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00:01This time on Car SOS, the king of the hot hatches.
00:07It needs some work, but it's all very doable.
00:11Has gone colder than a snowman's carrot.
00:14Now, a few of the items that need servicing are not currently present with the car,
00:18but I think you can get the vision.
00:21Tim takes the crew hostage in a toilet.
00:23Get in here, don't complain. Just get in.
00:26Fuzz discovers what we already know.
00:28Not normal. A sticker that ought to be on Tim Shull's forehead.
00:31And the countdown begins to make another deserving owner's dream come true.
00:36My heart's racing.
00:37OK.
01:00Right, well, here we are, Timmy. This is a lovely part of the world.
01:04Today, the reason we're here in your hometown in Birmingham is because this year we are celebrating the 50th birthday
01:11of the car that, in my mind, gave birth to hot hatches, man.
01:16Now, I know what you must be talking about now, because today, we must be picking up the Volkswagen Golf
01:22GTI.
01:24A Volkswagen Golf GTI.
01:24A Volkswagen Golf GTI.
01:26Now, here's the thing, Fuzz. I reckon that this car is single-handedly responsible, not only for the whole hot
01:31hatch scene,
01:32but more importantly, it's given birth to tens of thousands of engineers around the world because it's said to everyone
01:38who had one, modify me.
01:42Yes, it's fitting, really, that the Golf GTI became every mod-mad petrolhead's dream car, because that's exactly how it
01:50started life.
01:51Back in the mid-1970s, a faction within the VW team felt the standard car was too tame.
01:58So, with some spare time and a warehouse full of parts on their hands, they set about spicing things up.
02:05They swapped the standard 1.1-litre engine with a 1.6 fuel-injected monster that had more than doubled
02:12the horsepower,
02:14sharpened the suspension, and improved the gearbox and clutch, creating a car that offered Porsche-like thrills on a working
02:21-class budget.
02:22Which is why, by the time they hit the second-hand market in the late 80s, every Boeing racer with
02:29a socket set wanted one.
02:30Because, thanks to their relatively simple mechanics, engines could be fettled on your driveway, suspension slammed,
02:38and, before long, the streets were filled with shiny wheels, loud exhausts, and body kits galore,
02:45making the GTI no longer just a car, it was a movement, a badge of belonging, something you built, modified,
02:52and made your own.
02:54So, whose golf are we picking up today?
02:56The car is owned by Saj.
02:58Okay.
02:59But Saj isn't going to be where we're going.
03:01Of course not, because otherwise we couldn't car rest.
03:03Yes, but the two guys who are there are his mates, who are Nav and Shant.
03:06Okay.
03:06They're going to let us take the car away, tell us his story, and let's get on with it, man.
03:10Fantastic.
03:11Right, let's get there.
03:12I cannot wait to get my hands on it.
03:20Have we come to the right?
03:21Are you expecting us, chumps?
03:22The right place, boys.
03:23Welcome.
03:23Lovely going back.
03:24Nice to meet you.
03:24Nice to meet you too, Tim.
03:25Yep.
03:26Great to see you, Tim.
03:29Can we see the car?
03:30Yeah.
03:30Well, you can get to.
03:33Where is it?
03:34Have a look, let's see what you can spot.
03:35There!
03:36Okay.
03:37My question to you guys is this.
03:39Is this a car to be modified, or is it one of the very few cars that's going to go
03:44original
03:44the way Fuzz it like?
03:46Complete full modifications for us.
03:48That's where we're going.
03:50Go and have a look around your car.
03:51Right.
03:52Go and get stuck in.
03:52Get your hands mucky.
03:53We'll go and talk about those mods, shall we?
03:55Because they're going to be huge.
03:57Are we talking about...
03:58Take your list.
04:02Right.
04:02Well, the dog needs to see the rabbit, so I'm going to have to get all of this
04:06stuff out of the way.
04:07And then, and only then, can we take a look at the car.
04:11Gloves on.
04:13Let's get shifting.
04:20Oh, look.
04:21It's coming.
04:21It's coming.
04:22Bit by bit.
04:30There's our engine, but hold on.
04:32Wait a minute.
04:34That does not look like a standard unit.
04:37Right.
04:40So, yeah, it's not normal.
04:42A sticker that ought to be on Tim Shaw's forehead.
04:45This is an engine out of an altogether different beast.
04:49I'm assuming that this is one of the first of the modified parts.
04:55Saj wants this engine in his GTI.
05:01So, tell me about Saj.
05:02What kind of guy is he, and why is he into that car?
05:04That car's been with him near around 30 years.
05:07Right.
05:08He originally built it up into a show car,
05:10and then he decided he wanted to take it to the next level,
05:13and took it off-road, and it never come back out.
05:15Right.
05:16Does Saj know his cars?
05:17Does he know his VW?
05:18He's the guru.
05:19Yeah.
05:19He's the Oracle.
05:21He's the go-to guy.
05:22He's everybody's friend.
05:24You take him to a show.
05:25Everybody's...
05:26You can't get around the show,
05:27because everybody wants to sort of save him.
05:28He's like the central force in all our car community.
05:31He's got connections to everyone.
05:33He's the magnet.
05:34He's the glue in the bones.
05:35Everything revolves around him.
05:37As we come back here, well, new door.
05:40That's great.
05:42The news is not so great around this wheel arch,
05:45because I can see...
05:46Well, I've got filler here.
05:48We've got rot.
