05x01 - We Build Bitchin Rides

[bunniefuu]

♪♪

1964 Ranchero --
pretty cool project.

I mean, tell me a little bit
about this car.

to my knowledge, you know,
it's built solid.

There's a lot of rust in here,

And then not to mention
a whole lot of bondo.

A half an inch
of body filler there.

Yeah.
It's not going to be as fun

As I was hoping...

[ Whirs ]
...or as easy.

[ Sprays ]
[ bleep ]

[ Laughs ]

This is exactly what we were
chasing, huh?

You can see the welds,
which I like.

The lines were pretty wavy
starting out,

But right now,

We're dialing them in,
getting them straighter.

That is awesome.

♪♪

Dave: clean...

Custom...

Bitchin'.

♪♪

My name's 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.

--[Font color="#ffff00"] captions by vitac[/font] --
[font color="#00ffff"] www.vitac.com[/font]

Captions paid for by
discovery communications

[ Tone rings ]

Hey, kenny. How are you?

good, dave. How you doing?
I'm doing great.

So I guess the car is
shipping out this way.

I got your photographs.

♪♪

We have a very unique project
coming in from back east.

This is a 1964 ford ranchero.

It looks like this car
has had quite a bit

Of work done to it already,

But it's time for me
to talk to the client

And see what he thinks.

Pretty cool project.

I mean, tell me a little bit
about this car.

it just kind of fell
in my lap as a car

that had some money in it
that I was able to buy cheap,

and I kind of said to myself
I'd never do a project car,

but I decided to go ahead
and do it anyway.

it's got the full
drivetrain in it,

going to need
some transmission work

because it doesn't meet
horsepower standards.

to my knowledge, you know,
it's built solid.

It's a good thing it sounds
like it's built solid.

That way, we can just go
straight to customizing it.

There's a couple of things
that I might change or suggest

To change on it,
just because, like,

The taillights
and some of that stuff

Might be a little bit
more trendy

That may not last forever
in that style.

if you certainly got
better suggestions,

that's why the car
is coming in your direction

because I really love
your work.

I love the style, and I want
my car going in that direction.

that's certainly the reason
it's coming your way.

Awesome. Well, my goal for you
is to make sure

That we still have
all of that horsepower

And the coolness of the overall
styling of the car,

But there might be
some suggestions.

Once we get the car here,

I'll get an opportunity
to look at it,

And we'll just, you know,
I'll throw some ideas at you,

And if you're hip on it,
we'll make a couple of changes

And continue on.
that sounds great.

I look forward to it. I can't
wait to get it out to you.

All right, buddy.
Sounds great.

Thank you very much
for your time today,

And we'll talk again soon.

[ Whirring ]

♪♪

♪ Yeah, yeah, yeah ♪

♪♪

Dave:
we are drawing kenny keith's
1964 ranchero.

This is kind of what
I'm coming up with.

What I want to do is actually
put a little bit of a spin

To the original
grille assembly.

♪♪

And right now,
there is no grille,

So we're going to basically
emulate from the original

What we want this one
to look like.

♪ Yeah, yeah ♪

What I want to do is,
I want to be able to capture

All of these lines on the body
because they change direction

So many times with all
of these different facets,

And they're really cool,
dramatic long lines.

♪♪

We're going to take this tired,
old ranch-hand truck,

The ranchero, and turn it
into a "ranch hero."

Oh.

♪ Yeah, yeah, yeah ♪

♪♪

The ranchero arrived,
and actually, you know what?

We got a chance
to start looking at it.

We found a few things
that we're questioning.

There might be a few more.

♪♪

♪♪

That's nasty.

The windshields are usually
leaded in,

You know, right around
the old windshield.

It's usually leaded in
right around here.

But we just noticed
a little bit of rust,

And, hey, let's dig back just
a little bit to see where it is,

And there's a lot
of rust in here.

And then not to mention
a whole lot of bondo

That's just been
crammed up in here.

Look at that.

If this is a problem area,

There's probably going to be
a lot more of this.

Oh, this is no good.

A lot of this car is just
sculpted out of bondo,

So, yeah,
let's see what's down here.

Oh, yeah, more of it.

What did you find?

Oh.

All the way down in here.

♪♪

[ Scrapes ]

Finding this much bondo on this
a-pillar is really bad.

I mean, there's not a lot
of structure to a roof.

These things are small.

If you're filling them
half full of mud,

Then something's really
structurally wrong.

