0:00:04 > 0:00:08Many of the things that we work on are "mission critical".
0:00:08 > 0:00:11They save lives, they protect our troops.
0:00:11 > 0:00:13It's a big responsibility to carry.
0:00:20 > 0:00:23Our robots are silent stalkers
0:00:23 > 0:00:26and they see in the dark better than humans.
0:00:35 > 0:00:38The people that work at QinetiQ are all fairly technical
0:00:38 > 0:00:43and we've all got to be fairly secretive about what we do, so we're all nerds at heart.
0:00:43 > 0:00:47We all grew up studying science and technology.
0:00:48 > 0:00:51I know how important it is to get things done on time.
0:00:51 > 0:00:56If we keep these deadlines, the quicker they come out and can be used to save lives.
0:00:59 > 0:01:03I go home after a 12-hour day and I'll wake at 3.00am thinking about the aircraft.
0:01:05 > 0:01:09There's so much going on in your head, so much information and that is pressure, that's hard work.
0:01:24 > 0:01:30This Chinook helicopter is one the most important military aircraft in the world.
0:01:32 > 0:01:36200 of Britain's top aviation engineers have worked
0:01:36 > 0:01:39around the clock to rebuild it for the war in Afghanistan.
0:01:39 > 0:01:43Definitely a lot of extra pressure. It's a big milestone in the project
0:01:43 > 0:01:49and the last thing we want is any unservicabilities, due to us missing anything on the ground.
0:01:50 > 0:01:53This is what we're doing, we're making sure it is actually safe.
0:01:55 > 0:01:58I'll keep an eye on the instruments, if you're looking outside,
0:01:58 > 0:02:01so you do control and I'll do the engines.
0:02:01 > 0:02:06If we're going to have a problem, I'd like to have it at six inches, not 10 or 15 feet, it's much easier.
0:02:07 > 0:02:10Quite nervous, cos this is my first proper servicing.
0:02:10 > 0:02:14I've only just been trained up to do this, so quite nervous.
0:02:14 > 0:02:17It's an achievement, the amount of hours we put into it,
0:02:17 > 0:02:21doing the nights and days, being on the aircraft all the time.
0:02:21 > 0:02:23Coming to this final stage is good.
0:02:23 > 0:02:27It's taken the team ten months and nearly £9m.
0:02:27 > 0:02:33For all of them, today is a big day, as this Chinook will finally fly for the first time.
0:02:33 > 0:02:36The delivery of Aircraft Four is important,
0:02:36 > 0:02:42cos this is the day we prove that the aircraft flies, we've actually achieved the goal of the re-version.
0:02:42 > 0:02:46It will be good to see it in the air. The culmination of a lot of hard work.
0:02:48 > 0:02:50This is the story of the people who work
0:02:50 > 0:02:55on some of Britain's most secret and complicated engineering projects.
0:03:11 > 0:03:15QinetiQ is one of Britain's biggest defence contractors.
0:03:15 > 0:03:18The company isn't without its critics, but it does employ
0:03:18 > 0:03:22around 7,000 people in the UK alone.
0:03:24 > 0:03:30Most of their £1.5bn turnover comes from military technology.
0:03:30 > 0:03:33Controversial products to many, but the team here
0:03:33 > 0:03:37are trying to develop those innovations for civilian markets.
0:03:37 > 0:03:41QinetiQ's stock in trade is really intellectual property.
0:03:41 > 0:03:46We solve the problems that most people think about.
0:03:46 > 0:03:51It's quite interesting that 10% of our UK workforce have PhDs,
0:03:51 > 0:03:56so we employ a very strong group of very bright, clever people.
0:04:01 > 0:04:05QinetiQ work on classified government projects,
0:04:05 > 0:04:06so everybody is security cleared,
0:04:06 > 0:04:10at least as far as "restricted", often up to as far as "secret".
0:04:14 > 0:04:18There's not very many females in my field, but the great thing
0:04:18 > 0:04:24that I love about robots is that it really, really can save a life. It can take the human
0:04:24 > 0:04:26away from a dangerous situation,
0:04:26 > 0:04:29so the human never has to be exposed to a danger.
0:04:31 > 0:04:37I'm a mechanical technician by trade. Basically, I joined the Air Force back in 1991, Seven Squadron,
0:04:37 > 0:04:40and from there left and started working for QinetiQ on the Chinooks.
0:04:40 > 0:04:46That's everywhere from Norway, up in the Arctic, to Afghanistan,
0:04:46 > 0:04:51Bosnia, United Nations work, so I've seen and done a lot of operations with them.
0:04:52 > 0:04:57We spend time worrying about the things that are going to impact the country, both militarily
0:04:57 > 0:05:04and economically, in the future. We're a provider of good advice to governments all over the world.
0:05:07 > 0:05:10But the company has a controversial past.
0:05:13 > 0:05:18Originally a military research arm of the government - the real Qs of James Bond fame -
0:05:18 > 0:05:26in 2006, the company was floated on the stock exchange and two civil servants became multi-millionaires.
0:05:26 > 0:05:30Now the company operates under the commercial pressures of the private sector.
0:05:36 > 0:05:40Deep in the English countryside, in the heart of Salisbury Plain,
0:05:40 > 0:05:42is one of the company's key sites.
0:05:44 > 0:05:48Boscombe Down is a Ministry of Defence-owned facility,
0:05:48 > 0:05:50employing over 2,000 people.
0:05:50 > 0:05:52The men and women who work here
0:05:52 > 0:05:54develop and test cutting-edge technology.
0:05:55 > 0:06:00Today, one of the most important projects is the modification of Chinook Helicopters.
0:06:00 > 0:06:06They're being refitted for deployment into warzones around the world, including Afghanistan.
0:06:09 > 0:06:14Chinooks are one of the world's most iconic and powerful helicopters.
0:06:14 > 0:06:19They've been designed and built by American company Boeing since 1961.
0:06:19 > 0:06:23Used to transport troops and heavy loads, Chinooks can lift
0:06:23 > 0:06:27a double-decker bus or carry two Land Rovers in the back.
0:06:28 > 0:06:30The Chinook is used in a number of roles.
0:06:30 > 0:06:34It is in the basic resupply role at times, which is ammunition, food,
0:06:34 > 0:06:37bringing troops in and out of the operating base.
