00:19 - Hi my name is Cari Gross we're here at

00:20 - Pepperell Braiding company in Bradford Pennsylvania

00:23 - we're actually known as holgate toys

00:25 - we moved up

00:26 - here in two thousand and seven from Kane Pennsylvania

00:29 - in seventeen eighty nine when George Washington was the first president

00:33 - there was also known.

00:35 - As Cornelius

00:36 - holgate he

00:37 - introduced

00:38 - handles for paint brushes and other to tools

00:41 - known in the home

00:42 - the farm

00:43 - and industry Jarvis Rockwell started holgate toys he

00:46 - worked there from nineteen thirties and nineteen sixty

00:49 - and he made

00:51 - toys for children

00:52 - and he was known

00:53 - worldwide for having a sturdy toy

00:55 - and from then on from nineteen thirty.

00:59 - We were introduced to

01:01 - mister Rogers we were asked to make the mister Rogers.

01:05 - Trolley

01:06 - and as we're going to show you today how that trolleys made from start to finish.

01:11 - Hi i'm Duane Shirley production manager of holgate toys.

01:16 - Show you

01:16 - some of the parts

01:18 - that we use to make classic trolleys.

01:23 - And here i want to show you the part step where.

01:26 - We start to cut some of the wood.

01:29 - This part here.

01:32 - There's the small top

01:33 - for the trolley.

01:35 - Here we're going to set up the jig

01:38 - to cut it.

01:45 - Here he uses one that's already cut

01:48 - to make sure the measurement is exact.

01:55 - He puts a camp on to make sure everything's sturdy

01:59 - so nothing

02:00 - changes.

02:06 -

02:14 - checking his measurements

02:33 - Make sure everything

02:35 - that everything is exact

02:41 - we can begin

02:43 - begin cutting.

02:44 - The rest of it.

02:46 - Go ahead and cut.

02:50 - This here's

02:51 - the trolley sign.

02:53 - Then check make sure measurements are exact.

03:01 - Before he cuts

03:02 - a finished product.

03:24 -

03:31 - Here he is pre measuring

03:32 - the full seat

04:10 - This year the jig can stay the same.

04:18 - Because the half seat

04:19 - and the full seat.

04:21 - are exact same length.

04:41 - This here's the cowling

04:48 - the front part of the trolley.

04:50 - he's going to have to adjust the length of the jig

04:53 - to make sure everything

04:55 - is right.

05:12 - After this part is cut I'll

05:14 - bring you to the next step.

05:16 - Which will show the drilling of the cowling.

05:40 -

05:56 - That is all the parts.

05:58 - That have to be cut to make a trolley.

06:01 - Now take you out to the drill.

06:05 - Where we do the cowling drilling.

06:07 - That first step we're going to do here.

06:25 - drill the front hole

06:27 - Which later on down the process I'll show you

06:29 - why the hole is needed.

06:31 - He's adjusting the screw.

06:51 - On the side

06:52 - of the drill to make sure the drill bit goes

06:54 - the whole way through.

07:12 - next he'll have to reset the drill

07:21 - the top holes

07:25 - Which I'll show you why they are needed.

07:28 -

07:38 - we have to change drill bit because the hole sizes are different.

07:42 - For each step

07:42 -

07:48 - Here he's adjusting the side rail.

08:20 - so he can slide the piece

08:21 - that side by side

08:23 - to drill the holes.

08:28 - here he's raising the height of the drill.

09:01 - so the piece will fit.

09:08 - he's drilling the hole.

10:09 - adjusting his step

10:17 -

11:00 - And from this step I'll take you in

11:04 - and show you the balking process

11:06 - typically with these small parts we use the tumbler which is over here to the left.

11:11 - but with

11:12 - the small amount of parts we have we are going to use the buffer.

11:27 - He's buffing the side

11:28 - We do this to make sure there's no sharp edges.

13:29 - And now with all parts

13:31 - being smooth

13:33 - I will bring you into the painting area.

13:38 - Here he's painting the trolley bottom

13:46 - He stacks them here. Have to have perfect spacing

14:59 - First and second coat.

15:01 - up here is the tops.

15:04 - Painted with first and second coat.

15:14 - This step here she's printing the

15:16 - trolley sides.

16:07 - I am Justin Middlebrough I assemble the trolleys.

