Car SOSSeason 13 Episode 7
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00:00And Fuzz winging it.
00:02It would be so much easier just to cover it all over with a panel.
00:06But that would be cheating, wouldn't it?
00:08So, can the boys make this 1930s classic?
00:10On Carus West, this is an absolute first.
00:12Fly again for its owner.
00:14How's your evening going?
00:15Brilliant.
00:16Fuzz, you're jumping.
00:30Fuzz, Fuzz, Lancashire, not so far away from where I live, pal.
00:42Fantastic.
00:43Today, we are here to pick up a Wolseley Hornet,
00:48which is a car that I know very little about.
00:51You're missing all of the tricks.
00:53You're missing all of the fun to drive anything at all modern.
00:57You don't need any skill.
00:58It does it all for you.
01:00Whereas, with the Wolseley Hornet, it's raw excitement.
01:04They are a proper handful.
01:06You have to be able to drive properly.
01:09They were quick.
01:10They were quicker than most other things of their size and capacity.
01:14Launched in 1930 as a four-seater saloon or a two-door open racer,
01:19Hornet 6s were capable of hitting up to 75 miles an hour
01:23at a time when 60 was considered fast.
01:25Wolseley, once Britain's biggest car maker,
01:30had been bought by Morris after falling on hard times.
01:33Morris developed the Hornet but branded it a Wolseley.
01:37It was a hit with the prosperous middle classes
01:39and single-handedly revived the Wolseley name.
01:43The engine featured an overhead camshaft,
01:45a technology pioneered in early race cars
01:48but rarely found on passenger vehicles.
01:52Like many cars of the era,
01:53the frame was wood and the roof vinyl
01:56as steel couldn't be rolled big enough.
01:59Race enthusiasts bought the chassis and engine,
02:02adding their own body to create specials.
02:04But there are just a handful left of the saloons
02:08with a sliding sunroof that the boys are off to see.
02:13So today we're meeting Emma...
02:15Yes, I know.
02:16...who is the daughter of John,
02:17whose car we're sliding away
02:19without him knowing anything about it.
02:20Come on, let's get there.
02:22I cannot wait.
02:23Come on!
02:26Come on, Tom.
02:27Calm yourself.
02:28Be cool, man.
02:29You are so annoying.
02:30You know, I'm so...
02:31You've been waiting for a...
02:32For a Wolseley.
02:34Hi.
02:34Hi, you must be Emma.
02:35Hi, you're welcome.
02:36Hi.
02:36I'm happy to meet you.
02:37Hi.
02:37Please excuse me.
02:38That annoying face,
02:39he's so excited to do a Wolseley.
02:41I am very excited.
02:42But, first of all, where's John?
02:44John's on Holiday in Rhodes.
02:46OK.
02:46Right.
02:47Right, so where's the car?
02:48It's in the garage.
02:49Right, OK, let's get in there.
02:51Brilliant.
02:51Come on, then.
02:52It's locked.
02:52You're going to have to go around the side.
02:54The side?
02:54I don't know.
02:55Hang on.
02:55Hang on.
02:55It's not...
02:55Are you all right with him?
02:57Fuzzbot, that's a bit rude, man.
02:58You don't live here.
02:59This isn't your house,
03:00and that's not your gate
03:01that you just slammed.
03:02Sorry about that.
03:05Fuzzbot.
03:06Fuzz, open up, dude.
03:07Oh, yeah.
03:08Look at this.
03:09Can I open the door, mate?
03:10Look at those lovely latches.
03:12For a fuzz?
03:13Can I open the door out here, dude?
03:14Excellent.
03:15Here are, fuzz.
03:16Oh, yes!
03:17So, here it is.
03:18Look.
03:18Isn't it beautiful?
03:19It's such a rare car.
03:20It's such a rare survivor.
03:22Well, let's shot you in there.
03:23We're going to talk about John.
03:24Okay.
03:25Bye-see-bye.
03:26Ah, yes.
03:28Now, here we have
03:30a beautiful mid-1930s
03:33Wolvesley Hornet.
03:35The honeycomb stone guard
03:37on the radiator here,
03:38this fake lattice here,
03:41that has obviously got some damage,
03:42so we need to address that.
03:44But then we've got this lovely little
03:46temperature gauge here,
03:48calorimeter,
03:49just sitting on the top.
03:51Literally dipping straight into the radiator
03:54so that you can tell how hot or cold it is
03:57from the driving seat.
04:02What kind of guy is your dad?
04:04Because that is a...
04:05It's a car that is Marmite, dare I say it.
04:08Something that some people are going to love
04:09and some people know very little about
04:11or dislike, even.
04:12He's always loved cars.
04:13Cars have been in his blood.
04:14He was a mechanic.
04:16He was a car salesman.
04:18He's loved cars forever.
04:20We've always been tinkering with cars.
04:22But he's always wanted to have a classic car.
04:25His whole life has been about cars.
04:26Absolutely.
04:29Here we have the pièce de résistance
04:31because this is a six-cylinder.
04:34It's around about a 1,300 cc engine,
04:37or thereabouts.
04:38It's got an overhead camshaft.
04:40A very modern set-up here.
04:43And that meant that pound for pound,
04:46you got more punch out of this engine
04:48than a similar side-valve one.
04:50But we will probably have to pull it apart
04:52to make sure that we haven't got any stuck valves.
