1
00:00:01,367 --> 00:00:04,467
[Mike] This time,
we want to make
the ultimate hot hatch.
2
00:00:04,467 --> 00:00:06,767
-[Elvis laughs]
It's yellow.
-I know!
3
00:00:06,767 --> 00:00:10,166
[Mike]
Yes, out of this battered
Peugeot 205...
4
00:00:10,166 --> 00:00:13,166
It's quite tatty around the
edges, and the bumper's
inside the car.
5
00:00:13,166 --> 00:00:15,967
[Mike]
...the French gave us Brits
the underpowered version...
6
00:00:15,967 --> 00:00:18,667
-Put your foot down.
-What do you mean,
put my foot down? It is.
7
00:00:18,667 --> 00:00:20,800
[Mike] . ..but we want to
boost its performance...
8
00:00:20,800 --> 00:00:22,567
-I want to go
with throttle bodies.
-What?
9
00:00:22,567 --> 00:00:25,200
[Mike]
...and beat the Europeans
at their own game.
10
00:00:25,200 --> 00:00:26,900
Come on, Brewer. Come on.
11
00:00:26,900 --> 00:00:28,634
Oh, this car is insane!
12
00:00:29,867 --> 00:00:31,867
[opening theme music playing]
13
00:00:41,100 --> 00:00:43,266
Go on, son. Off we go.
14
00:00:43,266 --> 00:00:45,266
I mean, look how tight
this corner is.
15
00:00:45,266 --> 00:00:47,100
My face is gonna get torn off.
16
00:00:47,100 --> 00:00:49,333
It's been a hard week
in the workshop...
17
00:00:49,567 --> 00:00:50,567
Get in.
18
00:00:50,567 --> 00:00:52,400
...so I'm treating Elvis
to a day out
19
00:00:52,400 --> 00:00:56,000
driving one of the most
iconic rally cars of all time.
20
00:00:56,000 --> 00:00:59,767
Well, it sounds great.
It feels very special.
21
00:00:59,767 --> 00:01:03,500
The T16 205
is a pocket rocket.
22
00:01:03,500 --> 00:01:06,667
They wanted to go rally
in Peugeot,
and the only way to do that
23
00:01:06,667 --> 00:01:09,867
is you have to make
a certain amount
of road-going versions
24
00:01:09,867 --> 00:01:11,634
of the rally car.
25
00:01:13,667 --> 00:01:17,166
-They only made
200 of these.
-Yeah.
26
00:01:17,166 --> 00:01:20,367
They're so rare.
It's a very special
car because
27
00:01:20,367 --> 00:01:23,567
everything was designed
only around performance.
28
00:01:23,567 --> 00:01:27,166
It had that powerful engine,
but it's got a tubular
space frame chassis.
29
00:01:27,166 --> 00:01:29,166
It weighs nothing.
30
00:01:29,166 --> 00:01:32,166
-It's all about performance.
-It's all about performance.
Yeah.
31
00:01:32,166 --> 00:01:34,433
[engine revs]
32
00:01:38,166 --> 00:01:40,867
Do you know
how much this is worth,
what you're driving?
33
00:01:40,867 --> 00:01:43,100
It's too, I'm kind of not
thinking about it.
34
00:01:43,100 --> 00:01:45,367
I'm gonna terrify you
when I tell you.
35
00:01:45,367 --> 00:01:48,000
-Quarter of a million quid.
Yeah. [laughs]
-No! No!
36
00:01:48,000 --> 00:01:50,333
That's madness, utter madness.
37
00:01:51,600 --> 00:01:53,634
[engine revs]
38
00:01:56,967 --> 00:01:59,900
[Elvis] Out of this car
was born the 205 GTI,
39
00:01:59,900 --> 00:02:02,400
which became such an iconic
little hot hatch.
40
00:02:02,400 --> 00:02:05,066
Yeah, this is
the granddaddy of that.
41
00:02:07,900 --> 00:02:10,000
[Elvis]
Thanks, Peugeot and Mike.
42
00:02:10,000 --> 00:02:13,033
But where exactly
is all this going?
43
00:02:14,266 --> 00:02:16,066
-What a car!
-[laughs]
44
00:02:16,066 --> 00:02:18,467
-And what a day.
-Mate, what an experience.
45
00:02:18,467 --> 00:02:21,567
It certainly
reinvigorated my need
46
00:02:21,567 --> 00:02:25,166
to somehow get
us a Peugeot 205.
47
00:02:25,166 --> 00:02:29,500
But even a 1.9 GTI these days
are running at, like,
15 grand,
48
00:02:29,500 --> 00:02:33,567
however, there is a cheap
entry point into the
205 world,
49
00:02:33,567 --> 00:02:35,367
and that's the 205 Rallye.
50
00:02:35,367 --> 00:02:37,467
Yeah, they did
a couple of versions of that,
51
00:02:37,467 --> 00:02:39,367
one of them,
the European spec version,
52
00:02:39,367 --> 00:02:43,000
that was actually
quite a good, fun little car.
Decent horsepower for its day.
53
00:02:43,000 --> 00:02:46,800
I'm not talking about
the European version because
they're quite a lot of money.
54
00:02:46,800 --> 00:02:50,667
I was talking about this car
that's actually out there
online at the moment.
55
00:02:50,667 --> 00:02:52,767
Bids are up at £2,500.
56
00:02:52,767 --> 00:02:54,467
There's a very good
reason for that.
57
00:02:54,467 --> 00:02:56,800
It is the UK version,
which was a bit rubbish.
58
00:02:56,800 --> 00:02:58,767
-And it's yellow.
-It's mustard, actually.
59
00:02:58,767 --> 00:03:01,166
-It's definitely yellow.
However,
-That's mustard.
60
00:03:01,166 --> 00:03:03,667
as a project, all cars
can be improved, can't they?
61
00:03:03,667 --> 00:03:05,367
[Mike] They're the words
I want to hear.
62
00:03:05,367 --> 00:03:08,000
So, shall I put in a nice,
cheeky bid for us?
63
00:03:08,000 --> 00:03:09,767
It's cheap, innit?
So, why not?
64
00:03:11,166 --> 00:03:13,266
[Mike] I'm going to stick
my neck out and say it,
65
00:03:13,266 --> 00:03:16,867
the 205 was the greatest
hatchback of them all.
66
00:03:16,867 --> 00:03:20,266
And the model
that made its name
was the T16,
67
00:03:20,266 --> 00:03:23,600
the king of rallying
in the 1980s.
68
00:03:23,600 --> 00:03:26,467
That success was a catalyst
for an extraordinary
69
00:03:26,467 --> 00:03:29,300
15-year production run
of cars.
70
00:03:29,300 --> 00:03:32,467
A whopping five million
were sold worldwide.
71
00:03:34,300 --> 00:03:36,867
Everything from the
XS to the GTI,
72
00:03:36,867 --> 00:03:40,266
but they all come
at top dollar prices
these days.
73
00:03:41,266 --> 00:03:43,367
But there is one little
bargain out there,
74
00:03:43,367 --> 00:03:46,700
the Rallye, a pared down
super lightweight road model.
75
00:03:46,700 --> 00:03:51,567
Manufactured from
1988 to 1992,
there were two versions,
76
00:03:51,567 --> 00:03:55,000
a Euro spec with
a decent 103 horsepower,
77
00:03:55,000 --> 00:03:57,667
and the UK model with just 75.
78
00:03:57,667 --> 00:04:00,500
Did we upset the French
or something?
79
00:04:00,500 --> 00:04:03,767
So, with that puny power,
models like the one
I'm bidding on
80
00:04:03,767 --> 00:04:05,400
will go cheap.
81
00:04:05,400 --> 00:04:07,100
And guess what? I've won.
82
00:04:07,100 --> 00:04:10,066
Time to take delivery of it
at the workshop.
83
00:04:11,467 --> 00:04:13,400
Mate, dry your hands,
grab your coat,
84
00:04:13,400 --> 00:04:16,266
-because guess what's
arrived outside.
-What?
85
00:04:16,266 --> 00:04:17,900
The 205 Rallye.
86
00:04:17,900 --> 00:04:19,867
Oh, wow. That was
the one you took a gamble on.
87
00:04:19,867 --> 00:04:21,266
You mustn't have
even seen this yet. [bleep]
88
00:04:21,266 --> 00:04:23,467
No, this is gonna be fresh
for the both of us.
89
00:04:23,467 --> 00:04:24,533
Let's have a look.
90
00:04:25,266 --> 00:04:27,867
[laughs] Ah-ha.
91
00:04:27,867 --> 00:04:31,266
-It's yellow!
-I know. I know.
92
00:04:31,266 --> 00:04:34,000
[Elvis]
That is even more yellow
than it looks in the pictures.
93
00:04:34,000 --> 00:04:36,166
I didn't know it was
going to be that bright.
94
00:04:36,166 --> 00:04:37,967
But listen, really,
we have no choice.
95
00:04:37,967 --> 00:04:41,000
If you're going to buy one
of these
205 Rallyes in England,
96
00:04:41,000 --> 00:04:42,800
we've got three
different flavors.
97
00:04:42,800 --> 00:04:46,066
You've got 500 in Bianca,
which is white,
98
00:04:46,066 --> 00:04:49,367
250 in Express Yellow,
which is this color,
99
00:04:49,367 --> 00:04:52,567
of which there's only
a handful left,
and 80 in blue,
100
00:04:52,567 --> 00:04:54,767
or the white ones
people tend to keep.
101
00:04:54,767 --> 00:04:57,467
The blue ones
are non-existent,
so if you're gonna buy one,
102
00:04:57,467 --> 00:04:59,467
you have to go for the
Express Yellow.
103
00:04:59,467 --> 00:05:01,467
[Elvis]
It's also quite tatty
around the edges,
104
00:05:01,467 --> 00:05:04,500
and the bumper's
inside the car,
and it's cracked.
105
00:05:04,500 --> 00:05:06,200
-It's not ideal, is it?
-[laughs] No.
106
00:05:06,200 --> 00:05:08,767
We paid £2,850 for this.
107
00:05:08,767 --> 00:05:11,634
I've got a funny feeling
we've wasted that money.
108
00:05:12,667 --> 00:05:14,467
It's what's under there
that lets it down, isn't it?
109
00:05:14,467 --> 00:05:16,100
Let's have a look.
110
00:05:16,100 --> 00:05:17,867
It's a 1.4-litre,
111
00:05:17,867 --> 00:05:21,066
single carb, it produces...
Are you ready for this?
112
00:05:21,066 --> 00:05:24,667
-Seventy-five horsepower.
-Seventy-five horsepower?
113
00:05:24,667 --> 00:05:27,100
My lawn mower's got more
than that, mate.
That's terrible. [laughs]
114
00:05:27,100 --> 00:05:28,600
It's... Yeah.
