Car SOSSeason 13 Episode 5
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00:00Absolutely amazing.
00:01The boys make a shocking discovery about this Land Rover discovery.
00:05I thought that might be some burnt-out wiring, but it's okay.
00:09It's just a plant.
00:11And that's not all that's being unearthed.
00:13This feels like we've discovered something, an archaeological dig.
00:17So can they take this rusty wreck from field...
00:20That there is the carpet.
00:22...to finery.
00:24You're witnessing a miracle here.
00:26And with a little help from Britain's most famous farmer.
00:29Is this the first time you've ever travelled with a body in the back?
00:32Nope.
00:33Move its owner to tears.
00:55Right, Fozbot, Newmarket.
00:57Is this Cambridge around here?
00:59Yes, it is indeed.
01:00Anyway, listen.
01:01I'm going to make a very bold claim about this car that you might not like.
01:04But anyway, the car, first of all, is a Land Rover Discovery Series 1.
01:10I love these cars.
01:12I think this is the car that saved the company, that saved Land Rover itself.
01:18What?
01:19Really?
01:20Yeah.
01:21What?
01:22You reckon?
01:23Is that a real fact?
01:24Well...
01:25Or is that a Timmy fact?
01:26Well, it's a Timmy fact at the moment, but I think it's going to become a real fact.
01:27Yeah?
01:28Yes, he might actually have a point.
01:34Today, Land Rovers may be driven by everyone from the couple next door to Spice Girls and famous farmers.
01:41But 40 years ago, things were very different.
01:45Back then, a top-end Range Rover Classic cost about half the price of the average house.
01:50At the other end of the market were the forerunners for the Defender, perfect for chasing sheep up a Welsh valley.
01:57But a lack of creature comforts, speed and a turning circle on a par with a supertanker meant they weren't so great for the school run.
02:06And this is where Land Rover missed an opportunity that the Japanese manufacturers didn't.
02:12In the mid-1980s, they flooded the market with affordable, well-built, family-friendly 4x4s that flew off the forecourts.
02:21In a desperate bid to compete, the discovery was rapidly conceived.
02:27It offered a blend of family-friendly design and farmyard ruggedness.
02:33Underneath, it was as tough as a Defender.
02:36Inside, as well-built as a Range Rover, but importantly, cost £10,000 less.
02:42To date, over 1.2 million have been sold, making it Land Rover's most popular model of all time.
02:51Right, today we're going to go and meet Kate, right? Now, the car is owned by her son, James.
02:55Yeah?
02:56But it was passed down to James by her husband, his dad, Jim.
03:00OK.
03:01So, sad thing that Jim is no longer around anymore.
03:03Oh, right, OK.
03:04But the car has been stored, this is the bit you're not going to like, outside, in a field, for years.
03:10Have you got a dustpan and brush?
03:11Yeah, I think we'll need a big one.
03:13LAUGHTER
03:19Hello, lovely to meet you, I'm Kate.
03:20Nice to meet you, Tim.
03:21Hi, I'm Buzz, how are you doing?
03:22Right, what's this fancy place?
03:24This is our friend's farm.
03:26His name's John, he's looked after the car for five years now.
03:28OK.
03:29Two weeks he should have had it for.
03:30Right, OK.
03:31But now, we're five years.
03:33Where's James?
03:34He is working three hours away, thank goodness.
03:37Right, OK.
03:38We're in the clear.
03:39Right.
03:40Don't take us the wrong way.
03:41What's going on with that horrible sandwich bag?
03:43Don't you know what it is?
03:45That is a Terence Conran-designed bag that goes with the Land Rover Discovery Series One
03:50with the Terence Conran interior.
03:51There's the stuff.
03:52Can I take a look?
03:53Come on, let's go and have a chat about James.
03:55That this has survived is absolutely amazing.
04:02Because you can imagine what happens when your farmer takes possession of their brand-new Discovery One.
04:09That's right.
04:10Off it goes.
04:12Never to be seen again.
04:14It's survived.
04:16And so has the car.
04:18But only just from what I can see.
04:21Because look.
04:22What we have here is a missing wing and beneath it galloping rot.
04:29So it's rotted out here.
04:31It's rotted out the other seams here.
04:33That there is the carpet.
04:36That's all that's keeping all the rain from getting in.
04:40And then, have a look down here.
04:43I'm telling you, that shouldn't do that.
04:48The bodywork should be solidly mounted.
04:52Where the body mounts onto the chassis, it has completely gone.
04:58Interior.
05:06What do you do as a family?
