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AW, GREAT. ALREADY GOT FIRST BLOOD ON IT.

ONE, TWO, THREE, FOUR

Mike: THE KARMANN GHIA IS A FABULOUS DESIGN,

BUT IT GOT PRODUCTIONIZED.

NO WAY THIS GUY IS EVER GOING TO BUCKLE THIS.

-[BLEEP] -CAREFUL.

I'M GOING TO GO GET A BEER.

OKAY. GET 30 OF THEM.

Dave: I'VE NEVER BEEN IN A FOUNDRY BEFORE.

Greg: CRAZY PROCESS.

TO THINK THEY'VE BEEN DOING THIS STUFF FOR 3,000 YEARS,

THAT'S PRETTY WILD.

-BOOM. -I'M TELLING YOU.

Dave: CLEAN...

CUSTOM...

BITCHIN'.

♪♪

MY NAME IS DAVE KINDIG.

DESIGNING AND BUILDING CUSTOM CARS IS MY LIFE'S PASSION.

WITH THE BEST MECHANICS, TECHNICIANS, AND FABRICATORS

IN THE BUSINESS, QUALITY IS OUR ONLY FOCUS.

WE BUILD BITCHIN' RIDES.

-- Captions by VITAC -- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

♪♪

SO ME AND DAVE GOT THE OPPORTUNITY TO COME UP HERE

AND CHECK OUT UB TECH.

THIS SCHOOL IS AMAZING.

Dave: BUT EVEN COOLER EVEN IN THIS INSTANT

IS THE FACT THAT THEY'VE JUST OPENED UP A WELDING CLASS.

THEY'RE TRAINING THE KIDS ON HOW TO BE CERTIFIED WELDERS,

A GREAT SKILL THAT'S VERY IMPORTANT TO MY INDUSTRY.

AND NOW, BE GOOD HERE

BECAUSE I DON'T WANT TO GET THROWN IN DETENTION.

-HEY, HOW ARE YOU GUYS? -GOOD. HOW ARE YOU?

GOOD. DEAN WILSON.

DEAN, VERY NICE TO MEET YOU. NOW YOU CAN MEET KEVIN.

NICE TO MEET YOU. I'M KEVIN.

KEV, DAVE, WELCOME TO UB TECH.

WE ARE SUPER EXCITED TO HAVE Y'ALL HERE TODAY.

WELL, THIS LOOKS LIKE A NICE PLACE.

REALLY NICE.

YOU KNOW, WHEN WE INVITED DAVE AND KEV DOWN,

WE WANTED TO FIRST SHOW THEM

THE AWESOME NEW FACILITIES THAT WE HAVE HERE,

AND WE WANT THEM TO BE A CHAMPION TO TECHNICAL EDUCATION.

EVERY SINGLE CHAMPION STARTS OUT AS A CONTENDER,

AND EVERY CONTENDER NEEDS CHAMPION IN THEIR LIFE.

HOW LONG HAS UB TECH BEEN AROUND?

WE JUST CELEBRATED OUR 50th ANNIVERSARY LAST YEAR.

WE'RE ACTUALLY THE OLDEST TECHNICAL COLLEGE

IN THE STATE OF UTAH, AND WE'RE VERY PROUD OF THE FACT

THAT WE PRODUCE THE WORLD'S BEST

WHEN IT COMES TO TRADES OR ANY OF THE OTHER PROGRAMS.

Kevin: THIS FACILITY HAS PRETTY MUCH EVERYTHING

THAT YOU COULD ASK FOR AS FAR AS AUTOMOTIVE,

AND THEN THE CROWN JEWEL OF THEIR SCHOOL, IN MY OPINION,

IS THIS STATE-OF-THE-ART WELDING FACILITY

THAT THEY JUST PUT TOGETHER.

THEY HAVE THE NICEST EQUIPMENT.

THEY HAVE NICER EQUIPMENT THAN WE HAVE IN OUR SHOP.

WHERE'S DAVE? I GOT TO TALK TO HIM.

-THIS IS IMPRESSIVE. -ARE YOU GUYS HIRING?

ALWAYS, ALWAYS.

IN FACT, I DON'T KNOW HOW YOUR CURRENT BOSS IS,

BUT WE CAN TALK OFFLINE FOR SURE.

ALL RIGHT. LET'S DO THAT.

HE'S REALLY, REALLY A GREAT GUY.

Dave: THIS PLACE IS GOING TO REALLY PRODUCE SOME GREAT PEOPLE THAT,

HOPEFULLY, IN THE FUTURE THEY'LL BE DOING GREAT THEMSELVES.

WE HAVE TWO STUDENTS THAT WE'D ACTUALLY

LIKE TO HIGHLIGHT TODAY.

I'M NOT QUITE SURE WHAT THEY'RE INTO.

THEY'RE ALWAYS INTO SOMETHING, SO WE CAN CREEP UP ON THEM

AND SEE WHAT THEY'RE WORKING ON, SO...

McKINLEE, DALTON, YOU GUYS GOT A PROJECT HERE.

I THINK THESE GUYS WILL PROBABLY WANT TO KNOW

A LITTLE BIT ABOUT IT. -HOW'S IT GOING?

-NICE TO MEET YOU. -NICE TO MEET YOU GUYS.

I HEARD YOU GUYS ARE, LIKE, THE ALL-STARS OF THE SCHOOL.

WE PRETEND TO BE.

I HEARD YOU PRETTY MUCH HAVE ABOUT EVERY CERTIFICATE

THIS SCHOOL HAS TO OFFER. -FEW OF THEM, YEAH.

-STUDENT OF THE YEAR. -YES, SIR.

AND THEN, WHAT, YOU'RE...

WHAT ARE YOU GUYS BUILDING RIGHT NOW?

THIS IS ACTUALLY A HAMMOCK HOLDER FOR MY TRUCK.

THIS IS THE IMPORTANT THINGS TO LEARN IN SCHOOL.

THESE GUYS ARE MILES AHEAD OF WHERE I WAS AT THEIR AGE.

I MEAN, THEY'RE, LIKE, 18 YEARS OLD.

THEY ALREADY HAVE ALL OF THEIR A.S.E. CERTIFICATES

AND CAN WELD LIKE NOBODY'S BUSINESS.

SO WAIT A SECOND, YOU KNOW HOW TO WELD.

YOU'RE WORKING ON CARS, AND YOU HAVE A CDL?

YES, SIR.

THAT'S NOT FUNNY. IT'S NOT FUNNY.

SORRY, KEVDOGG, YOUR JOB IS GONE.

OBVIOUSLY.

I MIGHT NEED TO COME BACK HERE AND BRUSH UP ON MY SKILLS.

AFTER THIS, I'M GOING TO U.V.U.,

WHERE I'M GOING TO FINISH MY BUSINESS MANAGEMENT

AND MY AUTO-BODY DEGREE,

AND THEN I'M GOING TO COME WORK FOR KINDIG-IT.

-SOUNDS GOOD. -THAT'S WHAT I'M TALKING ABOUT.

-HECK, YEAH! -SHE'S GOING TO TAKE YOUR JOB.

WE'RE NOT WORTHY. WE'RE NOT WORTHY.

WE'RE HOLDING UP YOUR EDUCATION. WE'LL LET YOU GET BACK AT IT.

BEFORE YOU LEAVE, WE WANT TO GIVE YOU A GIFT REAL QUICK.

-OKAY. -OOH, I LOVE GIFTS.

WE'RE EXCITED TO CROWN YOU, FINALLY, THE KING OF CUSTOMS.

AW, MAN.

THAT'S A LOT OF BIG.

Kevin: IT WAS SUPERCOOL THAT THEY MADE

DAVE A CROWN FOR KING OF CUSTOMS.

I FEEL A LITTLE BAD ABOUT THE WHOLE SITUATION NOW

BECAUSE I TELL EVERYONE DAVE HAS A HUGE HEAD,

AND I THINK THAT'S WHY THEY MADE IT A LITTLE OVERSIZED.

WELL, THIS IS SUPERCOOL, YOU GUYS, WHAT A GREAT HONOR.

NOT ONLY WAS IT A TREAT TO COME OUT HERE

AND CHECK OUT THE STATE-OF-THE-ART FACILITY,

BUT I WON, ONCE AGAIN, KING OF CUSTOM.

I'VE JUST GOT TO FIGURE OUT HOW TO GET IT TO FIT.

-IT FITS IF YOU HAVE A HAT, DOG. -SO IT DOES.

HEY, IF THE CROWN FITS, WEAR IT.

UH-HUH? GIVE ME MY CROWN BACK.

A FEW YEARS AGO, A CAR THAT WE HAD BUILT

PREVIOUSLY HAD COME BACK TO US

AND HAD A COUPLE OF UPGRADES MADE.

SO, BOOM, REMEMBER THIS?

Dave: THIS LITTLE KARMANN GHIA CAME BACK INTO OUR LIVES.

WE REBUILT THE FUEL SYSTEM,

THE CARBURETORS, THE GAS TANK, AND GOT IT RUNNING AGAIN.

