Narrator: AROUND THE WORLD, THE RACE TO WIN WARS
AND EXPLORE THE UNIVERSE HAS CREATED SOME OF THE MOST
INCREDIBLE PRODUCTS EVER DESIGNED,
AND WE USE THEM EVERY DAY,
UNAWARE OF THEIR AMAZING ORIGINS.
INCREDIBLE INVENTIONS.
ON INCREDIBLE INVENTIONS: THE SWISS ARMY KNIFE,
AN ENTIRE TOOL-KIT
IN A POCKET-SIZED RED PACKAGE.
THE WINGLET, A NASA DEVELOPED DESIGN
THAT NOW HELPS YOU JET AROUND THE WORLD.
THE ENGLISH SADDLE,
WE SADDLE UP AND EXPLAIN
HOW A HORSE RIDING ESSENTIAL
CREATED THE SHOCK TROOPS OF THE MIDDLE AGES.
WE REVEAL THE AMAZING HISTORY
AND ENGINEERING BEHIND THESE INCREDIBLE INVENTIONS.
-- Captions by VITAC -- www.vitac.com
CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS
Narrator: THROUGHOUT HISTORY AN ARMY'S SUCCESS
HAS DEPENDED ON THE QUALITY OF THEIR GEAR
AS MUCH AS THE TACTICS DEPLOYED
IN THE HEAT OF BATTLE.
Man: ONE OF THE KEY THINGS FOR EVERY SOLDIER,
EVERY INFANTRYMAN WANTS TO BE ABLE
TO CARRY ALL HIS KIT WITH HIM.
AND THE LIGHTER IT CAN BE AND THE MOST FUNCTIONAL IT
CAN BE ENHANCES HIS CAPABILITY ON THE BATTLEFIELD.
Narrator: FROM THE ROMANS OF ANTIQUITY
TO THE MODERN MILITARY COURSES OF TODAY,
MOBILITY AND FLEXIBILITY ARE THE KEY WORDS TO DESCRIBE
THE MOST EFFECTIVE FIGHTING FORCES IN HISTORY,
AND THEIR EQUIPMENT HAS TO REFLECT THIS.
IN FACT YOU MIGHT BE SURPRISED TO FIND
THAT A PRODUCT LIVING IN A DRAWER
AT HOME WAS DEVELOPED
TO MEET THIS MILITARY NEED.
IT'S THE ABSOLUTE DEFINITION OF MULTI-PURPOSE --
THE SWISS ARMY KNIFE.
THE IDEA OF INCORPORATING SEVERAL TOOLS
IN A SMALL, PORTABLE UNIT IS NOT A NEW ONE.
THE ROMANS HAD THEIR VERY OWN VERSION OF A SWISS ARMY KNIFE
NEARLY 2,000 YEARS AGO, COMPLETE WITH SPOON,
FORK, BLADE,
AND THE OBLIGATORY TOOTHPICK.
MADE FROM SOLID SILVER, THIS LUXURY ITEM
AND THE IDEA FOR A MULTI-TOOL
SEEMS TO HAVE BEEN LOST IN TIME.
THAT'S BECAUSE FROM THE 1600s THE BASIC POCKETKNIFE
BECOMES THE HANDY TOOL OF CHOICE.
THEN, IN THE 1880s,
THE SWISS ARMY REPLACES THEIR OWN POCKETKNIFE,
GIVING BIRTH TO A REVOLUTIONARY NEW PRODUCT.
Man: IT WAS DEVELOPED IN ORDER TO ENABLE THE SOLDIERS
TO DISMANTLE THEIR RIFLE AND TO CLEAN IT,
AND ALSO TO OPEN CANNED FOOD.
THEREFORE IT NEEDED TWO ATTACHMENTS,
A TIN OPENER AND A SCREW DRIVER.
SO THE SOLUTION WAS THE MODEL 1890
WHICH WAS A KNIFE MANUFACTURED
BY THE COMPANY VESTA AND CO.
WHICH IS ACTUALLY A GERMAN COMPANY.
Narrator: SO THE ORIGINAL MODEL 1890 SWISS ARMY KNIFE
IS ACTUALLY GERMAN.
A YEAR LATER BUSINESSMAN CARL ELSENER
TAKES PRODUCTION OF THE KNIFE TO THE SWISS TOWN OF IBACH
AND STARTS IMPROVING ITS DESIGN
AND THE NUMBER OF TOOLS IT CAN CARRY.
