To make the right decisions. Starting to seminar on on d w. Its three meters and thirteen centimeters high three meters thirty six wide and weighs more than twenty five tons thats roughly equivalent to five fully grown elephants its more is up to twenty seven centimeters there more than four thousand dollars have already gone into making it when completed it will be the largest freely swimming church bell in the world and the pride of a New Cathedral in bucharest where it will bring in gods on up the centuries to come. The contract for the bell went to pay to and your hand is cast maya bell founders in the fourteenth generation almost a year ago in eighteen thirty six the family stopped being an itinerant business it opened its workshop right below the bag insole hill in innsbrook. Its not just any foundry thats able to manufacture a bell of this size your hand is cast maya who is in charge of the Family Business is Administrative Department set the course on for this. Year. In the year two thousand we built a new bell sound four hundredth anniversary. We expanded this foundry into the courtyard and prepared everything so that we could cast a ballot up to forty times. And for that was forward looking so that my son or my future grandchildren would still be able to use it. And the connection between the foundry and book arrest has a little bit of tradition. For anything. You have a few years ago we were allowed to cast new bells for the old patriarchal cathedral it was a much Smaller Church with particularly beautiful bells. They really stood out from other bells with the quality of their sound. That was why we were allowed to cast this big bell here and instruct the sculptor christina. Is in the factory modeling the bells commissioner out of plasticine patriarch danielle was appointed the head of the Orthodox Church in romania in two thousand and seven his countenance is to be immortalized on the bow the working method for want to mentation has changed little in many hundred years while pater class maya now uses the latest software when planning and constructing the Bell Software he was able to develop in collaboration with universities and expat institutes. It took us fifteen years to create the program oh i thought it would take two to four years now we can cost absolutely perfect bells in a large variety of thicknesses. This bell has to say no just the palmer and bell in st stephens cathedral in vienna but its five tons havea it has much thicker wards which brings out the partials much more it just sounds more intense. Yes you look at it we calculated the bell and then we drill it and then we transferred it to the stricken and attached it to a spindle it could turn so we could make the move. This mode is made of bricks then rendered with clay and shaped by the street by the end it corresponds exactly to the hollow space of the finished bell now we can cut out the folds bell from this trickle and foam the folds bell you can see the crosssection of the bell very nicely. In simple terms costing about require three prepare a tray components of which the middle one the full spell is subsequently removed thereby creating the hollow space into which the bell metal is cost the first component the in a mold is ready now the fool spell is made it exactly matches the size and appearance of the later bronze bow a particularly sandy clay is used for this fall spell it mustnt be too compact so that it can be removed again easily later on. And then separating layer made of graphite ensures that the fourth bell can be separated easily from the in a mold. The method for shaping the full spell hasnt changed in center is. Only available employees in the foundry are required five tons of clay have to be layered up after all. And end of year komi at the other two trained bell found as also help their boss. The portrait of the patriarch is now ready in the workshop and negative is now made of it out of pasta this plastic cost will allow an unlimited number of copies to be made of wax. While the plasters hardening on the fool spout continues. The lower section is fully formed but the two meters sixty four cant just be was up to from the bottom. The clay wall gets steeper and steeper without the tour ropes to help the clay stick it would slide down there in a moment. The plastic cost is set and the portrait of the patriarch is clearly visible. The hot wax is ready on the stove it can be poor dong to the moaned this wax cast will later be applied to the fools. A problem has occurred with the full spell despite all the supporting measures some of the clay has slid off the hole has to be patched up again an unforeseen loss of time. Its nice to have. Its three hours work but three hours with five employees is fifteen hours. Its a bit annoying we want to make progress and weve got a schedule to keep in mind. Of a fight. But theres nothing to be done about it the full spell has to be finished today otherwise its possible more of the sandy clay will break off overnight as it dries. The workshop meanwhile is ready to proceed the wax cast of the patriarch is a success. And now the tray of the full spell has been redone the hot wax fulfills two jobs it stabilizes the clay and the wax layer creates a perfectly smooth surface which is necessary in order to attach ornamentations to the bell. With a bell of this size the amount of liquid wax required is immense. Four large pots full are spread out over the clay. Yeah and. This trickle goes round and round about every time it goes round it removes even the smallest irregularities the oak and with that this trickle has done its job it wont be needed and. Like many of its predecessors this one too will find an honorary spot on the foundry wall with. The overnight the full spell shamus as if covered in icing. The next morning the sculptors attach they want to mentation all of the spots calculated for the different letters a mocked the wax letters on made to measure in the workshop