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00:16This time on Car SOS, it's small, it's British, and it's falling to bits.
00:22These two ramp arms here are going to cut through this thing like a knife through hot
00:26butter. Ooh, that is bad. So, can the boys revive this old rust bucket? Walk over the crunchy
00:33autumn leaves. Or is it the end of the road for this British icon? Oh, God, we're in big trouble.
01:00We are in South Wales, Timmy. And let's talk about why we're here, because today we are
01:05picking up a very cool plastic mini. Yes. I'm going to be honest with you, I don't get the
01:11mini thing. What do you mean you don't get the mini? Everybody gets the mini. No, no, I
01:14don't. I've owned three of them, we grew up with them, but I just don't get the little
01:18minis. They're like toy cars, they're like my first car. No, but the mini is everything
01:23or anything to anyone. Launched in 1959. Yes. You could fit a family of four in it comfortably
01:30with all their luggage and go on holiday. And then, of course, in the 1960s, people thought,
01:35wait a minute, if we soup that up, that's going to be an absolute ripper of a rally car. And
01:40it was. And then pop stars and movie stars in the 1960s went, hey, if I got a little mini
01:46and painted it in psychedelic colours, hey, it's going to look super cool. And it was.
01:52Yes, few cars have left a mark on Britain's roads, racetracks and culture quite like the
01:58mini. Born out of the 1956 Suez oil crisis, its tiny 848cc engine could return over 40 miles
02:07to the gallon at a time when most family cars barely managed 30. It was also affordable.
02:13Could parking spaces regular drivers wouldn't even register, yet spacious enough for four.
02:18Its brilliance came from its space-saving separate front and rear subframes that carry
02:24the engine, gearbox and suspension independently of the body shell. Plus, a sideways mounted engine
02:30and gearbox, ultra-thin lightweight doors and tiny 10-inch wheels that are pushed out to
02:36the corners to free up cabin space. A move which inadvertently gave it the handling of an
02:41espresso-powered go-kart that, when empty, shifted quicker than a terrier after the posties' ankles.
02:49And while the one the boys are on their way to see is a later 1980s mini Mayfair, under the
02:55skin,
02:55it's still a national treasure and proof that size isn't everything.
03:00Come on, then. Whose car are we picking up today?
03:03We're picking up Donna's car today. We're meeting her best mate Tamina and her brother Bernie.
03:07All right? OK.
03:12Hello.
03:13You must be together. How's it going?
03:14How's it going? How's it going?
03:16Where are we? What's this place?
03:17We're in Bernard's friend's garage in Caerphilly.
03:20Right.
03:20And Donna is currently about 30 minutes away in Cardiff. She's in work, so she's got absolutely
03:25no idea. She thinks the car has gone into storage.
03:29OK, fantastic.
03:30Go on, let's have a look.
03:31Go on, then.
03:41That's a thing of beauty, look.
03:42What?
03:43Listen, let's me and you, just me and you, are going to talk about Donna's story.
03:46Come on to me, let's go.
03:50It's in a bit of a bad way, isn't it?
03:52The arches, they're coming off, aren't they?
03:55Everything about it is screaming out, total, total rebuild.
04:03How long has the car been around?
04:05So, the car has been around since about 2014.
04:09Right.
04:10Donna's dad sadly passed away and he always said he was going to buy her her dream car,
04:15which is the Mini.
04:16Right.
04:17So, when he did pass away, with the small amount of money that was left and what she'd
04:22saved up, she ended up buying this Mini now.
04:25OK.
04:25Would you say it's the single most important material item she owns?
04:30Yes.
04:30Without a doubt.
04:31I reckon more than her wedding ring.
04:33Really?
04:34Really?
04:34But that's nothing against her husband, though, right?
04:36No, it's not.
04:37So, she still loves her husband.
04:40Has he got an engine?
04:42Yeah.
04:42It's a 12.75 GT.
04:44It's a 12.75.
04:46Yeah, she always wanted a Cooper, she did.
04:48She wanted a Cooper, but this...
04:49Is a Mayfair.
04:50It's a Mayfair.
04:52Right, let's have a look around the back.
04:54Oh!
04:56That is bad.
04:57I mean, where does she live?
04:58Does she live on a beach?
05:00It's kind of sad to see a car that's sort of got into this state.
05:07So, what has happened in Donna's life for the car that she loved so much?
05:11I'm assuming it wasn't in that condition when she bought it.
05:13No.
05:13Donna's sister was diagnosed with cancer, and the car basically took a back seat.
05:19And in the meantime, she was experiencing her own problems.
05:23She'd noticed some difference, and there was difference in the way she was acting and behaving.
05:29There was issues with her memory, and eventually, she was diagnosed with encephalitis.
05:36At one point, the doctors did say to her that her brain was shrinking.
05:42How bad has it got for her?
05:43So, she needs to write everything down.
05:45At one point, the situation was so bad that she forgot her own children's names.
05:52Hang on, there's more to it than the car.
05:54Yeah.
05:55This is about reminding her of memories as well, isn't it?
05:57Yes, exactly, yeah.
05:58So, it's always going to be a reminder of, this is what my father always wanted to give me.
06:03What do you know about how she wants that car to look?
06:06I do know she wants it blue.
06:08I know she's always loved a Mini Cooper.
06:10So, a Mini Cooper is the dream?
06:12Yes.
06:13Let's go see how fuzz is going on.
06:14Come on.
06:17Come on, then.
06:18Forwards we go.
06:28OK, come on.
06:29Let's get this last one done, Billy.
06:31Yeah.
06:31Right, locked and loaded.
06:34Right.
06:35We'll look after it.
06:36Hungry much.
06:38For a small car, it's got a lot of big, big problems.
06:43It may be tiny, but the boy's task is anything but.
06:46Because not only do they need to build Donna her dream Cooper,
06:49they've got to do it in a way that hangs on to as much of her original car
06:53and, with it, the memories of her dad as they can.
06:59Ramp legs under?
07:00Right, hang on.
07:01Under what?
07:02I mean, under what?