16:11 - These are the bottoms.

16:13 - They use this jig.

16:16 - Take the middle seats like a mushroom.

16:19 - set em in here

16:21 - Taking the half seats which are the ends.

16:25 - When you take his place it on top

16:28 - make sure it's nice and tight

16:31 - Make sure you don't get your fingers.

16:48 - on off

16:50 - change seats

16:56 - And here's the axle that she was printing over there.

17:00 - get the wheels

18:08 - Now the axle's with the wheels.

18:10 - Flip the base over.

18:12 - with wheels up

18:15 - give a spin

18:17 - watch your fingers.

18:21 - that's the bottom done.

18:24 - Then we add the top here.

18:33 - needed the vents

18:34 - that were cut and screwed.

18:36 - The top.

18:49 - this is the Jig for the signs that were

18:50 - painted over there by Katrina.

19:05 -

19:05 - will now

19:06 - three nails in em

19:48 - here's the top of them.

20:02 - The

20:03 - gallons they come over here.

20:06 - The got a rivet.

20:08 - in here

20:09 - put it on the press.

20:16 - press em down

20:17 - keeps them in place.

20:30 - And here's the jig that we're going to assemble the top and bottom.

20:36 - Take your top.

20:38 - run your bolts down through.

20:45 - Make sure you grab hold or they'll fall out.

20:48 - Place in there.

20:55 - grab your spacers

20:58 - run em down the bolts

21:05 - take those gallons

21:13 - there's those sides that were printed over there.

21:22 - take the Bottom.

21:23 - make sure it lines up on the side over there.

21:39 - make sure it's

21:40 - flat

21:41 - or you'll break the sides out

22:04 - drill them

22:04 - down about halfway so they

22:06 - don't pull on one side.

22:29 - and that is a complete trolley

22:31 - check the side so it ain't broke.

22:34 - don't wanna ship out a bad product.

22:36 - Then they come

22:38 - over here

22:44 - these are the trolleys that get packed

22:46 - there's these people

22:47 - stacked in fours

22:48 - there's a

22:49 - king and queen

22:50 - and there's a blank one to draw whatever you want on there.

22:54 - They get

22:54 - inserted in.

22:56 - When you pack them in a box.

23:03 - She's stuffing paper in there so they don't bounce around.

23:21 - Back sticker on there has a barcode.

23:39 - put the front sticker on the front and identify what it is and where it's made

23:47 - I'm Ken Lawhead i'm going to try and run you through the

23:49 - 550 production here in Bradford, PA

23:53 - What we do

23:53 - we start with

23:55 - receiving into a 840 nylon

23:58 - it comes into colors of our specification

24:01 - for the customers. what we do

24:03 - you take this material we check it in

24:06 - and will run it over to the winder over here

24:09 - and we'll try and get it on the bobbin

24:11 - for thirty two carriers per machine

24:13 - this machine is where we wind material

24:23 - We need to get thirty two.

24:25 - bobbins per set

24:33 - each machine will take 32 bobbins

24:57 - let's go down here

25:14 - 32 sets of braiders per machine

25:17 - Thirty two carriers per set

25:26 - The Five fifty four takes seven

25:28 - fillers to the back of the machine

25:30 - runs up through the center

27:11 - We're in the paracord room

27:13 - we just left the braiding area this is what it

27:14 - looks like once it comes from the braiding room

27:17 - we

27:17 - now take it

27:18 - from here.

27:20 - Show you a machine that we hang it down and sell it

27:22 - for resale.

27:37 - The spool goes here on the shaft.

27:40 - Fed up through.

27:46 - She presses on the foot pedal.

27:48 - It stops automatically to make this one

27:50 - as measured to sixteen feet.

28:05 - We also do those

28:07 - in one hundred foot

28:08 - coils.

28:11 - Package them down into several different

28:13 - kinds different styles

28:16 - to make different bracelets.

28:18 - That's a key chain.

28:20 - This is a glow in the dark kit.

28:23 - This is our hundred foot.

28:26 - Bag for retail.

28:37 - Want to thank everybody for watching the tour of our factory

28:40 - in the making of the mister Rogers' neighborhood trolley.

28:43 - You can visit our website

28:45 - at www

28:46 - dot holgate toys

28:48 - dot com for more product.