2003 IS WHEN WE BUILT IT.

Kevin: YEAH, YOU GOT A LOT LESS WRINKLES.

OKAY. SO ANYWAY...

IT'S REAL LIFE. THAT'S JUST WHAT HAPPENS.

WE'VE TAKEN IT FOR A SPIN.

Charity: OH, MY GOSH. IT'S FREEZING.

ALL RIGHT. YOU'RE RIGHT. IT DOES GO FAST.

THIS WAS SUCH A GREAT BUILD FOR US, OUR FIRST REAL CUSTOM.

LET'S KEEP IT. IT'LL FIT IN THE GARAGE.

IT'S SMALL.

ALL RIGHT. WE'LL KEEP IT.

AND MY WIFE WAS REALLY UNDER THE IMPRESSION

THAT WE WERE GOING TO KEEP IT UNTIL I GOT AN OFFER

THAT I DIDN'T WANT TO REFUSE.

-WELL, THERE IT IS, MIKE. -LOOKS AWESOME.

IT'S A COOL CAR.

Mike: MY NAME IS MIKE WETZER.

I'M HERE TO TALK TO DAVE ABOUT THIS KARMANN GHIA,

WHICH WE SAW WHEN TOOK A LITTLE TOUR OF THE SHOP.

I'M KIND OF SAD TO SEE IT GO,

BUT I KNOW IT'S GOING TO A GOOD HOME.

THE KARMANN GHIA IS A FABULOUS DESIGN,

BUT IT GOT PRODUCTIONIZED.

GHIA WAS, YOU KNOW, AN INCREDIBLE DESIGN STUDIO

BACK IN THE '50s, RIGHT? -RIGHT.

IF YOU'RE A STYLIST OF THAT ERA,

YOU WOULD'VE BEEN APPROACHED BY VOLKSWAGEN

TO DO SOMETHING THAT WAS,

YOU KNOW, REALLY GOING TO CHANGE UP THEIR IMAGE.

THEY WANT TO DO SOMETHING REALLY COOL.

VOLKSWAGEN IS SAYING, "HEY, MAKE US A PRODUCTION CAR

THAT WE CAN AFFORD." AND THEY MADE COMPROMISES.

SO I'M THINKING MAYBE WE BRING IT BACK

TO WHAT THE GHIA DESIGNERS WOULD'VE DONE.

MY CLIENT IS AN ACTUAL GHIA AFICIONADO.

HE KNOWS EVERYTHING ABOUT THE GHIA DESIGN TEAM.

ONE OF THE THINGS THAT I NOTED ABOUT THE GHIA,

PARTICULARLY THE MASERATIS THAT THEY HAD DONE...

BUT IF YOU LOOK AT ALL OF THE OTHER STUFF THEY DID

WHERE BUDGET WASN'T AS LIMITED...

AND WE GO BACK TO WHAT THEY WOULD HAVE DONE...

FROM THE PICTURES I TOOK A LOOK AT...

IT REALLY WENT PURE BECAUSE IT REALLY WENT BACK

TO WHAT THE DESIGNERS HAD IN MIND WHEN THEY BUILT THE CAR.

YEAH, SO AGAIN, FROM A DESIGN STANDPOINT,

THAT WOULD LOOK VERY MUCH LIKE WHAT THE DESIGNERS HAD IN MIND.

MM-HMM.

HE'D LIKE TO MAKE A COUPLE OF INTRICATE

AND VERY CHOICE CHANGES TO THIS CAR

TO MAKE IT MUCH MORE HIGH-END

AND NOT SUCH YOUR TYPICAL '71 KARMANN GHIA.

WHAT I LOVED ABOUT THE CAR WHEN I SAW IT

WAS THAT YOU'VE ALREADY MOVED IN THE DIRECTION

OF WHAT THE DESIGNERS WOULD HAVE DONE.

THE CHANGES THAT WE HAVE IN MIND ARE SUBTLE,

BUT WHAT WE'D LIKE TO DO IS SORT OF FRESHEN IT UP A LITTLE BIT.

THE BUMPERS, PROBABLY WANT TO GO CHROME AGAIN.

I'M OKAY WITH THAT.

I'M LOOKING THESE VENTS IN THE REAR.

-MM-HMM. -I'M THINKING MAYBE THOSE GUYS

WANT TO BE A LITTLE BIT DIFFERENT.

WATCH THIS.

WHAT IF WE LEFT THESE MAIN BARS,

CUT ALL OF THIS OUT AND MAKE OUR OWN TRIM RINGS.

ONE DART OF CHROME GOING ACROSS OR GOING THIS WAY ACROSS.

LOVE THAT.

WE'RE THINKING THAT THE WHEELS WOULD BE ONE OF THE THINGS

THAT REALLY MAKE THE CAR FIT THE CHARACTER OF THE TIME.

THESE ARE REALLY COOL WHEELS. -MM-HMM.

-I LOVE THEM ON HERE. -YEAH.

BUT ERA-WISE, THAT'S NOT

WHAT YOU WOULD HAVE USED BACK IN THE DAY.

-NO. -SO I'M THINKING MAYBE WIRES.

Dave: SO WHAT WE'VE GOT HERE IS KIND OF A MIX BETWEEN A STREET ROD

AND A COWELL-STYLE VW. -YEP.

AND WHAT WE WANT TO DO IS SOMETHING A LITTLE BIT

MORE REMINISCENT OF MID- TO LATE-'50s EUROPEAN STYLING,

MAYBE KIND OF REMINISCENT, AGAIN,

OF THE MID-'50s TO LATE-'50s GHIAS.

THEY HAD THOSE TWO LITTLE CHROME BARS

THAT WENT ACROSS. -THE GRILLE, YEAH, YEAH, YEAH.

AND SO MAYBE WE ADD A LITTLE DART.

COLOR-WISE, THE SILVER LOOKS REALLY NICE.

LOVE THE RED FOR THE INTERIOR.

I'M GLAD THAT WE'RE BOTH ON THE SAME PAGE

FOR THE VERY SUBTLE CHANGES THAT HE WANTS TO DO.

THAT SOUNDS GOOD TO ME. -VERY GOOD, DAVE.

THANKS, MIKE. COME ON UP.

NOW WE HAVE A REALLY GOOD IDEA OF THE DIRECTION WE'RE HEADING,

AND IT'S TIME TO START HEADING THAT WAY.

RIGHT NOW, MY TASK IS TO TEAR DOWN THIS KARMANN GHIA,

SO I CAN GET IT READY FOR PAINT.

I'VE GOT 98% OF THIS CAR TORN DOWN.

I JUST NEED TO POP THE DANG HOOD

SO I CAN GET TO THE BUMPER AND THESE LITTLE VENTS HERE,

BUT I CAN'T GET THE HOOD POPPED.

I DON'T KNOW WHAT'S GOING ON WITH IT.

I KNOW THERE'S A LEVER IN THE GLOVE BOX,

BUT THE LEVER IS NOT WORKING,

SO I'M GOING TO CALL SOMEONE OVER THAT MAY HAVE A LITTLE

MORE EXPERIENCE WITH IT, TRY AND GET THEM INVOLVED.

KEVIN.

CAN I JUST SAY THAT I'M NOT A FAN OF VWs IN ANY FORM AT ALL.

WHAT ARE THESE FOR?

I'M USED TO BIG THINGS, SO I WAS TRYING TO USE THAT.

THESE ARE BIGGER THAN THE CAR, BRO.

PRETTY MUCH.

MAYBE BRYCE WOULD HAVE A LITTLE MORE SUCCESS

USING SOME PLIERS THAT ACTUALLY FIT IN THE GLOVE BOX.

I NEED YOUR HELP.

IT'S BECAUSE THAT CABLE AIN'T IN THE SHEATHING ON THE OTHER END.

THIS HAS BECOME A LITTLE BIT HARDER THAN I THOUGHT.

YOU WANT THOSE GIGANTIC PLIERS?

HMM, THEY MIGHT WORK, BUT I DON'T...

I THINK THEY MIGHT JUST BE TOO BIG.

GRAB THEM. -YEP.

HAVE WE TRIED...

JUST DON'T TELL BRYCE.

WE GOT THIS.

YOU NEED TO ADAPT TO YOUR SITUATION.

YOU NEED TO KNOW WHICH TOOL TO USE,

YOU NEED TO KNOW WHEN TO BE DELICATE

AND YOU NEED TO KNOW WHEN YOU HAVE TO JUST USE A LITTLE FORCE.

WHOSE SCREWDRIVER IS IN THERE?

I KNOW, RIGHT? SOMEBODY HAD IT OPEN.

I'M AN EXPERT, AND I KNOW WHAT I'M DOING.

I USE FORCE ALL THE TIME.

[BLEEP], [BLEEP], [BLEEP].

♪♪

THERE YOU GO.

FOUND THE SCREWDRIVER.

CONGRATS ON FINDING THE SCREWDRIVER,

BUT LET'S FIGURE OUT HOW TO GET THIS THING OPENED.

WELL, LOOK AT THIS.

IS THERE A SAFETY THERE?

RIGHT THERE.