115
00:05:28,600 --> 00:05:31,467
The European spec version,
they've got 103 horsepower,
116
00:05:31,467 --> 00:05:33,100
which is where you come in.
117
00:05:33,100 --> 00:05:35,467
See, this is the idea
behind this car.
118
00:05:35,467 --> 00:05:37,867
You're used to
making stuff go faster,
119
00:05:37,867 --> 00:05:40,567
so you can turn it into,
oh, I don't know,
120
00:05:40,567 --> 00:05:44,800
let's say 104 horsepower,
maybe 105.
121
00:05:44,800 --> 00:05:47,300
We'll have a car that
we can take on the Europeans.
122
00:05:47,300 --> 00:05:49,767
It's a huge amount of work.
Even the engine alone,
123
00:05:49,767 --> 00:05:52,367
massive amount of work,
let alone the rest of the car
124
00:05:52,367 --> 00:05:55,066
-which is also
in a right state.
-No, you'll do this easy.
125
00:05:55,066 --> 00:05:57,867
Why don't we take it out
for a spin around here now
126
00:05:57,867 --> 00:05:59,767
and just see what else
is wrong with it?
127
00:05:59,767 --> 00:06:02,700
It's not strictly legal,
it's got no headlights
or bumper,
128
00:06:02,700 --> 00:06:05,934
but we are on private ground.
So, yeah, let's go drive it.
129
00:06:07,767 --> 00:06:09,567
Right, then. Come on, Elvis.
130
00:06:09,567 --> 00:06:13,367
Let's see how much of this
75 horsepower is still there.
131
00:06:13,367 --> 00:06:16,066
Go on, put your foot down.
132
00:06:16,066 --> 00:06:18,333
What do you mean,
put my foot down? It is.
133
00:06:20,000 --> 00:06:23,500
-That's it?
-Are you sure it's got 75
horsepower, not 7.5?
134
00:06:23,500 --> 00:06:26,000
[both laugh]
135
00:06:26,000 --> 00:06:29,000
Mate, wait, is that it?
And Peugeot sold
this as a Rallye.
136
00:06:29,000 --> 00:06:31,233
Oh, it's got a
little noise to it.
137
00:06:32,867 --> 00:06:35,400
[Elvis] Mate,
that is so underpowered.
138
00:06:35,400 --> 00:06:37,867
To measure nought to 60
you need a calendar,
139
00:06:37,867 --> 00:06:39,834
not a stopwatch. [laughs]
140
00:06:41,467 --> 00:06:44,467
Well, look, whatever happens,
we're stuck with his car now,
141
00:06:44,467 --> 00:06:45,567
so we're going to do it.
142
00:06:45,567 --> 00:06:48,166
So, if we've got
75 horsepower,
143
00:06:48,166 --> 00:06:52,367
how do we get to
107 horsepower?
144
00:06:52,367 --> 00:06:55,400
This has got a single
carburetor on it,
pretty basic.
145
00:06:55,400 --> 00:06:57,100
You could easily go twin carb.
146
00:06:57,100 --> 00:07:01,166
Then you talk about
rebalancing things like
crank shafts, maybe pistons.
147
00:07:01,166 --> 00:07:03,700
Now that's going to start
really pushing the boundaries.
148
00:07:03,700 --> 00:07:06,166
It's only a little engine,
but I'm sure we could squeeze
149
00:07:06,166 --> 00:07:08,367
-107 horsepower out of it.
-Oh, see.
150
00:07:08,367 --> 00:07:10,667
That's exactly what I'm after.
151
00:07:10,667 --> 00:07:12,867
But, mate, listen,
that's got me excited.
152
00:07:12,867 --> 00:07:15,700
And if you could
pull that off,
this little car
153
00:07:15,700 --> 00:07:19,000
might live up to its name
of it being a Rallye.
154
00:07:19,000 --> 00:07:21,600
I would be good, wouldn't it?
And I would love to beat the
Europeans.
155
00:07:21,600 --> 00:07:24,567
Oh, that'd be fantastic.
156
00:07:24,567 --> 00:07:28,600
[Elvis] This is currently more
like a rally bicycle than
a rally car.
157
00:07:28,600 --> 00:07:30,867
It's gonna need a huge
injection of power,
158
00:07:30,867 --> 00:07:34,100
and that means overhauling
the engine from top to bottom.
159
00:07:34,100 --> 00:07:36,233
[upbeat music playing]
160
00:07:40,667 --> 00:07:44,066
To kick everything off,
I need to get that
puny power unit out.
161
00:07:45,166 --> 00:07:47,467
It's always a bit of a risk,
buying a car online
162
00:07:47,467 --> 00:07:50,467
that you haven't
actually seen,
and that is what Mike's done,
163
00:07:50,467 --> 00:07:52,266
but this one's turned out
to be pretty solid,
164
00:07:52,266 --> 00:07:55,166
and has turned up exactly
as it was described.
165
00:07:55,166 --> 00:07:57,166
Now, these cars
were a bit of a mystery.
166
00:07:57,166 --> 00:07:59,567
Why on earth didn't Peugeot
bring the full-blown
167
00:07:59,567 --> 00:08:01,767
Euro spec version to the UK?
168
00:08:01,767 --> 00:08:04,066
And there are a couple of
schools of thoughts on
why that happened.
169
00:08:04,066 --> 00:08:06,600
It could have been
too complicated or expensive
170
00:08:06,600 --> 00:08:09,100
to convert the
left-hand drive car
with that engine
171
00:08:09,100 --> 00:08:11,400
to right-hand drive
for the UK market.
172
00:08:11,400 --> 00:08:14,100
Or it could have been
that Peugeot saw enough value
173
00:08:14,100 --> 00:08:16,200
in creating this car
as a limited edition
174
00:08:16,200 --> 00:08:19,567
with just a few
hundred ever made,
compared to the 28,000
175
00:08:19,567 --> 00:08:22,333
that they made
of the Euro spec version.
176
00:08:24,867 --> 00:08:27,400
It does, though, have some
endearing characteristics,
177
00:08:27,400 --> 00:08:29,467
like the fact that
it's super lightweight
178
00:08:29,467 --> 00:08:31,266
at less than 800 kilos,
179
00:08:31,266 --> 00:08:34,200
so if we get the engine right,
there's performance to be had.
180
00:08:34,200 --> 00:08:37,000
So my first job is to get
this lump out of here,
181
00:08:37,000 --> 00:08:39,066
and then start work
on turning it into the
182
00:08:39,066 --> 00:08:42,400
Euro spec version beater
that I know it can be.
183
00:08:42,400 --> 00:08:44,100
[upbeat music playing]
184
00:08:44,100 --> 00:08:45,800
To remove the 205 engine,
185
00:08:45,800 --> 00:08:49,600
I need to disconnect
the drive shaft from the
gearbox and also the hubs.
186
00:08:49,600 --> 00:08:51,800
But first, I've got to
remove the wheels,
187
00:08:51,800 --> 00:08:55,500
uncouple the suspension
and undo the mounts.
188
00:08:55,500 --> 00:08:57,634
[upbeat music playing]
189
00:09:04,600 --> 00:09:07,333
Then finally, I can
lower the engine out.
190
00:09:09,467 --> 00:09:12,266
All right, so this
is our starting point,
191
00:09:12,266 --> 00:09:15,667
1.4-litre block,
single carburetor.
192
00:09:15,667 --> 00:09:18,300
of 1360CC
193
00:09:18,300 --> 00:09:22,166
thanks to bore stroke
of 75 and 77 millimeters.
194
00:09:22,166 --> 00:09:26,767
It's got a massive power
output of 75 brake horsepower
195
00:09:26,767 --> 00:09:29,066
at 6,200 RPM,
196
00:09:29,066 --> 00:09:33,567
and maximum torque
figures of 80 pound feet
of 4000 RPM
197
00:09:33,567 --> 00:09:36,200
If you compare that
to the Euro spec version,
198
00:09:36,200 --> 00:09:40,266
that one has a 103 HP
at 6800 RPM
199
00:09:40,266 --> 00:09:44,700
and maximum torque figures of
89 pound feet at 5000 RPM.
200
00:09:44,700 --> 00:09:48,367
So if you got any hope
of trying to compete
with that engine with ours,
201
00:09:48,367 --> 00:09:50,467
we've got a massive amount
of work ahead
202
00:09:50,467 --> 00:09:54,233
and it all starts by stripping
this one down to find out
exactly what it has got.
203
00:10:00,400 --> 00:10:03,967
Now, if we want to get
the kind of power from this
engine that we're hoping for,
204
00:10:03,967 --> 00:10:05,767
there's a number
of things we can do.
205
00:10:05,767 --> 00:10:08,000
In fact, rarely is
it ever the case
206
00:10:08,000 --> 00:10:09,867
that you just bolt on an item
and away you go.
207
00:10:09,867 --> 00:10:13,300
We need to get more air and
fuel in to increase the
rate of combustion,
208
00:10:13,300 --> 00:10:17,400
but if we do that, we also
need to get rid of those gases
in a more efficient manner.
209
00:10:17,400 --> 00:10:20,800
If we're gonna do work
at the top end of the engine
to improve performance,
210
00:10:20,800 --> 00:10:22,700
we gotta kind of match it
at the bottom end
211
00:10:22,700 --> 00:10:26,900
by lightning and balancing
things like crankshaft
and flywheel.
212
00:10:26,900 --> 00:10:29,767
This engine is gonna be
under a whole load
more stress,
213
00:10:29,767 --> 00:10:32,066
so I need to go through
every single component
214
00:10:32,066 --> 00:10:33,667
to make sure it's up to it.
215
00:10:33,667 --> 00:10:36,467
I know from experience
that we're treading
a fine line.
216
00:10:36,467 --> 00:10:40,867
If I push it too far,
then that extra power
could tear this engine apart.
217
00:10:41,967 --> 00:10:43,367
We want to add
a bit of va-va-voom
218
00:10:43,367 --> 00:10:46,467
to our underpowered
British 205 Rallye.
219
00:10:46,467 --> 00:10:49,367
Our aim, to beat
the Euro spec version,
220
00:10:49,367 --> 00:10:51,500
and that means
overhauling the engine
221
00:10:51,500 --> 00:10:53,166
to cope with extra power.
222
00:10:53,166 --> 00:10:56,166
Step one is balancing parts
like the crankshaft,
223
00:10:56,166 --> 00:10:58,400
and with the car
about to head to
the paint shop,
224
00:10:58,400 --> 00:11:00,066
I'm up in Leicestershire.
225
00:11:00,066 --> 00:11:03,867
Having stripped down
the engine, I'm gonna start
with the crankshaft,
226
00:11:03,867 --> 00:11:06,266
but cos I haven't got
all the kit in my workshop,
227
00:11:06,266 --> 00:11:08,767
I'm meeting my mate, Billy,
here at Midland Balancing
228
00:11:08,767 --> 00:11:11,734
who's allowed me to come
and use his workshop
for the day.