0:06:37 > 0:06:40It means less troops move on the ground
0:06:40 > 0:06:45and their exposure to roadside bombs and IEDs is reduced.
0:06:45 > 0:06:51And finally, and perhaps the most rewarding role, is casualty evacuation, which is not ideal to
0:06:51 > 0:06:54have to do it, but it does make the crew realise the value they bring.
0:06:54 > 0:07:00They pulled something like 1,000 people out off the battlefield just last year alone.
0:07:05 > 0:07:09The urgent need for Chinooks in Afghanistan hit the headlines
0:07:09 > 0:07:12when the government was criticised for not supplying enough.
0:07:14 > 0:07:19They actually owned eight new aircraft that had been mothballed
0:07:19 > 0:07:22because of problems in the way they were purchased.
0:07:22 > 0:07:25These Chinooks could not be cleared to fly.
0:07:28 > 0:07:34The only way to get them into service, and fast, was to replace their entire flight system.
0:07:38 > 0:07:45Three of the aircraft have already been delivered to the RAF. Work on the remaining five is underway.
0:07:56 > 0:07:58If the new Chinooks are going to fly safely,
0:07:58 > 0:08:01nearly every wire and electrical connection must be changed.
0:08:01 > 0:08:07A new cockpit is being installed and engines and fuel tanks are being refitted.
0:08:10 > 0:08:15Ship's Captain Si Jones is responsible for the delivery
0:08:15 > 0:08:19of the next Chinook - and he has only 12 weeks before it must fly.
0:08:19 > 0:08:22As you can see, major components are removed at the moment,
0:08:22 > 0:08:26fuel tanks are obviously removed, a lot of the bays are empty.
0:08:26 > 0:08:30We have a lot of work going on, a lot of technicians on the aircraft.
0:08:35 > 0:08:37So, when we get this completed,
0:08:37 > 0:08:40it will be quite a transformation inside here.
0:08:40 > 0:08:45Where these metal tie-down rings are down here is where the seats and seatbelt mount
0:08:45 > 0:08:50and then we can also fit ballistic protection, which would mount on the walls and floors also
0:08:50 > 0:08:53and on the sides, so that when they're operating in theatre,
0:08:53 > 0:08:55it gives the troops sensible protection.
0:08:55 > 0:09:01You've obviously got a crew of four that operate on these aircraft in normal situations.
0:09:01 > 0:09:06You'd have two pilots in the front, to the left and right positions, and you'd also have two crew men.
0:09:06 > 0:09:11In the left hand bay, the avionics bay, really is the heart of the aircraft, where the majority
0:09:11 > 0:09:14of the flight-critical computers are located.
0:09:14 > 0:09:17As you can see from the mounting points, there are seven shelves here
0:09:17 > 0:09:21and each one will be populated with flight computers and other
0:09:21 > 0:09:23flight-critical equipment - comms, radios, etc.
0:09:23 > 0:09:26That is what we call a "critical path area" within the build.
0:09:26 > 0:09:31Clearly, you can see one man can stand and work in that area, there's a huge amount of work.
0:09:31 > 0:09:35It's vital when we plan this project we've got enough time
0:09:35 > 0:09:40to complete the work in this area. You can't just chuck three or four men in a space that small.
0:09:40 > 0:09:43Avionics technician Jade Watson has recently returned
0:09:43 > 0:09:46from the front line and has now joined the Chinook team.
0:09:46 > 0:09:49Before, I was in the Air Force, so I was out on the ERT,
0:09:49 > 0:09:54which is emergency response team, where we do the casualty evacuation.
0:09:54 > 0:09:59Because of the experience I've had, I know how important it is to get things done on time.
0:09:59 > 0:10:01The more we keep deadlines, the quicker they come out,
0:10:01 > 0:10:04the quicker they can be used to save lives.
0:10:05 > 0:10:09This programme's been 24/7 now for
0:10:09 > 0:10:15somewhere in the region of 15 months, so we've been working flat out
0:10:15 > 0:10:19to accelerate the delivery of the aircraft for operational needs.
0:10:21 > 0:10:24Each aircraft goes through the same refit process.
0:10:24 > 0:10:28First, almost every piece of electronic equipment and almost
0:10:28 > 0:10:31every wire is removed, leaving an empty shell.
0:10:35 > 0:10:39Then, the inside of the aircraft is completely rebuilt from scratch.
0:10:46 > 0:10:50It will take the engineers here 60,000 man hours to replace
0:10:50 > 0:10:55six miles of wiring. And a host of new equipment needs to be installed before the helicopter can fly.
0:11:03 > 0:11:07The cockpit, at the moment, is now fairly populated, most of the wiring in.
0:11:07 > 0:11:14Power distribution panels, as you can see, to the left and right open, and then the main inter-seat
0:11:14 > 0:11:17and main console area is now populated with wiring,
0:11:17 > 0:11:22but the LRUs, the line replacement units, gauges, etc aren't fitted yet and the floors are still out.
0:11:22 > 0:11:26We'll now be starting the build-up in that area in the coming weeks.
0:11:26 > 0:11:30There's all the flying controls, you've got pedal boxes that would normally fit in here,
0:11:30 > 0:11:34then all your standard controls, cyclic and collective sticks,
0:11:34 > 0:11:38which give you flying control operation. So, lots of equipment.
0:11:38 > 0:11:42Ballpark figure, there's somewhere in the region of 15,000 or 16,000
0:11:42 > 0:11:45wires that have been replaced in the aircraft, so a huge number.
0:11:45 > 0:11:48And if you can imagine, a lot of the wires start at this end
0:11:48 > 0:11:51and go down to the back end. That's a lot of wiring.
0:11:59 > 0:12:03At the moment we're scrutinising all the looms, all the cables.
0:12:03 > 0:12:08It's not like a car where you can say, "It's OK, it'll do the job."
0:12:08 > 0:12:13Unfortunately, there's no hard shoulders at 30,000 feet, so everything has to be perfect.
0:12:13 > 0:12:19There's troops flying these things, so we need to know that they're going to do the job properly.
0:12:19 > 0:12:23They've got enough to worry about, without worrying if the Chinook's serviceable.
0:12:23 > 0:12:26I'd rather not have to worry about that if I was flying.
