28x01 - Condoms, Classic Car Gauges, Chocolate Marble, Truffle Cake, Ghillie Kettles

[bunniefuu]

They may have stopped
making the car.

But they still manufacture
replacement gauges

That look just
like the originals.

After all,
modern digital instruments

Just wouldn't look right

In the dashboard
of a classic vehicle.

Technicians give the mechanism
a bit of an update,

But the look is all retro.

These car gauges are new.

But they have
the same old faces.

The old-style dials are built
to the original designs

As replacement parts for
classic and vintage vehicles.

Making a classic car gauge

Starts with
a zinc-coated steel blank.

A worker places
the blank on a tool.

A press stretches it
around the form

To shape it into the gauge case.

After a flange
has been formed on the rim

And holes punched
for assembly purposes,

It's on to the next operation.

A worker welds a stud
to the back of the case.

The stud will be used to mount
the gauge to the dashboard.

Another worker paints
the inside of the case white.

Next up is a brass tube
for the light bulb.

A worker secures it in a fixture
and places the case over it.

A press crimps
the top of the light tube

Around one of the holes
in the case,

Securing the tube to the back.

A mechanized printer pad

Picks up ink from engravings
on a metal plate

And transfers them to a dial.

For this gauge, they'll need
a hollow, curved spring,

Known as a bourdon tube.

To shape this flat brass tube
into a spring,

A worker tucks one end
into a forming tool.

He inserts a shim
into the other end

To keep the tube hollow

As he curls it
around the form.

This turns the flat tube
into a c-shape spring.

He then crimps one end
in this press.

He dips the crimped end
into a chemical cleaning agent

And then into hot solder.

The solder hardens

And seals this end
of the bourdon spring.

He solders a brass adapter

To the opened end
of the bourdon tube.

This hollow socket

Is the part that will receive
the fluid pressure.

That pressure will cause
the tube to unwind

And move gears that turn
the pointer on the gauge dial.

A worker places
the tube in water

And pumps pressurized air
into it through the socket.

He checks for bubbles that would
indicate there's a leak.

They make the gears
that move the pointer

Using a hobbing machine.

It's a spinning cutter
that carves teeth

Into brass parts,
known as racks.

A worker inserts a brass pivot
in a holding device.

Using a press,

She crimps the pivot
to the center of the rack.

She then assembles
a hair spring and a pinion

Between two brass plates.

She positions the rack
in the gear sandwich.

She secures the assembly
using a hand press.

Now, with tweezers,
she pulls the end of the spring

Through a hole
in one of the posts

And locks it in place
with a pin.

She turns the shaft to confirm

That the rack-and-pinion gears
engage and work smoothly.

Returning
to the bourdon tubes,

She transfers one to a fixture

And locks it in place.

She places the gears
on top of the bourdon tube

And screws it
to the side of the socket.

She then installs
the bourdon tube assembly

In the gas gauge casing.

A worker now connects the gauge

To a pressurized air source.

She pops the retro-look dial
into the device

And attaches the pointer
to the protruding gear shaft.

She then introduces air
at a known pressure

To calibrate the gauge.

She tucks a gasket
into the top rim

And then fits
a glass pane on top.

A chrome-plated bezel retains
the assembly and frames it.

A press snaps
the components together.

Made to measure,
this car gauge is now complete,

And it looks like a classic.

A chocolate truffle cake

Has nothing to do
with those rare and pricey fungi

That are a culinary delicacy,

Nor is it directly related
to the chocolate truffle,

A decadent confection consisting
of a chocolate ganache center

Coated in either chocolate,

Cocoa powder,
or toasted, chopped nuts.

A chocolate truffle cake
has many variations.

This version features

A flourless chocolate
truffle cake base

Under a layer
of chocolate marble cheesecake,

Garnished with fudge ganache.

To make the cheesecake layer,
they begin with cream cheese.

They mix for three or four
minutes to soften it,

Then blend in sugar and salt.

Next, they add sour cream

To make the cheesecake
creamier and fluffier.

The last ingredients
are whole eggs

Blended with vanilla extract.

Another three to four minutes
of mixing completes the batter.

To make the chocolate truffle
cake base,

They combine water, sugar,
corn syrup, and cream of tartar,

Which is a leavening agent

That works in flourless cakes
like this one.

It also prevents
the sugar they just added

From crystallizing.

While heating those
ingredients to a boil,

They soften butter in a mixer,

Then add melted
semisweet chocolate,

Which contains vanilla extract.