07:03Swiss cheese?
07:04I mean, look at it.
07:04You've got the back end, scuttle on the front, the wings, the bonnet, the bumpers,
07:08the doors, the sides, the B-post, the C-post, everything, the sills.
07:11There's no sills there.
07:12Probably no floor there as well.
07:15Everything, everything needs replacing, right?
07:17So, we're replacing a lot of this car anyway.
07:20It would be better to start with a fully, newly manufactured shell.
07:25I agree, dude, but there is a line.
07:27I cannot emphasise the importance of keeping this identity to Donna.
07:32We need to have a look underneath to see if we can save other components,
07:36like the subframes.
07:37Yeah.
07:37Things like that.
07:38If we can save those, then replacing the body shell is on.
07:43Well, the assessment underneath this vehicle is going to be at running speed.
07:46I'm going to run from the back to the front before it drops on me, man, I'm telling you.
07:55This is, up there, is one of the worst ones we've taken on.
07:58It is.
08:01Have you seen the sills on this thing?
08:03Well, I mean, it's rusty, but it's not, I've seen worse.
08:07No, it was a question in that I'm asking where are they.
08:09What?
08:10They don't exist.
08:11Have a look.
08:12Oh, God.
08:13Look at that.
08:15What about this hole here?
08:16I mean, watch this.
08:17Watch this.
08:20So the rear subframe is this section here, the section which would unbolt and drop down
08:24as a square, as you can see, or as a rectangle, as you can see here, right?
08:27That's correct, yeah.
08:29And that, what are you thinking?
08:30I think it's touch and go, really.
08:34Come on, let's go and look down the front.
08:36Walk over the crunchy autumn leaves.
08:38What do you mean?
08:38It's a lovely autumn's day.
08:40Walk through the park with me and get to the front of this car.
08:42Listen to it.
08:43Yeah, I see what you mean, actually, yeah.
08:46Right, now, I don't want to get too far ahead of myself here,
08:49but there may be some good news to be had,
08:52because maybe the front subframe is going to be okay,
08:56probably because of the generous oil leak.
08:59Yeah.
09:01Thank God for oil leaks.
09:02Yeah, that's right, exactly.
09:03But everything else, I mean, brakes, all the steering components,
09:08we are grasping at straws with this.
09:11Yes, swapping out the body shell for a replacement
09:14might seem like the perfect shortcut to creating Donna's dream Cooper,
09:17but doing it without losing the identity of her cherished Mini
09:21is going to be anything but straightforward.
09:25So, first things first.
09:27The priority is to assess Donna's original Cooper engine
09:30to find out if it can be saved.
09:32If it can, it allows them to keep the core identity of her car.
09:37Then, and only then, can they give the go-ahead
09:40to replace the rust-ridden body shell.
09:43Finally, if they somehow pull all of that off,
09:46this mundane Mayfair has got to become
09:48the super-cool, sporty Cooper Donna has always dreamed of.
09:52And to make things even more difficult,
09:55we'll also need the rotten subframes and suspension reconditioning,
09:59as well as a full gearbox rebuild.
10:03So, before the rust spreads any further,
10:06Fuzz is getting to work,
10:08carefully peeling away the rotten body shell
10:10so he can get a better look at the condition
10:12of everything else underneath.
10:14So, I'm going to go in,
10:17detach everything that connects this area
10:20with the inside of the car.
10:22Things like the accelerator, clutch, gear linkages, etc.
10:26And then, we'll see if we can get the subframe bolts out
10:30and drop it all down.
10:32And then, and only then,
10:34will we know if we can save it.
10:41We weren't going to be using that again anyway.
10:45The thing about Minis is,
10:47they kind of look great.
10:49And when they came out,
10:50there was nothing like them.
10:52They're fun to drive,
10:54and of course,
10:55they were cheap to buy.
10:59And, easy to modify.
11:01Of course, take the grille off,
11:03put some slightly wider wheels on.
11:05Instantly, even though you're driving a base model,
11:08it looks and feels like a,
11:10like a rally spec.
11:11It's like a modifier's dream.
11:15And that, in a way,
11:17is why they are evergreen.
11:21I'm having fun.
11:22I'm in the zone.
11:25Yes, Fuzz is taking full advantage
11:27of the Mini's unibody construction.
11:29Those detachable front and rear subframes
11:32let him strip the whole thing down quickly
11:34and see just how much of Donna's little car
11:37he can actually save.
11:39Hopefully,
11:41now,
11:42we are
11:42free.
11:47Now, this is the subframe here.
11:50This holds
11:51the engine
11:52and the gearbox
11:53and the transmission
11:54and the steering.
11:56This is absolutely
11:59horrible around here.
12:01Everything has got to be restored.
12:04This is a massive,
12:06full-on job.
12:07Make no mistake.
12:10Tim and Fuzz have faced
12:12some whopper-sized renovations before.
12:14But,
12:15in a hilarious twist of fate,
12:17this 1987 Mini
12:19might just be the biggest yet.
12:20Well,
12:21it's time to take a look at this engine
12:23because
12:23we've got to save this.
12:25And what I'm hoping
12:26is that it's not
12:27so badly worn
12:29and so poorly maintained
12:30that it's almost
12:32beyond the brink.
12:40They share
12:41their lubricating oil
12:42with the gearbox.
12:44So,
12:44you've got those gears
12:45churning together
12:46and
12:47you've got
12:48the engine
12:49also operating.
12:51So,
12:51it's a kind of
12:52massive compromise.
12:54So,
12:54I'm just hoping
12:55that once I
12:57get the cylinder head off
12:58that we'll find
12:59that the engine
13:00doesn't look
13:01too badly worn
13:03internally.
13:04And hopefully,
13:05there's a little bit
13:06of room left
13:07for us to be able
13:08to remachine it,
13:10put some fresh
13:11pistons in there
13:12and bring this
13:13old power unit
13:14back to life.
13:16Looking at it though,
13:19it's really bad.
13:21Sharing the oil
13:22between the engine
13:23and gearbox
13:23was a brilliant
13:25space-saving
13:25engineering trick.