05:07Builders.
05:08Right, okay.
05:09Yeah.
05:10Your son, Jim.
05:11Builder.
05:12Your son, James.
05:13Builder.
05:14And the purpose of the car was what?
05:16Meant to be a family car and never did.
05:18Because he filled it with tools and it became the workhorse.
05:21Every single day they went to work in that car.
05:24With their cups of coffee and their bowls of cereal.
05:27And their plans for wherever they were going for the day.
05:29Yeah.
05:30And for James, the car is better than any photograph of his dad.
05:33Because that car is his dad.
05:36They argued, they slept in it, they ate in it.
05:39It's just been a brilliant car.
05:42And it's a family friend.
05:43It's Jim.
05:44That car's Jim.
05:45Right.
05:46For the moment of truth.
05:51Now, what's that there?
05:54Oh.
05:55I thought that might be some burnt out wiring.
06:00But it's okay.
06:01It's just a plant that's grown through the engine bay.
06:04Now, this is the 200 TDI engine, which is a really great engine.
06:09They last for absolutely ages.
06:11They're reliable.
06:12And so long as they're regularly serviced, they are a great beast.
06:16But at 165,000 miles, I'd be expecting something to go bang or wear out pretty quickly now.
06:25So I think what we're going to have to do is take the engine out and fully inspect it.
06:30This wheel arch has rotted away on this side.
06:33So again, galloping body corrosion.
06:36I think we may have got to this car in just the nick of time.
06:42Another winter out here, I think it would have been done for.
06:46What happened to Jim?
06:50He became jaundiced.
06:54And then James took him to the hospital.
06:57And they diagnosed him with liver cancer.
07:01And they gave him a year to live, but he actually did last three.
07:04How did Jim respond to being told those flooring words?
07:10Very stoic, really.
07:12He just, yeah.
07:13He just accepted it, but worked.
07:15Still went to work, sick as anything.
07:18And then James took over.
07:19He just worked, and he's never stopped.
07:21He works six days a week.
07:23When you're self-employed, you can't take time off to do things like that car.
07:28So are we going to have a problem getting him away from that to go somewhere,
07:31to give him his car back?
07:33Yes, absolutely.
07:34What's he into?
07:35What would be something he'd go, OK, I'll go there, I'll do that.
07:38Does he watch any TV shows?
07:39He loves the Grand Tour.
07:40Jeremy Clarkson.
07:41He loves Clarkson.
07:42I feel like I've heard of that guy.
07:44Yeah.
07:45Well, we're going to do it, and we're going to do it in exactly the way that it was all
07:49those years ago, when he used to be in it as a young lad with his dad.
07:52Fabulous.
07:53So excited.
07:55No worries.
07:56All right, give us a kiss.
08:01How is it looking?
08:03It's terrible.
08:04This thing needs a lot of work.
08:06When I tell you the story of what this car means to the family, you won't believe it.
08:09What?
08:10Seriously.
08:11This car is more important than any photo that James, who now owns it, has of his father.
08:19Yes, this car is such a beloved member of the family that the boys not only have to save it from becoming a pile of dust, they also have to do it without removing Jim's spirit from within.
08:31Let's go.
08:32OK.
08:35It's probably the most rotten discovery that I've ever, ever come across.
08:41Yes, the boys are going to have to dig deep on this one if they're to unearth the memories behind the rust.
08:48So they've called in a favour from the Land Rover experts at Brit Park, who are giving over the specialist tools, workshop space and parts they're going to need to pull this discovery back from the brink of extinction.
09:01Yeah.
09:02Right, just a little bit further, a little bit further, a little bit more.
09:05That's, come on, keep going, keep going, keep going, keep going, keep going, that'll do.
09:09Are there?
09:10Yep.
09:12Try opening the door.
09:13OK.
09:19What have you done there?
09:21It's just literally just collapsed when I was opening the door.
09:25Look at the state of it, Fuzzbot.
09:27Yeah, I know.
09:28Come on then.
09:30It's just falling to pieces, like literally.
09:31At least don't break any more off it.
09:39Oh, no.
09:40Oh.
09:41Wow.
09:42Oh.
09:43This feels like we've discovered something, an archaeological dig.
09:46Look, we've got the forward rear body mounts here.
09:49Look, this one, can you see what that's attached to?
09:52That was supposed to be attached to a sill.
09:54That's right.
09:55Yeah, so where's the sill?
09:56It's gone.
09:57There's a big problem here, because what we need to do, really, is to lift the body off.
