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00:00This time on Car SOS.
00:04What? What's up with you? I haven't got the budget to send us to Italy.
00:08It's fast, it's beautiful.
00:11This is one heck of a driver's car.
00:14And over a quarter of a century late.
00:16I promised Jane this car to be completed for a 40th.
00:20She's now 65 and I'm still...
00:2225 years.
00:23So will the boys get this long overdue birthday present wrapped in time?
00:27I don't know if you've spotted it yet, but I think this car has a slight problem with rust.
00:31Or will they miss the party altogether?
00:34This is completely let go. It's utterly rotten.
01:01Well, here we are, Timmy, in lovely Lancashire.
01:05Beautiful up here, matey.
01:06Today, we're picking up a very special car.
01:09Yeah.
01:10We are picking up a car that probably wouldn't do too well in winter up here because we are picking
01:16up...
01:16An Alfa Romeo Spyder!
01:19Now, let's get it out of the way, shall we?
01:21Go on.
01:22They're terrible rotters.
01:24Not many of those cars were actually sold into the UK.
01:27No.
01:28So, consideration of British roads and the conditions over here...
01:32Yeah.
01:32...we're not high on the list.
01:34But I think it's at this point that Alfa Romeo got it absolutely...
01:39Bob on.
01:40Styling.
01:41Yeah.
01:41The styling is just so great.
01:45Yes, when it was launched in 1966, this incy-wincy Spyder didn't just turn heads.
01:51It set a new standard for cool.
01:54A four-wheeled embodiment of freedom, romance and a life lived with the top down.
02:01Immortalised on the silver screen by Dustin Hoffman in The Graduate.
02:04It was created by automotive legend Pininfarina, who sculpted every line and curve into a work of art.
02:12Even the 1.75 litre engine under the bonnet is a masterpiece to behold.
02:17Rear-wheel drive, lightweight and full of Italian charm, it's not a car for lap times or supermarket tricks.
02:25This was built to cruise the sun-soaked Italian Riviera with the top down and the wind in your hair,
02:32transporting whoever's behind the wheel from the humdrum of their everyday life and, for a moment, making them feel like
02:38a movie star.
02:40Like any screen idol six decades on, time takes its toll.
02:45Beneath the glamorous exterior, you'll find a wallowy ride, bare-bones interior and mechanicals that need more than just a
02:53light dusting of make-up.
02:55Add in the fact the British climate won't have done them any favours, making spare parts ultra-rare and any
03:02renovation a real blockbuster.
03:05So it's Jane's car.
03:07She's not obviously going to be where we're sneaking off to now.
03:10We're meeting Andy and Steve.
03:11Steve is Jane's husband, Andy's best mate.
03:13We're going to meet the boys, take the car away and get cracking.
03:19Are you expecting two strange men from the Midlands?
03:22Yes, we are.
03:22Hello, first.
03:24Andy, please see you, Andy.
03:25Where are we?
03:26We're on a farm where the car is stored.
03:29Can we see the car?
03:30We can indeed.
03:31Let's go and have a look.
03:32Do we need to steady ourselves?
03:35Yes.
03:36OK.
03:37All righty.
03:38Here we go.
03:40No, thanks.
03:40All right, then.
03:41That was lovely, wasn't it?
03:43It's lovely meeting you.
03:44What's for lunch, then?
03:45What are we having for lunch?
03:47Right, hang on, look.
03:48Just stop for a minute.
03:49The beauty of it.
03:50Forget the fact it's all rusty.
03:52It's in trouble.
03:52It's an Italian two-seater stunning little...
03:55There it is, cruising down the Amalfi Coast.
03:58Visualise it.
04:00OK, we'll leave you guys in there.
04:02OK, go on.
04:02You pile in there as well, Andy.
04:03Enjoy yourselves.
04:04OK, we'll go...
04:05No, shut your face.
04:05Just get stuck in.
04:06Come on, let's go and have a chat about Jane.
04:08I don't quite know what Tim's looking at.
04:11But what I can see is really quite terrible.
04:17This is probably the worst sort of rust.
04:21It's gone down into the surface of the metal,
04:24which means it's at an almost molecular level.
04:28Anything over the top of it, the rust is going to burst through.
04:30So, instantly, that is big job number one.
04:38How come your wife Jane chose an Alfa Romeo Spider?
04:41What is it about that car?
04:42Well, I think...
04:43I remember we watched The Graduate with Dustin Hoffman.
04:47OK.
04:48That'll do it.
04:49She saw it and thought, ooh, wow, that looks nice.
04:52I thought, you know, let's see if we can find one.
04:56And I managed to find this one in Stockport.
04:59Was it a runner?
05:01Well, it wasn't quite a runner at the time.
05:03She came back with me to collect the car and sat in it and...
05:08..all the dials.
05:09Was she excited?
05:10She was.
05:11She was.
05:11This is my car.
05:12This is, yeah, this is really what I'd like to drive.
05:19Dare we have a look underneath here?
05:20Well, hopefully there's an engine.
05:22Well, I'm hoping there is.
05:24OK.
05:25Well, that's good.
05:26Yeah.
05:27It's there.
05:28It should be shiny.
05:29It should be another moment of delight.
05:32But look, of course, it's very jaded.
05:34But because this car needs to be stripped,
05:37everything here has got to come out of it
05:39so that this surface rust can be dealt with.
05:43And that is a massive job.
05:46This is the start of a very long journey.
05:52So here she is.
05:53She's got this lovely little car.
05:55Yeah.
05:55Is she using it?
05:56Is it out on the roads?
05:57Is it, like, everything to her?
05:58We got the engine running,
06:01but the car was in need of some basic repair work.
06:06Right.
06:06I promised Jane this car to be completed for her 40th and then for her 50th.
06:12She's now 65 and I still...
06:1525 years?
06:1625 years.
06:17It's just crazy.
06:18What happened?
06:19The scam.
06:20In 2016, we had this terrible experience of losing all our savings.
06:28We received a call on a Saturday afternoon
06:31and they said that they were from NatWest's fraud.
06:35They believed that our accounts had been compromised
06:38and they needed to sort of set up new accounts
06:41to transfer the monies from these accounts
06:44to safeguard any potential fraud.
06:47Right.
06:48So that was the tack they took, the scammers,
06:51to get us to move the money, basically.
