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00:05I'm Don Chennair. I'm a mechanic and self-taught engineer.
00:13For the last seven years, I've been helping people to fix their treasures on the repair shop.
00:19My God! That's got me my surprise.
00:22Now, together with my wife, Maria...
00:24I still think we should have a castle door.
00:26You don't know that, Tom.
00:28I'm helpful. Very helpful.
00:31And dog Wendy.
00:33Come on, inside. Test it out for us.
00:36Yeah, very good. That is going to be your seat from now on.
00:39We're embarking on a more personal adventure.
00:42We've packed up our lives in Kent.
00:45This is it. I'm done. We are out of here.
00:48And moved to our dream Cornish farmhouse, complete with outbuildings and two-acre garden.
00:56There's a lot to do, but my first priority is transforming the derelict, very smelly cow shed.
01:02This is very strange.
01:04Into a modern, Cornish weatherproof workshop.
01:07Look at it!
01:10To help me settle into my new home, I'm going to use my skills to fix things in the local
01:16community.
01:17This is what it's all about for me, getting involved with people that need my help.
01:21I've recruited my new local friend and fellow engineering nut, Sam Lovegrove, to help.
01:27Yeah, now we're moving.
01:29Just like the Formula One teams, hey?
01:31As we hunt for some Cornish treasures.
01:33What are they doing here? Why are they not in the field?
01:35Wanted to come and say hello.
01:38That need fixing.
01:39Hey!
01:40Look at that.
01:41Yes!
01:41And polishing.
01:43I've got the vision. You guys have to deliver it, Sam Lovegrove.
01:47Thank you so much.
01:49It's a whole community and more that enjoy this.
01:54Even the chicken's happy about it.
02:05As the end of our first summer in Cornwall approaches, for both me and Maria,
02:10our new surroundings are starting to feel like home.
02:14Yeah, there's a lot of work to do here.
02:16But it's kind of, it doesn't matter because we're here.
02:19It's just so nice to be here.
02:21But that's not to say there aren't still challenges ahead in my workshop.
02:26I just hope that it's watertight and warm and also that the best thing is it's going
02:31to be at the bottom of the garden, so he'll be able to come home for dinner.
02:38But right now, dinner is a long way from my mind.
02:46Oh, for goodness sake.
02:56This place, this is hard.
03:01Just dealing with all of this.
03:04I knew it was an ambitious project, but it is testing me, to say the least.
03:09Constantly problems, constantly things that need sorting, things leaking.
03:13I lie in bed and hear the rain beating at the window.
03:17I'm thinking, that is coming in sideways through the walls here and all of my stuff is getting wet.
03:24It turns out this morning, my angle grinder, my drill, and a load of other tools have been left out
03:29soaking wet.
03:30And it's just, it's a lot to deal with.
03:36And it's hard to see an end at the moment.
03:44And with the summer sun soon to disappear in my rearview mirror, I need to get this place watertight.
03:51Right.
03:52I've got 11 of exactly the same sized original critter windows with a little hinging, pivoting opening section.
04:01I'm over the moon with these.
04:02These were such a find from, I think originally, from Exeter University.
04:07I've paid less than £200 for all of these windows.
04:10And there's three more of these bigger sized ones with five panes, but I just couldn't fit them in the
04:15van.
04:16These critter windows won't just keep the rain out, they'll also look great too.
04:21This style was a popular feature in the Art Deco movement and was even used on the Titanic.
04:27Let's hope these do slightly better against the elements though.
04:30I've got most of what I need to put one in every bay on this outside wall and block up
04:35the rest.
04:35Problem is, I've got to make wooden frames for every single one of them to fix, to screw the wooden
04:41frame to the wall to then screw this to the wooden frame.
04:44I've got a couple of local builders helping me out.
04:47But before I can start work on the frames, we need to finish work on the walls.
04:53This wall, it originally was just up to here, one more course on top.
04:58Fergus and Spike have cut the top course off because it was just really weathered and rounded off and crumbly.
05:04Chopped the top course off, cut out room and now they're starting on blocking up the walls all the way
05:09to the roof.
05:10This is the second bay that's now pretty much, well, hopefully after today, maybe.
05:16What do you reckon? Finished today?
05:17Just finished today and then onto the net.
05:19Onto the net. Hopefully you'll get the lintel in the third one.
05:21Yeah, we'll get the lintel in there today.
05:23Yeah? I'll give you a hand if you need.
05:25Yeah.
05:25You will, yeah.
05:25Yeah.
05:30The lintel's job is to offer structural support, supporting the weight of the wall above the window opening.
05:3718...
05:37Right, I'm on the end.
05:391885.
05:40Should be about there.
05:42At the top of it, yeah.
05:43That's just your edge.
05:44Yep, got it.
05:55OK.
05:56You ready, you ready?
05:57Yeah, I'm good there.
05:5830 mil.
05:59Done.
