:06:10,448
THEY WERE SIMPLE PUSH CARTS
WITH SMALL CHARCOAL STOVES
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00:06:10,448 --> 00:06:14,000
AND SERVED SAUSAGES ON BUNS.
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00:06:14,000 --> 00:06:16,758
THOSE SANDWICHES BECAME KNOWN
AS HOT DOGS.
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00:06:21,655 --> 00:06:25,758
A MODERN HOT DOG CART
IS A KITCHEN ON WHEELS.
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00:06:25,758 --> 00:06:27,931
EQUIPPED WITH A WATER TANK
AND SINK,
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00:06:27,931 --> 00:06:29,448
A STEAMER AND GRILL,
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00:06:29,448 --> 00:06:32,068
AND A COOLER,
IT'S MADE TO SERVE THE PUBLIC.
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00:06:35,137 --> 00:06:38,310
AND THEY'RE SOMETIMES DESIGNED
TO STAND OUT IN A CROWD.
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00:06:40,793 --> 00:06:42,448
TO MAKE THIS HOT DOG CART,
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00:06:42,448 --> 00:06:45,379
THEY START WITH MOLDS
FOR THE HOT DOG-SHAPED BODY.
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00:06:49,103 --> 00:06:52,793
A WORKER BRUSHES A NONSTICK
COATING INTO THE FIRST MOLD.
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00:06:52,793 --> 00:06:55,724
IT WILL ALLOW THE COMPLETED PART
TO BE EASILY REMOVED.
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00:07:00,068 --> 00:07:04,551
HE PLACES FIBERGLASS ONE SHEET
AT TIME IN THE MOLD.
102
00:07:04,551 --> 00:07:09,137
HE BRUSHES A GENEROUS AMOUNT
OF EPOXY RESIN ONTO EACH PIECE.
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00:07:09,137 --> 00:07:12,482
THE FIBERGLASS STARTS
TO SOLIDIFY VERY QUICKLY,
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00:07:12,482 --> 00:07:15,586
BUT HE LEAVES IT TO SET
OVERNIGHT FOR A COMPLETE CURE.
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00:07:21,137 --> 00:07:24,206
THEY ASSEMBLE THE TWO HALVES
OF THE HOT DOG-SHAPED BODY
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00:07:24,206 --> 00:07:27,896
AND APPLY BONDING TO THE SEAMS.
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00:07:27,896 --> 00:07:30,034
A COLORFUL PAINT JOB
COMPLETES THE LOOK.
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00:07:32,965 --> 00:07:35,068
NEXT, COMPUTERIZED TOOLS
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CUT HOLES IN A SHEET
OF FOOD-GRADE STEEL.
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00:07:38,206 --> 00:07:41,068
THESE HOLES WILL ACCOMMODATE
THE SINK, FAUCETS,
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00:07:41,068 --> 00:07:44,068
AND OTHER PARTS.
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00:07:44,068 --> 00:07:46,413
THEN, THE COOLER DOOR
TAKES SHAPE.
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00:07:46,413 --> 00:07:47,758
USING A PRESS,
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00:07:47,758 --> 00:07:50,310
THE WORKER BENDS UP THE EDGE
OF A PIECE OF STEEL
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00:07:50,310 --> 00:07:51,758
THAT'S BEEN CUT TO SIZE.
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00:07:54,724 --> 00:07:57,620
HE TRANSFERS THE PART
TO ANOTHER BREAK PRESS.
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00:07:57,620 --> 00:08:01,068
THIS ONE IS COMPUTERIZED.
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00:08:01,068 --> 00:08:05,758
IT FOLDS BACK THE BEND TO GIVE
THE DOOR A STRONG, SMOOTH EDGE.
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00:08:05,758 --> 00:08:10,103
HE REPEATS THIS PROCESS
ON TWO OTHER SIDES.
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00:08:10,103 --> 00:08:15,586
HE THEN CLAMPS A CONTINUOUS
HINGE TO THE ONLY UNFOLDED EDGE,
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00:08:15,586 --> 00:08:17,793
AND HE WELDS
AND RIVETS THE HINGE TO IT.