10:03Because if we lift the body off, we can get to all the mechanical items.
10:06But, to lift the body, we need to repair the body first.
10:10So it doesn't collapse.
10:11Yeah, because otherwise it will collapse like a deck of cards in the wind.
10:15So we need to do repairs to the repairs to be able to access the other repairs.
10:20Yeah.
10:25Tim and Fuzz have got their hands full with the car that saved Land Rover.
10:30They've just made some alarming discoveries about this much-loved 30-year-old Mark 1 Discovery.
10:36Do you know what happens with me and you?
10:38We, when it's so bad, I've noticed this thing.
10:41When things are so, so bad, we just start finding it funny.
10:44That's right.
10:45Because it's like it's somebody else's problem.
10:46Laughing in the face of adversity.
10:49But there's not much funny about what lies ahead,
10:52because James's discovery is not only riddled with holes,
10:56it's also packed full of memories of his dad, Jim.
11:00So, retaining the originality is key.
11:04Starting with rescuing the rust-ridden body shell.
11:07If the boys attempt to lift it now, there's a good chance it will crumble
11:11like a cheap biscuit in a hot cup of tea.
11:14So, it'll need to be strengthened before work can start on the chassis and suspension setup underneath.
11:20The 200 TDI engine and gearbox haven't been run for more than five years.
11:26So, when Dr. Fuzz opens it up, will it be keyhole surgery or a full-blown transplant?
11:32Finally, the exterior plastics are cracked and brittle from years of exposure to the elements.
11:38So, will either need to be repaired or replaced.
11:41It's also going to need a full interior clean and fresh paint job.
11:48This may be the car that saved Land Rover, but can the boys save this Land Rover?
11:53Or have they bitten off more than they can chew?
11:571989, Frankfurt Motor Show, the discovery was unveiled.
12:02Yep.
12:03It went on to become the best-selling 4x4 in Europe.
12:08And a lot of it came down to one man called Mike Sampson.
12:14And he designed that car.
12:16Yeah.
12:17And he changed the world forever.
12:18And he is the reason, in my mind, that Land Rover, the company, still exists.
12:23It would be great to meet him.
12:24I tell you what though, if you do find him, can you see if he's got any sills?
12:27Yeah.
12:28Yes, with the old ones reduced to compost, it's definitely going to need some new sills.
12:36But if Dr Fuzz can't resuscitate the original 2.5 litre turbocharged diesel engine,
12:41the boys are going to be facing a much bigger problem.
12:45I've got a power pack and a power probe here.
12:50The power pack will take the place of the flat battery,
12:53while the power probe will do the job of the starter motor.
12:56Now, I reckon these 200 TDI engines are so phenomenal that I reckon this thing will start up,
13:04or at least it will have a go.
13:06It's worth a try anyway.
13:09This engine is legendary thanks to its robust construction and durability,
13:14even after hundreds of thousands of miles.
13:17That and its low-end grunt, which is perfect for off-roading,
13:21and the 30-mile-per-gallon fuel economy.
13:24But after five years cultivating in a field, surely this is pushing it, Fuzz?
13:30Repress and hope that it's going to go.
13:34Look at that. Absolutely amazing.
13:44There's no loads of smoke or anything.
13:46No fuss, no mess. It just started up.
13:51Now, that is what I call an absolute brilliant piece of engineering.
13:59We've got a real bit of positivity right at the start of this project,
14:02and that's exactly what we needed.
14:04However, with 165,000 miles on the clock, both the engine and the gearbox will still need a thorough check-up,
14:14before they can tackle any treacherous terrain.
14:17And unfortunately, it looks like fixing up the rest of the car won't be as straightforward.
14:24With 80% of the body shell rustier than the Titanic's propeller,
14:29the team need to remove the rot before they can lift it away from the chassis.
14:33So, while they get on with that, Tim's on a voyage of discovery.
14:39Right, now, don't ask me how I've got this, but I think we have Mike Sampson's address.
14:45Yes, he's meeting the Oracle himself to find out how his design for the discovery made Land Rover's fortunes bloom.
14:54It's said that it's the discovery, your baby, that saved the company Land Rover.
15:02I guess there is a little bit of truth in that.
15:05Anyway, come in and we'll have a chat about it.
15:08Come on, then. Excellent.
15:11Wow.
15:24So, can we go from the beginning?
15:27Where did it all start for you?
15:29Well, I guess it started in the way that Land Rover saw a gap in the market.
15:35Range Rover was going ever more up market.