06:53Of all your life savings?
06:55All our, yeah, savings.
06:57We lost just over £60,000.
07:00What does that feel like?
07:03End of life, really.
07:05What's going on?
07:07How are we going to survive?
07:08How are we going to pay the mortgage?
07:10What are we going to live on?
07:12You know, we were just an ordinary couple
07:14with children to look after
07:17and here we were being sort of taken apart.
07:21So you've been left with nothing
07:22and a car that was a little bit of a way through a restoration.
07:26Yes.
07:27It's bare metal, hence why it's rusty to hell
07:30and that's where you're at now.
07:31That's it.
07:32Yeah.
07:33Yeah.
07:33I think this car symbolises winning for you guys
07:37and I think you need a bit of winning again
07:38because you've been utterly destroyed by this, haven't you?
07:42Yeah, but you try and put a brave face on
07:47but underneath it's churning away.
07:49So, right, here's a question for you.
07:52Will you get the car ready for a birthday?
07:53That would be good, wouldn't it?
07:55It would.
07:56Can we make it for the 66th?
07:57I hope so, yeah.
07:59Let's see if we can make that happen.
08:00Yeah.
08:01Come on then.
08:05This is going to be a big job.
08:07A big job.
08:08Jane wants to use this car regularly
08:10so this needs to be a car that will keep up with modern traffic.
08:14And won't rot.
08:15And most importantly, won't rot.
08:17Won't rot while it's sitting in modern traffic.
08:19Absolutely, yeah.
08:19I mean, really, that is a big ask.
08:23So, if the boys are going to give Jane a Hollywood ending to her story,
08:26it's a full nut-and-bolt, rust-banishing rebuild.
08:30And if that wasn't enough,
08:32it also has to work as a daily driver
08:34that can cope with the great British weather,
08:36something these sun-loving Italian classics
08:38were never designed for in the first place.
08:41Oh, and it needs to be finished in a couple of months for her birthday.
08:44No pressure then, chaps.
08:46Come on, a bit further, a bit further, a bit further.
08:48Come on.
08:49How's that?
08:50That'll probably do.
08:51Right, first of all, I don't know if you've spotted it yet,
08:53but I think this car has a slight problem with rust.
08:58Look at it.
08:59So, are you going to strip it for dipping?
09:01Yeah, that's what we'll have to do first.
09:03At least then we'll know how much we're going to get back.
09:06Right.
09:06And we'll know how big the task is.
09:08Where do I start?
09:09OK.
09:10You need to find out the modifications we can make
09:12to turn it into a daily driver.
09:15OK, good call.
09:15To make it more usable.
09:16OK.
09:17Any special stuff that can be done to these,
09:19make them handle better, drive better, start better, run better.
09:23Up we go.
09:24Right.
09:28Don't look up.
09:29Don't look up.
09:30I don't want to look up.
09:32I mean, this looks like it's just been sitting in a salty canal for a very long time.
09:39Look around here.
09:40There are holes in the sills.
09:41Yeah.
09:42The engines are not the strongest either.
09:45Known for leaks.
09:46Known for wearing very, very rapidly.
09:48And also things like valve stem oil seals.
09:51You know, you get smoky running.
09:53They look absolutely beautiful on the outside.
09:57Yeah.
09:57But on the inside, wherever they can attack you, they will.
10:00This car is a horror movie, Fuzz.
10:03Yeah.
10:03Of the highest order.
10:04It really is an absolute horror movie.
10:06And I don't like horror movies.
10:08Yes, be afraid.
10:10Be very afraid.
10:11Because turning this rust bucket into a daily driver that can cope with the British climate,
10:16well, it doesn't sound easy, does it?
10:18So, the first job is an obvious one.
10:21The body.
10:22It's going to need to be stripped and sent away for acid dipping.
10:26Only then will Fuzz know the true horror of what lurks beneath.
10:30The question is, will he be able to save it?
10:33Or is it destined for the scrappy?
10:35Next, Jane's dream alpha needs to become a car that she can actually rely on.
10:40Not one that burns through oil faster than a chip shop.
10:43So, that means a full engine stripped down to check for a potential leaks.
10:49Finally, the boys must make sure this classic isn't just beautiful,
10:54but a joy to drive through the sunshine in Sardinia.
10:57Or in the snow in Scumthorpe.
11:00That means carefully adding modern technology to its 60s charm
11:04to create a totally unique daily driver.
11:07So, with Jane's birthday bearing down on them
11:10and the rust seemingly spreading minute by minute,
11:12there's no time to waste.
11:15Wheel's off.
11:17It's always a good start.
11:20The team needs to strip every nut, bolt and washer.
11:24There we are.
11:25A little persuasion.
11:27Out it came.
11:28As well as remove any bits of treasure.
11:31Oh, ho, ho, ho.
11:33What have we here?
11:35Not a matching set of sombreros
11:38for some people with tiny heads.
11:40But these are the wheel centres.
11:43So, the shell can go off for a nice relaxing bath in sulphuric acid.
11:49A soap that will nibble away decades of rust
11:51and reveal the true horror of what's lurking beneath.
12:00Looking from the top, it doesn't look overly bad.
12:04But then, I can see light poking through,
12:06through little perforations here and there.
12:09And I know, from looking underneath,
12:11that below the waistline, this is completely let go.
12:15It's utterly rotten.
12:21The boys have taken on this Italian classic,
12:24a 1968 Alfa Romeo Spider
12:27that's less La Dolce Vita
12:29and more La Dirty Rust Bucket.
12:32At least it was before its acid bath.
12:35The question now, can what remains be saved?
12:39It's going to need to be braced.
12:41Now, when I say bracing, what I mean
12:44is fitting tubular steel,
12:46welding it to the body,
12:48to sound parts of the body,
12:50to attempt to keep
12:53flexing from happening
12:54because of the amount of metal
12:56we're going to have to cut out of here.
12:58And then,
12:59doing one side at a time,
13:01one area at a time,
13:03gradually
13:05replacing the old rotten metal
13:07with fresh new steel.
13:10we will build back in
13:12the strength
13:12that this car had
13:14when it was new.
13:15This job has gone from
13:17a big build
13:18into a very major
13:21restoration project.