0:12:26 > 0:12:30It's personal pride, just to get it right, make sure everything fits,
0:12:30 > 0:12:32cos everyone is going to be looking at your work
0:12:32 > 0:12:37for years to come. It's just nice to see it flying...eventually(!)
0:12:58 > 0:12:59I joined the Air Force back in 1991.
0:12:59 > 0:13:02Been on Chinooks since leaving school.
0:13:02 > 0:13:08Back in 2001, just after September 11th, Boxing Day of 2001, we got a phone call, into work,
0:13:08 > 0:13:10and the next thing we knew, two days later
0:13:10 > 0:13:15we were landing in Afghanistan, starting the "war against terror".
0:13:15 > 0:13:21With QinetiQ, and any of the civilian contract environments,
0:13:21 > 0:13:24in reality, when you finish work for the day, you finish work for the day.
0:13:24 > 0:13:29You're a civvy, you're a normal person, but the forces environment,
0:13:29 > 0:13:33you're expected to be ready at any moment, really.
0:13:45 > 0:13:50The Chinooks are just one of many aviation projects people here are working on.
0:13:50 > 0:13:54And the site at Boscombe Down has been used to develop and test
0:13:54 > 0:13:57futuristic military aircraft since 1939.
0:13:59 > 0:14:03The team here regularly upgrade the UK's fleet of fighter jets
0:14:03 > 0:14:07and other aircraft, enhancing and testing their performance.
0:14:07 > 0:14:13Mechanical technician Gaz Fountain has worked on Boscombe's Chinook project for 10 months.
0:14:13 > 0:14:16This is our hanger, where we keep the aircraft.
0:14:16 > 0:14:18Come and have a look over here.
0:14:19 > 0:14:20Mind your head.
0:14:25 > 0:14:29If you want to stay here a minute, you'll see this is the flight line here.
0:14:29 > 0:14:34If you look through those two jets starting up you'll see a green tower, that's air traffic control.
0:14:34 > 0:14:38And that hanger to your right-hand side, that's where they prep
0:14:38 > 0:14:42the cabs ready for flight and do scheduled minor servicing on them.
0:14:42 > 0:14:46It's a big old unit Boscombe Down, you've got the fixed wing,
0:14:46 > 0:14:48the fast jets, a training school for the pilots
0:14:48 > 0:14:53and they do a lot of testing for things which haven't been used on aircraft before.
0:15:07 > 0:15:13It may be an uncomfortable fact of life, but wartime innovation can and does drive breakthroughs
0:15:13 > 0:15:20in civilian technology, like thermal imagining used by rescue helicopters and new aircraft radar systems.
0:15:20 > 0:15:23In the future, unmanned aircraft controlled from the ground,
0:15:23 > 0:15:28could be used for crop spraying, traffic reporting or surveillance.
0:15:35 > 0:15:38The site also has the UK's only test pilot's school,
0:15:38 > 0:15:41where some of the world's best pilots and flight engineers
0:15:41 > 0:15:44test themselves, and aircraft, to their limits.
0:15:49 > 0:15:55The engineers and pilots are even working together to improve flight navigation
0:15:55 > 0:16:00and the possibility of the pilot commanding unmanned aircraft, whilst flying their own jet.
0:16:00 > 0:16:04This is effectively your command and control on the ground, so all
0:16:04 > 0:16:10of these assets and the command and control and Tiara are connected to each other via tactical data link.
0:16:20 > 0:16:24To exploit lucrative new markets, QinetiQ often takes
0:16:24 > 0:16:28military technology and adapts it to worldwide problems.
0:16:28 > 0:16:32Many of things that we work on are "mission critical".
0:16:32 > 0:16:35They save lives, they protect our troops,
0:16:35 > 0:16:42they keep us in forward operations. It's a big responsibility to carry,
0:16:42 > 0:16:46but the fun part about a company like this is that there are so many
0:16:46 > 0:16:51innovative, clever, technological ideas that spin out of that work.
0:16:57 > 0:17:04By 2020, the UK must increase its green energy production from 2% to 15%.
0:17:06 > 0:17:11And as we're Europe's windiest country, harnessing this resource
0:17:11 > 0:17:14could be the key to helping us meet this target.
0:17:14 > 0:17:21A single onshore wind turbine can meet the energy needs of 1,100 households a year.
0:17:21 > 0:17:24But there is a serious problem with them.
0:17:24 > 0:17:32Across the country, the construction of thousands of turbines, enough to provide power for 3.4m homes,
0:17:32 > 0:17:36are on hold, because of the unique effect they have on aviation radar.
0:17:40 > 0:17:45Air traffic controllers use bounced radar pulses to locate moving objects.
0:17:48 > 0:17:55Because of their spinning blades, turbines reflect these pulses in the same way as an aeroplane,
0:17:55 > 0:18:00so air traffic control can't distinguish between a wind farm and a rogue moving aircraft.
0:18:01 > 0:18:04At the moment, the problem is vast.
0:18:04 > 0:18:08Up to six gigawatts of power is being held up in the process,
0:18:08 > 0:18:09because of the aviation problem.
0:18:09 > 0:18:13There is a huge pressure on everybody to get this problem solved.
0:18:13 > 0:18:18The aviation problem affects many different stakeholders in the aviation community.
0:18:18 > 0:18:23On the MoD side, we have RAF bases and they have air traffic
0:18:23 > 0:18:26control services and air defence services to safeguard.
0:18:26 > 0:18:30Also, we have civil airports and then, on top of that, we have NATS,
0:18:30 > 0:18:36who are responsible for the on-route services, the transatlantic flights that don't even stop here.
0:18:36 > 0:18:39It really is like a motorway in the sky.
0:18:39 > 0:18:42But now engineers believe they may have found the solution...
0:18:46 > 0:18:47..stealth technology.
0:18:49 > 0:18:56For over six decades, they've been working on ways to make boats and planes "disappear" from enemy radar
0:18:56 > 0:19:01and now the team are applying these techniques to the wind turbine problem.
0:19:01 > 0:19:06- Ready?- Yeah.- Clear, yeah, its looking good. Round about 30 DBs.
0:19:06 > 0:19:09'Stealth is the shape of the vehicle and the materials it is made of.'
0:19:09 > 0:19:13You either reflect the signal away from the radar that's looking for it
0:19:13 > 0:19:16in a different direction and you do that by
0:19:16 > 0:19:20by shaping the aircraft or ship, or you make it out of something
0:19:20 > 0:19:23that absorbs the energy sent out by the radar.
