How It's Made - London Taxis

With curved lines and classic styling, The black cabs of london Are internationally recognized as british icons. Many say the london taxi system is the best in the world, And for many london visitors, A taxi ride is more than just transportation -- It's a tourist attraction unto itself. The modern black cab was born in 1948. Today, there are about 20,000 black cabs On the streets of london. Because the taxi can easily be driven 30,000 miles each year, The cars need to be robust. To start, operators position steel panels into a press That uses hydraulics and air pressure to fold them.

The press can apply up to 800 tons of force To fold and form each chassis component. Once they get their 3-dimensional shape, The supple panels become stiff side rails. Welders then assemble two side rail with a cruciform To create the chassis assembly. They clamp the side rails firmly in place before welding them. The taxi uses a 4-cylinder, direct-injection, Turbodiesel engine that is hoisted in with the gearbox. Then they connect the radiator
hoses and pipes to the engine. The axles, wheels, suspension, and exhaust system Are now in place.

To build the components of the taxi's body, Welders assemble sheet metal using a spot welder. The device has two copper electrodes That clamp the sheets together And concentrate electric current into a small spot. Forcing a large current through the spot Melts the metal and forms the weld. Now it's time to assemble the taxi's sides and floor. Since the floor is completely flat and the roof is high, Passengers with reduced mobility Can easily enter and exit the taxi. The body has been covered With an anticorrosion coat and a gray primer.

Before the car gets its final color, A worker inspects it for any surface damage. Infrared lamps warm the body shell to 122 degrees fahrenheit To make paint application easier. Not all london taxis are black. They spray this one with yellow paint. Later, they apply a shiny clear coat. Each painted car moves to the polishing room. The bright lights allow the technicians To check for any dirt, runs, dry spray, or other paint defects As they carefully polish the car. A worker bolts the hire sign to the roof. A rubber seal prevents water leaks.

They carry the front windshield with rubber suction pads And carefully put it in place. They seal the rubber sides to ensure they are watertight. The body is covered with plastic casing to protect it from damage As it's hoisted down onto the chassis. Although these taxis are large and roomy, Their mandatory 28-foot curb-to-curb turning circle Allows them to easily perform u-turns. A driver tests the car at different speeds, Changing gears, and testing the a.B.S. Brakes. Each taxi also undergoes a water test. They check for leaks through the glass and around the doors. With an access ramp and fold-down seats, It's easy for wheelchairs to board the taxi. The taxi offers enough space for five seated passengers. It takes about two weeks to build a taxi. Then it's off to navigate the streets of london.

How It's Made: Seasons 1 & 2 (2010)

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How It's Made - Rocking Horses

The ancestors of toy rocking horses May be the wooden horses on wheels of the middle ages, On which knights would practice their jousting skills. Child-sized wooden horses on bow-shaped rockers Emerged in England and germany in the 1700s, When queen victoria famously had dapple-gray rocking horses Made for her children. This rocking-horse company in the u.K. Handcrafts antique reproductions and originals. Some have
traditional bow rockers, But most glide back and forth on a safety stand. The horses are made of durable hardwoods, Such as oak, maple, and tulipwood.

After cutting off knots and other defects, Workers run each piece through a ripsaw, Slicing off the rough and discolored wood Directly under the bar. Then they cut the pieces into 12-inch-wide blocks, And with a planer, slice off a thin layer of wood. This makes the surfaces nice and smooth. These are the blocks With which they'll construct the horse's main body. To make the legs, an artisan Lays a template on an as-yet-unplaned piece of wood And traces it. Then he cuts along the trace line with a band saw And runs the leg through the planer. Each leg has a protruding piece on top called a tenon That fits into a slot called a mortise beneath the main body.

To build the body, they roll glue onto the body blocks And assemble one to the other, Building a large rectangular box with a hole at the center. This hole reduces the horse's weight And relieves structural stress. In some models, the hole Also serves as a secret locking compartment. After clamping the assembly and letting it set for 24 hours, They coat each leg tenon with glue And insert it into a mortise. After rough-carving the body, A highly skilled craftsman Outlines the head features in pencil -- Cheekbones, nostrils, eyes, teeth. Then he begins the meticulous task Of carving the horse to completion, Hitting a mallet against a u-shaped gouge.

This painstaking carving process takes 2 to 3 days. Now, after inserting a glass eye, He rough-files the whole horse Using a rasp to remove all the gouge marks. This takes another few hours. Then he smoothes the entire surface With an electric sander four times over, Using progressively finer sandpapers. He does the final sanding touch-ups by hand. The wood is now ready to be either stained Or painted to the customer's specifications. If it's the latter, The artist first applies a coat of water-based primer, Then, for this client's custom order, A coat of light-blue paint that turns gray when varnished.

Once the background color dries, he hand-stipples a pattern. After the surface is varnished and waxed, He dresses the horse in a suede saddle blanket. He uses brass tacks to affix it along the leather trim. Next, he nails the leather saddle in place. He squeezes globs of glue Into a slot running down the horse's neck And inserts the mane, a weft of genuine horsehair. Then he nails it in place. Now he applies glue to the tail hole and fits a tail,
Also made of real horsehair. Now they begin constructing the safety stand, On which the rocking horse will glide. To make the posts, They turn cylindrical blocks of wood on a lathe. Then they assemble the posts to the other parts of the stand And stain the wood.

They apply two coats of varnish And let the stand dry overnight. They install the stand's stained and varnished gliders And mount the horse. They drill a hole through each hoof and glider, Then join them with a nut and bolt. The gliders connect to the front and back of the frame With plated steel swing irons. The angle at which the irons are set Ensures a continuous smooth glide. So even though these rocking horses Are built to withstand the weight of two adults, Riding them is child's play.

How It's Made - Traffic Cone Dispensers

Traffic cones create a necessary diversion. They keep drivers away from dangerous situations. But sending workers out onto the highway To set up those cones can be a perilous job. Now there's an automated  machine That both dispenses and collects cones To keep everyone out of harm's way. The automated traffic cone dispenser Goes where some might fear to tread -- The middle of the highway. Its robotic arm swings back and forth For a speedy deployment of traffic cones. To make one, workers slide three big metal disks Onto a shaft and space them evenly apart. They pull a string from disk to disk To confirm all three are aligned. Once they're in place, A worker welds the disks to the shaft. They reinforce this installation job with several braces, Welding five to each disk at the point where it meets the shaft.