04:54What's happened in John's, in your dad's life?
05:00Because he's had a tough time, hasn't he?
05:02He's not had the best of runs,
05:03so he finally decided to retire.
05:05And then, of course, we started to move
05:07towards the pandemic and said to my mum and dad,
05:11look, you're not young anymore
05:12and you need to lock down.
05:13You're not going out.
05:14And they were really good.
05:15They did it.
05:16One day, my dad rang me up and said,
05:18she's not right, Emma.
05:19She's just collapsed upstairs.
05:21They sent the ambulance.
05:22They took her straight in.
05:23And the next day, it was confirmed as COVID.
05:26And from that time on in, I didn't see my mum.
05:29Everything was so severely locked down at that point
05:32that we weren't able to do anything.
05:34The dad was in pieces
05:35because he just wanted to hold her hand.
05:38And after 10 days of trying to resuscitate her,
05:40nothing could be done for her.
05:42Her oxygen levels were just too low.
05:43And sadly, she passed away on Good Friday of 2020.
05:49They just celebrated 50 years of being married.
05:52She was his right arm.
05:55They were a really good duo, a really good team.
05:59Yeah, it was a hard time.
06:02I cannot begin to imagine what your dad,
06:04what your family has gone through,
06:06but in particular your father.
06:07He lost his mojo and the car and everything else
06:11just was just put on the back burner.
06:14And I turned to him about six months ago and said,
06:17when are you doing that car?
06:18And he said, I just think I'm too old.
06:20And anyway, I can't take her for a ride in it.
06:23So he deserves a bit of good luck.
06:26Absolutely.
06:31Now, what we have here is an opening sunshine roof,
06:36which a lot of cars of the period had,
06:38which was great.
06:40Now, this one is missing in its entirety.
06:43So all we've got is a bit of sackcloth being used as headlining,
06:49and it will be lovely to restore that.
06:54We have the car painted currently yellow,
06:58and I'm hoping that John doesn't want it completely in yellow,
07:02because I can tell that originally it was green.
07:05What's the dream in your mind with the car?
07:10I just want him to see it beautiful.
07:13I know he physically won't have done the work,
07:15but that dream of the car is there,
07:18because the classic car's always been something
07:20that he's wanted to achieve.
07:22And never quite got there?
07:23Never quite got there.
07:24Where does your dad think the car's going to go?
07:27Well, I've told him that the local museum is borrowing it.
07:30And is he OK with that?
07:33It's been tricky.
07:35OK, there we go.
07:44There we go.
07:45Oh, hello.
07:46Yeah?
07:47Hello, car.
07:48Where have you gone?
07:48It's loaded, and we're ready to go.
07:50Emma, it was great meeting you.
07:52Thank you for letting us do your dad's car.
07:54You take good care of it?
07:55Of course I will do.
07:56In.
07:57OK.
07:57See you.
07:58Take care.
07:58Lovely to meet you.
07:59Thanks, Emma.
07:59The Wolseley Horner and pre-war cars are the dodo.
08:06They're extinct animals, Fuzzbox.
08:07No, no, you're wrong there.
08:09No.
08:09No, the extinct animals are the people that used to love them
08:13and owned them.
08:14Unfortunately, because it was a long time ago,
08:16a lot of them are no longer with us.
08:19We're going to repair this car,
08:20we're going to bring it back to life,
08:22and we're going to excite people about them.
08:30Look, come on.
08:31What's wrong with you?
08:31Spit it out.
08:32Why are you pulling that face?
08:33This is the BMW M3 of its day.
08:36I kid you not.
08:37Struggling.
08:37Phil, was this...
08:38Six-cylinder overhead cam.
08:39Was this the BMW of its day?
08:42It would, yeah.
08:43Really?
08:44The engine is superb.
08:46It's modern before its time.
08:49It's a sports saloon.
08:50You know, this car could do 65 to 70 miles per hour.
08:55I'm going to take some persuading with this one, Fuzz.
08:56There is a concern out there in the car world
08:58for people who are fans of these
09:00that there's no-one who cares to pass them on to.
09:02Yeah.
09:03So that's our job,
09:04to bring cars like this in front of people
09:07who would otherwise not ever consider looking at them
09:11or driving in them.
09:12We're going to start on the top here.
09:14We've got a sliding roof.
09:14We haven't got a sliding roof.
09:16There.
09:16It's missing.
09:17So we've got to reconstruct all of this
09:19to make sure that it works.
09:20And take a look at the fronts as well.
09:21What?
09:21Tell me if there are any more influences on modern cars.
09:26Modern cars.
09:26That is the new look.
09:28Honeycomb is everywhere.
09:29Stitched into seats,
09:30grills all over the place,
09:31Audis, BMWs, all of them.
09:32Porsche's the lot.
09:33Yeah.
09:34And you're saying it started here?
09:36Well, it looks like it, doesn't it?
09:37But look at the state of it.
09:39That's just completely rotted away.
09:40It's not great.
09:42So you've got to work out a way of getting a new one of those.
09:45Running boards.
09:45That's the coolest thing for me.
09:46Yeah.
09:47Well, look.
09:47They're missing.
09:48Yeah.
09:48OK.
09:49So come on.
09:50We know what we've got to do up top.
09:51Let's have a look underneath.
09:52OK?
09:52Go on, Hank.