13:26But it's also
13:27a risky one
13:28because if anything nasty
13:29has found its way
13:30into it,
13:31it can take out
13:32both components
13:33in one fell swoop.
13:35I can't see
13:37any signs
13:38of mayonnaise
13:39or emulsified oil.
13:41We haven't got that
13:42but
13:44still looks pretty
13:46grim in there.
13:47The oil smells
13:48like it's pretty old
13:49so it may have
13:51gone well past
13:52its service intervals.
13:54Still,
13:54on we go.
14:02now what I can
14:04see
14:05is
14:07rust
14:07around number
14:08three
14:09combustion chamber.
14:10To me,
14:11that would indicate
14:12that perhaps
14:13we have
14:14the start
14:15of a leaking
14:16head gasket.
14:17That's a relatively
14:18simple fix
14:19for a man
14:20of fuzz's talents.
14:21The real nightmare
14:23begins if the engine
14:24block is beyond
14:25saving.
14:25If they have
14:26to replace that,
14:27not only will they
14:28lose the heart
14:29of the car
14:29Donna's dad
14:30bought her,
14:31they'll have to
14:31find a way
14:32to refurbish
14:33her existing
14:33rust-ridden body shell.
14:35So we've got
14:36score marks
14:37in number two
14:38here.
14:39Now that means
14:41that either
14:42the engine
14:43has overheated,
14:44this piston
14:45has expanded
14:45and it has rubbed
14:47against
14:48the cylinder wall
14:49or it could be
14:50that one of the
14:51piston rings
14:52that are
14:53around the piston
14:54and form
14:55the gas-tight seal.
14:57If one of those
14:58was broken
14:59then it would
15:00cause scoring
15:01on the side
15:02of the ball
15:03like this.
15:03If it's too far
15:05worn on these
15:06two balls
15:07at the end
15:07here,
15:08we're in big
15:09trouble.
15:11So while the team
15:12dive in
15:13to saving Donna's
15:14all-important
15:14original engine,
15:16Tim's headed out
15:17on a crucial
15:17research mission
15:18accompanied by
15:19a genuine slice
15:20of Mini Cooper
15:21royalty
15:22and if this guy
15:23can't change
15:23his opinion
15:24of these
15:25British icons,
15:26nothing will.
15:27So if you're
15:28wondering who
15:28this man is,
15:29he might recognise
15:29the surname
15:30because your
15:30grandfather was
15:31who?
15:32He was John
15:32Cooper,
15:33the guy that
15:35started the
15:35Mini Cooper
15:36but before that
15:37won the Formula
15:38One World
15:38Championship twice.
15:40Yes,
15:40Tim's out for a
15:41drive with a
15:42Cooper in a
15:43Cooper.
15:43Because if this
15:44master plan to
15:45replace the body
15:46shell comes off,
15:47the boys are
15:48going to need
15:48a road map
15:49for how to
15:49turn a blank
15:50canvas into
15:51Donna's dream
15:52car.
15:53How did it
15:53happen?
15:54You've got
15:54Isagolis who
15:55designed this
15:55car, you've
15:56got your
15:57grandfather, how
15:57did the two
15:58meet?
15:59Well, they
15:59used to race
16:00together and
16:01he told him
16:01about this
16:02little car he
16:02was designing
16:04that was in
16:05response to a
16:06fuel crisis, to
16:07an oil crisis,
16:08that was supposed
16:08to be economical,
16:10family, city car
16:11but an unintended
16:12consequence of kind
16:14of the layout was
16:15how it handled.
16:16It handled really
16:16well.
16:17because the wheels
16:18are on each
16:18corner so the
16:19balance was really
16:20good for a front
16:21wheel drive car and
16:22yeah, that's when
16:23Grandad had a go in
16:25one and thought
16:25this is a good
16:27handling little car,
16:27maybe it could be a
16:28race car.
16:33What is it that
16:34makes a Mini Cooper
16:35a Mini Cooper?
16:37I mean, it's the
16:38sportiness, it's the
16:39fun, it's that little
16:41extra bit of smiling
16:42it gives you when you
16:43drive it.
16:43I'm sorry if I'm
16:44annoyed because I've
16:44got a smile on my
16:45face and I can't
16:46shake off it.
16:47Well, that didn't
16:48take long.
16:49I mean, this one
16:50probably has 90
16:51horsepower, still
16:52feels like you're
16:52going a million
16:53miles out.
16:54Absolutely, doesn't
16:54it?
16:55It's just so
16:56responsive, it's like
16:58just an extension of
16:59yourself.
17:00I mean, it's a
17:00cliched saying about
17:02Minis but it's a
17:03little go-kart.
17:04Yeah.
17:04Front wheel drive
17:04go-kart.
17:05Yeah, it really
17:05is, isn't it?
17:09Right, listen, so the
17:10reality of it is we
17:11are doing up Donna's
17:12little car.
17:12It's a Mayfair.
17:13It's not the Mini
17:14Cooper.
17:14So, have you got a
17:15bit more horsepower in
17:16it?
17:17We've got the 1275, so
17:18we've got the Cooper
17:19engine.
17:19But what about, like,
17:21what about brakes?
17:22So, yeah, upgraded
17:23brakes, one of the
17:23first things Grandad
17:24did from the Mini to
17:26the Mini Cooper was
17:26they got little disc
17:27brakes, smallest disc
17:29brakes in the world.
17:29Right.
17:30Because it didn't
17:30stop very well on
17:31those old drum brakes.
17:33You need the Mini
17:34light wheels, stripes,
17:35you've got to have
17:35the stripes, Cooper
17:36stripes.
17:36What's the story?
17:37Where did the
17:38stripes come from?
17:38So, back in the 50s,
17:41I think even in the
17:4140s, all the race cars
17:43at the time were
17:44always British racing
17:44green.
17:45Yeah.
17:45And Grandad, given
17:47that there were so many
17:48British cars in the
17:4950s, he just got a
17:50bit fed up.