-I didn't expect that.
-Yeah, me neither.

I was hoping it was
just underneath

The lead a little bit, yeah.
Right under the lead.

When you find bondo in the inner
structure of a car, you ask,

"How did they even
get it in there?"

This is going to be a mess.

♪♪

Greg to the metal office.
Greg to the metal office.

I'm going to have greg
dig around the back of the car

To see what he finds.

I hope it's better
than the front.

The first thing I want to do is,

I want to get that whole
bed area stripped down.

Let's see what's underneath it,
because just, like,

That car just looks
a little sketchy to me,

And I'm wondering if there's
something underneath

That that --
I'm just worried about it.

Moses may have found
just one problem,

But it very well could be
the tip of the iceberg.

We need to dig deeper
and find out.

That car is awesome.
It's got twin turbos.

It's got a huge
cubic-inch motor.

It already runs.

I mean, we just kind of
got to straighten

A couple things out
and make it pretty

And put it back together,
so...

Cool.
All right. Sounds good.

All right, man. Let me know.
Okay.

Let me know how it goes.
Cool.

It shouldn't take too long
to find out what issues we have

Or what the current condition
of this car is in.

Greg is going to jump
in and help.

[ Whirring ]

♪♪

♪♪

Kevin: I asked greg to grind
the metal back.

I think he's just grinding
bondo only.

This is a major problem.

Dave needs to get off
the design board

And quit worrying about
the designs of this car,

And we need to decide if this
car is even worth saving.

♪♪

Hey.

Dave's finally here.
It's time to ruin his day,

But he seems to be
in a good mood at the moment.

-Ta-da!
-Sweet.

Warm and fuzzy, huh?
You need to look at the car.

We might have call him.

In fact, we're going
to have to call him.

It's a mess.

Is that what all that dust is?
Yeah, just come here.

Let's look. Come on.
Aw, really?

♪♪

It's -- I mean,
that's a mess, okay?

I get it. There's patches
over patches over overlay.

Look at the gas cap.

It's sunk down,
like, a 1/4 inch,

But back here is where
it really starts to get fun.

-And there's --
-really?

I mean, there's holes.

Everything's tacked,
and then if you remember,

I don't know if you have
a picture of this car,

But this was flat.

That was full of bondo.
The entire --

Are you serious?
That's, like --

The entire thing --

That's, like, an inch
and a half, 2 inches.

Holy crap.
I mean -- oh.

Well, look at the wing.
Look at all this.

I mean, it's just a disaster.
[ Sighs ] yeah.

The whole car's --
I mean, both sides are the same.

It's overlapped
over overlapped.

I mean, none of
it's fully welded.

It's all just tacked.
This sucks.

I hate having to make these
types of phone calls to clients.

This looks like frankenstein.
A half an inch

Of body filler there.
Yeah.

I don't think kenny's
going to be very excited

For the news
I have to give him.

Dude, he is going
to be bummed.

He is going to be so bummed.

You can't even buy
quarter panels for this thing.

Well, we're going to have
to call him.

-Yeah. All right.
-In my opinion,

I mean, honestly,
I think it'd be better

To take what he has and start
with a new car, in my opinion.

That's exactly
what I'm thinking.

I don't want a --
we don't need a hobby.

♪♪

♪♪

Dude, he is going
to be bummed.

He is going to be so bummed.

I think it'd be better
to take what he has

And start with a new car.

Dave:
so we got a '64 ranchero,

And before we even got into
any of the fabrication,

We found out there's
a lot more work that's needed.

There's so much body filler
in this vehicle,

And we found out they actually
erased a lot of body lines

And indentations
with straight-up thick bondo.

Yeah.

I mean, there's holes in there.
What, did they just stuff it?

I think -- yeah.
This was completely stuffed.

I think the holes were
actually to grip the mud.

I mean...
This is terrible.

We're going to have to start
completely over.

All right. Well,
I'll go get ahold of him.

♪♪

[ Rings ]

Hey, good afternoon, kenny.
How are you?

hey, dave. I'm doing great.
great to hear from you.

I've got a little bit
of bad news,

And that is that metal finish
underneath is pretty choppy.

There's been a lot of patches
put together to make,

Like, the rear
wheel wells and the quarters.