15:39And I think we were seeing a lot of the competition arriving in the marketplace.
15:45Mitsubishi with the Shogun and...
15:47Land Cruisers?
15:48Of course, yeah. All that sort of stuff, yeah.
15:49And something had to be done.
15:51Were Land Rover, were they communicating how much trouble they were in at the time?
15:55We knew finances were tight.
15:57And there was a lot of other things that went on behind the scenes.
16:01And because the budget was very, very tight,
16:04it was decided to use the Range Rover Classic as a basis for this new vehicle.
16:10So the chassis, the running gear, all that sort of stuff was the starting point.
16:13And pretty much a lot of the body work as well.
16:16Because we were so limited on cost and budget, we had to use a lot of carryover components.
16:24Not just from Range Rover, but from other parts within Austin Rover.
16:30Things like the tail lights, which came, as you probably know, from the Maestro van.
16:36Yeah.
16:37I look upon that as a sort of happy accident.
16:41Because it actually fits the vehicle very, very well.
16:45And it gave us this character of the Shamford rear quarter.
16:49Yeah.
16:50Which has become part of Discovery language.
16:52It was proposed or thought that we probably wouldn't make more than about 300 vehicles a week.
16:58Right.
16:59How many did you end up getting made a week?
17:02Well, I know that within a very few weeks of production started, we were up to about 1,900.
17:08And it just grew from there.
17:11Why do you think it is, Mike, that this car did so well?
17:16I think it was all things to all men.
17:18It was smart enough to go out in the evening.
17:22But in the day, you could put the dogs in the back.
17:24You could put hay bales in the back.
17:26You could take, you know, the whole family somewhere with it.
17:29Um, and it had a freshness about it.
17:38So, it turns out the Discovery's stringent development budget, a raid in the parts bin,
17:44and some ingenious design are what saved Land Rover.
17:48But is Fuzz going to be able to save the shell of James' Land Rover?
17:53The team have stripped it down so that everything is rust free.
17:57The trouble is, they've had to remove so much rotten metal, it's now as flimsy as a jellyfish's handshake.
18:03What we have to do is make the body structurally sound.
18:08We've got to be able to lift the body off without it collapsing, folding and wobbling around.
18:14It needs to remain in three dimensions, really. That's what it is.
18:19But we're nowhere near getting the body away from the chassis.
18:23And we need to do that so that we can work on both of those assemblies at the same time.
18:28Because that's the only way we're going to hit the ground running and get this done in time.
18:32So, the next step for Fuzz is to weld in new metal to give the shell its strength back.
18:39Now, we can start building up our side section here.
18:44Because at the moment this is a little bit wobbly and flappy still.
18:48So, the next section that we're going to put in is the wheel arches.
18:53So, we've got this folded section here, this section here and then this flat piece here.
19:00Then, we can offer these in to this space here.
19:05This section of new metal will give the shell's inner wheel arch its structural integrity.
19:11An outer body panel will then go on top to give this car its iconic shape.
19:16To join the new wheel arch to the car, it needs to be welded into place for strength.
19:23This is our spot welder.
19:25These electrodes go down and they clamp on to the pieces that are going to be welded.
19:31At which point, electricity passes through them and creates heat, fusing the two pieces of metal together.
19:40Now, I've got a couple of bits of old scrap here, which I can test out.
19:46Clamp together.
19:47There we go.
19:52Absolutely rock solid.
19:55Spot welding is probably the one piece of automotive construction that made cars more affordable and so affordable that we have all been able to get on the roads with it.
20:07It's a brilliant piece of construction.
20:15First of all, if this goes wrong, it's all gone wrong.
20:18But for all its brilliance, spot welding does have drawbacks.
20:28With the engine blocking access to the back of the panel, Fuzz can't get his jaws into position.
20:34So, it's time to go full flash dance and finish it off with some plug welds.
20:39Plug weld is something that we do to imitate a spot weld.
20:45It's individual small welds, but done in a different way.
20:50And that then allows us to get in there where we cannot reach with a normal spot welder, which requires a lot of access.
20:58So, that's our wheel arch back in place, restoring much needed structural integrity to this Land Rover Discovery.
21:12A few more little bits and then we'll be able to lift the body off.
21:15Tim and Fuzz are restoring this 1994 Mark 1 Land Rover Discovery that spent the last five years discovering a corner of a farmer's field.
21:34It belongs to 39-year-old James, who along with his dad, Jim, used it as a workhorse for their building firm for 20 years.