instead large quantities of different sizes and phones are kept in stock while the sculptors a dealing with the letters Company Management gathers in the office of the head of the company christophe crass my still has a firm place in the Family Business. In our business they turn takes care of the casting process ideal with our clients and my fathers the master of ceremonies as it were. Made for them he oversees the casting commission before and during the casting. Of the right. Its paid his job to manage the casting process. If he has our back so we can concentrate on the actual work ensuring that our clients are perfectly looked after. Christophe grass my cares greatly about another representative duty. My sons have asked me to do a lovely job which is to do guided tours in our belle museum for which we once won the Austrian Museum prize. We have several guns and im allowed to do the rotor. Since i enjoy showing guests around the museum so much i put myself on the road a lot of. Work has progressed in the pit a mountain too is used for the wax cost of the patriarch glue sticks they didnt take this to four hundred years ago the feature ornament of the new bell work was very precise adjustment. At. The edges have to lie flush with the full spell there mustnt be a gap that anything could get into applying the wax costs to the full spell is a difficult job. Now the owner mentation is sprayed with a special clay mix that was developed by the family a long time ago up until two hundred years ago the bells were always cost on side because it was impossible to moved in across existent transport haitian roots thats why the grass my ancestors traveled haul off of europe and recorded in their Company Books what they had discovered and learned in the various locations. To fill the how it is were still finding things in these Company Books that we want to implement. Says. That this is the only mental clay for example its applied to the only mentation in a very fine layer theres a recipe for it in this book and we were very surprised by the composition so we tried it and it really was even smoother and thats. And thats one of the reasons why we have such a lovely surface on how girls beer is one of the ingredients the clay firm. Its like i used to let it stand for several weeks and then it collapses and its very smooth ready to be yours so. I wont reveal the other ingredients i have to keep some secrets. Ok. As soon as several layers of the ornamental clay have dried further thicker layers of clay are applied thats how the third component the outer mold is made the economy is creating the mix for it at the park now in addition to clay and hay menu has always been part of this mix once it dries it becomes hard like wood making it the perfect material for the bells out a mold. This is what the outer mode looks like when the clay has been applied and left to draw on the bill it is important now the mode in pots made of steel rings helps with that its filled with pure and sand a special mix that hardens completely but first the founders and a ceramic pipes to the base of the bow the idea is to channel the liquid bronze around the mold and let it rise from below. The resulting metal is much denser and better like this than if it were merely added from about five. To remove the fools about the individual parts of the mode involves have to be taken apart and then reassembled again for the casting process to find the exact spot for that again the founders punch then names into the future and sand after it hardens these markings fit like a lock and key after that the prepared hollow mode for the crown is placed on the full spell once again pipes are laid and the space is filled with fear and sand. Right at the top of the molding box the founders attached the costin holds a large cast in both is made of bricks that can withstand the bronze when its one thousand one hundred degrees the incoming metal will pool here before flowing down the pipes. A riser is placed at the center it will be used at the end of the costin process. The whole structure is stable enough now to remove the central part the fools belt from the molding box. When the upper sections are lifted off the name markings become visible now the rest of the molding box has to be lifted. Since the in a mold has been anchored to the ground the full spell crumbles remaining inside the mode invokes is the bells out on the road to claim that the mode in box will be lifted next to the pit. Oh dear theyre missing a few centimeters that can happen to the best bell found down again. With so much expertise on hand and with repeated measurements this problem is of course solvable. The mode invokes has to be strapped closer to the crane a second attempt. Success. Now pay tech i asked my and his colleagues have a long arduous job to do. The five and a half tons of clay sand that made up the spell have to be removed again completely and not just on the inside of the out among. The in a mold in the pit has to be gained by hand spade by spade. Overnight the outer mode is now heated to melt the wax that you want to mend haitians. But the file was only able to remove some of the rug. A lot of the wax that created the onan tensions in the outer mold is still attached to the clay it has to be stripped off with a gas burner. The in a mode is dried again to allow any residual moisture to escape through the clay. Has now been meticulously removed from every no can cranny of the outer mold if you want to and taishan and the portrait of the patriarch are respondent in the negative. The plastic cost of the patriarch can now join the hundreds of other portrayed in that sense of old countless works from decades past. Await a potential second use for a new bell. The mode in a box with the cleaned out a load is returned to its exact position over the in a mold during the casting process the liquid prongs exerts immense forces on the out i moaned to prevent the loading hawkes from