The tailgate's really...
Pretty bad in my estimation,

But I think the next step
is making the determination,

Is it faster and easier
to potentially even start out

With another body
or parts of the body?

the bad news is, is, you know,

we have to go to a greater
length than I expected.

um, if that's what's going to
be required of the car,

I mean, we're to the point now
where, you know,

we need to go ahead forward
and finish the car.

I'm really not surprised that
this is what kenny wants to do,

And to be honest with you,

I think it's
the right way to go.

We've already got
a pretty good start

On the function of the car.

We just need to address
some of the design elements.

I think we're probably sixes.

Might as well just go ahead
and start with the car

That we've got now.
All right, my friend.

Well, I'll keep
sending you pictures,

And we'll keep you posted
on what we find.

sounds great.
I look forward to it, dave.

♪♪

Kevin:
this 2011 gt500 convertible
is one awesome ride.

We did some full-length headers
on this car

A couple years ago
and a full exhaust,

And we're having a little
problem with emissions.

So we brought it back in
to upgrade the catalysts,

Or the catalytic converters.

We're going to beef those up

So the unburned fuel
gets burned more,

And now, after we get done
with these new cats,

It should pass emissions.

Because the problem is,
is our catalysts here.

These don't seem to be working
like they're supposed to,

So I'm going to pull it
and be able to look inside

And see if this still actually
has some material in there.

It's not looking to be as fun
as I was hoping.

♪♪

[ Whirring ]

♪♪

So I chose to tear
this exhaust apart

And check the catalysts
and the cats.

I thought it was going
to be easy.

[ Bleep ]
ain't coming apart.

♪♪

This sucks.
Where's jordan?

♪♪

[ Hammering ]

Catalysts here,
these don't seem to be

Working like
they're supposed to,

So I'm going to pull it
and be able to look inside

And see if this still actually
has some material in there.

♪♪

♪♪

See all the honeycomb pieces
are still in there?

I was told that this probably
would be missing

Out of these cats
because they're not that good.

These things are just so hard
to deal with sometimes.

The word on the street is,
is that the cats

That we have
in this thing are kind of weak,

So they're not burning
all the unburned fuel

That's passing
through the exhaust.

The post sensors are seeing that
and not allowing this car

To pass emissions,
so what we need to do is,

We need to put
a really good catalyst,

Or a new catalytic converter,

To burn all the fuel
so the post sensors

Will see that and turn
the check engine light off,

And everyone's happy --

E.p.a., The emissions, her,
dave, all of it.

♪♪

And you know what?
This is a job for jordan.

-What's up?
-What's up, dude?

Hey, what are you doing?
Nothing.

I don't know if you remember
we did that



It was white.

Dave did, like, a blue stripe
down the side,

Blue-faced wheels,

Built it specialties
or something like that.

Did headers and exhaust,
didn't we?

Headers and exhaust.

We're still fighting
that same problem

Where we can't get it
to pass emissions,

So what I'm thinking is,
is we get

Some good high-performance cats
we'll put on there.

I'll order a cat back system,
so we'll change the mufflers

And everything from
the tailpipes up forward,

And then obviously, we're going
to have to kind of meet the two

Because I don't want to take
the long-tube headers off

Because they're super cool.

I'm going to need
your help to get

That little piece
between the cat back

And whatever we need to do.
Okay.

-Cool?
-Okay.

-All right, buddy. Thank you.
-Okay.

Okay, we'll start
with these fugly pieces.

♪♪

Oh, nice. They didn't put
the nubbins on the back.

That makes life easier.

♪♪

Whoops.

Should be the same performance
as the last exhaust, roughly.

Kevin: all the old exhausts
has been removed.

We have all the new exhausts
laid out, ready to go in.

Jordan has all these degrees.

He's super smart,
and this next task,

Only a skilled
professional can do.

[Bleep] cheap stickers.

[Bleep] damn it.
[ Laughs ]

♪♪

They say to cut away from you,
and that's a pretty good idea.

Caution sticker
does not remove easily.

Nobody wants stickers
on their exhaust.

It's a good thing they don't
test iq with simple tasks,

Like removing a sticker.

I feel like so far I've spent
most of my time

Just removing stickers
than actually working.

Son of a b*tch, another sticker.
[ Sighs ]

♪♪

Ah! Ah!

Ah! Oh, lost it.

The amount of knowledge
and expertise

That jordan has in his complex
work cannot be understated.

[ Laughs ]

[ Sprays ]
oh, [bleep].

[ Laughs ]

[ Sprays ]

I just sprayed myself
in the face.