RIGHT WHERE YOU PULLED THE HEADLIGHT OUT.

HMM, PRETTY SMART OF THE BUILDER TO PUT THAT THERE.

TOO BAD NOBODY TOLD ME ABOUT IT.

LET'S TRY IT AGAIN.

Kevin: ARE YOU KIDDING ME?

I PUT MY MOST VALUABLE ASSET ON THE LINE FOR THIS?

WHO TOOK THE HEADLIGHTS OUT?

I DON'T KNOW.

SHOULD'VE ASKED WHOEVER TOOK THE HEADLIGHTS OUT.

THEY WOULD'VE SAW THAT.

IT LOOKED LIKE A GROUND WIRE,

AND I KNOW BETTER THAN TO TUG ON THOSE WIRES.

AW, GREAT.

ALREADY GOT FIRST BLOOD ON IT.

DID I GET BLOOD ON YOU?

SHOOT, SORRY. -IT'S ALL RIGHT.

WE'RE ALREADY BLOOD BROTHERS, BRO.

THAT'S TRUE. PRETTY MUCH TWINS AT THIS POINT.

DID I GET MY BRUISED FACE ON YOU?

MENTALLY, YES.

I'M GOING TO LEAVE YOU WITH THIS.

HAVE FUN. -THANKS, KEVIN.

Bryce: I'VE GOT EVERYTHING ELSE TORN DOWN,

I JUST NEED TO GET THE STUPID BUMPER OFF NOW AND THE VENTS.

THE CUSTOMER HAS REQUESTED THAT WE JUST KIND OF

SPRUCE IT UP A LITTLE BIT, SO ALL WE'RE REALLY GOING TO DO

IS KIND OF BLOCK THE OLD PAINT JOB,

AND THEN PREP IT FOR A NEW PAINT JOB,

AND THEN WE'RE GOING TO PUT SOME NEW METALLIC SILVER ON IT.

MIKE DECIDED HE WANTED TO GIVE A QUICK

SPRUCE-UP ON THE PAINT JOB.

WE'RE NOT DOING A FULL TEAR-DOWN ON THIS CAR,

SO IT'S GOING TO STAY ON THE GROUND.

Bryce: ALL RIGHT. IT'S GAME TIME.

THIS IS NOT ON A ROTISSERIE.

THERE'S A FEW MORE COMPLICATIONS THAT COME WITH THAT,

WHEREAS NOW WE GOT TO GET ON THE FLOOR AND KIND OF MAKE SURE

WE'RE GETTING THE BOTTOM SIDES REALLY WELL.

WE DON'T HAVE THAT LUXURY OF ROLLING IT.

♪♪

PROBABLY DO TWO TO THREE COATS OF SILVER,

AND THEN JUMP ON A CLEAR COAT, PUT SOME SHINE ON IT,

AND WE'RE GOOD TO GO.

♪♪

Dave: THIS KARMANN GHIA PROJECT IS GOING REALLY NICELY.

THE PAINT JOB IS DONE, AND IT LOOKS GREAT.

MIKE REALLY WANTED TO SEE WHAT CHROME BUMPERS

WOULD LOOK LIKE ON THE CAR, SO WE'VE GOT HOWARD

ACTUALLY STRETCHING THESE BUMPERS

ALL THE WAY INTO THE BODY, GIVING IT A VERY CLOSE REVEAL,

SO THAT IT LOOKS A LOT TIGHTER AND A LOT CLEANER.

FIRST THING I HAD TO DO IS CLEAN OFF THE CHROME

AND GET READY TO START CUTTING ON THIS BUMPER.

NOW THAT I'VE GOT THE BUMPER ALL CLEANED UP,

I NEED TO START GAPPING IT TO THE BOTTOM.

♪♪

NOW I GOT TO START NOTCHING THIS, SO I CAN GET IT CLOSER.

THE BUMPER NEEDS TO BE TIGHT TO THE BODY,

AND IT'S NOW IN A DIFFERENT POSITION

THAN WHERE NORMALLY WOULD BE,

SO THE BUMPER BRACKETS ARE GOING TO NEED TO BE ADJUSTED AS WELL.

TRYING TO GET THIS TO ABOUT 1/4 TO 5/16 AWAY FROM THE BODY.

THAT'S WHY I NEEDED TO SHORTEN THE BRACKETS TOO.

NOW I JUST GOT TO START MAKING IT ONE PIECE.

♪♪

♪♪

♪♪

THE BUMPERS ARE LOOKING AWESOME,

AND NOW THEY'RE READY TO GO OUT FOR CHROME.

LET'S ROLL THIS ALL THE WAY TO THE BACK

AND THEN FORWARD AGAIN TO SEE IF WE CAN RESET THE SUSPENSION.

READY? MICHAEL'S REALLY INTERESTED

IN SEEING A SET OF SPOKED WHEELS ON THIS CAR.

THE PROBLEM WE'RE RUNNING INTO THOUGH IS,

WE'RE REALLY TIGHT ON SPACE.

WHAT ARE WE STUCK ON?

LET'S TRY FORWARD, MAYBE.

AND THEN BACK AGAIN.

WE MIGHT, SHALL I SAY,

HAVE A SLIGHTLY BIGGER PROBLEM ON OUR HANDS.

SUPER PISS ME OFF IF I'M TOO WIDE ON THOSE THINGS.

SO I GOT A LITTLE BIT PROBLEM HERE.

THE BACK OF THE CAR HAS GOT A TAPER TO IT,

AND SO WHEN WE DID THE OFFSET MEASUREMENTS,

WE FIGURED WE HAD A LITTLE BIT MORE SPACE THAN WE OBVIOUSLY DO.

I'M GOING TO LOWER THE CAR, WHICH HAS A TENDENCY

TO CAMBER THE WHEEL,

WHICH WOULD GET US TILTED IN JUST A LITTLE BIT,

WHICH WOULD GIVE US SOME CLEARANCE,

BUT I'M AFRAID THIS TIRE IS JUST A LITTLE TOO SQUARE ON THE RIM.

I NEED SOMETHING THAT'S A LITTLE BIT MORE TAPERED IN,

SO A LITTLE LESS TRACK WIDTH,

AND THAT SHOULD HELP US WITH THE CLEARANCE.

YOU KNOW, YOU'RE ALWAYS TRYING TO PUT BIGGER,

BADDER WHEELS THAN WHAT CAME ON THEM STOCK,

AND SOMETIMES YOU JUST RUN INTO THIS STUFF,

AND WHAT LOOKS GOOD ON PAPER

DOESN'T NECESSARILY WORK OUT TOO GOOD IN PERSON.

I'LL GO AHEAD AND LOWER IT TWO NOTCHES,

WHICH SHOULD EQUATE TO ABOUT 1 1/2 INCHES TO 2 INCHES.

Dave: THESE KARMANN GHIAS WERE NEVER BUILT

ORIGINALLY WITH A COILOVER SUSPENSION,

AND THIS ONE IN PARTICULAR IS STILL STOCK,

WHICH IS USING TORSION BARS.

THE ONLY WAY TO REALLY LOWER IT PROPERLY

IS TO TAKE ALL OF THE SUSPENSION APART,

TURN THE TORSION BARS AND PUT THEM BACK

IN INDEXED A COUPLE OF DEGREES DIFFERENCE.

OUR WORK IS CUT OUT FOR US.

WELL, IT LOOKS A LOT LIKE A VOLKSWAGEN.

IT'S BEEN A LITTLE WHILE SINCE I'VE DONE ONE OF THESE.

Dave: EVERYTHING THAT I'M DOING HERE

IS BASICALLY JUST REDIRECTING WHAT ALREADY EXISTS.

THERE'S NO CUTTING AND WELDING OR ANY OF THAT KIND OF STUFF.

IT'S JUST GET IT OFF, CHANGE THE DIRECTION

OR YOU KNOW, MOVE THE SPLINES WHERE I WANT THEM

AND PUT IT BACK TOGETHER.

WHOLE SIDE IS OUT.

PROBABLY GOING TO NEED TO GET A BUDDY SYSTEM ON THIS.

SOMETIMES PROJECTS IN THIS SHOP GO A LITTLE BIT BIGGER.

INSTEAD OF ONE PERSON REQUIRED, IT MIGHT TAKE TWO.

OKAY, WELL, SO HERE'S WHAT I'VE GOT.

I'VE GOT EVERYTHING DISASSEMBLED.

I GOT THE SHOCKS DROPPED OUT THE BOTTOM.

DO YOU KNOW HOW MUCH YOU WANT TO DROP IT?

I THINK ONE NOTCH BECAUSE I THINK

WE'VE ALREADY DROPPED THIS CAR ONCE.

-I'M SURE YOU DID. -I FIGURE IF WE GO TWO NOTCHES,

I THINK IT'S GOING TO BE TOO MUCH.

MM-HMM.

THERE WE GO.

WE MIGHT NEED A BIGGER TOOL.

OKAY, READY? -YEP.

THERE YOU GO.

NOW THAT WE'VE GOT THE SPRING PLATE LOOSE,

WE JUST NEED TO SIMPLY ROTATE IT AND PUT IT BACK TOGETHER.

