Car SOSSeason 13 Episode 6
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00:00Having an E46, a few photos for the family album.
00:03Can the boys take a dilapidated driveway relic?
00:07We have found beneath the surface cracks in the body shell.
00:11And turn it into an homage to the Ultimate M3.
00:15No, no, not okay, keep enjoying it.
00:20Using nothing more than Tim's weekly shop.
00:23Spark plug, a carrot.
00:25A Formula One favour.
00:27Is that what I think it is?
00:28And help from a comedy legend.
00:31Why are there no addicts in the jungle?
00:35To make its owner's automotive dreams come true.
00:41That's my car.
00:58Here we are in the beautiful Staffordshire Moorlands.
01:06I've never been here before.
01:08This is amazing.
01:08It's not big enough.
01:09What do you mean?
01:10It's not big enough to contain my excitement.
01:13I have planned for this day.
01:14Oh, I know, I know, it's written all over you.
01:18How many of these cars have you owned?
01:20Seven.
01:20Seven of them?
01:21Yeah.
01:21I mean, that's just not healthy.
01:23That's an obsession.
01:25Absolutely.
01:26And I couldn't care less what you think.
01:27Because today, we are picking up a very special car.
01:31But I've been waiting for this very moment in time to announce this car all my life.
01:37BMW M3 E46.
01:43Launched in the year 2000, the E46 is the third generation of 3 Series to emerge from BMW's top-secret motorsport division.
01:52Based on their championship-winning touring car, it's the automotive equivalent of Usain Bolt in a tuxedo.
02:01The ultimate blend of power and sophistication.
02:05A practical supercar that's as at home on the track as it is on the school run.
02:10Under the bonnet sits a 3.2-litre, naturally-aspirated power plant, producing over 340 horsepower, 50 more than the previous generation M3.
02:29Which means a sprint to 60 takes a shade over five seconds.
02:34Fast enough to give Porsche 911 owners a squeaky bottom at the lights.
02:3820 years ago, that thrill would have cost you the equivalent of £80,000.
02:45But today, a used E46 can be had for around 10.
02:53However, before you rush out to buy one, remember that after 20 years of working harder than a mosquito at a nudist colony,
03:01many of these cars are hiding worn-out components and potentially expensive repair bills.
03:08It is the best car that has ever been made.
03:12Absolute fact, as far as I'm concerned.
03:14Nobody will ever persuade me otherwise.
03:15You're wrong.
03:16No, I'm not wrong.
03:17Oh, you're so wrong.
03:18No, I'm not wrong.
03:19Didn't they have a problem with the rear floor area where the rear subframe mounts onto it?
03:25What about the BMW variable valve timer system?
03:30The Vanos system, and also, of course, engine problems as well.
03:34Whatever.
03:35I'm not talking to you about this anymore.
03:36We've got to go meet Amy, right, and Brent.
03:38OK.
03:39OK, so Amy is the partner of the guy who owns the car.
03:41Rick, yeah.
03:42It's called Rick.
03:43So are we off to Amy and Rick's place?
03:44No, we're not, actually, because the car has been stolen away by Brent, who is Rick's brother.
03:49OK.
03:50Too many car SOS found where Rick and Amy lived.
03:52OK, fantastic.
03:52Cool.
03:53Avoiding the twitching curtains.
03:55Yep.
04:01Right, come on, now, remember, keep it on the down low.
04:03Nice and calm.
04:05Keep calm.
04:05Look at that.
04:10Hiya.
04:11How are you doing?
04:11How are you?
04:12Mr. Brent on Fuzz, how's it going?
04:15Hi, you're Mr. Amy.
04:16Amy.
04:16Oh, Brent.
04:17How are you going?
04:17How are you doing?
04:18How are you?
04:18How are you?
04:19How are you doing?
04:20Right, OK, first and foremost, have we got the car here without Rick being SOS?
04:24He thinks it's going into a unit down the road here in storage.
04:28Oh, OK.
04:28Yeah.
04:29So we've got the green light?
04:30Yes.
04:30Excellent.
04:31Right, you guys, look around the car.
04:33Let's get it loaded up and out of here.
04:34We're just going to talk about your boys.
04:35Let's do it.
04:36OK.
04:43Look, we've got a complete and standard engine bay here.
04:48Now, to me, that puzzles me.
04:52Why has this car not been being driven?
04:54Well, it's been off a road for a while and it don't run properly, so...
04:57Right, so it's got an engine fault?
04:59Yeah.
05:00Well, how long has it been off the road?
05:012015.
05:02Really?
05:03Yeah.
05:03Oh, right, OK.
05:04How many miles has it done?
05:06110,000 miles.
05:08It's an old car that has been sitting around.
05:11It looks great, but underneath it, there's a proper old rotter, I reckon.
05:16What kind of guy is Rick?
05:19Oh, he's a great guy.
05:20He's a really good dad, he's a good boyfriend.
05:24Is he a car guy?
05:25Yeah, he loves his cars.
05:26I want to know what that car means to him, because it's a very, very special car.
05:30Oh, it means absolutely everything to him.
05:32How long has he had it?
05:35Maybe 14 years.
05:36He had it before we got together.
05:38How long have you been together?
05:3813.
05:39Right, so, hang on, it was the car that helped, did it?
05:41It took me out.
05:42Did it take you out in it?
05:43Yeah, he used to pick me up on a Wednesday night.
05:45Oh, is that good times, good memories?
