Car SOSSeason 13 Episode 3
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00:00Bash dunes in a Californian classic.
00:02Guaranteed to put a smile on your face.
00:05But face a battle to bring this battered beach toy back from the dead.
00:09One that would suit a farmer's field or a scrapyard.
00:12So, can they turn it from a soggy day at the seaside...
00:16I don't think there's going to be anything usable on it.
00:19...to a way to have some serious fun in the sun...
00:22Beautiful. You've done very well.
00:24...and make its owner's dream a reality.
00:28Really?
00:28Hello, mate. Hello, fella.
00:31How you doing?
00:32Yeah, you've got me.
00:54Here we are in lovely North Yorkshire, Timmy Boy.
00:57Driffield, to be precise, my son.
01:01Buzz, go back to when I'm eight years old.
01:02OK, a very long time ago.
01:03A very long time ago. I couldn't drive.
01:05That's still the same.
01:06What?
01:07Anyway, listen, I was obsessed with cars.
01:09So what did I get? What am I into?
01:10Uh, a little radio control car.
01:12Radio control cars and I happen to have the small version of what we're picking up today.
01:17A VW June Buggy.
01:19Yes.
01:20Yes, nothing quite says 1960s Californian surf culture better than these grown-up beach toys.
01:28Artists, surfer and boat builder Bruce Myers wanted an off-roader to explore the beaches north of Los Angeles, but it wasn't all plain sailing because loose sand and salty sea air play havoc with standard vehicles.
01:41So he turned to another 60s icon, the VW Beetle.
01:45It was easy to modify and its rear engine provided greater grip on loose sand.
01:51Myers ditched the metal body and made a replacement from fiberglass, as it wouldn't corrode and was cheap and easy to shape into a buggy's classic curves.
01:59The concept made it to the UK in the late 60s. While it was never mass-produced, Myers' design was copied by dozens of companies and became a cult classic in the 70s.
02:12Over the last 10 years, they've enjoyed a revival with waiting lists topping six months.
02:17So with Myers' original buggy having just celebrated its 60th birthday, there's no better time for the boys to restore one of these iconic vehicles.
02:26Right, it's owned by a guy called Paul.
02:28Yeah.
02:28Now, here's the mission. The problem with the car is it's on his drive.
02:31His daughter, Emma, who's basically nominated him for the car SOS treatment, she works as a teacher.
02:38OK.
02:38She's contacted her dad, Paul, and said,
02:40Dad, the kids at school would love to have a car to draw as a project in art.
02:44OK.
02:44So that's going to the school, or so he thinks, but the people picking it up art and the school's people are actually art people.
02:51OK, got you.
02:53So Fuzzle gets a watch on as his mate and VW expert Lee picks up the car,
02:57and they are under the pretense of it going to the school. But first, the boys are meeting Emma.
03:02Hi, Emma. How are you doing?
03:03I'm good, thank you. How are you?
03:04Where is your dad?
03:06He's at home with the car.
03:07Keep your head down.
03:08OK, will do.
03:08Good luck with that one. We're going to have a chat about your dad.
03:10OK.
03:10And we'll get back together and take the car away and get on with it.
03:12Good luck.
03:14Right, shall we go this way?
03:18I'm trying to build up an image, an idea of what your dad, not having met him, what he's like,
03:23because people who drive dune buggies, in my mind, fascinate me.
03:26He loves life. He likes, you know, he enjoys being out and about.
03:30So when he got it, how long ago was that?
03:32I think it was about 14 years ago.
03:33Right, so when he got it, was he driving it?
03:35Yes.
03:36And that's the memory you've got?
03:37Yes. Dad just driving around and, you know, just enjoying the sunshine.
03:41It was a dream to have this car, you know, to enjoy life.
03:46It was something that he was passionate about and he really wanted to get stuck into.
03:52So, we are very close now.
03:56And I've got just enough time to get into stealth mode.
03:59Oh, yeah, I'm going to be covert, inconspicuous, and the one thing is, I mustn't get caught.
04:12Right, we're parked up now.
04:14We're very, very close.
04:16With Fuzz tucked out of sight, Lee, who will be helping with the rebuild,
04:20is chatting to Paul about his pride and joy.
04:23Let's just hope he doesn't smell a rat.
04:26It's just the right weather for a beach buggie, though, mate.
04:29It is, isn't it?
04:30Well, there it is.
04:34Doesn't look that good.
04:36I'm hoping that I just keep down out of the way.
04:39Is it my bubble showing?
04:41I hope not.
04:45What's happened in your dad's life, to me, that his pride and joy, am I right in calling it that?
04:49Mm-hmm.
04:50He loves this thing, doesn't he?
04:51Yeah, he does.
04:51How about?
04:52A lot.
04:53I think it's been a build-up of everything.
04:57So he used to be in the RAF.
04:58It meant a great deal to him, and I think he would still be there now.
05:04It's just because my mum grew up in the RAF, and she didn't want that for me and my sister.
05:09So my dad left the RAF when I was about three or four.
05:12That must have been a real tough spot, though, because when he's found a career that he loves, and I can see by your face that he loved it.
