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00:01Here at The Repair Shop,
00:03countless treasures have been brought back to life.
00:07Ka-ching!
00:08That reveal so much about who we are
00:11and where we're from.
00:14It's like it's brand new.
00:15But there's so much more out there
00:18that's not yet made it to the barn.
00:20This is amazing.
00:22So the team are hitting the road.
00:24I just love getting up close and personal with the objects.
00:27And we're going to get a glimpse into some amazing heritage crafts.
00:31I cannot wait.
00:34On a unique adventure.
00:36Oh, yes.
00:37This is terrifying.
00:39To join forces with expert craftspeople.
00:43Whoa!
00:44If we don't point these joints, moisture's going to penetrate.
00:47On their most ambitious restorations, yes.
00:50To think every day you come up, this is your office.
00:52Wow! It's big!
00:54Keeping heritage crafts alive.
00:56Keep going.
00:57Keep going.
00:58It's getting hot in there.
01:00On precious restorations around the country.
01:03I can't even imagine what it looks like.
01:06There's a legacy here that needs to be protected.
01:15This time, Will and Dorma are heading into Scotland's central belt.
01:21In search of a massive lift.
01:24A full-cut wheel.
01:26What a beauty.
01:28And it's mini-me.
01:30This is it?
01:31This is a lot bigger than I was expecting, I'll be honest.
01:33In the barn...
01:35Meet Wappy.
01:36Julie and Amanda...
01:37Hello, lamb!
01:38Hello, Wappy!
01:40...combine forces to rescue a much-loved companion.
01:43One head, one body.
01:44Yeah.
01:46And Will has designs on silversmithing.
01:49Yeah, that's looking really good.
01:50You've not even jumped out the line or anything.
01:52Because I've been holding my breath whilst doing this.
01:57Once at the forefront of Scotland's industrial revolution,
02:01the historic town of Falkirk lies in the fourth valley
02:06between Edinburgh and Glasgow.
02:09The town's tradition of engineering expertise
02:11is reflected in the Kelpies,
02:14steel sculptures of mythical creatures from Scottish folklore.
02:18And just a few miles down the road,
02:21the team are headed to another marvel of the modern age.
02:27Falkirk!
02:27Falkirk.
02:28I quite like this area.
02:30It looks nice here.
02:31I've been invited to the Falkirk wheel today.
02:34It is a mind-blowing feat of engineering.
02:38I don't know really how it works, so I'm not too sure.
02:40I'm going to find out more.
02:42Oh!
02:42I think I know what that is.
02:43Do you?
02:44I think I know what that is.
02:45The Falkirk wheel is world famous.
02:48There it is!
02:49A rotating boat lift bridging a 35-metre gap between two canals.
02:55And Will's never had the chance to visit until today.
03:00Look at the size!
03:02But he's not here to fix that wheel.
03:05Instead, he's at the visitor centre,
03:08home to an elaborate scale model of the original.
03:12Richard.
03:13Hello, Will.
03:14Good to see you.
03:15Will has been called in by Richard Miller from Scottish Canals.
03:19This is it.
03:20This is the model.
03:23It's a brilliant example of how the Falkirk wheel works.
03:27So this model was built by local college students
03:31to learn about how the Falkirk wheel is constructed.
03:34You can look at the Falkirk wheel,
03:36you can see it gracefully moving in the sky,
03:40but there's nothing like actually just getting close in,
03:43understanding the mechanism.
03:46And when it worked,
03:47there's an engine here at the back
03:49that drives that central axis
03:51just like it does up there.
03:53But it's just not working?
03:54Unfortunately not.
03:55That's why I'm here.
03:57How long has this been out of action for?
03:59It was put away about 2003.
04:02Really?
04:02We found it recently in a cupboard.
04:04It still turns,
04:06but some of the wheels,
04:08it runs on little wheels,
04:10some of them are broken in there.
04:12The motors have gone
04:14and actually the cog mechanism here at the back
04:18that is so crucial to keeping these gondolas in place,
04:22the cogs have come out as well.
04:24Why is it so important to have this repaired?
04:26What we want to do is to get it back operational
04:30so young people, future engineers coming in,
04:34exploring this model,
04:35getting an understanding of it
04:36and then heading inside the real thing.
04:39Well, we'll do our very best to get it working.
04:41I can't wait.
04:43But before restoring the model,
04:45Will needs to understand how the real thing works
04:48and why it was built.
04:52Now, the need for a boat lift,
04:54that's quite high up, right?
04:56And we're a lot lower here,
04:57so you need some kind of way of bringing the boat down.
05:01So the canals in the past
05:03had been the first sort of major transport system
05:06for the Industrial Revolution.
05:08And then they'd fallen into disrepair and decline.
05:11And in 2000, our job was to bring them back to life.
