Vintage Voltage (2020) - full transcript

A team of car designers, fabricators and mechanics restore classic cars to modern electric vehicles.

THIS TIME
ON "VINTAGE VOLTAGE,"

MOGGY AND THE TEAM
TRANSFORM A LANCIA FULVIA.

BUT THEIR FIRST
FRONT-WHEEL-DRIVE CONVERSION

CAUSES PROBLEMS
FOR WORKSHOP MANAGER TONY.

THE GEARBOX
MOUNTS ARE SO SLACK.

YOU CAN SEE HOW MUCH MOVEMENT
IS THERE.

THE OWNER WANTS THIS COOL
COUPE TO RETAIN ITS UNIQUE CHARACTER.

THESE WERE KNOWN AS QUITE
A LIGHT AND NIMBLE-HANDLING CAR.

AND HE'S NOT THE ONLY ONE
WHO'S DESPERATE

TO GET BEHIND THE WHEEL
OF THIS ELECTRIFYING RALLY ICON.

SO I'M QUITE EXCITED
THAT THE FIRST LANCIA



I'M ACTUALLY GOING TO DRIVE
IS GOING TO BE ELECTRIC.

HERE IN THE BROODING
VALLEYS OF MID WALES,

A REVOLUTION
IS UNDERWAY.

THESE CARS WERE ONE OF
THE BEST-LOOKING CARS EVER.

ICONIC CARS OF THE PAST

ARE BEING GIVEN
A NEW LEASE OF LIFE.

SLOWLY THEN, SLOWLY.

OWNERS WANT MORE POWER,
MORE PERFORMANCE,

BUT AT LESS COST TO THE POCKET

AND TO THE PLANET.

THE SOLUTION IS ELECTRIC.

SO ELECTRIC CAR, AS SOON AS YOU
PUT THAT PEDAL DOWN,

OOH, YOU'RE AWAY.

RICHARD "MOGGY" MORGAN



AND HIS TEAM
OF CUTTING-EDGE MECHANICS

ARE TAKING CLASSIC CARS

AND RE-ENGINEERING THEM
AS ELECTRIC CARS FOR THE FUTURE.

IT'S EXACTLY
WHAT IT SHOULD BE.

IT'S PERFECT.

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

AH, PEDRO, JUST THE MAN.YES, MATE.

LANCIA FULVIA,
DO YOU REMEMBER IT?

OH, YEAH, BEAUTIFUL COUPE SHAPE,
BRILLIANT AT RALLYING?

LEGENDARY AT RALLYING.

I USED TO RALLY, SO I'M SO
EXCITED WE GOT ONE COMING HERE.

GREAT HANDLING,
FRONT-WHEEL DRIVE?

YEP.

NOT DONE A FRONT-WHEEL
DRIVE BEFORE.

WE HAVEN'T.

IT'S PROBABLY GOING TO BE
A CHALLENGE,

BUT WE'RE ALWAYS UP FOR IT.
ANYWAY, THE CUSTOMER IS HERE.

HE'S CALLED JERRY.
HE'S OUTSIDE.

DO US A FAVOR.
GO AND HAVE A CHAT WITH HIM.

TAKE A BRIEF OFF HIM
AND THEN COME BACK AND SEE ME.

- GOOD.
- ALL RIGHT. AWESOME.

- YOU MUST BE JERRY.
- I AM.

HI. PEDRO. GREAT TO MEET
YOU.GREAT TO MEET YOU TOO, PEDRO.

NOW WHEN DID YOUR LOVE AFFAIR
WITH THE FULVIA START?

FIRST TIME I SAW THIS IN 1979,

I THOUGHT IT WAS SUCH
A BEAUTIFUL LITTLE CAR,

BUT AT THE TIME,
I NEEDED A BIGGER CAR

BECAUSE I HAD TWO
SMALL CHILDREN,

AND I HAD TO BUY
A FORD CORTINA,

BUT THE LANCIA FULVIA
JUST WOULDN'T GO AWAY,

SO EVENTUALLY ABOUT
20 YEARS LATER, WE GOT THIS ONE.

ABSOLUTELY FANTASTIC.

BUILT BETWEEN 1963 AND 1976,

THIS FRONT-WHEEL-DRIVE COUPE

HAS A BIG REPUTATION
IN THE MOTORSPORT WORLD.

ITS ADVANCED INDEPENDENT
FRONT SUSPENSION,

WHICH HAS ONE LARGE
CROSS-MOUNTED LEAF SPRING,

GAVE IT GREAT HANDLING.

AFTER A MEMORABLE WIN
AT THE FAMOUS MONTE CARLO RALLY,

IT WENT ON TO SECURE THE 1972
INTERNATIONAL CHAMPIONSHIP

FOR MANUFACTURERS.

THE BIG QUESTION IS, THOUGH,

YOU'RE WANTING TO CONVERT
THIS TO ELECTRIC.

WHAT'S THE STORY
AND THINKING BEHIND THAT?

IT'S NOW MY SON'S CAR.
HE DRIVES A TESLA.

HE WANTS TO BE ABLE
TO DRIVE THIS...

- OKAY.
- ...ELECTRIC.

DO YOU HAVE ANY IDEAS WHAT
HIS AIMS ARE IN TERMS OF RANGE

AND PERFORMANCE
HE'S AFTER FROM THE CAR?

CITY DRIVING AND WHATEVER
REASONABLE DISTANCE CAN BE GOT.

KEEP UP WITH TRAFFIC AND...
HE DOESN'T NEED QUICK ANYMORE.

- NO.
- NO.

AS LONG AS THE CAR STILL BEHAVES
LIKE A FULVIA LIKE IT USED TO.

SO WE WANT TO HAVE THAT
BALANCE BETWEEN IT,

YOU KNOW, ENOUGH RANGE
BUT MAINTAINING THE FULVIA FEEL.

YES.

NOW I NOTICE IT'S RIDING
QUITE HIGH.

WELL, THE ENGINE IS
OUT OF IT,

SO THERE'S NO WEIGHT
IN THE HE FRONT.

SO YOU'VE ALREADY TAKEN
THE ENGINE OUT,

AND YOU'RE
FULLY COMMITTED NOW

TO TURNING IT
INTO AN ELECTRIC CAR.

- YES.
- HOW ABOUT ON THE INSIDE?

DO YOU WANT US TO DO ANYTHING
ON THE INSIDE WHILE --

IT IS GOOD, BUT THE SEATS
NEED A BIT OF CARE.

I'VE GOT SOMEBODY IN MIND TO FIX
THEM ONCE WE GET IT BACK HOME.

OKAY, SO YOU'RE GOING TO
DO THAT. EXCELLENT.

SO OUR JOB THEN, OBVIOUSLY DO
THE ELECTRIC CONVERSION.

WE'RE GOING TO GIVE YOU
AS MUCH RANGE

AS WE CAN
WITHOUT COMPROMISING THE CAR.

I THINK IT COULD DO
WITH POWER STEERING BECAUSE,

EVEN WITH THE ENGINE, IT WAS
A LITTLE HEAVY ON THE STEERING.

WE GET SPOILED NOWADAYS.

ALL MODERN CARS HAVE
POWER STEERING,

AND YOU KIND OF FORGET THAT...
THAT'S RIGHT.

...NOT THAT LONG AGO,
THEY DIDN'T,

AND IT REALLY DID TAKE A BIG
DRAG TO GO AROUND THE COURSE.

THAT'S RIGHT.

NOW HAVE YOU GOT
ANY EXPECTATION OF BUDGET?

WHAT'S HE GOING TO GIVE US
TO PLAY WITH?

I THINK HE'S EXPECTING
ABOUT 40,000.

OKAY.

IF YOU COME ACROSS THINGS
THAT NEED DOING, JUST DO THEM.

YEAH, I MEAN, WHEN WE ENTER
A PROJECT LIKE THIS,

WE NEVER KNOW WHAT MIGHT
BE AROUND THE NEXT CORNER.

IT'S GOT TO BE RIGHT
AT THE END OF THE DAY.

YES, IT'S GOT TO BE RIGHT.WE
DON'T WANT TO CUT CORNERS.

BUT I'M SURE WE CAN WORK
WITH THAT KIND OF NUMBER.

THAT'D BE GREAT.

WELL, JERRY, IT'S SUCH
A BEAUTIFUL, ICONIC CAR.

I'M SURE WE'RE GOING TO
MAKE IT PERFECT

FOR THAT NIPPY
RUNNING AROUND TOWN

AND JUST LOOKING REALLY COOL
AT THE SAME TIME.

THAT'D BE PERFECT.
YES.WE NEED TO GET THIS CAR

OFF THE TRAILER
SO MOGGY CAN START

HIS ASSESSMENT
OF THE CAR,

AND THEN WE CAN GET WORKING
AND RETURN IT TO YOU

WITH A NEW LEASE OF LIFE.GREAT.