They mix for another
five minutes or so

Until the chocolate
is thoroughly blended in.

Then they add
the boiled ingredients,

Then coffee syrup...

...then blended whole eggs.

A final
five minutes of mixing,

And the chocolate truffle
cake batter is ready.

They pump it into

The funnel-shaped feeder
of a depositor.

Workers meanwhile line
aluminum cake pans with silicone

And place them
on a conveyor belt.

The depositor is set up
to squirt

Exactly 28 ounces of the thick
chocolate truffle cake batter

Into each pan.

They pump the thinner
cheesecake batter

To the feeder
of a second depositor,

Which squirts an identical
amount of cheesecake batter

Into the pan.

This batter is much lighter

Than the dense chocolate
truffle cake batter.

So rather than blend,

The two batters form
separate layers.

Using the squeeze bottle,

They drizzle on some extra
chocolate truffle cake batter

And drag a knife back and forth,

Creating what's known
in pastry making

As a napoleon-style design.

They put the pans in the oven

For 90 minutes
at 90 degrees fahrenheit.

The long baking time
at a relatively low temperature

Ensures the heat penetrates

The dense truffle
batter gradually.

Otherwise, the outside
of the cake would burn

Before the inside
is fully baked.

The cakes cool
at room temperature,

Then go into
a freezer overnight.

The next day, workers

Easily pop the rock-solid cakes
from the pans

Thanks to that silicone liner.

They place the cake
on a cardboard circle,

Then, with a pastry bag,

Garnish the edge
with fudge ganache.

The ganache is made
of heavy cream,

Corn syrup and the same
melted chocolate

They put in the truffle
cake batter.

They placed the finished
chocolate marble truffle cake

Into an automatic cake slicer.

The turntable rotates after
each strike of the blade

Until the machine has cut
the cake into 12 slices

And separated them
with paper dividers.

They wrap the cake
in a cardboard band

Printed with the brand name.

Then they put the dessert
through a machine,

Which encases the cake
in plastic film,

Then applies heat
to shrink the film taut.

To serve this decadent dessert,

You let it defrost
at room temperature

For four to five hours

Or in the fridge overnight.

Impatient chocoholics
take note --

You can also defrost
a slice in the microwave

In just 30 seconds.

Invented in the 1890s
by irish fishermen,

The ghillie kettle is still
popular off the beaten path.

Simply stuff twigs,
leaves or other scraps

In the bottom chamber
and ignite.

The water in the surrounding
chamber boils in minutes,

Allowing you to have
a quick cuppa

In the middle of nowhere.

Roughing it
in the wilderness?

With the ghillie kettle,
you can still have

A civilized cup of tea
unplugged.

Making a ghillie kettle starts
with a thick aluminum disk.

A metalworker clamps the disk
against a form in a lathe.

As the lathe spins,

He presses the disk
to the form using a blunt tool.

This transforms the disk
into a flared vessel,

One that looks like
a flower pot.

A cutter at the side
trims the rim.

They call this flower-pot shape
the draft.

The next phase takes the draft
from flared to cylindrical.

A worker presses the spinning
draft to another form.

This stretches the aluminum
shape longer and narrower.

Finally, they taper the cylinder
at the top

To form a slanted chimney

And slice off the bottom.

From flat disk
to a tall kettle,

It's a dramatic change.

He drills a hole
in the gradient of the kettle.

He inserts a screw
that's attached to a punch.

Then, using an allen wrench,

He turns the screw,

Forcing the punch into the metal

To cut out a hole
for the kettle spout.

He now slides the kettle body
over a post

With a die that fits
into the spout hole.

He places the spout over the die
and hammers it into the hole.

The die helps form the seam
as the metal spreads

Due to the impact,

Tightly locking the spout
to the kettle body.

A worker transfers
the kettle to a jig

With a template for drilling.

He drills holes into
the kettle body,

Relying on the template
to space them correctly.

These holes are for the handle
and chain attachments.

Next, the inner wall of
the ghillie kettle takes shape.

Wielding a tool with force,

A worker pulls and stretches
the aluminum disk

Into a long cone.

He inserts the cone
in the kettle body.

A gap between them will serve
as the water chamber.

And smoke will be
vented out the center.

He rolls
the upper lip of the cone

Around the kettle's top rim,

Locking them together.

He also secures them
at the base the same way.

He transfers the ghillie kettle
to a stand

To keep it upright
as he rivets steel ears to it.

The ears are for attaching

The handle and a chain
for the kettle whistle.