05:15At the bottom of the hill,
05:16we had the Forth and Clyde Canal.
05:18And at the top of the hill,
05:19we had the Union Canal.
05:20Travelling all the way into Edinburgh,
05:22what we needed to find was a really modern
05:24and exciting way of saying,
05:26these canals are back
05:27and we're going to connect them back together.
05:29And that's how we ended up with the Fulcook Wheel.
05:31Wow.
05:33In the past,
05:34the Union and the Forth and Clyde canals
05:36were linked by a series of eight locks.
05:40But when railways replaced the canal system,
05:42the locks were dismantled.
05:45The wheel was built as a state-of-the-art alternative.
05:48to revitalise the area,
05:50opened by Queen Elizabeth in May 2002.
05:57That is the world's only rotating boat lift.
06:01And it's super, super efficient.
06:03It runs on the power of six kettles.
06:05Hold on.
06:05It runs on the power of what?
06:07Six kettles.
06:091.5 kilowatt hours is all it takes
06:12to operate 1,800 tonnes of steel and water.
06:16And the reason for that is Archimedes' principle.
06:20Archimedes worked this out,
06:21that anything that floats in water
06:23displaces its own weight in water.
06:25So you can have a massive boat in one gondola
06:27and a canoe up in the other,
06:29and it will still be in balance.
06:31And that allows it to have this really simple, graceful movement.
06:34Very clever.
06:38The Falkirk wheel is an engineering triumph,
06:41but the repair shop's challenge
06:43is to restore the same mechanical perfection
06:46to the model.
06:48To help with that,
06:50Will's bringing in a member
06:51of Edinburgh Society of Model Engineers,
06:54Dan Coop.
06:56Oh, hey.
06:58Hey, Dan.
06:58What's this?
06:59Pretty cool, isn't it?
07:00What a model, yeah.
07:00This is the model, or the Falkirk wheel.
07:03This was made over 20 years ago.
07:04Yeah, oh, wow.
07:06Well, it's showing a little bit of that age.
07:08Yeah?
07:09That's for sure, I think.
07:10Could do with a good clean and a scrub up.
07:13It needs more than that, Dan.
07:14I mean, it's meant to sort of turn around
07:17and there's sort of all these different flats
07:19and everything else.
07:20Oh, right, yeah, fully functioning.
07:21It is like a miniature model of the main wheel.
07:23Unfortunately, it's just not turning.
07:25Oh, yeah.
07:26This is more your kind of area of expertise than mine.
07:29Yeah, models, miniatures, yeah.
07:31Dan has a passion for constructing
07:34and restoring model steam locomotives.
07:37He has the engineering skills
07:39and a fully equipped workshop
07:41to take on this challenging task.
07:44I think perhaps we've got a wee bit
07:47of a job on our hands,
07:48but nothing's impossible.
07:50There are some little motors on the back here.
07:52I'm not too sure.
07:54A little bit of electrics involved, perhaps.
07:56We'll dig into it.
07:57If it doesn't move,
07:58there's maybe some kind of part of the mechanism,
08:01the motors, maybe the gears,
08:03maybe even one of the bearings could be damaged.
08:06I know that these should sit horizontal.
08:10Pretty level, yeah.
08:11Whereas if it didn't...
08:13This one looks quite stiff.
08:15You can imagine it would never be like that
08:17because water would be pouring out
08:19and you'll fall out as well.
08:20Exactly.
08:20That wouldn't be fun.
08:21It's a boat lift, not a roller coaster.
08:24Exactly.
08:25At the moment,
08:26the metalwork looks really tired and dull.
08:28The paintwork is cracking, flaking away.
08:32So not only does this need to function properly,
08:34but it also needs to look really eye-catching too.
08:36Yeah.
08:37So this is something that you could do for me?
08:39Certainly.
08:40It'll be fun to work on a model of the real thing
08:43which I've been on in the past myself.
08:45Have you?
08:46Yeah.
08:46Oh, it's fantastic.
08:48There's so many different scopes of engineering
08:50that fall within this model
08:53and the full size, of course.
08:55You've got the right person for the job.
08:56I love it.
08:57Good fun doing it as well.
08:59Lovely. Perfect.
09:00As Will puts the model wheel in the safest of hands,
09:06Dom's been out on the road
09:07in search of a treasured possession
09:09in need of TLC from the team in the barn.
09:14He's travelling to meet a brother and sister
09:16from the city of Dundee,
09:19Robbie and Chris Parkin.
09:23Exciting.
09:24What a beautiful day.
09:25Yeah, that is.
09:26Who are joined by Robbie's very special friends.
09:31Hi, Dom.
09:32Hi.
09:32Please take a seat.
09:35There you go.
09:36We'll go sit Wappy here.
09:38Who is this?
09:39This is Wappy.
09:41I've had Wappy for a massive 51 years.