[ Laughs ]

[Bleep] just got everywhere.

That's better.

Hopefully putting
the actual tailpipes in

Goes a little bit faster
than removing the stickers.

♪♪

♪♪

Kevin: the tailpipes are
temporarily hung.

Now we got to get the x-pipe in
so we can install the new cats.

Most of it should just be
a bolt-in thing,

But we got different cats,
so I'll have to make those fit.

♪♪

Kevin:
so normally, when we buy these
aftermarket exhaust systems,

They just bolt right in,
and everything's done.

Well, this car is
a little bit different.

It has a long-tube
set of headers on it.

That complicates things
a little bit.

Obviously, things aren't
where they were factory,

So we have to make
a couple modifications

To get everything
to fit right.

What I won't be using
are these

Ball-and-socket flanges.

♪♪

Well, it looks pretty good,
nice and symmetric.

With everything in and lined up,
now it's time for the new cats.

Koo, koo, kachoo.

Aw. But they're
pretty damn long.

Should be able
to fit them in.

I'll probably have to cut it
right at the bend, weld it on.

I think I'd like to weld on
a slip fit guy right here

And clamp it on there.

That way, I won't have to try
to weld with this in the car

Or take this out.

♪♪

[ Whirring ]

♪♪

Kevin: jordan's going to use
the chain cutter for this job.

He just likes to use
all of the funky tools

That he has in his toolbox.

Yeah, you just wrap it
around like this

And just start going
to town on it, really.

[ Cranking ]

Kevin:
we use the chain cutter because
you can get it in the car.

If you just had this piece
on the bench,

You could just run it
right in the saw,

But since it's in the car,
a chain cuter

Is the perfect tool to use.

♪♪

[ Crackling ]

♪♪

Kevin:
now that everything is fit,

It can all come down,
get final welded.

She'll be good to go,
double-check the sensors,

So she's out the door.

♪♪

♪♪

Think -- it wasn't passing
emissions last time.

We think it could've been
because of the position

Of the o2 sensor last time,

So I'm going to put them
a little closer

To the cats, and...
[ Whirring ]

♪♪

Now it's time to weld
that stupid bung in.

[ Crackling ]

Kevin:
with the exhaust all welded up
and the sensors moved forward,

It's all ready to go
right back in the car.

♪♪

Cool, then you just
lick the rest off.

♪♪

♪♪

Looks pretty good so far.

Finally got everything
cinched down

And in the position
that I want.

Voilà.

Giggity. Done.

♪♪

Kevin: the first system
we had in here

Just wasn't cutting it
on the emissions side.

We had tons of problems.

We replaced it with an awesome
cat back system from borla

With a little modification,
some harder cats.

Functionally, this is going
to work way better

As far as emissions
is concerned.

The performance is going
to stay the same,

And aesthetically,
thing looks awesome.

I couldn't be happier
with the tips.

I actually like them
a little bit better.

[ Whirring ]

Overall, this '64 ranchero
started out

As a complete
and total mess.

Just noticed
a little bit of rust,

And, hey, let's dig back just
a little bit to see where it is,

And there's a lot
of rust in here.

Dude, he is going to be
bummed.

He is going to be so bummed.

I think it'd be better
to take what he has

And start with a new car,
in my opinion.

That's exactly
what I'm thinking.

I don't want a --
we don't need a hobby.

After talking to the customer,

He says he looked
for other options,

But there really
wasn't anything,

And he loves
this body style.

So I think we'll just make
the best of this situation

And make it better.

First thing we're going to do
is tear out what we can't use,

Even though that might be
75 percent of the car.

I am removing the rear wing
right now,

And the hard part is it's got
all this hidden structure

On the inside
that you can't see

Because they put stuff
on top of stuff

On top of other stuff
with bondo in between,

And, like, literally,
if you look in here,

There's bondo on the inside
of the structure.

I don't know what that does,

But apparently it does
something.

♪♪

♪♪

One of the very first things
that we need to do to this

'64 Ranchero is get rid of
that ugly wing.

It looks like a pro-stock wing
or something like that.

It's not going to fit
with the style

That we're going to go with,

So we need to remove that
and start completely over.

♪♪

♪♪

♪♪

Dave:
the tailgate we got is perfect,
other than the fact

That it's just
a little bit short.

We're going to make this flow
right into

The taillight corners.

Therefore, we're going
to have to stretch it.

♪♪

The tailgate section
is turning out great,

And now it's time
to address the quarter panels.