CONVERTING THIS CHARACTERFUL
ITALIAN CLASSIC TO ELECTRIC

WILL CHANGE THE WEIGHT
BALANCE FRONT TO BACK.

MOGGY AND THE TEAM HAVE TO
BRING IT INTO THE 21st CENTURY

BUT RETAIN
ALL THE CHARM, PERSONALITY,

AND HANDLING
OF THIS DISTINCTIVE DRIVE.

COOL. A LANCIA FULVIA.

YOU DON'T SEE MANY OF THESE
OUT HERE.

GREAT, QUIRKY CAR.

I LOVE LANCIAS FOR THE SOLE
REASON OF RALLY CHAMPIONSHIPS.

NEVER DRIVEN A LANCIA,
BUT WOULD LOVE THE OPPORTUNITY,

SO I CAN'T WAIT
UNTIL THIS ONE'S FINISHED.

1.3 ENGINE IN IT,

AND I THINK THEY EVEN SQUEEZED
ABOUT 90 HORSEPOWER

OUT OF A 1.3 ENGINE,
WHICH IS SAYING SOMETHING.

THE CUSTOMER HAS VERY KINDLY
TAKEN THE ENGINE OUT FOR US.

WE'VE JUST GOT TO LITERALLY FIND
A HOME FOR THE ELECTRIC MOTOR,

SO OUR IDEA IS, WE'RE GOING
TO PUT A HYPER 9 MOTOR

JUST HANGING OFF THE GEARBOX,
THE FRONT HERE.

WE'LL NEED TO MOUNT
THAT OBVIOUSLY.

A HYPER 9 IS A TYPE OF MOTOR
THAT WE USE A LOT.

IT'S A VERY MODERN DESIGN
OF MOTOR.

IT'S A SYNCHRONOUS RELUCTANCE
PERMANENT MAGNET MOTOR,

WHICH IS QUITE A MOUTHFUL,

AND IT'S A VERY THERMALLY
EFFICIENT MOTOR,

SO IT'S MORE EFFICIENT
THAN MOST OTHER MOTORS

LIKE INDUCTION MOTORS OUT THERE.

IT'S A GREAT MOTOR.

ABOVE THE MOTOR, WE'LL HAVE
ALL THIS SPACE IN FOR BATTERIES.

THERE'S A REQUIREMENT
OF ABOUT 120,

125-MILE RANGE ON THIS,

SO WE'RE PROBABLY LOOKING AT
AROUND ABOUT, SAY,

16 LG CHEM BATTERIES.

I'M THINKING EIGHT AND EIGHT
OR SIX AND A 10 AT THE BACK.

SO THE INTERIOR LOOKS
PRETTY GOOD TO ME.

THE ONLY THING WE NEED TO FIND
A HOME FOR IN HERE

IS A STATE-OF-CHARGE METER,

WHICH JUST TELLS YOU
HOW MUCH CHARGE

THERE IS LEFT IN THE BATTERY,

SO I'LL REPURPOSE ONE
OF THOSE BINNACLES IN THERE

FOR A STATE-OF-CHARGE METER.

THAT'S ALL WE NEED TO DO,
VERY LIGHT TOUCH

IN THE INTERIOR.

LET'S HAVE A LOOK IN THE BOOT.

SO I'M LOOKING FORWARD
TO A BIT OF SPACE IN HERE

TO FIT SOME BATTERIES.

THERE'S A HOLE IN THE FLOOR
HERE

WHERE THE PETROL TANK
USED TO GO,

SO WE CAN EITHER SINK
SOME BATTERIES INTO THE FLOOR,

OR WE CAN PUT SOME BATTERIES
BACK THERE OR EVEN BOTH.

IT'S GOING TO BE QUITE
A PRACTICAL LITTLE CAR

WHEN IT'S FINISHED AS WELL.

SO I THINK THERE'S A FUEL FILLER
CAP THERE, LOCKABLE AS WELL,

SO PROBABLY HIDE THE CHARGE
SOCKET IN THERE MAYBE.

FROM THE OUTSIDE,
YOU'LL NEVER KNOW IT'S ELECTRIC.

I'M REALLY LOOKING FORWARD
TO ACTUALLY DRIVING THIS ONE

ON THE ROAD
BECAUSE I LOVE RALLYING.

I'VE DONE RALLYING
FOR A LONG TIME,

BUT I'VE NEVER GOT
TO DRIVE A LANCIA,

SO I'M QUITE EXCITED
THAT THE FIRST LANCIA

I'M ACTUALLY GOING TO DRIVE
IS GOING TO BE ELECTRIC.

THE FULVIA WAS BUILT AT A TIME

WHEN CAR MANUFACTURERS
WERE ALL EXPERIMENTING

WITH DIFFERENT SUSPENSION
AND ENGINE SETUPS.

MOGGY HAS A PLAN
FOR THE CONVERSION,

BUT THE LANCIA IS A RARE
AND UNUSUAL CAR,

WHICH WILL NEED A LOT
OF TIME AND ATTENTION.

- ALL RIGHT. STEADY.
- WE'RE GOOD.

STEADY.

FIRST JOB IS FOR EXPERIENCED
MECHANICS PETE AND NEIL

TO TEST-FIT
THE NEW ELECTRIC MOTOR,

BUT ACCESS IS TIGHT.

OKAY.
STEADY, STEADY, STEADY, STEADY.

STOP THERE.
STOP.

I THINK THIS BOTTOM GEARBOX
MOUNT'S GONNA HAVE TO COME OUT.

IT'S PROVING
A BIT OF A PROBLEM.

LOCATION PROBLEMS.

GETTING IN THE WAY,
IT'S A LOCATION PROBLEM,

SO WE HOPE WE GOT
ENOUGH CLEARANCE,

BUT IF WE HAVEN'T,
TONY IS GOING TO HAVE TO COME UP

WITH SOMETHING TO ALTER
THE FRONT CROSSMEMBER.

THAT BELL HOUSING ON THE GEARBOX

IS QUITE FAR FORWARD
IN THE ENGINE BAY,

SO IF YOU GOT A BELL HOUSING
THAT'S QUITE FAR FORWARD

AND THE FRONT
OF THE CAR IS HERE,

YOU'VE ONLY GOT A LITTLE BIT
OF ROOM THEN FOR A MOTOR.

WORKSHOP MANAGER AND
EXPERT FABRICATOR TONY IS CALLED IN.

THE MOTOR IS SITTING
ON THE BEAM THERE.

THAT'S WHAT WE DON'T WANT
TO HAPPEN.

THINGS ARE STARTING
TO LOOK A BIT IFFY.

THE FRONT OF THE MOTOR
IS FOULING A STRUCTURAL PART

IN THE ENGINE BAY
KNOWN AS A SUBFRAME.

THAT MEANS NOW THE WHOLE FRONT
OF THE MOTOR ASSEMBLY

HAS GOT TO CUT OUT.

THE MOTOR IS REMOVED SO PETE
CAN TRY

AND CUT A ROUNDED SECTION
FROM THE STEEL SUBFRAME.

ALL THE WAY.

BUT THIS IS A STRUCTURAL PART
OF THE CAR,

SO ONCE HE'S MADE
THE MODIFICATIONS,

HE'LL ALSO HAVE TO WELD

A STRENGTHENING METAL PLATE
BACK IN.

IN ADDITION, THE WHOLE SECTION
WILL NEED TO BE GALVANIZED

TO MAKE SURE
IT DOESN'T RUST IN THE FUTURE.

I'VE CHOPPED OUT
THE FRONT SUBFRAME

FOR THE CLEARANCE FOR THE MOTOR.
NOW I'M GOING TO OFFER UP

THE MOTOR AGAIN
JUST TO MAKE SURE

THERE'S ENOUGH CLEARANCE
ON A DRY FIT.

WITH THE SUBFRAME
MODIFIED AND AN ADAPTER PLATE

ATTACHED TO THE MOTOR,

IT CAN NOW BE FITTED
TO THE GEARBOX.

SLOWLY, SLOWLY, SLOWLY.
STOP.

WHAT WE NEED TO DO IS DROP
THE HOIST IN A MINUTE

AND CHECK THE BOUNCE
BECAUSE I DON'T KNOW

HOW MUCH BOUNCE I'LL NEED.

THE MOTOR IS IN
AND BOLTED UP TIGHT,

PROBLEM SOLVED -- OR IS IT?

BECAUSE THE GEARBOX MOUNTS
ARE SO SLACK,

YOU CAN SEE
HOW MUCH MOVEMENT IS THERE.

YEAH, GOT ANOTHER
BIG PROBLEM NOW.

THE TEAM HOPED TO JUST BOLT
THE NEW MOTOR TO THE OLD GEARBOX,

BUT THE MOUNTS ON THE BOX
ARE NOT UP TO THE JOB.

TONY CAN MOVE
THE WHOLE ASSEMBLY BY HAND,

AND THIS AMOUNT OF PLAY
WOULD LEAD TO HUGE VIBRATION,

CAUSING INTERNAL DAMAGE
TO THE MOTOR AND GEARBOX.

