32x13 - Peaked Caps; Custom Water Heaters; Electric Boats; Fencing Foils

[bunniefuu]

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Narrator: throughout europe
in the late 1700s,

Peaked caps were traditionally
worn by industrial workers.

Today, they are worn
by professionals

Such as security personnel,
members of the military,

And police officials
that wear uniforms.

In the united kingdom,
some police officers

Still wear
the classic custodian helmet,

But now many officers
have chosen to wear

The lightweight, comfortable,
and practical peaked cap.

To make these caps,
a hat maker, or a milliner,

Assembles a number of components
using patterns

To cut out the required pieces
of wool, foam, and plastic.

A milliner bends a strip
of polypropylene plastic

Into a circle.

She sews the joint
with a high-strength thread,

Creating the hat band
that will go around the head.

She positions a smaller piece
of polypropylene,

Known as the badge support,
and sews it in place.

The support will prevent
the weight of a police badge

From distorting
the shape of the hat.

These crescent-shaped components
are pieces of wool

Glued to thin, flexible foam.

She sews the crescents together,
creating a circular piece,

Which will form the bevel.

She uses a specialized,
long-arm sewing machine,

Which has been customized
to make hats.

The seams are carefully ironed
flat to prevent any bulging.

If the iron is too hot,
the foam will melt.

Too cool,
and the wool won't flatten.

She aligns two strips
of 100% wool fabric

And sews them together
at the ends.

This piece will cover
the plastic stiffener

Forming the outer band.

To ensure the sizing is correct,

The milliner places the wool
cover over the stiffener.

♪

The stiffener is installed

At the end
of the production process.

Next, the milliner irons
the seams of the band covers.

She finishes the band covers
on a sewing machine

Known as a flat bed

And creates a fold
to hold the plastic stiffener

And sews the edges together.

Then the band cover is sewed
to the bevel.

While it's difficult to attach
two pieces of cloth

At different angles,

This step creates an even seam
that runs 360 degrees.

It takes at least six months
of training

To learn how to make hats.

The crown is made
from three materials --

A combination of wool and foam,

A polyester lining,

And a protective-grade
p.v.c. Layer.

Once the three materials
have been sewn together,

The machinist trims
the perimeter of the crown.

She marks the side edges

And aligns them with the seams
on the bevel.

Then she sews the crown
to the bevel.

Having spent a great deal
of time perfecting the skills,

This milliner
makes it look easy.

Finally, the components
begin to resemble a hat.

Using a polypropylene template,
the machinist positions

And marks
two spots on the bevel.

She places two small brass rings
on a special device

And aligns the marks
with the device's posts,

Which cut out two holes
through the fabric.

Then she places two cup-shaped
rings on the posts,

And the machine
punches them down,

Forming eyelets for ventilation.

Next,
the polypropylene stiffener

Is inserted into the hat.

Finally, the hat begins
to take on its final shape.

The tag containing the hat's
size is sewed on hat band.

She places a checkered-pattern
band on the brim of the hat,

Called dicing
or the sillitoe tartan.

The milliner inserts
a replica badge

Through holes
in the badge support

And secures it with a pin.

This is a replica,

Since we can't show
real police badges on tv.

Next, the milliner sews
the peak onto the band.

It took a highly skilled
milliner

More than half an hour
to sew this hat.

They might look straightforward,

But peaked caps
are surprisingly complex.

♪

Narrator:
a home water heater stores
and heats water in a tank.

This is how it works.

When you turn on a faucet,

Hot water flows out of the tank
from the top,

While cold water flows
into the tank from the bottom.

Conventional water heaters
are fueled by natural gas,

Electricity, propane, or oil.

This company custom-builds
several types of water heaters

For use with different types
of heat sources,

Such as boilers, heat pumps,
and solar panels.

Each work order includes
a picture outlining

The pipe configuration
and the connecting valves,

Along with a list of the
water heater's specifications.

To make a copper tank,

A technician cuts a thick sheet
of copper to a specified length.

He aligns the end of the sheet
to the gradation on the table

That corresponds to
the tank's circumference.

Then he actives the guillotine
blade with a foot pedal.

A computer-guided machine
punches holes for the valves.

This water heater requires
two valves

At each end of the heating coil

And one that will connect
the water pipe to the tank.

The technician inserts
the copper sheet

Into a mechanical roller.

The rollers apply pressure,

Forming the sheet
into an open cylinder.

One end of the cylinder
is clamped into a machine

That welds linear seams.

The technician inserts
the other end

Of the cylinder
through the machine

And joins it
against the clamped end.