These scabbed-together
hunks of [bleep]

Are coming off
and going in the trash.

♪♪

Dave: because of a lot of
the patchwork

That was done
on the original quarters,

I think it's the safest way
to go about it

By just simply changing them.

♪♪

These new quarter panels are
basically just put on a brake

And made to look
like the originals.

We'll have to finesse them
a little bit

And, of course,
open up that rear wheel well.

♪♪

Dave: pete's done a great job
by opening up this wheel well

To make it proportionate
to those bigger wheels.

Now he just needs to finish up
the wheel well lip.

♪♪

[ Hissing ]

♪♪

[ Crackling ]

♪♪

Dave: pete needs to open up
this wheel well,

So alls he's going to do
is move half of it forward,

Half of it back, which is going
to create a 4-inch gap,

And alls he needs to do
at that point

Is just simply make a piece
to fill it in,

Continuing that same line,
and it'll look perfect.

[ Clattering ]

♪♪

Dave: the wheel well
turned out k*ller,

And it's going to give us plenty
of room for these massive meats.

♪♪

The quarter panel
that we're welding on

Is -- is a reproduction panel.

♪♪

[ Whistles ]

♪♪

The original panels
are pretty easy

Because they're all made
the same way,

But the reproduction
panel was --

It kind of wasn't, uh...

Wasn't made exactly the same,

But when someone makes
a reproduction panel,

Usually they're not really

Making them
to the same standard.

So when we get these
front fenders on,

We want to make sure this line
goes straight down the fenders

And the doors
and the quarter panels.

♪♪

So I got that fender
lined up.

Your line is lined up good

Up at the front there
with your door.

-Yeah.
-But...

How goes it, dudes?

-Hey, what's up?
-What's going on?

You about ready to put
the new quarter on?

We're going to have to
bead roll these

A little bit deeper...
Okay.

...to match the rest
of the car and everything,

And it'll both, like --
it'll pull the lines

Where they need
to be on both sides,

Because they're both
sitting kind of --

They're just not as exaggerated
as the original lines.

But we have the capability.

We do.
Far out.

We're just making sure
they're symmetrical and...

Cool.

Coming along pretty good.
Right on.

♪♪

You want to hop over?

♪♪

Oh, yeah.

So this is a template
that I took off of this panel

Before I started
bead rolling it,

And as you can see,
there's a big gap there.

Got to do this to the bottom
line and the top line as well.

-Got it?
-Got her.

All right.

♪♪

We want the shape of the panel
to match the doors,

So I need to bead roll it more

To be able to pull
the shape in deeper.

I got to move over.

All right. There we go.

♪♪

So now after a few more passes,
we're pretty close.

I think it looks good,

But big test
is going to be whether or not

Will likes it.

[ Chattering in background ]

Hmm.

♪♪

Well, yeah.
Based upon the door,

It just kind of looks
like a big mess.

♪♪

♪♪

Hmm.

Well, yeah,
based upon the door,

It just kind of looks
like a big mess.

Will: we've got these new
quarter panels,

And, of course,
we've got to make them match

With the original car.

Well, they're not our usual
really high-quality stamping

That we'd like to see.

I mean, the whole trick
to this car, really, honestly,

Is it's --
it's been chopped apart

And put on a whole
'nother chassis,

And even when
it got to us,

I don't think they really had
the car structurally straight.

There's a lot of wavy lines.

And then we have basically
deconstructed the whole thing,

And right now
is the point in time

Where we got to get
everything back straight.

So we're trying to match
these new quarter panels

To the existing car,

And they're not
lining up the greatest.

Right now, the bottom one's
kind of this way,

And the top one's
coming down.

Yeah, this panel's
a little low.

But...

I think when this all gets
sucked up, like,

When you close these gaps,
that'll bring that line up.

I think so, too.
I think so, too.

So, really, honestly,

I think you're good
to move forward,

And I think we're going
to be fine

Once you pull
some of this in.

So what we're trying to do
is make this thing

Straight as an arrow.

The quarters are still
kind of fat,

So we need to shrink that up,

Get the back of the car
flowing with the front.

I think you've got
the right idea.

Let's just move forward,
get this put together

And work our way down.

That's the way your side
seemed to go best.

Cool.

♪♪

[ Crackling ]

♪♪

So we've worked our way
from back to the front.

It looks like we just need
a little more

Modification on the back.

