" -Take a look at that. A very beautiful cast iron wood-burning stove, energy efficient but in a Victorian design, you might say, especially this deep red color. If you wanna find out how these are made, just watch."

" -Hi, Richard."

" -Hi, Bob. How are you?"

" -Well, we're really excited about learning how the cast iron stoves are made. What's the first step."

" -Well, Bob, after the stove's design has been decided upon, the first thing is to take the individual components and make them into master patterns."

" -So this would be a front component."

" -Right. This is the front plate from our newest product, the Radiance gas stove. "

" -Okay."

" -Now, the purpose of making a master pattern is that we need to go and make production plates out of it."

" -Okay."

" -Now, the creation of production plates is actually a 2-step process. First, we take a plastic impression of the master that we see here."

" -Which is what we're looking at here."

" -That's right. This is, and there is a front and a back side of this plastic impression."

" -Both sides of that, yeah."

" -Then the next thing we do is cover the impression, the plastic impression with a metal coating."

" -Why is that?"

" -Well, these production plates are gonna be used to make impressions in a block of sand."

" -Thousands of times?"

" -Thousands of times, literally, and if we didn't have a metal backing, a metal face to it like this, what would happen is after a few hundred impressions, it would start to loose the fine detail."

" -You lose the crispness of the line, yeah."

" -Yeah. And these, what these 2 production plates do is in effect they create a hollow cavity in a block of sand into which molten cast iron can be poured."

" -Okay, so that would be the next step actually at the foundry."

" -That's right and that's where we should go out right now."

" -Great. That way?"

" -That way."

" -Wow, so Richard, this is all the raw material, right?"

" -Right, Bob. This is where all the material is collected to make into our cast iron plates. The cast iron actually come from 3 different ingredients. One is re-melt from the production process itself."

" -Sure."

" -The second is cast iron and scrap. The third ingredient we use is pig iron ingots."

" -Okay."

" -The reason why I use pig iron ingots is because it's high in carbon and silicon, and this allows the cast iron to have a little softness so that when it expands, it doesn't break, it doesn't crack or turn brittle on its own."

" -So what's going on here?"

" -Well, Bob, this is the machine that makes the sand molds."

" -Uh huh."

" -The production plates we saw earlier are put in this machines, the space between the plates is filled with sand."

" -Alright."

" -Then the plate is compressed against the block of sand with the force of 750 pounds per square inch--"

" -So where is--"

" -In effect creating the sand mold."

" -And then the molten metal that we see over here is actually going on to the sand."

" -Well, there's actually a hole in the top of the sand mold, yes, that's true, then it's filled with molten cast iron just the amount necessary for that particular plate."

" -Wonderful."

" -Bob, we're at our enameling facility here, and what we have here is one of the cast pieces that we just saw, and to enamel it, we have a shop to make sure this is clean and as free of dirt as we can make it, and then as in the second process, right, is to put a ground coat on it. This is ceramic grafting material that we use in order to protect the enamel from the high heat it's gonna be subject to."

" -Alright. And where does the actual color gets put on it? Which way?"

" -The actual color is in the spray, being applied in the spray rooms right now."

" -Now, let's go at it."

" -Even though that's colorless, somewhat violet, it's actually our red enamel finish and when that goes through the kiln to cure it at 1500 degrees for 2 hours, it's gonna come out and actually be dark brown for a little bit, but when it cools off, it's gonna be that beautiful red that we're looking for."

" -Okay, can we go look at the other end where they--"

" -Sure, let's go."

" -Boy, you weren't kidding, that is a beautiful shade of red."

" -Okay, so these are the pieces that connect the transition to the stovepipe, right?"

" -Right."

" -So we're gonna be going out to assembly area shortly to see how your stove is actually put together."

" -Wonderful. So all the different components are in these different hoppers here."

" -That's right."

" -Right."

" -Let's go see the assembly line."

" -Richard, how many different parts go into putting together a stove? "

" -This iron stove takes 26 individual cast iron pieces to make its shell."

" -What's he doing here?"

" -Right now, he's applying a bead of furnace cement to all the exterior seams."

" -Why do you need that?"

" -Well, the furnace cement keeps unwanted air from entering the firebox and shortening the burn time and making it very hard to control the heat output of the stove. "

" -Okay. And then here's some of the beautiful front piece."

" -Front piece is now sold. This is the shell being constructed. Now the exterior side piece is put in."

" -Okay. Now, you've got the basic side. What about the innards?"

" -Well, the next thing to install is the catalytic converter."

" -So, Richard, what does the catalytic converter do?"

" -Catalytic converter increases the efficiency of the stove by almost 50%."

" -This is it right here?"

" -That's right. But more importantly, it also reduces the amount of pollutants emitted by a wood stove from 50 grams an hour down to a certified 2 grams per hour."