Man: CARL ELSENER REFINED THE DESIGN BY
ADDING A CORKSCREW AND SCISSORS.
AND THIS MODEL HE CALLED IT
[ SPEAKING GERMAN ] THE --
WHICH ACTUALLY MEANS "SWISS OFFICER KNIFE."
AND AFTER THE SECOND WORLD WAR,
THE [ SPEAKING GERMAN ]
WAS ACTUALLY HARD FOR AMERICANS TO PRONOUNCE.
SO IT WAS DECIDED TO NICKNAME IT THE SWISS ARMY KNIFE.
Narrator: WITH OVER 800 TOOLS TO CHOOSE FROM,
THE VICTORINOX FACTORY IN IBACH PRODUCES
350 DIFFERENT VERSIONS OF THE KNIFE
WITH AN EYE-WATERING 17 MILLION KNIFE PARTS
BEING MANUFACTURED EVERY YEAR.
THE MANUFACTURING PROCESS STARTS
WITH A 3 MILLIMETER THICK COIL OF HIGH QUALITY
STAINLESS STEEL BEING FED INTO A PUNCHING MACHINE.
THE METAL IS FORCED AGAINST THE DIE
TO PUNCH OUT THE BASIC BLADE SHAPES
INCLUDING THE NAIL GROOVE USED TO OPEN THE KNIFE.
A SINGLE COIL CONTAINS
ENOUGH STEEL FOR 30,000 BLADES
TO BE PUNCHED IN ONE PASS.
THE OTHER TOOLS SUCH AS THE CAN-OPENER
ARE MADE IN THE SAME WAY.
THE BLADES ARE THEN FED INTO A MACHINE
THAT CONTAINS A VIBRATING MIXTURE OF STONES
AND WATER WHICH POLISHES THE STEEL.
ONCE POLISHED A POWERFUL MAGNET REMOVES
THE BLADES FROM THE STONE.
THE BLADES ARE STILL FAR TOO THICK,
SO THIS MACHINE GRINDS THEM FLAT TO
WITHIN A TOLERANCE OF LESS THAN THE WIDTH OF A HUMAN HAIR,
TO PREVENT THEM JAMMING
WHEN THE KNIFE IS OPENING AND CLOSING.
AT THIS POINT THE BLADES ARE STAMPED
WITH THEIR TRADEMARK AND THEN ENTER A FURNACE
THAT IS HEATED TO 2,000 DEGREES FAHRENHEIT.
ONCE HEATED TO THE CORRECT TEMPERATURE THE BLADES
ARE QUICKLY COOLED WHICH HARDENS AND TOUGHENS THE METAL FURTHER.
ONCE THE BLADE IS SHARPENED IT IS READY FOR ASSEMBLY.
THE SHAPE OF THE BLADE INCLUDES A NOTCH AT THE BACK
OF THE KNIFE EDGE WHICH IS PART OF AN OPENING
AND CLOSING SYSTEM FOR POCKETKNIVES
THAT HAS BEEN IN EXISTENCE FOR OVER 300 YEARS.
THIS IS CALLED A SLIP JOINT.
Man: SLIP JOINT KNIVES HAVE AN INTERNAL SPRING
WHICH IS MORE LIKE A SMALL PIECE OF METAL
AND THIS SPRING NEEDS TO BE OVERCOME IN ORDER
TO CLOSE AND OPEN THE KNIFE.
Narrator: THE FLAGSHIP VICTORINOX KNIFE
IS THE SWISS CHAMP
WITH AN AMAZING NUMBER OF DIFFERENT TOOLS.
THIS HAND-ASSEMBLED MULTI-TOOL WONDER STARTS LIFE
WITH FOUR PINS THAT ALL THE PARTS
WILL SLOT ONTO TO CREATE ONE BIG METAL SANDWICH.
A MIXTURE OF TOOLS, SPACERS, SPRINGS AND ATTACHMENTS
ARE BUILT UP TO FORM THE CHAMP,
WITH METAL FITTINGS CALLED BUSHINGS MACHINED
ONTO THE PINS TO FIX THE TOOL TOGETHER.
THE BLADE IS THEN GIVEN A FINAL FINISH.