229
00:11:14,367 --> 00:11:17,100
-Billy, how are you, mate?
-Hi. You all right?
230
00:11:17,100 --> 00:11:18,967
This is what I was
telling you about.
231
00:11:18,967 --> 00:11:21,700
Excellent. Yeah, you know
where the balancing
machine is,
232
00:11:21,700 --> 00:11:23,767
-so help yourself.
-Brilliant.
Cheers, mate.
233
00:11:23,767 --> 00:11:26,667
A crankshaft converts
the vertical movement
of the pistons
234
00:11:26,667 --> 00:11:28,367
into rotational movement,
235
00:11:28,367 --> 00:11:31,166
which ultimately drives
the wheels by the gearbox.
236
00:11:31,166 --> 00:11:34,000
If it's unbalanced,
then it won't do
that job properly,
237
00:11:34,000 --> 00:11:38,266
and we won't make the most
of any extra power
regenerating the engine.
238
00:11:38,266 --> 00:11:40,567
Of course, balancing
the crankshaft was done
239
00:11:40,567 --> 00:11:42,567
when it was first made
at the manufacturers,
240
00:11:42,567 --> 00:11:45,867
but that's when the engine
was only producing
75 horsepower.
241
00:11:45,867 --> 00:11:47,700
If we want to push
this harder,
242
00:11:47,700 --> 00:11:49,767
the tolerance has become
finer and finer,
243
00:11:49,767 --> 00:11:54,200
and so the impact of any
imbalances become magnified
at the higher RPM
244
00:11:54,200 --> 00:11:55,834
that we want to now
push our engine to.
245
00:11:57,567 --> 00:12:00,066
Balancing it involves
adjusting the counterweights
246
00:12:00,066 --> 00:12:02,266
to compensate
for the moving components
247
00:12:02,266 --> 00:12:04,900
so everything runs true
with no wobble.
248
00:12:04,900 --> 00:12:08,000
First, I'm stripping down
the bottom end
rotating assembly
249
00:12:08,000 --> 00:12:11,200
and removing the clutch cover,
flywheel and front pulley,
250
00:12:11,200 --> 00:12:13,734
so I can work on
just the crankshaft.
251
00:12:16,266 --> 00:12:19,166
Now, this is a dynamic
balancing machine.
252
00:12:19,166 --> 00:12:22,000
It spins via a drive belt
and an electric motor.
253
00:12:22,000 --> 00:12:25,400
It's gonna spin
the crankshaft at 450 RPM.
254
00:12:25,400 --> 00:12:28,467
The reason we use 450 RPM
is that it's fast enough
255
00:12:28,467 --> 00:12:30,767
to give us an
accurate reading,
yet not too fast
256
00:12:30,767 --> 00:12:33,567
to start introducing
imperfections or distortions
257
00:12:33,567 --> 00:12:35,400
as we measure the
crankshaft's load.
258
00:12:35,400 --> 00:12:37,967
When we get the information,
we can take away material,
259
00:12:37,967 --> 00:12:40,467
either by linishing
little parts
of the metal away,
260
00:12:40,467 --> 00:12:44,066
or as the manufacturers did
back in the beginning,
drilling holes.
261
00:12:44,066 --> 00:12:47,000
The process is laborious,
it's a case of doing it
a little bit,
262
00:12:47,000 --> 00:12:49,000
tweaking it, put it back
on the machine,
263
00:12:49,000 --> 00:12:52,867
and taking more measurements
until we get it as close
to zero as we possibly can.
264
00:12:52,867 --> 00:12:55,767
The machine
will measure precisely
how much the crankshaft
265
00:12:55,767 --> 00:12:57,900
deviates from a straight line.
266
00:12:57,900 --> 00:12:59,667
To keep my own
measurements accurate,
267
00:12:59,667 --> 00:13:02,767
I'm marking a
starting position
called a datum point,
268
00:13:02,767 --> 00:13:04,400
so every time I
use the machine,
269
00:13:04,400 --> 00:13:06,634
I know where to take
my readings from.
270
00:13:09,000 --> 00:13:12,567
Then we spin
it for about a minute
to find any imperfections.
271
00:13:17,567 --> 00:13:20,567
Okay, so I've got a set
of numbers now,
a reading on here.
272
00:13:20,567 --> 00:13:23,467
Now, what this represents
is these two numbers here,
273
00:13:23,467 --> 00:13:25,367
which are either end
of the crankshaft,
274
00:13:25,367 --> 00:13:27,500
are how far out
of balance it is.
275
00:13:27,500 --> 00:13:30,567
The 22.5 reading
immediately tells me
276
00:13:30,567 --> 00:13:32,867
we're a good way
out of balance.
277
00:13:32,867 --> 00:13:34,867
Now, there's 17,
the number underneath,
278
00:13:34,867 --> 00:13:38,200
that's the angle of rotation
from our starting position.
279
00:13:38,200 --> 00:13:40,800
So, we look at it on here,
we can see the start point,
280
00:13:40,800 --> 00:13:44,900
and here, that zero,
and if we rotate it
17 degrees,
281
00:13:44,900 --> 00:13:47,467
which is probably going to be
somewhere around there,
282
00:13:47,467 --> 00:13:49,767
that's where we need to
start removing material.
283
00:13:53,066 --> 00:13:55,133
There is an element
of guesswork to this.
284
00:13:58,667 --> 00:14:04,467
So I'm taking my time and
shaving just a little bit off
to begin with.
285
00:14:04,467 --> 00:14:08,100
Mess it up, and I'll be
spending the next week
rummaging around scrapyards,
286
00:14:08,100 --> 00:14:11,467
trying to find
a replacement crankshaft.
287
00:14:24,300 --> 00:14:26,700
So we're definitely heading
in the right direction.
288
00:14:26,700 --> 00:14:29,500
The numbers are coming down
towards that magic zero point,
289
00:14:29,500 --> 00:14:31,300
which we may
never finally achieve,
290
00:14:31,300 --> 00:14:34,634
but if I can get them
below five,
I think I'll be pretty happy.
291
00:14:36,567 --> 00:14:41,066
A smidge more,
and I think we're
almost there.
292
00:14:47,100 --> 00:14:50,467
Oh, yes. Both ends
are now less than two.
293
00:14:50,467 --> 00:14:53,166
That's great.
[laughs] It's amazing.
294
00:14:53,867 --> 00:14:55,567
I am really happy with that.
295
00:14:55,567 --> 00:14:57,500
You know, you could
chase that for hours
296
00:14:57,500 --> 00:15:00,767
and never quite end up
that close to zero.
297
00:15:00,767 --> 00:15:04,667
Job done. With the crankshaft
more balanced than
a Zen master,
298
00:15:04,667 --> 00:15:06,600
it's ready to cope
with the extra power
299
00:15:06,600 --> 00:15:09,066
we're hoping to get
out of the engine.
300
00:15:09,066 --> 00:15:11,467
I'm putting it back together
part by part,
301
00:15:11,467 --> 00:15:13,967
so I can run the
whole assembly
through the machine,
302
00:15:13,967 --> 00:15:16,533
and check the rest
of the bottom end
is also balanced.
303
00:15:18,066 --> 00:15:20,266
The reason that we
go through this process
304
00:15:20,266 --> 00:15:22,500
with each of the
components individually
305
00:15:22,500 --> 00:15:26,266
is that the flywheel
and the pulley, they're all
interchangeable parts,
306
00:15:26,266 --> 00:15:28,700
so if at some point
throughout the engine's life,
307
00:15:28,700 --> 00:15:30,367
these parts get replaced,
308
00:15:30,367 --> 00:15:32,567
we still know that the bit
at the center of it,
309
00:15:32,567 --> 00:15:34,467
the crankshaft,
is perfectly balanced,
310
00:15:34,467 --> 00:15:36,834
and it's only these bits
we need to worry about.
311
00:15:40,367 --> 00:15:41,667
[Mike] But there's still
a long way to go
312
00:15:41,667 --> 00:15:44,867
before our 205's more powerful
than my lawn mower.
313
00:15:44,867 --> 00:15:48,967
Step two is the tricky job
of making some new pistons.
314
00:15:48,967 --> 00:15:50,867
Do you know? I'm really
loving this challenge
315
00:15:50,867 --> 00:15:52,800
that me and Elvis
have set ourselves
316
00:15:52,800 --> 00:15:57,100
to try and do better
than the Euro spec 205 Rallye,
317
00:15:57,100 --> 00:16:00,467
and I reckon what we need
is some lightweight pistons.
318
00:16:00,467 --> 00:16:02,500
So, I'm on my way
to the West Midlands
319
00:16:02,500 --> 00:16:05,367
to go and meet a company,
they're called Omega Pistons,
320
00:16:05,367 --> 00:16:10,066
and they reckon
they can forge me
my very own bespoke set.
321
00:16:10,066 --> 00:16:11,266
This is gonna be cool.
322
00:16:12,567 --> 00:16:14,667
Our current
factory-standard pistons
323
00:16:14,667 --> 00:16:17,367
just won't be up to hand,
they need extra power,
324
00:16:17,367 --> 00:16:19,567
so I'm getting some
new ones made,
325
00:16:19,567 --> 00:16:22,266
and not just by
any old company.
326
00:16:22,266 --> 00:16:24,667
The guys here make pistons
for Formula One,
327
00:16:24,667 --> 00:16:28,333
Moto GP, and speedway teams,
amongst others.
328
00:16:29,266 --> 00:16:31,166
I do love these places.
329
00:16:31,166 --> 00:16:35,200
And the chap I'm meeting,
Andy, is one of the best
in the business.
330
00:16:35,200 --> 00:16:37,100
Andy. Hey!
331
00:16:37,100 --> 00:16:38,667
So when I spoke
to you on the phone,
332
00:16:38,667 --> 00:16:40,567
I told you I've got
this 205 Rallye.
333
00:16:40,567 --> 00:16:43,066
I'm determined to beat
the European spec car,
334
00:16:43,066 --> 00:16:45,967
they get a much
higher horsepower
than we ever did in the UK.
335
00:16:45,967 --> 00:16:48,567
-So what have
you come up with?
-What I'm thinking of is
336
00:16:48,567 --> 00:16:50,967
we'll go for a semi-style
forge piston.
337
00:16:50,967 --> 00:16:53,367
A forge piston,
it's just lighter, is it?
338
00:16:53,367 --> 00:16:55,367
It's much lighter,
and so it moves faster.
339
00:16:55,367 --> 00:16:57,367
It can be,
but it's also a lot stronger,
340
00:16:57,367 --> 00:17:00,567
-so it will withstand the RPM
without any distortion.