17:51He was like, look around
17:51the corner of the pit
17:52straight, like, is that
17:53a Cooper, is that my
17:53car?
17:54So he's put the two
17:55white stripes on, and
17:55that was the start of
17:56the two white stripes.
18:00My Grandad's philosophy
18:02was, it is what you
18:03want it to be.
18:04He broke the rules.
18:06He was about a rule
18:07breaker.
18:07So, that said, what
18:09about if I was to
18:11present you with, from
18:13Donna's car, which is
18:14a Mayfair, the flap
18:15off the glove box, could
18:16you possibly sign that to
18:18Donna and make it the
18:20Charlie Cooper, one of
18:21one-off-one?
18:22Why not?
18:23Do you do that?
18:23Of course, yeah.
18:24Pull over now before
18:25you change your mind.
18:26Let's do it.
18:26I've got a pen, I've
18:27got everything.
18:30Here we go, Charlie
18:31Cooper, one-off-one.
18:32There you go.
18:34That's it.
18:35There it is.
18:36Right, for the petrol
18:37heads out there, for the
18:38minifans out there, who's
18:40jealous?
18:42Man, that is so cool.
18:45Let's just hope the new
18:47body shell plan pays off.
18:48Otherwise, Tim's got a
18:50lovely new Cooper part and
18:52nowhere to stick it.
18:53Meanwhile, with the team
18:55still battling to save
18:56Donna's engine, gearbox,
18:58original subframes and
18:59suspension components, Fuzz
19:01is paying a visit to
19:02Alan to pick up a
19:04refurbished carburetor for
19:05Donna's engine that will
19:07help reinstate that iconic
19:08Cooper punch.
19:09Now, what is the job of
19:12the carburetor?
19:14Carburetor is a fueling
19:15device.
19:16It is designed to mix air
19:19and fuel at exactly the
19:20right viscosity to make an
19:23engine perform correctly.
19:25The mini Mayfair's original
19:27848cc engine was all about
19:29economy.
19:30But thanks to Charlie's
19:31granddad, the 1275 upgrade
19:34not only has a larger bore and
19:35stroke giving more power, it
19:37has bigger valves and a
19:39modified cylinder head that
19:40improves airflow, which, when
19:42combined with this SU carb,
19:44give it more torque and top
19:45end power.
19:48And if you're thinking,
19:49that's all well and good, but
19:51how do carburettors work?
19:53Tim's put together a
19:54demonstration for you that
19:55absolutely sucks.
19:57Now, I want you to imagine
19:58that this thing here, this
19:59wet and dry vacuum cleaner,
20:01Donna's engine, and there is
20:02the fuel that we need to get
20:03into Donna's mini to make it
20:05run.
20:05So how do we do that?
20:07Well, we do that with the
20:08carburettor.
20:08But how does the carburettor
20:09work?
20:10How does it work out how much
20:12fuel to put in to the wet and
20:17dry vacuum cleaner so it's the
20:19right amount?
20:20One thing's for sure, it doesn't
20:22just pour it in, does it?
20:23There isn't a great big funnel in
20:24your car.
20:25The solution involves making use
20:27of a scientific principle
20:28discovered in 1797, known as
20:31the Venturi effect.
20:33Now, let's see.
20:42Now, look.
20:43Look at that.
20:45There it is.
20:46And that's it.
20:47There is your fluid going into
20:50the engine.
20:53So, how the hell does that
20:55work?
20:56Well, it's amazing because
20:57actually what's happening here
20:58is the air moving through this
21:01hole, because it's a smaller
21:02hole, is being forced to speed
21:03up.
21:04And as a result of that air
21:06speeding up, you get the
21:07crucial thing, which is a
21:09pressure drop.
21:10And as a result of that
21:11pressure drop, we've got a
21:12little bit of a vacuum being
21:13created inside this pipe.
21:15And guess what goes flying up
21:17that pipe to equalise that?
21:19That is your fuel.
21:20As you put your foot down on
21:22the accelerator, it draws in
21:24more air.
21:25And if you're going slower,
21:26it draws in less air.
21:27So, it actually chooses the
21:29amount of fuel relative to the
21:31air going in, which is just
21:33this self-governing, incredible,
21:35mind-blowing system.
21:37And if Donna wants her Mayfair to
21:39feel like a proper Cooper, the
21:41carburetor is a critical
21:43component.
21:45So, Alan, what's our next
21:47step?
21:47We've got the throttle
21:48butterfly, we've got the choke
21:50mechanism on there.
21:51What do we do now?
21:52Right, let's put the float
21:54valve in.
21:54Do you want to put that one
21:55in, then?
21:55OK, yes, please.
21:56Right, there we go.
22:01OK.
22:02There we are.
22:02And then, in with the needle.
22:05The float valve and needle
22:07control the flow of fuel in and
22:09out of the carb.
22:10As fuel enters, the float
22:12rises, pushing the needle into
22:13its seat and shutting off the
22:15supply.
22:16That's right.
22:17Minis use this style of SU carb
22:19for decades because they're
22:20incredibly tunable.
22:21A tiny tweak of the needle and
22:23float can transform how lively
22:26the engine feels, which is why
22:27petrolheads love them.
22:29Right, so, is that our
22:31carburetor rebuilt?
22:32Yes, all done.
22:33When it's finely tuned, we'll be
22:35producing exactly the right
22:37amount of power.
22:39That's going to be utterly
22:40perfect.
22:41Yes, let's just hope the team
22:43have been able to save Donna's
22:45original engine to go along
22:46with it.
22:47Tim and Fuzz are working their
22:49magic on this 1987 Mini
22:51Mayfair.
22:52A tiny car with a big list of
22:55problems.
22:56Their plan is to replace the
22:58entire body shell before it
22:59crumbles to dust.
23:01To transform it into the
23:02Mini Cooper Donna always
23:04dreamed of.
23:04But that can only happen if
23:07they save her original engine,
23:08the beating heart of the car
23:10her dad bought her.
23:12Now, here is an engine with a
23:15difference.