06:00I'm letting go.
06:02God, that's heavy.
06:03I don't know how you do this every day.
06:06Dear me.
06:07I lost it.
06:08God, hell yeah.
06:10Just need to check the level.
06:12Go on.
06:18Oh, brilliant, brilliant, absolutely brilliant.
06:22I'll get on.
06:22I'll leave you to it.
06:23Ideal.
06:25Maybe it's because it's stopped raining, but I'm beginning to feel a lot more positive.
06:30There's still a long way to go before we're weatherproof, but it's a start.
06:51One of the things I love the most about moving to Cornwall is the chance to use my engineering skills
06:57to help my new community.
06:59Especially when the challenge is as delicious as this one.
07:05Today, I've come down to see someone that has an ice cream shop down here in Newland.
07:10It's been here for a very long time and he needs a hand with something.
07:13So, I'm here to help and hopefully get some ice cream.
07:18Harry's place is a local institution down here.
07:21His ice cream is made just up the road and he brings it down fresh every morning.
07:26This is so cool in here.
07:28It's like stepping back in time.
07:29And famously, you can have whatever flavour you like as long as it's vanilla.
07:37There's no bells or whistles about our shop, Dom.
07:40It's pretty old school, but she serves a good purpose for us.
07:42Just ice cream. That's it.
07:44One flavour of ice cream.
07:45We've been here since 45, doing our thing.
07:4780th anniversary this year.
07:49So, how can I help then?
07:51We're at a stage where we've probably maxed out on what we're achieving from our shop.
07:55And we want to take things on the road and serve some ice cream with some wheels.
08:00An ice cream van wouldn't work?
08:02An ice cream van is probably suited to when you've got a big offering, but we're small.
08:07We're making one flavour of ice cream every single day.
08:10And we don't need a massive chest freezer like this one.
08:13We just need to fit in a 25 litre bucket of ice cream.
08:17A few tubs, cones, and then, yeah, we're good to go.
08:22Well, that's definitely food for thought.
08:24An ice cream van does not a van.
08:28But, after conspiring with my engineering partner-in-crime, Sam...
08:33What do you reckon?
08:34We found something that, like Harry's ice cream business, is compact, historic, and proudly British.
08:42Yeah.
08:43Classic Mini.
08:44Hang on, it's three quarters of a classic Mini.
08:46Three quarters of a classic Mini.
08:47So, one quick call later.
08:52Hello?
08:52Hello.
08:53I've phoned in you about your Mini you've got advertised.
08:56You've still got it?
08:58Yeah, yeah.
08:58It might be really suitable for us because it's already been a bit cut up.
09:02We're looking at building a Mini ice cream van.
09:05Okay.
09:11We did a deal on Harry's behalf.
09:16With the promise that we would make the necessary adjustments.
09:20Although, he does seem to have some rather grand ideas for it.
09:25I've got a vision.
09:27I've got a vision.
09:27Yeah.
09:28Yep, this is me, freezer, bucket of ice cream, scoop, some ice cream paraphernalia, cones, flakes, tubs, spoons, napkins, scoop,
09:42water.
09:43It's all within reach and giving the people what they want.
09:47I love all these ideas.
09:48Brilliant.
09:49But the freezer's going to take up most of this square, I imagine.
09:52It's all half the space.
09:53Yeah.
09:53I've got the vision.
09:54You guys have to deliver it, Sam.
09:56You told me to buy it, I bought it.
09:59Over to you, chaps.
10:00Does it run?
10:02It better.
10:02Soon find out.
10:03Yeah?
10:04Okay.
10:04There's plenty to be getting on with, but we're petrol heads, so we have to test if there's anything under
10:10the bonnet, too.
10:11This red interior is quite shocking.
10:13It's quite as bold choice.
10:14It's contrasting is the word.
10:18Tiny little steering wheel.
10:20It's a go-go.
10:22This is quite nice back here.
10:23It's quite nice out here.
10:25Is it right?
10:25Yeah, yeah, yeah.
10:28It needs a tune-up, for sure.
10:30It's hope, isn't it?
10:32Yeah.
10:32I can see it.
10:36Come on the post.
10:37Keep going.
10:37That's it.
10:39Blue power steering, isn't it?
10:40No.
10:41I think we can all agree, some work to be done, but a good start.
10:46So long as your ice cream's better than your driver's.
10:59Back at my workshop, and we've got big plans for that little mini.
11:03We want to start by creating an adjustable parasol, so Harry can keep his vanilla scoops out the sun.
11:10And after a hunt online, Sam thinks he's found the perfect thing, a 1950s Australian industrial rotary washing line.
11:23Hey, Tom.
11:24Hello.
11:24We're about to see you inside it.
11:26Oh, okay.
11:28Come on, have a look.
11:29This is where it's, this is make or break, really, if it's going to work.
11:32Oh, wow, look.