05:49It's had modifications.
05:50I can see possibly a little bit of fiberglass in there,
05:53but it's not looking pretty.
05:56So, crispy arch again, and then looking in here,
05:59I've got a box with wiring loop,
06:01although that does not look standard at all.
06:05If we can find some wheels, get it on,
06:07then hopefully we'll be able to roll this thing out of here.
06:13What happened in Saj's life
06:15to mean that, unfortunately,
06:16that has been left like that.
06:18Back about...
06:19I'd say it's probably about 30 years.
06:22He went off on holiday,
06:24swam out to sea.
06:25He was a really strong swimmer,
06:27and suddenly found himself that he couldn't swim back.
06:30Didn't think anything of it.
06:31Must have been tired.
06:32Come back home.
06:34A couple of things happened.
06:35He had a few falls,
06:36and then eventually went down to the doctors,
06:39and he got the worst news ever,
06:41and he was diagnosed with muscular dystrophy.
06:45Can he still walk?
06:46Does he still have movement in his arms and his hands, or...?
06:49It's just his fingers and hands, really, yeah.
06:51So, let me ask you a question.
06:53His whole life has been about that car.
06:55Yeah.
06:55About Mark 1 GTIs.
06:56Yeah.
06:57What's the dream?
06:59See it back on the road.
07:01Yeah, his vision.
07:02His vision.
07:02Mm.
07:03As a complete package.
07:05Is he going to want to take it to shows?
07:07Yeah.
07:08Definitely.
07:09Yeah.
07:10He's a show guy.
07:10It's all about the show.
07:11He loves it.
07:12Right.
07:12If we could get him in the driving seat,
07:14it would just be amazing,
07:15even if it's just for a short duration.
07:18Get to drive it himself, control it himself.
07:20Dude, look, I don't know.
07:21I'm not going to promise anything.
07:22Even a partial experience of driving the car,
07:25even if it's just the braking or the accelerator
07:26or the steering or something.
07:28But where there's a will, there's a way.
07:30Shall we go see how it's getting on?
07:31It's fantastic.
07:35Right, there's the sunlight hitting the car.
07:36When was the last time this car saw sunlight?
07:3820 years ago.
07:39Yeah, it's 20 years ago.
07:4020 years.
07:40Yeah.
07:41Because you and I need to talk modifications, mate.
07:43There are going to be lots of them.
07:49The engine's not in it.
07:51The interior's not in it.
07:52It's a shell and a load of bits.
07:54We don't even know if we've got a complete car.
07:56I think we're going to uncover
07:58a few nasty little bits here and there.
08:02Look, we know who can help us with this kind of thing.
08:07Rick would.
08:07Yeah, yeah, exactly.
08:09It's a big mountain to climb.
08:10It's the biggest.
08:11Nothing else will be as big as this.
08:13Come on. Nothing.
08:13Let's go for it.
08:15Yes, if there's one person who can help Sherpa the boys
08:18up this mountain of modifications,
08:21then it's the Prince of Performance Motors, Rick Wood.
08:25Rick, we've got something for you.
08:26We want to show you.
08:27Yeah.
08:27This is just a little...
08:28It's a minor restoration.
08:29It's not your restoration.
08:31It's more of a service.
08:31Service, really.
08:32Yeah.
08:33Oh, really?
08:34Here we are.
08:35Really?
08:36I'm holding on to you so you can't get away.
08:38No.
08:41Now, a few of the items that need servicing are not currently present with the car, but...
08:46Yeah.
08:46...I think you can get the vision.
08:49Come on, mate.
08:50It needs some work, but it's all very doable.
08:53What was that, Rick?
08:54Get it in.
09:01Keep going.
09:01Keep going.
09:02Keep going.
09:02Look.
09:04Yes.
09:06Have a little look round it.
09:07Start from the back.
09:11Well, I can already see some welding that kind of needs to be probably...
09:18Cut out.
09:19Cut out, yeah.
09:20What do you reckon there, Rick, those arches?
09:22Arches.
09:23And then when you come round to the sills...
09:25Oh, yeah, it's got a banana shape.
09:27It's a banana.
09:27So that is scary.
09:29Erm, so that needs redoing.
09:31Shall we have a look under?
09:35There's nothing that is great about this.
09:38It's just been made to look pretty.
09:40On a scale of one to ten, where would you put it?
09:42Ten being great.
09:43Zero being...
09:44One being rubber.
09:45Generous two.
09:46Right, this is a guy who has dedicated his life to Volkswagen.
09:50Yeah.
09:50So he can't turn up to a show with a car that's anything other than the show winner.
09:55Yeah.
09:55You're talking about show cars.
09:57Yeah, yeah.
09:57It's not just MOT standard.
09:59We can't possibly leave it like that.
10:02Got to redo everything that's done.
10:07The boys are up to their necks in what should be the ultimate hot hatch, a Mark 1 Golf GTI.
10:15But unfortunately, this one's gone colder than a polar bear's giblets.
10:20Guys, got something to show you here.
10:24This is the engine built by Saj himself.
10:28What can I tell you about it?
10:30It is from a Mark 2 Golf.
10:33What?
10:34Well, let's hope it's in better condition than that.
10:38All right, do you want the bombshell then?
10:40I've just sat there with Shannon Nav.
10:43Yeah.
10:44And talked about a dream.
10:46That Saj is going to get to drive his car again.
10:48Just getting that car back on the road is going to be absolutely something.