05:47Definitely, yeah.
05:48What I do worry about is the rear subframe underneath here and the floor where it all attaches,
05:54because that all cracks and it's a known fault area.
05:58If this one hasn't been modified or upgraded, then we're going to have to do all of that work on it as well.
06:04I can't help but think that it might be hiding stuff.
06:07We've got corrosion, we've got engine problems.
06:11There's potentially, we've got rear cracks where the subframe mounts and stuff like that.
06:16So, there could actually be a lot of work waiting to burst out of this car.
06:21Right, should we start by getting it loaded up?
06:23Yeah.
06:24Well then.
06:28Why is the car in the state it's in for a guy who clearly knows what that car is and it means a lot to him?
06:35I think there's a few problems with it.
06:37What were the problems?
06:39Conrods.
06:40Sweet.
06:41Buried deep inside the engine, connecting the pistons to the crank, the Conrods.
06:44There's a problem with them.
06:45Anything else you need to drop on me?
06:47Vanos.
06:48Vanos.
06:49No, yes, that's right.
06:50It's called Vanos.
06:51It's a variable valve timing system.
06:53Also, money as well.
06:55It's very expensive for all the BMW parts.
06:59Is that the reason why it stayed off the road?
07:02It's had quite a tough few years, actually, because it got quite poorly.
07:06How did that start?
07:07He actually had a hernia operation and it was after the operation that he started to get this rash.
07:14He was ill with it as well.
07:15It's not just like, oh, I've got a rash.
07:17He was actually in bed.
07:19Like, he couldn't go to work.
07:20He didn't know really what it was, like what was causing it.
07:24He was then diagnosed with low-grade non-hodgkin lymphoma, which is a type of blood cancer.
07:29What happened on that day?
07:32We just thought I wanted to be at one of his normal routinely check-ups, as he does.
07:36So he went on his own and he actually texts me at work and says, it's cancer.
07:43That's not nice, really, for anyone to go to the hospital on your own and be told that you've got cancer.
07:49OK, is it curable?
07:55No, it's incurable.
07:57How's it affected him?
07:59We'll start to have six months' worth of chemo.
08:03That made him really, really badly.
08:05I've never, ever seen him that poorly, ever.
08:09So for him to know that the car's going to get done?
08:12Oh, God.
08:13He'd love it.
08:14Would he?
08:14Yeah, definitely, 100%.
08:17Come on, let's go and see how far this is going.
08:18Come on, let's go.
08:20Right, come on, let's go.
08:21Whoa, whoa, whoa, whoa, whoa, whoa, stop, stop, stop, stop, stop.
08:24Oh, come on.
08:25Carry on, carry on, get it shot.
08:27Yeah, C46 M3 coming back to our place.
08:30Who's got an E46 M3?
08:32Not you.
08:33Rick has.
08:35Yes, it might be Tim's dream car, but this one could be turning into a nightmare.
08:41Oh, right, OK, I can see it written all over your face.
08:44You love those cars.
08:45Oh, man.
08:45But look, I'm worried about this.
08:47Right, well, Amy did mention to me, she said something about the issue.
08:51Well, Ricky mentioned Conrods to her.
08:53Conrods, it's going to be bearings.
08:55Yeah.
08:55Vanos, I think it's called.
08:56OK, ding, there we go, there's another one.
08:58Yeah, well, there you go.
08:59Brilliant, sounds like the best car in the world.
09:01Yeah, yeah.
09:02And wait till we get that subframe down.
09:03I bet there's cracks there.
09:04Yeah.
09:05Yeah, so points made prizes.
09:07The boys would be big winners,
09:09because they've already got Conrod, bearing and Vanos issues.
09:12Two out of three problems that can kill off this generation of M3.
09:17So, despite its good looks,
09:18saving Ricky's pride and joy from the jaws of the Scrappy
09:22won't be straightforward.
09:24Come on.
09:24Right, come on, then.
09:25Let's go underneath perfection.
09:28Well, I'm just looking at some of the best rust that I've ever seen.
09:32What are you on about?
09:33Well, it's the rust on the best car ever built.
09:35Oh, shut up.
09:36Look, I know we've got rust, OK?
09:37I can see this car is rusty.
09:38It is a classic car,
09:39but it is,
09:40and I do believe it is the greatest car in the world, Fuzz.
09:43Hold on.
09:43There's something that I do want to look at here.
09:45What are you doing here?
09:47And as I can see,
09:48there are some hairline cracks starting to form there.
09:50But sometimes it's so bad
09:52that it can actually write the cars off.
09:54Right, hang on.
09:55So let's think about this.
09:56So we've got problems with the Vanos,
09:58problem with the engine bearings.
10:00I mean, to be fair, Fuzz,
10:01you'd walk away from this car for less.
10:09The boys have got their hands
10:11on what should be the ultimate driving machine,
10:15a BMW E46 M3.
10:17I want to show you the S54 engine.
10:19It's the engine, man.
10:20OK, OK.
10:21And although Tim's more excited than a dog with two tails
10:24to have his favourite car in the world on the ramp...
10:273.2 litres, 24 valve.
10:30Naturally aspirated.
10:31No cheating, no turbos, no superchargers.
10:34Fuzz is less convinced.
10:37It's still, in my mind, Fuzz,
10:38and I don't care what you say,
10:40the car that we're sitting on the bonnet of
10:41is still the greatest car in the world.
10:44The greatest degraded, rusting old heap of a car in the world.