NAIL IT UP.

SHE'S GOING, CAPTAIN.

OW.

Dave: OKAY, SO THIS IS GOING TO WORK, IT'S JUST GOING TO BE REALLY...

-TRICKY. -...SKETCHY.

MM-HMM.

YOU GOT TO GET FORWARD... DO YOU GOT ANOTHER SCREWDRIVER?

NOT AT THE MOMENT.

-WHAT DO YOU NEED? -ANOTHER SCREWDRIVER.

BIG ONE, LIKE THIS. PAUL, YOU GOT ONE?

IN FACT, WE'LL JUST BORROW ANOTHER SET OF HANDS.

GO IN FRONT OF ME.

-ABOVE. -IT WAS ALMOST THERE.

AS SOON AS I GET IT SPRUNG DOWN SO FAR, IT WANTS TO CRAWL,

SO WE NEED A SECOND LEVER.

OKAY.

GO AHEAD, LET IT GO IN.

LET IT GO IN, DON'T TAKE IT OFF. ONE MORE SCREWDRIVER.

STICK IT BETWEEN THERE AND SPREAD THEM.

THERE YOU GO.

GOT IT. BINGO.

HOO-WHEE, I ALMOST GOT MY BRAIN.

OKAY.

THAT WAS SKETCHY, BUT I THINK EVERYTHING IS LINING UP.

SO THIS LINE WAS THE LINE WE WERE AT,

AND THEN THIS IS WHERE IT'S AT NOW.

WE'VE PROBABLY GOT A GOOD INCH-PLUS DIFFERENCE.

-OKAY, COOL. -THANKS, BRO.

THANKS.

Dave: THEORETICALLY, WE SHOULD BE GOOD,

AND ONCE I GET IT ALL BACK TOGETHER,

I'LL BE ABLE TO DETERMINE WHETHER I CAN STILL USE

THE TIRES THAT I BOUGHT FOR IT OR IF I HAVE GO TO OTHER TIRES.

♪♪

SO WHEN YOU LOWER THESE THINGS, IT JUST SITS POSITIVE CAMBER.

IF I PUT SOMETHING THAT WOULD SLIDE,

I CAN JUST PULL ON THE WHEEL AND PULL THEM OUT.

I'LL TAKE A GREASE PLATE.

THANKS, PARTNER.

OH, [BLEEP].

IS THAT ALL THE WAY DOWN? -YEP.

THE GREASE PLATE HELPS MOVE THE TIRES A LITTLE BIT,

BUT IT HASN'T BEEN ENOUGH.

WE HAVE ONE FINAL OPTION LEFT.

I'M GOING TO LOWER THIS DOWN.

IF WE LUCK OUT, MAYBE IT CAMBERS MORE,

BUT I DON'T THINK WE'RE GOING TO GAIN ENOUGH.

DAMN IT.

SO WE RAN INTO A LITTLE BIT OF FITMENT ISSUES

WITH THE REAR WHEELS.

I GOT A LITTLE GREEDY AND WENT A LITTLE FAT ON THE TIRES AND RIM.

IF WE CAN JUST ROLL THIS CAR BACK AND FORTH,

IT'LL RESET THE REAR SUSPENSION, AND WE'LL KNOW IF WE'RE GOOD.

GOING TO ROLL IT AND SEE IF IT MOVES IT AT ALL.

THEY ARE?

YEAH.

SO YOU'RE SAYING WE'RE STUCK?

THAT DIDN'T WORK,

SO THERE'S REALLY JUST ONE THING LEFT TO DO.

WE'LL TRY THE OTHER TIRES TOMORROW.

I'M GOING TO TAKE THE WHEELS AND TIRES BACK

OVER TO THE TIRE SHOP AND NOT BE SO GREEDY.

I'M GOING TO HAVE THEM TAKE 1/2 INCH OFF OF THE INSIDE

AND OUTSIDE OF THE HOOP,

REDUCING IT DOWN TO A 7-INCH HOOP.

HOPEFULLY, THIS WILL WORK.

WELL, WE GOT THE LAST TEST FIT OF THE REAR WHEEL,

MAKE SURE IT CLEARS THE WHEEL WELLS AND EVERYTHING ELSE.

HOPEFULLY THIS IS OUR LAST TRY.

WHEEL HAS BEEN MACHINED DOWN A LITTLE BIT.

THE HUB HAS BEEN MACHINED DOWN A LITTLE BIT.

EVERYTHING IS BROUGHT IN ABOUT AN INCH OR SO,

SO I THINK WE SHOULD HAVE ENOUGH CLEARANCE ON THIS ONE.

♪♪

♪♪

WELL, SO FAR, SO GOOD.

PUT HER DOWN AND CHECK IT AGAIN.

Dave: I REALLY HOPE THIS NEW WHEEL WORKS

BECAUSE IF IT DOESN'T, I MIGHT HAVE TO GO BACK

COMPLETELY TO THE DRAWING BOARD

AND MAKE SOME DIFFERENT SUGGESTIONS.

♪♪

WELL, EVERYTHING LOOKS LIKE IT'S GOING TO CLEAR.

Dave: THIS FIX WORKED FINALLY.

NOW THAT WE'RE OUT OF THAT PROBLEM,

IT'S TIME TO FINISH UP AND GET THIS THING OVER TO JUSTIN.

♪♪

Cody: THESE ARE THE DOOR PANELS FOR THE '71 GHIA

THAT DAVE BUILT, LIKE, 15 YEARS AGO.

THESE ARE THE ORIGINAL PANELS THAT JUSTIN BUILT.

I'M JUST RECOVERING THEM.

♪♪

GOT THE ARMRESTS ALL BUILT.

WE'RE GOING TO WRAP THEM LIKE THE DESIGNERS WOULD'VE WANTED,

NICE AND CLEAN, EUROPEAN-LOOKING.

HOPEFULLY THIS SHOULD WORK OUT.

WRAPPING THESE ARMRESTS WITH A SINGLE PIECE OF LEATHER

LIKE THIS, IT'S VERY TRICKY.

SO YOU GOT TO REALLY STRETCH IT.

YOU CAN'T REALLY OVERSTRETCH IT,

IT JUST GETS REALLY THIN RIGHT HERE ON EDGES,

SO IF YOU HIT IT, IT'LL NICK IT,

BUT WE JUST GOT TO BE CAREFUL, WORK ON THE BLANKET.

I THINK IT MIGHT WORK.

♪♪

♪♪

NOW, I'VE GOT TO WRAP THE REST OF THE PANEL,

MAKE IT LOOK AS NICE.

CODY IS CREATING THE SAME DESIGN IN THESE DOOR PANELS

AS WE DID IN THE SEATS.

Cody: JUST GOT TO SEW THESE UP, PUT SOME GROMMETS IN THEM,

AND THEN WE'LL BE ON TO THE NEXT THING.

NOW, IT'S UP TO JUSTIN TO ADDRESS THIS TOP.

IT LOOKS LIKE WE'VE GOT A LITTLE BIT OF WARP ON THAT FRONT BOW.

LET'S GET THIS HEADER OFF.

LET'S SET THE NEW ONE UP HERE,

AND THIS ONE IS WARPED, OBVIOUSLY.

THAT'S WHY THERE WAS A GAP LIKE THIS,

AND THE JUICE WASN'T WORTH THE SQUEEZE

TO TRY TO RESHAPE THIS, SO WE ORDERED A NEW ONE IN.

SO IN 15 YEARS, THIS ONE WON'T FIT

BUT THAT'S 15 YEARS FROM NOW, SO I'LL BE RETIRED.

WITH CONVERTIBLE TOPS, NOTHING LASTS FOREVER.

YOU HAVE THE SUN. YOU HAVE THE WATER.

THEY SHRINK. IT HAPPENS.

OKAY, SO LET'S TAKE THIS NEW HEADER AND SEE HOW IT FITS.

IT'S HARD TO TELL UNTIL WE GET THIS TO GET SCREWED ONTO HERE.

BEFORE THIS GETS SCREWED ON, WHAT'S GOT TO HAPPEN IS,

WE GOT TO PUT THE ALIGNMENT PIN BACK ON HERE.

WE'LL ALIGN IT IN THESE HOLES, PUSH IT DOWN,

AND THEN WE'LL DRILL A COUPLE PILOT HOLES

AND SET SOME SCREWS, OKAY?

SO DO YOU KNOW WHERE THE ALIGNMENT PINS

ARE THAT I TOOK OFF?

I KNOW WHERE EVERYTHING IS IN THIS SHOP.

THERE'S A METHOD TO THIS MADNESS.

THE HELL DID I DO WITH THEM? -WE DON'T HAVE ALL DAY, JUSTIN.

HIS MIC IS OFF, RIGHT?

-HEY, ARE THESE IT? -SEE?

LIKE I SAID, I KNOW EXACTLY WHERE EVERYTHING IS.

THEY WERE JUST SITTING ON THE FLOOR.

-THEY WERE? -YEAH.

OKAY.

IT'S GOING TO BE TIGHT.