10:54Now that is where you should set your dreams.
10:58Yes, this one isn't your standard renovation.
11:01So, where do the boys start?
11:04First up, they need a car that runs and a solid body shell to build around it.
11:08That means Fuzz needs to work out if Saj's more powerful Mark 2 engine is salvageable.
11:15And then get busy chopping, grinding and welding in some fresh sills.
11:20Next, they've got to modify it so Saj can drive it.
11:24So, not only do they need him to get into his dream car,
11:27Tim also needs to find a way for him to control it using just his sum.
11:32Finally, they've got to modify it even further to turn it into a show car,
11:37petrol head Saj has always wanted to drive.
11:40Which involves somehow getting to the bottom of his custom master plan and making it a reality.
11:48Which makes this less restoration, more full blown reinvention.
11:53And with the clock already ticking, there's no time to waste.
11:57So, the team dive straight into stripping what's left of the car and removing those rotten sills.
12:04Leaving Fuzz to get on with making Saj's dream of having a more powerful Mark 2 engine in his Mark
12:111 car come true.
12:14At the moment, it's a complete unknown quantity.
12:18Lots of modders stick a Mark 2 engine in a Mark 1 car because it gives you 30 more horsepower.
12:24But these engines didn't come without their problems.
12:28So, what I'm going to do is strip all the ancillaries off it and then take the cylinder head off
12:34so that we can see in the bores.
12:36And also, flip it over, get the pistons out and then we can check out the crankshaft as well.
12:41It's really just seeing what we've got.
12:44The Mark 2's engine was considered pretty reliable.
12:48But, as with any other car, only as long as the cooling system was properly maintained.
12:53That doesn't strike me as recently changed or will.
12:56I think that this engine has probably done quite a few miles.
13:01So, with what appears to be years of DIY fixes under its belt, this engine could already be on borrowed
13:08time.
13:13Right, we have liftoff.
13:20Right, so, looking at this cylinder head, the edges of our waterways are nice and crisp and sharp.
13:27And that means that at least this engine has been run with probably the correct coolant in it.
13:33Which means that these haven't corroded away.
13:36So, that's a good sign.
13:37But what are the bores like?
13:42Right, it's not looking like great news in here.
13:45We have scores in the bores.
13:49Now, that means that either the piston or the piston rings or something has got inside here
13:57and been dragged up and down the wall of the cylinder.
14:00And it's made a little groove.
14:02Hmm.
14:03I don't even need to look at the bottom end now because the whole thing's got to come apart.
14:08We know we are now in for a total rebuild.
14:14If a visit to the scrapyard was the worst possible outcome, this is getting a silver medal.
14:19Because a rebuild is going to swallow up heaps of time that the team should be using to turn this
14:24into Saj's dream car.
14:27On the plus side, it gives Tim more of a chance at pulling off the seemingly impossible.
14:32Finding a way for Saj to control his car using nothing more than his thumb.
14:37I admit that we can't get Saj in the position that I'm in now to drive his golf.
14:42Unfortunately, with his condition, that's not possible.
14:45So, what about this?
14:47When you drive a car like I am now, I'm mainly steering and braking and accelerating, right?
14:52Now, which of those three is the most exhilarating?
14:55Which is the one that gives you...
14:57Well, the buzz is the accelerator pedal, isn't it?
14:59So, I'm just wondering if we could...
15:01And this is a big deal.
15:03Imagine if we could give Saj the control of the accelerator from the passenger seat.
15:10So, there's one bloke I know that could answer me the question whether or not it's possible.
15:14And that is a guy called Luke at a company called Haltech.
15:18And these guys... Well, listen, we're going there now.
15:20Buckle up.
15:23Haltech are one of the leaders in advanced vehicle control systems.
15:27But, even for them, Tim's plan is a tall order.
15:31Oh, my word. What is that?
15:34Oh, my good God.
15:38Four-litre, twin-turbo, V8.
15:42In the back of a Volkswagen Caddy.
15:44Right, dude, knock it off. Knock it off for a minute, right.
15:47I've got a challenge for you.
15:48OK. This is a big one.
15:50Right, we're doing a car.
15:51So, Mark will golf TTI for a guy called Saj.
15:54He has muscular dystrophy, so he's a wheelchair user.
15:56And he basically controls the wheelchair with his thumb, which is still working.
16:00So, I want to give this guy, I'm pleased you're sitting down for this,
16:03the control of the throttle from the passenger seat.
16:07I'm not entirely sure it's been done before.
16:10No, but... Yeah, I know. That's fine. I'm sure it hasn't.
16:13But what I do know is that the car as it is, is cable controlled.
16:17Yes.
16:18I think we would need to revert away from mechanical throttle control.
16:24Yeah. So, no cables.
16:25No cables. Good.
16:25And go towards an electronic throttle control system.
16:28Should we have a look?
16:29Let's have a look. OK.
16:30We'll see what we can do.
16:32Luke's put together a simple test rig to demonstrate how a modern car's accelerator pedal,
16:36ECU, and electronic throttle body control the flow of air into the engine.
16:42In theory.
16:43Yeah.
16:44When I quickly press it.
16:45Oh, look at that. It opens.
16:47In this setup, pressing the pedal sends an electrical signal to the car's brain, the ECU,
16:53which then opens the electronic throttle body by just the right amount, depending on how
16:58hard you push.
16:59Now, thinking about it, you're right to have two pedals here because we need the ability
17:03for Sarge to have the control taken off him if required.