13:23With only a handful
13:25of right-hand drive models
13:26left in the UK,
13:28Fuzz can't exactly
13:29pop down the breakers
13:30and pick up a spare shell,
13:32so he's got to try
13:33and resurrect it.
13:35Watch your eyes,
13:36don't look at this.
13:37But, in its current state,
13:39the shell is far too weak
13:40to start welding in new metal.
13:42Any attempt to do so
13:44could twist or flex the body,
13:46locking in weakness
13:47that would be almost impossible
13:49to undo.
13:50So, the braces are added
13:52just to hold the car's shape
13:53while the new panels are fitted,
13:55which means a lot more time
13:56and effort
13:57than anyone anticipated.
14:02So, that
14:04is our bar
14:05in place
14:06across here.
14:08So, now
14:09what we can do
14:11is start making
14:12more of a frame
14:14in here.
14:14Once we've done that,
14:16and only when we've done that,
14:18we can restore this car
14:20to as close to
14:21a factory-build look
14:24as we possibly can.
14:27So, while Fuzz
14:28attempts to restore
14:29strength
14:29to the equivalent
14:30of a wet paper bag,
14:33Tim's getting to work
14:34on transforming
14:35the rest of Jane's car
14:36into something
14:37she can actually use
14:38as a daily driver.
14:40We've come down
14:41to Bristol
14:42because there's a company
14:43down here
14:43that makes
14:43super uprated parts
14:45for Alfa Romeos
14:46and we want to make
14:47Jane's a daily driver.
14:49It's got to be
14:49a comfortable, usable car
14:50and these guys
14:51are as good as it gets.
14:53Jane's Alfa
14:54was built for touring
14:56Tuscany, not town centres.
14:58So, to make sure
14:59it's up to the task
15:00of navigating
15:01the modern world,
15:02Tim's come to the experts
15:03at Alphaholics
15:04because with decades
15:05of experience
15:06restoring, upgrading
15:08and racing classic Alphas
15:10under their belts,
15:11they certainly know
15:12a trick or two.
15:12Right, let me tell you
15:13what I know
15:14about what you guys do.
15:15You take a standard,
15:16beautiful car
15:16like this little GT here
15:18and you do
15:19that to it.
15:20Now, to the naked eye,
15:21some people might think
15:22that is not a lot
15:23of difference
15:23but you're going
15:25to tell me it is,
15:25aren't you?
15:26There's a huge difference.
15:27Drive chain,
15:28engine,
15:29suspension,
15:30brakes,
15:31differential,
15:32interior.
15:32Pretty much everything.
15:33Yeah, yeah.
15:33Have you got some
15:34of that stuff
15:35for a little spider?
15:36Yeah.
15:36Where's that?
15:37Yeah, yeah.
15:37Next door.
15:38Got it.
15:39It's more than
15:40half a century
15:41since Jane's car
15:42left the factory
15:43and technology
15:44has come a long way.
15:46So, here at Alphaholics
15:47they're using
15:48modern materials
15:49and upgraded components
15:50to completely transform
15:52how these classics handle.
15:54Is this all alpha gear?
15:56Yeah, yeah,
15:56it's all for the 105 series.
15:57This whole place
15:58is just full of gear
16:00that would fit our car down.
16:02Right, well,
16:02I'll take ten of everything,
16:04please, the lot.
16:05I'll take the lot.
16:06OK, so before you get
16:07carried away,
16:08what's the car
16:09and how is it going
16:09to be driven?
16:10Right, the car is a spider,
16:111968.
16:12Yeah.
16:12It's for a girl
16:13called Jane.
16:14She's never driven it before.
16:15OK.
16:15But it's going to be,
16:16here's the thing,
16:17the daily driver.
16:19No problem.
16:19That's good.
16:20Stage one kit.
16:21Yeah.
16:21Stage one kit?
16:22Yeah.
16:22OK, what does that mean?
16:23It's perfect for that.
16:23OK, so it replenishes
16:25everything within
16:26the suspension system.
16:27Right.
16:28New springs,
16:29new dampers.
16:30Yeah.
16:30Slightly stiffer
16:31anti-roll bar
16:31to stop the body roll.
16:33They're known for body roll,
16:34these cars.
16:34Yeah.
16:35Well, it's just like
16:35a big Savaloy
16:36round down the road,
16:37aren't they?
16:37Yeah, so this will
16:38firm that up.
16:38OK.
16:39So, by adding
16:40some modern upgrades,
16:41this 1960s
16:43Sunday afternoon cruiser
16:44will soon become
16:45something she can drive
16:46every day.
16:51To prove just how
16:52much of a difference
16:53a stiffer
16:53anti-roll bar
16:54can make
16:55to a car's handling,
16:56Tim set up
16:57a little demo,
16:58thankfully,
16:59with no sausages
16:59involved.
17:00Now, imagine a car
17:01like yours
17:02is pegging it
17:02down her own.
17:04All of a sudden,
17:04you're like,
17:05I need to make
17:05a sharp left.
17:06Now, something
17:06called inertia
17:07dictates that
17:08things like to keep
17:09going in a straight
17:10line, basically.
17:11So, you're forcing
17:12it left,
17:13it's going,
17:13no, no, no,
17:13I want to go
17:14in a straight line.
17:14So, it takes a dip
17:16into the right here,
17:17meaning this suspension
17:18has gone right up,
17:19look, it's gone
17:20right up there.
17:21So, actually,
17:21there's a load of lean,
17:22there's a load of
17:23body roll.
17:24It's only a step
17:25away from
17:26whatever.
17:27So, what they
17:29worked out,
17:29these clever engineers
17:30who designed these
17:31things,
17:31the best thing to do
17:32is to minimise
17:34that roll,
17:35to minimise the lean
17:36of the car
17:37by basically,
17:38look, I'll just
17:38pop this shock off
17:39so you can see it,
17:40creating a system
17:41so that as soon
17:42as this wheel
17:42goes up,
17:43what's the other one?
17:43Whoa, look,
17:44it's copying.
17:45So, what it does
17:46is it brings
17:47the body down,
17:48the centre of gravity
17:49down and prevents
17:50too much roll.
17:52And because he's
17:53an overgrown child
17:54and because this demo
17:55wouldn't be nearly
17:55as much fun
17:56if he didn't,
17:57Tim's removing
17:58the anti-roll bar
17:59from his remote
18:00controlled car
18:00to prove just
18:01how important it is.