11:34That's quite simple, isn't it?
11:36Oh, look at that.
11:37Oh, wow.
11:38Wow.
11:39That really is a simple piece of technology, isn't it?
11:42Isn't that amazing?
11:44So that just turns on that thread there.
11:46Needs a bit of a clean-up, but that couldn't be simpler.
11:48This thing is 50, 60 years old, been sitting in someone, concreten into somebody's patio in their back garden.
11:53Yeah, right.
11:54For his entire life, and now made in Australia, concreten in someone's garden, I think in Leicester.
12:00Yeah, right.
12:01And now it's going to be bolted into a mini.
12:03I love it.
12:04Yeah, it's a perfect recycling opportunity, isn't it?
12:07It's perfect for what we need.
12:09So that's it at its fully lowered position.
12:12Right.
12:13So basically that dictates how short the bottom tube can be.
12:17So that, this, that, yeah, that goes inside this tube.
12:21Yeah, so the clamp sits there.
12:23It's kind of at this hole.
12:25Yeah, and then we want a little bit more.
12:26So what do you reckon?
12:27There.
12:28Yeah, it's the end of the hole.
12:29And then it just gives us a bit of material to weld.
12:32Yeah, there's so much to think about.
12:34So many variables.
12:34Do it one layer at a time.
12:35The bottom of the mini floor is where it is.
12:37Yeah.
12:37This is as long as it is.
12:39Yeah, and then we'll cut that, make the bracket for the bottom or a plate to weld to.
12:44Get that sort of like balanced in place.
12:46Bolt it back together.
12:48And so then that, as you turn the crank handle, this threaded part, this rusty bit, shoots up.
13:03Things are a little more challenging as the parasol needs a wide reach as Harry is six foot
13:08five in his sandals and socks.
13:11There's no going back now, Sam.
13:19I mean, this is like the first time we, you know what I mean?
13:23Ready this end.
13:24Hey, that's great.
13:25You're making speedy progress.
13:27Yeah, we're getting there.
13:28Here, I don't want to drop it on you.
13:31I've got to come in over the top.
13:32You got it?
13:33Yeah.
13:35That's about it, I reckon.
13:37Fire up the mig, weld it in.
13:39Before we can weld the parasol in place, we first need to configure a plate for it to sit on.
13:45So I've got some, um, some quite nice wide flat bar.
13:50Look, I thought a couple of lengths of that bent to fit on there.
13:55And then we'll bird mouth the end of the tube.
13:57Weld it to that.
13:58Yeah.
13:59Should be all right.
14:08Nice.
14:14That's what I was thinking.
14:15And it's flat for the piece of tube to sit on, then we can weld the tube to that.
14:18Yeah, spot on.
14:22Of course, you can't serve ice cream without a freezer.
14:26And Harry's brought his along to fit in the mini's boot.
14:30Although we may have spotted a problem.
14:34That's, that's, um, that's a bit tall, isn't it?
14:39Well, she's made for an ice cream bike.
14:41I thought we could squeeze that into a mini.
14:44Harry, this is big.
14:45If we can fit it in a bike, we can fit it in a mini.
14:47That's my theory.
14:49Yeah, I think the height is a problem, isn't it?
14:5285.
14:54Oh, look at that.
14:56We're up here somewhere.
14:58I love the ambition, though, Harry.
15:00I had a vision.
15:02I can see it.
15:02Quite heavy.
15:03And my engineers were going to make it happen.
15:06Oh, I hate to disappoint.
15:08Well, now I'm in a situation.
15:11Let's hope I kept the receipt.
15:13I'm sorry.
15:14Back to the drawing board.
15:16Yeah.
15:16See what we can see.
15:17Slam B.
15:18That was one of the drawbacks, I suppose, of talking him into buying a mini.
15:24Well, that went well.
15:27I feel so bad.
15:29I'm sorry, Harry.
15:30I feel terrible.
15:31Don't worry, it makes me laugh.
15:33Look, just driving off with his freezer.
15:36Don't look.
15:37It's fine.
15:38Anyway, moving on.
15:52While we park the problems with our mini, I'm going to try to keep the wind and rain out
15:58of my workshop.
15:59The walls are now finished and just need something to go into those window-shaped holes, which
16:06means I need to get a move on with my critter windows.
16:11I've quite quickly realised why these were cheap, because it is a mammoth job trying to
16:18clean these frames up, reglaze them, make frames, and try and get them in the walls.
16:23But I'm getting there.
16:25They certainly look the part in the new frames I've built, but not all the windows made it
16:30out of my van unscathed.
16:32So, I need to replace some of the panes.
16:36As soon as I got the windows, I knew I was going to have to do this.
16:38So, I did go and buy a tube of glazing putty, like a tube of silicon with a gun.
16:43And I tried on the first window, and it was an absolute disaster.
16:47It was just horrible.
16:48It didn't work.
16:49I don't know if it's user error or just an error.