They spin the shaft and inspect the work. Next, they install the tracks That will shuttle the traffic cones to the robotic arm. They weld 13 of them to the disks. The framework for the automatic traffic cone dispenser Is now complete, so it's over to the paint booth. They prime and paint it bright yellow, So it will be clearly visible on the highway. Here, a technician Then assembles the main control panel. It's the brains behind the cone-dispensing robot. The technician connects cables That deliver power to the motors. He installs a series of switches and relays That will activate the motors that rotate the drum, Swing the robotic arm, and deliver the traffic cones. Finally, he tests
the circuit breakers To confirm that all systems are go.

Down the production line, This worker attaches the gripper to the arm. A pivot bolt allows the gripper to open and close, And this chain will keep it pointed downward, So it's always in position to deploy a traffic cone. He tightens the turnbuckles and then checks the chain's tension. He swings the arm to confirm That it and the gripper move freely. Now he installs the transmission For the motor that will move this robotic arm. Finally, he snaps a retainer ring Onto the transmission shaft. Two workers then carry a heavy extender mechanism Over to the gripper arm and bolt the mechanism to it. This extender will both support the arm And allow it to move easily From one side of the dispenser to the other.

A sensor device, called an encoder, Will keep track of the gripper arm's position when it's moving. The technician then installs the motor That will power the gripper arm To oscillate and deploy the traffic cones. Once the gripper arm has been attached to the cone dispenser, They mount the whole unit on a trailer, With the main control box on the front. They adjust the settings for traffic-cone deployment And put the machine through all its paces. This test run ensures that all the parts Are functioning properly. A technician tweaks the machine's computer program To fine-tune the drop-off coordinates.

After all, releasing the cones too soon Could cause them to topple. Every automatic cone dispenser Undergoes a road test on the open highway To confirm that it will perform in real conditions. The driver activates it from the safety of the truck cab, While the robotic system is at center line, Doing all the lifting and taking all the risks. If they find a problem now, They'll send it back to the factory for modifications, But this machine handles the drop-offs and pickups With precision, And that means it's ready for traffic duty.

How It's Made - Replica Foods

This meal may look delicious, But it actually tastes like plastic. This is fake food. It's not for tasting -- it's for tempting. Restaurants and food stores Use these imitations to entice customers. Fake food is also used as props in movies and tv Because the camera loves it. This fake food will keep that fresh-cooked look forever. That means there will be no waste From the restaurant display case. These authentic-looking fakes start out with the real thing.
In this case, it's a sea bass. The worker blots up excess oil from the skin. He then uses an adhesive to glue the fish To the base of a wooden box. Next, he immerses the fish in liquid silicone. 24 hours later, after the silicone is set, He breaks open the box and removes the fish.

This detailed silicone negative Can now be used to mold exact replicas of the original fish. They preheat the mold until it's warm to the touch. This kick-starts the curing of this liquid plastic, Which they pour into the mold. Once the mold is filled, They zap it in a microwave oven for 45 seconds. It solidifies the plastic significantly, But it still needs a bit more curing, So the worker transfers it to a conveyor. It carries the mold under a lamp, Whose intense energy completes the curing of the plastic. The worker now extracts the mold and plastic replica. Spillover from the molding has created a few ragged edges, So he trims them with a pair of scissors... ...Then grinds the edges to smooth away the rest. He also uses the grinder to do some contouring.

Now for the real artistry. The worker sprays silvery paint onto the plastic bass. It gives the fish scales a lifelike, luminous texture. A bit of dark-gray paint Brings out the silvery undercoat. Brown paint on the tail and fins make them look more realistic. Using an artist's brush, he paints the eyes. He brushes on fine lines that look like natural creases And adds some other typical sea-bass markings. A coat of lacquer keeps the paint from chipping And makes the sea bass look moist. Now the sea bass Will always look like the catch of the day. And unlike a real fish, it won't start to decompose. At this faux-food factory, there are 3,500 molds. Each one can be used hundreds of times And will produce an exact copy of the original every time.

For things like meat and potatoes, They add color to the liquid plastic Before they do the molding. This reduces the amount of painting They'll need to do later. It takes some trial and error to get the pigments just right, But when they do, this fake meal looks good enough to eat. They drizzle the beef and side dishes with gravy-colored glue That makes the fake food adhere to the plate. Now that they've pulled this meal together, It should never come  apart. It takes a couple of days to produce all these dishes, But it should be worth it because, compared to real food, It will last forever.

How It's Made: Seasons 1 & 2 (2010)

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How It's Made - Luxury sports cars

Luxury sports cars Are coveted by people around the world, And with good reason. The extraordinary skills and materials That go into making them Were developed from a long racing heritage. Each one of these automobiles Is born from expert craftsmanship And a passion for racing. Underneath the beautiful exterior of these cars Lie a chassis and power train Capable of delivering remarkable performance. The aluminum frame is engineered
to be lightweight, yet rigid, And provide crumple zones That can evenly distribute force in the event of an impact. It takes highly skilled technicians To perform these complex welds.

On the factory floor, robots transport the body panels That will later be fitted onto the chassis. Once the frame is completed, Technicians use a pneumatic hoist To position and attach exterior panels and doors. Door panel cutouts reduce the car's weight While retaining a high degree of structural integrity. The elongated cutouts on this model Will house its stylized headlights. Next, they coat the car in a compound Which fluoresces under a special lighting system. This helps technicians detect any minute imperfections. These imperfections are then filed down by hand. Here, a robot fully immerses and rotates the chassis In a galvanizing solution that prevents corrosion.

Once the body has been primed, It passes through a device that dusts off the entire body With ostrich-feather brushes. Next stop, the paint room, Where robots spray the car body With a smooth, even coat of paint. Once the paint dries and cures, The robots apply several coats of varnish. The final step in body prep is a meticulous waxing by hand To remove any remaining blemishes. Moving on to the chassis, a technician uses a hoist To position and fasten the engine and gearbox in place. Here, robots transport the completed power train To the assembly area... Where an automatic crane Gently lowers the car body onto the chassis, Which includes the fully assembled suspension, Gearbox, and engine. This step is known as the marriage.

Next, a worker installs the wheels With some help from a hydraulic lifting system. At the next station, Technicians test all the dashboard components. This vehicle features a combination Of analog and digital displays. A master computer Runs the electronics and information systems. Again with the help of the crane, Technicians install the finished dashboard. The next step is the steering wheel. Assisted by a special assembly jig, A technician positions And tightens it onto the steering column. Workers lower the trunk cover And convertible hardtop into position, Which is particular to this model of car. A worker double-checks the installation Of the hydraulic mechanism.

This beautiful road machine Is the culmination of years of racing history, Modern engineering, and dedicated craftsmanship. Now watch this. This is one of the few cars That features a fully automated convertible hardtop. This beauty is now ready for the sun, wind, And the open road. If you have any comments about the show, Or if you'd like to suggest topics for future shows, Drop us a line at...