0:19:23 > 0:19:27QinetiQ don't build wind turbines, so they're working with
0:19:27 > 0:19:32one of the world's biggest turbine manufacturers, Danish company Vestas, to solve the problem.
0:19:32 > 0:19:35It's been a hugely complex challenge.
0:19:35 > 0:19:40Because every inch of a turbine blade has been precisely engineered for maximum performance,
0:19:40 > 0:19:44the shape, weight or manufacturing process can't be changed.
0:19:44 > 0:19:47Engineers here are working on a special solution
0:19:47 > 0:19:51to add stealth material layers into the composite skins of the blades.
0:19:51 > 0:19:53Almost weightless, but complex.
0:19:53 > 0:19:56These guys are just measuring
0:19:56 > 0:19:58and marking the position of the various materials,
0:19:58 > 0:20:02so we get them in the right place.
0:20:02 > 0:20:05It's important that we put these materials to within
0:20:05 > 0:20:10a few millimetres, otherwise we could upset the later joining of the two parts of the mould.
0:20:10 > 0:20:13It's nice to get away from computer models of what we're doing
0:20:13 > 0:20:17and work with these guys and see it coming together as a component.
0:20:24 > 0:20:29The composition of these layers is a closely-guarded secret, but they work by absorbing most of
0:20:29 > 0:20:34the radar pulses, so only a very small amount is reflected back.
0:20:34 > 0:20:40With the weakened returned pulse, the turbines become distinguishable from aircraft to radar operators.
0:20:56 > 0:20:59Initial tests are positive and the teams are now building
0:20:59 > 0:21:03what will become the world's first "stealth turbine".
0:21:06 > 0:21:10The success of this project could mean cleaner energy for everyone,
0:21:10 > 0:21:16with a British company at the forefront of a multi-billion pound expansion worldwide.
0:21:36 > 0:21:41Stealth turbines are one of an increasing number of civilian projects in development.
0:21:41 > 0:21:45But this company still relies on the Ministry of Defence
0:21:45 > 0:21:50for most of its contracts and has been working with Boeing to deliver the helicopters on time.
0:21:55 > 0:21:59These Mark 3 Chinooks also have upgraded fuel tanks.
0:21:59 > 0:22:04Gaz Fountain is in charge of preparing them before they can be refitted.
0:22:04 > 0:22:05You all right, boys?
0:22:05 > 0:22:12Double the size of standard fuel tanks, the Chinooks exact range is a closely-guarded secret.
0:22:15 > 0:22:22Each tank is lined with a large rubber bag, that is divided by baffles into five sections.
0:22:22 > 0:22:27These stop the fuel swilling back and forward when the aircraft climbs or dives.
0:22:29 > 0:22:33And today, one of the fuel pipes inside this tank needs replacing,
0:22:33 > 0:22:36so Gaz will have to crawl inside to sort it out.
0:22:36 > 0:22:41It's not a nice job and breathing in aircraft fuel vapour can be deadly,
0:22:41 > 0:22:45so the site's fire service is on standby, in case things go wrong.
0:22:45 > 0:22:50Hopefully, I've got this mask on, so I won't be able to smell a thing, but it does smell pretty, er,
0:22:50 > 0:22:55imagine being at a petrol pump, filling your car up - it's ten times worse, basically.
0:22:55 > 0:22:59It smells nice for a while, but, no, it's not the best smell in the world.
0:22:59 > 0:23:03We've got this equipment here, which the fireman have provided,
0:23:03 > 0:23:07forced oxygen, they do all their checks before I go in, anyway.
0:23:07 > 0:23:09- All right, buddy?- Let's do it.
0:23:09 > 0:23:12I've got a first aid kit, with general first aid equipment.
0:23:12 > 0:23:16We also have an oxygen bottle just in case he collapses in there.
0:23:16 > 0:23:19We keep that handy. A gas monitor, which is in the tank
0:23:19 > 0:23:21at the moment, that's monitoring the levels inside.
0:23:21 > 0:23:23And we've also brought along this
0:23:23 > 0:23:29little electrical cotton saw. We will try and take him out manually
0:23:29 > 0:23:32and if we can't, absolute last case scenario,
0:23:32 > 0:23:36we will hack away at this carbon fibre chassis to get him out.
0:23:38 > 0:23:44To stop the fumes from building up dangerously, a second hatch is opened at the other end of the tank.
0:23:59 > 0:24:04Gaz will have to be careful, as the tank is packed full of delicate fittings.
0:24:09 > 0:24:15The cramped conditions and vapours mean it's only safe for him to stay inside for 20 minutes at a time.
0:24:35 > 0:24:37- Backtrack. - See you at the other end.- OK.
0:24:47 > 0:24:48Head clear.
0:25:01 > 0:25:04Toasty... Very toasty!
0:25:09 > 0:25:14With Gaz's new fuel pipe installed, the aircraft's tanks are ready to be fitted.
0:25:15 > 0:25:20You've obviously got a very, very close fitting tank and you've got areas like very delicate strings,
0:25:20 > 0:25:28beams, IFIS beams that it mounts on, and the guys have actually got be careful they don't damage anything.
0:25:28 > 0:25:33This is probably one of the most time consuming and awkward jobs within the tank section.
0:25:33 > 0:25:40It's very easy to cause damage, so it requires a large team of guys and a lot of careful supervision.
0:25:42 > 0:25:46A tense moment for the whole team - and Gaz, in particular.
0:25:58 > 0:26:00Stop, you need to go down a touch.
0:26:00 > 0:26:05Down, down... Down about half an inch.
0:26:05 > 0:26:12Where the bag tank is supported inside by para chord strings. If they were to be sheared,
0:26:12 > 0:26:16which they could do by just touching the structure, the tank would have to be reworked,
0:26:16 > 0:26:20the tank would have to come back off and the strings would be replaced.
0:26:20 > 0:26:25You're looking at a couple of hundred man hours of work, clearly a lot of time, effort and money, to boot.
0:26:25 > 0:26:28Down. Down.
0:26:28 > 0:26:31It's a very delicate operation. Once it's in position,
0:26:31 > 0:26:35they've got the laborious task of bolting it up, which will then take
0:26:35 > 0:26:39a further five or six hours to get the tank installed, so it's a long process.