23:16It's Donna's car's same
23:18engine, but it's been
23:20rescued.
23:20And that is an amazing thing.
23:23I thought that it was going to
23:24need reboring, but actually,
23:26it's just needed a good
23:28honing.
23:29Now, what is honing?
23:30Well, honing is like a set of
23:32three spinning stones that go down
23:34inside the bore and then open
23:36out as they're spinning
23:38centrifugally and just lightly
23:41dress, lightly clean up the
23:43bore.
23:43So it has standard sized
23:45pistons still, new piston
23:47rings, new bearings.
23:49The only thing Donna will need
23:50to do is make sure that it gets
23:53oil changes on a very, very
23:55regular basis.
23:56Not like a modern car, but like
23:58perhaps every 3,000 miles.
24:00And that will keep this in tip
24:02top condition.
24:02It looks superb.
24:06So, time to put the cylinder head
24:08on.
24:10It's been checked.
24:10It's all nice and flat.
24:12Just had a little bit of dressing
24:13here and there.
24:19This is great.
24:20We are in the business of
24:22restoration.
24:23So now, our cylinder head is in place.
24:28Now, we can start doing our valve
24:30clearances.
24:31That is the distance between the rocker
24:36arm and the stem of the valve right here.
24:39Now, we have to set those with a little bit
24:41of clearance because as the engine
24:43warms up, all of the metal
24:45items expand
24:47and the valve stems
24:49get longer.
24:50So, if we had these
24:52tight down,
24:54then what would happen is
24:55there wouldn't be any room
24:57for expansion, which would mean that
24:59the valves would be left ever
25:01so slightly open, which
25:03would reduce the compression
25:05within the cylinders, which
25:07then means that we will get
25:08much less power.
25:11We need to get this to a set
25:13amount of clearance, a set distance.
25:16So, what we use
25:19these feeler gauges.
25:21All of these
25:22are different
25:24thicknesses.
25:25Tiny, tiny thicknesses.
25:27Tiny increments.
25:29But, they all count.
25:31So, I just put it
25:32in between
25:34the rocker arm
25:36and the valve stem.
25:39Then,
25:41get my screwdriver
25:42and I wind down
25:44the adjuster screw
25:46until
25:47I've just got
25:48a bit of resistance
25:50so that I can just
25:51drag the feeler gauge
25:53back and forth.
25:55It's not much longer now
25:56until this engine
25:57is completely built
25:58and then
25:58we'll marry it up
25:59to the gearbox
26:00which fits underneath
26:02at which point
26:03we're getting close
26:04to fitting it
26:04back in the subframe.
26:06It's going to be
26:07mega.
26:09So, with Donna's
26:10engine saved,
26:11it's go, go, go
26:12on replacing the body shell.
26:14If you've ever wondered
26:16what the motoring
26:16industry in this country
26:17was like back
26:18in the 50s and 60s,
26:20it was like this.
26:23So, Tim has come
26:24to the experts
26:25at British Motor Heritage,
26:27one of the largest
26:28makers of classic
26:29car body shells
26:30and panels
26:31anywhere on the planet.
26:33It's the smell,
26:34the noise,
26:34the place is frenetic,
26:36it's just full of energy.
26:37In this vast aircraft
26:39hangar-sized workshop,
26:41the team have churned out
26:42over 7,000 body shells
26:44and panels
26:44for now defunct marks
26:46like Austin,
26:47Triumph and BMC,
26:49mostly crafted
26:50on machinery
26:51rescued from the very
26:52factories
26:53where these cars
26:53were first built.
26:56Damon.
26:57Hello, mate.
26:58Question for you.
26:59That spot welder
27:00there,
27:01was that from back
27:02in the day,
27:03making mini doors?
27:04Yes, it was.
27:04That is so cool.
27:06This place is incredible.
27:07A working museum.
27:08A working museum.
27:09That's the way
27:10I like to put it.
27:10So, we've literally
27:11gone back in time.
27:12Right, man,
27:12I need to talk to you
27:13about a body shell.
27:14Yes.
27:14I need to get a full
27:15body shell
27:15for a classic mini
27:16and I'm here
27:17to basically
27:18help you make it.
27:20Can we start
27:21with the door?
27:21Start with the door,
27:22yeah.
27:22So, if I set it up,
27:24we've got the bottom
27:24tapping plate.
27:25Yeah.
27:26Top tapping plate.
27:28First off,
27:29Tim needs to spot
27:30well together
27:31the components
27:32that make up
27:32the inner frame
27:33of the door.
27:34We want to put
27:35a couple of spots
27:36on here.
27:38Original mini doors
27:39were designed
27:40to be extremely thin
27:41compared to other
27:42cars of the era.
27:43That's it.
27:44Yep.
27:44And then bring it
27:45on to the next one.
27:46This not only saved
27:47weight but also freed up
27:48precious elbow
27:49room between
27:50the driver
27:50and passenger.
27:52One of the mini's
27:53mini tricks
27:54for making it feel
27:55bigger on the inside
27:56than it looked
27:56on the outside.
27:58Now,
27:59we have our
27:59sub components
28:00for a door.
28:01So, now,
28:02we'll go over
28:03to the original
28:04multi-wolder
28:05over there.
28:05Okay.
28:06Place components in
28:07and we'll
28:08swap welding
28:08together.
28:09Come on,
28:09let's do it.
28:14What the hell
28:15is that?
28:15What is that thing?
28:16It's a multi-wolder
28:18to produce doors
28:19for a mini
28:20part three
28:21onwards.
28:22So, it's a jig
28:23that is going to
28:23accept some of
28:25what we've just
28:25done.
28:26Yes, correct.
28:27Spot welding
28:27is where you've
28:28got two electrodes,
28:29high current
28:30being forced
28:31through the material.
28:32Its natural
28:33resistance creates
28:34heat and therefore
28:35creates a fused
28:37nugget.
28:37That's what they call it.
28:39Yeah.
28:39Did you know that?
28:40No.
28:40That's what they call it,
28:41a nugget.