21:47However, after mechanical faults took it off the road and Jim tragically passed away, James has had to take on running the family business,
21:55putting his plans of restoring this family heirloom firmly on hold.
22:00He just worked and he's never stopped. He works six days a week.
22:04When you're self-employed, you can't take time off to do things like that car.
22:13This is one of the biggest renovations the team has ever taken on.
22:18They've already put in nearly 200 hours of work and they're barely halfway through.
22:23They're finally ready to separate the body from the chassis.
22:27So, have they done enough for the shell to survive the lift in one piece?
22:33With the shell safely lifted, the team can tackle the chassis and suspension.
22:49Just like the shell, they're rusty and rotten.
22:52So, the spine will need to be blasted and repainted with what can't be saved from the suspension setup and running gear replaced with new parts.
23:02The engine and gearbox also need to be serviced.
23:05And someone still needs to bag that famous farmer.
23:08So, while the team press on with yet another mountain of work.
23:15How did you manage to do this?
23:17How did you manage to find the oldest existing Land Rover Discovery?
23:21Tim and Fuzz are grabbing their wellies and getting behind the wheel of one of the only remaining prototypes of the car that saved Land Rover.
23:30Friends in high places, Fuzzbot, that you'll never make. This is a coup, isn't it?
23:36Oh, this is absolutely amazing. I cannot believe it. And to feel where it all started.
23:42What I love about this is it was shrouded in secrecy. So, the world didn't know about these vehicles until 1989.
23:52Yeah.
23:53But this thing was out in 1987.
23:55Yeah.
23:56But this car was actually used in different climates to test it, to see, we need to see if this car works there.
24:03Whereas nowadays, you'd put a car on a rig and simulate that sort of off-road testing.
24:08Back in these days, you took it to Canada. You took it to Australia. You made it suffer hell to see if it lived and survived.
24:14And this one did and does.
24:16Yeah, it still does. And it feels taught. And it feels like it could even be new.
24:22Can you imagine being part of the team? Because now I'm driving this for the first time.
24:27Yeah.
24:28And I'm just going...
24:31We nailed it!
24:33This is... The company's going to be safe. It's going to be alright. It's going to be alright.
24:42What does it feel like to drive it then? Talk to me about it, baby.
24:45This is not like driving a 40-year-old vehicle. It really isn't.
24:51But this car is quiet. It's comfortable. It's well-mannered.
24:56This field is absolutely sopping wet. Yeah. Waterlogged. And this is just romping through.
25:03I could be here in my evening frock. Yeah.
25:06And I'd be absolutely fine. Yeah. And so is your wife and five kids behind you. Yeah.
25:10You can use this to go out to a fine dining, but you can also do what we're doing with it.
25:17Yeah. Use it as a tractor. Compared to a Range Rover, I just think that this has a lot more accessibility.
25:26In a way, it's said to people, everybody can own this. Yeah.
25:30The Range Rover said, no, sorry, you can't come in. Your name's not on the list.
25:35It works for all types of people, from all social strata. It's just absolutely on the money.
25:52Something else that's on the money is the body of James' discovery.
25:55Now it's finally been separated from the chassis, the team have been able to fill, flatten and prime it.
26:02Ready for a coat of original matching Air Force blue paint.
26:06To finish it off, it's going to need its original plastic exterior trim.
26:11But there's a problem with that.
26:13All this stuff is mega brittle, like this thing here.
26:16If I even touched it hard there, it would just punch through again.
26:19Yes, it might take hundreds of years to decompose completely, but plastic does start to degrade a lot faster than that.
26:28Decades of exposure to UV radiation, water and changing air temperatures has caused the chemical bonds within the plastic to break down, leading to the brittleness.
26:38Sourcing an entire set of exterior trim parts would take an age. Thankfully, Tim thinks he's found a quicker solution to repair them using toys.
26:48I'm going to reinforce all these pieces of plastic here with Lego.
26:53And Fuzzy's lunch.
26:56There are two key differences in the main sorts of plastic. There's a plastic called thermosetting plastic.
27:02And actually, I can use an egg to demonstrate.
27:06The thing about an egg is that once you heat it up, it becomes a fried egg and you cannot reverse it back into being, you know, a runny white and a runny yolk.
27:14That's the way it is. And that is what a thermosetting plastic is.
27:19The other one, the other plastic, is called a thermopolymer.
27:23These plastics, when heated, become soft again and can be reformed.
27:28Meaning that the contents of that box, despite the way it looks now, can be reformed to reinforce the areas around the back of such components as those brittle headlights surround.