17:07Yeah, we can do that.
17:07Or if the car is being driven on a normal road.
17:10Yep.
17:11It's just a standard drive without any extra additional.
17:13Absolutely.
17:14We can do that. We can do that.
17:16But we need to modify one of those to be controllable instead of it being the large movement of an
17:25accelerator pedal, we need to be operational by a thumb.
17:29Right. Do you want to power it down while I open it up? Are you all right with me?
17:31No, go for it.
17:32Well, let's have a look at what's inside here.
17:35So from what I'm looking at here, this is what in my day would be called a potentiometer
17:38or a variable resistor.
17:39Yeah.
17:40So what a standard resistor is, it is just the narrowing of a pipe.
17:45So electricity, the electrical current comes down a tube that's say this big.
17:49And if you restrict it, it loses some of the energy and heat.
17:53But this is a variable resistor, which means it can change the diameter of that hole.
17:57So it can squeeze it down to nothing and turn it off like you're...
17:59It's just like a tap.
18:00Yeah.
18:00It's just like a tap.
18:02So in theory then, if I now slide my thumb up, it'll slide up those contacts, bridging those four tracks.
18:08And hence the throttle body opens and closes.
18:11And if you look, I'm doing it all with my thumb.
18:13Yep.
18:14And the movement is about the full range of motion that I have in my thumb of about 20mm,
18:19without using my wrist.
18:20Yep.
18:21So that, actually, is what we need.
18:27Right, can you deal with the ECU side of things, this pedal side of things, all of that stuff?
18:32Yep.
18:33And I will take this and this and the four screws and work on a joystick for Sarge himself.
18:38That sounds good to me.
18:39Yeah?
18:40Yep.
18:40That works.
18:40Should we get lunch?
18:41Yes, please.
18:41But don't start popping the champagne just yet, boys.
18:45Because grafting 21st century tech onto a four decade old golf that was built before cars were commonly fitted with
18:53ECUs,
18:54it's going to be like turning your toaster into the space station.
18:57And don't forget the rust-ridden body shell still crumbling away around Fuzzy's ears.
19:02So, it's time for him to try and repair those banana-shaped sills.
19:08Well, we're out with the old sill and in with a new one.
19:14But what I'm trying to do is get it to fit nicely in here.
19:18So, what I'm doing is I've drawn a line just along here.
19:24I'm going to take it up to a point around at this bit here.
19:28And I'm going to try and tuck the new sill under the old ones.
19:36Because brand new panels rarely fit perfectly straight out of the box, Fuzzy's patiently trimming them down inch by inch.
19:44A little bit more material to lose.
19:47To achieve the perfect fit.
19:55Open it up again.
20:01Right.
20:04I need to make a little fold, basically drop this section back as well as this section so that it
20:12fits snugly onto here.
20:14And hopefully, we should start getting it into place from now.
20:19So, whilst Fuzz shapes the edge of the sill, he's got time to perfect his stand-up routine.
20:26It's hammer time.
20:29If I didn't laugh at my own jokes, nobody would.
20:31Meanwhile, across the workshop, the mission to get Sag's engine back on the road is well underway.
20:36The block has been re-bored to remove the scoring, which turns out to be a blessing in disguise.
20:43Because it's allowed the team to fit it with larger pistons that will create more power.
20:48An upgrade petrol head Sag will undoubtedly be happy about.
20:52Right.
20:54Right.
20:54Now.
20:55Will this go behind?
21:00There we are on there.
21:03Right.
21:04Well.
21:05It's not looking too bad.
21:11So, thanks to Fuzz's handiwork and Rick's team of experts, the engine and body are on the road to recovery.
21:18Giving them five minutes to think about the final part of the plan.
21:22Well, you see, I like the dark, the light green.
21:26Well, I quite like, yeah, I like the darker green.
21:29Deciding what Sag's show car should look like.
21:32Guys, stop a minute.
21:33What?
21:34What's going on in here?
21:35We're just...
21:36We're building a show car here.
21:37Yeah.
21:37That is a true reflection of somebody's personality.
21:40Now, the last time I checked, it wasn't your personality's, it was Sag's.
21:44Yeah.
21:44So, what are you doing?
21:45Well, we can't ask Sag, can we?
21:47Look, I'm going to make a suggestion here.
21:49I am going to go...
21:50Because there's no other way of doing this.
21:53I'm going to go deep, deep, deep under cover and I'm going to get it from Sag's mouth.
21:57Well, hold on.
21:57You can't do that.
21:58Look.
21:59What are you going to do?
21:59Go in disguise.
22:00Six foot six.
22:01Great big honking voice that anybody could recognise from a mile away.
22:05It's not going to happen.
22:06You're going to blow it.
22:10The boys are up to their eyeballs trying to transform this heap of rust and broken parts
22:16back into a Mark 1 Golf GTI.
22:18And, as you can tell, there's still a long way to go.
22:23Because they still need to crack how to get its owner Sag from his wheelchair into the car,
22:29build a controller for him to operate the throttle,
22:32completely refit every single nut, bolt, screw and washer.
22:36And, tougher than all of that, figure out what Sag's dream golf actually looks like.
22:42Since right now that master plan is locked away between his ears.
22:46So, in a desperate quest for answers...
22:49Just get in here. Don't complain. Just get in.
22:51Or, out of sheer panic, Tim's locked himself and the crew in a portable toilet.