10:50Yes, Ricky's BMW M3 might look like a dream,
10:54but it turns out it's nothing more than a pig in lipstick.
10:58Because underneath its handsome exterior
11:00lies the entire set of issues
11:02that can lead to this generation
11:04of the ultimate driving machine
11:06being recycled into the ultimate washing machine.
11:10First off, there are the conrod bearings.
11:13They ensure the crankshaft rotates smoothly.
11:17We know there's a problem with those.
11:19But what damage have they done
11:20to the rest of the engine's components?
11:22Then there's the Vanos unit.
11:24A nifty bit of kit when it works.
11:27But according to Amy, this one doesn't.
11:29Which means Ricky's already tired engine
11:31will have been working even harder to compensate.
11:34And then there's the cracks in the body
11:36where it mounts to the rear subframe.
11:38If it's not dealt with properly,
11:40it can tear these cars apart.
11:41So, will the boys have caught it in time?
11:44And can they fix it?
11:45So, with no time to waste,
11:48the 3.2-litre power plant is being stripped out.
11:52So, Tim can try to find an expert
11:54to repair the complex Vanos unit.
11:57Which leaves Fuzz to investigate
11:58what damage 20 years of over-enthusiastic driving
12:02has done to those conrod bearings.
12:04So, what we need to do is inspect our big end
12:09and main bearings at the bottom here on the crankshaft
12:11to make sure that they are not worn and scored.
12:15If they are, then we've got a bigger job on our hands.
12:18To see how bad they can get
12:20is a bearing out of another engine.
12:22Now, this one has worn all the way away.
12:25And that means that that would be knocking
12:27and clattering about in the bottom of the engine.
12:30A sort of unholy rumbling sound
12:33that you get when an engine's under load
12:36and its bearings are worn.
12:37Now, BMW M3s tend to be driven very hard.
12:41But the way to get more life out of the engine
12:43is let it warm up a little
12:45before giving it the beans.
12:48Because if you've got lubrication all around the engine,
12:51then it's going to be up to temperature
12:53and ready to take everything
12:55that the nut behind the steering wheel is going to give it.
12:58This may have been engine of the year in 2001,
13:04but more than 20 years of being ridden harder
13:06than a Grand National winner takes its toll on the bearings.
13:09If they're badly worn, they can produce metal shavings,
13:12which contaminate the oil,
13:14potentially causing further damage,
13:16which would require a full engine replacement.
13:19So, while the investigation continues...
13:25Tim should be working on getting the Vanos unit repaired,
13:29not playing Banksy.
13:34Anyone know what that is?
13:36That is the variable valve timing device
13:39made by BMW on Rick's engine,
13:42which has a problem.
13:43Amy mentioned that that thing's pretty much battered.
13:45It's called the Vanos.
13:47Now, the challenge is to explain what that thing there does.
13:52And in order to do so, I'm going to go back to basics.
13:55Yes, to truly grasp how the Vanos works,
13:59it's essential to first understand the basics of an engine.
14:02And as Tim's just got back from the supermarket,
14:05he's using his weekly shop to demonstrate how one works.
14:09A carrot, a spark plug, the lemonade bottle.
14:12That is the cylinder, the potato masher.
14:14That is the piston.
14:17So, let's have a look when we rotate this.
14:24So, have a look.
14:25We've got the masher at the top,
14:27and as it rotates and comes down,
14:29the valve, or the little door here,
14:31has been opened thanks to that spud,
14:33and in goes some nice new petrol and air.
14:36And when this masher gets to the bottom,
14:38the valve shuts.
14:39So, now, inside of there, we have petrol and air mix,
14:43at which point the spark plug, the carrot, goes...
14:46A little spark, which then sets fire to that explosive mixture inside of them.
14:53What happens?
14:54Well, the potato masher goes flying down with such ferocity,
14:58it generates so much momentum,
15:00it's still going, and it comes back up again,
15:02at which point Mr. Spud over here,
15:05he's opened the exhaust door,
15:07and allowing out the burnt petrol and air,
15:09as in the black smoke.
15:11When it gets to the top, he shuts that door.
15:14And that is one full cycle.
15:17So, that can repeat again and again and again.
15:19But what the hell is a Vanos?
15:21Well, BMW, they looked at this standard BOGO internal combustion engine,
15:26where the doors open and close at precisely the same time every single cycle.
15:31What about if we could change the length of time
15:33at which they stay open and they close for?
15:35It's a cold day, you want to get a bit more fuel in there,
15:38so this door stays open for a little bit longer.
15:41And what about when you're thrashing your car,
15:42you might want the exhaust opening a bit longer.
15:44So, hang on a minute,
15:46what we could really benefit from
15:47is that if you give the engine the ability
15:49to open and close the doors at different times,
15:52then you can get better performance from an engine.
15:54And that is precisely what that thing does.
15:58Yes, all he needs to do now is hurry up
16:02and track down a specialist who can fix it.
16:07Back with fuzz.
16:10There we go.
16:11There is our oil pump and pick-up.
16:14Now, we can get to all of our journals.
16:18So, just loosen these off.
16:21Are Ricky's bearings in the same state as Tim's grocery shop?
16:25I found this bearing
16:29as the worst worn example,
16:32this big end bearing.
16:34So, this fits into the connecting rod
16:37and goes onto the crankshaft.
16:39Now, I can just see at this point here
16:42a little bit of orangey-red showing through.
16:46Now, that is the copper substrate.
