How It's Made (2001–…): Season 20, Episode 5 - Replica Clay Pipes/Drinking Fountains/Orange Liqueur/Compound Bows - full transcript

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

Narrator:
LONG BEFORE TRAINS AND BUSES,

THE STAGECOACH TRANSPORTED
PASSENGERS AND GOODS.

THE COACH WOULD TRAVEL
AN ESTABLISHED ROUTE IN STAGES.

BUT OVER TIME,
THE WORD "STAGE" WAS USED

TO DESCRIBE THE COACH ITSELF.

DRAWN BY TWO OR FOUR ANIMALS,

IT RELIED QUITE LITERALLY
ON HORSEPOWER.

LIKE A CLASSIC MOVIE SCENE
COME ALIVE,

SEEING A STAGECOACH IN ACTION
IS A THROWBACK TO A BYGONE ERA.

EVEN TODAY,
BUILDING A STAGECOACH,



HORSE-DRAWN CARRIAGE,
OR COVERED WAGON

BORROWS TECHNIQUES FROM A TIME

WHEN ENGINEERING AND DESIGN
WERE DONE BY HAND.

THE CREATION OF THE STAGECOACH
BEGINS WITH DRAWINGS

DETAILING BOTH THE LOOK
OF THE FINAL PRODUCT

AND ITS EXACT DIMENSIONS.

THEY START WITH CONSTRUCTION
OF THE STAGECOACH BODY.

A WORKER PUTS FRAMING RAILS
FOR THE BACK WALL INTO PLACE

USING A MORTISE
AND A TENON JOINT.

THE FINAL PANEL
SLIDES INTO PLACE,

AND ANOTHER FRAMING RAIL
HOLDS THE END WALL TOGETHER.

THE END WALL IS ADDED

TO OTHER PIECES
OF THE STAGECOACH BODY

THAT HAVE ALREADY
BEEN ASSEMBLED.



THE END WALL HAS RIBBING
FOR ADDED STRENGTH.

ALTHOUGH THE FLOOR
IS PARTIALLY CURVED,

PASSENGERS WILL SIT OR STAND
ON THE PART THAT IS FLAT.

THE COACH MAKER INSERTS THE DOOR
PILLARS INTO THE MORTISE

WITH A FEW TAPS OF A HAMMER.

HE LOWERS THE ROOF BEAM ONTO
THE TOP PART OF THE DOOR PILLARS

AND FASTENS IT
FIRMLY INTO PLACE.

FORGING OF STAGECOACH SUSPENSION
COMPONENTS IS DONE BY HAND.

THE BLACKSMITH BEGINS STRETCHING
THE HEATED BAR OF STEEL

INTO A COMPONENT CALLED A JACK.

HE REPEATEDLY HEATS AND HAMMERS
THE STEEL BAR

UNTIL IT REACHES
THE DESIRED SHAPE.

HE HAMMERS THE TAPERED STEEL BAR
OVER AN ANVIL

TO SHAPE IT INTO A CURVED HOOK.

ONCE THE HOOK BECOMES AN EYE,
HE HAMMERS A PIN INTO IT.

THE BLACKSMITH WRAPS
THE HEATED STEEL AROUND THE PIN

TO FORM A SNUG JOINT.

THE TRANSFORMATION IS DONE

WITHOUT THE HELP
OF PRESSES OR DIES.

IT'S THE BLACKSMITH

WHO ESSENTIALLY SCULPTS
THE METAL BAR

INTO A PIECE THAT HAS
BOTH FUNCTION AND FORM.

THE BLACKSMITH POSITIONS
THE FINISHED AND COOLED JACK

ONTO THE UNDERCARRIAGE

AND ATTACHES IT FIRMLY
INTO PLACE.

THE ASSEMBLY HAS TO WITHSTAND
THE STRESSES

OF THE LEATHER SUSPENSION

USED TO MAKE THE STAGECOACH RIDE
MORE COMFORTABLE FOR PASSENGERS.

USING A CLIP,
THE BLACKSMITH ATTACHES THE STEP

USED TO CLIMB
INTO THE STAGECOACH

TO THE JACK ASSEMBLY.