28:42But that is a weld,
28:43ultimately.
28:43Can I have a go?
28:45So, is this going to go
28:46on there?
28:46This goes on there,
28:47yeah.
28:49Right.
28:51Now what?
28:52Hit the two black
28:53buttons.
28:53And what'll happen?
28:54And that'll weld it
28:55together.
28:56Just like that?
28:56Hopefully, yeah.
29:01And get ready to cut
29:02stuff.
29:03No way.
29:05And there you have
29:06a door.
29:07That was amazing.
29:09Next, Damon adds
29:10a few more spot welds
29:12to give the door
29:13additional strength.
29:16Then the outer door
29:18skin is glued
29:18onto the frame.
29:21I've done a lot of
29:22corking, believe it
29:23or not.
29:23It doesn't show.
29:27Then it's back
29:28under the spot welder
29:29to lock everything
29:30in place.
29:31before the edges
29:32of the skin
29:33are hammered
29:33under the frame
29:34for a new finish.
29:36So this is the way
29:37that every single
29:38mini door would have
29:39been done back in the
29:40day?
29:40Yeah, it would have
29:41been.
29:41I hope Donna
29:42appreciates how much
29:43hard work goes into
29:44the making of a
29:45replacement shell for
29:46her.
29:47There's a lot of
29:47work.
29:48Yes, but after all
29:49that hard graft comes
29:50a reward.
29:51Swanning in and
29:52acting like you built
29:53it entirely on your
29:54own.
29:57First spot, I've got
29:58a little tiny
29:59something I'd like to
29:59show you.
30:00Have a look.
30:04Made from the
30:05original mini
30:06pressings from way
30:07back when.
30:08I give you a brand
30:10new shell for Donna's
30:11car.
30:12It looks very
30:14lovely.
30:15I can't hear you
30:16over the crowd
30:16roaring, Fuzzbots.
30:18Yeah, it's great.
30:19That's brilliant.
30:21That's fantastic.
30:21That's fantastic.
30:22Okay.
30:22The parts-blagging
30:23petrol head has
30:25delivered.
30:27Before Tim's head gets
30:29any bigger and they
30:30can't get it out of the
30:31door, the shell is
30:32straight off to be
30:33prepped and sprayed
30:34Donna's dream colour,
30:36Tahiti Blue.
30:37While her bonnet gets a set of
30:39those all-important iconic
30:41Cooper white stripes.
30:43Do you want to see
30:44something absolutely
30:46amazing?
30:48Come on, come in here.
30:51Now look, look at this.
30:54Wow.
30:56And the shiny new
30:58components that are
30:59going to transform this
31:00blank canvas into a
31:01Cooper don't end there.
31:03So here's the rear
31:04subframe assembly.
31:05All completed, put back
31:07together.
31:08Now, I'll admit that we
31:09have had to change the
31:11subframe itself.
31:13We've managed to save the
31:14front subframe because,
31:15of course, lots of oil
31:16splashing around the
31:17front, lots of oil
31:18leaks, lots of corrosion
31:19protection.
31:21We have kept most of the
31:23suspension components and
31:24hub components, so we've
31:25got a lot of originality
31:27here.
31:28But what I wanted to point
31:29out was the genius of the
31:31Mini.
31:32And that is, in the
31:33original design, we had
31:36rubber suspension.
31:37When the car goes over a
31:39bump in the road, this arm
31:40moves up and that levers
31:41against this rod here.
31:43And as it squashes that
31:45rubber cone, that cone gets
31:46progressively half-legged
31:48harder, tougher to squeeze, so
31:50you have progressive
31:51suspension.
31:52It's an idea of genius and
31:55it's what made the Mini
31:57possible.
31:58Just fitting everything into
31:59these tight little spaces
32:01allowed the maximum space for
32:03passengers.
32:04That's why the Mini stayed in
32:06production for over 40 years.
32:09That is a thing of utter, utter
32:12genius.
32:13So, while Fuzz gets busy
32:15fitting them to the car, Tim is
32:17off sorting four little
32:18details that are going to help
32:20transform Donna's mundane
32:21Mayfair into a Corking Cooper.
32:24Hang on a minute.
32:25Is that actually Donna's wheel?
32:27Those are her original wheels.
32:29They look brand new.
32:30Yes, to become the real deal,
32:32it's going to need the right
32:33wheels.
32:35Luckily, Donna already had this
32:36set of upgraded Cooper Mini
32:38lights fitted.
32:39And these puppies aren't just
32:40about looks.
32:41They're another ingenious upgrade
32:43made by John Cooper.
32:45Cast from magnesium, they're
32:46lighter than the standard
32:48steel rims that improves
32:49handling and grip.
32:51And that open-spoke design,
32:52that channels more air onto the
32:54brakes for cooling when things
32:56get spicy.
32:58Adam has already given them
32:59a full refurb.
33:00So, now it's time to add the
33:02finishing touch, diamond
33:04cutting the rims back to their
33:05shine.
33:07Oh, mate, that's a lovely
33:07thing.
33:08Question for you.
33:09With a diamond cut wheel,
33:10how many times can you diamond
33:12cut a wheel before you go,
33:14not enough metal left?
33:15Rule of thumb, three or four
33:17times, maybe.
33:20All done.
33:21Is it done?
33:22It's done.
33:22Let's have a little shifty
33:23there.
33:24Have a little peek.
33:29Like, that is beautiful.
33:32If you thought that was
33:33beautiful, Tim, have a look
33:34at this.
33:36No, not that.
33:37Donna's original engine,
33:39the true beating heart of her
33:41car, has been saved.
33:43Paired with her rebuilt
33:44original gearbox, suspension
33:46and front subframe, the team
33:48have kept the memories intact
33:49and they're on the road to
33:51giving her the Mini Cooper
33:52styling she's always dreamed of.
33:53So here we have the engine
33:56assembled together with the
33:57gearbox.
33:58So the engine part is this bit,
34:00the red bit.
34:00And then we have our drop
34:02gears and clutch over this
34:04end.