27:39So, in order to do it, according to the science, you need this stuff, which is acetone, which is nail polish remover.
27:49For Lego fans, it's probably best to look away now. And definitely don't try us at home.
27:56So, acetone basically breaks down the molecular bonds of the thermoplastics.
28:01OK, I'm going to put those down there. And in two hours time from now, hopefully that will be a pace that we can reform to reinforce parts of Land Rover Discovery.
28:19So, while children up and down the country hide their Lego sets, the team has a new toy of its own.
28:29The chassis has been blasted and repainted, ready for a new set of coil springs to be fitted.
28:35One of the key components that gave this vehicle the edge over the inferior Japanese leaf springs.
28:40And a Discovery isn't a Discovery without its permanent four-wheel drive gearbox.
28:48And this one hasn't moved in five years. It's long overdue a service.
28:52Here we have the gearbox out of James's Discovery.
29:00Now, we've had a Discovery of our own here.
29:03And that is that this is not the original gearbox from the car.
29:07Meaning that it's likely to have come out of a Land Rover Classic.
29:12Swapping out the original gearbox was a common occurrence.
29:15Spare Range Rover parts were cheaper, easier to come by and also improve the Discovery's off-road capability.
29:24Unfortunately, this upgrade came at a cost.
29:27Now, what happened when these gearboxes were fitted into Discovery's was that an unexpected occurrence happened.
29:37And that was that they started to fail.
29:40Now, when that happened, it meant that the whole of the gearbox needed to be rebuilt.
29:49So, to see if it can be saved, Fuzz starts by stripping it down.
29:58There we go. There's one bit.
30:00Turn the gasket off.
30:02Ah, yeah. There we go.
30:04Now, I'll just check.
30:10So, looking down here, if there was wear, you would see that the edges of the spline would be slightly worn to an angle.
30:19Instead of being nice and sharp as they are now.
30:23And also, they would not be smooth all the way along the line inside.
30:27Because of all the problems that Land Rover had with these gearboxes, they did a modification.
30:33And that was to put in these holes, this cross-drilling here, which allowed oil to get through and onto these splines in here, which allowed lubrication.
30:46And that solved the problem.
30:47This one has already been modified.
30:50So, I don't think that we need to replace the whole gearbox on this.
31:00So, you can see what's happening there.
31:03Already, look at that.
31:04It's melting the plastics.
31:05This is such a bizarre thing to see.
31:08That is liquid plastic in there.
31:11It is a bit of a race against time.
31:14I mean, you can see, look at the consistency of it.
31:18And all the time that acetone is evaporating, this is becoming thicker and thicker.
31:25So, I'm literally going to just start applying this to this area here to begin with.
31:35This is massively going to reinforce this.
31:37It's going to be three or four times as thick as it was.
31:42So, overlook the colour, because the colour is irrelevant.
31:44It's never going to get seen.
31:46It doesn't matter.
31:47All that matters is the strength.
31:51You're witnessing a miracle here.
31:52You really are.
31:53That is self-leveling, plastic-reinforced, rear-end parts of a discovery.
32:00That, now, is a game-changer.
32:02Yes, whilst Tim gives himself a pat on the back, Dr Fuzz is giving James' engine a thorough health check before it's reunited with the gearbox.
32:15We've already started this engine up, so we know that it runs, and it runs without rattles or smoke.
32:20So, what we're going to do is do a service on it.
32:23So, we're going to change the cam belt.
32:24We're going to change the water pump, and then it can go back into the car.
32:29There we go.
32:32There's our water pump away.
32:34Now, the cam belt should be changed roughly about every 50,000 to 60,000 miles.
32:45So, this engine has done about 150,000, 160,000 miles, so we're pretty much on cue for getting this changed.
32:54Off with our front plate.
32:59And there we have it.
33:02There's our cam belt.
33:04This engine is famously about as bulletproof as a tank.
33:09But because the off-road punishment the old cam belt will have experienced on the building site,
33:14it will have worked harder than the one in your average family runaround.
33:18Here we have our fresh built, all lovely.
33:22So, replacing it is essential.
33:27So, all I need to do now is box it all up by putting the front cover on and the new water pump.
33:33And then, that's our engine service done, apart from filters and oil.
33:39So, with just 24 hours before the boys hand James' car back to him,
33:43all the major mechanical work is finally done.
33:47I just wanted you to take a look at this chassis because this is amazing
33:53and we'll never, ever get to see it like this ever again
33:57because there's going to be an engine on there, gearbox and, of course, a body hiding everything.
