0:00:01 > 0:00:04He's menacing.
0:00:06 > 0:00:08He's mad.
0:00:09 > 0:00:12He's the Doctor's most dangerous enemy.
0:00:13 > 0:00:15He's been 20 years in the time void.
0:00:18 > 0:00:20And now he's back.
0:00:41 > 0:00:47On set in Cardiff, the most evil being in the universe is getting ready to make an entrance.
0:00:47 > 0:00:51- I've never seen Davros's face in this.- Right.
0:00:51 > 0:00:53I didn't want to show him too quickly.
0:00:53 > 0:00:57I didn't want to show Davros's features so you see him too early.
0:00:57 > 0:01:02- And action. - I warned you, Supreme One,
0:01:02 > 0:01:07just as Dalek Caan foretold, the children of time are moving against us.
0:01:07 > 0:01:11But everything is falling into place.
0:01:11 > 0:01:14It was quite hard to show a little bit at a time,
0:01:14 > 0:01:20because you've got the skirt, you've got a gloved hand and you've got some dials at the top.
0:01:20 > 0:01:22The rest of it's a leather jacket, then the face.
0:01:22 > 0:01:27Just move your hand through that speech, move your hands slowly across on the speech.
0:01:27 > 0:01:30So you go with it, and it's that one.
0:01:30 > 0:01:31Action.
0:01:31 > 0:01:35I could almost mistake that tone for one of victory.
0:01:35 > 0:01:37Beware your pride.
0:01:37 > 0:01:40The Doctor cannot stop us.
0:01:40 > 0:01:44And yet Dalek Caan is uneasy.
0:01:47 > 0:01:48Thank you.
0:01:48 > 0:01:51That was my huge responsibility to start. From there onwards...
0:01:51 > 0:01:53Back to your positions...
0:01:53 > 0:01:59..to make sure the prosthetics and the body and figure looked authentic and terrific.
0:01:59 > 0:02:02It's just getting the right kind of shots to show him off.
0:02:02 > 0:02:03Action!
0:02:03 > 0:02:08Supreme One, this wave network, I would address it, give me access.
0:02:10 > 0:02:11We've lost them!
0:02:11 > 0:02:17No, there's another signal coming through, there's someone else out there. Hello? Can you hear me?
0:02:17 > 0:02:19Rose?
0:02:19 > 0:02:22Your voice is different and yet...
0:02:22 > 0:02:25its arrogance is unchanged.
0:02:25 > 0:02:27No.
0:02:27 > 0:02:29But he's dead!
0:02:31 > 0:02:35Welcome to my new empire, Doctor.
0:02:35 > 0:02:37Cut!
0:02:37 > 0:02:40But it's not Davros's first appearance in the studios.
0:02:40 > 0:02:43Complex creations need a trial run.
0:02:45 > 0:02:47Wow. This is brilliant, absolutely brilliant.
0:02:47 > 0:02:49That chair looks so mean.
0:02:49 > 0:02:51With most of the big designs of the monsters
0:02:51 > 0:02:53we have a "show and tell",
0:02:53 > 0:02:55so a couple of days before the first day of filming,
0:02:55 > 0:03:01we'll get the actor in, we'll get the prosthetics on them, if that's what they need, or the costume on them.
0:03:01 > 0:03:05We'll get them in the chair or the device, or whatever.
0:03:05 > 0:03:06Can I have a lift?
0:03:06 > 0:03:09And we'll put the whole thing together and see how it works.
0:03:09 > 0:03:12How malleable are you?
0:03:13 > 0:03:17- It's fairly flexible. - It's absolutely brilliant!
0:03:19 > 0:03:20Eyebrows go and everything...
0:03:20 > 0:03:22Here's the Doctor!
0:03:25 > 0:03:27- It's brilliant.- Cool!
0:03:27 > 0:03:30- How's it feel?- All right, thanks.
0:03:30 > 0:03:32It's very comfortable.
0:03:32 > 0:03:34Very comfortable!
0:03:34 > 0:03:40David and I spent the entire morning in a state of complete frenzy
0:03:40 > 0:03:44because we knew we doing the Davros show and tell that afternoon.
0:03:44 > 0:03:47We just kept laughing at each other. We were so excited.
0:03:47 > 0:03:50One of my earliest memories of Doctor Who is Davros.
0:03:50 > 0:03:53It was 1975.
0:03:53 > 0:03:58I was a very small child, absolutely captivated by this extraordinary creature.
0:03:58 > 0:04:01Do the wires come out?
0:04:01 > 0:04:04'It doesn't disappoint when these things from your own cultural memory
0:04:04 > 0:04:08'are suddenly now part of the job you're doing for real.'
0:04:08 > 0:04:11You never quite get over those slightly surreal moments.
0:04:12 > 0:04:17In a nearby rehearsal room, another cultural memory is being awakened.
0:04:17 > 0:04:21What we're doing today is a bit of trouble-shooting.