How It's Made - Leather Bike Saddles

Leather bike saddles Feature a leather top suspended on a metal frame. With time and use, the leather molds itself To perfectly suit the rider's anatomy And their cycling style. And just like a pair of leather shoes, The saddle becomes very comfortable. Leather bike saddles look almost the same As they did 100 years ago. They are still made by hand And by some machinery that is sometimes over 60 years old. Saddles are made exclusively of metal and leather, Traditional materials that retain The style and quality of the early days. The first step is making the steel wire springs For saddles that have a suspension. The machine coils and cuts the wire to the proper length. Liquid lubricant keeps everything running smoothly.

Depending on the saddle's model, some springs are then chromed. This machine folds and curls steel or titanium wire To form brackets. It's adjustable, So it can make brackets of different sizes and shapes, Depending on the model being produced. A technician assembles the springs and brackets To form the saddle's frame. He attaches the clamp so that the saddle Can be attached to the bicycle's seat post. Saddles come in different sizes and shapes, With or without suspension springs To accommodate various riding styles -- Racing, mountain biking, or city commuting. Now for the saddle's leather top. Using a hydraulic clicking press, The worker cuts the leather with a sharp blade.

The blade cuts ventilation holes at the same time. Tanneries provide leather in any color required by the factory. After the tops are cut, They soak in tepid water for 20 minutes to an hour, Until the leather is completely saturated. The wet leather top then goes to a press, Which applies 2,000 pounds of pressure per square inch. Using a leather cushion, The technician pads the leather piece To help reinforce the shape, Especially in the narrow front end. Because the top is wet, It retains the shape and does not bounce back. They carefully sand the leather to get a smooth edge.

The tops now go into the oven for three hours At a maximum temperature of 130 degrees fahrenheit. Now they're ready for the finishing process. A worker rivets a name plate to the rear of the saddle... ...Then stamps a trademark on each side. Each saddle model has its own trademark. They attach the nose to the front of the saddle Using solid copper rivets. They hammer each one down carefully To follow the contours of the leather without scratching it. This machine now rivets the frame to the back of the saddle. They insert a tension pin between the frame and the nose. This pin will allow the rider to adjust his saddle If the leather starts sagging after a few years. It takes about three days to make a leather bike saddle. And with careful care, It can be used for years to come.

How It's Made - Rock climbing Gear

Rock-climbing is no pastime for the faint-hearted. Scaling natural rock formations or manmade rock walls Requires a certain fearlessness, Along with good physical conditioning, Balance, agility, And you must be well-trained in climbing techniques And use specialized equipment. Climbers usually work in pairs, Using a system of ropes and other devices To catch them if they fall. A key piece of gear is the spring-loaded camming device.
The climber pulls the trigger to contract the cams And position it in a crack Then releases the trigger to expand the cams, Which securely grip the rock on either side, Then attaches a rope through a device called a carabiner. Climbers typically carry several types and sizes of cams, Carabiners, and other devices.

The equipment must be as lightweight as possible, Yet, at the same time, Strong enough to save a falling climber. Which is why this manufacturer uses aircraft-grade aluminum. To make carabiners, Automated saws cut  aluminum bars into pieces the required length. Then a bending machine forces each piece around a form In the basic shape of the carabiner. Carabiners come in various sizes and shapes. Workers simply mount the appropriate form on the machine.  Next, they place the roughly formed carabiner onto a hot die. Another die slams down on it with up to 800 tons of force, Forging the final shape.

Then the most critical part of the manufacturing process -- A multi-phase heat treatment To harden and strengthen the aluminum. Next, they use a clipping press To slice off excess metal along the perimeter. This leaves rough edges, Which they now smooth out using an abrasion process. The carabiners go into a vibrating tub, Where they rub against porcelain chips for the next 20 hours. Next, workers drill holes for the rivets On which the spring- loaded  opening mechanism will hinge. That mechanism, called the gate, Has channels which align with these holes. Assemblers slide a spring and spring-pusher into the gate, Then insert the rivets through the aligned holes and channels. A riveting machine locks each rivet in place By rounding and widening the head.

Then they adjust the carabiner's frame Until the alignment is perfect. After a thorough inspection, A laser etching machine inscribes product information And a unique serial number. Random samples undergo strength and other quality-control tests. Elsewhere in the factory, Camming device production is under way. Computer-guided equipment machines the same aluminum alloy To a preliminary shape, Saws off slices, Then machines each slice to the final shape of a cam. An assembler attaches a wire to each cam... Then takes four cams and joins their wires To the trigger wires with a metal crimp. The cams, by this point, are different colors. That's because they've undergone chemical treatment To make them corrosion-resistant.

This process can, in fact, produce various colors. So, at the same time, The company can color-code the different models. As assembly continues, they thread the cams Onto an axle-like component called the spindle, Positioning a spring in between each cam. The springs provide the resistance required To expand and retract the device. A cone-shaped washer on each end of the spindle Holds everything together. This time, the riveting machine locks in the components By flattening and widening the end of the spindle To fill the hole in the washer. With that, the camming device is finished. This is how camming devices, carabiners, And other climbing gear all work together To catch climbers who lose their foothold. Not only do they keep the climber safe, They also protect nature, Because they attach to the rock face Without damaging it in any way.

How It's Made - Pipes

When christopher columbus discovered the americas, He also discovered the tobacco pipe. The pipe was an important part of native culture To be shared during times of negotiation and celebration. Columbus and other explorers brought the concept home, And the rest is history. Since the 19th century, pipes have been made from briar, A hard, fire-resistant wood From the root of a mediterranean heather shrub. After the briar has cured for several months, The pipe-maker saws it into a rough pipe shape. Using a lathe and chisel, he rounds the larger block To approximate the shape of the pipe bowl.

He bores through the center To carve out the tobacco chamber. Then he slims down the stem, Marking the center for drilling later. The pipe-maker finalizes the shape by hand. He now sands both the inside of the tobacco chamber... ...And the outside of the pipe bowl. Next, the pipe's mouthpiece takes shape. The pipe-maker pierces a piece of hardened rubber Called vulcanite to establish the center And then drills a channel through it.
Using a grindstone, he sculpts one end, Taking it from round to oval, A shape that fits more comfortably Between the lips.

He checks his work with a sizing template... Then shaves the exterior of the mouthpiece, Reducing it considerably. He shapes the other end to form the tenon, Which fits into the pipe stem. He polishes the tenon with a special compound. The smoother surface makes this part easier To join to the pipe stem. Using a series of sanding disks with progressively finer grit, He gives the exterior of the mouthpiece a sleek finish. Then he steadies it in a clamp And widens the hole in the center of the mouthpiece To broaden it into a funnel-shaped cavity. Attention now turns to the seam Between the rubber and wood parts.