05:18Yeah, yeah.
05:19So what did he go on to do?
05:20He went into HGV driving.
05:23He loved the job.
05:24He loved driving.
05:24But he had a really severe road accident in the truck, and that ended his driving career.
05:30There was a driver who drove into my dad's truck.
05:35So had he been loaded, the truck would have gone completely over, and he probably wouldn't have been here now.
05:42The accident, he fractured his neck.
05:44He had PTSD.
05:46He was out of work for two and a half years with his injuries.
05:50Where does the beach bucket come into it?
05:52So he's gone through all this, you know, this trouble in his life, and he wanted to just have a car to rebuild with my brother,
06:01have that bit of bonding time that he's missed out on while he's been driving.
06:05And then, unfortunately, my mum received a diagnosis that she had dementia.
06:11So my dad's world has kind of come crashing down, and the time that he could spend on the car has gone.
06:20Yeah.
06:20I don't think he realises how caring and loving he is.
06:24It's just his nature.
06:25He will do anything for anybody.
06:27Never asks for anything in return.
06:30Utterly selfless.
06:31Yeah, absolutely.
06:32The car.
06:33Yeah.
06:34The design.
06:35The dad.
06:36How's this thing got to be?
06:38I'm thinking maybe RAF would be incredible if we could have something.
06:42So a nod to the RAF?
06:43Yes.
06:44As he's getting a little bit older, his body's kind of giving up on him a little bit, and it's just making him really uncomfortable.
06:51Okay.
06:51He struggles to get in and out of things, so if we could lower the sides, perhaps, so he's not having to step into it.
06:57Okay.
06:58That'd be incredible.
06:58So come up with a mechanism to help him get in, some sort of system.
07:01Yeah.
07:02Across town, Fuzz is hoping Paul, who's a big fan of the show, doesn't spot him and blow the surprise.
07:08What we need now is for the doors to be shut, the buggy to be tethered down, and Lee to get out of here, fast.
07:18Then the action can really start.
07:22Paul is still none the wiser.
07:25I work out for the day, Paul.
07:27The buggy's secure, and everything's going swimmingly, until...
07:32He's looking at us.
07:33He's looking at us.
07:34He's looking at us.
07:36He's looking directly at us.
07:39Do not come walking this way.
07:44See you, guys.
07:54Tim, come on.
07:55That's a guilty face.
07:56I've seen that face before.
07:58Go on, then.
07:58What happened?
08:00Hopefully, Fuzz got away with it, as the boys need to get busy with that buggy, which has made its way to Lee's Yard, a mecca for all things visual.
08:08I bet you were seen, honestly.
08:10No, I was not seen.
08:12Look, will you just leave it, please?
08:15Yes, Tim, let's move on.
08:17Especially as Fuzz finally has a chance to inspect the buggy.
08:21There it is.
08:22Look at that.
08:23Hey, there we go.
08:25Wow.
08:25Look at that.
08:26It does look great, and it looks to me like it's quite an early body.
08:34Yeah, I'll say it is.
08:35Yeah?
08:36But don't overlook the fact it is an everything car.
08:39Right.
08:39Everything needs work.
08:41Yeah.
08:41You've got the body off.
08:42Yeah.
08:42All right, have a look at it.
08:43Right, let's get the body off, because it's just sitting on the chassis.
08:47Okay.
08:47Then we've made a start, haven't we?
08:49You go on that corner.
08:50All right, here we go.
08:51Oh, my word.
08:57Wow, okay.
08:58Yeah, that's cool.
09:00And as if by magic, all of a sudden, the cooler's gone and left us with a Volkswagen Beetle.
09:07Underneath the fiberglass body, there's a VW Beetle chassis with its distinctive floor pans.
09:13The chassis was chosen as it's easy to shorten, cutting out a section and then welding it back together.
09:19While the trailing arm's suspension made for an easy ride over rough surfaces.
09:24That's not very good, really, at all, is it?
09:26I mean, look at it.
09:27One that would suit a farmer's field or a scrapyard.
09:30This thing is terrible, isn't it?
09:32So, floor pans, for a start.
09:34Yeah, needs a frame with the underneath toast.
09:36Okay, so floor pans completely rotted out.
09:39So, what about up the front here?
09:42What would we like at the bottom?
09:44Okay, so rust at the bottom.
09:45And, in fact, it's had a few dodgy repairs on it, hasn't it?
09:48Yeah.
09:48Nothing to save. Save the body shell and the centre of the spine and that's it.
09:52Okay, right, so the engine needs completely rebuilding.
09:54Motor C solid, really.
09:55Okay.
09:56This is bad. It's double bad.
10:02Tim and Fuzz have got their hands on the ultimate big boy's beach toy, a 1967 dune buggy.
10:08They want to make it road legal again for owner Paul, but so far, all they've discovered is a chassis and engine that's about as attractive as a sand-filled sandwich.
10:17Let's hope the body's fared better.
10:19I would say that this body shell is remarkably good.
10:23It's pretty strong and it's kind of got a lot of material in all the right places.
10:28It's pretty well preserved.