-Gotcha.
341
00:17:00,567 --> 00:17:04,200
Distortion creates friction,
friction slows the
engine down.
342
00:17:04,200 --> 00:17:07,600
Gotcha. So what we need to do
is keep a solid, stable piston
343
00:17:07,600 --> 00:17:09,567
within that bore
going up and down.
344
00:17:09,567 --> 00:17:13,166
That piston will go
up and down the bore
345
00:17:13,166 --> 00:17:16,100
-300 times a second.
-That's amazing.
346
00:17:16,100 --> 00:17:18,867
-Think about that.
Three hundred times a second.
-A lot, isn't it?
347
00:17:18,867 --> 00:17:23,200
When it's at top dead center,
it stops momentarily,
348
00:17:23,200 --> 00:17:26,200
it then goes to
bottom dead center,
stops momentarily,
349
00:17:26,200 --> 00:17:28,600
and then repeats the cycle.
In between there,
350
00:17:28,600 --> 00:17:31,000
it is accelerated
to 85 miles an hour,
351
00:17:31,000 --> 00:17:32,900
-and stopped again.
-That's crazy.
352
00:17:32,900 --> 00:17:34,900
It goes through
a lot of pressures.
353
00:17:34,900 --> 00:17:37,600
There's a lot to take
into account when you're
doing the design work.
354
00:17:37,600 --> 00:17:39,500
So, you're telling me
that we can build
355
00:17:39,500 --> 00:17:42,200
a lightweight piston
unique to my car.
356
00:17:42,200 --> 00:17:44,667
-This is designed
specifically for us.
-Yeah.
357
00:17:44,667 --> 00:17:46,300
-Er... because
-I love it.
358
00:17:46,300 --> 00:17:47,867
I've looked at the
compression ratio
359
00:17:47,867 --> 00:17:50,967
that you want to run,
the standard piston,
nine to one.
360
00:17:50,967 --> 00:17:53,500
I think we can safely go
up to 12 to one.
361
00:17:53,500 --> 00:17:56,800
Finally, you're going to get
a bigger bang on the top
of your piston,
362
00:17:56,800 --> 00:17:58,700
-which is what we want.
-Oh, fantastic.
363
00:17:58,700 --> 00:18:01,667
Yeah, I love the
sound of that.
But can we actually build one?
364
00:18:01,667 --> 00:18:03,166
Yeah, of course, we can.
365
00:18:03,166 --> 00:18:05,233
-Let's go. We'll go this way.
-Lovely.
366
00:18:05,767 --> 00:18:07,834
[upbeat music playing]
367
00:18:08,600 --> 00:18:10,467
[Mike]
To create my new pistons,
368
00:18:10,467 --> 00:18:14,634
aluminum is cut
to 40mm chunks called billets.
369
00:18:16,500 --> 00:18:21,567
Then they're put into an oven
and heated to 450 degrees.
370
00:18:21,567 --> 00:18:24,367
At this temperature,
they are malleable to forge
371
00:18:24,367 --> 00:18:27,033
but not enough to lose
the strength of the structure.
372
00:18:28,667 --> 00:18:32,266
And his colleague, Jason,
has got one ready to work on.
373
00:18:32,266 --> 00:18:33,467
Yeah, I can feel the heat.
374
00:18:33,467 --> 00:18:36,567
Yeah. So what
he's gonna do now
is he's rolling the billets
375
00:18:36,567 --> 00:18:39,166
in a lubricant,
so it doesn't stick
in the pot.
376
00:18:39,166 --> 00:18:40,767
So that billet is 450 degrees?
377
00:18:40,767 --> 00:18:42,266
-450 degrees. Yeah.
-Right.
378
00:18:42,266 --> 00:18:44,300
[Mike] And it's gonna go
into that mold
379
00:18:44,300 --> 00:18:47,266
-which is obviously
very hot as well.
-Yeah.
380
00:18:47,266 --> 00:18:50,467
[Mike]
In the mold, it's pumped
with 600 tons of pressure
381
00:18:50,467 --> 00:18:53,133
to hollow it out
into the correct shape.
382
00:18:53,767 --> 00:18:55,467
And there you have it.
383
00:18:55,467 --> 00:18:58,667
-Just see it pop up...
Pop up out to come out.
-Yeah.
384
00:18:58,667 --> 00:19:01,700
-That is fantastic.
-And what'll happen is
385
00:19:01,700 --> 00:19:03,600
that will then come out,
but you can see,
386
00:19:03,600 --> 00:19:06,200
-nothing is stuck,
because of all the lubricant.
-Yeah.
387
00:19:06,200 --> 00:19:08,600
What we'll do now,
we're going to
check it all out,
388
00:19:08,600 --> 00:19:10,000
so if you have
a look at that!
389
00:19:10,000 --> 00:19:11,200
Oh, look at that.
Look at the inside.
390
00:19:11,200 --> 00:19:13,867
So we want to make sure
that all the lettering
is made,
391
00:19:13,867 --> 00:19:18,333
there's no drag marks anywhere
and that it looks even.
392
00:19:19,667 --> 00:19:21,367
[Mike]
Before they're finished,
393
00:19:21,367 --> 00:19:23,367
my new pistons
are being precision turned
394
00:19:23,367 --> 00:19:26,867
down to the exact diameter
of our 205 cylinders.
395
00:19:26,867 --> 00:19:28,500
The holes are bored in them.
396
00:19:28,500 --> 00:19:31,333
Finally, they're cleaned up
and heat-treated.
397
00:19:32,100 --> 00:19:34,000
It's an incredible process,
398
00:19:34,000 --> 00:19:36,300
and I know these pieces
of engineering genius
399
00:19:36,300 --> 00:19:38,900
will make a real difference
to our engine.
400
00:19:38,900 --> 00:19:43,200
Plus, the whole set
cost me just £400, a bargain.
401
00:19:43,200 --> 00:19:45,500
I'm gonna say, Andy,
I've really enjoyed seeing
402
00:19:45,500 --> 00:19:47,500
a range of pistons
being made here today.
403
00:19:47,500 --> 00:19:50,266
I suppose the shame is,
with all this work
you've done,
404
00:19:50,266 --> 00:19:52,667
they're like little trinkets,
like a little jewel,
405
00:19:52,667 --> 00:19:54,367
and yet, they're never
gonna be seen,
406
00:19:54,367 --> 00:19:56,467
-they're gonna be buried
in an engine.
-Yeah.
407
00:19:56,467 --> 00:19:59,166
All this is gonna get covered
in carbon, have oil on it,
408
00:19:59,166 --> 00:20:02,767
it's gonna have all those
pressures that we spoke
about earlier go through it.
409
00:20:02,767 --> 00:20:06,166
But what we do know is
we've got a quality piston
going in your engine.
410
00:20:06,166 --> 00:20:09,667
It's absolutely brilliant.
Listen, I appreciate
you today, I really do.
411
00:20:09,667 --> 00:20:11,767
I can't wait to get my set
sent down to me.
412
00:20:11,767 --> 00:20:13,667
As soon as they're finished,
we'll get them on down to you.
413
00:20:13,667 --> 00:20:15,967
Super, mate. And, er,
it's been a real honor.
414
00:20:15,967 --> 00:20:17,567
Yeah, it's been good
having you here today.
415
00:20:19,000 --> 00:20:20,700
[Elvis]
Whilst Mike's been away,
416
00:20:20,700 --> 00:20:23,100
our 205 has returned
from the paint shop.
417
00:20:23,100 --> 00:20:26,700
I've fitted two new bumpers
I bought online for £75,
418
00:20:26,700 --> 00:20:29,166
plus the crankshaft's
back in the engine.
419
00:20:29,166 --> 00:20:31,367
I've also added
a performance camshaft
420
00:20:31,367 --> 00:20:34,166
and had the cylinder heads
polished and ported.
421
00:20:34,166 --> 00:20:36,867
Now, I'm confident
it can cope with more power.
422
00:20:36,867 --> 00:20:40,300
So next, I've got to start
generating that extra
performance,
423
00:20:40,300 --> 00:20:42,500
and I've had a
light-bulb moment.
424
00:20:42,500 --> 00:20:44,567
Right. With the car
now looking amazing
425
00:20:44,567 --> 00:20:46,767
and the engine well
on its way,
426
00:20:46,767 --> 00:20:49,000
I'm gonna turn my attention
to the fuel system.
427
00:20:49,000 --> 00:20:51,767
And what I want to do
is upgrade the
single carburetor
428
00:20:51,767 --> 00:20:55,767
that the car
came with to this,
a set of throttle bodies.
429
00:20:55,767 --> 00:20:58,166
Now, normally, throttle bodies
are very expensive,
430
00:20:58,166 --> 00:21:00,166
but these, well,
these are second-hand
431
00:21:00,166 --> 00:21:03,166
and off a Suzuki
GSX-R600 motorbike,
432
00:21:03,166 --> 00:21:07,867
and came at
a fraction of the cost,
just £125 for the set.
433
00:21:07,867 --> 00:21:10,767
But they operate at
a much higher fuel pressure,
434
00:21:10,767 --> 00:21:13,367
and that means
it's quite a lot
of work to do to the car
435
00:21:13,367 --> 00:21:15,000
to make this happen.
436
00:21:15,000 --> 00:21:18,667
The engine generates power
by combining fuel and air.
437
00:21:18,667 --> 00:21:21,200
The more fuel and air
we can get into the cylinders,
438
00:21:21,200 --> 00:21:23,500
the more power we can get out.
439
00:21:23,500 --> 00:21:26,467
The throttle bodies
will hopefully
help us to do just that,
440
00:21:26,467 --> 00:21:28,300
as they'll move us
from a carburetor
441
00:21:28,300 --> 00:21:30,100
to a fuel injection system.
442
00:21:30,100 --> 00:21:33,266
Before I tackle the air side,
I'm starting with the fuel.
443
00:21:33,266 --> 00:21:36,000
There are four
throttle bodies,
one for each cylinder,
444
00:21:36,000 --> 00:21:38,066
and they need
a high-pressure fuel feed
445
00:21:38,066 --> 00:21:40,166
which our 205 never came with.
446
00:21:42,500 --> 00:21:44,767
And this here
is our high-pressure pump.
447
00:21:44,767 --> 00:21:46,800
I'm just mounting it
onto the bulkhead
448
00:21:46,800 --> 00:21:49,900
using these rubber bobbins,
which are gonna take up
the vibration
449
00:21:49,900 --> 00:21:53,467
and stop that irritating sound
from penetrating through
to the cabin.
450
00:21:54,900 --> 00:21:56,767
Now the original
carburetor, of course,
451
00:21:56,767 --> 00:21:59,800
has its own
little fuel reservoir
inside the carb itself
452
00:21:59,800 --> 00:22:01,767
that the throttle bodies
don't have that.