09:53Let's get it up.
09:53Look, we've got rust in the arches.
10:02But also, along here, we've got evidence of galloping woodworm.
10:08Galloping woodworm makes a change from the usual rust.
10:12We need to sum this car up.
10:14It needs mechanical, electrical.
10:17It needs woodwork, metalwork, body, roof.
10:21It's an everything car.
10:22It's a big, big job.
10:25It's concerning, actually, Fuzz.
10:27There's a whole lot of work.
10:34The boys are busy refurbishing a Wolseley Hornet that's been garaged for 20 years.
10:40And Fuzz is buzzing about its potential.
10:44We need to make sure that these cars are loved by future generations.
10:48But Tim hasn't been bitten by the Wolseley bug yet.
10:51These cars, at the moment, are approaching being a dying breed.
10:55To breathe life back into this old motor, it's going to take a full head-to-toe restoration.
11:04With no manual to work from, Fuzz will need to design and build the roof, including a sliding section from scratch.
11:11And since this car's so rare, forget about finding pre-made running boards, they're going to have to be custom-built.
11:18And that engine hasn't turned for decades, so it needs a full reboot.
11:23Plus, replace the radiator grille, pick a colour, and get the interior looking as good as new.
11:28It's one of the boys' biggest ever challenges.
11:31So, Fuzz dives straight into the most difficult job, the sliding roof.
11:38The roof is divided into two.
11:40The back section is fixed, but the front should have a sliding panel.
11:44Fuzz needs to make it all, something he's not done before.
11:47He's saving the rusted runners for the sliding section to help design a new set.
11:54So, I think this is the original vinyl underneath here.
11:59And if we can get some vinyl or similar material as close to that sort of grain pattern as we've got here,
12:06we can make this car look totally authentic.
12:08Vinyl was invented in the late 1800s, but only became widely used in the 1920s after manufacturing techniques improved.
12:16It was ideal for roofs, as it was more durable than the canvas used on early cars and horse-drawn carriages.
12:22It would be so much easier just to cover it all over with a panel.
12:26But that would be cheating, wouldn't it?
12:28There's absolutely no doubt in my mind that this is going to be a very tricky job.
12:34Possibly one of the trickiest I've ever undertaken.
12:38Fuzz will need to get a section of vinyl specially made.
12:42And with next to no spares available for this car, the same goes for the running boards.
12:47So, Tim's visiting panel beater Tommy.
12:50The seal here that we're using to fold into the running board.
12:53That's right.
12:54What's bizarre about this is, it feels like quite a heavy-duty thing to do,
12:57but I don't see much equipment in front of me.
12:59It's a very powerful magnet.
13:01Right.
13:01I think it's six tonne of force.
13:04Right, OK, so it's now pulling everything down with six tonne of force.
13:06Pulling it all down with force.
13:08OK.
13:08Totally safe to be around as long as you don't have metal hands.
13:11Right.
13:12And we literally just pull it gently up.
13:22It's great, isn't it?
13:23It's a mark.
13:23It's formed a nice.
13:25Yeah.
13:25But that will form the extremity of the actual running board.
13:28So this would be the outer edge.
13:29Yeah.
13:30That runs along the outside of the car.
13:31Now there is another fold along the bottom.
13:35Right.
13:35As a return.
13:36Finally, Tommy shapes the section to fit against the car.
13:49Right.
13:49So what we're going to do is we're going to take a bit of material off here.
13:55Yeah.
13:56Here we go.
13:57Now it can be a bit hard work because we're doing the gauges.
14:00OK.
14:02So that's quite a thick stick, isn't it, actually?
14:04It is, yeah.
14:05That's the running board shapes.
14:07But Tommy wants to add his own little stamp.
14:10I'm thinking right in the middle, as you open the door.
14:13Right.
14:13The BOS logo.
14:14We press it right in the middle.
14:16With what?
14:16Well, earlier...
14:18Oh, hang on a minute.
14:20You've made something already.
14:21I've actually already made a press.
14:23Oh, no way.
14:23Ready to go.
14:24This goes on top using the fly press, and we're going to form it right in the centre.
14:30Because if you look at, say, this Porsche, for instance...
14:32Yeah.
14:33...everything nowadays has the name on it.
14:35On the front, everywhere.
14:37So how many hours of work have gone into making that die?
14:39Maybe four or five hours.
14:41No, maybe longer.
14:42For us, on Car SOS, this is an absolute first.
14:45We've never done pressing of a logo before.
14:50So we want to get the dies hot as well.
14:52Oh, OK.
14:52We don't want them so hot that you damage the metal when you bring it down,
14:57because you'll make the dies soft.
14:58OK.
14:58You want to get on the handle.
15:00Yeah.
15:01And then when I turn off and grab hold...
15:02So what is it?
15:03I mean, is it a slam?
15:05Is it a steady press?
15:07A good slam.
15:08You can get your foot on it, yeah.
15:09Yeah, OK.
15:10OK, you ready?
15:11Yeah.
15:11Go for it, dude.
15:12And again.
15:15One more.
15:15There we go, beautiful.
15:18Come on, let's get it out of somewhere.
15:19Look at that.
15:20That is looking nice.
15:21No way.
15:23That is absolutely stunning.
15:24It's lovely.
15:25Brilliant.
15:26And it's unique to this one car.