The machine is programmed
to weld a seam

To the length
of the connected ends.

The technician monitors
the welding arm

Through a u.v. Lens
to protect his eyes.

The machine stops automatically

When it reaches
the programmed seam length.

This process closes the cylinder

With a strong,
pressure-resistant seam,

Creating the water-heater
tank's structural component.

Another technician places
the tank's top on a press.

The press punches a hole
for a threaded pipe fitting.

The fitting connects the pipe
to the hot water.

Using a different press,

The technician makes
another hole

Into the cylinder
for a threaded fitting.

This fitting connects to
an electrical element

That heats water
in conjunction with a boiler.

Another technician makes
the tank's heating coil

By running a straight copper
tube through three rollers.

The tube is bent under pressure,

Forming it into a coiled shape.

The heat from the boiler,
pump, or solar panel

Flows through the heating coil,

Heating the water stored
in the tank.

Since the copper-tube wall
is too thin to weld,

A technician uses a fusing
technique known as brazing.

This metal-joining process
brazes a flow fitting

On one end of the heating coil

And a return fitting
on the other.

Next, the heating coil
is placed in the tank.

The fittings protrude through
a hole at the top and bottom.

The technician secures each one
with a nut,

Then tightens the nuts
with an impact wrench.

Like the dome top, the bottom
component's edges are grooved,

Allowing the tank
to fit perfectly

Into the cylinder base.

Once the top and bottom
components are installed,

The tank goes back
to the brazing station

For final assembly.

A welder brazes
the top and bottom components

To the cylinder,

Then he brazes
a feed fitting to a hole

Near the bottom of the tank.

This location is where
cold water enters

The tank to be heated.

Next, a technician conducts
a quality-control test.

He blocks the three fittings,
fills the cylinder with air,

Then submerges the tank in water
to check for air bubbles,

Which would indicate a leak.

♪

A stainless-steel water heater
is constructed

Just like a copper heater,

Except that they don't require
any brazing.

A robot sprays the tanks with
expandable polyurethane foam

For insulation.

The customer selects
the degree of insulation,

One to four inches thick.

The foam takes just five minutes
to cure.

As the tank stores hot water,
the insulation reduces

The amount of heat
the tank loses over time.

♪

Narrator:
electrically powered vehicles

May seem like
a 21st-century phenomenon,

But they were actually
first invented in the 1880s.

During that time,
they were very popular,

Until combustion-engine vehicles
became the new normal.

Today,
these electrically powered

Alternative-fuel vehicles
are making a comeback.

This manufacturer produces
a wide range of electric boats.

Thanks to powerful batteries,
some of these vehicles

Can travel
over 35 miles per hour.

Craftspeople apply
a gel-coat skin to a mold,

Using a product
derived from vinyl.

Then they layer on
a dry fiberglass fabric

And vacuum-bag
the entire assembly.

The vacuum suction
draws in liquid resin,

Infusing the material.

A craftsman marks a dry spot
as a test point

To monitor and ensure
complete saturation.

The infusion process
takes about two hours.

Once complete, the assembly
will cure for four to six hours,

Depending on the general
humidity and temperature levels.

Once cured, the assembly
is removed from the mold.

Despite the structure's
light weight,

This deck is incredibly
strong, rigid, and durable.

The fiberglass decks and hulls
make up the boat's shells.

A craftswoman applies
a high-strength marine glue

To a recessed area of the deck.

She installs an anti-skid
deck insertion.

This material is a composite
designed to resemble wood.

Unlike real wood,
this composite material

Will last the lifetime
of the boat

And won't require
any additional maintenance.

The craftswoman uses a roller
to apply pressure evenly

Across the entire
decking surface.

This step will eliminate
any unwanted air pockets.

Next, a mirror-image
decking section

Is applied to the other side.

A specialist installs
the electrical-wiring harness.

To avoid corrosion,
marine-grade wiring is stored

In a sealed environment
under the deck.

Since the decking
is lightweight,

It only takes two people to lift
and install it on the hull.

The lip of the deck
fits snugly into place.

The most powerful boat models
require lithium-ion batteries.

These boats are built
with military-grade foam.

The density of the foam
adds structure,

Causing the boat
to become unsinkable.

Using a hoist, technicians
install the deck

Of a large, powerful
electric boat.

The deck lip slides
over the top of the hull.

Depending on the boat model,

The manufacturer uses
either lithium-ion

Or lead-acid batteries
as a power source.

A specialist installs a series
of marine-grade

Dc31 lead-acid batteries.

At 6 volts, 225 amps,

They're similar to batteries
used in cars.