10:29A little bit of micro-blistering around here, but generally speaking, it's pretty together.
10:34What do you reckon, Lee?
10:34Yeah, I think it's probably the best-conditioned old body shell I've seen for a while.
10:38So it's going to need some wide wheels with some, like, Testarossa, Countach wheels, you know, tyres and something big.
10:44Yeah, some monstrously sort of, you know, super-wide.
10:46To make it look right.
10:47Yeah, the paintwork on it.
10:49From speaking to Emma yesterday, she said her dad was ex-RAF and she thought he should have an RAF nod.
10:55Hold that thought, Tim, as there's a whole heap of other work that needs to be done first.
11:00A rust-ridden chassis and seized engine both require a full nuts and bolts stripped down to see what parts can be saved and what's off to the scrappers.
11:07The tired old fibreglass body shell will need to be sanded down, its holes filled and then repainted.
11:15And saving the best challenge to last, how do you make this rough-and-ready beach basher accessible enough for Paul to actually get in and out of with ease?
11:24First job is for the team to strip the car to its bare bones so the years of rust and rot can be revealed and then removed.
11:33Where we're at now is we're ready to cut out these floor pans.
11:36So, what I need to do is cut along the edge here but leaving a little bit of a lip so that we've got enough material to weld the new pan onto.
11:46Getting into it.
11:47Let's do it.
11:49Wish me luck.
11:50The floor pans were manufactured separately to the frame then welded onto it so it's easy to sort a new set.
12:00The next step will be getting the rest of it blasted so that it's clean as a whistle and so that we can see any further repairs that need doing because there will be some.
12:11A typical dune buggy spends its life in salty sea air so it's no surprise this one's such a rust bucket.
12:18As for the body, luckily fiberglass doesn't rust but although rot-free it still requires some tricky fabrication.
12:28The problem with this particular bonnet section here is we only need one place to fill it up with petrol.
12:33That is going to be in the center here.
12:35So this one, ah, we're going to do with that.
12:38Now if this was steel, how would you fix it?
12:40Well, you'd cut a plate in, you'd put it in, you'd weld it in but it's not steel.
12:44It's fiberglass and in my mind fiberglass is something that is top of the list of impressive materials on the planet.
12:51The thing I love about fiberglass is it's strong, it's quick to produce and easy to shape without needing expensive tooling.
12:57So it's ideal for bespoke bodywork, like the beach buggy.
13:01To fix the hole, Tim has clambered up on the roof of Lee's yard where he's spotted a bonnet just like the one on Paul's buggy.
13:09So we are taking a mold of a section of this bonnet with a piece of fiberglass.
13:13I'm actually going to use fiberglass to make the mold, to make the negative.
13:17But this is where this comes in.
13:19Because if I just fiberglassed on top of that, it would stick.
13:23But that is basically, it's a release agent.
13:26It's not exactly the right one, but it works.
13:28So if you apply this between the two, I can take the top one off, take it downstairs.
13:33So we basically put a layer of fat between the shape that we want and the mold that we're making,
13:39so that we can peel off the mold and stick it on downstairs.
13:42The release agent is now on top of the bonnet.
13:44So below it we have the shape, on top we have the release agent,
13:47and this is the stuff we're going to use, which is glass fiber matting.
13:50So that is basically fibers of glass.
13:52But the amazing stuff about the glass fibers is actually, if you look at it,
13:56they're all in different directions.
13:57So they're all interwoven.
13:59They're all interlocked, meaning that when you actually bond this onto the shape of the car,
14:03you just get so much strength from it.
14:04We're going to bond it all together with this stuff.
14:09Now this is polyester resin.
14:10Let's get messy.
14:11It's the combo with the resin and glass fibers that give fiberglass its strength.
14:16That is now pretty much wet.
14:19Now I need to lift this off, put it on the shape that we want to copy.
14:22It's a thermal reaction, it's a chemical reaction, and it's now like a brick.
14:34So that means one thing.
14:37Hopefully this is going to release.
14:39So let's have a look.
14:42Look at that.
14:43How cool is that?
14:46Yes, very clever.
14:48If it fits the bonnet.
14:49Look at that.
14:51It fits perfectly.
14:52So the mold is attached to the car with screws.
14:57Fiberglass mold secured.
14:59It's time to flip the shell over and fill the hole in from the other side.
15:02So we're only going to glass from the back on this.
15:05So it's the same process as I did on the roof just now.
15:08After letting the new fiberglass set, will the mold have done its job?
15:13Right, showtime.
15:15And I'd be biting my nails if I didn't have gloves on.
15:17Shall we see if this comes off?
15:18Just one last time.
15:21You can tell without even needing to get close to it, is the perfect shape.
15:25Absolutely bang on.
15:27Look at that.
15:28You don't even need to get any closer to that to see that the profile is absolutely perfect.
15:35And that is precisely why I love fiberglass.
15:37I think Tim loves fiberglass.
15:40Not so loved up a fuzz and the engine.
15:42A buggy's motor sits in the open air rather than under a bonnet.
15:47Fine if you live in sunny California.
15:49Not so good in rainy Yorkshire.