18:04To exaggerate
18:05the roll,
18:07I'm going to bolt
18:08down to there,
18:09we'll do a few
18:10corners.
18:12Okay.
18:15Look at that!
18:19The one wheel
18:20is dipping,
18:22the body is rolling
18:24and it's a hard right,
18:26it's a hard left.
18:27Oh!
18:29It's rolled.
18:30And that is precisely
18:31why we have
18:32anti-roll bars
18:33on our cars
18:34for that reason.
18:37Yes, that's not
18:38what you want
18:38from your daily driver,
18:40is it?
18:40So, by fitting
18:42a slightly stiffer
18:43anti-roll bar
18:44into Jane's car,
18:45it's going to sharpen
18:46the handling
18:46by removing
18:47some of that body roll,
18:48making it a whole lot
18:49easier to thread
18:50through modern traffic.
18:52But on its own,
18:54it's not going to be
18:55much of a birthday present.
18:56So, the boys
18:57are going all out
18:58on bracing the body,
18:59chopping out the rust
19:00and letting in
19:02new panels.
19:04And, while they
19:05get on with that,
19:06the boys are off
19:07doing some very
19:08damp, cutting-edge
19:09research.
19:10What?
19:11What's up with you?
19:12I haven't got the budget
19:14to send us to Italy.
19:15We're in Wales.
19:16It's a wonderful
19:16part of the world.
19:17Yes, it's raining,
19:18but it's always raining
19:19in the UK.
19:20Yes, to experience
19:21the worst of what
19:23Jane's Alpha
19:23will have to endure,
19:24the boys have brought
19:25it to South Wales,
19:27one of the wettest
19:28places in the entire UK.
19:30Stop your mourning, pal.
19:32to get a feel
19:33for what needs
19:34to be done
19:34to make it usable
19:35in even the worst
19:37great British weather.
19:38I'm going to deal
19:40with the negatives.
19:41Right, the windscreen wipers
19:43are kind of battling
19:44against the rain
19:45a little bit.
19:46This car shouldn't
19:47really have
19:47windscreen wipers.
19:48It shouldn't be
19:49out in the rain.
19:50The pedal spacing
19:51is very tight.
19:53They're very close
19:54together, so
19:55it makes it
19:57slightly unnerving
19:58when it comes
19:59to sort of
20:00putting the brakes on.
20:01Right.
20:01However,
20:02the rest of this car
20:04is absolutely
20:06magnificent.
20:11The whole thing
20:12is light.
20:12This
20:13is one heck
20:15of a driver's car.
20:16This is
20:16absolutely brilliant.
20:22No wonder
20:23people raved
20:24about these cars.
20:25I can't imagine
20:26why they didn't
20:27sell millions of them.
20:28And I think
20:29it outguns
20:30the competition
20:31such as MGBs
20:32and the like
20:33by a country mile.
20:36I thought it was
20:37going to be like
20:38a little tiny
20:39pencil and feel
20:40like it was going
20:41to tip over
20:41on every corner.
20:42But no,
20:43it feels great.
20:45It could possibly
20:46be a little bit
20:47stiffer on the
20:48suspension.
20:49Right.
20:49Just for that
20:50more modern feel.
20:51What,
20:52rolls a little bit?
20:53Just a tiny little
20:54bit, yeah.
20:54But other than
20:55that, it's an
20:57absolute 10 out
20:58of 10.
20:59Really?
20:59Really, it is.
21:03You know,
21:04sometimes you see
21:04somebody with a
21:05convertible
21:05with a roof down
21:06on a rainy day
21:08and you think
21:08what are you doing?
21:09Actually, this car
21:10is a reminder
21:10of precisely
21:11what they're doing
21:11and that is
21:12enjoying life.
21:17I can imagine
21:18driving all the way
21:20from grey old
21:21Great Britain
21:22all the way
21:23down through France
21:24gradually getting
21:26into better
21:26and better weather.
21:27Yes.
21:28Just having
21:28a fantastic time
21:30around the
21:31Mediterranean coast.
21:33Yes.
21:33It's a game
21:34changer for me.
21:37It's a wincy-wincy
21:38spider drove
21:39around the track.
21:40Fuzzy drove it
21:41out there
21:41and it's never
21:43coming back.
21:44Come on,
21:45let's go on holiday.
21:53Tim and Fuzz
21:55have taken on
21:55this Italian classic,
21:57a 1968
21:58Alfa Romeo
21:59spider.
22:00Car designed
22:01for top-down
22:02pleasure cruises,
22:03though this
22:04particular example
22:05has seen more rust
22:06than Riviera.
22:09And that extreme
22:11corrosion has caused
22:12all manner of headaches
22:13because this car's so rare
22:15that the boys have been
22:16forced to save
22:17the original body shell,
22:18which has eaten up
22:20over half their build time.
22:22And with Jane's birthday
22:23now just under a month away,
22:25time is running out
22:26and there's still a lot of car
22:28left to fix.
22:32Right, today I'm going to do
22:34something that is almost
22:36bound to end in failure.
22:39Today I'm going to try
22:41and do some soft
22:43metal filling.
22:44Yes, with the body
22:45structurally sound
22:46and all the new metal
22:48let in,
22:48the next job is
22:49smoothing out the joins
22:51using this artisanal technique.
22:53Now, traditionally
22:54that has been called
22:55lead loading
22:56but nowadays
22:58well we've got this
22:58slightly more modern alloy.
23:00This is part of a tradition,
23:03a great tradition
23:04of panel beating
23:05and coach building.
23:07So let's try and keep
23:08a few of these traditions alive.
23:10I'm going to have a go
23:11but I can tell you
23:12for sure
23:13that it's not easy.
23:15Lead loading
23:17has been around
23:17since the very earliest days
23:19of mass car production.
23:20It allowed panel beaters
23:22to smooth joins
23:23between sheets of steel
23:24and sculpt perfect contours.
23:27Today Fuzz would normally
23:28use a modern filler
23:29to do this type of work
23:30which delivers
23:31the same results
23:32without the risk
23:33of ending up
23:34covered in molten metal.
23:36So, first of all
23:38let's get our flux.