0:26:39 > 0:26:43OK, I think we need to give the guys a bit of breathing space now.
0:26:43 > 0:26:48It's at a point where it's make or break with getting the tank fitted.
0:26:50 > 0:26:51Stop!
0:26:53 > 0:26:58With the fuel tanks almost in place, Gaz can finally go home.
0:26:58 > 0:27:04That's me done and dusted. Probably going to just shoot off. The lads will meet us down the pub
0:27:04 > 0:27:08for a quick half, then get a good night's kip, ready for tomorrow. Long day again.
0:27:08 > 0:27:11I start in the dark and then come back and it's dark again,
0:27:11 > 0:27:15so not much goes on, really, feel a bit like a vampire.
0:27:15 > 0:27:19This is my first contract away since we've had our little nipper.
0:27:19 > 0:27:23It's the longest period of time away from my partner and kids, so...
0:27:26 > 0:27:31Like Gaz, most of the Chinook workforce have been specially recruited because of their expertise
0:27:31 > 0:27:36and that can mean working and living away from home.
0:27:36 > 0:27:38They come in after work and we talk about
0:27:38 > 0:27:40our grandchildren, who are four and five,
0:27:40 > 0:27:43and they tell us what their children did at the weekend.
0:27:43 > 0:27:47I suppose it makes them feel that their families are a bit nearer.
0:27:49 > 0:27:52It can be tough. I live 100 miles away.
0:27:52 > 0:27:55Basically, work and live for each weekend.
0:28:08 > 0:28:10Home sweet home.
0:28:10 > 0:28:15It's a little bit on the old chilly side, but the radiators soon warm that up.
0:28:19 > 0:28:22Right, I'm having a brew. See you later, lads.
0:28:41 > 0:28:46At the company's Farnborough HQ, over 2,000 scientists and researchers
0:28:46 > 0:28:49are tackling complex engineering problems,
0:28:49 > 0:28:53from the vastness of space, to sub-atomic particles.
0:29:04 > 0:29:07Thrusters are being developed, which it is hoped can propel
0:29:07 > 0:29:09space craft to the outer limits of the solar system.
0:29:09 > 0:29:15Nano-materials are being created that could change the way we manufacture everyday objects.
0:29:16 > 0:29:23Flight simulators are blurring the line between reality and computer-generated fantasy.
0:29:27 > 0:29:30And the performance and durability of cutting-edge equipment
0:29:30 > 0:29:34is being tested under the most extreme conditions.
0:29:42 > 0:29:47And it's here that an established military device is being developed for civilian use.
0:29:47 > 0:29:51So, it's quite simple, that's battery levels, video signal,
0:29:51 > 0:29:56video signal level there, which is useful. Obviously you've got a video channel.
0:29:59 > 0:30:03To expand this area of the business and build on the UK robotic team,
0:30:03 > 0:30:08the company needed to seek out some of the world's top robotic talent.
0:30:27 > 0:30:323,000 miles away from their UK HQ, in a sleepy suburb of Massachusetts,
0:30:32 > 0:30:36is the company's robotic division of North America.
0:30:39 > 0:30:42The wars in Afghanistan and Iraq are forcing engineers here
0:30:42 > 0:30:48to continually redesign their robots to deal with the latest threats.
0:30:48 > 0:30:49Firing.
0:30:51 > 0:30:54To date, 3000 Talon robots have been sent to Afghanistan
0:30:54 > 0:30:58and the Middle East, to help in the fight against roadside bombs.
0:30:58 > 0:31:01Our defence correspondent Caroline Wyatt has been talking
0:31:01 > 0:31:05to the men and women who risk their lives to save others.
0:31:07 > 0:31:12- REPORTER:- The single biggest killer of British troops in Helmand - the roadside bomb.
0:31:12 > 0:31:16Some 80% of British deaths at the hands of the Taliban are down to these -
0:31:16 > 0:31:19improvised explosive devices, or IEDs.
0:31:21 > 0:31:26Talon robots are used to reduce the risk to soldiers' lives.
0:31:26 > 0:31:29When cell phones and garage door openers
0:31:29 > 0:31:33created a command-detonated IED explosion,
0:31:33 > 0:31:38service members needed to go with a robotic piece of equipment,
0:31:38 > 0:31:42rather than going up by hand to dismantle the roadside bomb.
0:31:42 > 0:31:48Here, the teams produce an army of up to 100 robots every single month.
0:31:48 > 0:31:53- We need to get the guys lined up on that and get the kits onto the floor.- Absolutely.
0:31:53 > 0:31:55And be able to go from there, so...
0:31:56 > 0:31:58Derek Daly is in charge of the production line.
0:31:59 > 0:32:06We keep a reminder on our manufacturing floor here of exactly why we come to work everyday.
0:32:06 > 0:32:12This is an inspiration for us all, because obviously without this tool
0:32:12 > 0:32:17that would have meant that either a first responder and or soldier would have had to suit up and go
0:32:17 > 0:32:21down-range and deal with the threat, with potential loss of life or limb.
0:32:21 > 0:32:25This particular system is obviously scrap, but wherever we can,
0:32:25 > 0:32:31if we can repair and or save any of the materials from this to go into another robot to help
0:32:31 > 0:32:34repair another robot and get that back into the fight, we do that too.
0:32:36 > 0:32:40A couple of systems here that have genuine Iraqi sand on board.
0:32:40 > 0:32:45They're back for an overhaul. They'll get refurbished a bit, get cleaned up and get ready to go.
0:32:45 > 0:32:52And we also have to demilitarise any systems that get damaged by IEDs and the like.
0:32:56 > 0:33:01In this factory, specialists modify the robots for the specific job they'll be asked to do.
0:33:07 > 0:33:10Talons are built to be repaired in battle,
0:33:10 > 0:33:15so their major parts can be removed quickly using fast release pins.
0:33:18 > 0:33:22The robots enable soldiers to keep a safe distance,
0:33:22 > 0:33:2412,000 metres away, from explosive devices.
0:33:30 > 0:33:34There's a misconception about the use of robots on the battlefield.
0:33:34 > 0:33:38there are no autonomous robots on it, making their own decisions.
