http://www.toolsofthetrade.net/Images/60095438_figure_1_tcm80-1807800.jpg
600
Sixth-generation family employee Ryan DeArment holds a billet of C1080 alloy steel where all Channellock tools get their start.
http://www.toolsofthetrade.net/Images/898575625_figure_2_tcm80-1807801.jpg
600
A massive die-forging machine used to form pliers parts out of a yellow-hot billet of steel.
http://www.toolsofthetrade.net/Images/502759318_figure_3_tcm80-1807802.jpg
600
The machine hammers out the parts with nine tons of pressure while bouncing the ground floor of the factory like a continuous earthquake.
http://www.toolsofthetrade.net/Images/458314902_figure_4_tcm80-1807803.jpg
600
Seconds after forging, the rough parts are separated from the scrap metal on a trim press.
http://www.toolsofthetrade.net/Images/945423198_figure_5_tcm80-1807804.jpg
600
The parts are diverted into bins by the lower conveyer belt while the scrap metal rides the upper belt into a large hopper to cool.
http://www.toolsofthetrade.net/Images/2090662747_figure_6_tcm80-1807805.jpg
340
After forging, holes are created in the pliers parts by a large punch press.
http://www.toolsofthetrade.net/Images/1081327716_figure_7_tcm80-1807806.jpg
600
Precise mating joint surfaces must be milled into the pliers.
http://www.toolsofthetrade.net/Images/610636330_figure_8_tcm80-1807807.jpg
600
The angled grooves in these tongue and groove pliers would be impossible to form with a forging process.
http://www.toolsofthetrade.net/Images/1905794150_figure_9_tcm80-1807808.jpg
600
After milling the joint surfaces and shaping the cutting edges, the two halves of a tool are riveted together and the rivet is ground flush as shown on these diagonal cutters.
http://www.toolsofthetrade.net/Images/1015946727_figure_10_tcm80-1807809.jpg
600
A mechanized grinding process in action.
http://www.toolsofthetrade.net/Images/1772460902_figure_11_tcm80-1807810.jpg
600
Hand grinding the heads of pliers for a finished appearance.
http://www.toolsofthetrade.net/Images/2027684915_figure_12_tcm80-1807811.jpg
600
Assembled linesman pliers after finish grinding.
http://www.toolsofthetrade.net/Images/823987197_figure_13_tcm80-1807812.jpg
600
Pliers' thin cutting edges are laser-hardened (a process I wasn't allowed to photograph), but radio frequency hardening is used to harden the entire head of some tools like these nippers.
http://www.toolsofthetrade.net/Images/1130914672_figure_14_tcm80-1807813.jpg
600
As part of the heat-treating process, large batches of pliers are run through a fiery furnace.
http://www.toolsofthetrade.net/Images/1079379323_figure_15_tcm80-1807814.jpg
600
Skilled "filers"? inspect and adjust the cutting edges and joints of the tools and make fine adjustments by hand if needed.
http://www.toolsofthetrade.net/Images/189531900_figure_16_tcm80-1807815.jpg
600
Pliers drying after their dip into molten plastic handle material.