453
00:22:01,767 --> 00:22:05,000
So we have to replicate it
using this,
it's called a swirl pot.
454
00:22:05,000 --> 00:22:07,166
This is gonna be
our little fuel reservoir
455
00:22:07,166 --> 00:22:10,266
which is filled up
via a low-pressure system
coming from the tank.
456
00:22:10,266 --> 00:22:13,467
It comes in via this
pipe here. Now what happens
as it goes in,
457
00:22:13,467 --> 00:22:16,066
it swirls around
in this circular motion
458
00:22:16,066 --> 00:22:19,467
inside the tank as
it fills it up. That's why
it's called a swirl pot.
459
00:22:19,467 --> 00:22:21,467
And that motion
not only fills the tank,
460
00:22:21,467 --> 00:22:24,767
which enables the
high-pressure pump
to draw a supply at the bottom
461
00:22:24,767 --> 00:22:26,467
and then feed
the throttle bodies,
462
00:22:26,467 --> 00:22:29,700
but in doing so,
it also separates
the air from the fuel,
463
00:22:29,700 --> 00:22:31,800
and any air pockets
or excess fuel
464
00:22:31,800 --> 00:22:33,800
will then come back
out of this overflow
465
00:22:33,800 --> 00:22:35,367
and find its way back
to the tank.
466
00:22:36,400 --> 00:22:38,767
Our new fuel pump
operates at seven bar,
467
00:22:38,767 --> 00:22:41,967
but our motorbike
throttle bodies
need just half of that,
468
00:22:41,967 --> 00:22:45,967
so I'm going to
step the pressure
down with this regulator.
469
00:22:47,700 --> 00:22:50,033
Then connect everything up
with these hoses.
470
00:22:51,900 --> 00:22:53,634
[upbeat music playing]
471
00:22:59,667 --> 00:23:02,467
That's kind of it.
I've got all the major
components now,
472
00:23:02,467 --> 00:23:04,867
and I've got a fuel supply
coming from the tank
473
00:23:04,867 --> 00:23:06,567
to fill up our swirl pot here,
474
00:23:06,567 --> 00:23:10,467
that's then going to be drawn
from by the high-pressure
pump via this regulator,
475
00:23:10,467 --> 00:23:13,867
dropping that pressure down
to three and a half bar that
the throttle bodies need
476
00:23:13,867 --> 00:23:15,800
which will supply it
directly into the engine,
477
00:23:15,800 --> 00:23:19,367
hopefully, giving us
that extra bit
of performance we need.
478
00:23:19,367 --> 00:23:20,934
But this is a bit of a gamble.
479
00:23:23,467 --> 00:23:26,400
We're trying to take on
and beat the Europeans
480
00:23:26,400 --> 00:23:30,100
by adding more power
to our UK spec 205 Rallye.
481
00:23:30,100 --> 00:23:33,266
And to do that,
I'm unleashing my inner biker
482
00:23:33,266 --> 00:23:35,600
by fitting throttle bodies
from a motorbike.
483
00:23:35,600 --> 00:23:38,000
Time to fess up to Mike.
484
00:23:38,000 --> 00:23:42,000
[laughs]
Look at the paint work.
That looks epic.
485
00:23:42,000 --> 00:23:44,400
So, my forge pistons
must be back in the engine.
486
00:23:44,400 --> 00:23:46,867
Yeah, they are.
There's a lot of
work done on here.
487
00:23:46,867 --> 00:23:49,900
It's got a new exhaust,
the whole bottom end
has been balanced,
488
00:23:49,900 --> 00:23:51,700
the crankshaft,
pulley, flywheel.
489
00:23:51,700 --> 00:23:53,867
We must be getting close
to 100 horsepower now.
490
00:23:53,867 --> 00:23:56,266
Right. Well,
it starts it off with
74 horsepower.
491
00:23:56,266 --> 00:23:59,600
The magic target for us to
even get close to the
Euro spec car
492
00:23:59,600 --> 00:24:02,767
will be, like, over 105,
so we've still got
a ways to go.
493
00:24:02,767 --> 00:24:05,166
-So, you got any ideas?
-Of course, I've got ideas.
494
00:24:05,166 --> 00:24:07,700
I've decided that instead
of going carburetors,
495
00:24:07,700 --> 00:24:11,166
I want to give each one
of the four cylinders
its own fuel source.
496
00:24:11,166 --> 00:24:13,867
I want to go
with throttle bodies.
497
00:24:13,867 --> 00:24:15,667
Throttle bodies?
It's a great idea,
498
00:24:15,667 --> 00:24:18,567
-but they are rather expensive
done over this.
-Well, they are,
499
00:24:18,567 --> 00:24:21,300
unless you get them
from a second-hand Suzuki
500
00:24:21,300 --> 00:24:23,000
GSX-R600 motorbike.
501
00:24:23,000 --> 00:24:24,166
-I beg your pardon?
-Yeah.
502
00:24:24,166 --> 00:24:26,166
So, you're going to take
motorcycle throttle bodies
503
00:24:26,166 --> 00:24:27,767
and put them on our
Peugeot engine?
504
00:24:27,767 --> 00:24:30,300
It will work.
There's a bit of work
to make that happen,
505
00:24:30,300 --> 00:24:32,967
but I've got total faith
that I can make it work.
506
00:24:32,967 --> 00:24:36,166
If you've got faith,
I've got faith,
cause this is what you do.
507
00:24:36,166 --> 00:24:40,166
You make stuff go faster,
and I'm going to find somebody
that we can go up against.
508
00:24:40,166 --> 00:24:42,166
-What, with the Euro spec?
-Yeah, why not?
509
00:24:42,166 --> 00:24:43,767
-It is a proper test, yeah.
But I love it.
-You do?
510
00:24:43,767 --> 00:24:45,600
-Yeah.
-Good.
All right, crack on.
511
00:24:45,600 --> 00:24:47,266
Nice one.
512
00:24:47,266 --> 00:24:49,467
[Elvis] While Mike gets
his roller decks out,
513
00:24:49,467 --> 00:24:51,100
I can get the engine back in
514
00:24:51,100 --> 00:24:53,300
and start part two
of the throttle body job,
515
00:24:53,300 --> 00:24:55,166
mounting them to
our car's engine.
516
00:24:55,800 --> 00:24:57,967
[upbeat music playing]
517
00:24:57,967 --> 00:24:59,967
They need to be attached
to the manifold
518
00:24:59,967 --> 00:25:02,000
which feeds the air
and fuel to the engine,
519
00:25:02,000 --> 00:25:05,266
but our 205 manifold
only has a single pipe,
520
00:25:05,266 --> 00:25:08,100
and I need to have four.
521
00:25:08,100 --> 00:25:11,100
Now I'm absolutely
convinced that fitting
these throttle bodies
522
00:25:11,100 --> 00:25:13,667
is gonna get as close
as that performance
we're after,
523
00:25:13,667 --> 00:25:16,400
the problem is
that unfortunately,
these throttle bodies
524
00:25:16,400 --> 00:25:18,266
will not fit
on the existing manifold.
525
00:25:18,266 --> 00:25:20,667
As you can see, it only had
a single carburetor on there.
526
00:25:20,667 --> 00:25:23,800
So that's got to go,
and that unfortunately means
527
00:25:23,800 --> 00:25:25,533
I've got to make
myself a new one.
528
00:25:27,500 --> 00:25:31,367
Not only do I have to
cut four pipes for the
four-pronged manifold...
529
00:25:33,767 --> 00:25:37,734
...but because the diameter
of the throttle body is larger
than the engine port...
530
00:25:39,700 --> 00:25:43,166
...the pipe needs to be
a different size at each end.
531
00:25:47,500 --> 00:25:50,667
To make the pipes fit,
I've cut strips out of them.
532
00:25:50,667 --> 00:25:53,000
To get them to the right size,
I'm using a hammer
533
00:25:53,000 --> 00:25:58,000
and an inlet flange
which you can pick up easily
online for just 20 quid.
534
00:25:58,000 --> 00:26:02,533
Then to stop any air escaping,
I'm welding the cuts shut.
535
00:26:12,967 --> 00:26:17,100
I also need to change the
angle so that I can match
the pipes up
536
00:26:17,100 --> 00:26:19,166
with the spacing of our
throttle bodies.
537
00:26:19,166 --> 00:26:21,266
If these parts were longer and
I was talking about
538
00:26:21,266 --> 00:26:23,767
some greater angles
than the ones I actually need,
539
00:26:23,767 --> 00:26:26,800
I just go straight in
and weld in some
preformed bends.
540
00:26:26,800 --> 00:26:29,667
But we're talking about angles
that are very, very slight,
541
00:26:29,667 --> 00:26:31,667
and the piece of pipe
is quite short.
542
00:26:31,667 --> 00:26:33,800
I'm going to use a technique
called pie cutting,
543
00:26:33,800 --> 00:26:36,266
where I cut out
a sort of wedge shape.
544
00:26:36,266 --> 00:26:39,200
It looks a little bit like
a slice of a pie,
hence the name.
545
00:26:39,200 --> 00:26:42,000
And then I can bend it over,
closing up that gap,
546
00:26:42,000 --> 00:26:44,000
giving me the angle
that I need.
547
00:26:44,000 --> 00:26:46,133
[upbeat music playing]
548
00:27:04,467 --> 00:27:07,266
Now we're getting there.
The pipes are cut, bent,
549
00:27:07,266 --> 00:27:11,066
and it's again time
to weld everything together.
550
00:27:19,066 --> 00:27:22,500
Nearly there.
Nearly made my own manifold.
551
00:27:22,500 --> 00:27:24,166
This turned out to be
quite a lot of work.
552
00:27:24,166 --> 00:27:27,567
What I've done has not only
saved us quite a lot of money,
553
00:27:27,567 --> 00:27:31,000
but hopefully got us
close enough
to the performance we need
554
00:27:31,000 --> 00:27:34,834
to beat the your
Euro spec version.
So I'm very happy.
555
00:27:36,000 --> 00:27:38,166
[Mike]
Whilst Elvis plays
with these pipes,
556
00:27:38,166 --> 00:27:40,767
I'm busy sorting something
for the weekend.
557
00:27:40,767 --> 00:27:43,600
Don't be so cheeky.
Yes, I've got the pictures.
558
00:27:43,600 --> 00:27:47,367
I'm looking at it now.
I know, it looks rather racy.
559
00:27:47,367 --> 00:27:51,567
[laughs] All right, mate.
See you later. Bye-bye.
560
00:27:51,567 --> 00:27:53,667
Elvis,
you're going to love this.
561
00:27:53,667 --> 00:27:56,000
-What's happened?
-Right,
Angus around the corner...