0:33:38 > 0:33:43They are human-operated machines, where the human decides
0:33:43 > 0:33:46where it goes, how fast it goes, what it does when it gets there.
0:33:46 > 0:33:48It allows a soldier on the battlefield
0:33:48 > 0:33:51to have an arm that is a mile long.
0:33:53 > 0:33:55Most of Talon's design specifications
0:33:55 > 0:34:01are a closely guarded secret, but their electric motors are powerful enough to pull a small car.
0:34:04 > 0:34:10They're equipped with up to four hi-spec cameras, allowing their operators a 360 degree view.
0:34:10 > 0:34:14And with infrared and night vision, Talons can see in the dark.
0:34:15 > 0:34:18Our robots own the night.
0:34:18 > 0:34:25They are silent stalkers and they see in the dark, so the vision systems are hugely important,
0:34:25 > 0:34:31that they are capable of seeing better than humans in the dark.
0:34:31 > 0:34:36The Talon uses a manoeuvrable gripper and arm to perform its tasks.
0:34:36 > 0:34:40A key design feature is that it can be replaced quickly and easily.
0:34:40 > 0:34:43New arms are attached to the robot in less than 20 minutes,
0:34:43 > 0:34:47because that arm is what gets blown up many, many, many times.
0:34:50 > 0:34:52We want an expendable hand.
0:34:57 > 0:35:00But these robots are not just used on the battlefield.
0:35:00 > 0:35:04They can be modified to enter other deadly environments.
0:35:04 > 0:35:09Jen Pagani is a sensor specialist, who has worked with robots for six years.
0:35:11 > 0:35:16She's currently adapting them to be used by civilian rescue services.
0:35:16 > 0:35:19This quick release rack has an array of detection instruments.
0:35:19 > 0:35:23One of the sensors is toxic industrial chemical detector.
0:35:23 > 0:35:28Another sensor is a radiation detector and then we have a detection instrument
0:35:28 > 0:35:34that is a confined space gas monitor so it will detect combustible gases and other gas-type threats.
0:35:34 > 0:35:39We also have a temperature sensor on this specific robot, as well.
0:35:39 > 0:35:40Thank you.
0:35:41 > 0:35:44We're just going to verify all of the detection instruments
0:35:44 > 0:35:49are communicating back to the operator control unit. Test one.
0:35:49 > 0:35:51BLEEPING
0:35:51 > 0:35:54- Communications check.- Check.
0:35:54 > 0:35:57- Clear check.- Check.
0:35:57 > 0:36:00The gases Talon detects are so deadly, Jen must use
0:36:00 > 0:36:05a safe chemical substitute, to check its sensors are working.
0:36:05 > 0:36:11- Communications check.- Check. - Clear.- Clear.- OK.
0:36:14 > 0:36:18Jen has been working with her colleagues in the UK on this new project.
0:36:18 > 0:36:21It will tell you chlorine, it will tell you carbon dioxide,
0:36:21 > 0:36:24but it'll also tell you your combustible limits, as well.
0:36:24 > 0:36:28Could we put a different sensor with it or would that be complicated?
0:36:28 > 0:36:32We'll get that right over to you and test it out.
0:36:32 > 0:36:35It would be great to hear feedback of which sensor they like better.
0:36:35 > 0:36:39- OK, I'll let you know how we get on when we get it. - Thanks, Rob, talk to you soon.
0:36:46 > 0:36:50This work means Talon robots are now being deployed on the streets of the UK.
0:36:52 > 0:36:59In London, a specialist team are already on 24-hour standby to be called to industrial fires.
0:37:00 > 0:37:03The idea is that we're a hazardous materials response team,
0:37:03 > 0:37:09so that if the fire brigade encounters a situation where any hazardous materials are involved,
0:37:09 > 0:37:13we can give them a stand-off to keep their guys safe, by deploying robotic vehicles.
0:37:17 > 0:37:18Talon and its big brother Bison
0:37:18 > 0:37:21are operated from a custom-fitted vehicle.
0:37:29 > 0:37:32So, this is the command centre of the van, so we can record
0:37:32 > 0:37:36all the video feeds from all the robots, including the van cameras,
0:37:36 > 0:37:40and everything that's going on automatically for forensic evidence,
0:37:40 > 0:37:43if the fire brigade needs it at a later date.
0:37:45 > 0:37:48If this London experiment works, we could see Talon robots
0:37:48 > 0:37:52dealing with deadly chemical incidents across the whole of the country.
0:37:56 > 0:38:01We're basically on a monthly contract where we could get called out any time of day, 24 hours a day.
0:38:01 > 0:38:07I'm part of the team that's on call, so I have to keep my mobile switched on and stay off the beer!
0:38:11 > 0:38:17Just like Rob, Jen just can't stop thinking about robots.
0:38:17 > 0:38:20I have been continuing my education at night,
0:38:20 > 0:38:26so within a month or two, I'll have my Masters in Mechanical Engineering.
0:38:26 > 0:38:32Everyone thinks that I'm an ultimate geek, you know. "The robotics engineer"!
0:38:32 > 0:38:34Isn't geek in now, I think?
0:38:34 > 0:38:37Is it cool to be a geek yet? I don't know.
0:38:42 > 0:38:46We all make fun of each other, really, in terms of the people who work at QinetiQ.
0:38:46 > 0:38:49We're all fairly technical
0:38:49 > 0:38:52and we've all got to be secretive about what we do,
0:38:52 > 0:38:54so we're all nerds at heart,
0:38:54 > 0:39:00we all grew up studying science and technology, so we were always the geeks at school, but trying
0:39:00 > 0:39:04to make up for it by drumming in a band and things like that, you know.
0:39:04 > 0:39:08Tuesday nights are normally our band practice nights, I'm in a band outside of work.
0:39:08 > 0:39:12There's a load of guys from QinetiQ who got together
0:39:12 > 0:39:15and formed a six-piece party band called Surrender Dorothy.
0:39:15 > 0:39:20We play all sorts really, but we try and play the covers that people want to hear.
0:39:20 > 0:39:23With the combined brain power of six of the company's graduates,
0:39:23 > 0:39:26this is quite possibly Britain's brainiest band!