A tenth of a degree changes
this, like, an inch.

♪♪

I think you've got
the right idea.

Let's just move forward,
get this put together

And work our way down.

Will: greg's got all these
panels lined up.

They're looking straight
and clean,

Just like they should be.

Now all he's got is
the last 3 inches.

♪♪

So this little piece used to
sit up like that,

And the lines didn't match up,
so I just put some cuts in there

So I can influence it to come
down a little bit and match up,

So that'll help me
make all these straight.

These ones lined up pretty well
as the panels came together,

And this is the only one
I'm having a little issue with,

But not a big problem.

So I'm just seaming this down

And -- and getting this thing
to kind of find its home.

♪♪

[ Crackling ]

♪♪

Kevin: with the lines
looking really good,

We're going to have
kris shrink a couple fat spots.

This is a shrinking disc.

It doesn't have any teeth, okay?

It's just smooth, and it just
rubs on the surface

And creates friction
on the high spots,

And then I quench them
with water to shrink them.

And just going to go at it.

If you need anything shrunk,
I guess kris is your guy.

It's the opposite of viagra.

[ Laughs ]

[ Hammering ]

[ Whirring ]

Kris: I need to shrink
this part of the hood

Because it's too high.

It needs to be brought down

To the level of the rest
of the hood,

So that shrinking disc is just
rubbing on the highest spots,

And then I'm going
to quench those spots.

That'll cause that to shrink.

♪♪

So kris got all of the fat areas
shrunk down on this hood,

And it's looking great.

So now that we've destroyed
all the work that they did,

We're just
going to rebuild it, huh?

Pretty much.

The sides and hood
are starting to come together,

But the bed looks like
it's in critical condition.

Looks like we're about ready
to start fresh

With some structure around
the back, around the turbos.

They even got
their own support,

So we don't need
to mess with that,

But we need to get somewhere
for this inner bed to land.

How much of the, uh, turbos
are we covering?

What are covering?

What are we leaving out
for exposure?

Well, every bit
above this floor level.

I mean, that floor-flat plane

And then, yeah,

Every bit of the turbo
that's up above that.

So we'll be seeing well
over half the turbo...

-Yes.
-...and the piping?

Mm-hmm.

Then you can go with this
inner bed,

And you can go with the floor

Pretty much independent
of each other,

And before you know it,
we'll be done.

-Yeah, that'd be a good day.
-I know, right?

Yeah, I know, rebuilding
the whole back of the car.

Okay, super sick.

I don't even know
what else to say.

♪♪

Will: the overall goal --

We're trying to make it look
really smooth, very race car,

But yet kind of, mm,
a little more showy

And a little more form
and a little more just nice.

♪♪

♪♪

So I can butt these sections up
to the center section here,

And make sure this fits real
nice and tight on the wheel

Before I transfer it over to
the room that I'm taking it to.

Dave: with the new inside
of the bed going together,

It's important
that jason makes templates.

Now, this is going to be
really kind of tricky

Because he's got to build around
all of the roll cage,

The new inner tubs, the new
inside panels of the bed,

And then also,
we've got the turbos

To work around
and the roll cage.

Did I already say "roll cage"?
There's a lot to work around.

♪♪

It burns the flesh.

[ Whirring ]

♪♪

Jason, jason, jason.

-What's up, will?
-I don't know.

-What's up?
-I got the floor in.

-It's looking pretty good.
-Yeah.

I mean, this is exactly
what we were chasing, huh?

You can see the welds,

Which I like,
little bit of detail going on.

I'm really digging it.
I just like the race style,

You know, where you can see
the tubing and aluminum panels,

Big, thick aluminum panels.

This is going to be
kind of a mix.

Not a bunch of bead rolling.

We went with some
thicker aluminum,

So we can just make them
shiny and smooth.

Yeah, it'll look good.

And then I really like this

One roll that we got
that pete's got going on

In these bed sides, so...

It makes everything look
smoother.

Mm-hmm.

So yeah, this is going
to be cool.

-Cool.
-Okay.

All righty. I'll carry on.
Thanks. I'll catch you in a bit.

Okay.

♪♪

The idea on this ranchero is
to basically build a new grille

That looks like the original
but just a little chunkier,

A little bit cleaner,
and a lot cooler.

♪♪

The first step to this custom
grille is going to be that

Greg is going to make
all of the uprights,

Basically the vertical splits.

He's going to make those
in two pieces

And then mend them together.