16:53I should have known better.
16:54And I went straight back to the glazing shop and bought the old traditional glazer's putty,
16:59which is this stuff.
17:00And yes, it took a bit of getting used to, but bearing in mind, I've got about 15, 20 windows
17:05to get through.
17:07I don't know how many pieces of glass.
17:09I think by the end of this job, I'll have got the hang of it.
17:13With a little bit of love, a little bit of care, they'll be as good as new.
17:17Although it's a time-consuming process, it is how the glass was originally attached.
17:23So, I think it's worth the effort.
17:26These windows were very close to being scrapped, which would have been such a shame, because
17:34they're in perfect condition.
17:36The latches, the hinge pivots, all the screws, the way they're joined together, it's just
17:39simple, effective engineering that just works really well and happens to be beautiful.
17:47Just need to get them all finished before that Cornish weather sets in.
18:08Finishing off the windows, we'll have to go on the back burner for a bit.
18:14While me and Sam work on the next stage of Harry's mini ice cream van.
18:20Sam.
18:21Hey.
18:22I have brackets.
18:23Oh, they are so smart.
18:25Hand drawn.
18:27I'm hoping that should slide over.
18:29That was the plan.
18:30Oh, look at that.
18:32Okay.
18:32Slide over there, weld to the tube.
18:34That's perfect.
18:35I think we're basically at the point now, with that brackets done, I think we can commit
18:40with at least this part.
18:46Those brackets might be small, but they've got a very big job to do.
18:50Those few tacks, these little spots here and there, will hold that in place enough for
18:55us to be able to do the canopy.
18:56Yeah.
18:56Once we're completely happy, we can weld the whole thing in.
19:00But until then, I'm not committing, because we've changed our mind far too many times
19:04already.
19:08That's a start.
19:10I think this may look a little bit...
19:13Bodgy.
19:14Bodgy, for a better word.
19:15But it's just setting a level.
19:18We know the roof's, we know the mini's level, we know the roof's level.
19:20We know the post is level.
19:21So we just need to get this exactly where we want it, clamp it in position, and then
19:26just join the dots.
19:34So I'm just shaping this nicely into a little, they call it bird's mouth, because it's a
19:39little bit like a beak shape, just so that the contours of it fit nice and neatly with
19:46no gaps, so you can weld a nice neat weld all the way around.
20:05We've got half a roof.
20:06Two more of those, and we're away.
20:08And with the final piece of the puzzle in place.
20:11Ready?
20:12Yeah.
20:13Let's do it.
20:14Let's give it a go.
20:20Once that's up like that, once this collar's in there with a clamp, Harry can just spin
20:25this round.
20:26Yeah.
20:27Keep him out of the sun, keep the precious ice cream out of the sun.
20:30Wherever the sun's going, he can just aim it round.
20:34End of the day, spin it back, wind it down, and head home.
20:37Perfect.
20:38Whilst we're on a roll, should we look at that freezer?
20:40Yeah.
20:42We couldn't fit Harry's freezer in the boot, but after another online search, we found
20:47one that's a more suitable size.
20:50I think it's going to fit nicely.
20:52It's not going to fit nicely.
20:54We will make it fit nicely.
20:55That's exactly what I meant.
20:56Yeah.
21:00You are good to go.
21:02Where are you going to go first?
21:03Up here.
21:11Up here.
21:14Hey!
21:15Look at that.
21:16Just made it into a four-seater.
21:20Oh, no.
21:21Not with you yet.
21:22Oh, sorry.
21:23Yep.
21:23Gloves are a bit slippy.
21:31Okay.
21:33Ice cream, sir.
21:35Ice cream.
21:37That is...
21:37It's really good.
21:38...so perfect.
21:40Really good.
21:40I can't wait for Harry to see it.
21:42Oh, it's lovely.
21:43Absolutely perfect.
21:55My plan, after making my workshop watertight, is to give it a proper relaunch, complete with
22:01a new sign.
22:03I want to create something that's connected to my new community.
22:07So, I'm on the hunt for tin.
22:10This is an amazing landscape, isn't it?
22:12Yeah.
22:12They've been mining tin in these parts for around 3,000 years.
22:18The industry was at its peak during the Industrial Revolution, but sadly declined towards the end
22:24of the 20th century.
22:26But not everyone has given up the old ways.
22:30Oh, wow.
22:32Look at that.
22:34Look at that.
22:34That is really good.
22:35That's beautiful.
22:37Mark's family produce tin using a process that starts by collecting ore from nearby beaches.
22:47So, this is ore.
22:48This is tin ore.
22:48This is tin ore.
22:49This to me looks like a rock.
22:49Yes.
22:50It's got a bit of sparkle to it.
22:52That is the crystals of the tin ore.
22:53Is it?
22:54Yeah.
22:54Glitter.
22:55Yeah.
22:55It's beautiful.