23:40Now this contains
23:41a bit of soft metal
23:42so applying this
23:44is like using
23:46a little bit of egg
23:47on your pastry
23:49just to get everything
23:50sticking together nicely.
23:54And we're just going
23:55to heat this up
23:57until
23:59this changes colour.
24:05Now
24:06I'm going to take some lead
24:08and I'm going to start
24:09melting this
24:10so I'm heating up
24:12the two surfaces together.
24:15Applying a bit of lead
24:17get a bit down
24:18in the valley here.
24:20Rather than using
24:21old school lead
24:22Fuzz has opted
24:23for a modern metal alloy
24:25with the same characteristics.
24:27Easy to melt
24:27simple to shape
24:28and once cooled
24:30it can be filed back
24:31to a perfectly smooth finish.
24:34Now what I need to do
24:35is get it to run smoothly.
24:37I'm going to use
24:38a paddle
24:39and this stuff
24:41which is tallow.
24:43Now tallow
24:44is beef fat
24:45or animal fat.
24:48The tallow
24:49acts like a lubricant
24:50allowing Fuzz
24:51to smooth out
24:52and shape the lead
24:53without it sticking
24:54to the paddle.
25:04So I'm just going to give it
25:05a little bit of a clean up.
25:10But I'm really pleased
25:11with that
25:12but it's quite hard
25:14to work it down
25:15to get everything
25:15nice and smooth.
25:16There's a lot
25:17of work to be done
25:18and
25:19we haven't even
25:20started the engine yet.
25:22When I mean
25:22start the engine
25:23I don't mean
25:23turn the key.
25:24What I mean
25:25is rebuilding it.
25:27A long way to go.
25:29Yes he's not wrong.
25:31So
25:31to stand any chance
25:32of making
25:33Jane's birthday
25:34the bodies
25:35getting sent
25:35out of house
25:36for paint
25:37freeing up Fuzz
25:38to finally get
25:39handsy
25:40with the engine.
25:41In the 1960s
25:42these engines
25:44were absolutely
25:45the epitome
25:47of cool.
25:49Now
25:49it's lightweight
25:50because instead
25:51of cast iron
25:53this block
25:54here
25:54the main part
25:56of the engine
25:56is made
25:57from aluminium
25:58which was
25:59a major advance
26:00from the engines
26:01of the 1940s
26:02and 50s.
26:03However
26:04the aluminium
26:05as it heated up
26:06would have a tendency
26:07to expand
26:08a lot more quickly
26:09which meant
26:10that gaps
26:11could appear
26:12which meant
26:12that oil
26:13could seep out.
26:14So
26:15there's a good chance
26:16oil and probably
26:17gases are going
26:18to be leaking
26:18from somewhere
26:19and that's going
26:20to cause misfires
26:21and make the engine
26:22harder to start
26:23and ultimately
26:25less efficient.
26:26Definitely
26:27not what you want
26:28from a daily driver.
26:29This is where
26:30we get to see
26:31what sort of state
26:32this engine's in.
26:33Here we go.
26:35There.
26:35We are
26:37off.
26:39Now
26:40there's a little bit
26:41of play
26:42from side to side
26:44so I think
26:45we're going to
26:46replace the valve guides
26:47and probably
26:48the valves as well.
26:49Let's get the cylinder
26:50head out of the way.
26:51We've seen all
26:51we need to see there.
26:56Now what I can see here
26:58is pitting
26:59on the cylinder
27:01walls.
27:01Just a little tiny bit
27:03so worn valve guides
27:05will allow oil
27:06to seep down
27:07and into the
27:07combustion chamber.
27:08The same thing
27:09can happen with
27:09this pitting
27:10on these bores.
27:12With that
27:13it's going to allow
27:13oil in
27:14and that can be burned.
27:15And I think
27:16that we've now
27:17got to a point
27:17where we know
27:18that at least
27:20the sleeves
27:20are going to
27:21either need
27:21re-machining
27:22or replacing.
27:24Which means
27:24we'll be looking
27:25at probably
27:26new pistons
27:27new piston rings.
27:29Realistically speaking
27:30this engine
27:31is in for a
27:32total rebuild.
27:33With Jane's
27:34birthday now
27:34just three weeks
27:35away
27:36it's an iceberg
27:37the boys could have
27:38done without hitting.
27:42To help the boys
27:43make up some
27:44lost time
27:45the shell's
27:46been prepped
27:46and is now
27:47getting its first
27:48of three coats
27:49of primer
27:50to ensure
27:51the rust
27:51can never return.
27:53Which gives
27:54Fuzz time
27:54to charge on
27:55with the engine
27:56rebuild
27:56and Tim
27:57to think
27:58about Jane's
27:59bottom.
28:00That is
28:00an electric
28:01element
28:02for a heated
28:03seat in a car.
28:05Fuzz and I
28:05when we took
28:06our one out
28:06it was freezing
28:07it was icy cold
28:08so this is going
28:09to keep Jane's
28:10bum hot.
28:11So they're very
28:11simple
28:12so power goes in
28:13basically the
28:14electricity all
28:15stacks up here
28:15and works its way
28:16through those
28:16very thin wires
28:17there.
28:18They're too thin
28:18for the amount
28:19of electricity
28:19trying to force
28:20their way through
28:20those very skinny
28:21wires so what
28:21do they do?
28:22They get agitated
28:23they get hot
28:23and they heat
28:24up your bottom.
28:25Yes after a few
28:27freezing cold
28:28soaking wet
28:29laps around
28:29that racetrack
28:30Tim's decided
28:31a hot bot
28:32is the perfect
28:33upgrade for Jane
28:34to make her
28:35little sports car
28:36usable all year
28:37round.
28:38Okay
28:39so the trim
28:40can go over
28:41that
28:42which will sit
28:42nicely
28:43over that
28:44and you'll not
28:45know
28:45and you won't
28:46feel there's a
28:47heated seat
28:47element in that
28:48so I can do
28:49the same thing
28:50over and again
28:50or you can go
28:52and see what
28:52Foz is doing.
28:54Time to start
28:55building up the
28:56engine
28:56but before I do
28:58that there's a
28:58few things to
28:59show and tell.