0:04:21 > 0:04:25It's 18 months, nearly two years, since we last did a Dalek episode.
0:04:25 > 0:04:26- Is that right?- Yeah.
0:04:26 > 0:04:29I have been summoned!
0:04:29 > 0:04:30We're making sure everything works.
0:04:30 > 0:04:34Having a trundle round, making sure things fit and the electrics work.
0:04:34 > 0:04:37We need more bodies immediately!
0:04:37 > 0:04:38Yes, Master.
0:04:38 > 0:04:42It's all about the legs. If you've got long legs, you're in trouble.
0:04:42 > 0:04:44Luckily it's all right.
0:04:44 > 0:04:47It's a simple seat which is a bit padded at the bottom.
0:04:47 > 0:04:50It's trying not to bang your knees.
0:04:50 > 0:04:53Daleks have no concept of worry.
0:04:53 > 0:04:56We've got quite used to it over the years,
0:04:56 > 0:04:58visibility is always a bit restricted.
0:04:58 > 0:05:00It's usually off to one side as well.
0:05:00 > 0:05:03The bit you can see out of is like that.
0:05:03 > 0:05:06If you need to look there, fine but if you have to look there...
0:05:06 > 0:05:08Come with me!
0:05:09 > 0:05:11Just using the force, really.
0:05:11 > 0:05:15- We're wearing these the whole time. - Oh, yes, have to do that.
0:05:15 > 0:05:16Then there's smoke and
0:05:16 > 0:05:20steam from the mini-bar and the Jacuzzi.
0:05:20 > 0:05:24The in-Dalek entertainment system. It's all in there!
0:05:24 > 0:05:25Now...
0:05:25 > 0:05:28join with me!
0:05:28 > 0:05:31The hardest part is keeping out of the way of the mutant,
0:05:31 > 0:05:32isn't it, mutant?
0:05:32 > 0:05:35Yeah, the mutant doesn't like it if you sit on him.
0:05:35 > 0:05:40You sort of get in sideways, or have him on your lap.
0:05:46 > 0:05:51# I've got you under my skin
0:05:54 > 0:05:59# I've got you deep in the heart of the me
0:06:01 > 0:06:07# You're so deep in my heart That you're really a part of me
0:06:08 > 0:06:14# And I've got you under my skin... #
0:06:16 > 0:06:19Once we are inside and the lids have been put on and everything.
0:06:19 > 0:06:22People do kind of forget that we're in there.
0:06:22 > 0:06:25Because it looks real and it moves and it twitches and we glide around.
0:06:25 > 0:06:28It's a testament to what an amazing piece of design it is.
0:06:28 > 0:06:31It comes to life and people think it's just a Dalek.
0:06:31 > 0:06:35It's not a bloke and some plywood and some fibre glass and some metal.
0:06:35 > 0:06:37It's a Dalek. Fantastic.
0:06:37 > 0:06:40- Hello, boys. - DALEK OPERATORS: Hello!
0:06:40 > 0:06:43- Look, can you show me your twitching?- Check us all out.
0:06:43 > 0:06:47The far one, are you switched on?
0:06:47 > 0:06:49I'm switched on, yes.
0:06:49 > 0:06:53- Can you move for us as well? - Yeah, sure, shall I just...?
0:06:55 > 0:06:59Yup, yeah, yeah. That's going to be good.
0:06:59 > 0:07:01Once you know who they are, you remember their names.
0:07:01 > 0:07:04But once they start moving, I haven't a clue!
0:07:04 > 0:07:07- Stage 42, take two.- Action!
0:07:08 > 0:07:11Dalek fleet in battle formation.
0:07:11 > 0:07:14All systems locked and primed.
0:07:14 > 0:07:17Crucible at 90% efficiency.
0:07:17 > 0:07:21The human harvest will commence.
0:07:21 > 0:07:23- Right, cut.- Yes, please.
0:07:23 > 0:07:26# I've got you
0:07:26 > 0:07:29# Under my skin
0:07:31 > 0:07:38# And I love you under my skin. #
0:07:38 > 0:07:41- Rehearsing!- Quiet!
0:07:41 > 0:07:42And, action!
0:07:42 > 0:07:46Negative! No reports of Time Lords.
0:07:46 > 0:07:49A big part of the Dalek is his voice. The voice.
0:07:49 > 0:07:52We are beyond the Doctor's reach.
0:07:52 > 0:07:56The person who realises that is Nick Briggs. He's a genius.
0:07:56 > 0:07:58He sits at the side of the set
0:07:58 > 0:08:02and delivers a completely chilling performance.
0:08:02 > 0:08:04The Doctor cannot stop us.
0:08:04 > 0:08:07Nick's involvement begins months before shooting
0:08:07 > 0:08:10when the cast gathers for a first read of the script.
0:08:10 > 0:08:13Nick comes to the read-through with his ring modulator.
0:08:13 > 0:08:16- Jacqueline Breen.- Gary Milner.