He sands it to make them perfectly flush. Hand-filing removes blemishes And adjusts the thickness for a more comfortable bite. The thickness can be customized for individual preferences. He drills a tiny hole into the top of the mouthpiece... ...Then dips a thin plastic rod in glue And inserts it in the hole. He sands it down, leaving a white spot, A marker that indicates the mouthpiece is right-side-up. For bent or curved pipes, The mouthpieces are heated in an oven at 320 degrees fahrenheit. This makes the vulcanite flexible enough To be shaped by hand. The pipe-maker bends the mouthpiece to the desired shape, And a quick cool-down in water re-hardens the vulcanite, Fixing its curve.

Next, he buffs the wooden part of the pipe. This removes fine scratches and brings out the wood grain. It also gives the wood a glossy finish. But for a different finish, A craftsman sand-blasts the briar wood, Giving it a ripple texture. He stains it darker with an alcohol-based dye, Working the stain into every crevice. And now for a neat trick. He sets it on fire, And the alcohol burns off to set the stain. The pipe doesn't go up in flames, Proving it's truly fire-resistant. He burns up to 10 layers of stain into the pipe, Depending on the effect he's trying to achieve. Finally, he stamps the company name And other information into the pipe.  After a final quality inspection, This handcrafted briar pipe Is on its way to making a statement at the country club.

How It's Made - Hurricane proof shutters

Hurricane-proof shutters Prevent violent winds and flying debris From shattering windows. Not only can breaking glass cause injury And let winds enter and wreak destruction inside, But the difference between indoor and outdoor air pressure Can cause the roof and walls to collapse. Roll-down shutters move vertically... Whereas accordion shutters Consist of two sections that move sideways. To make the accordion style, They cut stacks of blades to the height of the customer's window. Blades are interlocking aluminum strips Manufactured for the shutter factory by a supplier.

Workers assemble enough to build two shutter sections That cover the width of the window. These two sections are called vertical stacks. They punch holes in the last blade of each stack For a locking mechanism. These two blades are called center mates Because they overlap at the center of the window And lock together. They slide each center mate into its respective vertical stack. The next step is attaching nylon bushings and wheels, Which ride in horizontal tracks Installed at the top and bottom of the window opening. Each center mate has vertical locking pins. Activated by a thumbscrew, These pins slide through a hole in the track To lock the shutter open or closed. The horizontal slats of a roll-down shutter Are made of the same material As the accordion shutter's vertical blades.

After cutting the slats to the width of the customer's window, Workers assemble enough to cover the window's height. These slats have a different type of interlock Than the accordion shutter blades, But they connect the same way. The tongue edge of one blade Slides into the groove edge of the next. Nylon locks prevent the slats from disconnecting. After hammering the locks into place, They crimp the edge of each slat. The connected slats will later be coiled Around a motorized tube inside the shutter's aluminum housing. A technician installs a ball-bearing assembly In one side of that housing... Then a safety plate To prevent the slat roll from shifting sideways.

On the other side, they install a plate with protruding screws To which they mount the motor. Next, they install a safety plate to prevent the slats From catching on the motor's power cord. On each end of the motor, they fit spacers......Then, over the motor, a roller tube. They insert a connecting shaft, which attaches the tube To the ball-bearing assembly on the other side. All these steps assemble a motorized axle Around which the roll of slats
will wrap. Once a quality-control check ensures It operates flawlessly... They close off the back of the housing with an aluminum cover.

Working from the front of the housing, They rivet plastic rings along the length of the tube. These help muffle the noise the slats make As they roll and unroll. Workers rivet slat hangers to the roller tube. They slide the first slat onto these hangers. Then they slide the slat roll onto that first slat. The slat edges run in vertical side rails, Which installers mount in the window opening. Now for a last round of quality-control testing. Workers lift and lower the shutter in manual mode, As well as by remote control. When everything works perfectly, The shutters are subjected to one final test To ensure they can handle everything That a hurricane can muster.

How It's Made - Greenhouse Tomatoes

Some of the finest tomatoes Come not from the field, but from the greenhouse. When cultivating tomatoes indoors, Producers can strictly control the growing conditions, So greenhouse tomatoes are more uniform In size, shape, and color than field-grown tomatoes. Some would argue that they taste better, too. This company grows large cluster type And smaller cocktail-size tomatoes. It also produces a kit containing tomatoes, A pouch of italian spices, and a bruschetta recipe. In this hydroponic greenhouse, The tomato plants grow in a substrate rather than soil. The substrate is a block of coconut-shell fibers That retains and drains water very well.

Greenhouse workers mix fertilizer Primarily out of powdered iron and calcium nitrate. They dissolve these and additional chemicals in water, Which they then dilute and store in tanks. Computerized fertilizer injectors Shoot controlled amounts of the solution Directly into the irrigation-system water supply. A new tomato plant takes 30 to 55 days to blossom, Then another 8 weeks to produce fully ripened fruit. Each plant receives Up to one gallon of fertilized water per day Via an irrigation dripper. The irrigation system collects Whatever the plant doesn't absorb, Mixes it with fresh water, adjusts the fertilization, Then re-feeds it to the plants.

The task of pollination Is left to a resident colony of bumblebees. The plants grow at an astounding rate of 8 to 12 inches per week. To train them upright So they won't get tangled with neighboring plants, Workers twist each one around a nylon cord every week. Tomato plants grow to a height of more than 36 feet. That's taller than the greenhouse, Which is why, once a week, Workers lower the plants by 8 inches. The lowering process also lines them up at the same height, Which makes harvesting much easier. The greenhouse temperature Is 70 to 77 degrees fahrenheit during the day And 54 to 61 degrees at night.

Artificial lighting simulates 18-hour stretches of sunshine. Thanks to these controlled growing conditions, Greenhouse tomato plants, unlike field plants, Are in continuous bloom. Every week, A new cluster appears at the top of each plant, While a cluster at the bottom is ready for picking. In its one-year lifetime, A tomato plant yields some 200 large tomatoes Or 500 cocktail tomatoes. As conveyor belts move the tomatoes Through the packaging area, Workers separate the green ones from the ripe ones. Each shipping box must contain 11 pounds. Workers place the box on a tray scale And clusters of tomatoes on digital scales above it.

A computer calculates Which combination of clusters would total the target weight, Then illuminates the light under those clusters To tell the packer which ones to put in the box. Once filled, the box is passed Through an automated labeling machine. A camera takes a photo of the configuration, Then guides an applicator To slap a code sticker on every tomato. Besides selling bulk tomatoes in the bruschetta kit, This company packages cocktail
tomatoes in two formats -- Loose and still on the vine... ...Giving greenhouse-tomato lovers a few tasty options.