15:52Right, so this is as solid as a rock, isn't it?
15:55It's not going to move anywhere.
15:56That's well seized, that is, mate.
15:58Absolutely.
15:59Years of wind, rain and salty sea air means some serious rust.
16:03A little bit of a shake.
16:05That's some persuasion.
16:07So the engine has seized tighter than Tim's wallet at the local boozer.
16:11We've got a little theory here, and that is that this engine has seized at the top end
16:20due to water ingress, just from standing, just from water making its way in through the inlet.
16:26Now, if that has happened, if I tip this engine up, we should get some water at this point here.
16:34Let's just give it a try.
16:35And there we go.
16:42Water coming out.
16:43This is definitely not good.
16:45To keep this engine simple, it's designed to be cooled by fans and fresh air rather than a complicated water system.
16:52So water that's got inside shouldn't be there.
16:55So here we have it, exhibit one.
16:59So this piston has completely seized inside this barrel here.
17:03There is no way that the piston is going to force its way up past this rust.
17:10Having come this far, I think I'm going to call it.
17:13I don't think there's going to be anything usable on it.
17:16So I'm going to say it's a replacement engine time.
17:23Paul's engine is too far gone to repair because of the water damage.
17:26So while the boys hut for a replacement, they turn their attention to the bodywork.
17:34Time to consult Emma and her son Isaac about the overall look.
17:38Right.
17:39It's not all been plain sailing with this car because it was completely rotten.
17:44It's been an absolute everything car.
17:47There's not been a good bit on it.
17:50Really?
17:50I can see what you've done already.
17:54That's amazing.
17:55Only the centre section, only the spine remains.
17:58The engine, absolutely trashed.
18:02Oh, that bad.
18:04So have you got any ideas, any designs for us, anything for us to go on?
18:09Yeah.
18:10Talk us through this, what we're looking at here, dude.
18:12So planes on the side of the castle, like Spitfires and stuff.
18:16Yeah, that's cool.
18:17I think he'll really like that.
18:18Yeah.
18:19With your granddad's service number on?
18:21Yeah.
18:22Do you reckon we could pull that one off?
18:23Could you pull that one off, Timmy?
18:25Hell yeah.
18:25And thank you very much for your design ideas, Isaac.
18:28Can we keep hold of that?
18:29Yeah, you can keep it.
18:30Okay, fantastic.
18:31Excellent stuff.
18:32So can we talk about giving the car back to your dad?
18:34Yes.
18:35How are we going to do it?
18:36There is an air museum, an RAF museum.
18:39Okay.
18:40Nearby.
18:41So we thought that might be a good place because...
18:43I could ask him if he wants to come with me.
18:45We are going to get this car finished, and you are going to love it when you see it,
18:49and your dad's going to love it, and that day that you've been waiting for is going to happen.
18:53So it's an RAF theme for the bodywork and the car's big reveal.
19:05Before they get stuck back into the refurb, the boys are packing their bucket and spade
19:10to find out why these particular cars have such a devoted following.
19:13Right, okay.
19:16So where is it?
19:17What?
19:19Where's the car?
19:20Oh, the beach buggy.
19:21I can't see one anywhere, can you?
19:23Oh, no.
19:23Oh, I've got a minute.
19:24Oh, what's this little...
19:26Oh, my God, it's Timmy's beach buggy from the 80s, my very own toy, with Mr. Cool Cowboy
19:33driving it.
19:34You've brought me down here to play with your toy car.
19:37No.
19:39I haven't brought you down here for that.
19:40I'm going to show you some 80s magic.
19:41Hold that.
19:52Buzz!
19:53I'm the man!
19:54I am the guy!
19:55No, you've got to come and join me!
19:57All right, okay.
19:57Three, two, one...
20:00Yes!
20:03I'm reading a buzz ball!
20:05I'm tiny, you're tiny!
20:06Right, come on, seatbelts on, let's get out of here!
20:10You look good in a cowboy hat.
20:17Welcome to Car SOS, the miniseries!
20:22This is so much fun!
20:27Mate, do you know what, I get it now, I get it, until this moment in time, I looked at
20:32people in beach buggies and just thought, why do you drive one of those?
20:36But actually, the reality of it is, when you drive one of these things, you completely
20:40take leave of any concern about what you look like, who cares what I look like, this is
20:45about just enjoying life.
20:46And it's massively responsive.
20:48This one is actually significantly boosting, you know, this one is actually a bigger engine.
20:52Now, that is a very good point, because you've got much larger wheels, so you need that extra
20:58torque, that extra power to turn those wheels.
21:07Guaranteed to put a smile on your face.
21:10Dude, check this out, I'm just drifting it.
21:13Left to right.
21:14Oh, wow!
21:15Are you sure it's not somebody with a remote control?
21:21Go!
21:26Let's just do donuts all day, whoa!
21:29Yeah, but in order to do donuts, we need a bigger engine to put into Paul's gym buggy,
21:35that way, he'll be able to go drifting as well.
21:36So, bigger engine is an absolute bust.
21:38Buzz!
21:39There's a dog behind us!
21:40Ah!