15:27That is a lovely thing to see.
15:32It may look lovely, but it still needs painting, then fixing to the car.
15:36At the workshop, John's car has had to be completely stripped.
15:47The engine's gone to a specialist to have the cylinders rebuilt and the block re-bored, and fuzz needs to sort a hole in the floor.
15:57Wooden floors were common in cars up until probably about the late 1950s, early 1960s, but you still find them in things like kit cars and fiberglass cars.
16:07So they're not completely outmoded yet.
16:12Fuzz starts by making a template of the missing section.
16:16Right, there we are, template made, roughly speaking.
16:27Now, I'm going to use this to draw onto the piece of wood.
16:37All I need to do now is follow those lines with a saw.
16:42Goggles on, ear defenders.
16:43Right, let's see how that fits.
16:56Would you believe it?
16:58A perfect fit.
16:59Little bit of a sand on this side, but it's great, because this material, birch ply, is super lightweight, but super strong as well.
17:09And because it's dense, it can resist a lot of the damage that water can do to it.
17:14It's going to be painted and protected, so it's going to last for another, hopefully, hundred years or more.
17:21And it's not just a floor that's wooden.
17:24A new frame is being made from ash.
17:271920s and 30s carriage builders used this as it was super strong, but not so rigid it couldn't cope with bumpy driving.
17:34It all needs to be done by hand, but luckily, Will is a skilled carpenter, so they don't need to call a specialist.
17:41While he waits for parts for the roof, Fuzz is on a mission to show Tim that the Hornet is the car to be seen in.
17:48And knowing Tim's love for a convertible, he's opted for an open-top model to give him the full thrill.
18:03Right, Fuzz, we're off. This is my first go.
18:06Why? You know in the old movies, you see people moving the steering wheel loads.
18:09I get why now, because you move it loads and it doesn't out.
18:12Just relaxing.
18:15I can't relax.
18:16You can relax.
18:17I'm absolutely bricking it, Fuzz.
18:19What's that?
18:20It's just terrifying to drive. It's so different to normal driving.
18:26This is the thing. You've been used to the car driving for you.
18:30Yeah.
18:30Now you are driving the car, and you're not very good at it.
18:33I'm not. I'm rubbish at it.
18:35Where's third gear?
18:37It's down.
18:39Up.
18:42Well, 35 miles for that, Tim.
18:46Go for it. Go, Timmy. Go, Tim.
18:49That's it.
18:54I can tell that this car is tight and taut.
18:58Really?
18:59As it should be, yeah.
19:00Absolutely.
19:00So is it just a case of me accepting it, that we're safe and we're fine, and then relax it to that?
19:06It is one of the best-looking things I've ever seen.
19:09From where I'm seated now, the view of the reflective sky in the lights, it's all the chrome work, the blue.
19:16You are surrounded by something that makes you feel like you've succeeded.
19:20Yes, and you have, you have, because you're in a pre-war sports car here.
19:26You have succeeded.
19:27You cannot have the same sort of fun in a modern car that you can have in one of these.
19:33Actually, I've got to be honest with you, I'm getting into it now.
19:47First few moments of driving, you panic, because you just think, I'm not used to this level of play and slippage in everything.
19:54Yeah.
19:54But if you get over that and just accept it, it's great.
20:03I've worked out what this experience is for me.
20:05Yep.
20:06It's memory making.
20:08It's making, it's forming memories that I'll never forget.
20:10I'm never going to forget.
20:11That's right.
20:12Sitting beside you in this car, because it puts this weird smile on your face, and you're right.
20:16It's beautiful.
20:17Sounds great.
20:18It looks great.
20:19This car, considering, like you say, that these cars are the dodos, it's down to us, as you say, to save this thing.
20:31This is the car that has persuaded me that actually you can have a thoroughly good time in something of this age.
20:37That's right.
20:37For 30 years, you've been missing out, sir.
20:39Yeah.
20:40Looks like Fuzz might have another 1930s car convert on his hands, which is great news, as he'll need all the help he can muster to get John's back on the road.
20:51Yeah!
20:57Tim and Fuzz have taken on a 1934 Wolseley Hornet 6, a car with a sting in its tail.
21:04It belongs to 78-year-old former car salesman John, who had planned to restore it in his retirement.
21:11But after losing his wife to Covid and taking on greater responsibility caring for his grandkids, the restoration has ground to a halt.
21:19He's always loved cars. We've always been tinkering with cars. But he's always wanted to have a classic car.
21:26With the frame and bodywork finished, new wheel archers are being welded, and the refurbished chassis is nearing completion.
21:33After nearly 60 hours of repairs, the engine is back, complete with overhead camshaft, unlike many engines of the era, where the camshaft was near the bottom of the block.
21:44We have here the fantastic, and very advanced for its time, six-cylinder, 1,200cc engine out of the Wolseley Hornet.
21:53Now, I'm quite excited about this.
21:54There are a number of lovely little items on this engine, such as this external water pump, handy to get to, with its little greasing pots here.
22:05Then we have the oil pump, which is external here, and all the gallery of piping, which is external, which is lovely to see.
22:14But it's at the top of the engine, where it gets really super exciting, because this engine, designed in the late 1920s, is an overhead camshaft design, which eliminates a lot of the moving parts that were found in engines.
22:29The more moving parts you have, the more potential you have for wear, and therefore, it's easier for the engine to get out of trim.