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00:08:25,034 --> 00:08:28,379
WORK NOW BEGINS ON THE CHASSIS
OF THE HOT DOG CART.
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00:08:28,379 --> 00:08:30,413
A WORKER WELDS HEAVY WALL STEEL
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00:08:30,413 --> 00:08:32,586
TUBING TO CREATE
A RUGGED FRAMEWORK.
125
00:08:35,034 --> 00:08:36,275
AFTER PAINTING IT,
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00:08:36,275 --> 00:08:39,034
HE BOLTS THE WHEEL AXLE
TO BRACKETS ON THE SIDES.
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00:08:46,931 --> 00:08:48,172
HE TIGHTENS THE BOLTS
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00:08:48,172 --> 00:08:50,827
TO AN EXACT TORQUE
USING A PNEUMATIC WRENCH.
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00:08:53,931 --> 00:08:56,344
HE SCREWS TAILLIGHTS
TO THE BUMPER.
130
00:08:56,344 --> 00:08:59,758
THE LIGHTS ARE SURROUNDED BY
METAL BRACKETS TO PROTECT THEM
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00:08:59,758 --> 00:09:03,103
FROM BEING DAMAGED
BY CUSTOMERS WAITING IN LINE.
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00:09:03,103 --> 00:09:05,586
THE BRACKETS ALSO
SERVE AS A MOUNTING PLATE.
133
00:09:09,034 --> 00:09:11,896
THE TEAM NOW TRANSFERS
THE FIBERGLASS CART BODY
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00:09:11,896 --> 00:09:13,172
TO THE CHASSIS.
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00:09:16,103 --> 00:09:17,517
THEY DRILL LARGE HOLES
136
00:09:17,517 --> 00:09:20,965
TO VENT GAS FUMES
AND SMALLER SCREW HOLES
137
00:09:20,965 --> 00:09:22,827
TO SECURE THE BODY
TO THE CHASSIS.
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00:09:29,862 --> 00:09:34,068
THEY LINE THE CART WITH A MOLDED
FIBERGLASS AND STYROFOAM UNIT.
139
00:09:34,068 --> 00:09:37,275
IT HAS COMPARTMENTS FOR
THE WATER TANK AND FOOD COOLER,
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00:09:37,275 --> 00:09:39,689
AND IT ALSO SERVES
AS AN INSULATING LAYER.
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00:09:42,103 --> 00:09:44,862
THEY INSTALL THE STEEL FOOD
PREPARATION SURFACE,
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00:09:44,862 --> 00:09:47,344
WHICH HAS BEEN EQUIPPED
WITH A SINK AND FAUCETS.
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00:09:50,448 --> 00:09:53,965
A MEMBER OF THE TEAM TIGHTENS
A CRIMP RING AROUND THE HOSES
144
00:09:53,965 --> 00:09:57,965
TO SUPPLY WATER
TO THE SINK FAUCETS.
145
00:09:57,965 --> 00:10:01,137
HE RUNS A GAS LINE
TO THE STEAMER'S BURNERS
146
00:10:01,137 --> 00:10:03,413
AND LOWERS THE STEAMER
INTO PLACE ON THE CART.
147
00:10:08,000 --> 00:10:11,068
HE ASSEMBLES A BARBECUE
TO THE OTHER SIDE OF THE CART,
148
00:10:11,068 --> 00:10:13,103
AND THIS GIVES CUSTOMERS
A GRILLED OPTION
149
00:10:13,103 --> 00:10:14,172
FOR THEIR HOT DOGS.
150
00:10:18,931 --> 00:10:21,413
THEY HINGE THE COOLER DOOR
TO THE FRONT OF THE CART.
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00:10:26,931 --> 00:10:29,965
ONCE CLOSED, THE DOOR
SEALS THE INSULATED CHAMBER
152
00:10:29,965 --> 00:10:33,206
TO KEEP HOT DOGS, SAUSAGES,
AND SODAS ON ICE.
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00:10:39,000 --> 00:10:40,931
THE TEAM PRESSES BOLD GRAPHICS
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00:10:40,931 --> 00:10:44,379
TO THE FIBERGLASS SHELL
AND PEELS OFF THE PAPER LINER.