FABRICATOR RYAN
HAS THE JOB

OF CREATING
A BESPOKE MOTOR MOUNT

TO SOLVE
THE LANCIA'S PROBLEM.

THE MAIN PROBLEMS WE'RE
GOING TO HAVE WITH THIS CAR

IS SPACE IN THE ENGINE BAY.

THERE'S A LOT GOING ON.

WITH NOTHING IN THERE, IT SEEMS
LIKE THERE'S A LOT OF SPACE.

WELL, THAT FITS
A LOT BETTER NOW.

BUT WHEN YOU ACTUALLY
PUT THE ENGINE-MOUNT PLATE,

THE ENGINE ITSELF, AND THEN
WE'VE GOT THE BATTERY BOXES,

THE SPACE JUST DISAPPEARS,
AND BEFORE YOU KNOW IT,

YOU'RE WORKING WITH
MILLIMETERS, NOT INCHES.

THE LANCIA IS A LIGHT
AND DELICATE CAR.

IT'S GOING TO TAKE
CAREFUL FABRICATION

TO SUPPORT THE NEW
55-KILOGRAM ELECTRIC MOTOR,

SO RYAN IS TRYING
TO CREATE A CRADLE.

IT'S GOING TO BE VERY,
VERY CLOSE

TO GET ALL THIS
OUT IN ONE PIECE.

THAT FITS WITH
A COUPLE-OF-MIL GAP.

IT'S TOUCHING THAT SIDE,
SO, YEAH, IT'S CLOSE.

AT LEAST I'VE GOT CLEARANCE
TO GET THIS OUT AND UP.

TO KEEP THE MOTOR
MOUNT LIGHT BUT STRONG,

RYAN IS ALSO PLANNING
TO USE A TOP CROSSBAR.

SO IT'S JUST GOING TO PUT THIS
ACROSS HERE WITH A BEND IN IT,

TWO WELDS EITHER SIDE,
AND THAT WILL BRACE IT UP.

IT'LL STOP THESE FROM MOVING,

AND IT'LL STOP IT
TWISTING AS WELL,

SO THAT'S GOING TO BE
THE NEXT STEP.

RYAN USES
A ROLL BENDER, A MECHANICAL JIG

THAT COMBINES THREE ROLLERS

TO BEND THE METAL BAR
INTO A CURVED ARC.

IT'S GETTING QUITE CLOSE.

SHOULD BE NOT FAR OFF
FROM HEIGHT.

YEAH, ABOUT THREE-QUARTERS
OF THE WAY THERE.

YOU CAN'T SET AN ANGLE.

THE TRICK IS TO GRADUALLY
BEND THE BAR

TO CREATE THE PERFECT CURVE.

IF RYAN BENDS IT TOO FAR, IT'S
TOUGH TO FLATTEN IT OUT AGAIN.

YEAH.

PERFECT.

I CAN GET MY FINGER
UNDERNEATH IT.

THAT'S MORE THAN ENOUGH
CLEARANCE, WHAT WE NEED.

I CAN CUT THIS DOWN TO SIZE NOW
AND FIT IT INTO THE CAR.

OKAY. NICE AND FLUSH AT THE END,
A GOOD JOINT TO WELD ON.

PUT A FEW TACKS THERE,
AND THAT'LL HOLD IT SQUARE.

- SPOT-ON.
- IT'S GOOD, INNIT?

BASICALLY WE'VE GOT
THE CRADLE REPLACED NOW.

IT'S ALL TACKED TOGETHER.
IT'S NOT GOING TO MOVE.

WHILST WE TAKE IT OUT,

WE'RE GOING TO WELD
AROUND THE FOOT PLATE,

AND WE'LL GET IT BACK IN ONCE
IT'S WELDED UP JUST TO MAKE SURE

EVERYTHING IS WHERE
IT'S SUPPOSED TO BE,

AND THEN WE CAN CARRY ON
WITH THE INSTALLATION.

WELL, THE HAPPY THING IS,
I GOT IT OUT IN ONE PIECE.

TO BE STRONG ENOUGH,
THE MOUNT NEEDS TO BE BRACED,

AND THAT MEANS THE PLATES NEED
TO BE WELDED TOGETHER,

BUT WELDING PUTS A LOT OF HEAT
INTO THE METAL,

AND HEAT CAN CAUSE DISTORTION.

AFTER WELDING IT, IT'S PULLED A
LITTLE BIT MORE THAN WE THOUGHT

EVEN THOUGH I TRIED TO LIMIT
THE HEAT IN THE BACK PLATE.

THE ONE SIDE HAS PULLED
MORE THAN THE OTHER,

SO I CAN'T JUST RUN
A SPIRAL BRAND THROUGH IT,

SO I'VE GOT TO TAKE
EACH SIDE DOWN SLOWLY.

MEANWHILE AS RYAN
STRUGGLES WITH HIS MOTOR MOUNT,

WORKSHOP MANAGER
AND CHIEF FABRICATOR TONY

SETS TO WORK
IN THE BOOT OF THE CAR.

THE PLAN IS TO WELD A BATTERY
STORAGE TRAY

INTO THE SPACE WHERE
THE FUEL TANK WOULD'VE BEEN.

WELDING NEEDS A GOOD
CLEAN CONTACT WITH THE METAL,

BUT THE BOOT OF THE LANCIA
IS COVERED IN UNDERSEAL,

A THICK WAXY COATING
DESIGNED TO STOP RUST.

SO WHAT I'M DOING NOW,
SOME OF THE UNDERSEAL

IS REAL BLOODY HARD,
AND IT'S LAPPED UP SO JUST NEED

TO SOFTEN IT UP A LITTLE,
TINY BIT JUST TO GET IT FREE.

WITH THE UNDERSEAL
REMOVED, TONY CUTS OUT THE FLOOR

AND FABRICATES THE BATTERY
STORAGE TRAY.

YEAH, NOT TOO BAD
AT THE MOMENT.

SO THAT'S JUST GOT TO BE
REINFORCED UNDERNEATH THEN

AND CUT ALL THE OLD LIP OUT.

THEN TWO BATTERIES ARE GOING
TO FIT IN THERE,

AND THEN WE'RE GOING TO HAVE
OUR BATTERIES AT THE BACK.

TONY CHECKS THE BATTERIES
WILL FIT USING MOCK-UP METAL BOXES.

THAT'S JUST THE BATTERIES.

WHAT WE GOT TO DO
IS BUILD THE BOX NOW,

SO WE NEED TO LEAVE
JUST ENOUGH SPACE IN BETWEEN

SO WE CAN GET THE BATTERIES
LINKED UP,

AND ALSO TO SECURE
EVERYTHING DOWN,

AND THEN WHEN WE RELINE
ALL THE FLOOR,

ALL THAT'S JUST GOING TO BE
COMPLETELY COVERED OVER,

AND THEN WE'RE JUST
GOING TO UNDERSEAL

ALL THE BOTTOM END THEN.

BACK AT THE FRONT OF THE CAR,

RYAN IS STILL GRINDING DOWN
THE MOTOR MOUNT,

TRYING TO GET IT TO FIT.

IT'S NOT A MILLION MILES
AWAY NOW. IT'S ON.

NOW WE JUST HAVE TO FIGURE OUT
THE FINAL HOLE POSITIONS

IN THE RETAINING RING.

I'VE DONE THESE HOLES
EXACTLY 10 MILLIMETERS.

THEY NEED TO BE OPENED UP
JUST EVER SO SLIGHTLY

JUST TO AID
THE FITTING, REALLY.

WITH THE ENGINE MOUNT
FINALLY IN PLACE,

RYAN CAN TURN HIS ATTENTION

TO CONSTRUCTING BATTERY BOXES
FOR THE FRONT OF THE CAR.

TWO BATTERY BOXES
TO REINFORCE IT.

408.

OVERALL, THE AIM IS TO ACHIEVE
A PERFECT BALANCE

OF POWER AND WEIGHT.

ONE, TWO -- TWO BAR.

TOO FEW BATTERIES, AND THE
FULVIA WON'T HAVE ENOUGH RANGE.

THAT'S GOT TO BE ONE SIX TWO,
I, D, ONE SIX FOUR FOR THE TOP.

TOO MANY,
AND THE EXTRA WEIGHT OVER THE FRONT WHEELS

COULD LEAD TO PLOW ON UNDERSTEER

WHERE THE CAR DOESN'T TURN
INTO A CORNER,

AND YOU LOSE CONTROL.

JUST TRY AND WRITE
EVERYTHING DOWN

BECAUSE I GUARANTEE SOMEONE
IS GOING TO SEE THIS AND GO,

"OH, I'VE GOT ONE OF THEM.
CAN I HAVE ONE, PLEASE?"

SO IF EVER WE DO ANOTHER ONE,

WE CAN GET IT DONE
IN HALF THE TIME.