How It's Made - Traditional Bookbinding

Today's books are mass-produced By automated equipment, But before the industry was mechanized, Book pages were hand-bound, Their covers meticulously hand-crafted One at a time by talented book binders. This skilled trade still exists, but is now a specialty service. Book binders are part artist, part restorer, Because they craft new bindings, yet also repair originals. Before rebinding a book, the book binder has to unbind it. She uses a surgical scalpel To cut the strands of old binding thread. This separates the covers and the sections of assembled paged, Called signatures. Using a paper cutter, she trims the components Just enough to make their edges neat and smooth. Then she positions the signatures in a vice, Sandwiched between cardboard for support.

She draws lines across what will be the spine of the book. Then she carefully saws a groove in each line. The groove is just big enough To fit a piece of hemp binding cord. One at a time, She reconnects the signatures on a sewing frame. The frame has binding cords That correspond to the grooves she sawed into the signatures. She sews a linen thread horizontally, Looping it around the cords. A chain stitch on each end Links each signature
to the neighboring one. When she's done, she coats the sewn area with glue. She then lays a thin cloth backing over the glue, Then closes the vice tightly to round the back And form joints into which the book's covers will fit. She perfects the joints using a hammer. Next, she weaves the binding's headband By wrapping threads around support sticks In a specific pattern.

She does this on both the top Of bottom of what will be the book's spine. Next, by folding and gluing pieces of paper, She constructs a tube the exact width and length of the spine. She glues the tube to the spine. Now for the book's front cover. She layers pieces of cardboard to create a design, Then glues it onto a rectangular piece of leather. She presses the leather against the cardboard With a plastic tool called a bone folder. Next, she cuts a strip of thick paper The width of the book spine And glues small bands across it. Then she glues this onto the leather, Right next to the cardboard. Using the bone folder again, she presses the leather down.

After adding a second cardboard for the back cover, She glues and folds over the edges. Then she makes two swift incisions To remove a triangle of leather. This produces perfect corners every time. Next step -- to embellish the cover and spine With gold-embossed decorations and lettering. She lays down a sheet of genuine gold foil And hot-stamps the design onto the surface. After attaching the bound pages With leather hinges that match the cover, The book binder applies the finishing touch -- Decorative paper on the inside covers. From such traditional styles to ultramodern fish-skin bindings, It's hard not to judge these books by their covers.

How It's Made - Flight Simulators

Most hands-on pilot training occurs not in the air, But on the ground. The classroom in which this instruction takes place Is a flight simulator -- A high-tech replica of the aircraft cockpit. Through the magic of sophisticated computer software, The simulator mimics the process and feel of flying the aircraft. The flight simulator can produce darkness or daylight, Clear or stormy weather, Or an emergency such as engine failure
Or a runway tire blowout. Simulators are modeled after specific aircraft, Such as a boeing 737.

The simulator manufacturer buys the technical data From the aircraft manufacturer So it can build a cockpit Which is an exact replica in both look and feel. After assembling a steel frame And building the instructor's station behind the cockpit, They mount a sound system beneath the cockpit. This enables crew communication And produces realistic aircraft and weather sounds. A computer-driven image generator Produces the cockpit view
on a large, spherical mirror Made of a thin polyester film. A vacuum pump sucks it flat and wrinkle-free.

The image reflecting on the mirror creates the illusion Of the infinite view pilots have in a real aircraft. The image generator doesn't send the visuals Directly to the spherical mirror facing the pilots. A projector first shoots the image Onto a flat, rectangular mirror that reflects the image Onto a front projection screen -- That round part at the top. The image on the projection screen then reflects In the spherical mirror in front of the pilots. This diagram illustrates how the image travels. Technicians prepare the cockpit throttles, Adjusting the lever tension To be identical to that of the real aircraft. Inside each throttle, they check the thrust reverser That pilots activate upon touchdown To reverse air flow and stop the plane.

Next come the control panels, With all the buttons and switches to operate everything From the engines to the air-conditioning to the lights. Next, the motion actuators -- Giant legs which move the cockpit. They attach to a concrete slab with jumbo bolts. Technicians attach conduits Through which electrical cables and air hoses run To the actuators. The motion is electropneumatic, Meaning that air assists the electric motor That moves the legs.
To attach the actuators, Technicians activate the brake inside each one. This enables the leg to stretch far enough to reach the base. After checking the alignment with this tool... ...They insert a pin.

Then they test the movement of the entire apparatus. The test pilot runs the finished flight simulator Through different maneuvers To ensure it performs perfectly. The image generator is run by highly sophisticated software. It knows the design of every airport in the world, Enabling the instructor To conjure up any scenario imaginable... Takeoffs, landings, and taxiing at a specific airport, Any weather conditions or runway hazards, Or any unforeseen events, such as a blackout That plunges the entire airport into darkness. Faking it doesn't get any more real than this.

How It's Made - Parquetry

Parquetry was invented In France in the 1600s as an alternative To high-maintenance marble flooring. It's made from small pieces of wood Bonded together in a geometric pattern. The most common motif is squares. But it also comes in other patterns, Such as herringbone, lozenges, and triangles. Parquetry can be made of laminate or plywood. However, the best-quality flooring Is made from genuine wood, such as oak, maple, or yellow birch. The factory first cuts the wood into planks, Measuring 2 to 5 inches wide by about a yard long. A drum saw then cuts each plank Into 6 blocks about 6 inches long While an inspector discards any misshapen ones.

The blocks then move through a planer That shaves a fine layer off both sides. This reduces the blocks to a thickness of just under an inch And smoothes the top and bottom surfaces. Next, the blocks run through a saw With 10 blades that slice them into strips Measuring .3 inches wide by 6.2 inches long. Quality controllers remove any strips With inconsistent thickness, Which are usually the ones cut from the block's extremities. The good strips continue on to another area, Where they undergo a more thorough Quality-control inspection.

A worker checks the tops and bottoms, Then lines them up on a conveyor belt good-side up. She also discards any substandard strips That may have slipped past the first inspection. The conveyor belt then flips the strips over. This positions the strips underside facing upward. Saws then cut two parallel grooves through them. These grooves are set .9 inches in from the edge... ...And are just deep enough to hold a thin aluminum wire That'll connect strips together to form tiles. The next machine dispenses the parallel wires. A wheel pushes the wires deep inside their respective grooves. After every seven strips, The machine cuts the wires and starts new ones.