09:4551 years?
09:46Yeah, he's the same age as what I am.
09:49But what happened, Robert was born in a special baby incubator.
09:54Yeah.
09:55But at that same time, Ninewells Hospital, the teaching hospital in Dundee, opened.
09:59And so Robert was the very first baby in Ninewells in the special baby care unit.
10:04One of the most modern medical facilities in Europe, when it opened in 1974, Ninewells Hospital in Dundee is still
10:14renowned today for its pioneering neonatal care.
10:18Robbie was the first of thousands of babies given a better chance of life by the new hospital.
10:25Why were you in that special unit?
10:28Well, I was born six weeks premature.
10:32Six weeks premature?
10:34That's right.
10:34Yeah.
10:35That's scary.
10:36There must have been some nurse that brought Wappy to me, to look after me.
10:43It was really dark times.
10:45We nearly lost Robert.
10:47Wow.
10:47He had loads and loads of operations until he was about eight.
10:51Goodness me.
10:52So he's a miracle, really, eh?
10:55Yeah.
10:57And all the while, he's had his wee pal Wappy.
11:00Tell me about him.
11:02Well, he sleeps with me every night and he's been looked after me ever since then.
11:09I mean, it's even helped when there'd been, like, a six-year age difference between us.
11:15Wappy was like a bonding thing.
11:17That helped us to bond as brother and sister because I used to sit and draw Wappy for you, didn't
11:22I?
11:22That's right.
11:23So how was childhood for you growing up?
11:27Er, first thing I wanted to do was kick a football.
11:31Oh, really?
11:31And I've loved football ever since and I've even participated in the Special Olympics.
11:41Really?
11:41That was in 1993.
11:43How did you do?
11:44Won two medals.
11:46It was a gold and a silver.
11:48What are you hoping we're able to do?
11:51Well, I'm hoping for the same sort of eyes he's got, his ears.
11:59I've just noticed that he's got one leg longer than the other.
12:04He's obviously had quite a life.
12:06Oh, yeah.
12:07He had his full eyes.
12:09Yeah.
12:10And he had his bit round there and then his mouth coming up.
12:13He's sort of lost all of his mouth, hasn't he?
12:14So are you hoping to at least get him looking a bit more like he did whilst you were a
12:20kid?
12:21I'm hoping, yeah.
12:22It's my number one.
12:25Are you going to miss him?
12:26Yeah.
12:26Well, look, I promise you he will be in safe hands.
12:29We'll take good care of him and we'll do our best to get him looking a bit like he did
12:33when you were a kid.
12:34That'd be amazing.
12:36It's been a pleasure, Dom.
12:37Thanks very much.
12:40Nice to meet you.
12:41All right, take care.
12:44Thank you so much.
12:46All right, take care.
12:47You coming, bro?
12:47Yeah.
12:48Right, come on.
12:49Bye, Wapp.
12:51Oh, Wappie.
12:55As Wappie makes his way to the barn, in his workshop, Dan is wasting no time getting to grips with
13:02the scale model of the Falkirk wheel.
13:06So, here I have the, one of the main water troughs off of the Falkirk wheel model.
13:12These parts with the wheels, I would call these bogeys in the train world, in the railway world.
13:18They're a sort of pivoting assembly and it allows this whole trough to rotate within the wheel.
13:25But one of the bogeys is missing.
13:28I've got this piece of round bar, this piece of steel here.
13:32I'm going to fix it in the lathe and start machining.
13:37The miniature trains have a very similar sort of shape.
13:41The wheels, it's a sort of cone shape.
13:43They've got a couple of flanged pieces, which stop them falling off the circular hole that they're sitting on the
13:51Falkirk wheel.
13:54Next, I'm making the groove that runs on the rail, so the groove and the wheels.
14:00Nice and slow here.
14:09So, I've got all the constituent parts here.
14:12I've got the bogey frames, the wheels and some little brass washers.
14:18Slip those on.
14:23And then I'm going to pop it into the vise and tap that home.
14:32Right, I'm just going to compare this to the original one.
14:36See how close I got.
14:38Yeah, that's looking pretty much bang on like the original.
14:44Along the road, Will's getting the full Falkirk wheel experience.
14:51All right, here we go.
14:54First, he's taking a trip to the top.
14:58Archimedes BMK.
15:00On this sailing, we have 86 passengers and three crew.
15:03From the 4th and Clyde Canal, the boat moves into the lower gondola.
15:08Then the gates are closed.
15:10As hydraulic motors rotate the central axle...
15:14I've only just realised that we're moving.
15:18The gondola and boat start to rise.
15:22This is really smooth.
15:24To be moving something so heavy into the air.
15:28Mid-air, there's time for skipper Stephen Connolly to join up.
15:36Hi.
15:36Hello.
15:36Hello, Will.
15:37How are you?