THE DISTINCTIVE RED PLASTIC HANDLES
OF THE SWISS ARMY KNIFE ARE CALLED SCALES.
THESE ARE MADE IN THE FACTORY'S INJECTION MOLDING DEPARTMENT
AND ARE EMBLAZONED WITH THE VICTORINOX SHIELD,
READY TO BE ATTACHED TO THE FINISHED TOOL.
TWO SCALES ARE PLACED INTO A MACHINE
AND THE TOOL BUNDLE IS POSITIONED BETWEEN THEM,
AND THE SCALES ARE PUSHED DOWN TO FIX THEM TO THE BUSHINGS.
THE ONE INCH WIDE TOOL IS NOW FINISHED --
BUT ALL 33 OF ITS ATTACHMENTS
STILL NEED TO BE CHECKED BEFORE IT CAN BE SENT OUT
TO OVER 120 COUNTRIES AROUND THE WORLD.
WHICH INCREDIBLE INVENTION ALLOWS US
TO JET AROUND THE WORLD SAFELY
AND WITH LESS DAMAGE TO THE ENVIRONMENT?
FIND OUT AFTER THE BREAK.
Narrator: WHETHER IT'S JETTING OFF
FOR A MUCH DESERVED VACATION,
OR TRAVELING FOR BUSINESS, AIR TRAVEL
HAS BECOME A FAMILIAR PART OF EVERY DAY LIFE.
WE ASSUME THE AIRCRAFT WILL PROPEL INTO THE SKY,
BUT HOW MANY OF US ACTUALLY UNDERSTAND THE SCIENCE
BEHIND WHAT KEEPS IT UP THERE?
IT'S THE WINGS OF COURSE -- BUT HOW DO THEY WORK,
AND HAVE YOU EVER WONDERED WHAT THOSE VERTICAL WING TIPS
ON AIRLINERS ACTUALLY DO?
AND DID YOU KNOW THEY'RE CONNECTED TO NASA?
THE ANSWERS ALL LIE WITH UNDERSTANDING
JUST HOW AN AIRCRAFT WING ACTUALLY WORKS.
WITH WINGS YOU NORMALLY HAVE A CURVED SURFACE
WHICH MEANS THE AIR
THAT'S GOING OVER ON A NORMAL PLANE'S
TOP SURFACE OF THE WING HAS FURTHER
TO GO THAN THE AIR THAT'S ON THE LOWER SURFACE.
IF THE AIR ON THE TOP SURFACE HAS GOTTA GO FURTHER
THAN THE AIR ON THE LOWER SURFACE
THEN IT'S GONNA TRAVEL FASTER
AND THAT GENERATES EFFECTIVELY
A LOW PRESSURE ON THE TOP SURFACE
AND HIGH PRESSURE ON THE LOWER SURFACE.
AND IT'S ESSENTIALLY THE PRESSURE DIFFERENCE
THAT GENERATES A VERTICAL FORCE.
SO THE BIGGER THE WING THE BIGGER THE FORCE.
Narrator: THIS AMAZING AERODYNAMIC PRINCIPLE
HAS BEEN THE SECRET TO POWERED FLIGHT
EVER SINCE THE WRIGHT BROTHERS FIRST FLEW IN 1903.
THOUGH THE DIFFERENCE IN AIR PRESSURES
AROUND A WING ALSO GENERATE LESS FAVORABLE CHARACTERISTICS,
NAMELY WING TIP VORTICES.
A WING TIP VORTEX IS CREATED
AS HIGH PRESSURE AIR LEAKS
FROM BELOW THE SURFACE OF THE WING TIP.
THIS HIGH PRESSURE AIR SPILLS OVER THE TOP
AND INTO LOW PRESSURE SPACE ABOVE THE WING.
THIS BEHAVIOR CREATES A PATH OF SWIRLING AIR
THAT TRAILS EACH WING TIP WITH ITS STRENGTH
AND SIZE DETERMINED BY MANY FACTORS,
INCLUDING THE AIRCRAFT'S WEIGHT AND AIRSPEED.
Man: ON A LARGE PLANE YOU MIGHT SEE REALLY BIG VORTICES
COMING OFF THE WING TIPS
AND GETTING SHED OFF DOWN,
MAYBE STICKING IN THE AIR FOR A COUPLE OF MILES OR SO.
AND IT ALSO DETRACTS
FROM THE EFFICIENCY OF THE AIRCRAFT.
