16x08 - Liquor Jugs/Deli Meats/NASCAR Engines

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]] Narrator: the clay liquor jug

Is a product with an elicit

Past.

In 19th-century america, this

Distinct stoneware jug was used

To contain backwoods brew,

Moonshine whiskey that was

Produced under the cover of

Night to avoid scrutiny from the

Authorities so it could be sold

Tax free.

Today they still uncork the

Little brown jug to serve up

Old-time corn whiskey.

Replicas like this one add an

Authentic touch to the

Traditional brew.

The jug starts with raw clay dug

Out of the ground and crushed

Into little particles.

They also break up defective and

Damaged pottery and recycle it

Into the process so nothing is

Wasted.

Next, a shaft with protruding

Knives mixes the clay with water

And fortifying chemicals.

When the clay reaches a doughy

Consistency, a vacuum sucks out

The air pockets, and then

Machinery forces it through a

Dye to form a long log.

In log form, the clay is easier

To handle.

The potter pulls off some

Chunks of clay and shapes them

Into patties.

He presses the patties into

Molds of the top and bottom

Parts of the clay liquor jug.

He inserts each mold in a

Holding ring and spins it.

A wooden tool now sculpts the

Jug's top section from the

Inside.

Clay migrates up the walls of

The mold and takes its shape.

The potter pokes a wooden dowel

In the neck of the jug to round

It out.

As tools shape the lower body of

The liquor jug, the potter

Sprays water on the rim.

This makes the rim sticky, which

Will allow the bottom portion of

The jug to adhere to the top.

Still in the molds, he presses

The two parts of the jug

Together, and the moistened clay

Bonds.

Once the clay is dried, the next

Craftsperson pries it from the

Molds, and it comes out in one

Piece.

She removes any unwanted bits

And transfers the jug to the

Workbench.

She levels the lip of the jug

With a stick and spins the jug

On a pottery wheel to scrape off

Surplus clay at the seam.

She smooths down rough spots on

The exterior surface with a wet

Sponge.

At this point, the clay is still

Fairly supple and responds to

Moisture.

Meanwhile, jug handles are

Taking shape in this tub.

Steel paddles force the clay

Through holes in the bottom,

Producing ribbons of clay that

Will now be shaped into curved

Handles.

The potter moistens one end of

The clay ribbon and presses it

To the neck of the jug.

She must apply just the right

Amount of pressure, or it will

Fall off.

She pulls the clay ribbon into a

Distinctive curve and presses

The other end to the side of the

Jug.

The curvature must be similar

From jug to jug, and producing a

Consistent shape every time

Takes practice.

At the glazing station, an

Operator tests a pump that

Spurts glaze upwards, creating a

Brief fountain of glaze.

With a paddle, he swishes the

Solution around to keep the

Glaze particles suspended.

Then he immerses the top of the

Jug in the liquid to give the

Clay liquor jug that familiar

Two-toned look.

He pumps glaze inside the jug,

Giving it a leakproof lining

That will allow it to hold

Liquids.

The next worker stamps product

Information on the side of the

Jug using ceramic inks.

Next, they prepare a different

Glaze.

The worker dips the bottom

Portion of the jug in it, and it

Appears to completely obscure

The carefully applied product

Information.

But when the glaze dries, it

Will become transparent, and the

Stamp will be visible again.

The next worker scuffs off the

Glaze on the base to keep the

Jug from sticking to the shelves

In the kiln.

They fire the whiskey jugs at

Around 2,200 degrees fahrenheit

For eight hours.

This hardens the clay and

Deepens the glaze.

It's taken a total of 19 steps

And one week to transform a

Couple of lumps of clay into a

Little brown jug.

And it's sure to add a touch of

Nostalgia to c*ck hour.

]] Narrator: man cannot live by

Bread alone.

But add a few slices of chicken

Or turkey deli meat, and you've

Got a meal.

Poultry deli meat is a popular

Alternative to corn beef or

Salami, and that's because it's

Less fatty any way you slice it.

When it comes to making deli

Meats, it's all in the

Seasoning.

From fiery southwestern turkey

To hot-sauce-marinated chicken,

They really know how to spice it

Up.

They begin with plenty of

Filtered water.

It will be used to disperse the

Specially formulated seasonings.

There's a different blend for

Every product, and they include

Salt and different herbs and

Spices.

They add honey because this is a

Honey maple recipe.

And while that's all being

Mixed, they check the

Temperature of the raw poultry

To confirm it's in the safe

Range.

If it's even slightly off,

There's a risk of bacterial

Growth, so the whole batch would

Have to be rejected.

But this poultry has been

Well-chilled.

The stitch pump machine's

Long steel needles repeatedly

Inject seasoning solutions into

The breast meat.

