24x09 - Recycled Skateboards, Braided Pastry, Construction Trailers, Metalworking Vises

[bunniefuu]

Narrator: sixty years ago,

Surfers in california
were looking to ride the streets

Like they surf the waves.

They came up with an idea

To strap roller skate wheels
on their surfboards,

And the skateboard was born.

Since then, skateboarding has
evolved into a sport, a passion

And a lifestyle
for people all over the world.

In a backyard pool, a skater

Gauges the feel and response
of these recycled skateboards.

Recycled skateboards
give new life

To unrideable old boards.

The boards on this rack would
normally end up in a landfill.

First, the designer
heats up the old grip tape

And peels it off.

This reveals the board's
original graphics.

He grinds off the graphics,
leaving bare wood.

He applies epoxy on top
of a colored veneer coating

And stacks the boards

On the table
of a bottle jack press.

He glues another board

And places it on top
of the first one.

He repeats this stack process
with different colored boards.

The stacking continues
until the designer

Has about 20 boards
on the table.

He puts the bottle jacks
in place and cranks them up.

Each jack applies 10 tons
of compression,

Pressing the boards together
while the epoxy cures

And the excess glue drips out.

The designer makes a cross cut
in the stack with a bandsaw.

Each new board he makes comes
with a unique color design.

A worker traces a cutting mark
on the board

And makes a rough cut
along it with a jigsaw.

He sands down the rough profile

Of the board using
a table-mounted belt sander.

Before the board
goes to silk screening,

He uses a custom template
to drill holes

For the assembly bolts.

A designer pours water-based ink

On top
of a screen printing mesh.

He takes a squeegee

And pulls the ink
through the membrane

To print the company logo
onto the board.

He removes
the silk screening frame,

And the board continues on
to the epoxy phase.

A worker pours epoxy resin
on top of a fiberglass cloth.

He spreads out the epoxy
with a squeegee

In a slow, constant motion.

This keeps air bubbles,
runs, or drips

From ruining the finish
of the board.

The cloth absorbs the resin.

The worker cuts off the excess
cloth with a razor blade

And applies a finish coat
of epoxy,

Completing the board's covering.

A worker uses a router

To smooth out the curve
of a different board.

He finishes the board profile
with fine sanding paper.

A worker sprinkles
recycled crushed glass

On the epoxy-covered board.

This will provide grip for
the board instead of grip tape.

Before the resin hardens
and cures,

He presses the glass
into the epoxy with a wheel.

He sands the bottom of the board
with a sanding block.

He goes through seven
different grits of sand paper.

Then the board is washed

And polished before starting
the final assembly process.

A worker assembles the wheels
on a truck

And bolts them on with hex nuts.

He tightens the wheels
with a wrench

Until he's reached
the desired torque ratio

And gives them a test spin.

He inserts bolts
through the board

And places a urethane riser pad
underneath the skate deck.

Then he starts
assembling the truck.

He uses a screw g*n to secure
the wheel trucks in place.

Each skateboard is equipped
with polyurethane wheels

Mounted on metal trucks.

These allow the rider
to steer and control the board.

Recycled skateboards are made
form a wide variety

Of shapes, deck sizes,
wheels and trucks,

Suiting each rider's unique
tastes and performance needs.

Narrator: many years ago,

Danish bakers
got creative with pastry dough.

They began braiding it,

Putting a whole new twist
on deserts.

Braided pastry
looks more elaborate

Than ordinary pastry.

The flakiness of the dough
and the scrumptious fillings

Make braided pastry taste
as good as it looks.

Factory-made braided pasty

Can be kept frozen
until you're ready to eat it.

After just a few minutes
in the oven,

You will have
a fresh-baked desert.

The pastry looks as though it
takes many hours to prepare,

But of course,
it is no trouble at all.

To produce braided pastry,

This factory uses a number
of ingredients,

Including yeast...

Granulated sugar...

Pastry flour....

...dried eggs and water.

The ingredients go into a large
refrigerated mixer.

The cooling keeps
the yeast dormant

As beaters work the ingredients
into dough.

After the dough
leaves the mixer,

It tumbles into a hopper.

A cutter wheel chops the dough
into several pieces.