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00:10:46,965 --> 00:10:50,689
AND WITH THAT, THIS HOT DOG CART
IS READY TO HIT THE STREET,
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00:10:52,793 --> 00:10:54,551
JUST IN TIME FOR LUNCH.
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00:11:08,517 --> 00:11:10,620
Narrator: DECADES AGO, PEOPLE
HAD TO GET OUT OF THE CAR
158
00:11:10,620 --> 00:11:15,379
WHEN ARRIVING HOME IN ORDER
TO OPEN THE GARAGE DOOR.
159
00:11:15,379 --> 00:11:18,517
TODAY, IT'S ROUTINE TO OPEN
AND CLOSE YOUR GARAGE DOOR
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00:11:18,517 --> 00:11:21,275
AT THE PUSH OF A BUTTON,
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00:11:21,275 --> 00:11:25,310
EITHER ON A WALL-MOUNTED PAD
OR ON A REMOTE CONTROL.
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00:11:27,758 --> 00:11:31,448
A GARAGE DOOR OPENER'S MOTOR
DRIVES EITHER A BELT, A CHAIN,
163
00:11:31,448 --> 00:11:33,896
OR A SCREW ROD,
LIKE THESE MODELS.
164
00:11:33,896 --> 00:11:38,310
IN TURN, THEY MOVE A CARRIAGE
CONNECTED TO THE GARAGE DOOR.
165
00:11:38,310 --> 00:11:39,689
AT THIS FACTORY,
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00:11:39,689 --> 00:11:42,896
THE PRODUCTION LINE STARTS
AND ENDS AT THE SAME PLACE.
167
00:11:42,896 --> 00:11:46,241
THEY TAKE ONE COMPLETED GARAGE
DOOR OPENER OFF THE LINE,
168
00:11:46,241 --> 00:11:47,586
THEN START A NEW ONE
169
00:11:47,586 --> 00:11:52,724
BY ATTACHING A POWER CORD
TO THE UNIT'S STEEL CHASSIS.
170
00:11:52,724 --> 00:11:54,206
THEN, THEY PLACE THE CHASSIS
171
00:11:54,206 --> 00:11:56,206
ONTO A TRAVELING ASSEMBLY
FIXTURE
172
00:11:56,206 --> 00:11:57,724
AND PLUG IN THE POWER CORD
173
00:11:57,724 --> 00:11:59,827
TO PREP THE UNIT
FOR TESTING LATER.
174
00:12:01,931 --> 00:12:06,827
THEY PLACE THE UNIT'S PLASTIC
HOUSING NEXT TO THE CHASSIS,
175
00:12:06,827 --> 00:12:09,517
THEN SNAP
IN THE PLASTIC SAFETY COVER.
176
00:12:09,517 --> 00:12:11,896
THIS GOES OVER THE DIRECT
CURRENT MOTOR,
177
00:12:11,896 --> 00:12:15,862
THE EQUIVALENT
OF 1 1/4 HORSEPOWER.
178
00:12:15,862 --> 00:12:18,965
THEY ATTACH AN OPTICAL ENCODER
TO THE MOTOR.
179
00:12:18,965 --> 00:12:22,517
THE ENCODER IS A SENSOR
WHICH READS THE DOOR'S POSITION
180
00:12:22,517 --> 00:12:25,413
SO THAT THE MOTOR KNOWS WHEN
TO STOP MOVING THE CARRIAGE.
181
00:12:27,758 --> 00:12:30,137
THEY PLACE THE MOTOR
AGAINST THE SAFETY COVER,
182
00:12:30,137 --> 00:12:31,620
THEN SCREW IT IN PLACE.
183
00:12:34,827 --> 00:12:37,965
IN THE HOUSING,
THEY INSTALL THE MOTION SENSOR.
184
00:12:37,965 --> 00:12:39,724
IT TURNS ON THE OPENER'S LIGHT
185
00:12:39,724 --> 00:12:41,862
AS SOON
AS YOU WALK INTO THE GARAGE
186
00:12:41,862 --> 00:12:43,620
OR WHEN THE GARAGE DOOR OPENS.