29:01Yes after working
29:02day and night
29:03he's somehow
29:03managed to
29:04complete the
29:04first stage of
29:05the engine
29:05rebuild
29:06so it's time
29:07to start
29:07sticking it
29:08all back
29:08together.
29:09Now we
29:10thought we
29:11might have
29:11worn valve
29:12guides
29:12and indeed
29:13there's quite
29:15a lot of
29:16play there.
29:16What would
29:17have resulted
29:17there would
29:18be oil
29:19passing down
29:20between the
29:21valve guide
29:22and the
29:22valve stem
29:23into the
29:23combustion
29:24chamber
29:24so oil
29:25would have
29:26been being
29:26burned as
29:27well as
29:28fuel and
29:28air.
29:29So these
29:30valve guides
29:31have been
29:32replaced in
29:32the cylinder
29:33head and
29:34new valves
29:35as well
29:35and it's
29:38out with
29:39the old
29:39liners and
29:41out with
29:41the old
29:42pistons.
29:43So now
29:44we can
29:45start the
29:45process of
29:46building the
29:47engine up.
29:48Alongside the
29:49new valves
29:50and cylinder
29:50liners
29:51Fuzz is
29:51fitting a
29:52replacement
29:52set of
29:53bearings
29:54because as
29:54the engine
29:55was clearly
29:56leaking oil
29:57faster than
29:57a battered
29:58cod there's
29:59a good chance
30:00it wasn't
30:00reaching the
30:01originals
30:01meaning they
30:02could have
30:02become worn.
30:04There are
30:05our end
30:06bearings in
30:07place.
30:08They also
30:09had the
30:09camshaft
30:10machined down
30:10by about
30:11half the
30:12thickness of
30:12a human
30:13hair.
30:14If it
30:14also suffered
30:15from an oil
30:16leak it
30:16could have
30:17become scored.
30:18So restoring
30:19its surface
30:20is crucial if
30:21it's going to
30:21live happily
30:22with all the
30:23new components.
30:34So that is the
30:35first part of
30:36the build.
30:37What will
30:38happen now is
30:39we'll go for
30:40fitting the
30:41liners which
30:41need to be
30:42pressed in and
30:43gradually this
30:45will be built
30:45up and we
30:47are officially
30:48on our way
30:49back home.
30:50Yes but
30:51will they get
30:52there in
30:52time for
30:53Jane's
30:53birthday?
30:54With just
30:55ten days to
30:56go everyone
30:57is working
30:58flat out to
30:59make it
30:59happen.
31:01Over at
31:01iBox the
31:02primer's dry so
31:03it's straight on
31:04with a coat of
31:05original matching
31:06blue paint.
31:07But there's no
31:08time to stop and
31:09admire it.
31:10It's straight back
31:11to the workshop so
31:12Fuzz can crack on
31:13with the monumental
31:14task of taking
31:15Jane's dream car
31:16from an empty
31:17shell to a fully
31:18cooked Italian
31:19classic.
31:20I've started
31:21building up the
31:22upgraded suspension
31:23on the Alfa.
31:24Tim's package from
31:26the experts at
31:26Alphaholics have
31:28firmer upgraded
31:29bushes, fresh
31:30springs and that
31:31stiffer anti-roll
31:32bar.
31:33Get the nut and
31:37tighten it up.
31:40There we go.
31:41Right.
31:42There we have it.
31:43Upgraded suspension
31:44installed.
31:46Which will give it
31:47the handling of a
31:48modern car wrapped
31:49in a classic shell.
31:51And speaking of
31:52wrapped, with that
31:53in place, this
31:54quarter of a century
31:55overdue birthday
31:56present needs to
31:57hurry up and get
31:58ready for the party.
32:01Replacement wiring
32:02looms are threaded,
32:03switches connected,
32:05the battery fitted
32:06and lights tested.
32:09Under the bonnet,
32:10the engine's back in
32:11but before it's
32:12fired up for the
32:13first time in more
32:14than 25 years,
32:16Fuzz is adding
32:17another upgrade
32:17designed to help
32:18turn Jane's Alphah
32:19from weekend toy
32:20into a genuine
32:21daily driver.
32:24The car is pretty
32:25much mechanically
32:26complete, so we're
32:28ready to try and
32:30fire it up.
32:30But we've done one
32:32little extra
32:33modification to bring
32:34this car slightly
32:36further forward,
32:37maybe almost into
32:38the 21st century.
32:39An upgraded
32:41distributor.
32:42Now, here's the
32:45old distributor
32:45and the distributor
32:47distributes the
32:48powerful electrical
32:49current out through
32:51each of the spark
32:52blood leads in turn.
32:53The difference that
32:54will be made by the
32:55new electronic
32:56distributor versus
32:57the old
32:58electromechanical one
32:59is that the old
33:01one would need
33:01constant adjustment
33:03every few thousand
33:03miles.
33:04So it means visits
33:06to the garage or
33:07tinkering around with
33:08the engine on the
33:09driveway.
33:09Some people love
33:10that sort of thing.
33:11Other people just
33:12want to get in their
33:13car and drive.
33:15The fitting of this
33:16is simple.
33:17It's just the same
33:17as the old
33:18distributor.
33:18It just slots in
33:20and we have a
33:21slightly offset
33:22drive peg here
33:23and that can only
33:25go in one position.
33:25So once it's in,
33:27it's in.
33:29Fit the distributor
33:31cap.
33:33Now, hopefully,
33:35if I connect up
33:37the temporary fuel
33:38pump, we should
33:41get a tune out of
33:42this.
33:43We're going for an
33:44engine start.
33:45Engine start, this is
33:45it.
33:46Come on, everybody
33:46line up.
33:47Here we go.
33:48Here we go.
33:48Do you want to give
33:49it a go?
33:49Come on, then.
33:55OK.
33:56Yes!
33:58Give a round of applause.
34:00And for the first
34:01time in over 25
34:03years, Jane's long
34:04overdue birthday
34:05present runs.
34:06Come on, everybody,
34:07back on your heads.
34:08Let's get this car
34:08finished.
34:09Let's get it done.
34:11But what has Tim
34:12got planned for the
34:13party?
34:15Oi, Tim.
34:16What?
34:17Here a minute,
34:18please.
34:19What do you need me
34:20to hold?
34:21I'm not holding that.
34:22I don't know.