22:36And it was those design elements that meant that people sought these engines out as power plants for race cars, all kinds of specials.
22:45One of the loveliest quirks that I've found on this is the method of setting the valve clearance.
22:49The valve clearance is the space between the valve and the rocker arm.
22:53It needs to be big enough to allow the valves to expand when they get hot, without them getting stuck against the rocker arm.
22:59Now, I've come across many ways of setting valve clearances, but this is the first time I've seen this.
23:05Now, we've got here a lovely system, which is adjustable by moving this nut.
23:11So, what I need to do is give myself just enough clearance.
23:16So, I use a feeler gauge here, which is a known thickness piece of steel, which represents the distance between the top of the valve and the rocker arm.
23:29That's eight thousandths of an inch of clearance.
23:32And then I'm just going to adjust down, quite tight in here, just about there, and then tighten up the lock nut here.
23:45There we go.
23:46And that is our clearance set.
23:48It's just a tiny little bit, but you can just hear that little click.
23:53And that gives enough clearance for that valve stem to open.
23:59There are so many little quirks and little ideas that individual companies incorporated into their designs.
24:06And it makes everything much more different.
24:08And therefore, I think, much more lovely.
24:11With the body work nearly finished, the boys need to choose a colour.
24:16So, they called in John's daughter, Emma.
24:19So many people at this stage, when they come in to see their loved one's car, they just brick themselves.
24:23Oh, my God, this is... whatever it is.
24:24But are you not scared by that?
24:26Not at all.
24:26I know what you guys are capable of.
24:28It's going to be phenomenal when it's finished.
24:31So, I'm just more excited than scared.
24:33Right.
24:33OK, that's good.
24:34So, lots of new woodworks that had all rotted at the bottom down there.
24:37And some of the metalworks being replaced.
24:39Having picked up the car, it was yellow.
24:41We've knocked it back and we've found a green.
24:44I would suggest maybe green is the way to go.
24:48Perhaps with black wings and a black roof.
24:50That sounds fantastic.
24:51Yeah?
24:51Yeah.
24:52Right, green it is there.
24:52OK, that's good.
24:53Next thing, question for you.
24:55Is your dad into his food?
24:57He loves food.
24:58OK, so here's the idea.
25:00Somewhere local, something food-related, could you get him there without being sus at all?
25:05Yeah, shouldn't be a problem.
25:06A bit of a meal with a twist, something unusual, but ultimately it's all put on just for him to get his car back.
25:11This sounds exciting.
25:14Not so exciting were the leather seats.
25:17Unsurprisingly, after 90 years, they were showing their age.
25:21It's difficult to find new ones.
25:22So, the boys have set them off to be re-upholstered, the covers repaired and everything cleaned.
25:29But they can't go back until the rest of the interior is finished and that tricky roof.
25:35With the delivery of new materials, fuzz starts by cutting the headliner to the interior section.
25:41I'm going to glue it around the perimeter here and then cut away any excess material, but not make it too tight, just tight enough.
25:52Then, before the sliding section goes in, he needs to make the whole thing waterproof with the vinyl.
25:59He's cut this to size, then adds glue to the material and car frame.
26:05While that dries a bit, what we do need to do is put our calico in.
26:11So, it just gives a little bit of padding in between the vinyl and the framework here.
26:18Next, fuzz needs to call in some help.
26:21The glue is so strong that if the vinyl is positioned incorrectly, it's impossible to lift off without destroying it.
26:27So, if they get this wrong, they'll have to start all over again.
26:31You ready?
26:32This is it.
26:33One time only.
26:35Can you see that?
26:37Your markings on the corner.
26:41I'm okay here in the middle.
26:43I've committed.
26:44This has touched.
26:47No, no, no.
26:48It's fine.
26:49It's fine.
26:50Absolutely fine.
26:51There's an overlap.
26:53Okay.
26:55So,
26:56I've gone into the middle.
26:58Give it a tug.
27:01Yeah.
27:14I think
27:15we have a success.
27:18Right.
27:18So, there we are.
27:19The roof
27:20is watertight.
27:22There'll be a big hole cut out here
27:23because obviously this is going to be a sunshine roof.
27:26But we've done the major job.
27:29If this had gone wrong,
27:30it was all going to go terribly wrong.
27:36Tim, meanwhile, is visiting Rob,
27:38who's been painstakingly rebuilding the wrecked radiator and grill.
27:43Rob.
27:44Hello, mate.
27:45Morning, Tim.
27:46How are you getting on with the radiator?
27:47Very well.
27:48So, your radiator's been fully restored.
27:50Is that it?
27:51This is it.
27:52Mate.
27:52So, this has been completely dismantled.
27:55All of the tanks have been cleaned, bead blasted, repaired or replaced as necessary.
27:59How can you say that without a huge smile on your face?
28:01It's just like, look how proud you should feel.
28:02Well, this is fairly run-of-the-mill for us.
28:05So, this has just come back from the chromers.
28:06This is the pretty bit.
28:07That is the pretty bit.
28:08Wow, look at the shiny.
28:09It's got tape on it so that we don't scratch it.
28:10So, the job of that thing is to cool the water.
28:13Yeah.
28:13And the water, in turn, cools the car, cools the engine.
28:15Right.
28:16So, that thing has a purpose.