0:08:16 > 0:08:17Nick Briggs.
0:08:19 > 0:08:24And he sets up a little speaker. He sits there and he patiently waits
0:08:24 > 0:08:26for the first Dalek line to come around,
0:08:26 > 0:08:29Knowing that when it does and when he first booms across
0:08:29 > 0:08:32that read-through room he's going to get a shiver of delight
0:08:32 > 0:08:34from everyone in the room.
0:08:34 > 0:08:38I'm receiving a communication. They have a message for the human race.
0:08:38 > 0:08:39Put it through, let's hear it.
0:08:39 > 0:08:43Exterminate! Exterminate!
0:08:43 > 0:08:46Exterminate! Ex-ter-min-ate!
0:08:46 > 0:08:51CHEERING, LAUGHTER AND APPLAUSE
0:08:57 > 0:08:58It's lovely for an actor's ego.
0:08:58 > 0:09:01I got a huge round of applause on my first line
0:09:01 > 0:09:04and then any little different nuance I did,
0:09:04 > 0:09:05another round of applause.
0:09:05 > 0:09:09Daleks are the masters of the Earth.
0:09:09 > 0:09:13IN DIFFERENT PITCH: Daleks are masters of Earth.
0:09:14 > 0:09:20And we're a massive multiplication shot of the Daleks on the floor, everywhere. All chanting.
0:09:20 > 0:09:22Everyone together now...
0:09:22 > 0:09:25LAUGHTER
0:09:34 > 0:09:38It's late at night on a street in south Wales.
0:09:38 > 0:09:40There's an invasion in progress.
0:09:42 > 0:09:47It's the first time ever in the new series of the Daleks I'v have gone on location.
0:09:47 > 0:09:52So we've got rain and we've got cold and weather and it's brilliant. I love it.
0:10:00 > 0:10:04We're doing the scene where Rose and the Doctor are reunited
0:10:04 > 0:10:06after so many years.
0:10:06 > 0:10:09Just before they embrace,
0:10:09 > 0:10:12a Dalek comes out of the shadows and kills the Doctor.
0:10:12 > 0:10:17Barnaby, on action, you're trundling from the back up to the front,
0:10:17 > 0:10:20- turning and firing.- Yup.
0:10:20 > 0:10:23With an exterminate.
0:10:23 > 0:10:24Exterminate, then gun?
0:10:26 > 0:10:28Exterminate, then gun, yeah. Pow.
0:10:28 > 0:10:33After 45 years it feels good to be the Dalek who got him.
0:10:33 > 0:10:34HE SNIGGERS
0:10:37 > 0:10:39Exterminate!
0:10:49 > 0:10:50Long time no see.
0:10:52 > 0:10:55Been busy, you know. Don't die.
0:10:55 > 0:10:59It's...a moment of high emotion for all involved.
0:10:59 > 0:11:03- Don't die.- Argh.- Oh, God, don't die.
0:11:03 > 0:11:08We can't have happy endings. Especially not when there's a cliffhanger to be worked up towards.
0:11:08 > 0:11:111/10, take one... And action.
0:11:13 > 0:11:18What do we do? There must be some medicine or something!
0:11:18 > 0:11:21Rose is faced with the fact that she might lose another Doctor.
0:11:21 > 0:11:24Just step back.
0:11:24 > 0:11:25Rose! Do as I say and get back.
0:11:25 > 0:11:31Just as she's managed to come, goodness knows how many zillion light years to be reunited with him.
0:11:31 > 0:11:34He's dying, and you know what happens next.
0:11:34 > 0:11:36What do you mean?
0:11:36 > 0:11:39She's very fond of this version of the Doctor.
0:11:39 > 0:11:41She hasn't seen him for a long time.
0:11:41 > 0:11:44She's completely in love with him and he's about to change form again.
0:11:44 > 0:11:45I've come all this way.
0:11:45 > 0:11:47What do you mean?
0:11:47 > 0:11:51She knows what it means and it frightens her.
0:11:57 > 0:11:59It's starting.
0:11:59 > 0:12:03So yeah, the Doctor is...is mortally wounded and needs to regenerate.
0:12:03 > 0:12:05There's not really any going back from that.
0:12:05 > 0:12:07But you can't.
0:12:07 > 0:12:09I'm sorry. It's too late.
0:12:11 > 0:12:13I'm regenerating.
0:12:13 > 0:12:18So, at the end of this episode, the Doctor is dying...
0:12:20 > 0:12:22He starts to glow, he starts to boil...
0:12:26 > 0:12:31He's changing into a new man. I've got no idea what happens next.
0:12:31 > 0:12:37I'm going to be sitting down next week watching as rapt, as excited, and as in the dark as everyone else.
0:12:37 > 0:12:39Honestly.
0:12:39 > 0:12:42HE LAUGHS
0:12:54 > 0:12:57Subtitles by Red Bee Media Ltd
0:12:57 > 0:13:00E-mail subtitling@bbc.co.uk