34:22You don't have to
34:23hold anything.
34:24I just need to know
34:25what's happening
34:25tomorrow because you've
34:26not explained anything
34:27to me.
34:28In fact, you do need
34:29to know what's
34:30happening tomorrow
34:30because you are
34:31playing a key role
34:32in giving this car
34:33back to Jane.
34:34Oh, yeah.
34:35Now, what's
34:35happening is Stephen's
34:36taking Jane away
34:37for a night in a hotel.
34:38Yeah.
34:38There's a bit of a
34:39twist going on there
34:39that's going to
34:40involve you in a
34:41big way.
34:42You're playing the
34:44leading role.
34:45The leading role.
34:45So I'm not just
34:46driving the car.
34:47No, no, no.
34:47In this performance,
34:48you're playing a key
34:49role.
34:50You are at the
34:50nebulous.
34:51You are the centre
34:51of the atom.
34:52Without you,
34:53tomorrow doesn't
34:53happen.
34:54OK.
34:55Yeah.
34:55I won't let you
34:56down.
34:56Sweet.
34:57I won't.
34:58But it also
34:59doesn't happen
34:59without a finished
35:00car, which means
35:01a very long
35:02night ahead as
35:03the team try to
35:04get this birthday
35:05present wrapped
35:06in time.
35:11It's been over
35:1225 years since
35:14Jane first dreamt
35:15of getting behind
35:16the wheel of her
35:17little Alfa Romeo
35:18spider.
35:19And today, her
35:21quarter of a century
35:22overdue birthday
35:23present can finally
35:25be unwrapped.
35:26Look at that!
35:28What an amazing
35:30transformation!
35:30Hello, baby!
35:32I think it's probably
35:34one of the best
35:35rags to riches
35:36I think you're
35:37right.
35:37that we've ever
35:37done.
35:38Talking of rags to
35:38riches.
35:39Yeah.
35:40Yeah, yes.
35:41Actually, why are you
35:42wearing my wardrobe?
35:44Listen, I'm the lord of
35:45this manor here,
35:46Storchhorn.
35:46Let me explain why.
35:47Come with me.
35:48Follow me, sir.
35:48Right, OK.
35:49Come along.
35:55Fuzzbots, I give you a
35:57real-life crime scene.
35:59Welcome behind the
36:00lines, behind the police
36:01tape.
36:02Yeah.
36:02Because this is where
36:03Jane and Stephen like to
36:04come on a weekend, a
36:05murder mystery weekend.
36:07Fantastic.
36:07And that's what's
36:08happening.
36:08Yeah, brilliant.
36:09Where's the body?
36:11Where's the body?
36:12Yeah.
36:12It's over there, look.
36:15Give me that!
36:17No.
36:18You're the...
36:18I'm not...
36:19You're the body.
36:20What do you mean I'm
36:21the body?
36:22You're the body.
36:22Get down.
36:23This is where you've
36:23got to go.
36:24You're the murder
36:25victim, and they've
36:26got to work out.
36:27Who done it?
36:28I'm going to bring
36:28them out here.
36:29Car's going to be
36:29there.
36:29They're not going to
36:30bother about you.
36:30I'll give you a
36:31little nudge.
36:31You jump up.
36:32We give them a car
36:32back.
36:33You just wanted to
36:33do that, didn't
36:34you?
36:36Yes, Tim's dead happy
36:37with his plan, and
36:38so he should be.
36:39It's the perfect crime.
36:41He's cast a troop of
36:42actors to play the chief
36:43inspector and forensics
36:46detectives are her
36:47friends and family, and
36:50she's been told the
36:50whole thing is being
36:51filmed for the hotel's
36:53social media, and
36:54thanks to Jane making
36:55the frankly unpardonable
36:57mistake of not being a
36:58devoted car SOS viewer,
37:00only one of these two
37:01has to hide.
37:03Get yourself down.
37:04So with Thars in
37:05position.
37:06Yeah, that's perfect.
37:07Right, now I'm going
37:08to cover you up.
37:09It's time for a
37:10killer surprise.
37:16I'm hearing a car
37:17coming up to drive.
37:19Hello there.
37:20Hi.
37:20Hi, welcome.
37:22Welcome to Storrs Hall.
37:23Are you here for the
37:24murder mystery event?
37:25We are.
37:25You are, right.
37:26OK, brilliant.
37:28So with Jane blissfully
37:30unaware as to what's
37:32really going on...
37:39The car can be moved
37:40into position, and the
37:42fun can begin.
37:46Hello, ladies and
37:47gentlemen.
37:48Hi.
37:49Welcome to Storrs Hall,
37:50detectives.
37:52Right, so far, so good.
37:54She's in there at the
37:54moment being briefed by
37:56the murder detective
37:57guys, and at a certain
37:58point, the lord of the
37:59manor is going to come
38:00bursting through the
38:01door and say,
38:02there's a body on my
38:03property, we need to
38:04solve this crime.
38:06In fact, shall we do it
38:08now?
38:08Come on, let's go.
38:11Who's running this
38:12operation?
38:13It's me.
38:13There is a corpse, there
38:14is a body on my land
38:15here.
38:16We've got crime scene
38:17here, we've got the
38:18police on the way down
38:18here, we need this
38:19dealt, I want this
38:19cleared up and dealt
38:21with instantly.
38:22These morons are the
38:23detectives, are they?
38:25We are trying to give
38:26them the best detective
38:27skills to get out there.
38:29They are a likely bunch.
38:29Well, I want this
38:30solving straight away, so
38:31look sharpish, please.
38:32OK, ladies and
38:33gentlemen, you heard the
38:34man, the lord of the
38:34manor.
38:35It's outrageous.
38:36Jane is the lead
38:37detective.
38:37If you want to take
38:38the lead, please.
38:40So far, so good.
38:42It looks like
38:43Detective Jane hasn't
38:45got a clue in more
38:46ways than one.
38:48Come on, then, come
38:49along.
38:50It's there.
38:51What's that there?
38:52A body.
38:52That is a body.
38:53It needs to be dealt
38:54with, doesn't it?
38:54Yes.
38:55Well, let's have a look
38:56around at the crime
38:57scene, shall we?
38:57Is there anything else
38:58that looks slightly
38:58suspicious here?
38:59Anything else you
39:00recognise?