The pieces of dough travel
between conveyors

That squeeze them
into ribbons of dough

That will be fed to an extruder.

The extruder shapes
the elongated dough pieces

Into one continuous sheet.

At the exit of the extruder,

An employee
dusts the conveyor with flour.

This prevents the dough
from sticking to it.

A pump at the extruder exit
spreads big blocks

Of soft butter across
the newly formed sheet of dough.

Down the conveyor,

Plow-like flaps
fold the buttered dough over,

Creating a double layer.

This folding process,
called lamination,

Will build up multiple layers
of buttered dough,

Resulting
in a very flaky pastry.

Next, the dough
travels into a drum

With spinning rolling pins.

These rolling pins flatten
the folded dough significantly,

Compressing the layers
into one thin sheet.

Now, a conveyor
takes the compressed sheet

Through a device
that will fold the dough again.

Next, rolling pins
squeeze the stack of dough

Into a single piece once again.

Revolving cutters
slice the laminated dough

As it moves forward.

The cuts create angled strips
for braiding.

At the next station,
a sweet cherry filling

With a jam-like consistency
is waiting.

Nozzles deposit precise amounts
of cherry filling

Between the angled cuts.

Next, workers braid the dough
over the center filling,

Creating
an attractive-looking pastry.

Sensors determine

Where the blade
will slice the braided pastries.

The braided pastries
are transferred

To another conveyor
with a scale.

The scale confirms that there is

A sufficient amount of filling
in each pastry.

The braided pastries
now head into a freezer

Set a temperature
of 29 degrees below zero.

Inside the freezer,

The pastries revolve
on carousels for 45 minutes.

This gradual freezing process
preserves the yeast.

Next, the pastries
wind their way

Toward the packaging station.

Here, workers place
a packet of icing

Under each braided pastry

And send them
to an automated packager.

Machines wrap a plastic sleeve
around the pasty.

To minimize the amount

Of time the pastry
is out of the freezer,

Things must move quickly.

The pastries
pass over a weigh station

To confirm the correct amount
has been packaged.

When baked,
the pastry rises significantly,

Allowing the braided profile
to expand.

The layers of dough separate
and become flaky.

The cherry filling seeps
into the pastry.

Endings don't get
much sweeter than this.

Narrator:
pass by any construction site,

And you'll probably see
a trailer.

Construction trailers provide
room for an on-site office

Or lunch room
for the construction workers.

A trailer can also be used
as a decontamination room

For workers to remove
their protective clothing

And shower after handling
hazardous materials.

Construction trailers
are typically 10 to 13 feet wide

And up to 59 feet long.

The inside of the trailer
can be equipped

For whatever function
it will serve.

The structure of the trailer
is made of spruce, pine, or fir.

Workers start with an underfloor
made of wood particle board.

Then they nail floor joists
to the boar and frame them.

The insulate the floor
with fiberglass wool

And nail a plywood subfloor
on top.

Then they spread tile glue
over the subfloor.

The glue is freeze-proof
and mold resistant.

They complete the floor
by laying down

Commercial-grade vinyl tile
or linoleum.

To build the walls
of the trailer.

They nail pieces of woods
called studs

Every 15 inches
along the sole plate.

The sole plate is the bottom
section of the trailer's wall.

Then they build rough openings
for the windows and doors.

Finally, they nail
another horizontal piece

Along the top of the studs.

This is called
the double top plate.

The structure
of the wall is complete.

Now, they apply glue
to the studs and nail

On a sheet of plywood
to the lower part

Of the wall structure.

They repeat this process

With the three other walls
of the trailer.

Then they raise each wall

And nail a sole plate
to the floor.

The plywood exterior wall
extends below the sole plate,

Covering the side
of the floor frame.

They glue the plywood
to the floor frame

And reinforce it with nails.

Next, the roof of the trailer --

It is constructed in layers.

First, they lay
down the fiber board ceiling,

Then install
a plastic vapor barrier.

Next, the roof joists --

The joists have sloped edges
to drain water off the roof

And holes
for electric cables.

Once the joists are installed,

Workers frame the roof structure
with end plates.

Then they thread in
electric cables

For the lights, outlets,
baseboard heaters,

And other electrical components.