shattering the pit is filled with us. Steel beams provide Additional Support for the molding box the earth is compacted what are the opening lines of free trade shares poem the song of the bell rolled up in a steady burn from clay the moment doc stand this day and ask the bell be ready fresh a workman be at hand. The grass my only needs to be ready the following day but first theres a logistical problem that needs solving this that will help with that its to serve as an oversized thermos flask for its day to day operation the foundry needs one furnace in which ten tons of bronze can be molten down but today more than thirty tons a needed. One furnace full of prongs was already melted overnight. At half past five in the morning its hot enough to be transported. Over the next few hours the bronze must maintain its temperature in the vat which is being coated with fire and. With that the next load of bronze can be tackled every prongs in god weighs ten kilos meaning there are a thousand in gods to make up ten tons their own thrown into the large vaness one at a time the foundries old furnace has been revived for this casting job several hundred additional in got delivered the required amount of bronze pallet after pallet the thousand in got same neverending. And. Several sacks of charcoal i did to the prongs in the insulated fact. They catch fire right away and prevent the liquid hot brungs from cooling down. And the bronze in the furnace is has to be brought up to the right temperature over several hours time to ramp up the f. Now. At around lunchtime the preparations for the casting process are going full steam ahead all of the transport routes to the casting hole are heated with charcoal to facilitate the flow of the bronze. For the casting process the bronze has to reach a temperature of one thousand one hundred degrees its hot enough shortly before the casting process the hot charcoal has to be removed again including from the channel to the old fantasy that was built especially for this job. Everythings ready now though the Blessing Comes from higher as chena would remind us to that end father nikolai klingons so a close associate of the patriarch has come from bucharest with a small delegation from the congregation to watch the cost thing and celebrate and orthodox service. One tradition is considered particularly important before every balinese cost were all going to pray the lords prayer together everyone in their own language for the kingdom the power and the glory are yours now and forever amen. Then things get hot. The. The a thanks to make sure the alloy is well mixed the bronze is given a good stuff. In. The trunk of an old is used for this job it triggers a Chemical Reaction if it is is the metal any hydrogen that could create gas bubbles during the cooling process is removed from the bronze. The bronze in the vat meanwhile has kept its temperature as soon as the vat has reached its position the process can begin. The sindo will flow to the top of the casting vote and one contaminate the battle tapping the bat is a matter for the boss of course. The founders will open the access from the old furnace fussed over with the blessing of god of course. When the found hole is more resistant than expected rushes in to help. Health and safety a secondary right now the safety of just gets away. And with that the most nerve wracking and dangerous part of making this bell begins nothing can go wrong over the next fifteen minutes. The bronx needs a helping hand Weather Channel levels out its a job for the children of the family who want ways extremely keen on casting day. The bronze of the old fun as reaches the collecting pool thats the signal to open the big fun us. Once the bronze from the family of five his added the foundry floor resembles a golden river system. The splash protectors slips into the boiling hot bronze but its recovered again quickly now damage has been done. Every second around sixty kilos of prongs flowed to the base of the caustic head. Its too soon to give the all clear immediately after the bronze rivers dry up. Thanks. To a. Paid his daughter isabella cant believe how eyes but sure footed climbing comes naturally to a tyranny and even above the remains of boiling hot prongs. Its own less than. The ballast full we just have to follow up with that full but the ballot self is full. As the bronze cools down it contracts. To make sure theres enough metal to keep the bell full fresh hawt. Wrongs has to be added regularly. Thank you and. Thank us the bronze doesnt have to take the detour via the ceramic pipes anymore it can be poured right into the top. Ok. You know almost a whole extra ton of bronzes added to the bow this way. To a two more ladles to be on the safe side then everyone involved has and themselves where. The relief is palpable. Thanks. The employees are visibly inflated and relieved as they have their photo taken to commemorate this balcony. But they are uncertain to remains of a gunnies that shyness poem describes an alliance in the us that is received full the mode is happily made when its beauty be perceived so be toil and repaid. To get the answer to that question bell found us have to be patient the metal has to cool sufficiently over the course of two weeks as winter comes to innsbruck. Finally the pit is opened up again thanks to special because that can even dig around who knows the modem box makes an appearance again. One hundred twenty five cubic meters of earth a send back they were merely borrowed from a construction company. The moment of truth has arrived there is tension in the air well all the hard work of recent months have paid off. It looks great. Its beautiful its shiny you can see the structure at first glance i give it a thumbs up and the temperatures go to. The balcony as cool down nicely. That means the bell can be lifted into daylight. Two hundred years ago frederick described the following moment perfectly. Now for me break up the building