562
00:27:56,000 --> 00:27:57,767
-Yeah.
-...who's got
a restoration company,
563
00:27:57,767 --> 00:28:00,567
his son, Max,
is a bit of a race driver,
564
00:28:00,567 --> 00:28:02,567
and guess what? The family own
565
00:28:02,567 --> 00:28:07,667
-a proper Peugeot 205
European spec Rallye.
-No way!
566
00:28:07,667 --> 00:28:10,367
He's just sent me the pictures
of it. How good is that?
567
00:28:10,367 --> 00:28:12,166
-That looks cool.
-That is Rallye spec.
568
00:28:12,166 --> 00:28:14,800
-It's got a little roll cage
in it as well, so...
-Yeah.
569
00:28:14,800 --> 00:28:16,600
He reckons
he's going to rinse us.
570
00:28:16,600 --> 00:28:20,567
-Does he? [laughs]
That's fighting talk, that is.
-It is fighting talk.
571
00:28:20,567 --> 00:28:23,266
So I've asked him to meet us
at Pembrey Race Circuit.
572
00:28:23,266 --> 00:28:26,500
-Good track, yeah.
-Good track, where we can
put our UK spec car
573
00:28:26,500 --> 00:28:29,667
up against his more powerful,
so he thinks,
574
00:28:29,667 --> 00:28:33,600
European spec car,
and hopefully,
we can rinse him.
575
00:28:33,600 --> 00:28:35,867
That is a proper challenge,
isn't it? But, erm,
576
00:28:35,867 --> 00:28:39,100
I suppose until we get ours
finished and then
to a rolling road,
577
00:28:39,100 --> 00:28:41,867
we won't have any idea,
really, how powerful ours is,
578
00:28:41,867 --> 00:28:43,567
but I think it might be close.
579
00:28:43,567 --> 00:28:46,700
The only thing that
sets our car
apart from this install was
580
00:28:46,700 --> 00:28:49,500
is those wheel arches,
which I absolutely love,
581
00:28:49,500 --> 00:28:51,200
those European arches.
582
00:28:51,200 --> 00:28:53,500
So I've taken the liberty
of ordering a set,
583
00:28:53,500 --> 00:28:55,266
they're on their way
to the workshop.
584
00:28:55,266 --> 00:28:58,000
If you can paint them mustard
to match the rest of the car
585
00:28:58,000 --> 00:29:00,166
and get them screwed on,
it'll look the part.
586
00:29:00,166 --> 00:29:02,767
It's literally the most
yellow car we have ever done.
587
00:29:02,767 --> 00:29:04,867
Something must be wrong
with your eyesight.
588
00:29:04,867 --> 00:29:07,000
-It's mustard.
-Nice one.
I love a challenge.
589
00:29:07,000 --> 00:29:09,133
Yeah, top work.
590
00:29:10,767 --> 00:29:13,100
[Elvis]
But before our showdown
with the Euro spec,
591
00:29:13,100 --> 00:29:15,767
I need to finish
my throttle body upgrade.
592
00:29:15,767 --> 00:29:19,767
I've connected them up to the
engine via my newly
fabricated manifold.
593
00:29:19,767 --> 00:29:21,834
Next, I need to
configure them.
594
00:29:23,400 --> 00:29:25,400
And the purpose
of these throttle bodies
595
00:29:25,400 --> 00:29:28,467
is to give each cylinder its
own individual air
and fuel source
596
00:29:28,467 --> 00:29:30,867
to aid performance.
And just down here,
597
00:29:30,867 --> 00:29:33,367
behind these throttle plates,
is a vacuum port,
598
00:29:33,367 --> 00:29:35,166
whose job is to make sure
599
00:29:35,166 --> 00:29:38,100
that each cylinder is getting
the correct amount of airflow
600
00:29:38,100 --> 00:29:39,767
when you put your foot
on the throttle.
601
00:29:39,767 --> 00:29:41,700
So at low revs
or low throttle,
602
00:29:41,700 --> 00:29:43,900
if each cylinder is getting
a different amount of air,
603
00:29:43,900 --> 00:29:45,867
it will run lumpy
and less smooth,
604
00:29:45,867 --> 00:29:48,066
and over time, it can even
make it less reliable.
605
00:29:50,767 --> 00:29:52,767
The vacuum ports
are adjustable,
606
00:29:52,767 --> 00:29:56,967
so I'm gonna use these gauges
to measure the amount of air
that's going through each port
607
00:29:56,967 --> 00:29:58,667
and then tweak
them all individually
608
00:29:58,667 --> 00:30:00,567
using these little screws.
609
00:30:00,567 --> 00:30:02,266
There's one primary
one on the end
610
00:30:02,266 --> 00:30:04,266
which actually adjusts
all four cylinders,
611
00:30:04,266 --> 00:30:07,300
and then there are
little individual ones
in between each port.
612
00:30:07,300 --> 00:30:10,500
Now, once the
engine's fired up, I'm gonna
tweak those one by one,
613
00:30:10,500 --> 00:30:11,800
moving from left to right,
614
00:30:11,800 --> 00:30:13,767
now that I've got
each of the cylinders
615
00:30:13,767 --> 00:30:15,967
individually isolated
via these clamps,
616
00:30:15,967 --> 00:30:19,100
and I'm gonna be
looking at the gauges
to make sure that all four
617
00:30:19,100 --> 00:30:21,066
are nicely balanced
between each other.
618
00:30:21,066 --> 00:30:24,367
So, I think we're just
about ready
to fire it up and get started.
619
00:30:24,367 --> 00:30:25,867
[upbeat music playing]
620
00:30:28,000 --> 00:30:30,667
[engine starts]
621
00:30:30,667 --> 00:30:32,667
This is a bit like
tuning a guitar.
622
00:30:32,667 --> 00:30:34,900
Each string has to
be tuned individually,
623
00:30:34,900 --> 00:30:38,867
so when they're all
played together, the sound
harmonizes perfect.
624
00:30:42,700 --> 00:30:46,100
I'm not really looking for an
exact measurement on
these gauges,
625
00:30:46,100 --> 00:30:48,767
but what I am trying to find
is a point where they're all
626
00:30:48,767 --> 00:30:51,100
nicely balanced with
each other.
627
00:30:51,100 --> 00:30:55,900
And it often means
the tiniest of tweaks,
one by one,
628
00:30:55,900 --> 00:30:57,900
and it might need
quite a few passes
629
00:30:57,900 --> 00:30:59,767
until I get it really,
really close.
630
00:31:01,400 --> 00:31:04,333
It's very small adjustments.
631
00:31:07,000 --> 00:31:09,634
After a bit of fettling,
I think we're pretty close.
632
00:31:11,800 --> 00:31:13,667
Yes, perfect.
633
00:31:13,667 --> 00:31:16,166
Each one of the gauges
is reading very similar,
634
00:31:16,166 --> 00:31:18,467
which tells me that
each of our four cylinders
635
00:31:18,467 --> 00:31:21,166
are perfectly balanced
with each other.
636
00:31:21,166 --> 00:31:23,100
And that means
that this great engine
637
00:31:23,100 --> 00:31:27,533
and this great car
are now ready
for the race of its life.
638
00:31:29,700 --> 00:31:32,166
[Mike]
We bought a UK spec
Peugeot 205 Rallye
639
00:31:32,166 --> 00:31:35,100
with a pretty pathetic
75 horsepower.
640
00:31:35,100 --> 00:31:37,867
Mate, that is so underpowered.
641
00:31:37,867 --> 00:31:41,367
To measure nought to 60,
you need a calendar,
not a stopwatch.
642
00:31:41,367 --> 00:31:44,900
[Mike] But if anyone can make
it run faster than a
Euro spec,
643
00:31:44,900 --> 00:31:46,266
it's my Elvis...
644
00:31:46,266 --> 00:31:47,367
I want to go with
throttle bodies.
645
00:31:47,367 --> 00:31:48,667
-I beg your pardon?
-Yeah.
646
00:31:48,667 --> 00:31:51,166
[Mike] ...with a helping hand
from yours truly.
647
00:31:51,166 --> 00:31:53,266
We can build
a lightweight piston
648
00:31:53,266 --> 00:31:55,200
-unique to my car?
-Yeah.
649
00:31:55,200 --> 00:31:56,467
I love the sound of that.
650
00:31:56,467 --> 00:31:58,767
[Mike] So now it's ready
for the ultimate test,
651
00:31:58,767 --> 00:32:01,867
a track showdown
against its European rival
652
00:32:01,867 --> 00:32:05,266
before we, hopefully,
sell it on for a
decent profit.
653
00:32:05,266 --> 00:32:09,800
I bought a car
in an online auction
for £2,850.
654
00:32:09,800 --> 00:32:12,967
Elvis's fuel system
upgrade was £130.
655
00:32:12,967 --> 00:32:16,967
The motorbike throttle bodies
and ECU were £701.
656
00:32:16,967 --> 00:32:19,667
Pistons and parts
for the engine rebuild,
657
00:32:19,667 --> 00:32:21,667
£962.
658
00:32:21,667 --> 00:32:26,066
New bumpers, decals,
arches and paint, £1,790.
659
00:32:26,767 --> 00:32:29,967
Fresh tires and suspension,
£860,
660
00:32:29,967 --> 00:32:33,367
while seat covers
and carpets were £645,
661
00:32:33,367 --> 00:32:35,200
which means our 205 Rallye
662
00:32:35,200 --> 00:32:40,367
owes us a grand total
of £7,938.
663
00:32:40,367 --> 00:32:43,567
A hefty price tag
for a 75 horsepower car.
664
00:32:43,567 --> 00:32:45,767
But I reckon
ours is well beyond
that now...
665
00:32:47,467 --> 00:32:49,600
So we're heading
to a race circuit in Wales
666
00:32:49,600 --> 00:32:54,533
to see if our little yellow
beauty can finally
cut the mustard.
667
00:32:55,000 --> 00:32:56,233
[laughs]
668
00:32:57,100 --> 00:32:59,467
How good is this?
Look at us. Listen to it.
669
00:32:59,467 --> 00:33:02,100
We're in the Welsh valleys,
right?
670
00:33:02,100 --> 00:33:07,166
The scenery outside is epic.
This little car sounds pfff.
671
00:33:07,166 --> 00:33:10,367
I just, I can't believe
how good it sounds,
it sounds astonishing.
672
00:33:10,367 --> 00:33:12,266
[Elvis]
I'll tell you what, mate,
this has been
673
00:33:12,266 --> 00:33:13,967
a huge amount of work,
674
00:33:13,967 --> 00:33:16,066
mostly of course
in the engine,
but on top of that,
675
00:33:16,066 --> 00:33:18,567
we've upgraded the suspension
because it needed it.
676
00:33:18,567 --> 00:33:22,100
It's had the heads polished
and ported, upgraded camshaft.