WE'VE GOT THE BASIC SHAPE
OF OUR BOX

NOW AFTER A LOT OF MEASURING,
A LOT OF SQUARING UP

AND CUTTING A LITTLE BIT
OF THE BODYWORK AWAY,

MANAGED TO GET A SIZE NOW
WHERE WE CAN FIT SIX BATTERIES.

WE'LL TRY A DRY FIT IN THE
ENGINE BAY AND SEE HOW IT GOES.

THIS IS A TEST TO SEE
IF THE PART FITS,

HOW IT MIGHT BE MOUNTED,

WHERE TO DRILL
ANY LOCATING HOLES

SO THAT LATER IN THE BUILD
WHEN IT'S ALL READY

TO GO TOGETHER FOR REAL
THAT NO MISTAKES ARE MADE.

- ALL RIGHT.
- LET GO.

NOW LOOK AT THE FRONT.

RIGHT.

HOLD THE BOX.

DROP.

TA-DA.

TRY SHUTTING THE BONNET.

YEAH.

OH, YEAH.

IN THE ENGINE BAY,
THE SIX-BATTERY BOX

THAT I'VE PUT IN IS THE BEST ONE

THAT I'VE DONE TO DATE SO FAR,
I WOULD SAY.

IT REALLY DOES SUIT
THE STYLE OF THE CAR.

IT'S -- IT'S NICE.

THE LANCIA HAS
OLD-FASHIONED MANUAL STEERING.

TURN THE STEERING WHEEL,

AND THAT INPUT IS FED THROUGH
MECHANICAL PARTS TO THE WHEELS.

JERRY WANTS POWER ASSISTANCE,
A PROGRESSIVE ELECTRONIC SYSTEM

WHICH AUTOMATICALLY HELPS
THE STEERING AT LOW SPEED

AND GIVES LESS ASSISTANCE
AT HIGH SPEEDS,

SO PETE NEEDS TO GET THE
STEERING COLUMN OUT OF THE CAR.

SO WHAT I'M DOING NOW IS THAT
I'M JUST UNDOING THE BOLTS

THAT PINCHES UP
THE STEERING RACK.

WE'VE GOT TO SEND
THE STEERING RACK

OUT TO A SPECIALIST COMPANY

WHICH WILL ADD POWER
STEERING TO THE UNIT.

A POWER-STEERING UPGRADE
ON A CAR LIKE THIS ISN'T UNUSUAL,

BUT IT WILL HAVE TO BE DONE
BY A SPECIALIST,

SO MOGGY NEEDS
TO FIND AN EXPERT

WHO CAN ADAPT
THE STEERING COLUMN.

HERE WE GO.

OKAY, SO THERE'S
THE ELECTRONICS,

AND...

THERE'S
THE WHOLE THING.

WORK IS GOING WELL,
BUT A NEW JOB LIST

HAS JUST APPEARED ON
THE WINDSCREEN FOR TONY.

I'VE JUST HAD THAT TURN UP
ON THE WINDSCREEN OF THE CAR.

I SHOULD'VE HAD THIS
AT THE START OF THE BUILD.

JERRY HAS HAD TIME
TO THINK ABOUT IT.

HE DECIDED NOW, ON THE LIST
OF WHAT WE GOT ALREADY,

I'VE GOT A COMPLETE
CARPET REFURB

SO BASICALLY A BRAND-NEW ONE,
SO, YEAH, WITH THAT,

WHAT I THINK I'M GOING TO DO
IS CALL THE TRIMMERS

AND JUST GET A TRIMMER
TO JUST DO THE LOT FOR ME.

ON PAPER,
IT DOESN'T LOOK A LOT,

BUT IN REALITY,
THAT'S A HELL OF A LOT OF WORK.

THE TEAM HAVE NO CHOICE
BUT TO PULL OUT ALL THE SEATS

AND SEND OFF THE OLD CARPET
TO BE REPLACED

BECAUSE THE CUSTOMER
IS ALWAYS RIGHT.

MEANWHILE, PEDRO IS
IN EAST SUSSEX TO MEET NEIL,

WHO IS A POWER-STEERING
SPECIALIST.

HE DOES SYSTEM CONVERSIONS
ON CLASSIC AND MODERN CARS.

COME THIS WAY.

OH, NOW THAT LOOKS LIKE
A PRETTY SPECIAL E-TYPE.

AND IS THIS IN
FOR POWER STEERING, I GUESS?

- IT IS INDEED, YEAH.
- WELL, THERE YOU GO.

THAT'S EXACTLY WHAT
I NEED FOR THIS.

BRING IT THIS WAY.

SO, YES, WE TOOK THIS OUT
THE FULVIA.

YEAH.

SO HOW DO YOU GO ABOUT
TURNING THIS

INTO A POWER-STEERING COLUMN,
AND WHAT'S THE PROCESS?

SO WE LIAISE WITH THE CAR,

AND THEY WOULD SEND US SOME
PICTURES OF THE COLUMN IN SITU

SO WE CAN SEE WHERE THE MOTOR
UNIT WOULD SIT ON THE COLUMN

AND HOW IT'S ORIENTATED.

SO THERE'S OBVIOUSLY, LIKE,

A METAL BAR
FROM THE STEERING WHEEL.

IT GOES ALL THE WAY THROUGH HERE
DOWN TO THE STEERING RACK.

THAT'S IT.

SO YOU'RE GOING TO ACTUALLY
CUT THAT STEERING COLUMN

AND PUT THE MOTOR
IN BETWEEN?

INDEED, YEAH, WE'LL REMOVE
A SECTION OF IT, CUT THE COLUMN,

AND THEN WE USE A MOTOR
SIMILAR TO THAT.

IS THAT THE MOTOR?

THIS IS ONE WE'RE GOING TO USE
FOR YOUR LANCIA, YEAH.

IT'S NOT TOO HEAVY.

NO, IT'S ONLY A FEW KILOS.YEAH.

THIS IS GOING TO GO
IN THAT COLUMN.

YOU'RE STILL GOING TO HAVE FROM
THE STEERING WHEEL THROUGH TO

THE STEERING RACK A SOLID BAR,
SO IF WE LOSE POWER,

WE'RE STILL GOING TO BE
ABLE TO STEER THE CAR.

YEAH, IT WILL JUST GO BACK
TO MANUAL

THE SAME IT WAS
PRIOR TO FITMENT.

HOW DOES THIS VARIABLE
ASSISTANCE

DEPENDING ON THE SPEED

AND JUST THE GENERAL
INTEGRATION WITH THE CAR WORK?

OKAY, SO I CAN GET STEVE
TO ANSWER THAT FOR YOU.

OKAY.

STEVE DOES THE WIRING LOOM,
ELECTRONICS AND SO ON.

BECAUSE THE AMOUNT OF
POWER ASSISTANCE

NEEDS TO VARY
WITH THE CAR'S SPEED,

THE SYSTEM REQUIRES SENSORS
WHICH TELL IT

WHEN THE IGNITION IS ON
AND HOW FAST THE CAR IS GOING.

SO FOR THE SPEED SIGNAL, THAT
IS NOTATED BY THIS DEVICE HERE,

WHICH IS OUR SPEED SENSOR.

THIS SITS IN LINE
IN THE SPEEDO CABLE

BETWEEN THE GEARBOX
AND THE OUTPUT ON THE SPEEDO.

- AH, OKAY.
- OKAY?

THIS IS WHAT ONE
WOULD LOOK LIKE.

OH, SO THAT'S THE UNIT
JUST THERE?

YEAH, SO WE CUT THAT IN LINE
TO THE SPEEDO CABLE,

AND THEN THAT GIVES OUR ECU
THE SPEED OF THE VEHICLE,

BUT THE OTHER THING WE NEED IS,
THIS IS A SIGNAL BOX.

NOW ON A NORMAL
COMBUSTION ENGINE,

WE'D PICK UP THE SIGNAL
FROM THE DISTRIBUTOR,

BUT IN THIS CASE, WE CAN'T
BECAUSE IT'S ELECTRIC VEHICLE,

SO WE USE THIS,
WHICH SIMULATES A PULSE

FROM AN ENGINE
TO SAY IT'S ON.

WITH THE VARYING OF
THE ASSISTANCE

THAT THE UNIT
GIVES BASED ON SPEED,

WHAT KIND OF RANGE
ARE WE TALKING ABOUT HERE?

OUR PARTICULAR SYSTEM
WHEN IT GETS TO ABOUT

30 MILES AN HOUR WILL START
SHUTTING DOWN FROM THERE

SO THAT YOU DON'T GET
VERY SENSITIVE

STEERING AT HIGH SPEEDS.

AND YOU GET -- DO YOU GET MORE
ASSISTANCE AT THE LOWER SPEED?

YOU'D GET MORE ASSISTANCE
AT SLOWER SPEEDS

AND LESS AT HIGHER SPEEDS.

THAT'S SUCH AN ELEGANT
SOLUTION.