21:41Ah!
21:42Ah!
21:43Ah!
21:44Ah!
21:45Ah!
21:46Ah!
21:47Ah!
21:48Ah!
21:49Ah!
21:50Ah!
21:51Ah!
21:52Ah!
21:53Ah!
21:54Ah!
21:55Ah!
21:56Ah!
21:57Ah!
21:58Ah!
21:59Ah!
22:00Ah!
22:01Ah!
22:03Ah!
22:04Ah!
22:05Good idea!
22:06As the new engines arrived for Paul's beach buggy.
22:08When we took the buggy's engine apart, we found so few remaining components that we could
22:14reuse.
22:15It's all either new or replacement gear.
22:18The silver lining of replacing the engine is they can upgrade from 1300cc to nearly 1800.
22:24There we go.
22:26Boosting the horsepower from 50 to 80.
22:29We're going to reorient the engine back to here.
22:34To top it off, there are new exhaust valves made from stainless steel to make them stronger
22:40as they'll be running at higher temperatures.
22:42Now, you can see our exhaust valves there.
22:46They'll deal with the heat much, much better than the originals.
22:49And everything has been machined out and it's all ready to go on to the barrels.
22:54Next, Fuzz begins bolting the exhaust valve into place.
22:59Just check that those tubes are all sitting centrally here at the top and at the bottom.
23:07That's good.
23:08Right.
23:09Get our pushrods into place.
23:16There we go.
23:18Right now, I can start tightening down.
23:24He's using a torque wrench to ensure the bolts are all tightened evenly.
23:29And that is essentially the bulk of our engine rebuilt.
23:34Fuzz and Tim have taken on a 1967 dune buggy that's definitely more crime watch than it is Baywatch.
23:46It belongs to 67-year-old former RAF serviceman Paul.
23:50After a terrible lorry accident had ended his HEV driving, he'd hoped to spend his retirement fixing it up.
23:57But his plans had to go on hold after his wife was diagnosed with dementia and he devoted his time to caring for her.
24:06I don't think he realises how caring and loving he is.
24:09It's just his nature. He will do anything for anybody.
24:12Since picking up the buggy, what's left of the original chassis spine has been sandblasted to remove the rust.
24:19Now it's ready for the replacement frame heads and new floor pans to be welded into place.
24:30While the team pushes on with the chassis, Tim's devised an ingenious plan to bring Isaac's RAF-inspired design from the drawing board to reality.
24:39Right, I hope this works. I so hope this works.
24:43Right, the car. I'm going to start with one panel.
24:48Right, you want to see this place. It's well cool in here.
24:52Where is he? Dude! Yo! How's it going, man?
24:56Sorry to interrupt. Mate, I need a favour.
24:58Right, this man is not only the world's greatest tattooist, he's also also with an airbrush.
25:02Right, and this car here is a Tamiya Sand Rover, right?
25:05Okay. This is the panel off the side of our Sand Rover.
25:07We're rebuilding. I need down the side of it with your airbrushing skills.
25:09I need some Avro Lancasters, some Spitfire, Mark 14 Spitfires, some Halifax Bombers, all this sort of stuff.
25:15That's wonderful. Yes, I can do it. But you're in the tattoo studio.
25:19And we are super busy at the minute.
25:21Right. Excuse me, can I book in for a tattoo, like, straight away?
25:25Today? Yeah, right now. Definitely.
25:27So you're in my tattoo studio, we're going to paint your panels, and then you're going to get tattooed by me today.
25:32Yeah, done.
25:33Okay.
25:42We will sketch an idea of what we're going to do.
25:44So what I'm thinking, what we should have is, we've got the Spitfire, a Hurricane, a Halifax, all sort of key planes of ours, on either side.
25:53Yeah. But probably with that trajectory of moving forward.
25:56Yeah, it's got to move forward.
25:57What do you reckon?
25:58Coming through the clouds, with sun rays, fingers of God, the Spitfire leading the charge, and then the other two bombers behind them.
26:03Yeah.
26:04So everything will be facing forward, so we have this movement of aeroplanes moving through the clouds, with the wings and the detail.
26:12Are we going colour?
26:13No. So when you see the car, it's the treat, it's the Easter eggs. Oh, look at that, that artwork there.
26:17Yeah, no problem.
26:18I don't want to steal the show with this, that's why I want to go kind of monotone.
26:21OK, yep. So maybe just white over the blue.
26:24Yeah.
26:25Picky details out.
26:26Yeah.
26:27Leave this with me.
26:28No, no, we're doing this now, aren't we? We're doing the airbrushing now.
26:30No, well, you can leave this with me, and then we'll get you in the chair.
26:33Come on then.
26:37Work on Paul's upgraded engine is powering along.
26:40Fars has fitted upgraded twin Weber carburettors to give a richer mix of fuel and air to add even more power.
26:47So Paul's new engine's pretty much ready, but does it actually work?
26:51Now, we're getting close to the stage at which we can run up this engine and test it to make sure that it runs sweetly.
27:00Right, here we go.
27:02Place it down.
27:07There we are.
27:11Come on, first I've got a present for you.