677
00:33:22,100 --> 00:33:23,767
The list goes on
and on and on.
678
00:33:23,767 --> 00:33:25,667
Of course, the new ECU
to run all of that,
679
00:33:25,667 --> 00:33:27,767
and I had to take
it to a rolling road.
680
00:33:27,767 --> 00:33:29,567
Talking of rolling road,
horsepower,
681
00:33:29,567 --> 00:33:30,967
-how much have we got?
-Oh!
682
00:33:30,967 --> 00:33:34,200
Well, I do know the number,
but I'm not going to
tell you just yet,
683
00:33:34,200 --> 00:33:36,467
because I want you to feel
what this car is like
684
00:33:36,467 --> 00:33:37,767
-on the circuit.
-Tell me.
685
00:33:37,767 --> 00:33:39,667
No, mate, just be patient,
be patient.
686
00:33:39,667 --> 00:33:40,900
Because what you're
going to find,
687
00:33:40,900 --> 00:33:44,066
particularly on the racetrack,
it is gonna blow your mind
688
00:33:44,066 --> 00:33:46,767
how different this car is
to when we first picked it up,
689
00:33:46,767 --> 00:33:49,700
and I reckon it's going to be
a really close call, you know.
690
00:33:49,700 --> 00:33:52,066
A really close challenge
going up against
691
00:33:52,066 --> 00:33:55,400
a bona fide
Euro spec 205 Rallye.
692
00:33:55,400 --> 00:33:58,767
But, look, if we can
get through the day,
and the car survives,
693
00:33:58,767 --> 00:34:01,900
I've got a phone call to make
to a guy called Nige,
694
00:34:01,900 --> 00:34:03,567
who's found out
through contacts
695
00:34:03,567 --> 00:34:05,967
that we've got this car
potentially for sale,
696
00:34:05,967 --> 00:34:08,266
-because I haven't even
advertised it yet.
-Wow.
697
00:34:08,266 --> 00:34:10,266
-Guess where he is?
-Where?
698
00:34:10,266 --> 00:34:12,367
He's upside down,
he's in New Zealand.
699
00:34:12,367 --> 00:34:14,867
-Mate, that's incredible.
-And I think,
700
00:34:14,867 --> 00:34:18,567
possibly, I might be able to
get us a nice,
decent profit of 12.5 grand,
701
00:34:18,567 --> 00:34:20,400
and it might be
on his way down under.
702
00:34:20,400 --> 00:34:24,667
[Mike] But before a possible
11,000-mile trip to the other
side of the world,
703
00:34:24,667 --> 00:34:28,567
we've got just 1.4 miles
at Pembrey Circuit to tackle.
704
00:34:28,567 --> 00:34:30,467
Nestled in the south of Wales,
705
00:34:30,467 --> 00:34:33,467
it's the perfect place to see
if our pumped-up Peugeot
706
00:34:33,467 --> 00:34:35,667
can beat a genuine Euro spec.
707
00:34:35,667 --> 00:34:38,100
It's been brought along
by young race driver, Max.
708
00:34:38,100 --> 00:34:40,400
Right, Elvis.
This is the son of
a friend of mine,
709
00:34:40,400 --> 00:34:42,667
-this is Max, this is Elvis.
-Hello, mate, how are you?
710
00:34:42,667 --> 00:34:45,066
-Thanks for bringing down
the car, Max.
-No worries.
711
00:34:45,066 --> 00:34:46,967
It looks lovely.
Tell me a bit about it then.
712
00:34:46,967 --> 00:34:49,467
Well, this is my
Euro spec 205.
713
00:34:49,467 --> 00:34:51,667
It's been built
by Peugeot-Talbot Sport,
714
00:34:51,667 --> 00:34:54,367
so they've done
a fair few bits,
where it's got a cage,
715
00:34:54,367 --> 00:34:55,867
-it's got a limited slip diff.
-[Mike] Whoa!
716
00:34:55,867 --> 00:34:57,467
[Max]
Hasn't got a lot of carpet.
717
00:34:57,467 --> 00:34:59,667
So it's no longer
just a standard car,
718
00:34:59,667 --> 00:35:01,467
no door panels...
719
00:35:01,467 --> 00:35:03,467
-[knocks]
-That's not even glass, is it?
720
00:35:03,467 --> 00:35:06,266
-No, yeah. No, no...
-So you
saved weight everywhere,
721
00:35:06,266 --> 00:35:08,700
this is a full-going road car
with everything in it.
722
00:35:08,700 --> 00:35:10,000
-How old are you?
-Eighteen.
723
00:35:10,000 --> 00:35:11,066
How old are you, Mike?
724
00:35:11,066 --> 00:35:12,667
I'll be getting my
bus pass soon.
725
00:35:12,667 --> 00:35:14,000
Right.
How much do you weigh?
726
00:35:14,000 --> 00:35:16,600
Seventy-two kilos.
727
00:35:16,600 --> 00:35:20,100
Well, last time
I weighed myself
I was 18, I was 72 kilos,
728
00:35:20,100 --> 00:35:22,467
-so about the same.
-It's even.
Same, yeah. Okay.
729
00:35:22,467 --> 00:35:24,567
Well, it's gonna be close.
What I'm gonna do
730
00:35:24,567 --> 00:35:26,600
is I'm going to send you
both out onto the racetrack.
731
00:35:26,600 --> 00:35:28,700
You'll go on my
first countdown,
732
00:35:28,700 --> 00:35:31,266
and then five seconds later,
you'll go in our car.
733
00:35:31,266 --> 00:35:33,567
You're gonna chase him,
cos the last thing
I want you to do
734
00:35:33,567 --> 00:35:35,867
is get too close to each other
and start trading paint.
735
00:35:35,867 --> 00:35:37,800
I'm going to time
both of your laps,
736
00:35:37,800 --> 00:35:39,767
I'll meet you back here at the
end of that lap,
737
00:35:39,767 --> 00:35:41,166
and I'll let you know
how we got on.
738
00:35:41,166 --> 00:35:43,266
-Sounds good.
-Can I get lunch first?
739
00:35:43,266 --> 00:35:45,900
No. We need to
save more weight, mate.
740
00:35:45,900 --> 00:35:48,000
No more lunch. All right?
741
00:35:48,000 --> 00:35:50,834
-I'll see you out on track.
-Be prepared to lose.
742
00:35:51,800 --> 00:35:54,100
[dramatic music playing]
743
00:35:54,100 --> 00:35:57,800
[Mike] Whilst Elvis is keeping
shtum about the new power
of our engine,
744
00:35:57,800 --> 00:36:02,367
I know it's going to be
well over the original
75 horsepower.
745
00:36:05,200 --> 00:36:07,867
But will it be enough
to beat Max's Euro spec
746
00:36:07,867 --> 00:36:10,233
with his weight-reducing
race mods?
747
00:36:13,867 --> 00:36:15,567
Right. Here we go.
748
00:36:15,567 --> 00:36:19,300
Next to me is young
racing driver, Max,
749
00:36:19,300 --> 00:36:22,166
who looks quite mean
and menacing.
750
00:36:22,166 --> 00:36:25,300
He's got racing gloves on,
he's got a race suit,
751
00:36:25,300 --> 00:36:27,166
I'm in my shirt.
752
00:36:27,166 --> 00:36:29,166
I've got the carpet,
I've got the seats,
753
00:36:29,166 --> 00:36:30,767
he's got none of that.
754
00:36:30,767 --> 00:36:34,567
This is going to be tough,
and he's, I've got no chance.
755
00:36:34,567 --> 00:36:37,100
[Elvis]
With both cars in position
on the start line...
756
00:36:37,100 --> 00:36:39,166
-[engines revving]
-...it's time to race.
757
00:36:39,166 --> 00:36:41,200
Are you ready?
Here we go, then.
758
00:36:41,200 --> 00:36:43,000
This is terrifying.
759
00:36:43,000 --> 00:36:47,600
Max, three, two, one, go.
760
00:36:47,600 --> 00:36:50,900
Max is off.
He's got a little bit
of wheel spin off the line.
761
00:36:50,900 --> 00:36:52,600
[engine revving]
762
00:36:52,600 --> 00:36:56,567
-[radio beeps]
-And, Mike,
three, two, one, go.
763
00:36:56,567 --> 00:36:58,500
Oh, I've got a lot
of wheel spin off the line.
764
00:36:58,500 --> 00:37:00,266
I've got it off,
I've got it away.
765
00:37:00,266 --> 00:37:02,900
Whoa-ho-ho!
It's in second gear.
766
00:37:02,900 --> 00:37:06,400
Already I can see Max
disappearing
into the distance,
767
00:37:06,400 --> 00:37:09,266
but I'm catching him up
as fast as I can.
768
00:37:11,500 --> 00:37:14,300
Whoa! On the brakes,
on the brakes,
on the brakes, Mike.
769
00:37:14,300 --> 00:37:17,700
Turn into his first turn.
Look at me just turning.
770
00:37:17,700 --> 00:37:21,900
God, this car has
got so much power,
I'm just wheel spinning.
771
00:37:21,900 --> 00:37:24,467
That yellow car
has got a lot of power.
772
00:37:24,467 --> 00:37:27,333
He almost reeled him in
to down the straight.
773
00:37:29,767 --> 00:37:33,700
Oh, this little car
is revving so highly.
774
00:37:33,700 --> 00:37:35,967
Max is hard on the brakes.
775
00:37:36,967 --> 00:37:39,867
I'm following him,
I'm hard on the
brakes as well.
776
00:37:39,867 --> 00:37:45,100
[laughs] I can hear
those lightened forged pistons
777
00:37:45,100 --> 00:37:48,634
bouncing away there
under the bonnet of this car.
778
00:37:51,100 --> 00:37:53,567
So these two are
really pushing it,
779
00:37:53,567 --> 00:37:55,467
I'm not sure there's much
between them.
780
00:37:55,467 --> 00:37:57,834
He's not disappearing,
I'm gonna tell you.
781
00:38:00,900 --> 00:38:03,133
Oh, Max is on the
brakes heavy.
782
00:38:05,500 --> 00:38:08,266
So am I up on the brakes,
I think we're turning in.
783
00:38:08,266 --> 00:38:10,100
I'm catching him up.
784
00:38:10,100 --> 00:38:13,967
Yeah, I'm turning,
turning, turning.
785
00:38:16,600 --> 00:38:18,667
So, I've got...
786
00:38:18,667 --> 00:38:22,467
Oh, this car is insane.
Trying to chew my face off.
787
00:38:22,467 --> 00:38:24,967
Look at me, I'm being
thrown around the cockpit.
788
00:38:25,967 --> 00:38:28,467
Come on, Brewer. Come on.
789
00:38:28,467 --> 00:38:31,734
Right over onto the curbs.