HE ATTACHES A CLEVIS
TO THE JACK ASSEMBLY.

WITH FOUR JACKS
IN OPPOSING CORNERS,

THE LEATHER SUSPENSION
WILL REST IN THE CLEVISES.

NOW ON TO
THE STAGECOACH INTERIOR.

THE TRIMMER INSPECTS
THE HIDE OF LEATHER.

HE POSITIONS PATTERNS CAREFULLY,

CHOOSING LEATHER CUTS
THAT MATCH.

THEN HE'LL CUT
THE LEATHER PIECES

WITH EACH PATTERN DESIGNATED

FOR A SPECIFIC PART
OF THE STAGECOACH.

HE PLACES THE NEWLY UPHOLSTERED
CUSHION ON THE SEAT BENCH

AND BUCKLES THE RETAINING STRAPS
THAT HOLD IT SECURELY IN PLACE.

IN THE PAINT BOOTH,
THIS PARTICULAR UNDERCARRIAGE

IS GIVEN COATS
OF YELLOW AND BLACK STRIPES.

A WORKER COATS THE RUNNING GEAR
AND WHEELS WITH SEALER

TO WEATHERPROOF
THE UNDERCARRIAGE.

WORKERS GENTLY LOWER THE NEWLY
PAINTED AND UPHOLSTERED WAGON

ONTO THE UNDERCARRIAGE.

THEY CONNECT THE TWO
USING MOUNTING BOLTS.

THEY FIX THE NAME PLATE
TO THE CENTER OF THE REAR AXLE.

TO HELP PROTECT PASSENGERS
FROM THE ELEMENTS,

THIS PARTICULAR MODEL
COMES WITH A ROOF.

WORKERS LOWER THE ROOF POSTS
INTO RECEIVER EYES

AND MAKE SURE
THEY'RE SECURELY ATTACHED.

NEXT, A WORKER POSITIONS
A BRAKE PAD

AGAINST ONE
OF THE REAR WAGON WHEELS.

HE THEN TESTS
THE BRAKE ASSEMBLY.

THE FACE OF THE BRAKE PAD CAN BE
WOOD, STEEL, OR RUBBER,

DEPENDING ON THE VOCATION
OF THE WAGON.

NOW FOR A SUSPENSION TEST.

THE PROCESS THAT BEGAN
WITH RAW LUMBER AND STEEL

ENDS UP ABOUT 1,200 HOURS LATER

WITH A STAGECOACH THAT'S READY
TO HIT THE DUSTY TRAIL.

Narrator:
ROAD REFLECTORS ORIGINATED
IN BRITAIN IN THE 1930s.

A CAT'S EYES REFLECTED
IN HEADLIGHTS ON A FOGGY NIGHT,

ALERTING A DRIVER TO THE FACT

THAT HE WAS
ABOUT TO VEER OFF THE ROAD,

PROVIDED THE FLASH
OF INSPIRATION.

THE DRIVER WENT ON TO INVENT

A MECHANICAL VERSION
OF THE CAT'S EYES --

REFLECTIVE ROAD STUDS.

TODAY'S REFLECTIVE ROAD STUDS

ARE SHINING EXAMPLES
OF INNOVATION.

THESE VERSIONS ARE COMPUTERIZED
AND SOLAR-POWERED,

SO THEY'RE ENERGY EFFICIENT

AND THEY'LL FUNCTION
IN A POWER BLACKOUT.

IT TAKES MORE THAN 20 PARTS
TO MAKE ONE ROAD REFLECTOR.

THE ASSEMBLER
FIRST SOLDERS TWO WIRES

TO THE BACK
OF A SOLAR CIRCUITRY BOARD,

ESTABLISHING A CONNECTION.

SHE FLIPS THE SOLAR
CIRCUITRY BOARD AROUND

AND APPLIES DOUBLE-SIDED TAPE.

SHE PLACES TWO STRIPS OF COPPER

ON CONDUCTIVE PADS
IN THE CORNERS ABOVE THE TAPE.

SHE REMOVES THE BACKING
FROM THE DOUBLE-SIDED TAPE.

USING A VACUUM TOOL,

SHE TRANSFERS THE SOLAR CELL
TO THE TAPE.