THIS TOP SHRUNK UP JUST A LITTLE BIT, BUT IT'S NOT TOO BAD.

IT'LL REALLY SUCK IF THE TOP SHRUNK TOO MUCH.

WE'LL HAVE TO REPLACE THE WHOLE THING.

THIS ONE HAS TROUBLE STAYING CLAMPED.

THIS ONE FITS LIKE [BLEEP] TOO.

IT NEEDS TO GO BACK, FIRST OF ALL.

I THINK WE NEED TO TWEAK THESE BRACKETS.

♪♪

AND LET'S SCREW THIS DOWN, AND WE GET WHAT WE GET,

AND WE'RE JUST GOING TO HAVE TO FIT IT FROM THERE.

OKAY? I GOT TO HAVE THIS DONE TODAY.

IT'S FITTING THE ARCH, YEAH, BUT...

I JUST HOPE THIS TOP HASN'T SHRUNK UP.

THE ONLY WAY WE'RE GOING TO KNOW IS IF WE BUTTON THIS TOP UP

AND TRY TO LATCH IT DOWN.

♪♪

♪♪

ALMOST 5:00.

THAT MEANS DAVE IS PROBABLY GOING TO BE OVER

IN MY FRIDGE LOOKING FOR BEER.

[BLEEP], IT JUST GOT REALLY, REALLY TIGHT.

IF THE CONVERTIBLE TOP SHRUNK TOO MUCH,

WE'RE GOING TO HAVE TO REPLACE IT.

THERE IS NO GETTING AROUND IT.

OH, YEAH. -OH, MAN.

AIN'T NO [BLEEP] WAY THIS GUY IS EVER GOING TO BUCKLE THIS.

Dave: JUSTIN AND MASON GOT THE TOP UP,

BUT GETTING IT TO CLOSE AND SEAL?

WELL, THAT SEEMS TO BE ANOTHER PROBLEM.

WE JUST ADDED A LOT OF [BLEEP].

WE ADDED A PAD, A HEADLINER.

IT'LL GO.

EASY TO SAY, NOT SO EASY TO DO.

FRICK.

PUSH FORWARD, CAN YOU?

-YEAH, I'M LISTENING. -WHY IS JUSTIN ON THE PHONE?

WHAT COULD BE MORE IMPORTANT THAN THIS TOP RIGHT NOW?

Justin: OH, THERE WE GO. THIS TOP IS TIGHT.

I'M NOT SO SURE THE CLIENT IS GOING TO WANT

TO WRESTLE THIS THING EVERY TIME HE HAS TO CLOSE IT.

DID YOU SEE THE FRONT OF IT? THERE'S STILL A GAP THERE.

TECHNICALLY IT CLOSES, BUT IT REALLY DOESN'T FIT.

THAT PULLED THAT GAP AWAY EVEN FURTHER, HUH?

FROM THE PRESSURE FROM HERE TO HERE.

WELL, IT'LL BE DAVE'S CALL.

I... YOU KNOW WHAT?

I THINK IT NEEDS A NEW TOP, SO WE'LL BREAK THE NEWS TO HIM

AND SEE WHAT HE WANTS TO DO.

WELL, HE SHOULD BE HERE ANY SECOND.

IT'S BEER NIGHT. -ALL RIGHT.

-HI, DAVE. -HI.

SO YOU WANT THE GOOD NEWS FIRST OR THE BAD NEWS?

-I DON'T WANT ANY BAD NEWS. -OKAY.

WELL, I'LL GIVE YOU THE GOOD NEWS FIRST -- IT'S 5:00.

-OH, DO YOU HAVE BEER? -THAT'S PART OF THE BAD NEWS.

I'VE GOT A 30-PACK OVER AT MY PLACE

THAT WAS JUST DROPPED OFF BY A FAN.

-WELL, PERFECT. -WHAT'S THE BAD NEWS?

THE BAD NEWS IS, LOOK WHAT'S BACK.

ARE YOU [BLEEP] KIDDING ME?

THAT'S THE PROBLEM IS, THEY LEFT IT DOWN IT FOR 14 YEARS.

IT JUST...

AND THEN THE HEAT, YOU KNOW WHAT I MEAN?

IT DIDN'T DO THIS CANVAS ANY GOOD.

THERE WAS A LITTLE GAP THERE BEFORE WITH THE WOOD

BUT NOTHING LIKE THIS.

I'M GOING TO GO GET A BEER.

OKAY. GET 30 OF THEM.

WELL, THAT SUCKS.

WELL, BACK TO THE GOOD NOTE -- WE GOT 28 OF THESE LEFT.

Dave: IF THEY'VE ALREADY SWITCHED OUT THE BOW AND THE GAP

IS STILL THAT BIG, IT SOUNDS LIKE A NEW TOP IS IN ORDER.

WHILE WE WAIT FOR THE NEW TOP TO COME IN,

IT'S TIME TO TAKE CARE OF A COUPLE OTHER HERES AND THERES.

-HEY, GREG. -HI, DAVE. WHAT'S UP?

HEY, SO I JUST GOT OFF THE PHONE WITH MIKE ON THAT KARMANN GHIA.

HE WANTS TO CHANGE UP THE REAR DECK VENTS,

WHICH KIND OF LEADS ME TO SOME OF THE OTHER STUFF

THAT WE NEED TO DO ANYWAY.

WE'VE OPENED UP THE HOLES IN THE FRONT OF THE NOSE?

-YEAH. -RIGHT? I NEED TO COME UP

WITH SOME KIND OF A GRILLE FOR THAT,

THEN THERE'S A NUMBER OF THINGS.

THEY'RE GOING TO BE PRETTY CURVED PIECES OR...

YEAH.

I'D IMAGINE IF IT CAME ON A CAR, IT'D PROBABLY BE A CAST PIECE.

MM-HMM.

AND I WAS AT THIS TRADE SHOW IN DETROIT

A COUPLE WEEKS AGO,

AND I SAW THIS MACHINE THAT CAN PRINT FOUNDRY SAND,

AND THEN YOU CAN JUST TAKE YOUR DESIGN PIECE TO THE FOUNDRY,

AND THEY'LL JUST POUR ALUMINUM STRAIGHT IN IT.

THEY ACTUALLY 3-D PRINT IN SAND,

LIKE THE SAND CASTINGS THAT YOU NORMALLY USE

LIKE A PLUG OR WHATEVER THEY CALL IT.

SO RATHER THAN -- YEAH, RATHER THAN PRINTING YOUR PATTERN

AND THEN PULLING THE SAND OFF OF IT,

THEY JUST SKIP THAT WHOLE STEP,

SO THEY WOULD JUST PRINT THE SAND, SHIP IT TO US

AND THEN WE COULD USE THE FOUNDRY HERE IN SALT LAKE.

YEAH, SAME GUYS WE'VE USED BEFORE

WITH THE BRONZE STUFF, RIGHT?

YEAH, EXACTLY.

WHY DON'T YOU FOLLOW UP WITH THEM?

I'LL GET SOME SKETCHES AND THEN

LET'S SCAN THE CAR AND SEE HOW IT WOULD WORK.

-YEAH, SOUNDS GOOD. -AWESOME.

-ALL RIGHT. -WHOO, THAT GIVES ME CHILLS.

THAT COULD BE GROUNDBREAKING.

Dave: GREG'S IDEA OF HAVING THESE 3-D

PRINTED SAND CASTINGS IS GOING TO BE AWESOME.

I REALLY HOPE IT WORKS OUT.

I'VE GOT TO SCAN THIS CAR.

I'VE GOT TO DESIGN WHERE THE TRIM

IS GOING TO SIT ON THE BODY.

AFTER I'M DONE DESIGNING THE ACTUAL PIECES,

I NEED TO DESIGN THE CASTING PATTERNS,

WHICH IS A WHOLE OTHER PROCESS.

ONCE I FINISH THESE CASTING-PATTERN DESIGNS,

I'M GOING TO SEND THEM TO THE SAND PRINTER.

THEY'RE GOING TO PRINT THEM

AND THEN THEY'RE GOING TO SHIP THEM FREIGHT.

THESE ARE 3-D PRINTED WITH SAND.

WE'RE JUST INSPECTING THEM.

THESE GUYS DO A GREAT JOB OF PACKING THIS STUFF UP.

IT'S LIKE THEY DO THIS PROFESSIONALLY OR SOMETHING.

ALL THESE THINGS ARE IS JUST SAND AND GLUE.

WE'RE GOING TO TAKE THESE THE FOUNDRY,

AND THEY'RE JUST GOING TO POUR ALUMINUM

STRAIGHT INTO THESE PATTERNS,

AND THEN HOPEFULLY WE HAVE A COUPLE PIECES OF TRIM.

-AND THEN ARE THESE ONE-TRY? -YEAH.

-FIRST TRY AND DONE? -YEAH.

SO HOPEFULLY I DIDN'T DO SOMETHING WRONG.

HOPEFULLY THE FOUNDRY DOESN'T DO ANYTHING WRONG.

HOPEFULLY IT'S A PERFECT STORM. -YEAH.