27:13Oh, right, some fuel?
27:14And some headphones.
27:16All right, cheers, thanks for those ones, brilliant.
27:19Okay.
27:22Right, this is it.
27:23I'm going to get my ear defenders on because it's going to be loud.
27:27Okay?
27:28Yeah.
27:29Ready, connected.
27:30We've established that we've got a beautifully running engine, it's fantastic, it's going to be powerful, it's going to push that buggy along magnificently.
27:43And I cannot wait to see the finished job.
27:44Yes, great work Fuzz.
27:45Meanwhile, Tim is getting the needle.
27:46What's this then?
27:47So this is the remembrance of your car SOS journey for the last decade.
27:48Okay.
27:49This is something personal.
27:50This is something personal.
27:51Yeah, yeah.
27:52Yeah, yeah.
27:53This demonstrates to you my level of commitment to fixing your car.
27:54It's going to be powerful.
27:55It's going to be powerful.
27:56It's going to push that buggy along magnificently.
27:57And I cannot wait to see the finished job.
27:59Yes, great work Fuzz.
28:02Right, so all we're going to do now is we're going to drop a little bit of ink into these pots, and then we'll get tattooing.
28:09Three, two, one, nice breath, and away we go.
28:10So this is the remembrance of your car SOS journey for the last decade.
28:15Okay.
28:16This is something personal.
28:17Yeah, yeah.
28:18This demonstrates to you my level of commitment to fixing your cars and getting them back to you.
28:23Right, so all we're going to do now is we're going to drop a little bit of ink into these pots, and then we'll get tattooing.
28:33Three, two, one, nice breath, and away we go.
28:40While Tim is getting inked, it's time to bring Paul's dream dune buggy back together.
28:49Next job, making sure it can cope with the bigger engine.
28:52Paul's buggy now has more power from that increased in size rebuilt engine.
28:57So what we're doing is we're doing a disc brake conversion on the front axle here.
29:02Now the reason for that is that disc brakes give us more stopping power than the original drums that were fitted to this car.
29:10The new discs dissipate heat better, so work more efficiently at higher speeds.
29:21Ready to SOS age roll.
29:25Sausage roll.
29:26Get it?
29:27It's going to roll.
29:28All right.
29:29Suit yourself.
29:30With the engine upgraded and chassis coming together, Fuzz moves onto the suspension.
29:35It wants to add an adjustable air powered version so it's easier for Paul to get in.
29:40Now air suspension allows us the best of all worlds.
29:43It allows us to lift the chassis up and away from the ground when we're going over things like speed bumps or maybe even sand dunes or something like that when we're in the beach buggy.
29:55But also if we're at a show or in Paul's situation, if he needs it lowered down so he can easily get into it, we can eliminate the air and down goes the chassis so that we get a very, very low entry point.
30:11And here's Professor Fuzz demonstrating how it all works with a little help from Lee.
30:16Pay attention at the back there, Shaw.
30:18Now the whole point of this is it's a bit of an exaggeration but air ride gives us the opportunity to make the entrance and exit to the vehicle much lower down.
30:30Right, now imagine Paul's trying to get in, he's not so steady on his pins, he's got to climb up to get in and all that kind of thing so...
30:37Hold on.
30:39We should go right in.
30:43Hold on, hold on.
30:47What the hell are you doing?
30:48An experiment.
30:49Air ride, it's too high at the moment.
30:52Science, Tim.
30:53Science.
30:54This is science, isn't it?
30:55No, no, no, just wait.
30:56Wait, wait, wait, because look, once we take this out...
31:00There we are.
31:02There.
31:03The air ride's going down.
31:05It's going down.
31:06Look.
31:07It's going down.
31:08It's easier for Paul to get in.
31:11See?
31:12It works, mate.
31:14Science.
31:15Yes, I'm not sure anyone's going to be handing out a Nobel Prize for that.
31:20But if it does what the mad professors claim, it might just be the solution Paul needs.
31:26We've now got our air suspension unit, which comes in this nice, little, well-engineered set-up here.
31:34So we've got our airbags here, which get inflated by air from a compressor.
31:39We can just lift it into position, get the bolts in, and it's done, isn't it?
31:42So, based on that piece of cutting-edge research, the air ride system has bolted onto the chassis.
31:49Keep your fingers crossed this works.
31:52So what we're now going to do is we're going to inflate the air suspension using an ordinary airline.
31:57We've got a tyre valve fitted on the end here.
32:00Right.
32:01Come on, then.
32:02Shall we give it a go?
32:03So this is what will happen when Paul gets into the buggy, starts it up, the compressor kicks in, and it starts to rise up just that little bit.
32:13So here we go.
32:14Inflating.
32:17Yeah.
32:18Up goes the rear.
32:19Up goes the front.
32:21There we are.
32:22We are up to ride height.
32:26So that's pretty good.
32:27That's looking great to me.
32:28And the most important thing, Paul's going to be able to get in and out of his buggy really easily.
32:33Brilliant, eh?
32:34Finally, someone's making use of all the hot air in that workshop.