ONCE IN PLACE,
SHE TURNS OFF THE VACUUM

AND SMOOTHES THE CELL
TO THE TAPE.

SHE SOLDERS THE COPPER STRIPS
TO THE CONDUCTIVE PADS,

CREATING THE CIRCUITRY.

SHE CONNECTS THE SOLAR PANEL
TO THE BOARD

WITH SHORT, LITTLE WIRES
CALLED JUMPERS.

SHE SLIDES RUBBER PROTECTORS
ONTO THE BOARD.

EACH ROAD REFLECTOR WILL HAVE
TWO OF THESE SOLAR UNITS.

NEXT, SHE ASSEMBLES
THE FLASHING L.E.D. LIGHTS.

SHE SOLDERS WIRES
TO THE BACK PANELS

TO LINK THE LIGHTS
TO THE MAIN COMPUTER BOARD.

SHE THEN APPLIES ADHESIVE
TO THE PANEL

AND PRESSES THE FRAMEWORK
FOR THE L.E.D. LENS TO IT.

SHE INSERTS THE POLYCARBONATE
LENS INTO THE FRAMEWORK,

AND IT CLICKS IN.

THERE ARE TWO L.E.D. LIGHTS
PER ROAD REFLECTOR.

SHE NOW ASSEMBLES THE REFLECTOR.

SHE ANGLES SHINY ALUMINUM FLAPS
TO BOUNCE LIGHT.

SHE TUCKS THE LIGHTS
INTO THE REFLECTOR,

AND THEY ADHERE
TO THE DOUBLE-SIDED TAPE

APPLIED TO THE BASE.

SHE POWERS UP
THE FLASHING LIGHTS

AND CHECKS THE INTENSITY

AND THE EFFECT
OF THE REFLECTIVE FLAPS.

THINGS ARE LOOKING GOOD,
SO NOW SHE INSERTS FOAM

IN A SLOT AT THE CENTER
OF THE ALUMINUM CASING.

SHE PLACES THE REFLECTIVE
LIGHT UNIT ON IT.

SHE INSTALLS A FOAM-WRAPPED
RECHARGEABLE BATTERY

IN A COMPARTMENT
ON ONE SIDE OF THE LIGHTS.

SHE PLACES THE MAIN
COMPUTER BOARD AND SOLAR CELLS

IN THE COMPARTMENT
ON THE OTHER SIDE.

AND THEN A COMPUTER TECHNICIAN
PROGRAMS THE ROAD REFLECTOR

TO INTERFACE WITH A CONTROL
SYSTEM ON THE STREET POLE.

THE REFLECTOR IS NOW READY
TO STOP TRAFFIC

OR AT LEAST SLOW IT DOWN.

A CREW CARVES A SLOT IN THE ROAD

SIZED PRECISELY
FOR THE REFLECTOR.

TO KEEP THE PAVEMENT CLEAN
DURING INSTALLATION,

ONE OF THEM TAPES
THE PERIMETER OF THE HOLE.

HE THEN PUMPS

INDUSTRIAL-STRENGTH EPOXY
INTO IT.

HE INSERTS A CAST-IRON FRAMEWORK
INTO THE EPOXY-FILLED HOLE.

HE WIPES UP THE EPOXY OVERFLOW
AND REMOVES THE TAPE.

ENTRENCHED IN THE PAVEMENT,

THIS CAST-IRON FRAMEWORK
WILL ENCASE THE ROAD REFLECTOR,

ALLOWING IT TO HOLD UP
TO HEAVY TRAFFIC.

HE SCREWS A PROTECTIVE CROSSBAR
OVER THE LIGHTS

AND THEN SECURES
THE ROAD REFLECTOR

TO THE SUPPORT STRUCTURE.

THEY INSTALL THE WIRELESS
COMMUNICATION SYSTEM

ATOP A POLE.

THIS POSITIONS IT
TO ACTIVATE THE ROAD REFLECTORS

WHEN THE CURBSIDE CROSSWALK
BUTTON HAS BEEN PRESSED.

MODERN COMMUNICATIONS TECHNOLOGY

HAS IMPROVED
ON THIS 1930s INVENTION.