187
00:12:46,758 --> 00:12:50,103
NEXT ARE THE SWITCHES FOR
PROGRAMMING THE REMOTE CONTROL
188
00:12:50,103 --> 00:12:52,379
AND FOR SETTING
THE TRAVEL LIMITS.
189
00:12:52,379 --> 00:12:53,827
THESE ARE THE POINTS TO WHICH
190
00:12:53,827 --> 00:12:58,724
THE OPENER MUST MOVE THE DOOR
TO FULLY OPEN AND CLOSE IT.
191
00:12:58,724 --> 00:13:01,896
THEY THEN INSTALL THE CIRCUIT
BOARD, ROUTING THE ANTENNA
192
00:13:01,896 --> 00:13:05,724
FOR THE REMOTE CONTROL RECEIVER
TO THE OUTSIDE.
193
00:13:05,724 --> 00:13:08,482
THEY PLUG IN THE MOTION
SENSOR CABLE,
194
00:13:08,482 --> 00:13:12,310
THEN WIRE AND PLUG IN THE
CONNECTOR FOR THE LIGHT BULBS
195
00:13:12,310 --> 00:13:15,724
AND FASTEN THE BOARD IN PLACE
WITH SCREWS.
196
00:13:15,724 --> 00:13:19,689
THEY ATTACH THE ELECTRICAL
GROUND WIRE TO THE CHASSIS,
197
00:13:19,689 --> 00:13:21,206
CONNECT THE POWER CABLE,
198
00:13:21,206 --> 00:13:24,206
AND THEN, THE OPTICAL ENCODER
TO THE CIRCUIT BOARD.
199
00:13:26,724 --> 00:13:29,413
WITH ALL THE INTERNAL COMPONENTS
INSTALLED NOW,
200
00:13:29,413 --> 00:13:32,103
THEY AFFIX THE HOUSING
TO THE CHASSIS.
201
00:13:32,103 --> 00:13:34,655
THIS COMPLETES THE BRAIN
OF THE GARAGE DOOR OPENER,
202
00:13:34,655 --> 00:13:36,103
CALLED THE OPERATOR UNIT.
203
00:13:39,034 --> 00:13:42,620
AN AUTOMATED TESTING MACHINE
NOW CHECKS ALL THE FUNCTIONS,
204
00:13:42,620 --> 00:13:45,413
SIMULATING THE LOAD
OF THE GARAGE DOOR.
205
00:13:45,413 --> 00:13:48,896
IT ALSO CHECKS THE LIGHT BULB
SOCKETS AND THE CONNECTION PORTS
206
00:13:48,896 --> 00:13:53,000
ON THE CIRCUIT BOARD
FOR THE SAFETY BEAMS.
207
00:13:53,000 --> 00:13:55,655
THE BEAMS STOP
AND REVERSE THE CLOSING DOOR
208
00:13:55,655 --> 00:13:59,241
IF THEY DETECT ANY OBJECT
IN ITS PATH.
209
00:13:59,241 --> 00:14:04,103
ONCE THE OPERATOR UNIT
PASSES INSPECT,
210
00:14:04,103 --> 00:14:08,275
IT COMES FULL CIRCLE TO THE END,
WHICH IS ALSO THE START,
211
00:14:08,275 --> 00:14:09,379
OF THE PRODUCTION LINE.
212
00:14:11,655 --> 00:14:14,413
A PLASTIC LENS
TO ENCLOSE THE LIGHT BULBS,
213
00:14:14,413 --> 00:14:16,793
AND THE UNIT COMES OFF THE LINE.
214
00:14:21,034 --> 00:14:25,931
THE CARRIAGE RAIL
IS MILLED FROM GALVANIZED STEEL.
215
00:14:25,931 --> 00:14:28,758
IT HAS SLOTS
FOR LOCKING IN PLASTIC LINERS
216
00:14:28,758 --> 00:14:31,206
WHICH HOLD THE SCREW ROD.
217
00:14:38,413 --> 00:14:40,103
TO PRODUCE THE SCREW ROD,
218
00:14:40,103 --> 00:14:42,931
THE FACTORY MACHINES
A SOLID BAR OF STEEL
219
00:14:42,931 --> 00:14:45,517
TO THE REQUIRED DIMENSIONS
AND PROFILE.