15:38Good to see you.
15:40Who's in charge of the boat?
15:41One of my colleagues.
15:42OK, good.
15:42We've got a second person.
15:44This is great.
15:48So, it's actually been pretty quick to get from the ground level.
15:51Four and a half, five minutes, that's all.
15:52Which, years ago, would have taken you six or eight hours when we had a lock system.
15:59Why is this so important to the local community?
16:01It's given them a sense of pride back in their area.
16:04The area, for many years, was very heavily into engineering, foundries, metalworking.
16:09And, of course, 1950s and 60s all disappeared and area was in decline.
16:14So, this has really brought a focus back in and bringing lots of visitors, lots of tourists and just making
16:20the place really nice.
16:25Thank you so much for having me on board today.
16:27Is there any way, before I go back, I can have a look at the inner workings of this?
16:31Once we get back down, you absolutely can.
16:37Dom's hot-footed it back down to the barn.
16:42With Robbie's beloved companion tucked safely under his arm.
16:49Hello.
16:50Hello.
16:51Hello.
16:52Meet Wappie.
16:54Oh, Wappie.
16:55He's a little lamb.
16:56Wappie is entrusted into the expert care of soft toy restorers Julie Tatchell and Amanda Middleditch.
17:04Oh, isn't he lovely?
17:05He's beautiful, isn't he?
17:07Oh, look.
17:08There's a lot of love in there.
17:09There is, yeah.
17:10Look, he's got little crocheted feet.
17:13Wow.
17:15So, tell us a little bit more.
17:17Well, he was given to Robbie on the day he was born in intensive care because he was very premature.
17:22Oh, right.
17:22And it's been with him ever since.
17:24So, how old is Robbie now, then?
17:26Robbie's in his 50s now.
17:28Wow.
17:28That's amazing.
17:29I mean, I don't have soft toys or anything like that.
17:33Don't.
17:33But I know, I know.
17:35But from speaking to Robbie, I kind of get it.
17:37It's the way he would talk about Wappie was like talking about a friend.
17:41Yeah.
17:42And would help him through the tough times.
17:44Yeah.
17:44He's always there.
17:45Never looks sort of indifferent.
17:47He's just there.
17:48Yeah.
17:48OK.
17:49Did Robbie give you any sort of do's and don'ts?
17:51I think Robbie completely appreciates that Wappie's been through an awful lot.
17:55He's been loved.
17:56But he did mention that he used to have like a little, you could sort of see the faint outline
18:00of like a little sort of stitched mouth.
18:02I think a sort of considerate, cautious approach to preserving it.
18:06Do you feel that Robbie still uses him actively?
18:10Or does he sit sort of on show?
18:12No, no, no.
18:13He's with him.
18:14Yeah, yeah.
18:14So he's got to be strengthened from that respect.
18:16Yeah.
18:16OK.
18:17But importantly, still needs to look like Wappie.
18:19Yeah.
18:19I don't think his body and everything is too bad looking at it.
18:23His neck, I think he's been held probably like this.
18:26And obviously a lot of kissing.
18:28A lot of cuddling.
18:29Well, good luck.
18:29See you later.
18:30Thanks, Dom.
18:31He's very sweet.
18:33Yes, isn't he?
18:39How are we going to tackle it?
18:42Split him up?
18:43Yeah.
18:44Do you want the head?
18:44OK, yeah.
18:46My most worrying bit is this nose.
18:48Yeah.
18:49I'm so worried about, actually, once I take the stuffing out, because he could just disintegrate.
18:54So that is going to be really tricky.
18:56Well, shall I carefully unstitch his head and we'll just take it from there and see how
19:02it can get on?
19:04Be gentle with it.
19:06I know.
19:06I can see where the stitches are.
19:09Ooh.
19:10What's going on?
19:12Oh.
19:16I've never seen anything like that.
19:18How have I?
19:19Well, you wanted the head.
19:22I'm just going to carry on with this.
19:24Come on.
19:24Can't wait.
19:27As Wappi's being gently prepared for treatment, in Falkirk, Stephen is taking Will deep inside
19:34the wheel's workings.
19:38This is the brains of the operation here.
19:41We're in the engine room.
19:43Oh, my gosh.
19:44It's like setting foot inside the mechanism of a Swiss watch.
19:54Well, we've come up through three levels.
19:57Now we're up to hydraulics behind you, physical things that make the wheel move.
20:01And then around the outside, we've got the hydroelectric motors here.
20:06And then behind that, we have four reduction gearboxes.
20:10I almost feel like I'm in the centre of the model itself.
20:13Yeah.
20:13But this is like the real heart of the beast, isn't it?
20:15This is the heart of the beast.
20:19Nearby, model maker and engineer Dan begins the task of rebuilding the miniature version
20:25of the wheel.
20:28This is the typical size of spanner that I'm used to working with.