YOU CAN GET ADDITIONAL DRAG
FROM THE FORMATION OF VORTICES AND THE MESS,
THE LOSSES THAT COME ASSOCIATED WITH THAT.
Narrator: DRAG IS NOT THE ONLY NEGATIVE ASPECT
OF WING TIP VORTICES.
VORTICES ARE ALSO A COMPONENT PART
OF WEIGHT TURBULENCE, WHICH IS THE DISTURBED AIR
THAT FORMS BEHIND AN AIRCRAFT AS IT MOVES.
THIS TURBULENCE CAN POTENTIALLY BE A DANGEROUS HAZARD
FOR ANY FOLLOWING AIRCRAFT.
Man: IF YOU IMAGINE THE DIFFERENCE
BETWEEN FLYING INTO AIR
WHICH IS UNIFORMLY COMING TOWARDS YOU
AND THEN YOU IMAGINE FLYING THROUGH A VORTEX
WHICH IS EFFECTIVELY SPINNING.
DEPENDING ON THE SIZE OF VEHICLE THAT
YOU'RE IN AND THE POSITION
OF THE VEHICLE COMPARED TO THOSE VORTICES,
THEY CAN HAVE THE POWER TO FLIP AIRCRAFT OVER.
IF YOU'RE COMING TO LAND A SMALL PLANE
ON THE SAME RUNWAY, FOR EXAMPLE,
WHERE A LARGE PLANE HAS EITHER JUST TAKEN OFF OR JUST LANDED.
THEN THAT CAN BE PRETTY DANGEROUS.
Narrator: DANGEROUS TURBULENCE? DRAG?
NOW, THIS IS WHERE NASA AND THE WINGLETS COME IN.
THE WINGLET IS NOT A NEW CONCEPT,
WITH THE EARLIEST EXAMPLE DATING BACK TO 1910.
IN ITS MOST BASIC FORM A WINGLET IS AN ANGLED EXTENSION
OF A WING TIP THAT SITS AT 90 DEGREES TO THE WING.
TRADITIONALLY THIS EXTENSION SUNK
BELOW THE WING SUCH AS THE EXAMPLE
ON THIS GERMAN HEINKEL 162A
FROM WORLD WAR II.
SO WHAT ARE THESE DESIGNS TRYING TO ACHIEVE?
Man: THE IDEA BEHIND A WINGLET
IS EFFECTIVELY TO PROVIDE A BOUNDARY FOR THE FLOW
WHICH IS ATTEMPTING TO WRAP FROM THE PRESSURE SURFACE
OF A WING ONTO THE SUCTION SURFACE OF THE WING.
SO YOU'RE TRYING TO REDUCE THE EFFECT OF THIS TIP VORTEX.
Narrator: THE DESIGN AND PLACEMENT OF WINGLETS
ARE CRITICAL TO THEIR PERFORMANCE.
IN RESPONSE TO THE OIL CRISIS OF 1973,
WHICH SAW AN INCREDIBLE RISE IN THE COST OF FUEL,
NASA ENGINEER RICHARD T. WHITCOMB
DEVELOPED THE NEAR VERTICAL WINGLET DESIGN
WE ARE SO FAMILIAR WITH TODAY.
THROUGHOUT TIME AERODYNAMICISTS OBSERVED HOW SOARING BIRDS
IN FLIGHT SUCH EAGLES GLIDED WITH NEAR VERTICAL WING TIPS.
IF IT WAS GOOD ENOUGH FOR THE BIRDS,
THEN IT WAS GOOD ENOUGH FOR NASA.
WHITCOMB CAME UP WITH SMALL VERTICAL AIR FOILS
AND BY 1976 HIS RESEARCH SHOWS
THAT WINGLETS EMPLOYED ON TRANSPORT SIZED AIRCRAFT
CAN DIMINISH INDUCED DRAG BY APPROXIMATELY 20 PERCENT
AND IMPROVE THE OVERALL LIFT TO DRAG RATIO
BY 6 TO 9 PERCENT.
TWENTY YEARS LATER, THE COMMERCIAL AIRLINE INDUSTRY
STARTS TO SEE THE BENEFITS OF ADDING
A BLENDED WINGLET TO THEIR OWN FLEET'S WINGS.