THESE ONES ARE GOING TO BE HEAVY.

I THINK THESE ARE, LIKE, 180 POUNDS APIECE OR SOMETHING,

SO I DESIGNED THEM SO THEY HAVE HOLES IN THEM,

SO I SHOULD BE ABLE TO JUST GO PICK SOME PIPES,

SET THEM THERE AND THEN WE CAN PICK IT UP.

IT'S NOT GOING TO SNAP IN HALF, RIGHT?

I DON'T THINK SO.

LITTLE MORE, LITTLE MORE, LITTLE MORE.

-COOL. -RIGHT ON.

THAT'S ALL OF THEM.

700 POUNDS WORTH OF SAND.

THEY ALL LOOK GOOD.

♪♪

♪♪

Dave: GREG AND I ARE GOING ON A FIELD TRIP.

WE'RE GOING TO STATE FOUNDRY OUT IN TOOELE, UTAH,

TO CHECK OUT HOW THE ALUMINUM IS POURED INTO A MOLD.

AND LET ME TELL YOU, THIS PLACE IS INTENSE.

♪♪

WE'RE GOING TO DO SOMETHING PRETTY BITCHIN'.

THAT'S SO COOL.

Dave: HERE WE ARE AT STATE FOUNDRY.

NOW, THESE GUYS HAVE DONE STUFF FOR US BEFORE.

HOW YOU DOING? -GOOD.

HOW ARE YOU GUYS DOING? I'M DON.

HEY, DON. GREAT TO MEET YOU.

-DON, GREG. -HOW YOU DOING, GREG?

WE'RE PRETTY PUMPED ON THIS NEW DEAL.

-GREAT. -GREG KIND OF BLEW MY MIND

WHEN WE STARTED TALKING ABOUT MAKING THESE PIECES AND TALKING

ABOUT THE, YOU KNOW, SAND 3-D PRINTING.

PRETTY NEW TECHNOLOGY THAT'S COME THROUGH

OVER THE PAST COUPLE YEARS. WE'VE TRIED IT COUPLE TIMES

AND HAD REALLY GREAT RESULTS WITH IT.

-REALLY? -YEAH.

OKAY, SO IT'S NOT, LIKE, THE VERY FIRST EVER BEING SEEN

BY YOU GUYS, SO OBVIOUSLY... -NO, NO.

I'VE DONE SOME MORE INDUSTRIAL APPLICATIONS,

BUT THIS IS THE FIRST TIME CAR PARTS.

THAT'S REASSURING.

-BUT... -REASSURING.

SAME STUFF, SAME STUFF, YOU KNOW?

METAL GOES IN. CASTINGS COME OUT.

EVERYONE IS HAPPY, HOPEFULLY.

AWESOME. I CAN'T WAIT TO SEE.

I'VE NEVER BEEN IN A FOUNDRY BEFORE, SO, YOU KNOW...

I GUESS WE OUGHT TO GRAB THE PARTS, GET THEM UNLOADED.

♪♪

-THAT'S ALL OF THEM. -ALL RIGHT.

Dave: I'M SO PUMPED TO SEE HOW THIS WORKS.

WE'RE HERE IN TOOELE AT THE STATE BRASS FOUNDRY

TO GET SOME ALUMINUM PIECES CASTED.

EVEN THOUGH WE BROUGHT OUR OWN MOLDS,

IT'S PREPARATION THAT'S GOING TO TAKE A LITTLE BIT OF TIME,

AND IT'S PRETTY INTENSE.

THE FIRST THING THEY DO IS PREPARE THE CASTING MOLDS.

Don: WE'RE GOING TO PUT SOMETHING ON THERE RIGHT NOW.

-OH, YOU ARE? -YEAH.

SO WE HAVE A GRAPHITE-BASED WASH THAT WE DO ON ALUMINUM.

OKAY.

THIS GRAPHITE AND ALCOHOL WASH GETS THINNED DOWN,

SPRAYS IT ON THERE REALLY THIN,

AND ALL IT'S DESIGNED TO DO IS JUST FILL IN YOUR GRANULAR...

RIGHT, SO WE DON'T HAVE, LIKE, A SUPER ROUGH TEXTURE.

Dave: THIS GRAPHITE SPRAY ACTUALLY HELPS SMOOTH

OUT THE MOLD OF THE SAND CASTING

TO MAKE SURE IT FILLS UP SOME OF THE PORES,

SO IT'S NOT SO POROUS WHEN WE'RE FINISHED.

AND BECAUSE WATER CAN EXPLODE WITH HOT METALS AROUND IT,

THEY USE AN ALCOHOL BASE.

-THAT'S SO COOL. -WILD.

SO THAT BASICALLY WILL JUST BURN OFF ALL OF THE ALCOHOL.

YOU CAN SEE IT FADING AT THE BACK.

Greg: OH, YEAH. CRAZY PROCESS.

TO THINK THEY'VE BEEN DOING THIS STUFF FOR 3,000 YEARS.

THAT'S PRETTY WILD.

I'M SUPER EXCITED ABOUT THIS, BUT I AM PRETTY NERVOUS.

THERE'S A LOT OF THINGS THAT CAN GO WRONG,

AND I'VE NEVER DONE THIS BEFORE,

SO I'M JUST HOPING EVERYTHING GOES SMOOTH.

-LIKE A GLOVE. -LIKE A GLOVE, NICE.

Greg: NO GAP ON THE PARTING LINE,

NICE AND TIGHT, THAT'S WHAT WE WANT.

PERFECT. -FAR OUT.

HE'LL TAKE SOME NEWSPAPER OR MAGAZINE SECTIONS

AND COVER OVER ALL THE HOLES SO NOTHING CAN DROP DOWN

WHILE WE'RE WORKING ON THE OTHER MOLDS.

KEEPS THE DUST AND ANYTHING ELSE

THAT MIGHT BE FLOATING AROUND...

IT'S THAT TEDIOUS?

JUST LIKE PAINTING A CAR, RIGHT?

YEAH, I GUESS... YEAH, YOU DON'T WANT...

YOU DON'T WANT TO DO IT OUTSIDE, DO YOU?

NOPE.

YOU DON'T DO IT IN A WIND STORM IN THE BACK PARKING LOT.

-NOPE, WE DON'T DO THAT. -WOW.

I DIDN'T KNOW IT WAS THAT TOUCHY.

NOW THAT MOLDS ARE READY, WE CAN MELT SOME METAL.

I HAD NO IDEA HOW THIS PROCESS WORKED.

I ALWAYS THOUGHT THERE WAS A BIG KILN

WITH A LOT OF FLAMES AND LOT OF HEAT.

THERE'S NO FLAMES.

IT'S ELECTRIC. -START UP THE FURNACE.

IT'S LIKE A GIANT MICROWAVE. -OH, OKAY.

A THOUSAND HERTZ AND IT COMES OUT

THROUGH THE COPPER COILS AND BUS BAR

AND CREATES ELECTROMAGNETIC WAVE AND EXCITES THE METAL.

THIS ELECTROMAGNETIC FURNACE

IS LIKE SOMETHING FROM THE FUTURE.

MARTY, HE'S GENERATING THE 1.25 JIGAWATTS.

I'M NOT REALLY SURE ABOUT BEING CALLED "ARTY,"

BUT THIS FURNACE IS PRETTY COOL.

THIS IS THE ALUMINUM POT HERE.

SO IT'LL GET MELTED IN THE CRUCIBLE.

THE FURNACE HEATS THE METAL

BY RUNNING A CURRENT THROUGH A COIL

THAT SURROUNDS THE CRUCIBLE.

SO THAT'S THE CRUCIBLE WE USE FOR ALUMINUM.

THE CURRENT BLASTS THE METAL WITH ELECTROMAGNETIC WAVES,

WHICH CAUSES THE METAL TO HEAT UP.

AND YOU THOUGHT I WAS JUST A CAR DESIGNER.

IT'S DAVE NYE, SCIENCE GUY.

THE ALUMINUM IS SUCH A LIGHTER METAL,

I CAN'T REALLY RUN IT AT FULL SPEED

BECAUSE IT'LL ACTUALLY LIFT IT UP OUT OF THE POT.

THE MORE PRESSURE IT PUSHES IN, IT PUSHES IN ON THE METAL,

AND IT PUSHES IT UP BUT ONCE IT GETS UP

SO HIGH, THE WEIGHT, YOU KNOW, GRAVITY PULLS IT BACK DOWN,

AND IT JUST STARTS DOING THAT MORE AND MORE AND MORE.

I'LL MAKE IT DO IT JUST FOR YOU GUYS.

WE WON'T MAKE A MESS. WE'LL JUST HAVE A LITTLE FUN.

DON IS USING THESE HUGE BRICKS OF ALUMINUM THEY CALL INGOTS.

IF WE HAD GOLD LIKE THIS, I WOULDN'T BE DOING THIS, RIGHT?

THAT STUFF BACK THERE LOOKS PRETTY MUCH LIKE GOLD, THOUGH.

Dave: I'M REALLY NOT GOING TO STEAL HIS GOLD.