22:56That one, more of a solid pebble.
22:58Yeah.
22:59It's been rounded off by tumbling in the sea.
23:01That's really way heavier than any rock.
23:03They are.
23:04Yeah.
23:04That's because of the high tin content.
23:06So, you're looking at probably 50, 60% tin in those.
23:08In that?
23:09Yeah.
23:09Whereas that one, you've got about one, maybe 2%.
23:12Okay, yeah.
23:13That's really light.
23:14Once Mark's gathered the ore, it's put into that rather impressive crushing contraption.
23:21Those hammers, they can weigh anything up to about 500 pound weight.
23:25And how old's that piece of equipment?
23:27I would say it's something like 200 years old or more.
23:30No.
23:31Yeah.
23:31It's been doing that for 200 years.
23:33Yeah.
23:33Well built.
23:34That muddy water is basically what we're after.
23:36Collect that and then shovel the sand into this pit for separation.
23:40It's brilliant.
23:41Not a motor in sight.
23:44Once those grains of tin ore are released, the process moves inside so that precious metal
23:50can be separated from the sand and rock using the rather lovely named shaking table.
23:57So, what you've got there, the table shaking, moving everything forward.
24:00So, it's dropped on this end, it's moved that way.
24:03You've got water up here, trying to wash it off this side.
24:34As it goes along, it spreads out.
24:36You've got to look at it a dozen times.
24:37You're making absolute sure that you get every bit of tin out of it.
24:40We want to get it all.
24:41This is good.
24:42This is a maybe.
24:44Yeah.
24:44This is a no.
24:45Yes.
24:46We all do different things in our sheds.
24:48You know what I mean?
24:49I build motorbikes.
24:50Yeah.
24:50You're fixing cars making all sorts of metal things.
24:53And you're...
24:53I'm a mad idiot making tin.
24:55You're making tin metal out of the ground.
24:56I love it.
24:57Finally, that black tin concentrate gets smelted in the furnace until the white tin metal begins
25:04to flow.
25:05Then, it's ready to be cast into heavy ingots of pure Cornish tin.
25:10I'm hoping there's enough there for the five kilos I need for my sign.
25:15Here we go, Don.
25:16Those are tin ingots.
25:17I love it.
25:18Wow.
25:19Oh, that's so nice.
25:20Isn't that beautiful?
25:21There's something special, isn't there, about that?
25:23Yeah.
25:23It's beautiful.
25:24To think that that's come from the beach, just down there, up here, through this process
25:28that we've followed.
25:29Crushed it, separated it, smelt it into metal, ready for you to make your sign.
25:33All here, literally, in this building.
25:35Yeah.
25:35That's amazing.
25:36That's so nice.
25:36Now, I just need to get these back to the workshop to get my own creative juices flowing.
25:51Before we can create our new sign, there's the small matter of completing Harry's mini.
25:58We've got the freezer in place and a battery to run it.
26:03Just need to connect everything up.
26:06So, in theory, we're ready to put the inverter into position and actually plug some things in.
26:16Rather you than me.
26:17The inverter takes DC power from either a 12- or 24-volt battery and converts it to AC power
26:24that's suitable for the freezer.
26:28This is lovely and simple, isn't this?
26:30This could have been three different boxes and a charger and an inverter and all that.
26:33Yeah.
26:33It's all just, it's two wires.
26:35It's really lovely.
26:37I'll say that when it works.
26:39Of course it's going to work.
26:41I'm going to turn it on.
26:43Hmm.
26:44Nothing.
26:45Brilliant.
26:48I reckon it needs to be plugged in to wake it up.
26:50It needs a bit of mains power to give the brain a, you know, like a defibrillator thing.
26:55I'm going to plug it in.
26:58And if it breaks, you can blame me.
27:01Nothing.
27:05So back to the drawing board.
27:07Troubleshooting table.
27:09Problem.
27:10The inverter fails to operate when switched on.
27:13The battery voltage is too high or too low.
27:20And after doing what we should have done and read the instructions...
27:24We now have a 12-volt inverter, not a 24.
27:27That was quite a fundamental error to make.
27:31But we're back in the game again, ready to put the plugs in and see what it does.
27:36So here goes.
27:38Hopefully we get a light.
27:44Oh, that's a good sign.
27:46So we have inverter power.
27:49Dare I flick the switch on the freezer?
27:54Oh.
27:59That is a freezer.
28:01So this is now, what, running on battery?
28:03Yeah.
28:0315 minutes to pull it down from 10 to minus 10.
28:06Wow.
28:07So 20 degrees drop in 15 minutes.
28:10That is pretty cool, though.
28:11More than pretty cool.
28:12It's very cold.
28:13It's very cold.
28:13Minus 10.
28:15With the electrics finally working, we can add the finishing touches.
28:21It's kind of cheating in a way.
28:23I kind of made my own carbon paper.
28:26This is going to transfer.