220
00:14:45,517 --> 00:14:49,517
THEN, WITH HIGH-PRESSURE
ROLLERS, IT FORMS THREADS IN IT.
221
00:14:49,517 --> 00:14:53,310
WORKERS INSERT THE SCREW ROD
INTO THE LINERS IN THE RAIL.
222
00:14:53,310 --> 00:14:54,655
FOR THE RETAIL MARKET,
223
00:14:54,655 --> 00:14:57,586
RATHER THAN PRODUCE
ONE LONG RAIL AND SCREW ROD,
224
00:14:57,586 --> 00:14:59,862
THE FACTORY
MAKES THREE SHORTER CONNECTING
225
00:14:59,862 --> 00:15:03,551
SECTIONS THAT FIT
INTO A SMALLER PACKAGE.
226
00:15:03,551 --> 00:15:06,862
THIS MACHINE LUBRICATES
THE SCREW ROD WITH GREASE.
227
00:15:06,862 --> 00:15:09,620
IT HELPS IT ROTATE SMOOTHLY
IN THE RAIL LINER
228
00:15:09,620 --> 00:15:12,689
WHEN THE OPENER'S MOTOR
IS RUNNING.
229
00:15:12,689 --> 00:15:14,655
WHEN THE SCREW ROD TURNS,
230
00:15:14,655 --> 00:15:16,862
TEETH ON THE BASE
OF THE CARRIAGE INTERLOCK
231
00:15:16,862 --> 00:15:18,034
WITH THE THREADS,
232
00:15:18,034 --> 00:15:20,379
MOVING THE CARRIAGE
ALONG THE RAIL.
233
00:15:20,379 --> 00:15:24,620
WORKERS FIRST INSTALL THE
CARRIAGE BASE AT THE FACTORY.
234
00:15:24,620 --> 00:15:25,896
THEN, THEY PACK
235
00:15:25,896 --> 00:15:28,344
ALL THE GARAGE DOOR OPENER
COMPONENTS FOR SHIPPING,
236
00:15:28,344 --> 00:15:30,793
STARTING WITH THE RAIL SECTIONS
AND THE OPERATOR UNIT.
237
00:15:35,551 --> 00:15:39,620
LAST TO GO IN ARE
THE WALL-MOUNTED CONTROL PAD,
238
00:15:39,620 --> 00:15:42,724
THE REMOTE CONTROLS,
AND THE SAFETY BEAMS,
239
00:15:42,724 --> 00:15:46,827
WHICH YOU INSTALL ON EACH SIDE
OF THE GARAGE DOOR OPENING.
240
00:15:46,827 --> 00:15:49,034
WHEN YOU INSTALL
THE GARAGE DOOR OPENER,
241
00:15:49,034 --> 00:15:52,448
YOU INSERT THE SCREW ROD
INTO THE MOTOR'S DRIVE SHAFT.
242
00:15:52,448 --> 00:15:54,793
THEN, YOU ASSEMBLE THE REST
OF THE CARRIAGE,
243
00:15:54,793 --> 00:15:56,068
CONNECTING IT TO AN ARM
244
00:15:56,068 --> 00:15:58,413
WHICH ATTACHES
TO THE GARAGE DOOR.
245
00:15:58,413 --> 00:16:02,793
MOTOR RUNS,
SCREW ROD TURNS, CARRIAGE MOVES,
246
00:16:02,793 --> 00:16:05,241
AND YOUR GARAGE DOOR
OPENS OR CLOSES.
247
00:16:15,586 --> 00:16:17,275
Narrator: THE BICYCLE
248
00:16:17,275 --> 00:16:19,655
IS THE MOST EFFICIENT MODE
OF TRANSPORT EVER INVENTED.
249
00:16:19,655 --> 00:16:21,206
NINETY-NINE PERCENT
OF THE EFFORT
250
00:16:21,206 --> 00:16:24,551
PUT INTO TURNING A PEDAL
IS TRANSFERRED TO MOVEMENT,
251
00:16:24,551 --> 00:16:27,034
SO THE LIGHTER THE BIKE,
THE BETTER.