IT'S NOT REAL GOLD ANYWAY.

COOL. -ALL RIGHT.

LET'S GET COOKING. -LET'S GET IT FIRED UP.

IT'S GOING TO HAVE A HIGH-PITCHED SOUND HERE.

Dave: YEP, THAT'S HIGH-PITCHED.

♪♪

Don: IT'LL TAKE ABOUT 1/2 HOUR, 45 MINUTES TO GET IT UP

TO ABOUT 1,450.

GET EVERYBODY READY.

RISE.

Dave: WE'VE WELDED A LOT OF STUFF, AND SO YOU SEE

JUST TINY BITS OF LIQUID METAL.

NOT LIKE THIS. THIS IS AWESOME.

YEAH, TURN IT OFF, NEIL. I'LL GET IT.

MOVING AND POURING THIS LIQUID ALUMINUM INTO THESE MOLDS

IS BY FAR THE MOST DANGEROUS PART OF THE ENTIRE JOB.

♪♪

Don: DOWN MORE.

YEAH.

Greg: I'M JUST A LITTLE NERVOUS ABOUT IT.

YOU KNOW, IF THE METAL GOES IN THE RIGHT WAY.

IF THE METAL IS POURING OUT THE SIDES OF THESE THINGS.

I ONLY GET ONE SHOT ON THIS GUY.

Don: SO NOW THEY'RE BUBBLING THAT NITROGEN IN THERE,

AND YOU SEE IT'S KIND OF BRINGING

A DULL COLOR TO THE TOP, NOW?

-YEP. -SO THAT'S ALL THE IMPURITIES

IN THE METAL AND THEN WHEN HE'S DONE,

WE'LL JUST SCRAPE OFF THE TOP ON THE LID THERE.

♪♪

Don: OH.

OH, DAMN, I THINK IT'S LEAKING OUT THE SIDE.

-IS IT LEAKING OUT? -JUST FLOWING OVER THE TOP.

-COOL. -THIS IS SO COOL.

WE'RE NOT OUT OF THE WOODS YET.

EVERYTHING SEEMS LIKE IT'S GOING OKAY SO FAR,

BUT WE WON'T REALLY KNOW UNTIL WE BREAK THE SAND OFF OF THESE.

WE'RE GOING TO TAP ON THEM ON,

AND BASICALLY WE'RE GOING TO SACRIFICE THE SAND MOLDS.

Don: YEAH, THE SANDS ARE SACRIFICIAL, YEP.

-ONE-TIME USE. -ONE SHOT.

ONE SHOT.

♪♪

♪♪

Don: TA-DA.

-EASY-PEASY. -I'M RELIEVED.

Don: I'M RELIEVED. I'M VERY RELIEVED.

ONE OF THE TOUGHEST THINGS IS TO POUR SOMETHING

YOU'VE NEVER MADE BEFORE.

WELL, I'M NOT STRESSED AT ALL.

THIS WORKED OUT REALLY GOOD.

IT TURNED OUT AWESOME. I'M PLEASED.

I CANNOT WAIT TO SEE THESE PREPPED-OUT,

CHROMED AND PUT ON THE CAR. -ON THE CAR? YEAH.

I'M REALLY GLAD THAT WE USED THIS PROCESS.

THIS IS SUPER NEXT-LEVEL STUFF

AND IT DEFINITELY IS GOING TO GET DONE AGAIN AND AGAIN.

AS COOL AS GOING TO THE FOUNDRY WAS,

I'M GLAD TO BE BACK TO THE SHOP

BECAUSE IT'S TIME TO FINISH UP ON THIS KARMANN GHIA.

SO I GOT MY PIECES FROM THE FOUNDRY.

EVERYTHING LOOKS REALLY GOOD.

SO WHAT I HAVE TO DO NOW IS JUST SAND A LOT OF THIS STUFF BACK.

A LOT OF THE THINGS LIKE WHERE THE ALUMINUM

CAME INTO THE CASTING.

I JUST NEED TO MAKE SURE EVERYTHING IS

SUPER CLOSE-FIT TO THE CAR,

WHERE THERE'S NO LITTLE GAPS OR ANYTHING.

ANOTHER THING IS, ON THE CASTINGS,

BECAUSE OF THE SAND, IT'S REALLY ROUGH FINISH.

I NEED TO SAND THAT BACK BEFORE I SEND IT TO GET POLISHED

BECAUSE THING IS GOING TO BE CHROME-PLATED,

SO I NEED TO PREP IT OUT A LITTLE BIT.

♪♪

♪♪

I'VE GOT THE GRILLE PIECES SANDED DOWN.

I WANT TO TEST FIT THESE THINGS BEFORE I SEND THEM

TO CHROME, THOUGH.

DID YOU GET THEM? ALL RIGHT.

YEAH, SO I GOT THE CASTINGS HERE, AND THEY LOOK PRETTY GOOD.

I GOT ALL THE LITTLE PARTS FROM HOW THEY HAD TO POUR THE METAL.

ALL THOSE ARE TRIMMED OFF,

SO THESE THINGS SHOULD FIT IN THERE.

YOU KNOW, THE ONLY THING THAT WOULD'VE CHANGED IS,

WHEN THE CASTING, IF THIS THING HAD TWEAKED AT ALL, BUT...

-RIGHT. -LET'S TAKE A LOOK.

-OH. -AW, MAN.

THAT THING FITS PRETTY GOOD.

-BOOM. -I'M TELLING YOU...

WOW, TALK ABOUT THE EASY BUTTON. -YEAH.

LIKE, YOU'VE GOT A FINGERNAIL-EDGE

THAT YOU CAN PUT AROUND THAT WHOLE THING.

IT'S A PERFECT GAP.

Greg: I MADE SURE TO LEAVE A SPACE SO THAT

IF WE WANTED TO PUT MESH ON THE INSIDE...

-WE DO. -WE CAN SCREW THAT IN

RIGHT HERE. -OKAY.

AND I THINK THAT'D LOOK REALLY GOOD, TOO.

YEAH.

Dave: THESE CAST-ALUMINUM PIECES LOOK LIKE

THEY TURNED OUT REALLY NICE, SO WE'RE GOING TO GET THEM OUT

TO CHROME AND GET THEM INSTALLED.

-ALL RIGHT. -GOOD JOB.

-THANKS, GREG. -THANKS, DAVE.

Justin: WE'RE TEARING DOWN THE OLD CONVERTIBLE TOP.

ME DOING THIS CAR, PROBABLY 15, 16 YEARS AGO,

I'M NOT GOING TO LIE, I HAVEN'T DONE ONE SINCE,

SO IT'S KIND OF A REFRESHER TO ME.

I GOT TO GET THIS HEADLINER OFF.

I'M ACTUALLY GOING TO USE IT AS A PATTERN

BECAUSE I GOT TO BUILD ONE OUT OF ALCANTARA.

THEN WE'LL BUILD A NEW CONVERTIBLE TOP PAD,

AND THEN WE'LL INSTALL THE TOP ITSELF.

WE'VE PROBABLY GOT A GOOD, SOLID 20,

24 HOURS TO MAKE THIS THING LOOK RIGHT.

JUSTIN AND HIS GUYS ARE WORKING ON THIS TOP,

AND THEY'RE HAVING A COUPLE OF ISSUES.

IT JUST WASN'T FITTING GOOD.

THE BOW WAS ALL THE WRONG SHAPE.

MASON, COME LOOK AT THAT, WILL YOU PLEASE?

LOOK AT IT FROM THE BACK.

SEE IF IT MATCHES THIS GUY.

SEE IF THAT'S GOT SOME MORE ARCH TO IT.

AND IT'S STILL THERE?

IT'S SO TOUGH. I MIGHT JUST [BLEEP] BREAK THIS WHOLE CAR.

PUT SOME WEIGHT RIGHT THERE, WILL YOU?

JUSTIN, WILL YOU PUT SOME WEIGHT RIGHT THERE?

YEAH.

OH, YEAH.

THIS IS THREE PIECES.

YOU HAVE THE HEADLINER THAT'S GOT TO GO IN FIRST.

THEN YOU HAVE THE CONVERTIBLE TOP PAD,

AND THEN THE TOP GOES ON TOP OF IT.

THE WHOLE CREW BUSTING ON IT RIGHT NOW.

IT'S GOING TO BE A GOOD PATTERN. WE KNEW IT FIT.

THE ONLY THING THAT I WAS CONCERNED ABOUT WOULD BE,

BECAUSE THIS TOP HAD SHRUNK UP, WAS FRONT-TO-REAR.

WE'LL JUST ADD A LITTLE LENGTH TO FRONT

AND A LITTLE TO THE BACK AND THE REST SHOULD BE JUST FINE.

♪♪

I'M GOING TO CHECK RIGHT NOW TO SEE HOW IT LOOKS LIKE

IT'S GOING TO FIT.

THERE'S ACTUALLY A CABLE THAT GOES DOWN BOTH SIDES.

THE CABLE IS HERE.

THIS IS YOUR SIDE-TENSION CABLE.