28:27I'm going to just draw over the letters, and that's going to transfer a very faint piece of charcoal line
28:32onto the little mini.
28:34Then we'll colour it in with the brushes.
28:35And, of course, the canopy, which we got custom made by a local sail maker.
28:40One of the many advantages of living by the sea.
28:44Oh, Sam, that looks really good.
28:47It's that abstract moral support without looking.
28:50No, that was genuine.
28:53This mini-adventure has provided a fair few twists and turns.
29:00But I reckon it's going to be worth it when it makes its debut on the beach.
29:16With work on the mini complete, work on my tin sign can begin.
29:21Using those ingots we got from Mark.
29:25Those sparkling beauties will soon be heading into that bubbling crucible, which is also helping keep us warm in this
29:32weather.
29:34Right, Sam, every workshop needs a good sign, doesn't it?
29:37Yeah.
29:38This is it.
29:39It's great, actually.
29:40You like it?
29:41Yeah, I like it.
29:42Tin mine?
29:42Yeah.
29:43Lighthouse?
29:44Bit of sea.
29:44Sea?
29:45Some hills?
29:46This is Cornwall.
29:47This has been laser cut, and these bits have been 3D printed.
29:50My friend Paul is very clever with a computer.
29:53Although that would be quite nice just as the sign on its own, but...
29:56It might not last in this weather.
29:57Fair enough, especially with this today.
29:59Look at it!
30:02To turn this rather high-tech 3D printed design into a traditional tin sign, we need to start
30:08with this sand.
30:09It will help create the mould into which our molten tin is going to be poured.
30:14So that sand is special casting sand, isn't it?
30:16Yes, this is.
30:17Is this an oil sand?
30:18Yeah.
30:19Yeah.
30:19But look, if you squeeze it, it just stays in its shape.
30:22So I've sprinkled some on.
30:23Yeah.
30:24The most important bit, I think, is to get in all the details.
30:26Definitely.
30:26Pack it all in.
30:27Yeah.
30:28Screw the lid on.
30:29Flip it over.
30:30Unscrew the base.
30:31And hope that the pattern comes out.
30:33Let's see.
30:34There's only one way to find out, no?
30:36All right.
30:37Me first.
30:39So we're just like big kids today, doing sand castles.
30:44Sand is particularly good for this job, as it can withstand the higher temperatures of
30:49molten metals without melting or burning.
30:54It's like doing car body work, isn't it?
30:56Yeah.
30:57Let's get the lid on.
30:59It will hold the molten tin in shape until it cools.
31:04And then we'll remove the sand to reveal our work of art.
31:07I've slightly overdone it on the material thickness.
31:10No, no.
31:11I think it's good.
31:12I think it's a nice, stable material to use.
31:14I like it.
31:15At least it's flat.
31:16Yeah.
31:19May I?
31:20Absolutely.
31:21Oh.
31:22Oh, that's so close.
31:23Oh, that's good.
31:25Oh.
31:26So we've lost a little bit.
31:27It looks like the 3D print is the issue.
31:29The wood is all OK.
31:31This is too sticky.
31:32A few little imperfections around there I'm OK with.
31:35Absolutely.
31:35It's not worth a second attempt.
31:37It might not be as good.
31:38The crucible is now at the right temperature.
31:42232 degrees.
31:44So we can get ourselves ready to pour that molten tin.
31:48Right.
31:49Feeling brave?
31:50I'm quite nervous.
31:53It's very hot in there.
31:55Like, even through these gloves, you can feel it.
31:57It's seriously hot.
32:01Oops.
32:02Oops.
32:02Not too bad.
32:03Of course.
32:04My turn.
32:04Yeah.
32:05Step back.
32:07Go on, Sam.
32:07Get in there.
32:08We're making sure we use every last drop of those five kilos.
32:14It's looking pretty good.
32:17We had to pour this in stages.
32:20So we used a little heat to blend it together.
32:24Cool.
32:24That was quite an event.
32:25Very good.
32:26Well done.
32:28And after the molten tin has cooled and set, come on.
32:32Oh, it's very heavy.
32:34Yeah, it is a bit.
32:37Where are you going?
32:38Here we are.
32:40It's extremely heavy.
32:43How are we going to tip it over without it just falling out?
32:45Oh, we'd flip it over on the bench.
32:47OK.
32:47Unscrew the cover.
32:48Keep everything crossed, I guess.
32:50Here goes.
32:52Let's take the weighting out of this game.
32:54It fell out.
32:55That's nice.
32:56So I don't think we need to unscrew it.
32:59Let's, yeah, relift it.
33:00There we go.
33:01Perfect.
33:01Oh, hang on.
33:02Wait for me.
33:05Oh, look at this.
33:06What's that?
33:07You've got the workshop.
33:08Oh.
33:08It's my mine.
33:09The tin mine.
33:10I was so worried about.