28:18Yes.
28:18But the thing that is more aesthetic is this thing.
28:21Dummy honeycomb.
28:22We make it from start to finish.
28:24It starts off like that.
28:28It has a flat sheet.
28:29And it ends up like that.
28:31Let's see a piece of this that's made.
28:33Oh, my word.
28:34Look at that.
28:36Your original dummy honeycomb, Tim.
28:38Yeah.
28:38It was in fairly bad order.
28:40Yeah.
28:40Rotted away.
28:41So, we've produced a new sheet of dummy honeycomb, shaped to fit your shell.
28:45So, we used the original Morris Motors catalogue.
28:49Morris Motors made a lot of radiators in the day.
28:52They made them for Walsley, Morris Commercial, MG.
28:54We've taken the detail and the dimensions from this original book to replace that for you on there.
28:59So, that is exactly as it would have come out, using the same processes as they did in 1934.
29:04That's right.
29:05Yeah.
29:05So, can we reassemble this?
29:07We can.
29:10This needs to go in here now, and I just need to bend these tags over to hold it in.
29:18Oh, I need to take the tape off it.
29:20Is there anything better than chrome?
29:26This is the crown jewels.
29:27This is the most important part of this car.
29:31Would you like to just hold on to that for a second?
29:34Yep.
29:34We can pop that on.
29:46I'm going to take this and get out of here.
29:48Cheers, Rob.
29:48Thank you, mate.
29:50At the workshop, the chassis's now been fitted, but that hard-to-sort roof is still a long way off.
30:00Fuzz has cut a hole in the vinyl as the opening for the sunroof.
30:04Now, he needs to add the sliding section.
30:07Another job he's never done before.
30:08We've fitted the vinyl onto ply, and on the flip side, there is one extra bit that we need to deal with now, and that is the sliding mechanism itself.
30:21And so, for that, we're going to use some of this material.
30:25Now, this is called Delrin.
30:27It's like nylon, but it's got more water-resistant properties.
30:33We're going to cut this into four pieces.
30:38There's our four blocks there.
30:54Next, some of the blocks go onto the roof section.
30:57Right.
30:59This is what we have so far.
31:01Three blocks mounted, with one to go on when we get it on the car,
31:06so that we can slide this roof in nice and easily.
31:09Wish me luck.
31:10Here we go.
31:13Right, so, let's pop that on there.
31:16A little jiggle to get it in at the rear there.
31:19Yes.
31:21Beautifully.
31:22Okay.
31:23So, so far, so good.
31:27But at the moment, this is sliding perfectly.
31:31I'm just about to put the last block under here.
31:33It's going to be a little bit tricky.
31:34The blocks fit in the runners to help the roof slide.
31:40There we are.
31:45Don't want to slip at this point.
31:46If I slip and run the screwdriver into the vinyl,
31:50I've got to start all over again.
31:51Now, hopefully, this is going to slide smoothly backwards.
32:01Oh, yeah.
32:02And, hopefully, all the way forwards.
32:08Look at that.
32:09We are watertight.
32:11In reinstating this sliding roof,
32:14what we've done is taken the manufacturer's original idea
32:19and run with it.
32:21Open top motoring in a saloon car.
32:24Lovely, beautiful.
32:31After weeks of work, the body's finally finished
32:34and it's being repainted in a green
32:36chosen from Walsley's 1930s colour chart.
32:38It's been bolted onto the frame while the wheels are back on
32:42and the engine is going in.
32:44Meanwhile, Tim is busy getting to grips
32:46with one of the car's smallest but most significant features.
32:50You know, every now and again on a car,
32:52you find something which is just by itself is beautiful.
32:54And in my world, it's that.
32:56What is that?
32:57Well, that is the thermometer.
32:58That is the temperature gauge that sits
32:59on the front of the Walsley,
33:01right at the front on top of the radiator.
33:03And, look, you can see there's a black needle in there
33:04and it says cool up there.
33:06That's when your engine's running cool.
33:07All good.
33:07And then the one you don't want,
33:09the enemy is where it says boil there.
33:10But what's inside of that to make that needle move?
33:13Well, I've exploded the contents of that
33:15into this little demonstration here.
33:17So, at one end, a vice holding onto a piece of metal
33:19and at the other end, have a look at this.
33:21We've got a very thin piece of welding wire
33:23with a little black needle in there
33:25that's represented by this blue and white straw.
33:28So, if we are benefiting from the fact
33:31that when you heat metal, it expands.
33:33Let's have a look.
33:35Because most things in life, when you heat them up,
33:37the molecules get excited, they want more space,
33:40they're pushing, they're getting angry,
33:42you know, all that kinetic energy.
33:44This is basically the definition
33:45of the coefficient of thermal expansion,
33:48which is using heat to demonstrate
33:50mechanical displacement.
33:52So, as this piece of metal gets hot,
33:54it gets marginally longer.
33:56And in the process of doing that,
33:57it's literally rolling along
33:59that piece of welding wire there
34:01and rotating the needle.
34:03So, the only difference between this
34:05and the one on the Walsley
34:07is the fact that the metal in the Walsley
34:09is coiled up deep inside there.
34:11Anyway, I've got to go and fit that,
34:12so I'll see in a bit.
34:14The running boards are going on
34:15and the new radiator, grill
34:17and all-important thermostat have been fitted.