He now assembles the whistle.

He aligns a gap
in a round plate

With one in the whistle body.

This small gap will allow steam
to pass through.

He inserts a screw and
a ball knob in the center hole

To hold the whistle together.

The base of the ghillie
is this fire chamber.

For packing purposes,

He stacks it upside down
and places the kettle over it.

He wraps the entire kettle
in british newsprint

For shipping.

This protects it

And also gives the purchaser
something to burn

The first time
he or she tries it out.

He crimps the ends
of the handle

To the ears that protrude
through the headlines.

He places the whistle
over the wrapped spout

And then tucks the kettle
into a drawstring tote.

This ghillie kettle
is ready to provide

The convenience of hot water
in the backwoods.

The camper removes
the whistle from the spout

And pours water into it.

This particular model
can hold about 51 ounces.

He replaces the whistle

And lights the fire
in the bottom chamber.

As it burns,
smoke comes out of the center.

The cone-shaped cavity
creates an upward draft,

Ensuring rapid boiling

Even in windy
or damp weather.

Within minutes,
there's hot water

For beverages
or soup noodles.

Smoking and whistling
in the wilderness,

The ghillie kettle offers
some of the comforts of home.

It was an american nurse's
sensitivity to an antiseptic

That led to the development
of medical rubber gloves.

The year was 1890,

And the hospital
was johns hopkins in baltimore.

Sympathetic
to the nurse's plight,

The chief of surgery
asked a rubber company

To develop protective gloves.

Around the world,

Healing hands
wear rubber gloves

To stop the spread of germs
and save lives.

To make them,
they need a lot of hands,

The kind made from
ceramic or aluminum.

They'll serve as molds.

First, they need
to remove residue

From the last rubber
glove production.

So they do a thorough
washing in soapy water...

...and then in bleach.

They must remove
every speck of residue

Because even
the smallest contaminant

Could lodge
in the latex rubber gloves

And create holes.

Leaving the bleach,

The ceramic hands twirl
into round, revolving brushes.

Their bristles
scour the surface

And the hard-to-reach areas
between the ceramic fingers.

After this thorough scrubbing,

The hand molds dive
into a tub of hot water.

It's the last cleaning
before production begins.

As they exit the tub,

The hands swivel
on the rail carrier to drip-dry.

Still slightly damp
and spinning,

The hand molds head
into a chemical bath,

Which forms a film
on the surface.

It's a critical coating

Because liquid rubber
won't adhere to bare ceramic,

But it will to this substance.

The ceramic molds now
reach into warm liquid rubber,

Which has been enhanced
for extra strength.

The liquid rubber reacts
with the chemical coating

On the hands
and becomes gel-like.

Coated with the rubber gel,

The hands spin
to shake off any drops

As they head into an oven.

Under intense heat,

The rubber dries
to the hand form

And also undergoes
a chemical process,

Called vulcanization,

That makes the rubber
stronger and elastic.

After a wash and dry,

The gloves spin through brushes
which roll up the cuffs.

This cuff roll,
called the bead,

Has a specific purpose --

It makes it easier to pull
the rubber glove off the mold.

Workers grab the gloves
by the beads

To peel them off
the ceramic forms.

These particular medical gloves

Were molded
from synthetic rubber

For people who can't wear
natural latex rubber

Due to allergies.

These synthetic rubber gloves
are a bit stickier

Than the natural latex ones.

And they must be
removed by hand.

However, the natural latex glove

Come off much more easily.

Bursts of pressurized
air blow these gloves

Off the ceramic forms.

At a test station,
a worker now stretches

And inflates each medical glove

To check for weak spots
and holes.

Even a pinhole leak
would be cause for rejection.

Next, they take
a sample glove

From every batch
and pump water into it,

Again checking for leaks.

If the sample glove
is watertight,

They approve the entire batch
for shipment.

They color-code gloves
for strength.

These orange cleaning gloves
are thick and reusable.

Others,
like the medical gloves,

Are for limited use
and disposable.

Each rubber formulation
is customized

For color, strength,
and other characteristics.

It has taken a lot
of fake hands and real ones

To make rubber gloves.

And it all happens very fast.

They manufacture


At this factory.

That's about 12,000 gloves
per hour.

They pack them up
in batches of 100.

A cornstarch solution
applied earlier

Keeps them from sticking
together in the box.

Later, that starch
will also act as a lubricant

To allow the gloves
to slide easily onto hands.

And with that,
these rubber gloves are ready

To protect the public.