32:39And with the air ride fitted, up-rated disc brakes, the new suspension set up in place, the chassis of the car is properly taking shape.
32:47But now it's time to attach the engine onto the gearbox and therefore bring everything that makes up the chassis of the car back together.
33:03With the chassis complete, the car needs its next vital component.
33:07A fresh set of ultra-wide rubber onto new 15-inch rims.
33:12So Paul can tackle whatever terrain the Yorkshire coastline throws his way.
33:17So will we hear a pop still?
33:18Oh, you'll hear it pop.
33:19Yeah.
33:22Every time.
33:24Away from the garage, Cookie's been sketching and painting everything by hand using an airbrush.
33:30Now it's time to show off his handiwork.
33:32Right.
33:33Here we go.
33:34Just a little bit.
33:35Hold on.
33:36Have I come at the right?
33:37Wow!
33:38No, you've come at the wrong time.
33:39Fuzz your way.
33:40Hold on, hold on.
33:41Wait a minute.
33:42Hold on.
33:43What have you got there?
33:44Give us a look at them.
33:45Oh, you want to look at one of these little things, do you?
33:46Yeah, yeah.
33:47Come on.
33:48Don't worry, I won't leave you out.
33:49Oh, thank you very much.
33:50Oh, look at that.
33:51How is that?
33:52Beautiful.
33:53Very nice.
33:54You've done very well.
33:55These are going to look absolutely amazing on the side of that body there.
33:56You know when you go to a car show with your family?
33:57Yeah.
33:58And there's one car that wins that car show.
33:59That's great.
34:00But go on, put them somewhere safe.
34:01Come on.
34:02I've got lucky hands.
34:03Come on then.
34:04Let's get this on.
34:06The upgraded 1766 CC engine, running gear and gearbox are bolted into place.
34:14Then on go the fresh set of wider wheels.
34:18And just like the rest of us, this buggy can't show up to the beach topless.
34:23The old body's been polished, patched and painted.
34:26Now it needs to be refixed to the chassis and have the artwork panels added.
34:30Ah, look at that.
34:31Now that is 100% magnificent.
34:36Beautiful.
34:37Lovely.
34:38It does look great.
34:40It does, doesn't it?
34:41It does.
34:42Come on, let's get it out of here.
34:43I'll supervise, right?
34:44Come on then.
34:45Okay.
34:46Up.
34:47Right.
34:48We're going to need to spin it, so we need to rotate you guys round.
34:50Okay.
34:51Here we go.
34:52Yes.
34:53Careful.
34:54Like a Russian synchronised swimming team.
34:56This is wonderful.
34:57Look at this.
34:58Right.
34:59Right, there we go.
35:00Brad, you're going to have to straddle this.
35:02Oh, hold on.
35:03Ooh.
35:04There we go.
35:05Gosh, that was a bit close.
35:10There we go.
35:11Come on.
35:12Nearly there.
35:13Nearly there.
35:14A round of applause for the first time the Shell has seen the body.
35:17Yay!
35:18Yes!
35:19And the first time we can see it for real.
35:20Look at that.
35:21That looks absolutely great.
35:23Down on the air ride, it looks absolutely fantastic slam.
35:27Look, we've got the steering's put on, the nose cones put on, get the frame fixed on.
35:31We're nearly there.
35:32This is the home straight.
35:33But nearly is not going to cut it on this occasion because with the big reveal set for
35:38tomorrow, it'll be another late night in the workshop to get Paul's RAF themed Pride and Joy
35:44ready to return to him.
35:50It's chocks away and clear for take off for Operation Doom Buggy Return.
35:56And where better to hand back Paul's Pride and Joy than the plainly brilliant Yorkshire Air Museum.
36:03Oh, what do you say to that car for us?
36:09Well, doesn't it look absolutely amazing?
36:11For the first time out in the daylight, it looks great.
36:14The whole package all themes in nicely, but it's the attention to detail.
36:18That's right, yeah.
36:19Paul's service number on there.
36:20And also on the sides, you've got dot, dot, dot, dash, dash, dash, dot, dot, dot, SOS.
36:25This is a work of art.
36:28But what's the plan?
36:29Right.
36:30Paul is coming down here today for a bit of a behind the scenes tour of this place.
36:33Yeah.
36:34Bit of a treat.
36:35But he's going to bump into a load of guys over there with these huge model aircraft,
36:39which are radio controlled.
36:40Okay.
36:42Yes, there's not going to be any winging it today.
36:45The plan's been drawn up with military precision.
36:49Outside the hangar, the model aircraft aces are ready to act as a diversion
36:53to get Paul into position for the reveal.
36:55Fuzz, the buggy, and family and friends are maneuvered into position inside the hangar.
37:02And right on schedule, Paul is inbound on final approach.
37:06Are you expecting a tour?
37:08Yes.
37:09Oh, then there we go, I think, yeah.
37:10So how far have you come today?
37:13Driftfield.
37:14Oh, that's all right.
37:15Blancaster's did the Dambusters raid.
37:20They're like famous.
37:21Time for Tim to get in position.
37:24That's him dressed as a pilot, apparently.
37:27Looks more like Darth Vader to me.