They are really pushing it.
790
00:38:32,900 --> 00:38:36,500
It feels like he's about
the same distance
he was from myself
791
00:38:36,500 --> 00:38:39,767
holding onto him.
Look at that.
He's just there.
792
00:38:39,767 --> 00:38:41,634
He's not that far away.
793
00:38:44,300 --> 00:38:46,867
Come on, little car.
794
00:38:46,867 --> 00:38:51,166
Here we go to a fast part
of this circuit.
795
00:38:52,667 --> 00:38:56,000
Remember, we've got those
throttle bodies as well
on this car
796
00:38:56,000 --> 00:39:00,100
which is making it scream
its little lungs out.
797
00:39:00,100 --> 00:39:03,033
Here comes Max now
at the final corner.
798
00:39:04,367 --> 00:39:07,767
And I'm coming down
the last bend. Come on.
799
00:39:07,767 --> 00:39:09,467
The car is killing me.
800
00:39:10,867 --> 00:39:12,467
Here he comes. Look at him.
801
00:39:12,467 --> 00:39:14,834
Onto the
start-finish straight.
802
00:39:15,500 --> 00:39:17,700
Here he goes.
803
00:39:17,700 --> 00:39:19,867
-Go on, Mike. Go on!
-Come on!
804
00:39:19,867 --> 00:39:23,066
Come on, you can do it.
I hope that's within
five seconds.
805
00:39:23,800 --> 00:39:25,667
Whoa!
806
00:39:26,567 --> 00:39:30,000
What a lap!
Max did a great job.
807
00:39:30,000 --> 00:39:32,467
Well done, mate. Oh.
808
00:39:32,467 --> 00:39:35,767
I feel with some
of the improvements
that Elvis has made,
809
00:39:35,767 --> 00:39:39,767
I got a funny feeling I was...
I was within the same time
810
00:39:39,767 --> 00:39:41,467
as Max came around that lap,
811
00:39:41,467 --> 00:39:43,867
but we're about to find out
when we pull in.
812
00:39:43,867 --> 00:39:46,100
[Elvis] Well, I'm the one
with a stopwatch, matey.
813
00:39:46,100 --> 00:39:48,467
Trust me, there really
isn't much in it.
814
00:39:48,467 --> 00:39:52,000
-That looked epic.
-It was absolutely fantastic.
815
00:39:52,000 --> 00:39:55,467
-Mate, you have built
one astonishing little car.
-Oh.
816
00:39:55,467 --> 00:39:58,667
It is so fast,
it's wheel-spinning
everywhere.
817
00:39:58,667 --> 00:40:01,567
-What is the horsepower
of this car?
-You wanna know, then?
818
00:40:01,567 --> 00:40:03,967
-Yeah, go on then.
The horsepower.
-Horse power.
819
00:40:03,967 --> 00:40:06,500
I took it to the rolling road,
it started off with...
820
00:40:06,500 --> 00:40:09,066
Seventy-four, 75 horsepower?
...74, and you had...
821
00:40:09,066 --> 00:40:11,667
-About 105.
-...105. Yeah.
822
00:40:11,667 --> 00:40:13,967
A hundred and thirty-five
horsepower.
823
00:40:13,967 --> 00:40:15,867
-No way! Seriously?
-Yes.
824
00:40:15,867 --> 00:40:17,500
-That engine is brilliant.
-What?
825
00:40:17,500 --> 00:40:20,166
-That is astonishing.
And that explains it.
-Wow.
826
00:40:20,166 --> 00:40:23,266
I can really feel it,
the extra power
from that engine.
827
00:40:23,266 --> 00:40:26,000
-Nice. That is absolutely...
Well done, Elvis.
-Thanks again.
828
00:40:26,000 --> 00:40:28,667
But all the work
has really paid off.
It sounds great,
829
00:40:28,667 --> 00:40:31,266
and you could see you
closing it up
on the straights,
830
00:40:31,266 --> 00:40:33,367
and you were pulling away
a bit out of the corners,
831
00:40:33,367 --> 00:40:34,700
because you've got
a limited slip diff.
832
00:40:34,700 --> 00:40:37,800
With this, we haven't got it,
which means it was very close.
833
00:40:37,800 --> 00:40:39,367
-You wanna know
how close?
-Go on, then.
834
00:40:39,367 --> 00:40:41,166
How far behind him was I?
835
00:40:41,166 --> 00:40:43,800
All right, Max,
this is your stopwatch.
836
00:40:43,800 --> 00:40:48,367
-You did it in one minute,
29.10.
-One, twenty-nine...
837
00:40:48,367 --> 00:40:50,700
-[Elvis] Very respectable.
-[Mike] Oh, that's tough.
838
00:40:50,700 --> 00:40:53,467
-One, twenty-nine, one.
-Our little car,
839
00:40:53,467 --> 00:40:56,367
-One 29...
-One... Oh!
840
00:40:56,367 --> 00:40:58,000
-...point-two-eight.
-[laughs]
841
00:40:58,000 --> 00:41:00,066
Mate, this is... Mate,
842
00:41:00,066 --> 00:41:03,166
-18/100ths of a second behind.
-There's no way. Lovely.
843
00:41:03,166 --> 00:41:05,166
I'm so proud of what
we've turned out.
844
00:41:05,166 --> 00:41:06,900
That is a brilliant
little car.
845
00:41:06,900 --> 00:41:08,967
Oh, mate, you've done
such an amazing job.
846
00:41:08,967 --> 00:41:11,266
Max, thank you so much
for bringing that down
847
00:41:11,266 --> 00:41:12,667
and giving us the opportunity.
848
00:41:12,667 --> 00:41:14,867
You've been brilliant,
but now,
849
00:41:14,867 --> 00:41:18,200
now it's the time to sell it,
because I've got to
phone up Nigel
850
00:41:18,200 --> 00:41:19,967
and see if he wants
to put a deal together.
851
00:41:21,000 --> 00:41:23,367
After that
fantastic track test,
852
00:41:23,367 --> 00:41:25,667
I'd love to keep hold
of our hot hatch,
853
00:41:25,667 --> 00:41:27,567
but needs must.
854
00:41:27,567 --> 00:41:33,166
So let's see if Nige in
New Zealand wants to take the
205 off our hands.
855
00:41:33,166 --> 00:41:35,066
Nige?
856
00:41:35,066 --> 00:41:36,800
-Mike, how are you?
-I'm all right.
857
00:41:36,800 --> 00:41:39,100
Not bad at all, mate.
How are you?
858
00:41:39,100 --> 00:41:40,867
-I'm very well, thank you.
-Nige...
859
00:41:40,867 --> 00:41:43,500
Nige, your backdrop
looks astonishing.
860
00:41:43,500 --> 00:41:45,700
What an array of cars
you've lined up for me.
861
00:41:45,700 --> 00:41:48,300
And it's real, it's real.
It's not a fake background.
862
00:41:48,300 --> 00:41:50,467
What's that? A 996 GT?
863
00:41:50,467 --> 00:41:52,100
No, that's just the Turbo one.
864
00:41:52,100 --> 00:41:53,667
-Is it? Well, nice.
-So, this is close to that.
865
00:41:53,667 --> 00:41:56,266
-E-Type Jaguar?
-Yes, V-12, manual.
866
00:41:56,266 --> 00:41:59,700
Well, I can see
you've got the best British
and the best of German there,
867
00:41:59,700 --> 00:42:01,800
the only thing you're missing
is the best of France,
868
00:42:01,800 --> 00:42:06,166
which is this wonderful little
205 Rallye that we've got,
869
00:42:06,166 --> 00:42:09,100
so hopefully,
you've seen the pictures,
and you like what you see?
870
00:42:09,100 --> 00:42:10,967
It looks stunning.
It's amazing.
871
00:42:10,967 --> 00:42:12,467
Yeah, you've done a really
good job of it.
872
00:42:12,467 --> 00:42:16,367
Nige, why would you want
one of these little 205s?
873
00:42:16,367 --> 00:42:19,266
Growing up in the UK,
we used to see
them all the time,
874
00:42:19,266 --> 00:42:21,367
all the GTIs,
we've never seen the Rallyes,
875
00:42:21,367 --> 00:42:23,667
and Rallye was always
something from the '80s.
876
00:42:23,667 --> 00:42:24,800
I thought, "You know what?
877
00:42:24,800 --> 00:42:26,467
Nineties, this is gonna
be the car."
878
00:42:26,467 --> 00:42:29,467
So, I'm actually sat in the
space where it's gonna
go right now.
879
00:42:29,467 --> 00:42:32,800
[laughs] Well,
it sounds like you've already
decided you want to buy it.
880
00:42:32,800 --> 00:42:35,500
As you know, this car
is not even advertised yet,
881
00:42:35,500 --> 00:42:38,200
I need £12,500 for it.
882
00:42:38,200 --> 00:42:40,467
If I do put it out there
on the Internet,
883
00:42:40,467 --> 00:42:43,667
I think I'm going to
sell it in a heartbeat.
So what do you say?
884
00:42:43,667 --> 00:42:46,500
Yeah, I think that's
a good price, Mike.
I'm happy with that.
885
00:42:46,500 --> 00:42:48,567
-So, £12,500.
-Yeah.
886
00:42:48,567 --> 00:42:51,000
Hold out your virtual hand.
887
00:42:51,000 --> 00:42:53,166
You've got yourself a deal.
Well done, Nigel.
888
00:42:53,166 --> 00:42:54,567
You just brought a
cracking car.
889
00:42:54,567 --> 00:42:56,367
Fantastic.
Thanks so much, Mike.
890
00:42:56,367 --> 00:42:59,300
It's a pleasure, mate.
Hope you enjoy it
for many years to come.
891
00:42:59,300 --> 00:43:00,834
[upbeat music playing]
892
00:43:02,266 --> 00:43:05,567
Our little UK spec 205 Rallye
893
00:43:05,567 --> 00:43:08,867
really was a bold
and ambitious plan,
894
00:43:08,867 --> 00:43:10,567
but we pulled it off.
895
00:43:10,567 --> 00:43:13,166
We built a car
that can not only take on
896
00:43:13,166 --> 00:43:15,367
the best of France,
but equal it.
897
00:43:15,367 --> 00:43:17,900
And undoubtedly,
if it had a better driver
898
00:43:17,900 --> 00:43:21,800
behind the cockpit,
it'll win.
It'll even better it.
899
00:43:21,800 --> 00:43:25,166
Now it just goes to prove
that with Elvis
in the workshop,
900
00:43:25,166 --> 00:43:29,100
he is destined, that man,
to make stuff go faster
901
00:43:29,100 --> 00:43:31,467
and he can really pull it off.
And as for me,
902
00:43:31,467 --> 00:43:34,000
well, I can prove that
I can still wheel and deal.