16:49If that's showing through,
16:51that means the white metal has worn
16:53so the bearing is absolutely beyond redemption.
16:58So, it needs to be replaced,
16:59as do all its compatriot bearings.
17:03Looks like fuzz has caught the bearings
17:05in the nick of time
17:07before any catastrophic damage.
17:10Rick's engine has had a lucky escape.
17:12But if the bearings aren't the reason
17:14the car went off the road a decade ago,
17:16what is?
17:17The 40 Vanos looks like the prime suspect.
17:23Welcome to Darlington in the north of the country.
17:26We're driving up to see a guy called Mr Vanos.
17:29Guess what he fixes?
17:30Yeah, those things that you're now an expert on.
17:40Mr Vanos?
17:41Tim, how are you?
17:42How are you doing, Matt?
17:43Good to see you.
17:44Is that what I think it is over there?
17:47An E46 M3, best car in the world.
17:50I completely agree.
17:51Right, OK, anyway,
17:52this is something I'm hoping you recognise.
17:55It looks very familiar.
17:56First thing for this is,
17:58we'll strip it down,
17:59have a look inside,
18:00and see what's going on.
18:00OK.
18:01I know the job that it does,
18:08but I don't know how it does it.
18:09It's a hydraulic unit.
18:11Right.
18:11Nothing more.
18:12Oh, is it?
18:12It's two pistons with an electrical pack
18:14that moves the pistons in and out.
18:15Right.
18:16So what's the first problem
18:17that this unit's likely to have?
18:19First issue will be piston seals.
18:22Yeah.
18:22So that's like the plunger from a syringe.
18:24It is.
18:24Without the rubbery bit on it,
18:26or the rubbery bit that makes the sealers just perish.
18:28Yes.
18:28Yeah.
18:28So that will not get a seal inside of that,
18:30meaning that what?
18:31The oil just works its way around it.
18:33It leaks past it,
18:34and because that runs at such high pressure,
18:35it leaks past at quite a rate,
18:37and when you're driving the car,
18:38you usually feel it as a low RPM,
18:40jerky, and yeah, backwards and forwards.
18:42OK, right, yeah.
18:42Yeah, unpleasant to drive.
18:44Next problem is another well-known problem.
18:47Oil pumps.
18:48Hang on, so this unit here has its own oil pump
18:51to generate pressure for these two little pistons?
18:53Yes, that'll generate around about 90 bar pressure
18:55when it's running.
18:56So not only do they have a problem with those seals,
18:59but also you're saying the oil pump itself is weak?
19:01They can wear away the shaft in the middle,
19:04but the drive can also snap off.
19:06Right.
19:06Which is a really common problem.
19:08Wow, so this problem for the Vanos was actually...
19:11Well, that thing's riddled with problems, then.
19:12It's inherently flawed.
19:14So a faulty rubber seal in a worn-out pump
19:17was all it took to take Ricky's car off the road.
19:20Can we fix this one?
19:21It can be fixed.
19:22So to ensure that it lasts for the next 20 years,
19:25Tim's leaving it with Mr Vanos,
19:27who's going to recondition it with brand-new parts.
19:34And with that, the boys have solved two of the big three.
19:37This might be the most straightforward renovation
19:40in car SOS history.
19:42Time to share the good news with Amy and Brent.
19:45Fuzzbot, she's here.
19:48Ah-ha.
19:48Brent's here, Amy's here.
19:50How you doing, Brent?
19:51Bottom line is, this car's going to be sweet.
19:52OK, so we're going to get it back to you soon,
19:54but what's this?
19:56Tim, there's something I want to talk to you about.
19:58Right, OK.
19:58Well, then I'm here.
19:59Fuzz is here.
19:59Let's have it, then.
20:00He's been talking about the car,
20:02and he's planning on, in summertime,
20:04doing it up as a CSL look-alike.
20:06CSL look-alike?
20:07Yeah, right.
20:08Let me explain what that means, Fuzz.
20:09Yeah.
20:10A CSL look-alike.
20:11The CSL was a coupe sport lightweight.
20:13OK.
20:14They made 1,383 of them.
20:16That doesn't sound good.
20:17So are we talking wheels?
20:19No, no, dude, this thing,
20:20it was like BMW made this one,
20:22they made an even better one.
20:23They only made it in two colours.
20:24Silver grey metallic.
20:25Yes.
20:25It's a sapphire black.
20:27Absolutely beautiful.
20:28Wait, wait, is this the silver grey metallic?
20:30No, no, no, it's a complete colour change.
20:31That is a massive undertaking.
20:34It slows down everything.
20:35It's a big job.
20:36It means that we have to go even further into the car
20:39and take it apart even more than it's been taken apart so far.
20:42Excellent.
20:43Right, this is an important question.
20:45Which one's it going to be?
20:47Black.
20:49Gray.
20:50We're going to give you 30 seconds to think about that,
20:52because I've got another question for you whilst you're here.
20:54We want to create a reveal.
20:55Other than his car, what else is he into in life?
20:57Commodore.
20:58OK, so he likes comedians?
21:00Yes.
21:00Now the colour.
21:01Anyone got a coin on him?
21:02You're saying black.
21:03Black.
21:03You're saying grey.
21:04Hold on, do I get a say in this?
21:06I'd like a three-sided coin, please.
21:08Technically it is.
21:09So if it lands on its side, you're having what?
21:11Well, I'm having original colour.
21:13So original this colour, this silver.
