Ep 23. Bronze Bells, Wooden Airplane Propellers, Charcoal Briquettes and Gas Log Fireplaces

In season 5 episode 23 of How It's Made, viewers are taken on a journey to discover the fascinating process behind the creation of four very different products: bronze bells, wooden airplane propellers, charcoal briquettes, and gas log fireplaces.

The episode begins at the Verdin Company in Cincinnati, Ohio, where we see skilled craftsmen using age-old techniques to cast bronze bells. The process begins with a clay mold, which is formed around a wood pattern. Once the mold has been cast and allowed to dry, the craftsmen melt down bronze in a large crucible using a gas-fired furnace. The molten bronze is then poured into the mold, and after several hours of cooling, the bell is removed and cleaned using a sandblasting machine. Finally, the bell is finished by a skilled artist who adds the intricate details and designs that make each bell unique.

The next segment of the episode takes us to Sensenich Propeller Manufacturing in Lancaster, Pennsylvania, where wooden propellers for small aircraft are being made. Viewers will learn the importance of choosing the right type of wood for the job, and how each propeller is carefully crafted by hand to ensure perfect balance and performance. The craftsmen use a combination of traditional tools and modern machinery, including a CNC machine that helps to create precise cuts and shapes. In the end, viewers will see the finished product, a sleek wooden propeller that's ready to take to the skies.

Moving on to the world of consumer goods, the show then takes us to a Kingsford Charcoal plant in Summer Shade, Kentucky, where we see the process of creating the charcoal briquettes we all know and love. Viewers will learn about the origins of charcoal and how it's made from wood by heating it in the absence of oxygen. The next step is to grind the charcoal to a powder and mix it with a binding agent to form small, uniform briquettes. Finally, the briquettes are packaged and shipped out to stores across the country.

The final segment of the episode takes us to a gas log fireplace manufacturing facility in Nicholasville, Kentucky. Here we learn about the process of creating a realistic-looking fire using gas instead of wood. Viewers will see how the logs are made from a special type of ceramic that's both heat-resistant and realistic-looking. The logs are then carefully arranged with metal burners underneath, and a gas supply line is connected. The finished product is a gas fireplace that looks like a wood-burning fireplace, but without the mess or hassle.

Overall, How It's Made season 5 episode 23 provides a fascinating look at the processes behind the creation of four very different products. From ancient techniques used to cast bronze bells to modern machinery used to create wooden airplane propellers, viewers will see the skill and expertise that goes into each product we use every day.