its intent is felt all right that our hearts and eyes be feasting on the most successful side. Swing the hamma swing til the mantle spring when asked. If the bell being now awoken be the frame in pieces broken. Jaw i am to me god has given see that like a golden star from its hosking so blank and even peel if out the metal cool yeah. Congratulations to everyone. This is a high large enough four hundred year family history. May this bell like all other bells ring in on are of god that made also delighted listeners. The main task now is cleaning the bow. In particular the quality of the own a mentation his scrutinised. The pit has to be tied up to the. The brick mold has been lifted out the individual bricks will be recycled for the next battle. An important part of the ballast still missing however to complete it pater class maya and his sons and by us and. Head over to germany to convince tom comes home. Why do we have to drive so far to make the clap account to be done in austria and theres no company in austria that can do it the company or stock has specialized in big belt that has a big clapper for this bell has to be stable and ring well so that the bow has a nice sound the clapper has to last a long time it must not shut down for. Costing a clapper is an exciting event for young and old thats why the company haas fog uses the occasion of this commission to stage an open day. The clapper is made from a steel cylinder that weighs around seven hundred kilograms. Thus the individual sections of the trap are all measured and priest and. After the first step the metal has cooled down too much it cant be what anymore and has to be reheated in the furnace. The times when a hammer and anvil will use da long gone and metal working to their exact calibration of the item is still a dont play human. Hands but the grunt work is done via computer assisted Hydraulic Press after four tens in the press and in the furnace the clapper has taken shape the ideal clapper from a bell found his point of view would be a bore attached by a thread but of course that wouldnt work as a result there is no threat instead theres a shot that says narrow is possible. But because the shaft shifts the center of gravity away from the board theres a balance there at the other end of the trap and that way the center of gravity is perfectly in the bowl and the clapper can ring the bell as it should. Forging these exact weight requirements is and ought such a clappers real quality as the mercedes of clubbers. Even though it might not look that way the metal is so hard that a small mishap one do it any damage. The fact that. After around three and a half hours the forging work is complete the clapper can be presented in all its glory. The visitors are already impressed. But the trapper will still undergo fine tuning at the lathe in line with the foundries specifications the trapper was forged out of a special steel with a low nine stabilize ation that way it will be softer than the bell every time the flap a hits the bow it will be knocked back slightly thereby acting as aware in part nevertheless its designed to do its job for around seventy years and ensures the bell will be able to ring on home for centuries. Cutter works its way through the metal one micro meter at a time slowly the clapperboard that will strike the bell becomes a visible on the ladies thank. Him be handed over the quality of the steel is checked via ultrasound this material test is only done after the fine tuning since the service must be smoothed for this test. The clapper gets the all clear it can be sent to innsbruck. All the necessary cleaning work has been completed in the foundry the sandblasting alone took six days was the result of his breath taking the largest free swinging bell in the world is ready for book arrests National Cathedral of redemption was. Godless of how glorious it looks the bell needs to sound perfect to. The or double sound of a bell is made up of various partials that can be tested at different parts of the bow the whole known yes interaction between these partials gives a bell its an art. And the bells partials are all correct no whether theyre a happy everything is as calculated the bells fundamental is seen zero were going to hang the clapper and then well bring it about we count of the bells ringing in the foundry if it works with the clapper and it sounds nice and strong then our work will be done well be happy and well be able to sleep well tonight with the master. The trapper has arrived in innsbruck to protect the metal from corrosion its being covered with a black vanish here in the foundry. As soon as the clapper has been attached and the bell is rung the grass my family will have completed its commission transporting the ballot to bucharest and installing it in the cathedral along with setting up their Winning Technology will be done by were many and companies the bell will remain in the foundry for a few more weeks while preparations off finalized. Sheilas poem ends with the words peace be the first chime shes ringing words everyone hopes will ring true for this bell to. The or are. For sarah willis playing the horn is a passion. For fashion joined her on a journey as musical discovery. This time in cuba im here in havana for the two thousand and seventeen mozart festival out here on the streets you can hear cuban music on every corner and hear in the cathedral theres mozart going on. Fifteen minutes among the last of the. Chickens to fasten your seat belts. Blood. Look at this. Cut. The travel guide. In thirty minutes to w. We take it personally. With all the wonderful people and stories that make the game so special. For all true fans love. Love love more than football on line. Tells us stirring stories. It makes us laugh. And cry. Tremble and smile. Magical images and emotions emotions didnt. Go the busy every weekend on d w. In yemen fresh gun battles have broken out in the capital sana between forces loyal to