22:58Let me explain. First of all, through time I introduce you to Nav.
23:02Nav works on Car SOS, also on cameras.
23:04We've got Ainsley here, that's Ainsley.
23:05Now, why are we here?
23:07And the truth is, we're missing information on this car, on how we want it.
23:14So, to get the answers they desperately need,
23:17Tim's arranged for Sian to bring Sag along to the official Mark 1 Golf Owners Show.
23:23But, little does he know, it's all a ruse to extract the plans for his dream car from him,
23:28without him becoming any the wiser.
23:32I can't just bowl up and ask him, because he'll know he's been Car SOS,
23:35but Nav can. You've got headphones there, man.
23:37Yep.
23:37Put them on, tell me if you can hear me.
23:40One, two, can you hear me?
23:41Loud and clear.
23:42One, two, three. Right, let me just do the same.
23:44So, this is basically, you are my remote control, you're me, just with a different face.
23:54So, under the guise of filming the event for social media, Nav and Ainsley get into position,
23:59while Tim listens in from his throne.
24:03Who have we got here?
24:04We've got my pal Sag here, there's young Narayan there as well.
24:07Hi Narayan, hiya Sag, how are ya?
24:10You alright?
24:11Are you ready to answer a few questions? Are you okay with that?
24:14It'll be quick, it's just about the Mark 1s.
24:16Okay, first question. Nav asking why he fell in love with the Mark 1 Golf GTI.
24:20Why do you love Mark 1s? What is it about them?
24:23You know, I really wanted a Ford Escort, because that's what all the cool kids used to drive.
24:29But I bought this 1.1 Golf, and I fell in love with it.
24:33And do you still own the Golf? Is it still around?
24:35Yeah, it's not around, but it's in pieces, just like everything else.
24:40Talk to me about the wheels and the paint job.
24:43If you had the chance to get it back on the road, what kind of wheels would you put on
24:46it?
24:47What kind of engines? Is there any specifics?
24:50Yeah, I've got a particular engine that I've built back in the day.
24:54I'd like to put that back in there.
24:55This is great.
24:56And Porsche alloys, Porsche brakes.
24:59That's it, and colour-wise?
25:01Dark green.
25:01Oh, dark green. Nice, perfect.
25:04Nav, you've nailed it, man. You've absolutely nailed it, right?
25:06I'm getting out, it's absolutely steaming in here.
25:09Sorry, guys, it was a long one.
25:13So, armed with the key information, the body shell can finally go off for paint.
25:17And it's not a moment too soon.
25:19Because the guys have decided to hand Saj's dream car back to him
25:23at another car show he's planning to attend in just over a week's time.
25:28So, while the paint dries, a freshly showered Tim needs to get a move on,
25:33designing the hand grip for the all-important throttle control.
25:37Oh, you all right, Tim? Hello, Carl.
25:39With Rick's master builder and custom part genius, Carl.
25:45This is all to me about one thing, which is ergonomics,
25:47the way that machinery interacts with the mechanics of a human being.
25:51So...
25:52So, getting it right for the right hand is crucial.
25:55So, basically, we've got to make sure that as we rest,
25:57you've got to imagine that you're putting it in your hand.
25:59Yeah.
25:59So, you'd want to rest it on the fingers,
26:01and then imagine how the hand would naturally grip...
26:05Yes.
26:05..the device.
26:07Yeah.
26:08The ultimate would be...
26:09Something that shapes around the hand.
26:14Yeah.
26:14Or that the hand can shape itself around.
26:17So, we're hoping that Saj has this movement,
26:20because there's more travel there and more control.
26:22More travel, more control.
26:24Yeah.
26:24Than the tip of the thumb.
26:25Yeah, yeah.
26:26So, what do we need, then?
26:27So, we need something that's like a grip.
26:29OK.
26:30Something that the hand can wrap itself around
26:32and can fit comfortably in.
26:34Something that you can hold for a very long period of time.
26:38What, like that?
26:39Like what?
26:40That.
26:41Look.
26:42Oh, right.
26:42That, that there...
26:45Did the...
26:45Right, Andy, just take your hand off that a minute.
26:48Right, actually, can we have your...
26:49Just put your camera down here a minute.
26:52Right, so get your hand in there.
26:53Could you scan this?
26:54Could we make this work?
26:56So, this will have been designed by ergonomicists.
26:58So, it's...
26:59It's perfect.
27:00Yeah.
27:01So, hang on, Andy, when you use a camera like this,
27:03do you get...
27:04Does that get tiring?
27:05I...
27:06Hold that camera for hours.
27:07For hours.
27:08I'm pretty...
27:08I'm pretty sure...
27:10Yeah.
27:10Any camera brand will put a lot of money into developing something like this.
27:14Yeah.
27:14So, why should we...
27:16The answer was right there, attached to the camera.
27:18Why should we spend days trying to figure out something that's already been designed?
27:22Yeah.
27:23Why not be inspired by what other people have created?
27:25Shall we nick the strap as well?
27:27I think we should.
27:28Right, get scanning that.
27:30Andy, can you manage without that?
27:31Yeah, you're gonna have to.
27:33No, you can't.
27:34It's gone.
27:35You do what you've gotta do.
27:36Scan the hell out of that.
27:38Combine it with this stuff here.
27:39And let's make a complete one-off solution for Sarge.
27:42Absolutely.
27:44Apologies if Andy's camera work starts making you feel like you're on board a North Sea fishing trawler, but it's
27:49for the greater good.