TODAY'S ROAD REFLECTOR SYSTEMS
ARE FLASHIER THAN EVER,

DESIGNED TO ATTRACT
A DRIVER'S ATTENTION

AND KEEP IT ON THE ROAD.

Narrator: IN TRIBAL COMMUNITIES
IN THE AMERICAN SOUTHWEST,

POTTERY TAKES SHAPE
MUCH AS IT HAS FOR 2,000 YEARS.

IN THE HANDS OF NATIVE ARTISANS,

MUD BECOMES A COOKING POT
OR A STORAGE VESSEL.

NO POTTERY WHEEL NECESSARY,
NO KILN REQUIRED --

JUST A ROARING CAMPFIRE.

TIMES MAY CHANGE,
BUT IN THE SOUTHWEST,

TRIBAL CULTURE
IS TRUE TO ITS ROOTS,

CREATING POTS THAT LOOK LIKE
ANCIENT ARTIFACTS,

EXCEPT THEY'RE NEW.

CRAFTED FROM LOCAL CLAY,

THE POTS ARE BOTH LIGHTWEIGHT
AND DURABLE,

AND THEIR APPEAL
IS TRULY TIMELESS.

THE POTTER GATHERS HER OWN CLAY.

THIS IS MICACEOUS CLAY FROM
VOLCANIC DEPOSITS IN NEW MEXICO.

SHE ALSO MINES MINERALS
LIKE IRON OXIDE

TO PAINT THE POTTERY.

IN ITS RAW FORM, MICACEOUS CLAY
SPARKLES IN THE SUNLIGHT.

ITS NATURAL GLITTER WILL MAKE
THE FINISHED POTTERY SHIMMER.

SHE PICKS OUT LEAVES
AND TREE ROOTS

BECAUSE ANYTHING ORGANIC
WILL OUTGAS

AND CAUSE THE POTTERY TO CRACK.

SHE TRANSFERS THE CLAY
TO A BUCKET OF WATER.

AFTER THREE OR FOUR DAYS,
IT DISSOLVES,

AND SHE FILTERS IT
TO REMOVE SMALLER CONTAMINANTS.

ONCE THE CLAY THICKENS
TO A GRAVY-LIKE CONSISTENCY,

SHE TRANSFERS IT
TO A FABRIC-LINED MOLD.

SHE LEAVES IT TO SET

AND COAGULATE
TO A DOUGH-LIKE CONSISTENCY.

SHE KNEADS A CHUNK OF IT
TO REMOVE AIR BUBBLES.

SHE THEN SHAPES IT INTO A BOWL.

IT WILL SERVE AS THE BASE
OF A TRADITIONAL STORAGE POT.

SHE SCRAPES THE POT BASE
INSIDE AND OUT

TO THIN IT AS IT DRIES.

THE THINNING PROCESS ALSO WORKS
THE CLAY INTO A HARDER STATE.

SHE MOISTENS THE TIP OF THE BOWL
TO MAKE IT MALLEABLE

AND FLATTENS THE EDGE,

CREATING A FOUNDATION
TO BUILD UP THE POT.

SHE NOW ROLLS
ANOTHER PIECE OF CLAY

INTO A LONG, THIN STRAND

AND COILS IT AROUND THE POT.

SHE BLENDS THE STRAND
INTO THE POT BASE

AND THEN SHAPES IT
TO EXTEND THE POT UPWARD.

THE PROCESS IS CALLED COILING.

SHE CONTINUES
TO BUILD UP THE COILS,

BLENDING THEM UNTIL THEY BECOME
COMPLETELY ENMESHED

AND SEAMLESS
TO THE REST OF THE POT.

AS SHE COILS AND BLENDS,
SHE TURNS THE POT INWARD,

CREATING A SHOULDER
NEAR THE TOP.

SHE SMOOTHES THE LIP
AND THINS THE EXTENSIONS

TO ENSURE THE THICKNESS
IS CONSISTENT.

THIS WILL PREVENT
STRUCTURAL WEAKNESS.

IN THE HANDS A SKILLED ARTISAN,
A LUMP OF CLAY HAS BECOME A POT,

BUT THERE'S MORE WORK
TO BE DONE.

SHE NARROWS THE OPENING.