The 7-length strips form a 6-inch-square tile. An end-matching machine now squares each tile So that the four corners are precisely 90 degrees. Then it carves tongues on two of the tile's edges And grooves into the other two. Four tile feeders then drop tiles into an assembly machine That inserts the tongues into the grooves. The machine then applies hot glue Which bonds the four tiles into one larger tile Measuring 12x12 inches. The tiles are now ready for varnishing. Feeders drop them onto the automated varnishing line. The tile surface gets a sanding.

Rollers then apply an even coat of varnish. From there, the tiles immediately pass under Ultraviolet light. This dries the varnish within a second. Then the process repeats three more times For a total of four coats of varnish. Workers then stack them in 10s, At the same time doing a final inspection And discarding any tile that has a less-than-perfect finish. On the packaging line, Each stack gets a label and clear plastic wrapping. An oven shrinks the plastic tightly around the tiles. Those four coats of varnish made this parquetry superdurable, And because it's real wood, When the many years of wear do begin to show, You can simply refinish the floor to its original splendor.

How It's Made - Racing Wheelchairs

World war ii veterans disabled in combat Were the first to race in wheelchairs. But those chairs were clunky, steel models. Fast-forward to today and wheelchair racing Is a serious sport with aerodynamic chairs. These chairs have elongated mainframes And three wheels instead of four. This modern racing chair is tailored To the athlete's physique, specific disability, And skill level. They begin by taking detailed measurements of the athlete As she sits in a demo chair. They measure the width and height of her knees To determine the best seating position. They check the balance point To decide how the rear-wheel axle should be positioned, And they measure her arms so push rims can be sized for her. They then produce a digital drawing Of the racing wheelchair, Complete with any extras requested by the athlete. The fabricator selects the appropriate aluminum tubing And cuts it to the desired length.

This one will be the main tube for the racing chair's frame. Rollers curve the tube slightly at one end So the framework will accommodate the seat. A press then flattens the tube quite a bit. This stiffens the metal And will make the racing-chair frame more aerodynamic. This small tube, which they weld to the main tube, Will hold the racing chair's steering fork. He now tapes a steering mechanism for the front wheel Onto the framework And confirms that its placement is exact before welding. This device will keep the front wheel on autopilot, Freeing the racer's hands to push the rear wheels.

The welder now positions the other end of the main tube Perpendicular to the wheel axle. He inches the tube towards the center of the axle Until it's right on the mark. He welds the axle to the main tube, Giving the framework a "t" profile. Temporary wheels lift the axle So he can install the seat frame. Then, a hydraulic machine bends an aluminum tube Into a "u" shape to make the racing chair's seat frame. He positions the seat frame on the rear axle
And does a few more welds. Finally, he installs fenders on the wheels. The main framework of this racing wheelchair is complete. But to make it look flashy, they spray-paint it red. This is a powder coating. It's a thermoplastic paint That's tougher than the conventional kind.

Next, this machine rolls the push rims, Which the athlete uses to propel the wheelchair. They weld on pegs for attaching the rims to the wheels, Then glue a rubber sleeve onto each rim. They wrap it in tape to clamp the two as the glue dries. The tape stays on Until the chair is delivered to the customer. They install the rear wheels at an angle To make the racing chair more stable when cornering. They add padding for the athlete's knees, Then assemble the nylon seat to the chair. Next comes the front-wheel steering fork and handle.

They complete the assembly with a spring-loaded cylinder. That's part of the steering autopilot system. After testing the steering fork, they install the front wheel, Which is smaller than the rear two. Once it's been equipped with brakes, This custom racing chair Is ready to take on the competition. An elite athlete will buy a new racing chair every year. Some choose rear wheels made of lightweight carbon fiber Because any advantage is welcome in the push to win.

How It's Made - Desalinated Water

In regions where fresh drinking water is limited, Desalination plants remove salt from seawater, Converting it into freshwater suitable for human consumption. There are more than 13,000 desalination plants worldwide, Producing 12 billion gallons of water a day. The desalination plant that produced this drinkable water Is located right next to an electrical power plant Which uses seawater to cool down its condensers. Post-cooling, the water travels via underground pipes To the desalination plant. Before salt extraction, the water is pretreated In a multiphase cleaning process.

First, the water flows through screens That filter out large debris. From there, it flows into basins For the first pretreatment stage. As large paddles agitate the water, The plant adds two chemicals -- Sodium hypochlorite, a disinfectant, And ferric chloride, a coagulant. The coagulant binds together sand And other tiny particles of debris, Forming heavier clumps that sink to the bottom. This removes a significant portion of dirt from the water. But it's still far from being crystal clear. The water now moves into another set of basins For the second pretreatment phase -- sand filtering.

Inside each sand filter, Regulated by various pressure and flow gauges, A steady stream of air Continually moves sand in a circular motion. The seawater enters at the bottom of each filter And flows to the top. As the sand moves downward against the rising water, The dirt particles attach to the sand. The seawater now looks clean But still contains microscopic particles. So it enters the final pretreatment phase. This time, the filtering medium is diatomaceous earth, A powdered rock that contains algae fossils. Finer than sand, it filters out those microscopic particles. The seawater is now perfectly clean And ready for salt extraction.

They do that using membranes -- Cylinders containing layers of plastic sheets That have pores .001 the diameter of a human hair, Small enough to trap microscopic salt crystals. The plant pumps the clean saltwater Under extremely high pressure through long tubes, Each of which contains eight membranes. By the time the water passes through all the membranes And reaches the center of the tube, it's completely salt-free. Plant personnel and a slew of sophisticated instruments Continually monitor every one of the system's 10,000 membranes.

Meanwhile, the plant sends the debris removed earlier To large waste basins For another round of chemical treatment. After the solids settle to the bottom, The dirty water goes back to the front of the plant To be cleaned and recycled. Pressure rollers squeeze the remaining water Out of the solids. Trucks then transport the dry solids to a landfill. The extracted salt, meanwhile, goes to the power plant, Which dilutes it, then returns it to the sea In a way that doesn't upset the water's natural salinity level. Processing saltwater into freshwater Strips away the water's natural minerals. Not replacing them would create two problems.

First, the water wouldn't taste right. Second, it would damage metal pipes By aggressively trying to replace the missing minerals. Therefore, the plant adds liquid lime and carbon dioxide To the water. These two elements adjust the ph level and raise the alkalinity, Restoring the minerals and natural taste.

How It's Made - Train Rails

In the early days of the railroad, Train rails were made of either cast iron or wrought iron. Cast iron was too brittle and would break easily. Wrought iron was too soft and would wear out too quickly. So steel eventually became and remained The train-rail metal of choice. The train wheel's rim runs on the inside of the rail To keep the train on the track. This plant makes train rails entirely out of recycled steel From scrapyards, food cans, And recycled pieces from the rail-making process itself. Electromagnets pick up the scrap And dump it in a charging bucket.

