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.