PEDRO LEAVES THE
STEERING COLUMN WITH THEM.

THE WORK WILL TAKE A FEW WEEKS.

THE REASON WHY PEOPLE
WANT TO CONVERT CLASSIC CARS

TO ELECTRIC,
THERE'S ECOLOGICAL REASONS,

FOR INSTANCE, LESS EMISSIONS
OUT OF THE TAILPIPE.

THERE'S RELIABILITY
AND MAINTENANCE BENEFITS,

SO YOU'RE DRIVING
A CLASSIC CAR,

WHICH IS AS RELIABLE
AS A MODERN CAR,

AND WITH THAT COMES
COST SAVINGS NOT ONLY

BECAUSE DRIVING AN ELECTRIC CAR
IS ABOUT FIVE

TO 10 TIMES CHEAPER
THAN DRIVING A PETROL CAR,

BUT ALSO THE FACT THAT YOU'RE
NOT PAYING FOR MAINTENANCE COSTS

AND SERVICING ALL THE TIME.

THE BIG BENEFIT FOR ME IS,

IT'S JUST MORE ENJOYABLE
TO DRIVE AN ELECTRIC CLASSIC CAR

THAN IT IS
TO DRIVE A PETROL ONE.

SO RUST IS ALWAYS A DANGER
ON '70s CARS,

AND NOW WE'VE MODIFIED
AND WELDED TO THAT SUBFRAME,

THAT'S GOING TO BE AT RISK.

MOGGY OFTEN HAVES TO
GIVE PARTS EXTRA RUST PROTECTION.

THIS TIME, THE WHOLE
MODIFIED FRONT SUBFRAME

IS BEING SENT OFF
TO BE GALVANIZED.

GALVANIZING IS A PROCESS

WHICH USES A TOUGH
NEW ZINC COATING

TO DEFEND STEEL
AGAINST RUST.

PEDRO IS IN SHROPSHIRE

TO CATCH UP ON
THE PROGRESS SO FAR.

RIGHT.
HERE IS THE SUBFRAME, PEDRO.

OH, FANTASTIC.

- YEAH, LOOKING GOOD.
- YEAH.

WE'VE ALREADY BLASTED IT,
SHOP BLASTED IT,

AND WE'VE PUT SOME VENTILATION
HOLES IN IT AND SOME DRAIN HOLES

BECAUSE WE GALVANIZE
ON THE INSIDE AND THE OUTSIDE.

- AH, OKAY.
- BECAUSE THERE'S OBVIOUSLY

A RISK OF EXPLOSION WITHOUT
THE HOLES.

- HOW COME?
- BECAUSE SUPERHEATED STEAM

TRAPPED IN THE PRODUCT
CAN'T GET OUT.

IT JUST CAUSES EXPLOSION.

RIGHT, THAT'S NOT GOOD,
SO WE DON'T WANT THAT TO HAPPEN.

SO NOW WE NEED TO TAKE THIS

TO THE HYDROCHLORIC ACID
TO GET IT CLEANED UP.

- WOW.
- SO LET'S DO THAT NOW.

OKAY.

THE GALVANIZATION
PROCESS NEEDS THE PART

TO BE VERY CLEAN
TO BE EFFECTIVE,

SO THE SUBFRAME GOES THROUGH
A SERIES OF TANKS,

INCLUDING HYDROCHLORIC ACID.

AND FINALLY IT'S DRIED
IN A HEATED PIT.

WOW, HERE WE GO.

BECAUSE THIS IS QUITE
AN UNUSUAL PIECE,

SO THERE'S A POTENTIAL
DANGER THAT WE MIGHT --

THERE'S DANGER WITH EVERY

SINGLE PIECE THAT WE DO,
BUT THIS HAS GOT MORE HAZARD

TO IT THAN
A NORMAL PIECE OF STEEL.

YEAH.IT'S A BIT OF AN UNKNOWN REALLY.

NEXT, THE WHOLE PART
WILL BE HOT-DIPPED

IN 450 DEGREES
OF MOLTEN ZINC,

BUT THIS IS A TENSE PROCESS
BECAUSE THEY'RE NOT 100 PERCENT

SURE HOW THIS OLD PART
WILL REACT.

WE'RE GOING IN REALLY SLOWLY

BECAUSE OBVIOUSLY
THERE'S CLOSED SECTIONS.

IF WE GO IN TOO FAST,
THERE'S A CHANCE

THE HOLES COULD GET BLOCKED,
AND THE ITEM

COULD START FLOATING,
AND WE'D HAVE TO ABANDON IT.

IT'S QUITE VIOLENT.
THERE'S LOTS OF BUBBLES.

YEAH, YEAH, THERE IS --
IT'S BOILING OFF,

AND YOU CAN IMAGINE,
WITHOUT THEM VENT HOLES,

THAT SUPERHEATED STEAM,
NOWHERE TO GO,

AND THAT'S WHERE
THE EXPLOSION COULD HAPPEN,

SO VENT HOLES IN GALVANIZING
IS VERY IMPORTANT.

YEAH.
IS THAT BATH PURE ZINC OR --

IT'S 99.9 PERCENT PURE ZINC.

- WOW.
- WE'RE GOING TO BE IN THE ZINC

FOR AROUND ABOUT 4
TO 5 MINUTES PROBABLY.

WE'RE WAITING FOR THE STEEL
OF THE SUBFRAME

TO REACH THE SAME TEMPERATURE
OF THE ZINC.

SO THAT NOW MAKES THAT
COMPONENT CORROSION-RESISTANT.

SO THAT'LL BE
CORROSION-RESISTANT NOW

FOR PROBABLY 50 YEARS.

RIGHT, PEDRO. WE'RE GOING TO
GIVE YOU THE HANDSET,

AND YOU CAN LIFT THE SUBFRAME
OUT OF THE ZINC.

OKAY.

HOT DIPPING CREATES
A CHEMICAL REACTION

WHERE A LAYER OF STRONG
ZINC-IRON ALLOYS FORM

ON THE SURFACE
OF THE STEEL.

COMING UP NICE AND STEADY.
LOOKING LOVELY, ISN'T IT?

YEAH, IT LOOKS NICE.

THE BOYS ARE DOING
A GOOD JOB.

SO THE GUYS ARE KIND OF
SCRAPING OFF THE TOP SURFACE?

YEAH, THEY ARE.

THEY'RE SKIMMING BACK
THE TOP LAYER OF THE BATH

TO KEEP IT NICE AND CLEAN.

THAT STOPS ANY CONTAMINANTS
GOING ONTO THE SUBFRAME,

WHICH IS IMPORTANT BECAUSE
WE NEED IT TO LOOK NICE.

YEAH.
IT'S LOOKING GOOD THOUGH.

YEAH, THAT IS LOOKING
REALLY GOOD.

YEAH, THAT'S REALLY HARD.

I'M JUST NOT PUSHING IT
TOO HARD.

JUST INCH IT OUT. THAT'S IT.
HOLD IT. HOLD IT.

THAT'S IT.
AND THEN PRESS IT UP HARD.

OH, LOOK AT THAT.SO YOU'VE...

THERE YOU GO.YOU'RE A GALVANIZER.

THE FINAL STAGE IS TO
KNOCK OFF ANY EXCESS ZINC,

AND GALVANIZING
THE SUBFRAME IS COMPLETE.

WE'VE DONE A LOAD OF WORK
ON THE LANCIA SO FAR,

BUT THERE'S STILL
A MOUNTAIN TO CLIMB.

WE'VE GOT TO GET ON
THE POWER-STEERING SYSTEMS.

WE GOT TO SWAP OUT
THE LEAF SPRINGS.

WE'VE GOT TO PUT ON
THE ELECTRICAL SYSTEMS,

THE INTERIOR --
THE LIST GOES ON.

PETE IS TACKLING
THE LANCIA'S SUSPENSION.

REAR LEAF SPRINGS, WHICH FLEX
TO ABSORB ANY BUMP IN THE ROAD,

ARE FAIRLY COMMON
ON CLASSIC CARS.

BUT IT'S UNUSUAL TO HAVE
A LARGE CROSS-MOUNTED

LEAF SPRING ON THE FRONT.

THERE WE GO.

THAT'S THE ONE.

FRONT LEAF SPRINGS OFF NOW.

AND THERE IT IS.

IT'S GOT TO BE UPGRADED
TO HANDLE THE WEIGHT

THAT WE'RE GOING TO PUT
INTO THE FRONT OF THE VEHICLE.

THE REAR SPRINGS I'VE TAKEN OFF
AS WELL,

LIKEWISE THEY'RE GONNA BE
UP-RATED, SO HAPPY DAYS.

WAIT FOR THE PARTS.

BUT RIGHT NOW,

ANOTHER KEY PART
IS ARRIVING AT THE WORKSHOP.

- SURPRISE.
- MINT.

-FAIR PLAY.

CHECK THAT OUT.
NICE.

LOOKS GOOD, DOESN'T IT?
I'VE BEEN WORRYING ABOUT THAT.