252
00:16:27,034 --> 00:16:28,931
USING CUTTING-EDGE MATERIALS,
253
00:16:28,931 --> 00:16:32,206
A HIGH-PERFORMANCE SEAT CAN
WEIGH AS LITTLE AS FIVE OUNCES.
254
00:16:35,413 --> 00:16:37,206
THIS COMPANY MADE A SPECIAL SEAT
255
00:16:37,206 --> 00:16:39,931
FOR A PAST TOUR DE FRANCE
WINNER.
256
00:16:39,931 --> 00:16:43,586
IN FACT, HALF THE CYCLISTS ON
THE PRESTIGIOUS PRO TOUR RACING
257
00:16:43,586 --> 00:16:45,689
CIRCUIT USE THEIR SEATS.
258
00:16:45,689 --> 00:16:48,827
THE DESIGN PROCESS BEGINS WITH
THE SIMPLEST TOOLS --
259
00:16:48,827 --> 00:16:50,724
PENCILS AND PAPER.
260
00:16:50,724 --> 00:16:53,689
DESIGNERS SKETCH
OUT A FEW BASIC IDEAS.
261
00:16:53,689 --> 00:16:56,551
SPECIALISTS THEN TRANSFORM
THE SKETCHED IDEAS
262
00:16:56,551 --> 00:16:58,827
INTO 3-D DIGITAL IMAGES.
263
00:16:58,827 --> 00:17:03,379
THE MANUFACTURERS MACHINE-MODEL
THOSE IMAGES INTO A PROTOTYPE.
264
00:17:03,379 --> 00:17:07,344
AFTER TESTING, THEY
BEGIN THE MANUFACTURING PROCESS.
265
00:17:07,344 --> 00:17:08,896
A WORKER PLACES A BASE,
266
00:17:08,896 --> 00:17:12,241
OR SHELL,
ON THE UPPER SEGMENT OF A MOLD.
267
00:17:12,241 --> 00:17:13,965
THIS COMPANY MAKES THEIR SHELLS
268
00:17:13,965 --> 00:17:16,344
FROM A VARIETY
OF CARBON FIBER MATERIALS.
269
00:17:18,517 --> 00:17:21,896
POLYURETHANE POURS INTO
THE OTHER SECTION OF THE MOLD.
270
00:17:21,896 --> 00:17:23,482
THIS IS THE PART OF THE MOLD
271
00:17:23,482 --> 00:17:25,551
THAT WILL GIVE THE SEAT
ITS SHAPE.
272
00:17:25,551 --> 00:17:27,172
WHEN THE MOLD CLOSES,
273
00:17:27,172 --> 00:17:30,413
IT COOKS AT A MERE 104 DEGREES
FAHRENHEIT.
274
00:17:30,413 --> 00:17:33,482
A CHEMICAL REACTION TAKES PLACE
INSIDE THE MOLD,
275
00:17:33,482 --> 00:17:37,413
WHICH CAUSES THE POLYURETHANE
TO EXPAND.
276
00:17:37,413 --> 00:17:38,724
FIVE MINUTES LATER,
277
00:17:38,724 --> 00:17:42,448
AN OPERATOR REMOVES THE SEATS
FROM THE MOLDS.
278
00:17:42,448 --> 00:17:47,379
HERE, WE SEE WHAT THE SHELLS
LOOK LIKE BEFORE AND AFTER.
279
00:17:47,379 --> 00:17:50,482
A WORKER REMOVES EXCESS
POLYURETHANE FROM THE EDGES
280
00:17:50,482 --> 00:17:52,379
WITH A KNIFE.
281
00:17:52,379 --> 00:17:54,620
WHILE THE POLYURETHANE CURES,
282
00:17:54,620 --> 00:17:56,620
WORKERS
PREPARE THE COVER MATERIAL.
283
00:17:56,620 --> 00:17:59,172
THE MATERIAL IS
A PROPRIETARY MICROFIBER
284
00:17:59,172 --> 00:18:01,758
SPECIALLY MADE FOR THIS COMPANY.