34:21Next, they want to see if all that time
34:23and money spent on the engine
34:24has got it working again.
34:26Oh, yes!
34:28Oh, yes, baby!
34:30That sounds beautiful!
34:34Well, isn't that nice?
34:35That's lovely, isn't it?
34:36Yeah.
34:36Right, we have a running car.
34:38Fabulous.
34:38There's still work left to do
34:40to get this car to John.
34:41Tomorrow...
34:42Yes.
34:42...we've got to get this car done
34:43and the clock is against us.
34:47Every now and then,
34:48there's a little feature on old cars
34:50that brings me untold joy.
34:53And on this one,
34:54here it is.
34:56Yeah.
34:57And I'd say that's an indication
34:59to crack on getting the car finished.
35:02Otherwise,
35:02it will miss its dinner date tomorrow.
35:08It's time to serve up
35:09the revamped Hornet to owner John.
35:12He's a foodie,
35:13so the boys have laid on dinner.
35:15But with a difference.
35:17Welcome to Meals Hall,
35:19right on the coastline
35:20here in Southport Falls,
35:21wearing a beautiful Wolseley Hornet.
35:23I know,
35:23and doesn't it look amazing here?
35:26Ah, I'm pleased you said that
35:27because this car's torn my head up as well,
35:29totally because, like,
35:30E46 M3,
35:30my favourite car on the planet.
35:32Yeah, exactly.
35:32But this is...
35:33I think it might have replaced it
35:34because it's the M3 of its day.
35:35It's that overhead camshaft.
35:38It's compact,
35:39six-cylinder.
35:39It's great.
35:40And it runs brilliantly.
35:43What is the plan?
35:45Bang!
35:45There it is.
35:46Dining in the dark.
35:47Awaken your senses.
35:48Yep.
35:49Hold on, wait a minute.
35:49Is that a blindfolded meal?
35:51Yeah.
35:53Blindfolded.
35:53It tastes bigger and better.
35:54John has been brought down here
35:55by his daughter Emma.
35:57Yes.
35:57So he's excited to be
35:58dining in the dark.
35:59But it's not really the dark.
36:01It's only the dark for him.
36:01So we're blindfolding him
36:03and nobody else.
36:04Give him a bit of food.
36:05And then off comes a blindfold.
36:06Bang!
36:06Have your car back, mate.
36:07I told you to bring
36:08some nice food up.
36:08Yeah, you've got the nice food.
36:09What's up with your face?
36:11Well, when you said nice food,
36:12I thought you just meant
36:12workshop food.
36:14Workshop food?
36:15Yeah, I've got some
36:15chicken nuggets and everything.
36:16Well, it's not chicken nugget
36:17in the dark, is it?
36:19Well, I didn't know.
36:19Right, OK, listen.
36:20Let's get the car in there first
36:21and get this together.
36:22Right, I'm going to stick this on here.
36:23OK.
36:25Yes, eating blindfold is a thing.
36:27Makes the food taste better,
36:28apparently.
36:29Although, not sure it works
36:30when Fuzz is the chef.
36:32As John will be blindfolded,
36:34he'll have no idea
36:35Tim is his waiter
36:36or that friends and family
36:38are in the room.
36:39At a given moment,
36:40I'm going to direct you
36:42to sneak past John,
36:43who'll be on this table here,
36:44and get round the back
36:45of the car
36:45to give him his car back.
36:47That's the deal.
36:47But, he can't hear crowds moving.
36:50Outside, John's arrived
36:52with Emma and her family.
36:53Hopefully, he's still in the dark.
36:55How are you doing this evening?
36:57Can I just grab your names, please?
36:59Emma.
37:00Emma.
37:00Lovely, OK.
37:02John's blindfolded
37:04and led to his seat,
37:05thinking his family
37:06had been blindfolded as well.
37:09Meanwhile, Fuzz is auditioning
37:11for Ramsay's Kitchen Nightmares
37:13with a menu of beans on toast,
37:15party rings and...
37:16Sausages?
37:16No.
37:18Chicken nuggets
37:18that look like teeth.
37:19No, no, no, no.
37:20He's not going to be able
37:21to see the food,
37:22so he's going to believe
37:23that it's really fancy.
37:25I've got it written
37:25all out here in French.
37:27We have...
37:29Beans on toast.
37:35Beans on toast.
37:36Yeah, that's right.
37:37You just say it like that.
37:38Right.
37:39It's going to be great.
37:40Get it under the...
37:40Whatever that's called.
37:41OK.
37:41Get it under the...
37:42Right.
37:42There we go.
37:43Hold on.
37:44Hold on.
37:45And have you thought
37:46beans on toast was bad?
37:48Before that,
37:49there's sausage and pineapple
37:50on sticks.
37:52Rather you than me, John.
37:54That's quite nice
37:54whatever it is.
37:55Phew, the boys are getting
37:59away with it.
38:00Dinner nearly done,
38:02the other guests
38:02take their place.
38:03OK, the finale.
38:07This is some sort of
38:09pudding, isn't it?
38:12Just get it a bit up.
38:17Can you stand up, please?
38:19All of it.
38:20All of it.
38:23Quiet.
38:25Quiet.
38:29OK.
38:30On y va.
38:31Oh.
38:35You're joking.
38:36Do you know what that is?
38:37Do you know what that is?