SO WERE THEY.
THOUGHT IT WAS GOING TO BEND.

WE WERE REALLY WORRIED
BECAUSE IT'S GOT

SO MANY BOX SECTIONS.
THEY DIDN'T KNOW WHAT --

DID YOU SEE HOW MANY BITS
ABOVE THOSE?

SHH.

YEAH, FAIR PLAY.
THAT LOOKS GOOD.

JERRY'S GOING TO BE
CHUFFED WITH THAT.

YEAH.
GOOD.

WELL, YOU GOT NO EXCUSES
NOW, MATE.

- CRACK ON.
- CHEERS, BUDDY.

- CATCH YOU LATER, MATE.
- SEE YOU LATERS.

NEIL WASTES NO TIME IN
FITTING THE GALVANIZED SUBFRAME,

AND THEN THE MOTOR
CAN GO IN FOR REAL.

LOOKING FOR A GOOD BALANCE
SO IT'LL MEET UP

WITH THE BELL HOUSING
OF THE GEARBOX CLEANLY.

- OKAY.
- NEEDS TO COME OVER YOUR WAY.

SO THIS IS THE FIRST
FRONT-WHEEL-DRIVE CAR WE'VE DONE.

- STEADY, STEADY.
- WHOA.

TO KEEP COSTS DOWN,
WE DIDN'T DITCH THE GEARBOX.

IT JUST MAKES THE JOB
A WHOLE LOT SIMPLER,

BUT THERE'S STILL CHALLENGES
BECAUSE THAT MEANS

THAT THE MOTOR
IS MOUNTED FURTHER FORWARD,

SO SPACE BECOMES A PROBLEM.

STEADY, STEADY, STEADY.
RIGHT.

NOW YOU NEED TO JUST LOWER IT
DOWN A LITTLE BIT MORE.

OH, YES.
YES.

WE'VE GOT IT IN.

IT'S JUST SLIPPED IN,
A ABSOLUTE DAWDLE.

THE MOTOR SLID IN
EASILY IN DRY FITTING,

BUT FOR SOME REASON,
THINGS NOW DON'T QUITE FIT.

ARE THEY THE RIGHT PITCH,
THOUGH?

I THINK SO.

NO, THAT DEFINITELY
DOESN'T GO IN.

NO, OF COURSE.
I KNOW. I JUST SEEN THAT.

ON THE BOLTS, YOU HAVE
PEAKS AND TROUGHS,

AND THE PITCH IS THE DISTANCE
BETWEEN THE TWO PEAKS.

ON A COARSER THREAD, ON A METRIC
ONE, YOU'D BE TALKING ONE.

THEN YOU GO FINER, 1 1/2.

THEN YOU GO 1.25,
AND THAT'S THE PROBLEM,

SO...

SOMEWHERE ALONG THE LINE...

GOT A MIX-UP WITH BOLTS.

ONE, TWO, THREE,
FOUR, FIVE.

SOMETIMES, EVEN EXPERIENCED
MECHANICS LIKE NEIL AND PETE

GET CAUGHT OUT
BY THE SIMPLE THINGS.

IN THIS CASE, THE BOLTS WERE THE
WRONG PITCH FOR THE BOLT HOLES.

GOT THE RIGHT PITCH THIS TIME? YEAH.

- YEAH.
- IT WOULD APPEAR WE HAVE.

GOOD.

WITH THE CORRECT BOLTS IN PLACE,

THE MOTOR IS NOW
PERFECTLY SIGHTED.

SO NOW THE MOTOR
IS ALL INSTALLED,

I'M GOING TO PUT
THE MOTOR MOUNT IN.

IT'S BEEN A BIT OF A STRUGGLE,
BUT THEN AGAIN,

WE ARE ATTACHING
21st-CENTURY TECHNOLOGY

TO A 1970s GEARBOX HERE,

SO NOBODY SAID
IT WAS GOING TO BE EASY.

THE NEW UPGRADED
SUSPENSION PARTS HAVE ARRIVED,

AND NEIL IS FITTING
THE LANCIA'S LEAF SPRINGS

DESIGNED TO TAKE
THE EXTRA WEIGHT

THAT THE BATTERIES
WILL ADD TO THE CAR.

NOW WE GOT TO SECURE
THE AXLE TO THE SPRING

WITH A SANDWICHED PLATE.

IT WAS SANDWICHED ALL TOGETHER,

SO TO DO THAT,
WE NEED THE FOUR BOLTS.

TO FIT THE REAR
SPRINGS, THEY NEED TO BE OPENED UP

A LITTLE
TO REACH THE MOUNTING POINTS,

WHICH IS DIFFICULT,
AS THESE UP-RATED SPRINGS

ARE EXTREMELY STIFF.

TRY PUSHING IT AND EXTEND
--PUSH IT FIRST AND --

STRETCH IT OPEN FIRST
AND GIVE IT LIKE THAT.

YOU CAN ACTUALLY --
BEFORE YOU DO IT...

YEAH, JUST PRACTICE.

JUST PUT THAT ON THE FLOOR
LIKE THAT NOW.

PUT
IN BETWEEN AND STRETCH IT.

ALL YOU'LL FIND IS THEN
THAT IT'LL JUST START OPENING

AND OPENING AND OPENING.
BUT YOU GOT TO TWIST IT

TO A CERTAIN EXTENT
BEFORE YOU'LL BLOW IT.

YEAH, WELL, IT LITERALLY
ONLY NEEDS A SMALL AMOUNT.

YEAH.

SO GO THAT DIRECTION FIRST.

OKAY THEN.

TONY SUGGESTS A HYDRAULIC RAMP,

WHICH SHOULD PROVIDE THE POWER
TO STRETCH THE SPRING.

OKAY.

IT'S GOING IN THE RIGHT
DIRECTION.

GO ON.
GO ON.

YES!
YOU'RE IN.

WHAT A FIGHTER.

MOGGY HAS CALCULATED THE LOAD

THE NEW SPRINGS ON THE FRONT
AND REAR NEED TO TAKE,

BUT HE WON'T KNOW IF THEY'RE UP
TO THE JOB FOR SURE

UNTIL THE BATTERY BOXES
ARE LOADED UP.

SORTED.

ANOTHER KEY PART,

THE NEWLY MODIFIED
POWER-STEERING COLUMN,

IS BACK AT THE WORKSHOP.

PETE IS FITTING IT.

IT WAS ALWAYS GOING TO BE
AN EASY FIT.

IT'S BEEN MEASURED
OUT WAY BEFORE,

AND WE KNOW IT WILL FIT.

THAT IS NOT GOING TO
GO IN LIKE THAT.

IT IS INCREDIBLY TIGHT
IN THERE.

YEAH, THAT'S THE FULL EXTENSION,
AND IT'S NOT WORKING.

BECAUSE THE COLUMN HAS
BEEN MODIFIED FOR POWER STEERING

AND AN ELECTRIC
MOTOR FITTED,

THERE NOW ISN'T ENOUGH
CLEARANCE TO REFIT IT.

IT'S TIME TO GET HELP
FROM WORKSHOP MANAGER TONY.

THIS COLUMN, SO YOU'VE GOT
AN ADJUST ON THERE,

SO THE COLUMN COMES
IN AND OUT, YEAH?

I'VE GOT ALL SPLINES LINED UP
IN THE ENGINE BAY.

IT WAS MISALIGNED,
SO I GOT THE PIN IN THERE.

I'VE GOT THE ONE
IN THE COCKPIT.

I'VE EXTENDED IT.

THE FOUR HOLES WHERE
IT'S SUPPOSED TO MEET,

IT'S AN INCH SHORT.

WHAT DO YOU MEAN, THE FOUR HOLES
THAT'S MEANT TO MEET?

- WHERE THE --
- THE COLUMNS?

- WHERE THE COLUMNS...
- BOLT IN, YEAH, YEAH.

IT'S AN INCH SHY.
THERE'S NO MORE ADJUSTMENT.

YOU CAN'T -- IT WON'T FIT.

I'VE GOT THE ONE ADJUSTER LOW,
SO IT COMES IN AND OUT.

YEAH.

IT'S STILL 3/4 INCH SHORT.

YOU'RE LOSING ME COMPLETELY.

OKAY, SO JUST THERE
IS THE ADJUSTER, YEAH?

SO YOU CAN GET MORE RANGE, OKAY? YEAH.

RIGHT. THAT'S THE FURTHEST OUT
IT'LL GO,

AND THOSE FOUR HOLES
ARE NOT LINING UP, MATE,

NOWHERE NEAR IT.

IT LOOKS DRAMATIC,

BUT THE ONLY SOLUTION IS
FOR PETE TO MODIFY THE BULKHEAD

SO THE COLUMN WILL FIT.

HOPEFULLY THAT LITTLE SLIVER
OFF WILL CURE MY WOES.

WE SHALL SOON FIND OUT.