33:11Hang on.
33:12I'm just going for all of it.
33:15You're that kid, aren't you?
33:16I'm wrapping a present.
33:18Yeah, yeah, yeah.
33:19I've eaten the sweets.
33:20I'm feeling sick already.
33:23Oh, look at that.
33:24Oh, my goodness.
33:25I think that is an absolute success.
33:28I wish the sand came out easier, but...
33:30I'll get some in.
33:34I reckon it will scrub up nice and look right at home in my new workshop.
33:38I just need to find a place to hang it.
33:55At the workshop, it's time to get those framed critter windows in the wall.
34:01Spike, I think it's time.
34:03I think it's time.
34:05With the help of Spike and a forklift.
34:10Right, Spike, that's it.
34:13Yeah.
34:14I'm hoping, if you need to get it on the forks, I'll come and give you a hand.
34:17Hang on.
34:25As you bring it up, it's not going to want to stay there.
34:32All right, don't ruin the plan already.
34:34Yeah, I know, but it's not, is it?
34:36I don't know.
34:36Let's find out.
34:37OK.
34:38Are you nervous?
34:39Yeah.
34:39I am.
34:40It's a lot of work in this.
34:41I know.
34:43And, as ever with my projects, the path to success is rarely a straight line.
34:54Oh, it's so close.
34:56They're just going to come off the top, look.
34:59Is that enough?
35:01No.
35:01No.
35:02Drive in as close as you can.
35:05Yeah.
35:06And then we'll see if we can bring it over.
35:09A little bit off.
35:09OK.
35:10There.
35:12Yeah, that's good.
35:13That's it.
35:13That's all I can do.
35:17Oh, look.
35:17Perfect.
35:22All right.
35:23That'll do.
35:27Oh, man, that was a lot more stressful than I really anticipated.
35:31Now we can just walk it over.
35:35That's good.
35:36We'll just walk it over.
35:37Like me.
35:38Go on.
35:43That's it.
35:43Need to go your way a little bit.
35:44Yeah.
35:46Hold on.
35:48Come to me.
35:50All right.
35:51Rest in there.
35:51Yeah.
35:52OK.
35:52First part.
35:53Over.
35:53That's gone well.
35:55What do you reckon?
35:56What's your money on?
35:56It's going to work?
35:57Yeah.
35:57It's going to work.
35:58It's going to fit straight in.
36:00Well, I've made the frame.
36:01You made the wall.
36:02So we're going to blame each other if it doesn't fit.
36:04Yeah.
36:05Well, congratulate each other.
36:07Yeah.
36:08That's a positive way of looking at it.
36:10Fingers crossed.
36:18Oh, spire.
36:19Look at that.
36:20Hey.
36:22Your side in a bit.
36:25Yeah.
36:26Yeah, yeah.
36:26Happy?
36:27Yeah, that'll do.
36:28Finally, we can breathe again.
36:30It's perfect.
36:31It's perfect.
36:32Probably should have cleaned them before putting them in, though.
36:33Yeah, yeah.
36:37Just the final finishing touches.
36:43Straight in there.
36:51It's in.
36:53It's not going anywhere, is it?
36:55The slightly terrifying thing is that we've now got 15 more.
36:58I've tried not to figure out that.
36:59We know it can be done, though.
37:00Exactly.
37:01Exactly.
37:01It's possible.
37:02Yeah, let's have a cup of tea.
37:16All that's left to do is make an ice cream delivery.
37:27We're heading to the gorgeous village of Marazion and its stunning sandy shoreline.
37:33It's a hugely popular spot, with visitors drawn to the nearby St. Michael's Mount.
37:40At low tide, you can reach the island via this amazing granite causeway and explore the cobbled streets of the
37:48village.
37:49But today, I know Harry is hoping the tourists might prefer to ignore this iconic landmark and welcome a brand
37:57new one.
37:58I'm a bit nervous.
37:59I'm a bit nervous, really.
38:00It's all come to this.
38:01We've had a fair journey to get here.
38:02We've had a few trials and tribulations along the way.
38:05But here we go.
38:06I'm excited.
38:07I've got the sunshine.
38:08I've got the sunshine.
38:08Now I just need people.
38:09I need my scoop and I need to get to action.
38:13Although we've made some modifications to make the mini ice cream friendly, we've not made any structural changes, so it's
38:21still safe for the road.
38:23Although we're about to find out how well it handles on sand.
38:27Oh, wow.
38:28She's a pearler.
38:30She's just what we're after.
38:33Yeah.
38:35Fantastic.
38:35It's amazing, isn't it?
38:37Look, it's beautiful here, isn't it?
38:38Yeah.
38:39Here we are.
38:40Nice to see you.
38:41We made it.
38:41On the beach at last.
38:42Yeah, this is where we want to be.
38:43That was quite an entrance, it must be said.
38:47What a machine.
38:48Come on, then.