THERE ARE NOW A WIDE VARIETY
OF WINGLET DESIGNS AND MANUFACTURERS
AND IT HAS BEEN CALCULATED THAT PLANES
WITH WINGLET DESIGNS CAN SEE FUEL SAVINGS OF BETWEEN
4 TO 6 PERCENT. WHAT DOES THAT MEAN?
WELL, IT'S BEEN CALCULATED BY ONE MANUFACTURER
THAT THEIR BLENDED WINGS
HAVE SAVED OVER 5 BILLION GALLONS OF FUEL
SINCE THEIR INTRODUCTION 15 YEARS AGO.
AS A RESULT BILLIONS OF DOLLARS HAVE BEEN SAVED
AND TENS OF MILLIONS OF TONS LESS CARBON DIOXIDE
HAVE BEEN EMITTED INTO THE ATMOSPHERE.
THE WINGLET, TRULY AN INCREDIBLE INVENTION.
COMING UP NEXT, "INCREDIBLE INVENTIONS"
TAKES A LOOK AT A SHOCK-ABSORBING MARVEL --
BUT FIRST AN EXPERIMENT TO PROVE
JUST HOW EFFECTIVE WINGLETS ARE.
Narrator: THE INVENTION OF THE WINGLET
IS SAID TO BE SAVING AIRLINES
A GREAT DEAL OF MONEY,
BUT IT'S TIME WE TEST THE BENEFITS
OF THIS COOL INNOVATION FOR OURSELVES.
WE'VE COME TO "INCREDIBLE INVENTIONS" AIRFIELD
TO FIND OUT.
THE EXPERIMENT BELOVED BY BORED SCHOOL BOYS
AND FRUSTRATED FLYERS EVERYWHERE,
THE PAPER PLANE IS THE CLASSIC LOW COST ENTRY INTO
THE WORLD OF AVIATION.
TO BEGIN, WE CREATE FIVE IDENTICAL PAPER PLANES.
EACH FLYER IS MADE FROM A STANDARD
PIECE OF RED PAPER
USING THE BASIC FOLDING TECHNIQUE
REFINED OVER MANY GENERATIONS OF CLASSROOM CHAOS.
NOW, FOR THE WINGLET PLANES, USING GREEN PAPER THIS TIME --
WELL, THIS IS FUEL SAVING TECHNOLOGY --
FIVE OTHER IDENTICAL PAPER PLANES ARE MADE.
THE WINGLETS ARE CREATED
BY FOLDING THE WINGS IN ON THEMSELVES.
THIS CREATES A HALF-INCH LONG WINGLET
THAT SHOULD REDUCE THE AIRCRAFT'S DRAG
AND STABILIZE IT IN FLIGHT -- OR, SO THE THEORY GOES.
ONE FLIGHT AREA IS LAID OUT WITH MARKINGS
PLACED EVERY TEN FEET.
NOW THE TEST CAN BEGIN.
EACH PLAIN WILL BE RELEASED 5 TIMES
TO REDUCE ANY INCONSISTENCIES
THAT MAY OCCUR DURING EACH FLIGHT.
A CONSISTENT RELEASE IS CRITICAL
AND OUR TESTER EXHIBITS THE PERFECT TECHNIQUE.
A WIDE STANCE, SHOULDERS BACK,
PERFECT ARM BENDING ACTION.
THE PLANES ARE RELEASED AND WE SOON GET TO SEE
HOW THE WINGLET ADAPTED PLANES
PERFORM AGAINST THEIR STANDARDIZED COUSINS.
AFTER A HECTIC BARRAGE OF PAPER PROJECTILES
THE RESULTS ARE IN.
IN THIS SHOT WE HAVE PLOTTED
WHERE EACH OF THE RED PLANES LANDED.
IF WE OVERLAY THE GREEN FLIGHTS
I THINK WE CAN SEE A CLEAR WINNER.
THE WINGLETS ARE VICTORIOUS -- WITH ONE GREEN PLANE
ACTUALLY ACHIEVING THE LONGEST FLIGHT DISTANCE,
A REMARKABLE 40 FEET.
SO THERE YOU HAVE IT, POINT PROVED --
THE WINGLET REALLY IS AN AERODYNAMIC WONDER.
TODAY'S SADDLE ORIGINATES IN MILITARY HISTORY.
THE FIRST DEPICTIONS OF A SADDLE SHOW
THE ASSYRIAN CAVALRY FROM 700 B.C.