34:04And then here in the sump
34:07is the gearbox.
34:08Once this goes into the car,
34:10we are really bringing together
34:13Donna's dream.
34:22Keep going.
34:24Keep going.
34:26Right, we're okay at the front
34:27here.
34:29The engine's almost in.
34:31We've just been very delicate
34:32with it because we don't want to
34:33scratch the newly painted bodywork.
34:37But, do you know, I think that
34:39that looks a treat in there.
34:43See, my head tells me that
34:45you're thinking I need a grill.
34:46Yeah, that's right.
34:47Although, actually, I do quite
34:49like the open mouth look.
34:50No, you don't.
34:50Not on you, on the Mini.
34:52Right, shall I get your screws?
34:53I've got the screws here already.
34:55I'm going to slap a seat in.
34:57Yes, with the engine now back in
34:59and sporting a reconditioned carb,
35:01things can really start to motor.
35:03Donna's original interior has gone
35:06and in its place goes an upgraded
35:08Koopa one with sportier seats.
35:10Seats are in.
35:12And, on the advice of the man himself,
35:15the team have fitted an upgrade set
35:17of disc brakes to keep those
35:18freshly diamond-cut Mini Light
35:20wheels under control.
35:22And to complete the look,
35:24Vaz is adding the iconic
35:25Koopa rally-style spotlights.
35:32And breathe.
35:33Right, Vazbot, the badge is on, mate.
35:35Oh, what's that about badgers?
35:37Don't panic, Files.
35:38There's no badgers about.
35:39But there is a very important
35:41glove box flap being reunited
35:43with its natural habitat.
35:45This is just a special thing
35:46that I want Donna to discover.
35:48Oh, my word.
35:50It's an honorary Charlie Mini Cooper.
35:54Done.
35:55Right.
35:56Mum's a word.
35:59With the chrome work,
36:00with all the Koopa gear on it,
36:01the Koopa stripes,
36:02the white roof,
36:03the lot,
36:03the Mini Koopa badges.
36:05Yeah.
36:05Everything about this car
36:06is absolutely singing and dancing.
36:07This has been an emotional journey
36:09for me in the sense that,
36:10like, when we started this, Fuzz,
36:11gotta admit,
36:12I wasn't a Mini fan.
36:13No.
36:13But the thing about it is,
36:14as you said,
36:15it is a blank canvas.
36:16You can make it how you want it.
36:17But do you think we've got it right?
36:19Do you think that this is Donna's dream?
36:22I'm going to say yes.
36:23Yeah?
36:24We haven't met Donna.
36:25No.
36:25But I'm going to say
36:25you'd really struggle to find somebody
36:27who wouldn't just instantly say,
36:30that is cool, that car.
36:31Yeah.
36:32I think it's great.
36:33I think it is.
36:33But we have to wait until tomorrow
36:35to know that we've got it right.
36:39It's taken almost 700 hours of hard work,
36:42but the day has finally come
36:44to hand Donna's Mini back to her.
36:47Fuzz and the car have returned to South Wales.
36:50It looks like Tim is running late.
36:53Ah, come on, Tim.
36:54Where is he?
36:56Morning.
36:57Oh, no!
36:58It's me!
36:59This is all part of the plan.
37:01Anyway, stop for a minute, Fuzz,
37:02and let's just appreciate pure beauty.
37:05That's right,
37:06and we are talking about the car.
37:08Absolutely.
37:08Mate, what a transformation
37:10and what a stunning car.
37:12Yeah, it is.
37:13And hopefully,
37:14exactly what Donna wanted.
37:16Right.
37:16Do you want to know what's happening?
37:17Yeah, go on, Ed.
37:18Right.
37:18Donna, today,
37:20is sitting at home
37:20just chilling with Tamina.
37:22Right.
37:22Life is normal.
37:23The birds are tweeting.
37:25Everything's just going by.
37:26Nothing special's happening today.
37:27OK.
37:28But it is.
37:29Because what's going to happen
37:30at a certain point
37:31is there'll be a knock on the door.
37:32Because when she opens the door,
37:33there's going to be a parcel
37:34on the drive.
37:35Right.
37:35Lots of regular dimensions,
37:37of huge dimensions.
37:38You mean this size?
37:40Yes, with you inside it,
37:42in the car.
37:43OK, I don't like the dark.
37:44She's going to be like,
37:45what have I ordered?
37:47Yeah.
37:47Tamina's going to be like,
37:48what have you done?
37:48What have you clicked buy on?
37:50At a certain point,
37:51a runner is going to go past the house.
37:53Who's going to spot this massive box
37:55and go,
37:56yeah, I love what you bought there.
37:57Yeah.
37:57Get into conversation.
37:58Yes.
37:59And when the time is right,
38:00out comes you in the car.
38:01And the rest,
38:02as they say,
38:03is car SOS.
38:04Fantastic.
38:05Special delivery.
38:07So, with the plan in place,
38:09it's time for the fun to begin.
38:12Donna's house has been secretly rigged
38:14with hidden cameras.
38:15Her best friend Tamina
38:17has arranged a pot round
38:18to see her,
38:19which is actually all a roost
38:21to help keep Donna
38:22in the kitchen
38:22and away from her front door.
38:26Hello.
38:26Oh, my God.
38:27It's been ages.
38:28I know.
38:28Jesus.
38:29You all right?
38:30Yeah.
38:31Right, the kettle's on.
38:32Good.
38:33I need a coffee.
38:35Because just on the other side of it,
38:37the boys are getting
38:38the world's largest cardboard box
38:40and fuzz
38:41and the car
38:41into position.
38:47It's gone quiet.
38:49It's now a waiting game.
38:51We're on the drive.
38:52We're in place.
38:54My blood pressure
38:55is through the roof.
38:56So, it's time to play
38:57knock-a-door run.
38:58It's like you are here
38:59with us right now.
39:00This is going down for real.
39:10Someone knocking the door.
39:19Shut up.
39:21What is it?
39:22I don't know what it is.
39:23Are you taking pictures?
39:25Yeah, because it's...