20:32If you're building a scale model, you need scale-sized bolt heads.
20:39Let's see if it fits.
20:42Gently feed it through.
20:44Yeah.
20:47Keep the wheels on.
20:49These are the grooves here.
20:51These are my new wheels.
20:53You can see the wheels running on the rails.
20:56The flange at each side of the groove stops the whole trough sliding off the rails.
21:03And there we go.
21:05We have movement.
21:06We have success.
21:09But not everything is fitting together quite so sweetly.
21:14So the main bearing is a bronze material, and it's made up of two halves.
21:20Now, it looks like it's loose, if I just pull it off here,
21:23because there's a multitude of the screws missing, about five of them.
21:28So that's not going to help.
21:29But the ones that are still here look like they've actually broken or sheared off.
21:35Dan's now working on the central axle of the wheel.
21:39The same axle Will is about to walk through.
21:45Oh, yes.
21:48Hello.
21:49The acoustics.
21:51We're going to come in here after a few whiskeys.
21:54There we go.
21:55Look at that view.
21:57Come on.
21:59There you come.
22:02This is lovely.
22:03Oh, my gosh, you can see for miles.
22:04You can see for over 50 miles in that direction from the top.
22:08Thank you so much for today.
22:09It's going to be a real idea of what this is all about
22:12and what means so much to the community.
22:14Yeah, my pleasure.
22:15It's not a problem.
22:27Amanda, how are you getting on?
22:28Because I'm just washing those little hand and foot covers
22:31and I'm wondering how far off you are.
22:34Poor Wappy.
22:36I've got to be really, really gentle with him.
22:38In the barn, Julie and Amanda are busy working
22:41on Robbie's well-loved companion, Wappy,
22:44and it is a tough decision to be made.
22:48So, basically, this muzzle here is rotten.
22:52Yeah.
22:54So, do I line and down, as we usually would...
22:59Right.
22:59..or replace the muzzle with stronger fabric
23:04so that we future-proof him for Robbie?
23:07My gut's leaning to that.
23:09My gut is as well, but I'd wanted to be sure
23:12that we've made the right decision
23:13because Robbie needs him to last.
23:16I think it'll look nicer. I really do.
23:19Let's just go for it.
23:20Fabulous.
23:21OK.
23:22OK.
23:32This is Wappy's head, now in pieces,
23:36ready for me to start to repair him.
23:38Now that he's clean,
23:40it's very clear where the rotten pieces are.
23:43We can see the bits that are missing from his nose
23:46that need to be strengthened and replaced.
23:49So, I'm just going to make a template from this piece.
23:53As I'm handling these pieces,
23:55you can feel how fragile they are.
23:58It's very fortunate, from my point of view,
24:01that these are the two sides to his head
24:04and one has still got enough there
24:07that I can see the shape
24:09of where his snout or his nose was.
24:11So, that makes life a little bit easier for me.
24:16My ears go in here.
24:18So, I'm going to make a little bit easier for me now.
24:21Amanda is tracing carefully around the original pieces,
24:25forming templates for the new, stronger fabric.
24:30Right.
24:32So, that's my...my template.
24:36Now, this is the exact reason I keep scraps.
24:40I've just got this piece of material here.
24:42Might not look a bit like Wappy,
24:45because he doesn't have that sort of pile,
24:46but with a little bit of fettling and trimming,
24:52I think this is going to make a really good match.
24:57So, what I'm going to do
24:59is I'm going to trim the fur away
25:02and you will see my vision come to light.
25:08As Wappy receives intensive care in the barn,
25:12in Scotland, with the main bearing now mended...
25:15So, there we go, a little tweak up.
25:18That's that screwing.
25:20Dan is powering ahead.
25:22So, the next stage of the fix is the motor,
25:25which I think has sustained some damage
25:27because of the failed bearing.
25:30I'm going to remove this casing,
25:31so I think there's going to be something broken inside of this.
25:36This is actually a gearbox.
25:38So, the motor runs quite fast,
25:41but the model needs to spin quite slow.
25:43So, there's a gearbox which slows down what the motor's putting out.
25:48There you'll see all the gears.
25:50End of my screwdriver,
25:52you'll actually see there's a missing tooth.
25:54It's totally gone.
25:55And the two teeth either side of that gap
25:58have got significant damage to them as well.
26:01So, this is the prime culprit here.
26:03Instead of the outdated motor and gearbox,
26:07Dan has decided on an upgrade,
26:10more fitting for this modern engineering marvel.
26:13I've made the decision to replace
26:15the damaged motor and gearbox assembly,
26:18and I've decided to replace it with this stepper motor.
26:21It's fully controllable.
26:23I can determine what speed I would like it to do
26:26without having to change mechanical gears,
26:29and I can start and stop it whenever I like.