That will create a nice
three-dimensional piece

That looks cast.

♪♪

Dave:
I wanted to recess the grille
in just a little bit

And make the headlights just
a little bit more prominent

So it didn't look like
a flat piece of tin.

♪♪

There's just so much room here.

If we build it out of
too small material,

It'll kind of, you know,
have all this empty space,

So this will fill it up
a little better.

♪♪

[ Whirring ]

♪♪

♪♪

Greg: now that I got
the center section done,

I'm going to get with will
for an idea

On how to incorporate
these headlights buckets

Into the grille.

-With the end pieces...
-Yeah.

...they have quite a bit
of extra length,

So we can kind of figure out
if we're going to have these

Cut back a little bit

So that the angles kind of match
the headlight buckets.

The question is,
would it be easier

Just to make all this meld in?

Because then our little
extensions

That are going to end up
out of this end of the headlight

To fill these areas
could just be welded on, too.

And looking at that,
I mean, all of a sudden,

To me, that's, like,
maybe so.

Maybe it would be easier
just to make it all one piece.

Yeah, for sure.
I could see that.

Okay, that's good.

Will: I really like what greg
has come up with.

It's going to match
dave's design perfectly.

I think this is looking good.

Be able to finish it up
once you build these corners.

Have this thing done
in no time.

-Ready? Break.
-Cool.

Using dave's drawing
to form sheet metal isn't easy,

And he's nailed it.

[ Whirring ]

♪♪

♪♪

Dave: this was a very difficult
grille to make,

Utilizing old ford truck
headlight buckets

And shrinking those down,

Making all of the horizontals
and the vertical bars,

But now that it's done,
it's looking pretty damn good.

♪♪

Dave: we're at a huge milestone,
and to be completely honest,

I wasn't sure we'd
ever actually get here.

The amount of fab work that
we had to go through to redesign

And put this car back to more
of a understandable classic

Was quite a bit.

Our fab guys worked nonstop
to get this thing wrapped up,

And now it's up to the body guys
to make it smooth and perfect.

[ Whirring ]

This ranchero has been so crazy
in the aspect of its bodywork.

You know,
where it is a unibody.

The frame doesn't
come off of it.

There's a lot of angles
and different body lines

That are running
from front to the back.

♪♪

♪♪

Trying to bring this section
to match up with this section,

That's what this tape
is doing right here.

♪♪

We got to just make the surface
of the metal as straight

And as flat as possible.

♪♪

The lines were pretty wavy
starting out,

But right now,
we're dialing them in,

Getting them straighter.

They're still wavy.

-Shut up, bryce.
-Those don't look good.

[ Laughs ]
all in due time, bryce.

Is this your first time
doing this or what?

-Uh...maybe.
-No, no. It looks --

It's looking really good.
You know, and again,

When you got to think about
what you're actually doing,

You've got three
different lines.

Right.

Each has a different shape
to it.

-Exactly.
-You got your one in the center

That's straight,
this one's smiling,

This one's frowning.

You know, it's pretty
dang impressive

That you've been able
to get this line

Completely perfect
all the way down.

-Cool.
-Nope, you guys are doing good.

-Keep it up. Cool.
-Thanks, buddy.

Appreciate it.

Now that the guys have got
the car blocked

In the polyester primer,

We're going to go ahead
and put it in the booth.

Coming out of the booth
in the 2k primer,

And the car is going
to get put together,

It almost gives it the look
of it being painted.

So we're able to look down
the sides

And see, does it look good?

Is there anything wrong with it?

I honestly just heard that
the customer is coming in,

So just in time we're going
to put this sucker together

And let him take a look at it
and see how it goes.

[ Horns honking ]
[ clock ticking ]

[ Ticking continues ]

Come on through.

Well, my name's kenny keith.

I'm here to take a first peek
at the car

That dave's building for me.

Take a look back here.

Does that look
any different to you?

♪♪

That is awesome.

♪♪

Dave: this old ranchero has
definitely changed a bit

Since the last time
kenny's seen it,

And it's always a relief
to see a happy face.

So what's funny is,
actually, the car,

When you sent it in here,
looked like it had

Been in outer space.
Yeah.

We used a tailgate and actually
recreated this,

But, of course,
no tailgate opening,

And then we took
the original rear bumper --

We slivered that, which was
all completely shaved off.

They just roll-panned
the whole thing

And gave it kind of
a nice little,

You know,
nook for the plate to go in.