GLUE IT AROUND AND IN 4 TO 5 HOURS,

HOPEFULLY THIS THING IS DONE.

ONE BIG LAST PUSH AND THIS GHIA IS DONE.

♪♪

Dave: TODAY I'VE GOT A VERY GOOD FRIEND OF MINE, MIKE WETZER,

AND HIS LOVELY WIFE, CHRISTY, COMING OUT TO LOOK AT THE '71

KARMANN GHIA THEY BOUGHT FROM ME.

I'M SO EXCITED TO SEE THE LINES AND THE INTERIOR,

AND I WANT TO HEAR IT.

I WANT TO HEAR THE LOUD NOISE OF THE ENGINE ROARING.

WELL, YOU GUYS, IT'S BEEN A WHILE

SINCE YOU'VE SEEN IT, MIKE.

CHRISTY, YOU'VE NEVER SEEN IT. -OH, MY GOD.

NA, NA, NA NA, NA, NA

NA, NA NA, NA

IT'S SO SWEET AND SO BEAUTIFUL.

OH, IT'S LIKE A PIECE OF CANDY.

OH, MY GOD.

-YOU NAILED IT, MAN. -ARE YOU OKAY WITH IT?

IT'S SOMETHING SMALLER THAN I AM.

IT'S BEAUTIFUL.

I LOVE IT. -EVERYTHING I EVER GIVE MY WIFE,

SHE'S NEVER THAT EXCITED ABOUT IT.

WELL, YOU KNOW, DON'T TELL THEM ABOUT IT.

JUST, LIKE, SHOW UP WITH IT.

NO, IT'S WONDERFUL.

-YOU LIKE THAT? -YEAH, IT LOOKS AWESOME.

HEY, I'LL CALL IT "BITCHIN' BEAUTIFUL."

THERE YOU GO.

Mike: FIRST THING WAS REALLY LOOKING AT THE LINES AND THE WIRE WHEELS

WAS SOMETHING THAT REALLY STOOD OUT TO ME

BECAUSE THAT, TO ME, WAS REALLY WHAT REPRESENTED

THE STYLE OF THAT ERA.

YOU HAVE SUCH A GREAT GUY HERE.

HE WAS WORRIED ABOUT MAKING SURE THAT THIS WAS GOING TO BE

COMFORTABLE FOR YOU AT EVERY ASPECT,

AND THEN, OF COURSE, YOU GUYS ARE FROM FLORIDA.

MIKE HAD US PUT AIR-CONDITIONING IN IT, AS WELL.

I THOUGHT THE TOP-DOWN WAS THE AIR-CONDITIONING, AT FIRST.

NOT IN THIS CASE, HONEY.

NOPE, WE WENT ALL OUT.

Dave: BY PUTTING AIR-CONDITIONING IN, WE KIND OF ENFORCED THE ISSUE

OF THE FRONT-GRILLE SECTION.

WE DESIGNED, BASED ON A '56 KARMANN GHIA,

WHAT THOSE LITTLE GRILLES... THEY WOULD'VE BEEN MUCH SMALLER.

WHAT THEY WOULD LOOK LIKE IF THEY WERE

THIS SCALE AND FUNCTIONAL.

WHEN MIKE AND I GOT TOGETHER A WHILE BACK

AND WAS TALKING ABOUT WHAT WE WOULD DO TO CHANGE

THIS TO MAKE IT A HIGHER-END GHIA

AS OPPOSED TO VOLKSWAGEN MAKING SOMETHING THAT WAS LIKE

AN ENTRY-LEVEL SPORTS CAR. -YEAH, PRETTY IN PRODUCTION.

WE ADDED A COUPLE OF THINGS, LIKE THE CHROME BUMPERS,

BECAUSE THE ORIGINAL BUMPERS THAT WE BUILT FOR THIS CAR

WERE ACTUALLY PAINTED, AND THEN WE ADDED THAT SIDE TRIM

TO KIND OF GIVE SOMETHING TO THE SIDE.

I LOVE THAT YOU'VE GOT THE LITTLE GHIA SYMBOL

ON THE BOTTOM DOWN THERE, TOO. -NICE CATCH.

WHAT DAVE IS PROBABLY BEST KNOWN FOR

IS THE ABILITY TO TIE TOGETHER THOSE LITTLE STYLE ELEMENTS,

SO THAT NO MATTER WHAT YOU'RE LOOKING AT,

YOU REALIZE THAT THIS THING ACTUALLY GOES TOGETHER.

Dave: THIS NORMALLY IS JUST A PUNCHED BUNCH OF LOUVERS

THAT LET THE AIR IN OVER THE ENGINE,

BUT MIKE WAS LIKE, "DAVE, I WANT TO DO SOMETHING

THAT HAS JUST A LOT MORE DEPTH AND EVERYTHING."

SO I KIND OF USED THE SPOKES WE USED

ON THE FRONT THAT WERE HORIZONTAL

AND PUT THEM BASICALLY IN-LINE, FRONT TO BACK.

IT'S A FUNCTIONING PIECE,

BUT NOW YOU HAVE THAT CHROME-DECO LOOK WITH THAT.

THAT LOOKS INCREDIBLE.

WELL, LET ME SHOW YOU UNDER THE HOOD.

OH, MAN, LOOK AT THAT LITTLE GUY.

WE'VE DONE A LITTLE BIT OF CHANGES

FROM THE LAST TIME YOU'VE SEEN IT.

THE ENGINE BAY LOOKS AWESOME.

Dave: THIS IS THE PORSCHE 911-STYLE FAN SHROUD.

WE'VE HAD CUSTOM-BUILD THE TENSIONERS

AND THE BRACKET THAT HOLDS THE AIR-CONDITIONING.

THE PERFORMANCE IS STILL ALL THERE.

IT'S AWESOME, BUT WE HAD TO PRETTY THIS UP.

AND NOW, 15 YEARS AGO, OUR BUILD QUALITY

WASN'T MAYBE THE SAME AS WHAT IT IS RIGHT NOW,

SO WE WERE LOOKING AT A PRETTY, EH, ENGINE BAY.

WASN'T AWESOME.

WELL, WHAT BETTER THING TO DO THAN JUST COMPLETELY RIP

THE WHOLE CAR APART AND START OVER?

Mike: USING THE BERGMANN SHROUDS AND SOME OF THE OTHER THINGS

HE'S GOT IN THERE REALLY TRANSFORMS THE LOOK

OF THAT ENGINE COMPARTMENT TO SOMETHING THAT IS,

A, JEWELLIKE BECAUSE OF THE WAY IN WHICH IN IT'S BEEN EXECUTED

AND MORE CONSISTENT WITH THE ERA.

-SO YOU GOT TO SEE THE INSIDE. -AH, YEAH, I WOULD LOVE IT.

JUMP ON IN HERE.

OH, THIS IS COOL.

THIS IS BEAUTIFUL.

Dave: WHEN I FIRST SOLD THE CAR TO MIKE,

IT HAD VINYL, AND WE DIDN'T WANT THE VINYL.

WE WANTED LEATHER, SO WE CHANGED THAT.

YOU LIKE THE LITTLE CHROME BREATHERS IN IT?

YEAH.

ONE OTHER THING THAT MIKE REQUESTED

WAS THE ALCANTARA HEADLINER.

-OH, MY GOD, I FORGOT. -ISN'T THAT BEAUTIFUL?

-I DIDN'T SEE THAT. -YEAH.

WAY TO GO, HUSBAND.

SO NOW THAT THE CAR IS GOING TO GO BACK TO FLORIDA,

WHAT'S YOUR PLANS FOR THE CAR?

I'M WORKING WITH A SPECIAL OPERATIONS COMMAND GROUPS,

WHICH IS THE ORGANIZATION

THAT COVERS ALL THE SPECIAL-OPERATION FORCES,

AND WE'VE BEEN THINKING THAT WE MIGHT ACTUALLY GET MORE VALUE

OUT OF WHAT WE'VE DONE HERE BY PUTTING THIS WHOLE PROJECT

INTO A FOUNDATION THAT CAN HELP PTSD, TRAUMATIC BRAIN INJURY.

WELL, SIGN ME UP. I'M IN.

WE'RE THINKING WE'RE GOING TO CALL IT, "OBJECTIVE GHIA."

I THINK REALLY THE JOURNEY THAT MIKE AND I

WENT ON TRYING TO CREATE SOMETHING

THAT WAS A HIGH-END GHIA STYLIZED VEHICLE,

BUT NOT NECESSARILY WHAT EVERYBODY KNOWS

AS A KARMANN GHIA VOLKSWAGEN,

WE'VE MADE THAT CAR INTO ONE BITCHIN' EUROPEAN HOT ROD.

FOR A LITTLE CAR LIKE THAT, IT'S GOT A LOT OF GROWL TO IT.

Mike: DAVE HAD A VERY SPECIFIC TASK --

TAKE A LOWLY GHIA AND TURN IT INTO SOMETHING

THAT LOOKED LIKE IT CAME OUT OF THE GHIA STUDIOS,

AND I THINK HE PERFORMED BRILLIANTLY.

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