21:14Yes.
21:14OK, what's black?
21:16Heads.
21:17Black?
21:18Black heads.
21:19Your tail's grey.
21:23Heads.
21:24Heads.
21:25Oh, black.
21:26Black it is.
21:27Black it is.
21:28It's no longer grey.
21:29And that's a gutted look.
21:31Look at that.
21:32You're going to be a busy man.
21:33There's the quid.
21:33Better go.
21:34He's got a lot of work to do.
21:34Come on.
21:35Free him up.
21:35There you go.
21:36Crack on, mate.
21:36There you go.
21:37And just like that,
21:38this restoration got a whole lot more complicated.
21:42Unbelievable.
21:42Tim and Fuzz have their hands full restoring this 2003 E46 M3 that's been decomposing on the driveway for more than a decade.
21:56It was once the pride and joy of 48-year-old Ricky.
21:59But after the notorious Big Three took it off the road and he was diagnosed with cancer, he's been unable to get his silver dream machine back up and running.
22:09I want to know what that car means to him.
22:11That means absolutely everything to him.
22:13And as if rescuing this German rocket from the jaws of the scrapheap wasn't challenging enough, the team now face the epic task of turning this standard M3 into an ultra-rare CSL edition.
22:32So, to find out what they're up against, the boys are heading the road for some emergency research.
22:39You might regret this drive, Fuzzbot.
22:44Yeah.
22:45Because I'm driving the E46 M3, one of only 422, the CSL.
22:51Right, OK.
22:51Coupe Sport Lightweight.
22:53Why am I going to regret it?
22:54Hold on to your seat.
22:55What?
23:01Pugs into your back, Pete.
23:03OK, OK.
23:03No, no, not OK.
23:05Keep enjoying it.
23:07No, I'm not OK.
23:08You are.
23:09No, no, you're fine.
23:10You're fine.
23:10Oh, listen to that growl.
23:15Man, 360 horsepower, this CSL.
23:17It's 30 more horses than at 110 kilograms lighter than Rick's E46 M3, which is, and I maintain, the greatest car in the world.
23:25But it just tweaked it with this one, the CSL.
23:28This is the way Rick wants his car to look, dude, just like one of these.
23:32OK.
23:32So this car is considered the holy grail for anyone who loves an E46 M3.
23:37I have to say, it does feel remarkably sure-footed.
23:41Oh, it's just...
23:42No pun intended.
23:43Ferraris, Lamborghinis, supercars that do 250 miles an hour don't make sense on British roads.
23:53It's like taking a Grand National winner and doing donkey rides on the beach with it.
24:00The E46 M3 gets everything about motoring in the UK on the nail.
24:05Yes, it handles well.
24:08Yes, you can use it as a daily with the kids in the back and not hammer it.
24:11But yes, you can take it on a track and absolutely have it sideways.
24:16Would you call this the thinking person's supercar?
24:20Yes, in a way.
24:20What I want to know is, I mean, we know that Rick wants a CSL look-alike.
24:29Yeah, like this.
24:29So, yeah, like this.
24:31Right.
24:31So what can we do?
24:32I mean, it's lost 110 kilograms.
24:35We can't do that with Rick's car.
24:36No, no, we can't.
24:37They did it with the carbon fibre roof.
24:39They did it with all the carbon fibre centre console.
24:41And the plenum on the front, another 30 horsepower on the engine.
24:44There are so many things which make this car a car that we cannot make Rick's exactly the same as.
24:50It'll only ever be a looky-likey.
24:52But it's acceptable in the E46 M3 world because it's such a niche car.
24:57And so just having the look of it, the sort of is-it-or-isn't-it moment as it goes past people.
25:03Yes, that's it.
25:03I can understand that as well.
25:05OK, right, I'm on board with that.
25:07I understand that.
25:08I get it.
25:09We can make it that car that when it goes down the street,
25:11everybody else who knows their M3s goes,
25:13Ooh, I just saw a CSL.
25:15Yes!
25:15Yes!
25:26However, the big transformation can't begin until Fuzz conquers the final challenge of the big three.
25:33Cracks in the body around the rear subframe.
25:35Right, now, the BMW M3 E46 may be one of the hottest cars on the planet, according to Tim Shaw.
25:44But it's about to get hotter because we're going to have to weld in some reinforcement around this area of the shell.
25:52Now, this is where the rear subframe mounts.
25:55The rear subframe carries the rear axle and, of course, all the rear suspension.
25:59What happens is so much power comes through from that hugely powerful engine when it gets transferred out to the rear axle,
26:07puts the subframe under twisting and torsional stresses, which in turn leads to cracking of the body shell.
26:15But once we get this in and start welding it in, then we are adding strength, adding future proofing.
26:22And that is what we need to do to this car.
26:24And that starts with spraying the subframe and new brackets with a coat of whirled through primer
26:31to help protect them from rust in the future.
26:38I'm going to start with my section here and here.
26:44I've got my hat on.
26:47There's an early warning device.
26:48If I can smell a hot sheep, I get out of here and take my hat off pretty quickly.
26:59Yes, it brings a whole new meaning to the phrase hot under the collar.
27:03And that's not all that's causing fuzz to work up a sweat.
27:07We've just unearthed some of the reasons why people need to look very carefully at the back ends of their M3s.
27:16We've cut in to let in some new metal and we have found beneath the surface, in a hidden area, cracks.
27:24Cracks in the body shell.