IN THESE EARLY CARVINGS
WE CAN SEE WARRIORS RIDING HORSES
SEATED UPON A PIECE OF CLOTH OR LEATHER,
SECURED BY STRAPS NOT TOO DISSIMILAR
TO THE HORSE TACK OF TODAY.
BUT IT IS THE INTRODUCTION OF STIRRUPS
TO THE SADDLE THAT CAUSES A MILITARY REVOLUTION.
A MOUNTED WARRIOR SITTING A TOP A SADDLE WITH STIRRUPS
NOW GAINS ALL KINDS ADVANTAGES IN COMBAT.
HAVING THE STIRRUPS ADDED TO THE SADDLE
JUST CHANGES COMPLETELY THE WAY
YOU CAN FIGHT ON THE BACK OF A HORSE.
YOU CAN STAND UP, YOU HAVE A PLATFORM IF YOU LIKE.
SO SAY YOU HAVE A SWORD IN YOUR HAND,
FOOT SOLDIERS COMING CHARGING TOWARDS YOU,
YOU CAN STAND UP IN YOUR HORSE YOU CAN REACH OUT
AND YOU CAN REALLY GO FOR THAT FOOT SOLDIER
WITHOUT SLIPPING AND FALLING OFF THE SIDE OF THE HORSE.
Narrator: BUT WHAT MAKES THE MODERN SADDLE
EVEN MORE SPECIAL? WE FIND OUT
AND SEE HOW IT'S MADE WHEN WE RETURN.
Narrator: NOMADIC GROUPS SUCH AS THE SARMATIANS AND MONGOLS
CONQUERED LARGE SWATHES OF TERRITORY ON HORSEBACK.
THEN, WHEN THE STIRRUP IS INTRODUCED
TO A NEW EUROPEAN WARRIOR CLASS,
AN ULTIMATE FIGHTING MACHINE ARISES,
THE MOUNTED KNIGHT.
WE THINK OF KNIGHTS, ARMORED KNIGHTS,
WE CAN THINK OF THE NORMAN TIME,
THE NORMAN INVASION 11TH CENTURY,
THAT KIND OF PERIOD.
ON THE SPEED OF THEIR HORSE
AND THEIR LANCE COUCHED UNDER THEIR ARM
THE STABILITY OF THE SADDLE
AND THE STIRRUPS MEANT THAT ALL THAT POWER
IS TRANSFERRED DOWN THE END OF THAT POINT.
THEY WOULD DRIVE THROUGH,
PUNCH HOLES THROUGH THE ENEMY LINES,
A LITTLE BIT LIKE THE MODERN-DAY TANK.
Narrator: NEARLY 3,000 YEARS AFTER THEIR INTRODUCTION SADDLES
ARE STILL BEING MADE ALL OVER THE WORLD.
IN WALSALL, ENGLAND, THE SADDLE COMPANY
CONTINUES THE ANCIENT ART OF SADDLE MAKING.
AS A MASTER SADDLER
WITH 48 YEARS EXPERIENCE DAVID JOHNSON'S SADDLES
ARE MADE BY COMBINING TRADITIONAL CRAFTSMANSHIP
WITH MODERN TECHNIQUES AND MATERIALS TO IMPROVE
THE PERFORMANCE OF A SADDLE TODAY.
SADDLES ARE MADE FOR BOTH THE HORSE
AND THE RIDER IN TERMS OF COMFORT AND DURABILITY.
LIKE US HORSES COME IN ALL SHAPES AND SIZES,
AND EVERY SADDLE NEEDS TO BE TAILORED
TO COMFORTABLY FIT EACH INDIVIDUAL HORSE.
FOR THIS SADDLE THE FRAME, KNOWN AS THE TREE,
IS MADE FROM POLYURETHANE.
THE FLEXIBLE METAL STRIP
CALLED A GULLET PLATE IS ATTACHED TO THE TREE.
THIS PLATE CAN BE ADJUSTED TO CREATE A TAILORED FIT
FOR THE HORSE ONCE THE SADDLE IS FINISHED.
NEXT THEY RIVET A STIRRUP BAR THROUGH THE TREE
WHICH WILL BE USED TO ATTACH THE STIRRUPS TO THE SADDLE.
AN ADHESIVE IS BRUSHED ON TO THE TREE
AND A FOAM PAD IS GLUED INTO POSITION.