A truck hauls the bucket inside, Where a crane drops the contents into a furnace. An intense electric current Melts the scrap steel at 3,000 degrees fahrenheit. It then flows into a large brick-lined ladle, Where they add carbon, manganese, and other elements To make the steel more durable. The alloy then runs down a ceramic tube That shields it from exposure to oxygen, Which would ruin the metal. From there, the molten metal flows into molds,
Which extrude it into continuous rectangular blocks Called blooms. Acetylene torches cut each bloom into 12-foot lengths. A crane then transfers the blooms to a furnace, Which, over the next five to seven hours, Reheats them to 2,300 degrees fahrenheit.

This softens the steel for further shaping. Then the reheated blooms enter a machine called a rolling mill, Which elongates each bloom, more than quadrupling its length. A shear then slices the longer, thinner blooms into four pieces. The pieces now go into another furnace for reheating. This preps them for the next set of rolling mills, Which will gradually form them to the final rail shape. Different railroads used to use different-shaped rails, Which required changing the train's wheels When passing from one railway to another. By the turn of the 20th century, The t-shaped rail became the industry standard And remains so today.

For the final shaping, each steel rail Passes several times through three consecutive mills. This is what a mill's rollers look like. And here's the standard "t" shape To which they form the steel. Next, a saw slices off about 12 inches to square off the ends. The cut-off pieces go back to the scrapyard. The rails, meanwhile, are laid out Until they cool to about 930 degrees fahrenheit. Then an electromagnet piles them in a holding box, Where they sit for 10 hours Until they cool off to about 190 degrees fahrenheit. When they come out of the box, They run through two sets of rollers.

The first set flexes the rail vertically. The second, horizontally. This flexing process Straightens out the rails, which curve slightly Due to all that heating, shaping, and cooling. Next, each rail passes over a mirror, Enabling inspectors to examine the bottom, as well as the top. Finally, a saw cuts the rails To whatever size the railway ordered -- Most often the standard length of 82 feet. The quality-control department measures random samples
To make sure all the dimensions are precise. Every rail bears a number Identifying the batch of steel from which it came. In the event of a problem, that number Lets them trace all the rails made from the same batch. It's a system that ensures a safe, smooth ride.

How It's Made - Drag racing Clutches

This clutch is not for the family sedan. It's a racing clutch designed for a car With an 1,800-horsepower engine. Without this kind of heavy-duty clutch, There would be no way to transfer That much power to the wheels, And the racecar would be going nowhere fast. Racecars use a manual transmission To transfer power to the wheels, So a good clutch is behind every win. Production starts with a flywheel, Which connects the clutch to the engine. Computerized cutting tools shape this aluminum part, Then move on to carve the cover plate for the clutch.

They trim its perimeter to give it the correct profile And reduce its weight. Next they use a bolt with an industrial diamond tip To level the surface of an iron friction disk. This will allow for better contact With other parts of the clutch. There are typically two to three of these friction disks In a racing clutch. The clutch disks will ride against this steel insert Which they position on the flywheel. The technician applies locking compound to bolts, Then uses them to attach the insert to the flywheel. Here, the technician sets the bolts to a precise torque. Next he uses this grinder To flatten the surface of the steel insert, Again for better contact with the clutch disk. These bolts will anchor the
clutch assembly to the flywheel.

They're called stand bolts, and there are six. Here, they sculpt titanium cylinders To act as stands for the bolts That were just installed in the flywheel. Titanium is strong and lightweight, Which is important because of the huge amount of energy The clutch must transfer. The technician places a stand over each bolt, Then arranges the clutch disks And a floater plate on the flywheel. He presets the height of the stands. Then he prepares the pressure-plate assembly. He presses aluminum cups into holes in the cover. These cups will hold Springs That will be used to change the pressure of the clutch pack, But he holds off on inserting the Springs in the cups.

First he installs a series of levers on the cover plate. He slides pivot pins into each lever. These pins will enable the levers To compress and decompress the clutch pack. He applies lubricant to adjuster screws for the clutch Springs, Then threads each one into an aluminum casing. He inserts an assembly in each cup, Followed by a heavy-duty spring. He now installs the pressure ring On the underside of the cover. When the driver releases the clutch pedal, The levers cause the pressure ring To compress the clutch pack. That action transfers power from the engine to the transmission. He now slips the pressure-ring assembly over the stand bolts And secures it with nuts.

He adjusts each stand with a socket wrench, Then checks the height. He measures the tips of the levers to confirm they're even And makes any necessary adjustments. He pushes the levers to test this clutch, And the pressure ring responds as it should, Creating the necessary pressure on the clutch pack. Finally, a certification sticker And some strapping to secure it for shipping. At the track, this clutch will be serviced between every run, And if it's operating at peak performance, A win could be just down the road.

How It's Made - Corn Whiskey

More than three centuries ago, American bootleggers made corn whiskey by moonlight To avoid being detected  by the tax authorities, And so this whiskey became known as moonshine. Today, that whiskey has  emerged from the shadows of history And is produced legally, but people still call it moonshine. It was the nectar of outlaws -- Clear, fresh corn whiskey that's 50% alcohol, And centuries later, it still has a potent appeal. In Virginia, They still make this whiskey the traditional way, Allowing corn to germinate in a process called malting.
They mix a small amount of the malted kernels With regular corn in a big tank, Then funnel the mix into a mill. Inside this mill, automated hammers grind the mix To a cornmeal consistency. This frees some of the starch And exposes it to enzymes from the malted kernels. Those enzymes convert the starch to sugar. They'll use some of this ground corn To make a big batch of yeast. They add it to water in a tank And boil it until it becomes a thick soup. Once it reaches the desired consistency, They allow it to cool to room temperature. They add yeast and blow air into the mix to help the yeast grow, Making this one big batch of liquid yeast.

In another tank, a ton of corn Is being blended with water and boiled. This breaks down more of the starch, converting it to sugar. Once cooled, they pump the mix and the liquefied yeast Into the fermentation tank. Over a period of four days, The yeast turns the sugar to alcohol. The process also generates carbon dioxide, Which is vented into the atmosphere. Every so often, the brewmaster scoops up some liquid And scrutinizes it. If it looks too thick,
The conversion of sugar to alcohol is not yet complete. But when the viscosity is just right, They pump the batch into a big copper still. It's just like the type used To make moonshine in the backwoods centuries ago.