37:30This is the moment we've all been waiting for.
37:32Paul is at the museum.
37:34So we just need to wait until he gets to just the other side of that hangar door.
37:41Once he gets there, all I'm waiting for is for Tim to come in here, give me the signal.
37:46I start this up, Tim goes back around, goes behind Paul, ready to catch him when his car comes out.
37:53In fact, when you come out of admissions, there was a black hurricane.
37:57It's actually a...
37:58It's a dummy.
37:59So everything's off to a flying start and Paul hasn't suspected a thing.
38:03It's here, there.
38:05So it's game on, right?
38:06Right, in the car, rev it like a pilot.
38:23Really?
38:26Hello, mate.
38:27Hello, fella.
38:28How you doing?
38:29You all right?
38:30I'm good, yeah.
38:31I'm...
38:32Yeah, you've got me.
38:33Have I got you?
38:35All right, Paul, how you doing?
38:37I'm all right, fella.
38:38I've been outside your house before, listening to you.
38:40Have you?
38:41When that was picked up, I know all...
38:43Hopefully, hopefully we got it all right.
38:45If you're struggling to work out what's happening, there are also a few people here that you might know.
38:50Can we bring out Paul's family, please?
38:52All of this, everything that is going on here is all just a big scam.
39:01It's a big ruse just to get your beach buggy back.
39:05Emma, come here.
39:06Come on.
39:07Love you, Dad.
39:08Slipkin.
39:09Can we have a round of applause for that, please?
39:18Right, I did it!
39:22Yeah.
39:25Steve.
39:26You all right?
39:27Yeah, yeah, I'm fine.
39:28By me.
39:29I mean, it's very nice and, er...
39:34Yeah.
39:35It's not you, because everybody here loves you.
39:38Because you're a wonderful guy, you're a wonderful father-in-law, you're a wonderful father, and you put everybody else first.
39:44The reason we've done this is because you matter.
39:47So that's what that means.
39:51No?
39:52Yeah.
39:53Okay, good.
39:54Bye.
39:55Have a look round it then, will you?
39:56Go on, shoot.
39:57Get outta here.
39:58Go on.
40:00With Paul's retirement dream to build his dune buggy on hold, it was destined to a life of decay.
40:09Now, however, it's been totally transformed.
40:12The faded fiberglass body now honors his RAF past, thanks to Isaac's design.
40:23The rusted old engine's been replaced with a bigger capacity block, uprated pistons and carburetters, and a new exhaust providing an adrenaline-fueled 60% boost in power.
40:34New front disc brakes, ergonomic seats, and some ultrawide rubber will ensure it's comfortable no matter what surface it's thrown at.
40:43And finally, the ingenious air suspension system means that Paul should have no trouble getting in or out when he hits the beach.
40:54Get in and see how that does for you.
40:57These are all of your activators for the air ride, you know, if you want to go down.
41:04I hope you get in, and then, of course, once you start up, it'll...
41:07It picks itself back up again.
41:08Yeah.
41:12How's it feel?
41:15Absolutely brilliant.
41:16Does it?
41:17Yeah.
41:18Yeah.
41:19Really good.
41:20So what does this car mean to you?
41:21What does it represent, or what did it represent when you used to walk past it and it wasn't getting done?
41:28Oh, it was just soul-destroying.
41:31Absolutely soul-destroying.
41:32Because when I had the chance and retired, going to spend a bit of time doing the car up...
41:42Your wife?
41:43My wife, yeah.
41:44Diagnosed?
41:45Diagnosed with dementia.
41:46That's it.
41:47Everybody comes first.
41:49You said to me earlier on, why me?
41:52Explain that.
41:53Because things don't happen to me, usually, like this.
41:58So you've spent your life helping other people, and it's just one-way traffic, generally?
42:02Yeah.
42:03And you're fine with that?
42:04Oh, yeah.
42:05Yeah, I'm fine with it.
42:06I've got three kids, four grandchildren, and they come first.
42:11That gives me happiness.
42:13So for something to be done for you now, that's a new emotion?
42:16Oh, yeah, without a doubt.
42:18Lifelong?
42:19Lifelong.
42:20Never forget it.
42:21And the way it's been done, amazing.
42:23Absolutely amazing.
42:25And especially a tribute to all the armed forces.
42:29You can say no more.
42:30Okay, well, there's only one thing left to do.
42:32And that is to tell you that you've been Car SOS and handed the keys over.
42:36And thank you for your service.
42:38Thank you very much.
42:39Enjoy your car.
42:44Right, Paul.
42:45This is it, mate.
42:46How does it feel to be sitting in your beach bugger?
42:49Amazing.
42:50One of the best days of my life.
42:52Right, would anyone like to hear, Paul, start the beach buggy?
42:55Yeah!
42:56Come on, then!
42:57Hooray!
43:00Get it going and get out of here!
43:01Hooray!
43:03Yeah!
43:06That was a good one, wasn't it?
43:08What have you done?
43:09I've made a mistake.
43:10What do you mean you've made a mistake?
43:12A life-long mistake, but I don't want to talk about it.
43:15What are you on about?