The big exhaust, of course,
is going to come through there

And be really dramatic,
and we went back to something

That was a little bit more
fitting on the taillights,

You know, the originals.

I'd kind of really lost what
the tailgate looked like.

Right.
And this is dynamite.

Yeah, this looks really good.
Kenny: I love the bumper.

I love the way he's tucked
that in and kind of made it

As part of the car,
and it flows very well.

Back end is awesome.

You can see some of the work
that we've done in here.

So your turbos are still
going to be mounted here

And shown off.
Mm-hmm.

And it's just super slick.

♪♪

We actually have
the inlet tubes

Basically go through
the sides of the bed.

This has all been refabricated
to look like this

Might have been the way
an original

'64 Ranchero with...
Okay.

...3,000-plus horsepower
twin turbo would look like.

Right.

'Cause they didn't have
twin turbos. [ Laughs ]

Dave: the inside of the bed
really turned out nice

With all the custom panels
and all of the work

That the guys put into this.

And I think when those turbos
are put back in,

All shiny and all put together,
it's going to look fantastic.

Okay.
We built new tubs,

Which are removable,
which will be kind of nice

So we can make sure that
we put some really heavy,

You know, kind of rocker chutes
underneath there,

So when you're out
doing burnouts,

It's not going to tear up
all of your paint

Finish on the outside.
Right, right.

Kenny:
cut out around the turbos,

Which will also be shown
and seen in the car,

And then tidied up around
the sidewalls of the bed,

Which look really nice.

He made it more of a molded
figure into the car,

So, yeah, it looked great.

When you get one down low
like this

And as straight
as this one is,

Look how cool
those body lines --

Oh, yeah.
That big reveal down the side.

Yeah.
I mean, it just looks cool.

It looks like it's just
ripping fast,

And it's not actually
moving anywhere.

♪♪

It's kind of a little bit
of elongated front end

And a medium middle,

And the back end
just looks kind of squatty,

And with the big tires,
it just kind of adds

That pushed-up,
beefed-up look to it, yeah.

And with it down low like it is,
it looks really nice.

Yeah.

Dave:
the stance and the wheels

On this car
look absolutely perfect,

And this is exactly
what we were going for.

The understated design
of the outside,

The perfection the way
that we do it,

I think,
is going to look k*ller,

Especially when
there's paint on it.

The grille's going to
go out to chrome

As well as the bumper,
the rear bumper,

And then, you know, feather out
the last of that engine bay,

And I think we're about ready
to go to paintsville.

So we do need to come up
with a name for it then.

You know, with this thing,
I've kind of explained it as,

You know,
it looked like a spaceship

That started out
as a ranchero,

And so maybe we need
to do something

About returning from outer space
of some sort,

Maybe bringing the gremlins home
or -- I don't know.

You know, we've named
many cars down here,

And to be honest with you, it's
never been a problem for me.

If you need a car named,
simply send me the pictures,

And I'll name your car.

Call it, uh,
the dream weaver.

♪ Ooh, dream weaver ♪

I don't think I fit
the dream weaver look.

Okay, no.

You know, honestly,
I like kevin's names better.

You know, I always thought
kevin was more creative

In that fashion
of the shop area.

We have to think
of something really tricky.

Yeah.

You know, like, ufo.
Yeah...

[ Laughs ]
that's real tricky, yeah.

And then --
area 51.

And then what does
ufo stand for?

And it's just because when
you first look at the car,

You can't really
put it to words,

So it's unbelievable,
fantastic,

Outstanding -- ufo.

I don't know.
I'm reaching there.

Yeah, I was going to say,

"I think you're reaching out
there a little bit, yeah."

I thought I heard crickets
for a second there.

Everybody's laughing.
[ Both laugh ]

Yeah.

I think you can do better
than that, dave.

Yeah, I'll come up
with something.

We'll come up with a name
for this car later on,

But judging
from kenny's face,

It looks like he's happy,
which makes me happy.

♪♪

Kenny: I was a little concerned
about going back to original,

But now that I see it with
all the lines, it's perfect.

Kenny: it looks like the way
I want it to.

I don't know what it's supposed
to look like.

I know what it looked like
in 1964,

But I can tell you,
it looks exactly

The way I want it to be.

Dave, thank you very much.
You're very welcome.

It's awesome.
It was worth the trip.

Glad we came out.

Look forward to the next step.

Sounds great.
Yeah.