39:00Nice.
39:01This car.
39:02But whose is that?
39:05Mine.
39:06Well, clearly not yours.
39:07Why, do you have
39:08anything like that?
39:10I wish I did.
39:12Really?
39:12Well, we're here for
39:13one reason, to solve
39:14the crime.
39:14Yeah.
39:15So, I'd rather, I'd
39:16appreciate it if you
39:16looked at the body as
39:17opposed to the car.
39:17Why do you keep
39:18staring at the car?
39:19It's gorgeous.
39:20Is it?
39:20What is it?
39:21I don't even know
39:22what it is.
39:22I'm not into my cars.
39:23It's an office
39:24spider, Romeo.
39:25Oh.
39:26Is it really?
39:27Your detective work
39:28is very poor, but I
39:29have some explaining
39:30to do.
39:31Actually, everything
39:32that's happening here
39:32today isn't quite as
39:33it may seem.
39:34I'm a presenter, one
39:36of the two presenters
39:36of a television show
39:37called Car SOS.
39:39Where's Stephen?
39:40I'm here.
39:40Come here, Stephen.
39:41Come on.
39:42Come on.
39:42Stand alongside
39:42your wife here.
39:44Can you believe it?
39:46That's not my car.
39:47No, no, no.
39:47Let me look at you
39:48for a minute.
39:48No, it's not.
39:49That is your car.
39:50No.
39:50That is your car.
39:52We've had a team
39:53of people working
39:54with you, Stephen.
39:55I know this is a lot
39:56to take on.
39:58It's beautiful.
39:59Absolutely stunning.
40:00I'm holding on to you.
40:02It's good.
40:03Just don't faint.
40:04It's all right.
40:04It's good.
40:05It's all good.
40:05It's beautiful.
40:06Yes, it is.
40:07And if you don't believe it,
40:08there are a few people
40:09here you might recognise.
40:10Can we bring out
40:11Jane's family, please?
40:13What?
40:13Yeah, who have we got here?
40:15Oh.
40:17Hello.
40:19Come on out, guys.
40:20Come on.
40:20Keep coming.
40:24Can you explain
40:25to your wife,
40:26forget the fact
40:27there's anybody here,
40:29why you contacted us?
40:30Was it my intention
40:31to have the car restored
40:34for at least
40:35your 40th birthday
40:37and then your 50th
40:38and 60th?
40:41You're now 66.
40:44And I'm so pleased for you.
40:46Oh, I'm pleased for you, too.
40:47Can we have a round of applause
40:48for Jane and her alpha?
40:52It's done.
40:54It's actually done.
40:55I seriously can't believe it.
40:56It's absolutely gorgeous.
40:59As far as Jane was aware,
41:01her dream car
41:02was still in a barn,
41:04slowly rusting away
41:05like it had been
41:06for the past 25 years.
41:08But thanks to the boys,
41:11this Italian classic
41:13is now ready to say
41:14bonjourno
41:15to the British roads.
41:17The body has been stripped back
41:19of bare metal,
41:20every trace of rust removed,
41:22new metal let in,
41:24and fresh coats
41:25of modern primer
41:26and paint applied
41:27to ensure it can withstand
41:29whatever the weather
41:30sends its way.
41:31The beautifully sculpted
41:33aluminium engine
41:34has been completely rebuilt
41:36with new pistons,
41:38bearings,
41:38timing chain
41:39and exhaust manifold.
41:41Plus,
41:41to keep maintenance
41:42to a minimum,
41:43there's a modern distributor.
41:44Finally,
41:45to turn it into a car
41:47Jane can use
41:48for cruising to Capri
41:49or picking up cabbages
41:51in the Cotswolds,
41:52it now has heated seats,
41:54a stiffer anti-roll bar
41:56and upgraded suspension,
41:58meaning Jane gets
41:59modern comfort
42:00wrapped in classic
42:02Italian looks.
42:08How does it feel?
42:09I'm in a dream.
42:11Really?
42:11I'm totally in a dream.
42:13I mean,
42:13never in a million years.
42:15I'd sort of said to Stephen,
42:16we're never going to be able
42:17to do it.
42:17Why?
42:19Well,
42:19we're not going to have the money
42:20because we went through
42:21a terrible scam.
42:23How devastating
42:25is it
42:25for something like this?
42:26Because you hear scams
42:27all the time,
42:28they're just numbers
42:29in newspapers,
42:29but what does it feel like
42:30as a human being?
42:31It changes your life.
42:32He'd just retired,
42:34he got the money
42:35from his retirement,
42:36we were looking forward
42:37to our son getting married,
42:38we were looking forward
42:39to maybe doing this up,
42:41so we were actually
42:42going to make some memories
42:43and have some nice time
42:44and that was all
42:45taken away from us.
42:46Do you think,
42:47had you guys as a family
42:48written this off?
42:48Yes,
42:49absolutely.
42:50We'd lost faith
42:51and impetus
42:52in doing it
42:52and I just said,
42:53we just need to cut
42:54our losses
42:54and sell it.
42:55So what's the plan?
42:57Well,
42:57we live up near
42:58the Lake District
42:58so we're going to travel
42:59around the Lake District,
43:00hopefully on days
43:01like today,
43:03hood down,
43:03scarf on,
43:05looking like
43:05my 1960s self.
43:08Jane,
43:08it's with great pleasure
43:10that I give you
43:10your car,
43:12key rings
43:12and tell you
43:12you have been Car SOS.
43:14Thank you so much.
43:18It's unbelievable.
43:19It's so nice
43:20to drive.
43:21A proper gear stick,
43:23you know?
43:23And this steering wheel
43:25is beautiful.
43:26It's just,
43:27it's just a dream.
43:28It's just a dream
43:28come through.
43:32Do you ever think
43:33it's going to happen?
43:34No, never.
43:34Never in a million years.
43:36But it's absolutely
43:36wonderful.
43:37This is the best
43:38birthday present
43:40ever.
43:41Thank you so much.
43:46It's kind of awfully quiet.
43:48Where is everybody?
43:49Let's have a look.
43:53Where's everyone gone?
43:55Have they just left?
43:58What's all?
43:59Have they just left?
44:00Hey!
44:00They're fucking
44:00They're much closer.
44:00they're going to have a deal.
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