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