285
00:18:01,758 --> 00:18:05,034
NOT ONLY DOES THIS MATERIAL NEED
TO BE FLEXIBLE, WATERPROOF,
286
00:18:05,034 --> 00:18:06,068
AND COMFORTABLE,
287
00:18:06,068 --> 00:18:09,482
IT HAS TO BE INCREDIBLY DURABLE.
288
00:18:09,482 --> 00:18:12,034
ONCE THEY'VE CUT THE MATERIAL
INTO STRIPS,
289
00:18:12,034 --> 00:18:15,689
THE WORKERS
STACK THEM ON A STAMPING PRESS.
290
00:18:15,689 --> 00:18:19,793
A DIE HAS BEEN CUSTOM MADE
TO MATCH THE DESIGN OF THE SEAT.
291
00:18:19,793 --> 00:18:22,517
THE STAMPING PRESS
DESCENDS WITH ENOUGH FORCE
292
00:18:22,517 --> 00:18:26,068
TO CUT THROUGH MULTIPLE LAYERS.
293
00:18:26,068 --> 00:18:29,310
IT'S NOW TIME TO JOIN
THE THREE PANELS OF MATERIAL
294
00:18:29,310 --> 00:18:31,137
THAT MAKE UP THE SEAT COVER.
295
00:18:31,137 --> 00:18:33,655
THIS FACILITY
HAS TWO DIFFERENT METHODS
296
00:18:33,655 --> 00:18:36,172
FOR ATTACHING THE PIECES
TO EACH OTHER.
297
00:18:36,172 --> 00:18:37,620
IN THIS CASE,
298
00:18:37,620 --> 00:18:40,310
A SKILLED WORKER CAREFULLY
STITCHES THE MATERIAL TOGETHER.
299
00:18:43,482 --> 00:18:45,413
A DIFFERENT METHOD
OF JOINING THE PANELS
300
00:18:45,413 --> 00:18:49,241
INVOLVES A PROCESS
CALLED THERMAL WELDING.
301
00:18:49,241 --> 00:18:51,413
AN OPERATOR SKIVES, OR THINS,
302
00:18:51,413 --> 00:18:54,586
THE EDGES BY SHAVING THEM
SO THAT THERE WON'T BE A BUMP
303
00:18:54,586 --> 00:18:57,482
WHERE THEY OVERLAP.
304
00:18:57,482 --> 00:19:00,896
DOUBLE-SIDED TAPE
WILL HOLD THE MATERIAL TOGETHER.
305
00:19:00,896 --> 00:19:06,000
A SPECIAL TAPE DISPENSER APPLIES
THE TAPE TO THE SKIVED EDGES.
306
00:19:06,000 --> 00:19:11,793
A WORKER POSITIONS THE PANELS,
CAREFULLY OVERLAPPING THE EDGES.
307
00:19:11,793 --> 00:19:13,206
A VACUUM SYSTEM REMOVES AIR
308
00:19:13,206 --> 00:19:16,517
FROM BETWEEN THE TOP AND BOTTOM
SECTIONS OF THE PRESS,
309
00:19:16,517 --> 00:19:18,172
HOLDING THE PANELS IN POSITION
310
00:19:18,172 --> 00:19:20,965
AND ENSURING THERE WILL BE
NO BUBBLES AT THE SEAMS.
311
00:19:20,965 --> 00:19:24,103
THE PRESS THEN
HEATS THE MATERIAL
312
00:19:24,103 --> 00:19:26,724
UP TO 280 DEGREES FAHRENHEIT,
313
00:19:26,724 --> 00:19:31,689
ENSURING THAT THE ADHESIVE BONDS
THE PANELS TOGETHER.
314
00:19:31,689 --> 00:19:33,758
THE DESIGN
OF THE SHELL FOR THIS SEAT
315
00:19:33,758 --> 00:19:35,344
HAS SEVERAL SLOTS IN IT
316
00:19:35,344 --> 00:19:37,896
TO HELP CREATE
THE RIGHT COMBINATION
317
00:19:37,896 --> 00:19:39,551
OF FLEXIBILITY AND RIGIDITY.