38:49Let's get on with it.
38:50Canopy up.
38:51Get that canopy up.
38:53This is the first time we've operated the canopy in the wild.
38:57Fingers crossed.
38:59Is she going up?
39:01And it works.
39:03That's it.
39:03Look at that.
39:04So where would you like it?
39:06How are you going to be that side?
39:07The sun's going to go round that way, so I reckon...
39:12Is that my shadow?
39:13Yeah, that would be spot on there.
39:15And it looks like his vanilla will be good to go, too.
39:19Freezer's freezing.
39:21Is it?
39:21What temperature's it at?
39:22Very pleased to say, running entirely off its own power.
39:26Off its own battery.
39:26Off its own power.
39:27We're at minus 14.
39:28That's where I want to be.
39:30Yeah?
39:30See, we've never done this part of the job.
39:32No.
39:33Cone holder.
39:33I don't know about...
39:34Cone holder?
39:35Goodness me.
39:35There's a bit of an issue.
39:37It's in the state of my hands for serving ice cream.
39:41I think we've found our weakness here.
39:43I think we're...
39:43I'm very glad that Harry's here.
39:45Us setting up an ice cream shop.
39:47Not going so well, is it?
39:48You stick to the engineering,
39:49I'll stick to scooping ice cream.
39:50How about that?
39:50I think that's sensible, yeah.
39:52It's all under control.
39:53At least something is.
39:56Who wants an ice cream?
39:58Me, it's a cone.
40:00Which cone would you like?
40:01A wafer or a waffle?
40:03A waffle.
40:04And it looks like the car is going down as well as the ice cream.
40:08Is this music?
40:08The car is the new thing, yes.
40:11Have you done that yourself?
40:12No, these very clever engineers have.
40:14Enjoy your ice cream.
40:16Thank you, ladies.
40:16Take care.
40:17Although, I think Harry could do with getting out of first gear.
40:21In a cone or a tub.
40:22Harry, can we pick up the pace a bit?
40:24Look at the queue.
40:25Sorry, sorry, sorry.
40:26Yeah, yeah, yeah.
40:26Do you need a hand?
40:27Yeah, not enough hands on the job.
40:29Are you sure?
40:30Would you like one?
40:32Cheers.
40:33Thank you so much.
40:35Are you all right?
40:35What can I get for you?
40:36I'm just asking you to hold them up.
40:38Thank you very much.
40:39There you go.
40:41After all our work, there's just one thing left to do.
40:47It's nice.
40:47Perfect.
40:50Right, come on.
40:50Let's find somewhere to sit.
40:55This is the sweet bit.
40:58There's an ice cream man selling ice creams, man.
41:01Huge queue of people.
41:02I know.
41:04He's doing business.
41:05Smiles all round.
41:06This is what it's all about, isn't it?
41:07Yeah, right.
41:08Perfect.
41:09Canopy looks great.
41:11Mmm.
41:11Certainly draws a crowd, though.
41:12Look.
41:12Mmm.
41:15Perfect.
41:17You've got some ice cream in your beer.
41:18I'm not surprised.
41:19Why is it melting now?
41:30Back at my workshop, I'm pleased to say that Spike has been working wonders.
41:35So, I think it's time we give those walls a proper christening.
41:40Spike, what are you thinking?
41:41Where do you want this to go?
41:42It's your wall.
41:44Somewhere right there.
41:45There is one drawback of making my sign out of tin, though.
41:50It's extremely heavy.
41:52No, no.
41:53Down a bit, I think.
41:54There.
41:55Stop.
41:55Okay.
41:55I reckon.
41:57You happy there?
41:57Yeah, yeah.
41:58Go for it.
42:02The vision of turning this old dairy into a workshop is becoming a reality.
42:08The wall is very nearly finished.
42:10The wall is very nearly finished.
42:11Windows are going in.
42:12A flat floor that I now can work on.
42:14It is turning into something.
42:15Who knows what's next?
42:18Feels like a nice way to end our first Cornish summer.
42:22It's beautiful, isn't it?
42:23Insane.
42:24It hasn't always been easy.
42:26Look at him just ramming into the wall.
42:28From walls and floors coming down.
42:31Wow.
42:32Fuck.
42:32To ponds being dug up.
42:34This looks like absolute carnage.
42:37And rocks being crushed.
42:39They're just straight in the jaws.
42:43But I think me and Maria are ready for whatever Cornwall is going to throw at us next.
42:48More concrete blocks for the walls.
42:51It's locked.
42:51Yeah.
42:52It's coming together.
42:53Oh, look.
42:53We've finished the sign.
42:56Screwed it on the wall.
42:57It looks really good.
42:58It's cool.
42:58Yeah.
42:59You're definitely open for business.
43:01Exactly.
43:04Come on then, Wendy.
43:28We'll see you next time.
43:31We'll see you next time.
43:31Bye.
43:35Bye.
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