27:25So we'll weld these up, put the new plates in, and then the car will have that additional strength that it needs.
27:32So while Fuzz continues his hunt for cracks in the metal subframe,
27:36Tim is turning his attention to carbon fibre and those all-important touches
27:42that are going to transform the look of Ricky's car into a CSL.
27:47And, speaking of a CSL, Tim does know he has to give that car back, right?
27:52Neil.
27:53Hi, Tim.
27:53What a place to be.
27:54Fantastic to see you.
27:55Oh, my God, I'm jealous of your job.
27:56Is that what I think it is?
27:57That's Alex's car from last year.
27:59This is the home of British Formula One team, Williams Racing.
28:06A place where they certainly know a thing or two about this wonder material.
28:13What a thing to be in front of you, eh?
28:15It's incredible.
28:16It is a sight to behold.
28:18And let's be honest here, if it wasn't for carbon fibre, what would be left on the floor here?
28:23An engine and a gearbox, and that's pretty much it.
28:25You know, carbon fibre is 85% of the car now.
28:28Is it really?
28:29Yes.
28:29Well, even the gearbox is carbon fibre as well.
28:31Is it really?
28:32Yes, yes.
28:33Let me tell you what I'm hoping you might be able to help us with.
28:35We're doing a car up for a guy called Ricky.
28:37Well, his wife has just told me that she would love it if we could make his car, BMW E46 M3,
28:43a car you hopefully know and love.
28:44I do, yes, most definitely.
28:45Right, okay, right.
28:46So, that is the CSL version that's dripping in carbon fibre.
28:49Now, considering he's a fan of you guys, and you guys make carbon fibre stuff,
28:52is there any way you could have his favourite people make a bit of carbon fibre stuff for his car?
28:56That's the stuff dreams are made of.
28:57We won't say no, we'll most definitely support you on this project, most definitely.
29:01Oh, man, that is incredible.
29:03Since its introduction in the early 80s, carbon fibre has revolutionised Formula One.
29:09This is carbon fibre?
29:11Yes.
29:11Right in front of our eyes being laid, right?
29:13Yes.
29:13And what are we making here?
29:14This is an element one, so it's the forward element of the front wing of the current car.
29:19How can you say that without a smirk on your face, dude?
29:21You get used to it.
29:22I know, but it's so cool.
29:25This wonder material is up to ten times stronger than steel.
29:29And that incredible strength comes from the thousands of parallel strands of carbon atoms
29:35that have been tightly woven together into a sheet.
29:38So if you were to pull that across it at 45, you'd see that it just...
29:44Big time, it deforms.
29:45Yeah.
29:46Yeah, OK.
29:46If you go straight across it now at 90...
29:48Like that?
29:48Yeah.
29:49Oh, it's rigid.
29:50Very rigid.
29:50So you continually have to be thinking about the forces being applied to the car, and then
29:55lay this stuff in different orientations to make sure that it is strong in that direction.
29:59When laid up by the experts, carbon fibre is superior to metal, withstanding the high
30:05stress loads created by racing at over 200 miles an hour.
30:10And if that wasn't impressive enough, in a sport where every gram counts...
30:15That's the metallic version.
30:16Good God.
30:17Carbon fibre can be up to five times lighter than steel, making cars faster and more economical
30:24on fuel.
30:25Right, Tim, what would you like to make?
30:27What a great question.
30:28The whole car.
30:30But with a kilogram of high-end carbon fibre costing 100 times as much as steel, I think
30:36that's a bit ambitious, Tim.
30:38We've got front-end carbon fibre here.
30:39We have, yes.
30:40We've got those, but those are quite readily available.
30:42Right.
30:42The roof, I know you'd need the car here, our car here.
30:45Yeah.
30:45And I can get that wrapped actually in a carbon fibre.
30:48OK.
30:49Believe it or not, there are two choices around the back.
30:52The bit that I happen to know, because I've built many CSL reps myself, the tricky bit
30:57is the diffuser.
30:58So I'm wondering, how would we make one of those, though?
31:00Well, we need to scan it, so we need to bring Julie and Chloe in to do the scan.
31:07No way, what's that?
31:08Fantastic piece of kit.
31:09Oh, wow.
31:17Oh, look at that already.
31:18It's building up an image of that thing instantly on the screen.
31:21What are we seeing happening here?
31:22So it's scanning all the point data at the moment in reverse engineering and then created
31:27it on screen.
31:27It looks like it's just a video feed, so that looks like a video camera just sending video
31:31pictures, but that's not.
31:32That's a virtual recreation of the back end of the car, isn't it?
31:35From, what, millions of points that it's been up?
31:36Millions of points, yes.
31:38Is it pretty accurate?
31:39It's very accurate.
31:40It's a 0.7 millimeter.
31:41And how's that looking as far?
31:42I mean, that looks bang on.
31:43It's fantastic.
31:44Julian, we're nearly there.
31:45Nearly have a CSL bumper.
31:46Yes.
31:47Wow.
31:47Yep.
31:48Tim!
31:48What?
31:53What is that?
31:54Oh, are they...
31:55Tim, thanks very much for coming down, but...
32:01OK.
32:04Thanks, guys.
32:05Thanks for having me.
32:06I probably won't meet you guys again, but lovely to meet you and stick it in the post
32:09when it's done, yeah?
32:10Cheers, man.
32:12While the team at Williams try to iron Tim's mug out of Ricky's new diffuser...