ANOTHER THICKER FOAM PAD IS ADDED FOR CUSHIONING.
A KNIFE IS USED TO TRIM THE FOAM,
A TEMPLATE IS THEN USED TO TRACE THE SEAT SHAPE
AND THE FOAM IS ROUGHLY CUT INTO SHAPE.
A TOOL CALLED A RASP GRAZES AWAY EXCESS FOAM
AND GIVES THE SEAT A DEFINED SIZE AND SHAPE.
WHILE THE SADDLE SEAT IS BEING SHAPED,
ANOTHER WORKER STARTS TO CUT OUT THE LEATHER PIECES
THAT WILL MAKE UP THE SADDLE FLAPS AND COVER THE TREE.
FIRST HE INSPECTS THE LEATHER FOR ANY DEFECTS.
HE CAREFULLY TRACES THE DIFFERENT PIECES
THAT MAKE UP THE SADDLE WITH CHALK.
THE LEATHER PIECES ARE THEN FED INTO A SKIVING MACHINE,
THIS MACHINE SHAVES THE EDGES OF THE LEATHER.
THESE EDGES, NOW THINNER, WILL BE EASIER
TO STITCH LATER ON IN THE PROCESS.
A GLUE IS APPLIED TO THE CUT PIECES
TO HOLD THEM TOGETHER BEFORE A MACHINIST
WILL PERMANENTLY STITCH THEM INTO PLACE.
THE TWO PIECES ARE PUSHED TOGETHER
WITH THE AID OF A TOOL MADE FROM WHALE BONE,
THIS MATERIAL IS USED
BECAUSE IT DOES NOT SCRATCH OR SCAR THE LEATHER.
A MACHINIST THEN STITCHES THE PIECES OF LEATHER TOGETHER.
WITH THE LEATHER PIECES PREPARED AND MACHINED
A SADDLE MAKER STARTS TO CONSTRUCT THE SADDLE.
TO BEGIN THE WORKER STUFFS THE PANEL
WITH A MIXTURE OF WOOL AND SYNTHETIC MATERIALS.
TWO PANELS WILL BE ATTACHED TO THE UNDERSIDE OF THE SADDLE.
THE PANELS ARE DESIGNED FOR THE HORSE'S COMFORT
WITH ONE SITTING ON EACH SIDE OF ITS BACK.
NEXT, THE LEATHER SEAT COVER IS ATTACHED TO THE TREE.
THE COVER IS PULLED OVER THE TREE
AND FIXED IN PLACE WITH STAPLES.
AN EXPERIENCED EYE IS ALL-IMPORTANT
AS THE SADDLE MAKER TRIMS
AWAY EXCESS LEATHER AND SHAPES THE COVER INTO POSITION.
WITH THE SEAT FIRMLY IN POSITION ON THE TREE,
THE FLAPS, PANEL, STRAPS, AND VARIOUS FIXINGS AND BUCKLES
ARE BROUGHT TOGETHER AND STAPLED INTO POSITION.
THE PANEL IS THE LAST PIECE TO BE ATTACHED AND AFTER
STAPLING IT TO THE BACK OF THE SADDLE
THE FRONT IS HAND-STITCHED TO THE POMMEL.
THIS IS CALLED LACING IT IN.
THE SADDLE IS NOW COMPLETE
AND READY TO BE SHIPPED NEARLY 12,000 MILES
AWAY TO ITS NEW OWNER IN NEW ZEALAND.
SO, THE SADDLE,
THOUSANDS OF YEARS OF MILITARY DEVELOPMENT
USED FOR MORE PEACEFUL PURSUITS TODAY.
NOW, THAT IS AN INCREDIBLE INVENTION.
SO, THERE YOU HAVE IT.
A GLANCE THROUGH THE HIDDEN HISTORY, SUPER SCIENCE,
AND AMAZING PRODUCTS THAT YOU USE EVERY DAY
BUT YOU MAY NOT HAVE REALIZED
THEIR FASCINATING BACKGROUNDS.
THE SWISS ARMY KNIFE,
THE WINGLET, AND THE SADDLE.
THEY MAY SEEM COMMON AND ORDINARY
HOWEVER THESE PRODUCTS HELPED CHANGE THE WORLD
ONE INCREDIBLE INVENTION AT A TIME.