34:03But look, new springs, the axles have all been refurbished.
34:08There's been so much work has had to go into this.
34:11It's like a brand new car.
34:17Now, it's a final sprint for the finish as the team brings this family heirloom back together.
34:23The original body and chassis are reunited.
34:27The old plastic trim, Tim reinforced, is fitted back on.
34:31The iconic cargo door is re-hung.
34:36And the cleaned-up Terence Conran interior is back in place.
34:41There it is. Job done. That'll go for another half century at least.
34:46This is perhaps one of only two cars that we've ever done on Car SOS that I would love to see in my garage tomorrow morning.
35:03It looks great.
35:04Dude, this is going to James tomorrow. It's his car.
35:06I know it is.
35:07We're lucky to get to work on them for us. You've got to look at it that way.
35:09Yeah.
35:10There's nothing we don't know about this car.
35:12Well, I mean, we've seen virtually every single bit of this car.
35:16Good, bad and ugly.
35:18So we're going to which, er, Clarkson?
35:21What?
35:22Clarkson.
35:24How do you know? What?
35:25Jeremy Clarkson?
35:26Yeah, I know what this is.
35:28What?
35:29You couldn't get him, could you?
35:30You tried to get Clarkson.
35:31You couldn't get him.
35:32There's somebody you couldn't get.
35:35No, I haven't been beaten.
35:36I know what you're on about.
35:37If you want Clarkson, I'll get Clarkson for you, no worries.
35:39Go on, then.
35:40Come on, then.
35:41No, don't worry about it.
35:42No, you don't want him.
35:43I do.
35:45Shut up.
35:46Anyway, I'm going to the back of the car.
35:47So, whilst Fuzz and the team work long into the night
35:51to get James' car finished for tomorrow's big reveal,
35:55Tim's got some awkward phone calls to make.
36:00After months of painstaking renovation,
36:03it's time for the boys to return James' beloved discovery to him.
36:09Doesn't it look absolutely stunning here in the sunshine
36:13in, I've got to say, well done getting this place.
36:19Yeah, somehow Tim's pulled it out of the bag at the 11th hour
36:22and managed to harvest James a trip to a very special farm.
36:26But has he got the farmer?
36:29Now, I know where we are, and I can see the number plate on there.
36:33I've got to admit, you've pulled it off.
36:35So, what is the plan?
36:36James is coming down here today
36:38because he's a huge fan of Jeremy's farming show.
36:40So am I.
36:41So he's coming down here for a behind-the-scenes tour.
36:44Fantastic.
36:45Which is a bit of a treat by itself.
36:46Yeah.
36:47And in a very certain moment in time...
36:48Yeah.
36:49...this car is going to get driven round the corner.
36:52Yes.
36:53Driven by the one and only...
36:55Yeah, Jeremy Clarkson.
36:57You've never met him before?
36:58No.
36:59You've never met him before?
37:00No.
37:01Today's going to be a big day for you, mate.
37:02Do you want to meet him now?
37:03Shall we bring him out?
37:04Yeah, go on, mate.
37:05Shall we? All right, go on then.
37:06Brilliant.
37:07I'll bring him out.
37:08Hello.
37:09Nice to meet you.
37:10It's Jerry Clarkson here.
37:11How are you doing?
37:12Tell me that's not...
37:13No, that's Jerry Clarkson.
37:14Same sort of height, same sort of build.
37:16You know, complexion, hair colour, the lot.
37:20So you hide with the family, then I'll drive this round
37:23and at the right moment in time, ta-da!
37:25We give him his car back.
37:26Oz?
37:27What's wrong with that?
37:28It's a great idea.
37:30We've got the farm.
37:31We've got the plate.
37:33Cows?
37:34Oh, so near yet so far, Tim.
37:40So, while a disappointed Fuzz and James' nearest and dearest hide in a barn,
37:46he's just arrived for his VIP tour, which means it's go time on the Discovery.
37:54Blimey!
37:55That mask looks very realistic.
37:59Right, here we go.
38:00I'm hiding in the back of Discovery.
38:03And Jeremy's driving out the moment.
38:06And in a moment, it's going to change for James.
38:11Because completely unbeknownst to him, he's about to get to meet his TV hero
38:16and fellow Land Rover superfan, Jeremy Clarkson.
38:20Is this the first time you've ever travelled with a body in the back?
38:23No.
38:25Who's driving around in what he's planning to tell James
38:28as his new farmyard 4x4 runaround?
38:31Hi there.
38:33How are you?