Excess liquid drains through the

Conveyor as the chicken is

Transferred to a holding area to

Marinate for at least two hours.

Next, numerous lumpy rollers

Massage the chicken and break

Down fiber to tenderize the

Meat.

Then, in a tumbler, metal

Paddles vigorously knead the

Meat.

This tenderizes it even more and

Releases a natural protein that

Will eventually bind several

Breasts into one big piece.

Meanwhile in the turkey kitchen,

Workers shape and season

Previously marinated meat and

Apply strips of bacon to the

Top.

The employee arranges them in a

Crisscross pattern for full

Coverage.

He dusts it with a mix of

Seasonings and then wraps it in

Thick plastic.

Once enclosed in the plastic, he

Can press the turkey breast into

A more perfect shape.

For a different flavor, they

Drench some turkey breast in a

Spicy southwestern marinade.

After folding the turkey meat to

The desired shape, the worker

Adds salsa and seasonings to

Complete the recipe.

A little more hand shaping and

It's ready for the oven.

Back on the chicken line, it's

The same idea but with a

Different twist.

Chicken breasts are too small to

Shape by hand, so they funnel

Them into thermoformed plastic

Molds.

As the molds move forward, a

Worker sprinkles spices onto the

Meat while another swabs juices

To test for pathogens as part of

A quality-control program.

Equipment heat-seals the plastic

Molds and then cuts them free

From the matrix.

Then they're on their way to the

Smoke oven.

They spend six hours smoking at



The protein released earlier by

Kneading causes the chicken

Parts to adhere and take the

Shape of the mold.

Once they've been temperature

Checked, it's on to the next

Station.

Here, workers peel off the

Cooking mold and drain the

Excess juices.

Then the molded breasts go

Through a fryer.

The hot canola oil browns the

Outside of the chicken meat for

A more appealing and tasty

Effect.

Meanwhile, workers swish other

Cooked chicken breasts in hot

Buffalo-wing sauce to really

Kick up the spice a few notches.

And after extra seasoning, the

Chicken travels through a long

Arc of electric heat rods.

This is a special convection

Oven.

Fans blow the heat from the rods

Onto the meat to complete the

Cooking process.

By now the turkey deli meat has

Also been thoroughly cooked and

Crisped.

They transfer the turkey-filled

Bags to clam-like devices that

Close around them.

Inside, a vacuum sucks out the

Air to shrink the packaging

Around the turkey and keep it

Fresh.

It has taken about eight hours

To produce this poultry deli

Meat.

Refrigerated, it should last

About 35 days, unless there's a

Hungry crowd.

]] Narrator: nascar, an acronym

For the national association for

Stock car auto racing, is one of

The most popular spectator

Sports in north america.

Nascar vehicles are modeled

After certain american-made

Four-door passenger cars, but

With far more powerful engines.

No overhead camshaft engines on

This track.

For tradition's sake, nascar

Rules require an overhead valve

Engine, an older type of

Configuration also known as a

Push rod engine.

Designing the engine takes about

A year and a half.

It culminates in a detailed

Computer model, an anatomical

Rendering of the engine in full

Detail, right down to every last

Nut and bolt.

The computer model guides a

Stereolithography machine to

Produce a plastic prototype of

Each engine component.

The machine repeatedly outputs

Paper-thin layers of

Photosensitive liquid resin,

Which an ultraviolet laser

Instantly solidifies.

Over the course of several

Hours of resin layering, their

Prototype component takes shape.

Technicians test it in

Conjunction with other prototype

Components and make any

Necessary adjustments to the

Design.

Then, computer-controlled

Machining equipment produces a

Metal prototype.

When every component has gone

Through this process, the engine

Design gets the go-ahead to move

Into production.

The factory first casts the

Basic shape of certain

Components in a mold, then

Machines that shape to its final

Form.

Here, computer-guided hones

Finish the engine's eight

Cylinder bores, the chambers in

Which the power-generating

Combustion cycles will occur.

Technicians take very precise

Measurements to ensure the

Bores' diameter and roundness

Meet specifications.

Then they flip the engine block

Upside down, oil the crankshaft

Bearings, position the

Crankshaft on those bearings,

And lock it in with bolted-on

Caps.

As the pistons inside the

Cylinders move up and down, they

Rotate the crankshaft, driving

The clutch and transmission,

Which propel the racecar.

With this little black component

Called a wrist pin, they join

The piston to a connecting rod.

Next, they fit two rings on the

Piston.

The top one seals the cylinder,

Maximizing the pressure inside,

Which optimizes combustion.

The bottom ring skims excess oil

Off the cylinder walls between

Combustion cycles, which

Prevents the car from burning

Oil.