They heat it to 82 degrees celsius. At that temperature, alcohol will boil, but water will not. As the alcohol boils off the mix, It's recovered through a condenser. The recovered liquid is 80% alcohol. Talk about a stiff drink. So they add water to cut it down to about 50%, And then it's ready to bottle. To make a darker whiskey, they steep it With what looks like a big tea bag. It's actually wood chips wrapped in cheesecloth. The whiskey absorbs flavor and color from the wood Over a period of about two months. When the whiskey takes on a golden hue, They transfer it into oak barrels. They allow the whiskey to age for two years in a hot room.

The heat causes the whiskey to expand, Causing it to absorb the flavor of the wood, But the pressure can also cause cracks in the barrels, So the brewmaster routinely checks for leaks. After the whiskey has aged, They adjust the alcohol content by adding a little water. The water is always softened and filtered to remove minerals That could affect the whiskey's taste. At the bottling station, Machinery pumps the whiskey into the containers. There's no spillage, and not a drop goes to waste. Machinery then twists on the caps For an airtight seal that preserves the aroma and flavor Of this old-fashioned corn whiskey.

At the next station, robotic arms grab labels, Apply glue to them, then press them onto the bottles. It has taken a combination Of down-home methodology and modern technology To prepare this old-fashioned American whiskey for market. And whether it's aged or fresh, This historic whiskey is sure to set the taste buds ablaze.

Dollhouse CORN WHISKEY/CAP'N JACK

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How It's Made: Seasons 1 & 2 (2010)

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How It's Made - Kelp Caviar

Caviar is made By processing the unfertilized eggs of certain species of fish. For those who love the taste but not the price, There's simulated caviar made of kelp, a type of seaweed. A fraction of the cost, It looks, smells, and tastes similar to the real thing. Unlike fish caviar, the source of kelp caviar is a plant, So it's fat-free, cholesterol-free, And has zero calories. This company makes its kelp caviar plain, Which is vegetarian, As well as in several flavors. Kelp is chock-full of vitamins and minerals And is especially rich in iodine. Being a marine plant, it's quite different from land plants In that its consistency is gelatinous, Which makes it ideal for producing little rubbery balls That resemble fish eggs.

At the kelp caviar factory, They begin production with kelp that's been dried naturally, Then ground into a fine powder. The other ingredients are salt, citric acid, And, if they're making a flavored variety, Natural flavoring in liquid form. They add the ingredients one at a time to water. The mixer blends them thoroughly for about an hour, Producing a thick, gelatinous liquid. They transfer the mixture into a pot Connected to an extrusion machine. The machine pumps the mixture Through what looks like a showerhead, Only instead of outputting a steady stream, It squeezes out droplets, Producing tiny kelp balls called pearls, Which look exactly like fish eggs.

The pearls drop into a coagulation solution. Besides providing a soft landing, This solution helps hold the pearls' shape. The pearls roll down a chute into waiting containers. The water drains out the bottom. Workers empty the containers into large colanders. Then they rinse and strain the pearls To ensure they're all a certain minimum size. Pearls that are too small Simply fall through the colander's holes. They weigh out a specific quantity And mix in
an all-natural stabilizer Required to maintain the pearls' texture and round shape. The factory's quality-control lab Tests a sample from the batch To make sure the ph level is just right. Careful ph control, coupled with pasteurization, Is why this product doesn't require any preservatives. At the packaging station, workers fill glass jars, Then twist a tin lid onto each one.

Then the jars go into a pasteurization machine. It heats the caviar to a high temperature For a specific period of time, Which kills off any bacteria. This ensures a two-year shelf life without refrigeration. Once opened, the product stays fresh in the fridge For three months. After printing each lid with a lot number For tracking purposes, All that's left to do is dress the jar in a cardboard label. Kelp caviar contains no artificial colors or flavors. Unlike certain types of caviar, It doesn't bleed color to the surrounding food, Even when baked. And while real caviar Is typically either black sturgeon roe or red salmon roe, Kelp caviar comes in additional flavors, Such as truffle, cognac, and wasabi.

Kelp Vegetarian Caviar - Sturgeon - 3.5oz

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How It's Made - Crop-dusters

Crop dusters are airplanes Specially outfitted for aerial spraying. Farmers use them to seed fields And apply pesticides and fertilizer. The aquaculture industry uses them to feed fish, And emergency crews fly them to spread retardant on forest fires And dispersants on oil spills. Depending on its size, A crop duster can carry up to 2,700 liters Of liquid or dry material. The plane is designed to be able to swoop down low To accurately cover
the target spray area. At the factory, they manually weld Lightweight aircraft-grade steel tubes To construct the frame of the fuselage.

Next they use spring-loaded fasteners To affix aluminum panels to the sides. An anti-rust coating turns the aluminum golden color. All the plane's aluminum parts require this coating, Because many of the chemicals crop dusters carry Are corrosive. The tank that holds those chemicals is called a hopper. The factory molds it out of many layers of fiberglass, Which is deliberately transparent. This enables the pilot to see at a glance Roughly how much chemical remains. Inside each of the plane's wings Is a row of vertical supports called webs. To make each web, they lay a soft aluminum sheet on a mold, Place a rubber mat on top, then load the assembly into a press. A built-in water bag distributes the pressure evenly.

This helps form the aluminum sheet perfectly. Next they soak the web for a half-hour In molten sodium chloride At more than 900 degrees fahrenheit. Then they immediately submerge the web in lukewarm water. This triggers a molecular reaction That hardens the aluminum. Each wing contains 32 webs. Technicians line them up in an assembly fixture In between the wing's horizontal beams called spars. Once they've riveted the webs to the spars,
They cover the structure with aluminum panels Using spring clamps for now. The panels have holes in them To allow regular inspections of the structure inside.

After riveting the panels, Technicians screw covers onto the inspection holes. They also seal the seams between panels with liquid rubber So chemicals can't penetrate. Next they install the engine and the propeller, Which ranges from 750 to 1,400 horsepower. The prop has from three to five aluminum blades. Now the equipment that releases the chemicals from the air. For spraying liquids, they hook up horizontal pipes Lined with spray nozzles
called booms. To apply dry chemicals or disperse seed, The flight crew detaches the booms And installs a large stainless-steel funnel Called a spreader under the plane's belly.

At release time, The pilot opens a door at the bottom of the hopper, Enabling the wind to draw out the contents Through the spreader. To spray liquids, a wind-driven pump Moves the hopper contents to the booms. Technicians now assemble and install The instrumentation panel. To fill the hopper with liquid chemicals, They connect a pump to a valve on the side of the crop duster. For dry chemicals, they just lift the hopper's lid And fill her up.

How It's Made: Seasons 1 & 2 (2010)

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