26:32With the restoration of the model wheel moving on nicely,
26:38Will takes the opportunity to seek out a fellow crafter.
26:43Outside the border's village of Dunn's,
26:45he's meeting Katie Watson, silversmith.
26:50Hi, Katie. Good to see you.
26:52How are you?
26:52Not bad. I can hear you.
26:54Yeah.
26:54I was like, I wonder where Katie is.
26:56All the hammering.
26:58Katie specialises in chasing and repoussé,
27:01a metalwork technique that uses a hammer
27:04to create a design in low relief.
27:08Repoussé uses a hammer on the reverse side,
27:10whereas chasing works from the front.
27:14Katie's skills have won her a gold award
27:16from the Goldsmith Craft and Design Council.
27:20What are you working on?
27:21I'm making a shallow trinket dish.
27:23Oh, trinket dish.
27:24Yeah, so I'm just hammering it just now,
27:26smoothing out all the lumps and bumps.
27:28Lovely. So that was flat.
27:29Yes, it was a flat disc,
27:31and now I'm just planishing it.
27:33So I'm using a nice flat hammer,
27:36which is nice and shiny.
27:37Yeah, that looks very nice.
27:38Can I please give it a go?
27:40You want to have a go?
27:40Yeah, please, definitely.
27:42Planishing is shaping and smoothing out
27:44the surface of the metal
27:46so that it's ready to take on the design.
27:50Do you know what?
27:50Your hammers are in a better state than my hammers.
27:53Whatever surfaces on that hammer
27:55will be transferred onto the silver,
27:57so you want it nice and pristine,
27:59nice and shiny.
28:00So I'm just kind of hammering,
28:03going back and forth,
28:04going kind of round in circles.
28:05You can kind of see these guidelines.
28:07Yeah.
28:07You want to have a go?
28:08I'm slightly terrified.
28:09You've done such a lovely job so far.
28:10No, go for it.
28:11OK.
28:12Yeah.
28:13Right.
28:16Yeah, perfect.
28:16And just gradually turn it.
28:20It's kind of like tapping your head
28:22and rubbing your tongue, isn't it?
28:24OK.
28:28Yeah.
28:30So it all looks pretty smooth, though.
28:32Oh, actually, oh, no.
28:34Yeah, a few ripples.
28:36Would you like to show me how it's done?
28:37Yeah, I'll take over.
28:39It's quite addictive, actually.
28:41Yeah, you can kind of get lost in it.
28:42It's quite meditative.
28:49OK.
28:50I think that is more or less there.
28:52And I think we're ready to chase the design on now.
28:55That's great.
28:55Yeah, let's go.
28:56Let's go.
28:59So I've got some different kind of flowers drawn here.
29:02So I think we'll just take one of them.
29:05We'll use this carbon paper.
29:07Right.
29:07And then if you trace over those lines
29:10with this kind of embossing tool,
29:13it'll transfer the design straight onto it.
29:15That is really effective.
29:18Well, that's the first one.
29:19What's next?
29:20So the first tool I use is a line punch
29:23and placed onto the metal.
29:33So do you want to have a go?
29:36Yes.
29:37Yeah?
29:37Definitely.
29:38So if we start at this line here
29:40and follow it on.
29:43Yeah, perfect.
29:49Yeah, that's really good.
29:51You've not even jumped out the line or anything, so...
29:55I know that.
29:56Because I've been holding my breath whilst doing this.
30:03That's that leaf done.
30:04Yeah.
30:04Shall I pass them over to you?
30:05You can do the next one.
30:06Finish that off.
30:19Once the design is in place,
30:21the dish is then cleaned
30:22in a mixture of warmed water and pickle salts.
30:28OK.
30:29Let's take out the pickle.
30:30Oh, that's exciting.
30:33Have a look.
30:35There we go.
30:36Oh, turn it over.
30:38Oh, look at that.
30:39Look at that.
30:40We made a drinking dish.
30:41Yeah, we did it.
30:42OK, so now we'll give it a brass brush
30:44to brighten off the details.
30:46You're really buffing up the surface.
30:48Yeah.
30:48So that's taking off any surface dirt.
30:50Yeah.
30:51And really getting into all the grooves,
30:53all the details.
30:55Lots of work has gone on to make you miss.
30:57But that is fantastic.
30:59But it's nice to see what you've created
31:00at the end of the day with your hands.
31:03Yeah.
31:04Well, thank you for passing on
31:05some of your knowledge today.
31:06Yeah.
31:06What a wonderful thing to see.
31:19Back in the barn,
31:21Wappie's still undergoing major surgery.
31:24This time, it's Julie working on his arms.
31:29So I'm going to start by making a little patch of felt.
31:36So I am literally just backing the hole
31:39to then do my repair.
31:42And then using a pair of pliers,
31:46I have to feed the patch into the right place.