38:35Well, here we go. It's game on.
38:37I'm guessing...
38:39James, is it?
38:40I am, yeah.
38:41I'm Jeremy.
38:42How are you?
38:44Join the cows?
38:47You all right?
38:48Yeah.
38:49I recognise that car.
38:51I've just bought it.
38:53That's my dad's.
38:54What?
38:57Your dad's?
38:59Really?
39:02Yes.
39:03Even with the total transformation,
39:05somehow James has recognised this beloved Discovery as his dad's.
39:09Well, if you look in here...
39:12If you look in here, if you look...
39:15Come here.
39:16Hello, mate.
39:17How are you doing?
39:18You all right?
39:19Nice to meet you.
39:20I recognise that.
39:21Yeah, as soon as it came out of the corner.
39:22Really?
39:23You recognise you straight away.
39:24How's it feel?
39:25Amazing.
39:26Well, there are a few people here that I want to say hello as well.
39:29I think you might recognise.
39:30Can we bring out James' family, please?
39:32Yay.
39:33Yay!
39:34Yay!
39:35Yay!
39:40Yay!
39:42Yay!
39:43Come on!
39:48Yay!
39:49Yay!
39:50Yay!
39:51Yay!
39:52I know it's a lot to take on.
39:53Your life's just changed.
39:55So, Kate, can you explain why you wrote to us?
39:58Because you went to work in it for 20 years.
40:01I'm going to...
40:01Come on, people always run away.
40:03You argued in it, you made plans in it,
40:06you ate your lunches and breakfast in it,
40:07there were days when you didn't want to go to work in it.
40:10And then when Dad...
40:11The car sort of died a death when Dad was passing.
40:16And it's five years this month, as you know,
40:18and the car's back to life for you.
40:21Your mum said to me that you'd rather lose the photos of your dad
40:24than you would lose this car.
40:25And that's why we did it, that's why we put this car back on the road.
40:28But Jeremy only agreed to let us come down here and help us do this,
40:31if you help him with some groundwork.
40:35If we could just stop the blubbing,
40:37we have a serious problem up here, mate.
40:39You are a groundworker, because we've got the water coming down,
40:41we're trying to...
40:42We've dug a French drain in there to get it into that field.
40:46Can you help?
40:47Yeah, give me two weeks and four.
40:49No, no, no, no, no, we don't do two weeks.
40:53When James last saw this beloved family heirloom,
40:57it wasn't much more than a compost heap in the corner of a field.
41:02But after months of hard work from the boys,
41:04it's time to harvest the reward.
41:08Now the once rust-ridden body shell is stronger and shinier than ever,
41:13with reinforced plastic trim and handles that no longer snap at the slightest touch.
41:19The engine has had a super service
41:21and stands ready to tackle whatever terrain James throws its way.
41:26Underneath, the chassis has been stripped, blasted, repainted and fitted
41:30with an entirely new suspension set-up.
41:33Finally, the original interior has been cleaned and scrubbed,
41:37and for the first time in a few decades, doesn't resemble a building site.
41:42Tell me this, at what stage did you know that's my car?
41:49As soon as it came round the corner.
41:50Really?
41:51Yeah.
41:51I remember sitting in the back of this car at 10 years old when my dad bought it.
41:55Really?
41:55To then leaving school, going to work with my dad,
41:59and then this becoming our work vehicle.
42:01Yeah.
42:02And you've had quite a lot on you in the sense that it was unexpected, wasn't it, really,
42:06with your father, and then you've been given the family business.
42:09It's all on you.
42:10How's that been?
42:11It wasn't the side of the business I was struggling so much with.
42:14It was not going to work with my dad, because he was my best mate.
42:19There's not a moment that doesn't go past that I don't think about him.
42:22And now it's almost like he's next to me, and he's in this car.
42:28He's here now.
42:29There is one other thing.
42:32There's a guy who we managed to track down, a guy called Mike Sampson,
42:35who he and his team designed this car, and he created that for you.
42:41And that is your car, your dad's car.
42:44It's got the number plate on it.
42:46Wow.
42:46I wish my dad was here to see this.
42:49How are you feeling?
42:50Emotional.
42:53Really emotional.
42:54Well, there is only one thing left to do,
42:56and that is to give you the keys to your Land Rover
43:01and tell you that you have been Car SOS.
43:06I haven't started her up, yeah?
43:08Do you want to start her up?
43:09Yeah.
43:14There's the old sound.
43:16How does that feel?
43:16Like, I'm going to work again.
43:20And...