By contrast, the 7.7-kilowatt
lithium-ion batteries

Pack a charge of 48 volts.

The batteries are installed
under the seats.

To create a watertight seal
between the deck to the hull,

A craftsman installs
a rubber bumper

Around the perimeter
of the boat.

Holes have been pre-drilled
to avoid cracking

When installation is complete.

This manufacturer sources
their motors

From an outside
electric-motor company,

Which also builds motors
for cars.

The fin, made of aluminum
encased in marine-grade rubber,

Is installed on the bottom
of the motor.

The propeller attaches
to the motor with a zinc nut.

Two circuit boards located
on board

Will send instructions
to the motor.

A waterproof cover is placed
on top of the circuit boards

For added protection.

Locknuts with nylon washers will
prevent unnecessary vibrations

While the motor is on.

With the steering cables
installed,

The entire unit pivots
right and left,

Allowing the pilot
on deck to steer.

The powerful motor is equivalent

To a 10-horsepower
combustion engine,

And because it sits
in the water,

It stays cool and quiet.

Finally, a craftswoman places
the boat's sun canopy

Over the framework.

This will allow customers
to add solar panels

For charging the boat.

Also, a customer can choose
the colors

For both their canopies
and upholstery.

There's no denying
that electric boats

Are the future of fun
on the water.

♪

Narrator:
modern fencing is a sport

Consisting of three disciplines,
one of which is foil fencing.

While in play,
a lightweight foil sword

Is used to score points.

Points can be scored
when the tip of a player's sword

Makes contact onto
their opponent's torso.

A fencing foil is
a piece of equipment

That should only be used
by trained professionals.

This sword doesn't have
a sharp edge or pointed tip.

It's all about scoring hits.

Fencing foils are made
out of thin steel bars.

The steel is a low-carbon,
nickel-rich alloy

That's strong yet flexible.

An automated saw cuts the bars
to a length of 35 inches.

The bar will be stretched and
shortened as it's transformed.

A forge heats and hammers
the hilt end to a round shape,

Leaving the rest of the rod
rectangular.

Here you can see the difference
in the rod's shape.

Another forging machine
softens the end of the rod

And pushes the blade
through a series of hammers.

This tapers the blade
and stretches the steel,

Doubling it in size.

An operator clamps
the tapered blade in a jig

To hold it straight
while the steel cools.

Then the operator slices
the hilt end to length.

The excess steel will be
recycled into new swords.

Next, the blades are heated
in a 932-degree oven.

This step removes stresses

And makes the metal
less brittle.

After a second heating,

The blades soak in oil
to cool and harden.

The exposure to intense heat
causes a rusty scale

To form on the blade,
so technicians clean it off.

A sword maker clamps the blades
in a disc grinder.

The grinder carves a fine groove
from the hilt to the tip.

The groove will house a wire
for the electric scoring system.

The blade is cleaned to remove

Any remaining
surface imperfections.

A spinning belt
coated with an abrasive

Grinds all four sides
of the blade.

Then the sword is polished

Using a buffing wheel
and polishing compound.

You can see the difference this
makes in the blade on the right.

The craftsman hammers the blade
against an anvil

To straighten out any kinks.

Then he inspects the blade.

If needed, the craftsman will
make adjustments

To the blade with a hammer.

Now it's time to work
on the hilt end of the blade.

Another craftsman locks the end
of the blade in a threading die,

Applies lubricant,

And activates
the automated system.

The system turns the sword
in the die, carving out threads.

Then the threaded hilt
is cut to length.

At the next station,
a computerized laser engraves

The company logo into the steel.

After the sensor barrel
is installed

On the end of the sword

And the electrical scoring wire
is placed in the groove,

The technician applies glue
to keep the wire secure.

The sword blade is placed
in a rack

That holds it
in a bow-like bend.

This step will give
the glued wire

The flexibility it needs

To bend with the rest
of the sword while in use.

After the blade has cured,
a pressure sensor spring

Is inserted into the barrel
and capped with a sensor button.

The technician uses screws
to hold the components together.

To assemble the hilt,

The scoring wire is threaded
through a hole in the guard

So it can easily slide
into place.

Then the sensor wire
is connected to a socket.

The wiring assembly is covered
with a plastic pad

That allows the socket
to protrude.

Finally, the p*stol-grip handle

Is screwed into
the threaded end of the blade.

This fencing foil is now ready
for testing.

The technician plugs the fencing
foil into testing equipment,

Then he places a one-pound
weight on the sensor button

And checks to see
if it responds.

And the results are in.

This fencing foil is now ready
to stand up to its competition.