318
00:19:39,551 --> 00:19:40,965
A LASER MACHINE
319
00:19:40,965 --> 00:19:44,586
CUTS STRIPES IN THE COVER FABRIC
TO CREATE A GRAPHIC ELEMENT
320
00:19:44,586 --> 00:19:46,344
THAT REFLECTS THIS DESIGN
FEATURE.
321
00:19:48,551 --> 00:19:51,172
WORKERS GLUE SILVER MATERIAL
UNDER THE STRIPES
322
00:19:51,172 --> 00:19:52,448
TO HIGHLIGHT THEM,
323
00:19:52,448 --> 00:19:56,551
THEN BRUSH GLUE ALL OVER
THE UNDERSIDE OF THE COVER.
324
00:19:56,551 --> 00:20:00,137
MOUNTING THE COVER ON THE SEAT
REQUIRES TWO OPERATORS.
325
00:20:00,137 --> 00:20:03,103
THEY PLACE THE COVER GLUE SIDE
DOWN ON THE SEAT,
326
00:20:03,103 --> 00:20:05,310
ENSURING
THAT IT'S POSITIONED PERFECTLY
327
00:20:05,310 --> 00:20:07,137
AND THAT THERE ARE NO
AIR POCKETS.
328
00:20:09,379 --> 00:20:12,000
THEY WORK THE COVER
INTO A SMALL RECESS
329
00:20:12,000 --> 00:20:14,862
THAT RUNS AROUND THE PERIMETER
OF THE BASE.
330
00:20:14,862 --> 00:20:17,241
THEY WILL THEN TRIM OFF
THE EXCESS MATERIAL
331
00:20:17,241 --> 00:20:19,103
WITH A UTILITY KNIFE.
332
00:20:19,103 --> 00:20:21,310
THE AMOUNT
OF SKILLED MANUAL CRAFTSMANSHIP
333
00:20:21,310 --> 00:20:23,448
REQUIRED TO BUILD THESE SEATS
334
00:20:23,448 --> 00:20:26,172
IS A KEY FEATURE
OF THEIR QUALITY,
335
00:20:26,172 --> 00:20:30,413
BUT THE COMPANY ALSO RELIES
ON STATE-OF-THE-ART TECHNOLOGY.
336
00:20:30,413 --> 00:20:34,379
BICYCLE SEATS SIT ON A FRAMEWORK
CALLED A RAIL.
337
00:20:34,379 --> 00:20:37,137
THIS FACILITY MAKES RAILS
FROM BOTH CARBON FIBER
338
00:20:37,137 --> 00:20:39,000
AND METAL ALLOYS,
339
00:20:39,000 --> 00:20:41,103
AND IT TESTS EACH ONE
WITH A DYNAMOMETER.
340
00:20:43,206 --> 00:20:44,448
WORKERS PUT GLUE
341
00:20:44,448 --> 00:20:47,206
IN THE ATTACHMENT POINTS
ON THE BOTTOM OF THE SEAT
342
00:20:47,206 --> 00:20:51,413
TO ENSURE THAT IT
PASSES A STRINGENT SAFETY TEST.
343
00:20:51,413 --> 00:20:55,724
A CUSTOMIZED MACHINE BENDS
THE SEAT TO FIT INTO THE RAIL.
344
00:20:55,724 --> 00:20:58,896
THE SEAT WILL THEN BE BENT BACK
IN THE OTHER DIRECTION
345
00:20:58,896 --> 00:21:02,068
TO RETURN IT
TO ITS ORIGINAL SHAPE.
346
00:21:02,068 --> 00:21:04,724
THE SEAT IS NOW FINISHED.
347
00:21:04,724 --> 00:21:06,896
FUSING
STATE-OF-THE-ART TECHNOLOGY
348
00:21:06,896 --> 00:21:08,758
WITH SKILLED CRAFTSMANSHIP,
349
00:21:08,758 --> 00:21:12,137
THIS COMPANY
MAKES 520,000 BICYCLE SEATS
350
00:21:12,137 --> 00:21:13,379
EVERY YEAR.
351
00:21:20,758 --> 00:21:22,965
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
352
00:21:22,965 --> 00:21:25,551
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
353
00:21:25,551 --> 00:21:30,965
DROP US A LINE AT
sciencechannel.com/howitsmade.
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