Now, they begin their work
inside the trailer.

First,
fiberglass wool insulation

Is installed between the studs.

A plastic vapor barrier
is added.

Then they install
smooth wood panels.

The wood panels are laminated
with vinyl for a clean finish.

At the same time,

Work continues on the outside
of the construction trailer.

Under the floor, workers
install one to three axles.

The amount depends
on the trailer's length.

Each axle can support
around two and a half tons.

After workers install
all of the exterior plywood,

Workers begin
the finishing process.

At the top and bottom
of the trailer,

They install starter moldings
made of painted sheet steel.

Then they begin installing
panels of painted steel.

Windows and doors are installed

Before adding
the painted steel siding.

This is so the ends
of the steel siding

Will beneath the door
or window moldings,

Producing a neater finish.

Trailers longer than 32 feet

Have both heating
and air conditioning

Via a duct system.

Workers mount the air ducts
to the ceiling with brackets.

They also install
electrical outlets,

Light fixtures, interior trims,

And electric baseboards
for additional heating.

Trailers shorter than 32 feet

Only have
electric baseboard heaters

And a window-mounted
air conditioner.

However,
there is the option to upgrade

To the full duct system.

To finish the roof,

They staple white fiberboard
to the roof joists.

Then a hitch system
is installed.

This enables a truck
to haul the trailer

To and from
the construction site.

Narrator:
a metalworking vise

Holds a piece of metal in place

So that a computerized cutter
can shape it into a part.

You often see vises
on "how it's made."

Now it's time to find out
how they are made.

Metalworking vises
have parallel jaws

That close tightly
around a piece of metal.

Their firm grip allows a part

To be machined
with pinpoint accuracy.

To make a metalworking vise,
they start with a steel rod.

It spins in a lathe
as tools carve threads into it.

The result is a lead screw

That will be used to open
and close the jaws of the vise.

Next, cutters transform a piece
of aluminum into a thumb screw.

The thumb screw is used
for turning the lead screw.

The outside of the screw

Is given a neural texture
for better gripping.

The final tool
shaves the roughed-edge rim

Of the screw to make
it smoother to the touch.

This completes the thumb screw.

Now, an automated saw
cuts the steel bar

Into smaller pieces.

Each piece will be used
to make the base of a vise.

Next, a cutter sculpts
the outside of a base piece

To the desired profile.

Another tool carves a channel
in the center of the base piece.

The cutting machine
also creates components

For the vise's shuttle system.

Then a machine cuts
the reverse side

Of the vise base
flat and smooth.

It also drills holes

For mounting the vise
to milling equipment.

A constant flow
of coolant is applied

To protect the tool from wear.

Next, a steel block
is locked in a vise.

Yes, they used vises
to make new vises.

The vise holds the piece
of steel firmly in place

As tools shape it
into one of the new vise's jaws.

After a heat treatment,

They spray
small particles of sand

Onto the newly formed jaw.

The sand blasting
removes blemishes.

A worker now submerges
all parts of the vise

In a hot chemical solution,

Leaving them there
for eight hours.

This chemical solution gives
the parts a black oxide finish

And protects them from rust.

Here is the vise before
and after the oxide treatment.

Next,

A laser etches the brand name,

Part number,
and basic dimensions

Onto the base of the vise.

Then a probe gauges the size
of the mounting hole.

It also determines

If they've been drilled
in the correct location.

Now, it's time
to assemble all the parts

Of the metalworking vise.

The worker threads retainer
rings onto the lead screw.

Then he installs the lead screw
in the base.

He places shuttle devices
onto each end of the lead screw.

He inserts spacing blocks
in the channel.

He moves the shuttle devices
forward,

Using the spacing blocks
as guides

For the correct positioning.

After removing
the spacing blocks,

He adjusts the retainer rings.

He places steel jaws
on the shuttle devices

And bolts them in place.

Once the thumb screw has been
attached to the lead screw,

The assembly is complete.

Now, it's over to a computerized
measuring station.

The controller positions
the vise in the equipment,

Then a probe moves in.

The probe compares
the coordinates of the vise

To a computer model

And checks that it measures up
to standards.

Metalworking vises
take four weeks to make

And will hold up for many years.

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