Vintage Voltage (2020) - full transcript

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.

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.