27:52But not every part of this build is going so smoothly, because Rick and Fuzz have run into a problem
27:57creating Saj's dream Porsche rims.
28:00So, Rick, Saj is really particular about the wheels on his car. I mean, and who can blame him? He's
28:07got a vision.
28:08His dream was to have a three-piece wheel.
28:11Right, okay.
28:12So it's a separate inner, two separate outer rims.
28:14But here's the snag. The Porsche wheels Saj wants to use weren't designed for this job. Once Rick cut away
28:21the outer face to fit them to the new wider rims, he realised there wasn't enough metal left to safely
28:26join all of the pieces together.
28:28Okay, so, what's the solution there?
28:32Well, we have to have a rethink. So, the rethink was, these are famous for being on Golf Mark IIs.
28:42Okay, so those are known as P-slots.
28:44Yes. So, basically, it was a Pirelli kind of design.
28:47Yes.
28:49So, we thought, I tell you what, it'd be really nice to do a P-slot. So, we got some.
28:54Yeah.
28:55We've machined the edge off here.
28:56Yeah.
28:59We cut that off, and then, essentially, we will then bolt it all together.
29:04And those, I think, will look loads, loads better than the Porsche wheels.
29:10I think they'll look really cool.
29:11Yeah.
29:12But, the question is, will Saj feel the same way?
29:16And, as they can't exactly ring him and ask, and, with the car show under a week away, it's a
29:22risk the boys are going to have to take.
29:24And, sticking with the risky theme...
29:27Whoa, hang on, you're far too inexperienced to be doing this without me here.
29:30Tim's arrived to help fit the engine.
29:32What could go wrong?
29:34Do you think so?
29:35Right, hang on.
29:36Can we just...
29:36Oh, wow.
29:37Mate, right.
29:38So, the shell is painted and looking stunning.
29:40What have we done to this engine, then?
29:43Many things.
29:44Right.
29:44So, it's two litre.
29:46Okay.
29:47Forged pistons.
29:49Steel rods.
29:50Ported head.
29:50Different camshafts.
29:52There's going to be a supercharger slapped on here.
29:54Yeah.
29:54And, we've got to get this in there.
29:56When I've fitted these engines before, I've dropped them in from the bottom.
29:59Yeah.
30:00So, what are you doing with it flying in the air?
30:02The two-poster ramp's not working yet, so...
30:05Okay.
30:06Right.
30:06We've got to do it.
30:10And, don't forget, this is a Mark II engine going into a Mark I bay.
30:15So, this is some serious square peg round hole stuff.
30:19There's nothing quite like putting an engine in a cub.
30:21All this paint work here is beautiful and high gloss.
30:25And, as soon as you scratch it, you're through to the primer, which is a different colour.
30:28And, beyond that, it's metal, which is, once again, a different colour.
30:32It's like surgery, isn't it?
30:34It is.
30:35And, that makes putting the engine back in the equivalent of a heart transplant.
30:40And, would you want Tim operating on you?
30:42Ooh.
30:44Yeah, so watch that.
30:44It's close.
30:46No.
30:46Nor me.
30:47I do want Rick to scratch it a bit, because he gets everything...
30:50Argh!
30:53He generally gets everything so perfect.
30:56Stop talking, Tim!
30:58Tim, stop talking!
30:59And look!
31:02No thanks to Tim, the engine is back safely where it belongs, without any scratches.
31:08Allowing the boys to tick off one of their major jobs.
31:11And now, Fuzz can get on with fitting the new axle assemblies.
31:15Because, to add the bigger Porsche-inspired brakes Sag wants, the car's entire suspension and wheel hub set up needs
31:21to be upgraded.
31:23So far, I've got my side in, but the other side needs to be loosened off, so that we can
31:29get it all up.
31:30We're not winning at the moment.
31:32Because with the ramp broken, the boys are having to work with the car just up on axle stands, which
31:37makes doing this job like brushing your teeth with your nose pressed against the mirror.
31:41Right, hold on, let me have a look and see what you're trying to do.
31:44It's just going to pivot forward, like that.
31:46Pivot?
31:46That's going to go.
31:47Okay, hold on.
31:48If I push up here...
31:50Hang on, we'll do it.
31:51Who needs a gym?
31:54Clearly not Britain's sexiest mechanic, 1984.
31:58But with less than a week before the car needs to go back, there's no time to sit down on
32:02the job.
32:03Come to think of it, still nowhere for Sag to sit either.
32:07Luckily, Jamie from Mobility and Motion has arrived with a solution.
32:12So, let's discuss the seat.
32:14So, what is this going to offer us?
32:15Well, this is an electric turning rotating seat.
32:18Well, rewind, what electric...
32:20Oh, it is, there's a motor on it.
32:21Yes, it's powered rotation, making life a lot easier.
32:24So, this is going to get bolted down into here, and then press of a button, whee, comes out.
32:29Yes, rotates around 90 degrees, and then the seat can extend a little bit over the sill, making it a
32:34lot easier to transfer on.
32:35So, it looks like a show car.
32:36Exactly.
32:36So, it still has the VW seats in it.
32:38That's what we're going for.
32:39So, hang on a minute.
32:40When Sarge realise he's been car SOSed, he'll see his show car, and he'll see something in his mind he
32:45can't get into.
32:46But then we open the door and say, would you like to get in?
32:48We have to make this fit, we have to make this work, because it offers so much to Sarge.