0:39:26 > 0:39:30# Play that funky music, white boy
0:39:31 > 0:39:36# Play that funky music right
0:39:36 > 0:39:40# Play that funky music, white boy
0:39:40 > 0:39:42# Lay down and boogie
0:39:42 > 0:39:47# And play that funky music till you die... #
0:39:48 > 0:39:51For Si Jones and the Chinook team, social lives have been put on hold.
0:39:52 > 0:39:56It's too early. Holly appreciates the company first thing,
0:39:56 > 0:40:00but even she goes straight back to bed, so the rest of the house is in darkness.
0:40:02 > 0:40:06Sarah sort of rolls over when I get up and then straight back to sleep.
0:40:06 > 0:40:09It's the school holidays. I don't think anyone will surface before 9am.
0:40:09 > 0:40:13I'll have done three hours work by the time they get up.
0:40:13 > 0:40:17It's an early start, but you just get on with it.
0:40:23 > 0:40:29All the team are keen to work around the clock to get the Chinooks into service as quickly as possible.
0:40:29 > 0:40:33The task managers, which are like the main supervisors on the aircraft,
0:40:33 > 0:40:37they start shift an hour before me.
0:40:37 > 0:40:43So, a good friend of mine, Bryan, he will be getting up about 4.30am, leaving at 5am to be in for 6am.
0:40:43 > 0:40:48I normally start for 7am and then he'll work through till handover's complete at 7pm,
0:40:48 > 0:40:53so they're doing 13-hour days, plus travelling as well, and the technicians are doing
0:40:53 > 0:40:56much the same, 12-hour shifts, a lot of hours put in by a lot of people.
0:41:08 > 0:41:13Today, the team are about to tackle a really critical part of the refit.
0:41:14 > 0:41:19Everyone is feeling the pressure and there is no room for error.
0:41:19 > 0:41:25Divided into two shifts, day and night, this is a 24/7 operation.
0:41:27 > 0:41:30The second pedal box co-pilot went in last night.
0:41:30 > 0:41:35There's a couple of bits and pieces to wrap up on that to allow the interconnect rods
0:41:35 > 0:41:41between co-pilot's and pilot's pedal boxes to be fitted and 2,028 connections were also completed.
0:41:41 > 0:41:46- The hoist we talked about yesterday, did that go through QA OK? - I haven't spoken to the guys.
0:41:46 > 0:41:50Can we find that out? If it does, we need to get the de-graph guys
0:41:50 > 0:41:51lined up to come and have a look.
0:41:51 > 0:41:54We'll have to have a look to see and get that sorted.
0:41:54 > 0:41:58With almost all the flight system wiring replaced,
0:41:58 > 0:42:02the interior work can begin. First, the communications instruments can be fitted.
0:42:02 > 0:42:04- Paul, how you doing? - Yeah, good thanks.
0:42:04 > 0:42:07Just an update on the AV bay. How we getting on with pitostatics?
0:42:07 > 0:42:13Pitostatics, we're nearly in. We've got this lot up here to do, about half a day to do that.
0:42:13 > 0:42:20We're about 95% done on the connections, it's just the gap on the corner where they come in.
0:42:20 > 0:42:22That's a fairly big old connection.
0:42:22 > 0:42:25Rest of the stuff we've shrunk down, done the floor, so...
0:42:25 > 0:42:28And as soon as that's finished, we'll get the shelves in.
0:42:28 > 0:42:31The cockpit instruments mirror each other.
0:42:31 > 0:42:36one set for the pilot and another for the co-pilot, mean either can fly the aircraft.
0:42:36 > 0:42:38We're putting these in now
0:42:38 > 0:42:41just to trial fit, to make sure all the plugs reach,
0:42:41 > 0:42:43that they've got the right plugs on
0:42:43 > 0:42:46or that the right instruments have been supplied.
0:42:46 > 0:42:50The instruments will be powered up and tested independently.
0:42:51 > 0:42:54With the comms and flight instruments in place,
0:42:54 > 0:42:59the complete electrical system needs testing, luckily, not by hand.
0:42:59 > 0:43:06This custom-built machine analyses over 20,000 wires and flags up any faults it finds.
0:43:06 > 0:43:10It should take about two minutes to do all the pins,
0:43:10 > 0:43:12which is about 2,600 odd.
0:43:12 > 0:43:17Each click you can hear is the pulses going down.
0:43:17 > 0:43:22At the moment, fingers crossed, we've got no errors apparent. It's all good.
0:43:22 > 0:43:26The DTMCO tester was originally designed for drive-in movie theatres.
0:43:26 > 0:43:31I think it was such a clever bit of kit for testing wiring,
0:43:31 > 0:43:36it's been developed into aircraft use now and is used extensively across the aircraft industry.
0:43:36 > 0:43:41It's not just military aircraft, I think Airbus and all that sort of stuff use it.
0:43:41 > 0:43:45It's an automatic way of checking what is a huge amount of wiring on an aircraft very quickly.
0:43:45 > 0:43:50With any luck, it will just be one more 82 P7
0:43:50 > 0:43:54- and the probe, which we'll flag up, and that'll be us.- Brilliant.
0:43:56 > 0:44:00The Chinook re-fit is one of the company's highest-profile projects
0:44:00 > 0:44:05and Chief Executive Leo Quinn takes a close interest.
0:44:05 > 0:44:07This looks so much more advanced now.
0:44:07 > 0:44:12It's amazing what's happened in the last two or three months. It doesn't look like the same helicopter.
0:44:14 > 0:44:19All the flight controls are now in, all the flying control build up, all through the closet now is done.
0:44:19 > 0:44:22I think we're looking at getting the rigging started,
0:44:22 > 0:44:24possibly on night shift tonight.
0:44:24 > 0:44:28'The pressure on these guys at this moment of time is tremendous.
0:44:28 > 0:44:33'They're working 24/7, and, with that sort of pressure,
0:44:33 > 0:44:35'it's important that we strike a sense of balance'
0:44:35 > 0:44:40and it doesn't go so far we end up with unnecessary accidents
0:44:40 > 0:44:43or people are put under too much strain and pressure.
0:44:43 > 0:44:46So it's really important to deliver on the Chinook helicopters,
0:44:46 > 0:44:53to deliver a safe and healthy environment and also to make sure that people do get some rest.
0:45:00 > 0:45:05But throughout the project, all the team have been acutely aware of just how important their work is.