SHE CUTS THE LIP
IN SIX SYMBOLIC ORIENTATIONS,

REPRESENTING NORTH,
SOUTH, EAST, AND WEST,

THE SKY, AND THE EARTH.

SHE SCALLOPS THE EDGE

IN THE DIRECTION OF THE CUTS
TO ACCENTUATE THEM.

SHE SMOOTHES THE POT
WITH A WET SPONGE.

BEFORE DAWN,
WHEN THE WIND IS LOW,

SHE LIGHTS A FIRE AND PLACES
THE POTS DIRECTLY INTO IT.

SHE STACKS WOOD AROUND THE POTS,
AND FLAMES ENGULF THEM.

THIS CHANGES THE CLAY'S
MOLECULAR STRUCTURE

SO THAT IT CAN NEVER TURN BACK
INTO STICKY MUD.

SHE COVERS THE FIRE
WITH A METAL TUB.

THE FLAMES SUBSIDE,
AND THE POTS COOL.

CURING CLAY OVER AN OPEN FIRE
ISN'T AN EXACT SCIENCE.

HEAT IS UNEVEN,
AND THIS CAUSES FRACTURING.

20% OF THESE CLAY POTS
WILL BE DAMAGED.

SHE EXAMINES THEM CAREFULLY

AND REJECTS ANYTHING
THAT IS NOT INTACT.

IN ADDITION
TO THE MICACEOUS CLAY POTS,

SHE ALSO FIRES
SOME RED CLAY ONES.

SHE PAINTS GEOMETRIC MOTIFS
ONTO THOSE,

USING THE MINERAL PAINTS
SHE'S PREPARED HERSELF.

EACH POT IS ONE OF A KIND.

QUALITY VARIES DEPENDING
ON THE NATURE OF THE CLAY

AND SMOKE PATTERNS
CREATED DURING FIRING.

SHE LEAVES THE POTS MADE
OF MICACEOUS CLAY UNPAINTED

FOR TRADITIONAL REASONS.

SHE SIGNS THE VASE

AND INCLUDES
THE NAME OF HER TRIBE.

SHE TUCKS HER BIOGRAPHICAL
INFORMATION INTO IT.

SHE'S BEEN MAKING POTTERY
SINCE CHILDHOOD.

FROM A HANDFUL OF MUD

TO A STORAGE VESSEL
OR COOKING POT,

SOUTHWEST NATIVE POTTERY

CONTINUES TO BE
A TRIUMPH OF INGENUITY.

Narrator: AS A GROUP,

MOTORCYCLE RIDERS
AREN'T BIG ON CONVENTION.

SO WHEN IT COMES TO THE LOOK
OF THEIR RIDE,

THEY OFTEN GO THEIR OWN WAY.

THE GAS TANK PRESENTS
THE GREATEST OPPORTUNITY

WHEN CUSTOMIZING
THE FACADE OF THE BIKE.

PROMINENT AND UP-FRONT,

THE TANK BOTH FUELS THE RIDE
AND DEFINES IT.

ON A CAR OR TRUCK,

THE GAS TANK IS TUCKED AWAY
OUT OF SIGHT.

BUT ON A MOTORBIKE,
THERE'S NO PLACE TO HIDE IT,

SO YOU MAY AS WELL
JUST SHOW IT OFF.

TO MAKE A CUSTOM GAS TANK,

THE METALWORKER
STARTS WITH A SHEET

OF STURDY COLD-ROLLED STEEL.

HE TRACES AROUND PAPER PATTERNS

TO TRANSFER THEIR OUTLINE
TO THE STEEL.

THERE ARE SEVEN PATTERN PIECES.

THE DESIGN
IS A TAPERED CLASSIC ONE.

HE FOLLOWS THE LINES
WITH AN ELECTRIC METAL SHEAR.

WITH IT, HE CAN PRODUCE
A ROUGH CUT QUICKLY.

HE SWITCHES
TO A LEVER-OPERATED SHEAR

TO TRIM THE PARTS CLEANLY
AND PRECISELY.

HE PHYSICALLY BENDS
ONE PIECE AROUND A TUBE

TO CREATE THE TUNNEL.