38:41You're joking.
38:42Come here.
38:43Really?
38:45That is your car?
38:46Yeah.
38:47Let's talk about Emma
38:48for a moment.
38:48Can you explain
38:49to your lovely dad,
38:51John,
38:51why you wrote to us
38:52car as well as Emma?
38:53Not to me.
38:54Talk to you there.
38:57You've fixed
38:58everything
38:59in my life.
39:00You've picked me up
39:01when every single car
39:03of mine is broken down.
39:04So it's about time
39:05I fixed one of yours.
39:06Yeah.
39:08And because I love you.
39:09You're my hero.
39:10Yeah.
39:11Can we have a round of applause?
39:19We have been itching
39:21to meet you for ages.
39:22It's been a massive transformation.
39:23It's not anything at all.
39:24It's beautiful, isn't it?
39:25That is your little car.
39:26I can't believe it.
39:28And there was a lot of work
39:29that had to be carried out.
39:30There's a lot of work.
39:32I can't believe this car.
39:34It's beautiful, isn't it?
39:36Is it syncing in?
39:37That's cool.
39:38Incredible.
39:39Incredible.
39:39I'm sorry we can't
39:40turn back the hands of time.
39:42I'm sorry we can't get
39:43the most important
39:43to you guys back here.
39:45Your lovely wife, Anne,
39:46because she would have
39:46loved to have seen
39:46this thing finish.
39:47Of course she would.
39:48Of course she would.
39:49I'm sorry we can't
39:49make that happen,
39:50but we could at least
39:51make this happen.
39:51Yes.
39:52That's incredible.
39:53I can't believe it.
39:54I really can't believe it.
39:57That is your car.
39:58There it is.
39:59That pain you've had
40:00sitting in the garage,
40:01wherever it's been in your life,
40:02you know,
40:02needing so much work done
40:03to it.
40:03It's done, John.
40:05It's done.
40:06Yeah.
40:06You achieved it.
40:07Done.
40:07It's done.
40:08And that's thanks to
40:09the little girl,
40:10who wrote to us.
40:12We were like,
40:13absolutely,
40:13we're going to do this.
40:14Yeah.
40:14And we've done this
40:15for everybody
40:16who has lost somebody
40:17in COVID as well.
40:18Oh, thank you.
40:19Can we have a round
40:20of applause
40:20for John, please?
40:22And it's Walsley Hornets!
40:24It's completed.
40:25It's done.
40:26It's done.
40:32Come on in, John.
40:33Oh, man.
40:34Go have a quick look
40:34under there.
40:36Look at it.
40:37My God.
40:37Engine completely rebuilt.
40:39Everything has been gone through.
40:41The body has been off the chassis.
40:43And also,
40:44there was a big hole in the top.
40:45It was.
40:45Yeah.
40:46So now,
40:47you've got a fully opening
40:49sunshine roof on there.
40:50Now,
40:51you can have the fun bit.
40:52You can drive it,
40:53do a bit of maintenance,
40:55and it's fun then, isn't it?
40:56Fantastic.
40:57After John gave up
40:59on his dream
40:59of rebuilding the Hornet,
41:01it looked like
41:01it would be grounded
41:02in his garage forever.
41:04Thanks to the boy's hard work,
41:05it's ready to take flight
41:07once more.
41:07The neglected engine
41:11is running again,
41:13complete with that
41:13groundbreaking overhead camshaft.
41:16Peeling yellow paintwork
41:17has been replaced
41:18with a classic green
41:19that oozes 1930s glamour.
41:21Up top,
41:23the disintegrating sliding roof
41:25has been completely replaced
41:26so the car can be open
41:28to the rays
41:29when the sun shines.
41:31And down below,
41:31the new running boards
41:33mix classic lines
41:34with a modern touch.
41:36While the stylish look
41:37is completed
41:38by the sparkling new radiator
41:40and classic honeycombed grill.
41:45Describe the feeling
41:46of sitting inside
41:47your Wolsey home.
41:48After all this time,
41:50with it being sat
41:51in that garage
41:52to actually sit in it
41:54and look at it finished,
41:55it's just incredible.
41:57It really is.
41:58I can't describe to you
42:00just how much it means
42:01to me, this car.
42:02It was bought
42:03for me and my wife
42:06to do trips in
42:07because I've always loved
42:10the old cars
42:10when she was here.
42:13But it wasn't to be,
42:15unfortunately.
42:15I hope that you've had
42:17your tough times
42:17and they're done now
42:18and this is the beginning
42:19of a new era.
42:20Me too.
42:21Yeah.
42:22Definitely.
42:22Yeah.
42:23Definitely.
42:23I think you've dealt
42:24with enough.
42:26Me and the old girl
42:27here are going to have fun.
42:29I know.
42:30You are right at home, man.
42:31Yes, absolutely.
42:33There is only one thing
42:34left to do, John.
42:35It gives me great pleasure
42:36to tell you
42:37that you have been
42:37officially Car SOS.
42:43Enjoy the car.
42:45Get out there
42:45and do precisely
42:47what your wife
42:48would want you to do.
42:49Yes, exactly.
42:50Get out on the roads.
42:55How does it feel,
42:56huh?
42:57Oh, it feels brilliant.
42:58Did you ever think
42:59you'd be driving it?
43:00Never.
43:01So how did you...
43:02So how did you...