WITH THE ACCESS PROBLEM
OVERCOME,

PETE CONNECTS THE NEW
STEERING MOTOR

TO A FEED FROM THE EXISTING
12-VOLT WIRING LOOM

TO PROVIDE POWER

SO THE SYSTEM WILL KNOW
WHEN THE CAR IS SWITCHED ON.

ALL THESE ELECTRICS
I'M COLLECTING NOW,

THE ELECTRICS
FOR THE SHOCKS.

GREEN, BLACK AND WHITE, GREEN,
BLACK AND WHITE,

ROUND, GRAY, LOVELY,
JUST WHAT THE DOCTOR ORDERED.

JUST FITTED POWER STEERING
IN THE LANCIA NOW.

IT'S IN.

NEXT JOB IS THE LANCIA'S HEATER,

WHICH USED TO RUN ON HOT WATER
FROM THE ENGINE,

BUT WITH NO ENGINE,
THERE'S NO HOT WATER.

GOOD NIGHT.
UGH.

SO ONCE NEIL HAS REMOVED THE
HEATER MATRIX FROM THE CAR...

OKAY, TONE.
THERE YOU GO.

IT'S YOURS.EVERYTHING COME OUT RIGHT, YEAH?

YEAH, NO PROBLEMS.

...TONY'S JOB IS TO CONVERT IT
TO ELECTRIC POWER

BUT IN A SYMPATHETIC WAY.

WHAT I WANT TO DO
IS KEEP THE ORIGINAL --

GET THE ORIGINAL ONE,
PULL ALL THE INTERNALS OUT,

AND THEN JUST SWAP IT
FROM WATER TO ELECTRIC SOMEHOW.

THE PAIN END OF THIS ONE IS,

BECAUSE WE'VE TAKEN
ALL THE INNARDS OUT OF THIS

AND WE'RE USING
ELECTRIC INTERNALS,

IF IT'S TOO CLOSE
TO THE PLASTIC,

THEN YOU GOT TO WORRY ABOUT IT
MELTING THE HOUSING

OR ANYTHING LIKE THAT.

TONY REMOVES
THE OLD WATER RADIATOR

AND REPLACES IT WITH
A NEW ELECTRIC ELEMENT.

YES, THAT'S A GOOD FIT.

IT ACTUALLY FIT IN PERFECT.

THAT CRADLE ACTUALLY SAT
IN THERE.

IT WAS THE EXACT SAME SIZE
AS THE LANCIA MATRIX.

JUST WANTS A LITTLE BIT
OF A TRIM, AND THAT'LL FIT IN.

JUST ONE MORE FLAT
JUST TO GET BACK IN.

SO SOMETIMES IT CAN ACTUALLY
BE AS EASY AS THAT.

SO WHAT I NEED TO DO NOW
IS JUST BLANK ALL THAT OFF,

BLANK THE MIDDLE,
THEN BLANK THE BOTTOM OFF,

SO WHEN THE FAN IS GOING,
IT'S JUST SUCK IN AND DRAW IN

DIRECT HOT AIR
FOR THE ELEMENTS THERE,

AND THEN THAT
SHOULD WORK PERFECTLY.

WE'VE MANAGED TO
INTEGRATE THE ELECTRIC ELEMENT

INTO THE ORIGINAL HEATER
BOX IN THIS CAR,

SO THE CONTROLS FOR THE FANS
AND THE AIRFLOW

IS STILL GOING TO USE
THE ORIGINAL LEVERS IN THE CAR.

THE IDEA IS TO KEEP THE
CABIN LOOKING AS STOCK AS POSSIBLE.

KEEPING THE GEARBOX
MEANS RETAINING THE GEAR STICK

ALTHOUGH ONLY ONE OR TWO GEARS
WILL BE NEEDED.

MARTIN IS TRYING TO FIND A PLACE
TO FIT

A STATE-OF-CHARGE DISPLAY
INTO THE DASH.

HE'S HOPING IT WILL FIT
WHERE THE OLD CLOCK SAT.

HOPEFULLY IT'S THE SAME
DIAMETER, AND HOPEFULLY IT FITS.

YEAH, WE'RE GOING TO CUT THAT.

WHAT WE'LL HAVE TO DO IS SCULPT
AROUND HERE

THE SAME SIZE AS THAT,
SO AS IT GETS LOADED IN,

THERE'S JUST A SMALL, MINUTE GAP
AROUND THE HOLE.

WITH SOME CAREFUL MODIFICATION,

THE DASH TRIM IS CUT TO SIZE,

AND THE STATE-OF-CHARGE DISPLAY
LOCATES WHERE IT SHOULD.

WE'VE WIRED UP THE BATTERIES,

AND THEY'RE INSTALLED
IN THE BATTERY BOX,

BUT THAT'S WEIGHING
ABOUT 120 KILOS,

SO I'M QUITE NERVOUS
ABOUT GETTING THAT

VERY CAREFULLY
SLOTTED INTO PLACE.

PERFECT.

MOGGY ARRIVES TO OVERSEE

THE FITTING OF THE HEAVY
FRONT BATTERY BOX.

ARE YOU GOING TO WATCH
YOUR SIDE?

- FINGERS.
- YEAH.

- ALL GOOD?
- LOOKING GOOD.

YEAH.

IT NEEDS TO BE LOWERED

VERY GENTLY INTO
THE ENGINE BAY...

SLOWLY DOES IT.

...SO NOTHING GETS CRUSHED.

IT'S A TENSE MOMENT
FOR THE TEAM.

LET ME DROP IN.
I CAN MOVE IT SIMPLY.

I'VE GOT TO GET THAT OUT
BEFORE I CAN MOVE IT.

ALL RIGHT?

OH, NO, NO.

WHOA, WHOA.

- JUST SLOWLY, MATE.
- I AM.

THAT THERE, THAT'S FINE.
THAT'S ENOUGH.

I DON'T WANT THIS BAR
TO HIT THE BUSBAR.

THIS IS THE FIRST TIME
THEY'LL FIND OUT

WHETHER THE NEW LEAF SPRING

WILL TAKE THE INCREASED WEIGHT
ON THE FRONT OF THE CAR.

GREAT.WITH TONY'S EXPERTISE,

HE KNOWS CAREFULLY APPLIED
PRESSURE ON THE FRONT WING

SHOULD TELL HIM IF THEY'VE GOT
THE RIGHT SPRING RATES.

AH, LOVELY.

THAT IS REALLY NICE.

I'LL BE STRAIGHT WITH YOU.
THE UPGRADED LEAF SPRING

THAT WE SET UP FOR THE CAR,

I WAS REALLY WORRIED ABOUT,
IT DIDN'T LOOK RIGHT,

BUT ALL THE MEASUREMENTS
ARE GOOD,

AND I'M VERY HAPPY
WITH IT NOW, REALLY HAPPY.

WHILE THE TEAM
HAVE BEEN WORKING

ON THE MECHANICS OF THE CAR,

THE CARPETS
HAVE BEEN SENT AWAY

AND USED AS A TEMPLATE
FOR A COMPLETELY NEW SET.

NOW IT'S DOWN TO PETE
TO FIT THEM.

WHAT I'M DOING NOW IS JUST

PUTTING IN A BIT
OF SOUND DEADENING

SO THE NOISE INSIDE THE CAR
WILL BE LESS, BASICALLY.

BEAUTIFUL, PROPER JOB.

THE ORIGINAL CARPET WAS GREEN,

BUT THE CLIENT HAS TAKEN
THE OPPORTUNITY

TO SWITCH
TO A LIGHTER COLOR

TO BRIGHTEN THINGS UP
INSIDE THE LANCIA.

SO THAT'S JUST BASICALLY
TO HIDE THE HV CABLES AWAY.

PETE IS USING CARPET FIX
SPRAY TO STICK THE CARPET INTO PLACE.

IT'S A THING OF BEAUTY,
IF I DON'T SAY SO MYSELF.

AH, MOGGY, OVER HERE.

COME AND HAVE A LOOK AT THIS
CARPET I'VE JUST FINISHED.

- HOW'S IT LOOKING?
- YEAH, IT LOOKS FANTASTIC.

OOH, THAT'S ALL RIGHT,
INNIT?

YEAH, IT'S PRETTY GOOD,
PRETTY GOOD.

SWISH.

I'LL BET YOU CAN'T WAIT
TO DRIVE IT, HUH?

YEAH, IT'S ALL READY NOW
FOR ME TO DRIVE, INNIT?

YEAH, IT'S GOOD TO GO,
MY FRIEND, GOOD TO GO.

- AWESOME. CHEERS. GREAT.
- COOL.

GOOD JOB.

THE TEAM HAVE TRIED HARD

TO KEEP THE ORIGINAL
LANCIA CHARACTER,

BUT WILL MOGGY THINK
THEY'VE SUCCEEDED

WHEN HE DRIVES THE CAR
FOR THE FIRST TIME?

I'M OVER THE MOON IN THIS CAR,
OVER THE MOON.