THE TUNNEL IS
THE LOWER SECTION OF THE TANK

THAT FITS AROUND THE BACKBONE
PORTION OF THE BIKE FRAME.

HE CUTS THE TUNNEL TO SIZE
ALONG MARKED LINES.

HE DRILLS HOLES IN THE TUNNEL
FOR THE MOUNTING TUBES.

USING THREADED BOLTS
AS GUIDES NOW,

HE POSITIONS THE TWO
MOUNTING TUBES ON THE HOLES

AND WELDS THEM TO THE TUNNEL,
CREATING LEAK-PROOF SEAMS.

WITH RODS ATTACHED AS A MOCKUP
OF THE REST OF THE TANK,

HE TESTS THE FIT TO THE BIKE.

HE CONFIRMS
THE HANDLEBARS MOVE FREELY

AND THAT THERE'S NO INTERFERENCE
WITH THE ENGINE.

NEXT, HE USES AN ENGLISH WHEEL
ON THE TWO TOP PANELS.

HE ROLLS EACH PANEL
BETWEEN TWO WHEELS

TO TAKE THE PROFILE
FROM FLAT TO CURVED.

HE TESTS THE CURVATURE
AGAINST THE MOCKUP RODS.

IT NEEDS TWEAKING.

HE CONTINUES TO SHAPE IT

UNTIL THE CUSTOM GAS-TANK PART
MATCHES THE MOCKUP PERFECTLY.

USING ANOTHER MACHINE NOW,

HE FORMS A STYLISH CURL
ONTO THE EDGES.

THIS WILL ALSO ALLOW
THE TWO PARTS

TO BE JOINED NEATLY AT THE PEAK.

AFTER MARKING THE LOCATION
OF THE FUEL CAP,

HE PUNCHES SMALL HOLES
FOR MOUNTING SCREWS.

HE CUTS OUT THE HOLE
FOR THE GAS CAP.

HE JOINS THE TWO TOP SECTIONS
OF THE CUSTOM GAS TANK

WITH TACK WELDS.

A MORE PERMANENT WELD
WILL COME LATER.

HE DRILLS HOLES FOR MOUNTING

THE TOP PANEL ASSEMBLY TO
THE TUNNEL,

SPACING THEM TO CORRESPOND
WITH THE MOUNTING TUBES.

WITH THE MOCKUP RODS
REMOVED FROM THE TUNNEL,

HE JOINS THE TOP
PANEL ASSEMBLY TO IT.

HE THEN TACK-WELDS THE SIDES

TO THIS CUSTOM
GAS-TANK ASSEMBLY.

HE HAMMERS THE TANK'S FRONT CAP
AGAINST A FORM

TO GIVE THE OUTER EDGES
A ROUNDED PROFILE.

HE SANDS THE PART
AROUND THE EDGES

TO FINE-TUNE THE CONTOURS
AND ENSURE A PERFECT FIT.

HE TACK-WELDS THE FRONT CAP

TO THE REST
OF THE MOTORCYCLE TANK.

AND WITH THE TANK STRUCTURE
COMPLETE,

IT'S TIME TO MAKE IT LEAK-PROOF.

HE DOES A FULL PENETRATION WELD
ON EVERY SEAM.

USING A PNEUMATIC TOOL,

HE SANDS THE SEAM SMOOTH
AND FLAT.

HE THEN SANDS THE REST
OF THE TANK BY HAND

TO MAKE THE ENTIRE SURFACE
UNIFORM.

HE POSITIONS
THE TANK ON THE BIKE.

AFTER EQUIPPING THE GAS CAP
WITH A GASKET,

HE SCREWS IT TIGHTLY
TO THE CUSTOM TANK.

USING MOUNTING SCREWS
AND WING NUTS,

HE SECURES THE TANK
TO THE BIKE FRAME.

THIS CUSTOM GAS TANK
NOW BECOMES A CANVAS.

HE PAINTS IT
AND APPLIES SILVER BORDERS

AND GRAPHICS REQUESTED
BY THE CUSTOMER.

HE CONNECTS THE TANK
TO THE CARBURETOR,

AND THIS BIKE IS READY
TO SHOW OFF ITS NEW CUSTOM LOOK.

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