32:18Back at QRSOS headquarters, with the subframe now strengthened, it's foot to the floor on
32:25the CSL transformation.
32:28The body's off, having a coat of sapphire black paint applied.
32:32And the engine rebuild is almost complete.
32:36We've put fresh new bearing shells in and a lovely new timing chain, but we still have
32:43to fit the Vanos unit onto the front of the camshafts here.
32:48So, while Fuzz gets to grips with that...
32:52That's a thing of great joy for me.
32:56Because I'm a nerd.
33:00One of Britain's best rappers has popped by the workshop.
33:04No, it's not Stormzy.
33:06It's Dan, who's got the tacky task of applying the CSL lookalike carbon fibre style wrap to
33:12the roof of the M3.
33:17The engine and gearbox are being reunited and put back into the car.
33:23And look what's arrived from Williams Racing.
33:26Thankfully, minus Tim's mug.
33:29Here we have a rear bumper and that lovely carbon fibre diffuser.
33:33Right, come on, let's get this on.
33:35So now, we have to get it in here without scratching the rest of the body.
33:43Get a nut in place.
33:46You're up.
33:49Right.
33:50That looks a whole heap better.
33:52There's still plenty of work to do, though.
33:53Yes, it's all mechanics to the M3 to get Ricky's CSL lookalike ready for the big reveal.
34:00But with bonnets and body panels going back on, even Tim's getting his hands dirty.
34:05Time to put the centre caps into the CSL alloys.
34:08Now, a little trick for you, which is one of these things I guarantee you will use it.
34:11Line up the M or the middle of the badge with the tyre inflator so you no longer will have
34:16that problem of like, oh, I need to put air in the tyre and I can't find the inflator.
34:19Where is it?
34:20It disappears into the dark.
34:21So, line it up with the M there and there you go.
34:25You always know where the tyre inflator is.
34:28And with that, Rick's car is almost ready to go.
34:31Apart from the antique in the boot.
34:33No, not fuzz.
34:35Tim, come and have a look at this.
34:37What is it?
34:37What have you found?
34:38Ha-ha, you'll love it.
34:40Oh, no, oh, no.
34:41Yes.
34:42What's he listening to?
34:43What's Ricky?
34:43Yo, it's like, might as well be mine.
34:45Ibiza Classics.
34:46Brilliant.
34:47Dude, that is so cool.
34:48Man, I love this car.
34:50You know, what we've done to it.
34:51Think about the bomb that we had dropped on us.
34:53It looks great.
34:54And to anybody just seeing it on the street, as it goes past, they'll just glance at it
34:58and go, oh, a CSL.
34:59Saw a CSL today.
35:00Right, tomorrow.
35:01Come and sit down with me.
35:02Okay.
35:02I want to share something.
35:03Right, okay.
35:04Tomorrow is a big day for Ricky.
35:07Yeah, it's only short.
35:08Have you worked out something special?
35:10And it's a big day for you as well.
35:11For me?
35:12Yes.
35:13Okay.
35:13You and Ricky share something in common.
35:15Yeah.
35:15You both have love of British comedy.
35:18That's right.
35:18Well, I've worked with a comedian all the time.
35:20Do you?
35:21Who's that?
35:22Anyway, look, you share the love of the same guy.
35:24Oh.
35:25No, you don't really.
35:26No, no, no.
35:26Wait, wait, wait, wait.
35:27It's not just a video message.
35:29Tomorrow, if everything goes to plan, we're going to have a very special guest there.
35:33And you will not just be at the back of a comedy venue, waving, going, hello, I'm Fuzz.
35:37Do you watch Car at You Don't Watch?
35:38Are you sure?
35:39Are you sure there's not going to happen?
35:40No.
35:40There's going to be something.
35:41No.
35:41There's always something.
35:42You will meet your hero tomorrow.
35:43Really?
35:44And Ricky will as well, and we'll give Ricky his car back.
35:47You're not joking?
35:47No, I'm not joking.
35:48It's a done deal, though.
35:49Okay, fantastic.
35:50Can we get it finished?
35:50Yeah.
35:51Go on, then.
35:51Let's get it back to Ricky.
35:52Wow.
35:58After months of hard work, the boys have returned to Nottingham with a very special surprise
36:03for Rick.
36:05Bring it in, Fuzzbot.
36:06Bring it in, son.
36:07Oh, look at that.
36:10Sapphire Black DuckTales CSL.
36:12Mate, that is the best looking M3 I have ever.
36:17Dude.
36:17Doesn't it look amazing?
36:19Oh, dude.
36:19It does look absolutely amazing.
36:21Anyway, look, come on.
36:23What I want to know, look, you said that my favourite comedian was going to be here.
36:27Where is Johnny Vegas?
36:29Wait for it.
36:31Rick lives round the corner from here.
36:32Yeah?
36:32This is his mate Glyn's house.
36:34Yeah?
36:34Rick has no idea he's got the day off today.
36:36Right.
36:37When the time is right, our comedian is going to knock on random doors around here, pull
36:41some regular punters in to play street bingo.
36:43One of them's going to be Rick, and he's going to win this car.
36:46Hold on, hold on.
36:47Wait, just backtrack a little bit, because at no time have you mentioned
36:51Johnny Vegas' name.
36:53Where is he?
36:54Do you want the truth?
36:55Yeah, I do want the truth.
36:56Oh, that's amazing.
37:06He wrote me a letter, and I just scanned it, and I saw your name.
37:10Oh, it's fantastic.