32:54But with time slipping away, the sheer scale of this build means nothing is going to plan.
33:00Just ask Faz.
33:02We've got three out of four positions in place, but we just need to pivot this little bracket over and
33:10onto the stud that's mounted onto the body frame.
33:14I can't quite get enough movement on it.
33:18Can't get enough leverage lying under here.
33:22And there's no other way that we can do it right now, because we're stuck to working on axle stands.
33:27So, I'm going to get out of the way, then we'll get a jack underneath here, and that will help
33:31lift everything up.
33:37Just that nut and washer, which should be in place.
33:44OK, that's brilliant, we've got the front end in.
33:48Which means the bigger brakes Saj wanted can now be fitted, along with his new wheelchair accessible seat.
33:56And Luke from Haltech is back, and busy wiring in the ECU for the electronic throttle control.
34:02If you want an indication of how much work is involved in getting the hand grip for Sarge to actually
34:07accelerate this car,
34:09we'll have a look in here, because this is all the stuff that basically needed to get pinned.
34:14That is the car of brains.
34:16It's the brains, it's the nervous system, it's the spinal cord, it's the lock.
34:20That goes in the bin and gets replaced with...
34:23Yeah, can I have a look at this?
34:25All right, dude.
34:26How are we doing?
34:26Budge up a bit.
34:27Right.
34:28That lot, that old wiring loom has gone and been replaced with...
34:32So that's our flagship engine management system.
34:34Yeah.
34:35That is effectively controlling about 80% of the car.
34:38OK.
34:38Everything forward of the driver's seat, the passenger seat, that you can see is being controlled by that device.
34:45All of that is going in to mean that this is now a digital, that we can have as many
34:49copies of that wherever we want.
34:51Yeah.
34:51Particularly over there in the form of a hand grip.
34:54Exactly.
34:54Which we're working on at the moment.
34:56And the high-tech upgrades don't end there.
35:00We've attempted to copy the factory instrument cluster.
35:04So you're going to get a digital version of this.
35:07Oh, look at that.
35:09That is amazing, and it's still got the same appearance.
35:11So all the needles will work, everything will work?
35:12Yep, everything works.
35:14But new displays mean yet more electrical work, and that means more time.
35:20Mate, you're amazing.
35:21I know you're up against it.
35:22We've got...
35:22We're just over a day to complete this.
35:26I'm back on the workshop floor.
35:28That target's rapidly slipping out of sight, because the scale of what jobs remain is immense.
35:34The engine is back in place, but it still isn't connected up.
35:37There's hours of wiring left to finish, and wheels, doors and an interior and glass left to fit.
35:45I just want to hit you with a little bit of a reality check for a minute.
35:48I'm now counting hours down.
35:50And for the first time ever, I've heard...
35:52I can't believe I'm saying this.
35:54Maybe we have to give this one back as a static reveal.
35:57What does that mean?
35:58That means a non-runner.
36:04The big day has finally arrived.
36:07It's time to hand Saj's dream show car back to him.
36:12Tim's arrived at the iconic Caffeine and Machines The Hill Cafe, where the show is being held.
36:18The problem is, Rick, Fuzz and the Golf are missing.
36:22There are car people everywhere, and I cannot get hold of Fuzz.
36:26And it's going to be a non-runner.
36:27I'm going to ring him again.
36:29I'm absolutely devastated.
36:32OK, it's ringing.
36:35I'm really sorry that I can't take your call, but if you leave me a text, then I will probably
36:41get back to you.
36:42Thank you very much.
36:43I'm standing at the event waiting for you guys to turn up.
36:45Can you just do me the favour of letting me know what's going on with the car?
36:48Is it a non-runner?
36:51This is what I feared since the beginning of Car SOS.
36:54Where's it all going to go wrong?
36:56Well, I'm telling you right now, it's here.
37:01Guys, can we get everybody together for a moment, please?
37:03Could everybody come round here?
37:04Everybody together. Come on, come over here.
37:06We'll extend the cameras.
37:07Thank you for coming down.
37:08The problem we have at the moment is we have no fuzz and we have no car.
37:13We have to proceed assuming this is going to happen.
37:15Saj is going to get here.
37:16He's going to pull up into a car space somewhere down here?
37:19Just down here, yeah.
37:19OK.
37:20And I'm going to be hiding in the shop in there.
37:23As soon as he crosses the line, I'll run out and then we'll give him his car back.
37:26Literally behind.
37:26Right where you guys are standing there is where it's going to happen.
37:29But that all depends on whether his car arrives in time.
37:33And to pile on the pressure, the man of the hour has pulled in early.
37:40Sanjay's here.
37:41That's him just pulled up in the Mark 5 Golf there.
37:44What are you saying, lad?
37:45Just out.
37:45Everything cool?
37:46I'm really good, man.
37:47What's happening?
37:47You all right?
37:48Yeah, everything's all right, man.
37:49What a nice turnout, man.
37:50So, in a final Hail Mary.
37:53Come on, fuzz.
37:54Stop messing me about.
37:55Tim's giving it one last try.
37:59Look, we are on our way.
38:01We're just coming.
38:03We aren't on our way, honestly.
38:04What, with the car on the back or what?
38:07No, we're driving it.
38:08He's driving.
38:11Yes, fired off like a bolt of German lightning.
38:15The boys are hurtling straight from the workshop towards Saj.
38:19And it looks like they might actually get there in time.