After inserting a piston all the

Way down into the cylinder bore,

They grease the upper portion to

Prepare for measuring the

Compression ratio which must

Comply with nascar rules.

The compression ratio refers to

The volume of space in which the

Piston compresses the gas and

Fuel mixture entering the

Cylinder.

To take this critical

Measurement, they raise the

Piston all the way to the top

Dead center point, then verify

The positioning with gauges.

They seal the top of the

Cylinder with a see-through

Plastic plate.

Then, with a syringe, inject

Alcohol into the space in

Between.

The markings on the syringe tell

Them how many ccs -- cubic

Centimeters -- filling that

Space requires.

This volume measurement

Indicates the compression ratio.

The higher the compression

Ratio, the more horsepower the

Engine produces.

They repeat this test with each

Cylinder.

They flip the engine block

Upside down and put each

Piston's connecting rod in the

Corresponding position on the

Crankshaft.

Then lock the piston in place

With bolted-on connection caps.

Now the technician closes up the

Bottom of the engine.

Meanwhile, a device called a

Profilometer inspects the

Camshaft.

The camshaft moves the intake

And exhaust valves at the top of

Each cylinder, allowing the fuel

And air mixture in and the

Combustion gases out.

This testing ensures the

Camshaft is straight and that

Its surface is slightly rough so

That lubricating oil will cling

To it.

The engine build is now about

Halfway there.

]] Narrator: in a push rod

Engine, the camshaft is located,

As we've just seen, above the

Crankshaft.

It opens and closes the valves

With a system of lifters, rods,

And rocker arms.

In the more modern overhead

Camshaft configuration, the

Camshaft sits on top of the

Cylinders, moving the valves

Directly.

Building the nascar engine

Continues with the installation

Of this aluminum motor plate by

Which mechanics will mount the

Engine in the car.

Next, the timing belt, which

Links the camshaft to the

Crankshaft, ensuring they turn

In sync and maintain the correct

Timing.

At the core of the belt is a

Woven material that's five times

Stronger than steel.

Other technicians use a gauge to

Measure how much force it takes

To compress the valve springs.

This quality-control check

Ensures that spring tension is

Within a specific range.

Each cylinder has an intake

Valve and an exhaust valve.

Technicians use a compression

Tool to squeeze a spring over

Each one.

Then they secure the spring with

A locking clip.

The valves are located in the

Top section of the engine,

Called the cylinder head, that

Technicians now bolt on to the

Engine block.

Next, they assemble the push rod

System by which the camshaft

Opens and closes the valves.

First, rocker stands.

Then push rods.

These insert into lifters which

Connect to the camshaft.

And finally rocker arms.

One end of each arm goes on the

Push rod.

The other sits on the valve.

When the camshaft turns, the

System opens and closes the

Valves.

Technicians close up the

Cylinder head with a valve

Cover.

Next, they install the engine

Cooling system, starting with a

Water manifold.

After mounting a cover to

Protect the cam belt from rocks

And other debris, they install

The water pump.

It circulates cold water through

The engine to prevent

Overheating.

Having absorbed the heat, the

Water exits the engine via the

Manifold, then travels to the

Radiator which cools it back

Down.

Then the pump, driven by this

Pulley, sends the water back

Into the engine to repeat the

Cycle.

Next, technicians mount the

Alternator.

It generates electricity to run

The engine and other components,

Such as the air-conditioning,

The dashboard gauges, and fans

Which cool the brakes, tires,

And rear end.

This belt drives both the

Alternator and water pump

Pulley.

Next, technicians install the

Oil pump.

It sucks hot oil out of the

Engine, sends it to the oil

Radiator for cooling, then pumps

It back into the engine.

Now the distributor.

It sends electricity from the

Alternator-charged car battery

To the spark plugs.

The spark plugs fire, igniting

The fuel and air mixture in each

Cylinder, producing a mini

expl*si*n that drives the

Piston.

This component, the intake

Manifold, feeds the air and fuel

Mixture to the cylinder intake

Valves.

The carburetor regulates the

Mixture ratio by metering the

Right amount of fuel to the

Amount of air coming in.

Technicians install the numerous

Parts that make up the clutch.

Next, the starter ring, which

Engages with the starter to fire

Up the engine.

Finally, they mount the bell

Housing, a cover that protects

The clutch from debris and

Connects the engine to the

Transmission.

The factory hooks up every

Engine it produces to a testing

Machine.

The machine starts up and runs

The motor, analyzing some 300

Performance criteria, from

Revolutions per minute to fuel

Flow.

At the same time, three

Remote-controlled cameras

sh**ting from different angles

Enable technicians to zoom in

And view on a monitor anything

They need to visually inspect.

All this to ensure the engine

They've built will have a

Winning track record.

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