31:52I'm going to catch it with a pin
31:55and then gently remove the pliers.
31:59So now my piece of felt is in position
32:02behind the damaged area.
32:05I can start darning,
32:07knowing that I can pick up the felt
32:09underneath as I go.
32:21The colour of the thread that I'm using
32:23is determined by the colour of the skin of the bear
32:27rather than the fur.
32:29That's why I've chosen to go with a slightly more yellow thread.
32:48Amanda's been reconstructing Wappie's head
32:52and thankfully,
32:53it's all starting to come back together again.
32:56Now that I've got both sides done,
32:58I can see my idea, if you like, taking shape.
33:02This is the new fabric that I trimmed down
33:06and this is the line
33:08where that is going to join to the old fabric.
33:12And I think it's picking up really well
33:14the different colours here that you can see.
33:17The sort of lighter creams
33:18and the more beige-y colour maybe going on here.
33:21I think this is going to look like it's always been there
33:24and always been a part of him.
33:27So now I've got to continue this process
33:29with the other pieces
33:30and then I'll be ready to start putting the head back together.
33:45I'm just sewing on Wappie's second ear.
33:49This is the final stages of putting his head back together.
33:54Once he's done,
33:55I'll be able to start putting the stuffing in
33:57and then we'll see all my work come together.
34:01Right, there we go.
34:03That's the final stitch in his head.
34:09He's definitely starting to look a bit more like Wappie again.
34:15That's very sweet.
34:31All Wappie needs now is to get back in shape
34:38with some fresh stuffing
34:39before he's ready to head back up to Scotland
34:46where, in the shadow of the Falker Quill,
34:50Will is helping Dan reassemble
34:52the newly refurbished scale model.
34:56It's come along well, hasn't it?
34:58It's like a new machine.
35:01This is great.
35:02So you've touched up the paintwork.
35:03Well, not touched it up.
35:05Yeah.
35:05You've repainted it.
35:06Totally repainted it.
35:07And the metalwork as well, nice and shiny.
35:10Yeah.
35:11Giving that a good clean and polish up.
35:13So, aesthetically, it looks the part
35:15but does it actually function?
35:16Yeah.
35:17We can get ready to give it a test.
35:19So what's first?
35:19What we're going to do is feed it in
35:22through the two holes
35:23because it runs on the tracks and the holes.
35:26But at the same time,
35:28if you can hold this gear up
35:30at the end,
35:31so it's actually got to slot in.
35:34Oh, yeah.
35:35That's it.
35:35So like that.
35:36Yeah, that needs to feed through there.
35:38And this feeds through.
35:39And there's three bolts
35:41sticking out the end
35:43that actually locate into that gear wheel.
35:46This really is a multiple-person job, isn't it?
35:51Oh, I see.
35:52I can see the holes.
35:53You see the holes?
35:54I see those.
35:54Right.
35:55Okay.
35:56Coming in.
35:57Hold your horses.
35:59Hold on.
36:00There we are.
36:00I'm in.
36:00I'm in.
36:01Okay.
36:02It's really fiddly getting those nuts on, isn't it?
36:04Yeah, they are really small.
36:06Right, that's done.
36:07Right.
36:08With the wheel back in position
36:10and ready for unveiling,
36:13Dom's getting close to another very special reunion.
36:17I'm on my way back up to meet Robbie and Chris
36:20to reunite them with Wappy.
36:24The Teddy Bear ladies have done a brilliant job restoring him,
36:27and it was not an easy job.
36:30Wappy was given to Robbie as the first infant
36:33saved by the nurses in Ninewell's new premature baby unit
36:37back in 1974.
36:39For him and Big Sister Chris,
36:42this is a special day.
36:44I'm a wee bit excited.
36:47Well, he's a big bit excited.
36:49You have been going on non-stop about Wappy.
36:53Wondering about all these adventures and everything, haven't you?
36:57Yeah.
36:59He's under there, isn't he?
37:02He's still something, isn't he?
37:04When we last met, you left Wappy with me.
37:08That's right.
37:09Is this the first time that you've been without Wappy?
37:12Yeah.
37:12He's been with you since you were a baby.
37:15Yeah.
37:16He's been your sidekick, really, hasn't he?
37:18Oh, yeah, absolutely.
37:19Do you remember what Wappy looked like?
37:21What condition was he in?
37:23Frail.
37:24Oh.
37:24Like, in his lugs, his ears.
37:30Part of the eyes as well.
37:31Yeah.
37:32Yeah.
37:32And that whole bit on the face, that was all...
37:36That was quite bad, wasn't it?
37:38Yeah.
37:39Yeah.
37:39Are you ready?
37:41Yeah.
37:41Be reunited with Wappy again?
37:43Yep.
37:44OK.
37:46OK.
37:49Oh, wow!
37:51Oh, Wappy is wild.