I WANTED TO DO IT CREDIT
FOR ITS RALLYING HERITAGE,

AND THE HANDLING
HAD TO BE RIGHT.

I THINK WE'VE TAKEN ALL
THE AWESOMENESS OF A LANCIA

AND JUST IMPROVED
EVERY LITTLE ASPECT OF IT.

IF YOU LOOK AT THAT DASH,

YOU KNOW, YOU'LL STRUGGLE
TO PICK OUT WHAT'S DIFFERENT.

THE MODERN 21st-CENTURY SORT
OF ELECTRIC HEATER SYSTEM

IS ALL HIDDEN BEHIND THE DASH
IN THE ORIGINAL HEATER MATRIX.

IT'S OPERATED THROUGH
THE ORIGINAL LEVERS ON THE DASH.

IN FACT, THE ONLY THING
YOU MIGHT SPOT

IS THE STATE-OF-CHARGE METER,

WHICH IS PURPOSED IN EXACTLY
THE SAME POSITION

WHERE THE OLD CLOCK WAS
THAT DIDN'T WORK ANYWAY.

WHEE!

NICE LITTLE BIT OF POWER
AS WELL.

YEAH, I'M HAPPY WITH IT.

BUT HAS THE LEAF-SPRING
UPGRADE BEEN A SUCCESS?

CAN IT DEAL WITH THE 288
KILOGRAMS OF BATTERY WEIGHT?

BUT I WAS QUITE WORRIED,
TO BE HONEST,

BECAUSE THE GUY THAT WE USE,

WE KIND OF TOLD HIM
WHAT WE WERE TRYING TO ACHIEVE,

WHAT THE FRONT WEIGHT
DISTRIBUTION IS GOING TO BE,

WHAT THE REAR WEIGHT
DISTRIBUTION IS GOING TO BE.

WE SENT HIM THE ORIGINAL
SPRINGS,

AND HE TOOK A EDUCATED,
EXPERIENCED GUESS

AT WHAT HE THOUGHT WE'D NEED,
AND THAT'S ALWAYS A WORRY.

DOES THE GUY KNOW
WHAT HE'S DOING?

HAVE WE GOT THE FIGURES RIGHT?

BUT WE PUT THEM ON,
AND IT'S NAILED IT.

I CERTAINLY DON'T THINK WE'VE
TAKEN AWAY FROM THE LANCIA FEEL.

IN FACT, TO ME, IT FEELS
VERY MUCH

LIKE A LANCIA FROM THE INSIDE,
BUT EVERYTHING IS SMOOTHER.

I MEAN, THE POWER DELIVERY
IS INSTANT AND SMOOTH,

AND NOW THE HANDLING IS
JUST NICE AND PREDICTABLE,

AND YOU CAN POINT IT INTO
A CORNER AND ACCELERATE OUT.

I THINK WE'VE NOT ONLY PRESERVED

THE LANCIA'S
HANDLING CHARACTERISTICS,

BUT JUST BUILT UPON THEM
AND IMPROVED THEM A LITTLE BIT.

IT'S THE MIDDLE OF WINTER,
AND I'VE BEEN DOING SOME

RANGE TESTING IT SO FAR WITH
THE HEATER ON, EVERYTHING ON.

I THINK WE'VE GOT ABOUT
115-MILE RANGE,

AND THAT'S JUST
DRIVING NORMALLY

IN QUITE HILLY CONDITIONS
HERE IN WALES.

WITH 120, 125-MILE RANGE,
I THINK IT'S ABOUT BANG ON.

POWER STEERING IS GREAT.

WATCH OUT FOR THE SHEEP!

POWER STEERING IS FANTASTIC.

I MEAN, IT FEELS LIKE
A MODERN CAR.

I'D PROBABLY SAY IT'S EVEN
BETTER TO DRIVE

THAN IT IS TO LOOK AT.

I LOVE IT.

I'M NOT READY TO HAND IT OVER
TO JERRY.

I'VE GOT ABOUT 65 PERCENT
LEFT IN THE BATTERY,

A LOAD OF, LIKE, REALLY
QUIET MOUNTAIN ROADS IN WALES.

LET'S EMPTY THE BATTERY FIRST,

AND THEN I'LL GIVE IT BACK
TO THE CUSTOMER.

NOW THAT MOGGY
HAS FINALLY RETURNED

FROM HIS EXTENDED TEST DRIVE,

CLIENT JERRY HAS ARRIVED
TO COLLECT THE CAR.

- YEAH, IT'S GREAT.
- YOU READY FOR TODAY?

I'M READY.

I'VE BEEN WAITING FOR THIS
FOR A WHILE.

YEAH, WELL, SHE'S ALL WAITING
FOR YOU BEHIND THESE DOORS.

- OH, GREAT.
- YOU READY?

- LET'S DO IT.
- LET'S RAISE THE SHUTTERS.

TA-DA.

TA-DA.

NOW...
WHAT A SIGHT.

WE'VE LEFT IT
WITH THE BONNET UP

BECAUSE THE MOST
IMPORTANT THING IS,

THERE'S NO ENGINE
IN THERE ANYMORE.

KIND OF LOOK DOWN THERE.

YOU CAN JUST SEE THE BACK
OF THE MOTOR.

AH, YES.

SO THE MOTOR'S UNDERNEATH
THERE MATED TO THE GEARBOX.

THEN THIS IS THE BATTERY BOX,

SO IT SITS EITHER SIDE
OF THE MOTOR.

WE'VE GOT THE ELECTRIC
POWER-STEERING SYSTEM

THAT YOU ASKED FOR ALL
INSTALLED, WHICH IS...

LOVE IT, YES.
...VERY NICE,

AND THEN WHAT
YOU CAN'T SEE UNDER THERE,

BUT THE FRONT LEAF SPRING
AND THE REAR LEAF SPRINGS

WE'VE CHANGED TO DEAL WITH
THE NEW WEIGHT DISTRIBUTION.

OKAY.

SO HANDLING NOW IS
ABSOLUTELY SUPERB.

AND THEN IF YOU
HAVE A LOOK INSIDE,

I THINK YOU'RE
GOING TO LIKE THIS.

HERE YOU GO.
BEAUTIFUL.

SO IF YOU LOOK OVER JUST TO
THE RIGHT OF WHERE THE RADIO IS,

THERE'S THE NEW
BATTERY-STATE INDICATOR.

I MEAN, THAT LOOKS LIKE
IT'S ALWAYS BEEN THERE.

LOVELY.YOU READY FOR YOUR FIRST DRIVE?

LET'S SIT. OKAY.
LET'S...

IF YOU JUMP IN
THE DRIVER'S SEAT,

I'M GOING TO JUST PUT
THE BONNET DOWN,

AND WE'LL TAKE IT
FOR A SPIN.

OH, HERE WE GO.

-TA-DA. MAGIC...

SEE, HOPEFULLY YOU'LL FEEL
MUCH DIFFERENT

IN THE POWER-STEERING
DEPARTMENT, MUCH LIGHTER.

YEAH, LOVELY...

AND THEN JUST, I SAID,
THE WEIRD THING IS,

YOU WON'T NEED TO CHANGE GEAR,
JUST CAN JUST --

SORT OF INSTANT TORQUE.

WHAT DO YOU THINK?

YEAH, GREAT.
LOVELY, SMOOTH POWER, YEAH.

NICE AND SMOOTH?

NICE AND RESPONSIVE?

YES, LOVELY.

HEAR THAT? NIPPY.

YEAH.
THAT'S --

KEEP ON CHANGING GEAR,
THOUGH.

I KNOW.

THAT'S OLD HABITS
TO BREAK.

SO THERE YOU GO, YOUR NEW
ELECTRIC LANCIA FULVIA.

YOU HAPPY? YES, SIR. YEAH. GREAT JOB.

SO HERE WE ARE,
BACK WHERE WE STARTED.

LOVELY.
WELL, THAT WAS AN EXPERIENCE.

- YEAH?
- YES.

WELL, I AM VERY PLEASED
YOU LIKE HER.

THERE I GO. LOOK.
I'M CHANGING THE CLUTCH AGAIN.

HUH?
COME HERE.

PUT YOUR HAND.

STOP USING THE CLUTCH.

JERRY, SHE'S ALL YOURS.

PEDRO, LOVELY JOB.

I WAS SO EXCITED TO GET
THIS LANCIA IN

BECAUSE OF
ITS RALLYING HISTORY,

BUT IT WAS CRITICAL FOR ME TO DO
THAT RALLYING HERITAGE JUSTICE,

AND I'M REALLY HAPPY
THE WAY IT TURNED OUT.

I'VE TAKEN IT FOR A SPIN
ON THE ROAD.

THE BALANCE IS GREAT.
THE POWER IS GREAT.

JERRY'S HAPPY. I'M HAPPY.
IT'S FANTASTIC.

I LOVED IT.
IT'S JUST SAD TO SEE IT GO.