37:11It's you.
37:13What are you doing in this?
37:14Oh, this is...
37:15Can we get...
37:15I mean, he does everything he...
37:16Johnny, hello.
37:17Can we get the car hidden, and can we get you in character?
37:20Of course we can, Tim, because you've said so.
37:23Yes, whilst the new best friends get acquainted with each other...
37:26Fanboy or what?
37:27The set is in place.
37:31The neighbours are in on the surprise, and now they just need to get Rick to take part
37:36in Johnny's entirely fictitious new TV series.
37:40Hello.
37:40Hiya.
37:41He's been nominated.
37:42He needs three people now to come and play street bingo.
37:44Have you ever come and play?
37:45Yeah, yeah.
37:46Are you sure?
37:47Yeah.
37:48Right, please.
37:49Come on.
37:49So far, so good.
37:53Rick is playing along, and remains completely unaware of what's really happening.
37:58Rob and Al.
38:00And with Tim tucked round the corner and the car out of sight, it's over to you, Johnny.
38:06Hello.
38:07Welcome to another episode of Johnny Vegas' Street Bingo.
38:10Coming to you from...
38:12Nottingham.
38:13Nottingham.
38:14Round one.
38:15What does paying for accommodation in Yorkshire have in common with Nottingham?
38:22What does...
38:24To rent.
38:25To rent, to rent!
38:28Right, ibuprofen was discovered in Nottingham, but why are there no addicts in the jungle?
38:35How does the paracetamol...
38:38Correct!
38:41At the end of round one, Ricky has zero points.
38:45And zero clue about what's really going on.
38:48Right, put your blindfolds on.
38:55Can you tell me, to your closest guess, blindfolded, the make of the next vehicle that is about to pull up on this yard here?
39:06Listen now.
39:07The name of the vehicle, Glenn.
39:14That sounds like an Audi to me.
39:17Ooh.
39:18Rob?
39:20Ford Focus.
39:21Ford Focus, really.
39:25Rick?
39:25That is a BMW.
39:30Straight six.
39:31Right, can I turn you all round, kind of clockwise?
39:35There's your man.
39:36Take your blind balls off while I announce the winner!
39:38Oh, my God!
39:45Hello, mate.
39:46That's my car.
39:47That is your car.
39:50Recognise that?
39:51It's changed.
39:52You know all this street bingo thing?
39:54Yeah.
39:55All of this was all a ruse.
39:56It was all a scam just to get you here, to give you your car back.
40:01Amazing.
40:02You all right?
40:02It looked incredible.
40:03Can we bring out Rick's family as well, please?
40:06Come on out, guys.
40:07Come on out.
40:07You didn't have a clue!
40:10Come on.
40:11Come on.
40:11Come on.
40:11Give him a cuddle.
40:12Amy, come on.
40:14It's all her fault, Rick.
40:15It's all...
40:16Oh, my God.
40:18Amy, can you explain to your lovely man here, can you explain why it is he wrote to us?
40:23Don't talk to me.
40:24Forget all of that.
40:25Just talk to Rick.
40:26Because you've been through so much, like, for a couple of years now, COVID, chemo, lymphoma.
40:34We just wanted to give you something back, something nice that we all know that you absolutely love.
40:38And something we can all cherish forever as a memory.
40:42That's for words.
40:43And we love you all.
40:44Love you so much.
40:45Can we have a round of applause for Rick and his M3?
40:48That's your car, mate.
40:53It's not sinking in yet, is it?
40:54It's still not sinking in.
40:57When Rick last saw his beloved M3, it had been struck down by the big three problems that send these BMWs to the scrap heap in the sky.
41:11But thanks to the boys' hard work, it's been reborn.
41:14Not only are the mechanical issues no more, but Rick's got himself the car of his dreams.
41:20On the outside, there's CSL touches like the one-of-a-kind carbon fibre rear diffuser built by Williams.
41:30New wheels, a spoiler, and carbon fibre wrapped roof.
41:35Inside, there's a brand new CSL-style Alcantara-covered steering wheel.
41:40And finally, the whole thing has been re-sprayed sapphire black.
41:45Let's just hope he didn't want silver.
41:47So tell me this black.
41:50Oh, gorgeous.
41:52Gorgeous colour.
41:53Did we get it right?
41:54Perfect.
41:54Best colour I think you could have chose, honestly.
41:57How does it feel to be back in it?
41:59Amazing.
42:01Absolutely amazing.
42:03I can't believe it.
42:05You've been through a lot, dude.
42:08Still going through a lot.
42:09Amy just wanted to do, and Brent wanted to do something for you, because they love you.
42:17Sorry, I can't.
42:18It's all right.
42:18And they figured that this car might be the trick to put the smile on your face.
42:23It does.
42:28What is it about an E46 M3 for you, Rick?
42:31It's just a pure driving experience.
42:34You're connected.
42:36It's like strapping on a car.
42:38Yeah.
42:38Not sitting in a car.
42:40You're putting it on and you're wearing it.
42:42Mate, you just put in words.
42:43Exactly what I've been trying to get into words for my 20 years since I've owned these cars.
42:49Can we talk about what happened to you when you got diagnosed?
42:52How does it change you?
42:53It makes you think about life more.
42:55I'm lucky I've come out of the side.
42:57I'll never be cured, but...
42:59You're here.
43:00I'm here.
43:01So I just appreciate it at the moment.
43:02Well, there is only one thing left to do, and that is...