37:55Oh, Wappy is wild.
37:56Oh, Wappy is wild.
37:58Oh, Lidia is...
38:04That's me, Dip.
38:07Oh!
38:07Oh, dear missus.
38:13Oh, good to see you again.
38:17I've missed you.
38:30See what the tail's like.
38:32Oh, look at the tail.
38:34Wow.
38:36And they've got a new face as well.
38:40Wow.
38:41So, not only has he got a new face, but he's all been cleaned.
38:46Right.
38:47His ears have been repaired.
38:49His ears were nearly falling off.
38:51Oh, right.
38:52Did you get a wash?
38:54Yes, he's had a very good wash.
38:56He's nice and fluffy again.
38:57Yes.
38:58And even his hands and feet, they've been reinforced as well.
39:01Yeah.
39:03Robbie, I know that you were worried.
39:04What do you think now?
39:06Oh, yeah.
39:07You still Wappy?
39:08Oh, yeah.
39:09Yeah?
39:09Oh, yeah.
39:10Are you happy?
39:10Excellent.
39:11I'm happy to Wappy.
39:13Your smile says it all.
39:15He's enjoyed his stay.
39:18Yeah.
39:21And he also says, thank you very much for repairing me.
39:27Yeah, thank you very much.
39:29Not at all.
39:29Absolutely.
39:30I will pass your thanks on to Julian and Amanda.
39:32Oh, please do.
39:33And he says, I'll remember you.
39:41How are you feeling now you've got Wappy back?
39:44I'm like, oh, over the moon.
39:46And so is Wappy.
39:48Has he started telling you his stories already?
39:50Mm-hmm.
39:52He says, I'm looking forward to my chicken fried rice.
39:56Is that what he's having for tea tonight?
39:58Yeah, he's having the same as me.
40:00Is he?
40:00Oh.
40:01It's just so great to see him so happy.
40:06It's worth every single minute just to see him like that.
40:11And I love him as well.
40:12Give me a...
40:16Across the fork of Quill, Will has assembled an eager audience of staff and visiting students.
40:26Welcome, welcome.
40:27Hey, Richard.
40:28Hello.
40:28Steve.
40:29Nice to see you all.
40:30Such a big turnout.
40:32This is Dan.
40:33Dan has been working on the model.
40:35You've been working quite hard, haven't you, Dan?
40:37Quite, yeah.
40:37Quite.
40:39Today's a really exciting day.
40:41I remember seeing it way, way back there when we were just in the process of creating the
40:47fork of Quill and bringing it to life.
40:49So it connects us back to a really special time.
40:52What are you all hoping to see?
40:54I'd love to see it working.
40:55But even partially restored and looking good would be fabulous.
41:02Are we all excited?
41:04Yeah!
41:05Look at this.
41:06Right, OK, here we go.
41:09Wow, look at that.
41:12Amazing.
41:13Polished up.
41:14Amazing.
41:15Excellent.
41:16I mean, I think it's just brilliant.
41:19I mean, to see it brought back to life, shining there.
41:22But it's not just about the looks.
41:25This model's got some moves, too.
41:29Rich, fancy a guy?
41:30I would love to, yes.
41:36Jeez.
41:37Wow.
41:37Oh, my gosh.
41:39Wow.
41:42Brilliant job.
41:43Well done, Dan.
41:44Good job.
41:46Good job.
41:49And if the model's purpose was to explain and inspire,
41:53then this restoration has really done the job.
41:57I thought it was really cool.
41:58I thought it was really well built.
42:00I thought a lot about becoming an engineer myself,
42:02mainly just because I'm seeing a bunch of these amazing structures.
42:07I would love to be able to, like, make something like that
42:09and then be part of my work.
42:10But, yeah, I'd be supposed to make something, like, as big as that.
42:14Today has gone really well.
42:16What a turnout.
42:17And people of all ages as well, which is what this is all about.
42:21This is something we've been waiting for for so long.
42:23And just to see that model back with us operating was just the best of feelings.
42:28So that model is so important to us to learn about the engineering
42:33and to understand how this graceful giant works.
42:38By Dan fixing the model, even if it inspires just one person to get into engineering,
42:44one day they could possibly create something as fantastic as this.
42:53If you'd like to see more fantastic fixes and restorations,
42:57search BBC iPlayer for The Repair Shop on the road.
43:10For more information, visit our website at www.fema.gov.au.
43:14For more information, visit our website at www.fema.gov.au.
43:17For more information, visit our website at www.fema.gov.au.
43:19For more information, visit our website at www.fema.gov.au.
43:20For more information, visit our website at www.fema.gov.au.au.
43:20For more information, visit our website at www.fema.gov.au.au.
43:20For more information, visit our website at www.fema.au.au.au.
43:24For more information, visit www.au.au.au.au.
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