38:24That engine, though, is incredible.
38:26I can't get over the transformation.
38:29It's brilliant.
38:30A little different.
38:31It is, yeah.
38:33Come on.
38:33We're nearly there now.
38:40Come on.
38:41Here we go, Rick.
38:44Here we go.
38:45This is it.
39:02Oh, my God.
39:03How are you doing, man?
39:04You all right?
39:06You recognise that?
39:07Oh, my God.
39:10Oh, my God.
39:14How are you doing, man?
39:17You all right?
39:18Oh, my God.
39:20You recognise that?
39:22Yeah.
39:22Oh, my God.
39:26You're the catalyst.
39:31We don't meet up unless you're there.
39:32Yeah.
39:33I can't believe it.
39:35Oh, man.
39:36There are a few other people you might recognise.
39:37Your friends and family.
39:38Can we bring out Sash's friends and family, please?
39:41Guys, come on over.
39:41Give them a round of applause, guys.
39:43Come on.
39:43Come on.
39:44Come on, man.
39:46Dude, I know this is a lot.
39:47This is a lot to take on.
39:48You weren't expecting this at all, were you?
39:51My heart's racing.
39:52I bet.
39:53Yeah.
39:56The last time Saj saw his beloved Golf, it was as far from the show car he'd dreamt of as
40:02it was possible to be.
40:05But with a hefty dose of car SOS magic, the boys have transformed it into a bespoke Mark 1 masterpiece.
40:13Outside, every trace of rust has been banished.
40:16The body has been resprayed in Saj's rivage green colour of choice and topped off with a gold stripe that
40:23screams custom cool.
40:25Under the bonnet, his more powerful 2-litre Golf Mark 2 engine has been rebuilt to perfection with new forged
40:32pistons, a ported head and new camshafts.
40:36Inside, there's an electronically operated seat to help him in and out.
40:41A new digital driver's display as well as that one-of-a-kind throttle control system.
40:47Finally, it might not be sitting on the Porsche wheels he dreamt of, but there's no denying the bespoke P
40:54-slot split rims definitely complete the look.
40:57Will Saj agree?
40:59I'm aware of the fact that you wanted Porsche wheels on this. The ones we had wouldn't have been strong
41:03enough for this.
41:04To actually make you a set of custom P-slot Pirelli split rims, which is what these are.
41:11Awesome.
41:12Are you happy with them?
41:13Yeah, yeah.
41:14Good, so we got it right?
41:15Yeah, man.
41:16Is it sinking in yet?
41:18It's sinking in now that I'm sitting in my car.
41:20I'm not setting it up for years.
41:22How many years?
41:24Oh, since...
41:27Probably 2000, 2000?
41:29So like 25, 20?
41:30Yeah, 25 years.
41:31I'm still thinking, is this a dream?
41:33Really?
41:33I'm thinking, you know, is this real?
41:36How does it feel to sit in your car, man?
41:37Does it feel being you right now?
41:39I feel like jelly.
41:39Honestly, I would not think that day would come.
41:42Obviously, I've had this car for nearly 30 years now.
41:45Yeah, it's a long time, eh?
41:46It's a long time.
41:47You know, it's been with me through thick and thin.
41:51You know, from the highs and the lows and everything else.
41:53It's always been there in the back.
41:55And it's always in my mind, you know, I want to get it done.
41:58Had you written this car off in your mind?
42:00Had you put it down as something that wasn't going to happen and that was that?
42:02And truthfully, yes.
42:04You're limited every day where you can do, what you can do, where you can go.
42:10You know, and obviously, you know, things do get hard.
42:13There is a little something else that's hidden in this car,
42:17which is probably unlike any other VW Golf GTR on the planet.
42:22So let me explain.
42:24You take it with your right hand.
42:25Yeah.
42:25Tell me how that fits.
42:27Is that like that?
42:30Okay, okay, yeah.
42:30Okay, right.
42:31So can you hold that all right?
42:32Yeah.
42:33So this means that you take control of the throttle.
42:36Uh-huh.
42:37Yeah.
42:39So it means that you can have you and Shan or Nab sitting beside you,
42:43and you can be a co-driver.
42:44You can be part of the team of making this vehicle go.
42:47You're in charge of the go button.
42:48Oh, man.
42:50Oh, that'd be...
42:51That'd be fun.
42:52Yeah?
42:52Yeah.
42:53Mega.
42:53Oh, my...
42:54Yeah.
42:55Well, Saj, there is only one thing left to do,
42:57and if you know the show, you know what that is.
42:59Keys.
42:59Yeah.
43:00Okay.
43:01Hey, it's with great pleasure that I tell you, you have been Car SOS,
43:05and you totally deserve your inspiration on that.
43:07Wow.
43:07Absolutely amazing.
43:08Okay.
43:08Wow.
43:17Is that all right for you, mate?
43:18Oh, Mega.
43:20I was dazed and full of shock earlier.
43:22I'm wide awake.
43:24I can feel it.
43:24I can hear you.
43:25Oh, Mega, thank you very much.
43:27So unreal being back in this car.
43:30All good feelings out.
43:31Oh, yeah.
43:33Brought back an old friend.
43:35Oh, awesome.
43:37An old friend that now he's on a private road,
43:41Saj can finally drive again.
43:43Can you get your hand in there?
43:45So, how does that throttle control feel?
43:49Three, two, one, go.
43:52Oh!
43:54Oh!
43:55Oh!
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