39:26Don't touch it.
39:27You don't even know
39:27what's in there.
39:31Maybe...
39:31My God,
39:32what comes in a box
39:33that size?
39:33That's right.
39:34I'm trying to find out.
39:35What is it?
39:36What is it?
39:36What have you ordered?
39:38I reckon that's a...
39:39sofa suite.
39:40It's got a name on it.
39:41Maybe.
39:42It's got my name on it,
39:42but I don't know what it is.
39:43It's got your name on it.
39:45Shall I open it?
39:46Do you want me to...
39:47No, I don't know what it is.
39:47Yeah, I'm going to...
39:48Don't mind, I'm going to open it.
39:50So, hold on,
39:50see what's in it.
39:54What?
39:54Oh, my God.
39:57Don't, I'm suffering.
39:58Well, I'm eight.
39:59Stop it.
40:02Recognise that?
40:03No.
40:04Well, your one was yellow.
40:05Yeah, yeah, yeah.
40:06It's now the colour that you wanted.
40:08It was a car that your dad always wanted.
40:10An E993-WWG.
40:13That's my car.
40:13That is your car.
40:14That is your car.
40:15That's my Mini.
40:16That's your Mini.
40:16That's my Mini.
40:17And I'm Tim.
40:18And this is Foz,
40:18and we do a TV show.
40:20You want to...
40:20We do a...
40:21Yeah?
40:22Foz, come out, man.
40:23We do a TV show
40:24called Car Estimers.
40:25We've secretly restored
40:26your car for you,
40:27and that, Donna...
40:29Yeah.
40:31That is your car.
40:33And, well, if you don't believe us,
40:34there are a few people
40:35that might prove it to you
40:36if you look right.
40:37Guys, come on over.
40:37Come on.
40:38Come out.
40:40Tamina, come here.
40:42Talk to Donna.
40:43Talk to your best mate
40:43about why you wrote to Car Estimers.
40:45You're shaking.
40:46You all right?
40:46I am shaking.
40:46You all right?
40:47I'll hold you.
40:47I've got you.
40:48Because, despite everything
40:49you've been through,
40:50you're always there
40:51for everyone else,
40:51and I just wanted
40:53this as a surprise.
40:54for you to say thank you,
40:56and that we all appreciate you,
40:57and this is what you deserve.
40:59And we have
41:00a very well-deserved...
41:02A round of applause
41:03for Donna and her mini, please.
41:05Come on.
41:06Yay!
41:06Yay!
41:09When Donna last saw
41:10her beloved mini,
41:11it was rusty,
41:12tired,
41:13and barely holding itself together.
41:16But now,
41:17thanks to some first-class restoration work,
41:20the boys have delivered her a winner.
41:22They might have replaced
41:23her original shell
41:24with a brand new one,
41:26but underneath,
41:26it's still Donna's beloved car.
41:29Her 1275cc Cooper engine
41:31has been honed and rebuilt,
41:33and alongside it,
41:35the original suspension
41:36and gearbox
41:36have been fully reconditioned.
41:38Her original alloy wheels
41:40have been refurbed,
41:41repainted,
41:42and diamond-cut to perfection.
41:45It's now sporting
41:46the paint job
41:47she always dreamt of having.
41:49A Cooper-style grille,
41:50headlamps,
41:51and those all-important badges.
41:53From scrapyard
41:54to showstopper,
41:56Donna's mini might be small,
41:57but it's back,
41:58and it's mighty.
42:02Is it sinking in yet?
42:03Not yet.
42:03I can't.
42:04I don't think it will for a while.
42:05Did we get the car right?
42:06You got it perfect.
42:08This is more than perfect.
42:10I love the colour.
42:11What's special about the colour
42:12is that this colour,
42:15and it's probably this colour blue as well,
42:17it's my father's favourite colour.
42:18Knowing that your dad loved minis,
42:20did the car to you
42:21represent your father?
42:22Absolutely.
42:23And every time I'd come out
42:24and I'd just smile.
42:25I mean, even though
42:25the state that she was in...
42:26It doesn't matter.
42:27It doesn't matter.
42:27It was my dad's car.
42:29So what would he say
42:30if he was here now?
42:32Do you feel like he is here now?
42:33He is here now.
42:34I can hear his laugh.
42:35He'd be laughing.
42:38He's there, is he?
42:39Yeah.
42:40He'd just be like,
42:41Donna.
42:43Big smile.
42:44You'll see his smile.
42:45It's just, I don't know.
42:48I wish he was here to see this.
42:49It's a tough one to answer.
42:51What does this car mean to you?
42:53Memories.
42:54Memories, love, life.
42:56My father, family.
42:58When you say memories,
43:01how much weight is there on that?
43:03Is that the biggest thing to you?
43:05Yeah, remembering the old times
43:07is ingrained,
43:08but making new memories
43:09is difficult.
43:10And this is something
43:11that can help me definitely
43:13make new memories
43:14and ones I won't forget.
43:18So, Donna,
43:19it's been an absolute honour
43:20to tell you
43:22that you have been Car SOS'd.
43:24Thank you so much.
43:25There you go.
43:26Thank you so, so much.
43:27Thank you so much.
43:28No, it's all right.
43:28Should I put it in?
43:29There you go, put it in.
43:30Absolutely.
43:30Get it in you.
43:31Just start it up.
43:33All right.
43:34Go on.
43:34You ready?
43:35Yeah.
43:37Wow.
43:44Oh, hey, let's go.
43:46Let's go.
43:48Oh, this is a dream come true.
43:50Thank you so much, guys.
43:51This is unreal.
43:52This is unreal.
43:54I can't even remember the gears.
43:57Gosh.
43:58What do you think of the inside?
44:00It's stunning.
44:01It's a dream.
44:02It's a dream.
44:02Look, I'm getting into it now.
44:03I'm getting into it now.
44:04Warming up.
44:05Yeah, she's warming up.
44:07I can't stop smiling.
44:09I literally, every time I'm going to be driving this, you're going to just see this big, geeky smile.
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