0:45:07 > 0:45:11This has been the bloodiest month for NATO forces in Afghanistan,
0:45:11 > 0:45:15leading to questions, not just in Britain, over whether the sacrifices are worth it.
0:45:15 > 0:45:18As the death toll rises, the government here has come under
0:45:18 > 0:45:24increasing pressure over resources and equipment for the British troops fighting in Afghanistan.
0:45:24 > 0:45:26The pressure levels here are huge.
0:45:26 > 0:45:30I go home after a 12-hour day and I'll wake up at 3.00am thinking about the aircraft.
0:45:30 > 0:45:35That's not normal for a job. There's so much going on in your head. There's so much information there.
0:45:35 > 0:45:38And that is pressure. That's hard work.
0:45:38 > 0:45:42We know what we've got to do. We know what we've got to deliver.
0:45:42 > 0:45:44If you take a couple of days off for the weekend,
0:45:44 > 0:45:47come Sunday night, you know you're going to be out of the loop.
0:45:47 > 0:45:49Two days is a long time in here.
0:45:49 > 0:45:53In two days, we're achieving, what, 48 hours-worth of work.
0:45:53 > 0:45:57It's a 24/7 environment, so in any normal environment
0:45:57 > 0:46:00that's a week's worth of work happened in those two days you've been off.
0:46:00 > 0:46:04So coming in at 6.00am on a Monday morning, so much could have changed.
0:46:04 > 0:46:07So many problems could have developed, or you could have
0:46:07 > 0:46:09achieved a lot. The pressure's there.
0:46:27 > 0:46:32With the clock ticking, the aircraft is ready for its blades to be fitted.
0:46:34 > 0:46:40It's a delicate job - each blade costs up to £150,000.
0:46:40 > 0:46:44This is the last stage of the build that could really jeopardise delivery.
0:46:45 > 0:46:48Lift up square to start with, yeah?
0:46:48 > 0:46:49We'll be going straight up.
0:46:49 > 0:46:55As we get to well clear of the staging, we'll get the nod from Brian that we're clear of the staging.
0:46:55 > 0:46:57I want you then to walk the blade in.
0:46:57 > 0:47:01- Bri, do you want to receive the blade coming in this way?- That's fine.
0:47:01 > 0:47:06Once Brian's got a firm hold on this, you'll then be able to release that and go to the centre section.
0:47:06 > 0:47:10You'll possibly need to do some jiggling when you get it up there.
0:47:22 > 0:47:23Walk it round to him.
0:47:26 > 0:47:28Rotor brake's off, Bri.
0:47:33 > 0:47:39Basically, the guys are about to align the actual blade root tip into the housing.
0:47:39 > 0:47:41And then the big silver portion you can see,
0:47:41 > 0:47:45that's the blade pin, the pin that holds the rotor blade on.
0:47:45 > 0:47:51This is obviously a tricky moment now, getting it all aligned, and then the blade will slot into the housing.
0:47:51 > 0:47:56See the lines, literally, above and below, in line with the sling,
0:47:56 > 0:48:00that's the centre of gravity of the blade, so we know exactly where to put it on there.
0:48:00 > 0:48:03Too far either way, it wouldn't sit square and wouldn't fit.
0:48:06 > 0:48:11Now they're just wiggling it, to align all the seats of the blade pin.
0:48:11 > 0:48:14These rotor blades are big, heavy bits of kit,
0:48:14 > 0:48:21on average, 380lbs each in weight, so heavy blades. It's quite a time-consuming task.
0:48:23 > 0:48:24On now.
0:48:26 > 0:48:29Does it need to come down a touch more now, Bri?
0:48:30 > 0:48:31OK, come out of that.
0:48:33 > 0:48:35What blade's next?
0:48:35 > 0:48:38You have got...green. Shout when you're ready, Bri.
0:48:40 > 0:48:44Working as a team is crucial to get this job right.
0:48:57 > 0:49:01The blade-lifting crane can't move, so the aircraft is turned around
0:49:01 > 0:49:03before the front blades are fitted.
0:49:03 > 0:49:07But with a 100-metre turning circle, it's not a simple task.
0:49:27 > 0:49:30The nature and size of the blades, as you can see, it's a big sweep.
0:49:30 > 0:49:35You've got to be very careful, because obviously if you hit a blade on staging or whatever,
0:49:35 > 0:49:37they're made of composites, so they'll damage.
0:49:37 > 0:49:39They are very tough blades.
0:49:39 > 0:49:44They're designed to withstand bullet rounds, but we're not meant to be dinking them into anything,
0:49:44 > 0:49:46so a lot of care is taken when we move them.
0:50:01 > 0:50:06Most helicopters use a vertical tail rotor to stop the body of the aircraft spinning.
0:50:06 > 0:50:10Instead, Chinooks have two sets of main blades.
0:50:10 > 0:50:17The blades interweave, but are attached by a drive shaft and timed so they don't swing into each other.
0:50:17 > 0:50:21To make the aircraft stable, if one tries to spin clockwise
0:50:21 > 0:50:24and the other anti-clockwise, it will balance each other out.
0:50:24 > 0:50:29So forward and aft heads, one going one way and one going the other and it just balances out.
0:50:29 > 0:50:36This means a Chinook's centre of gravity is larger, making them more stable, so they can lift more.
0:50:36 > 0:50:43The aircraft weighs over ten tonnes and it will pick up about ten tonnes, so about 20 tons of lift is a lot.
0:50:43 > 0:50:47But at the end of the day, each one of these is the same as an aerofoil on an aircraft,
0:50:47 > 0:50:54like a normal wing, and you've got six wings effectively, so they'll generate a huge amount of lift.
0:50:55 > 0:51:00With its blades fitted, the Chinook will enter its final phase of safety checks.
0:51:00 > 0:51:03Then it will face its greatest challenge -
0:51:03 > 0:51:04will it fly?
0:51:17 > 0:51:22Finally, after ten months, Aircraft Four's refit is complete.
0:51:24 > 0:51:29It's been kitted out to precise RAF specifications,
0:51:29 > 0:51:32ready to move troops and equipment across the battlefield.
0:51:32 > 0:51:37And now, it's about to be put to the ultimate test -
0:51:37 > 0:51:41its first takeoff and flight.
0:51:41 > 0:51:43We're doing a before flight servicing.
0:51:43 > 0:51:47You don't miss anything out then, so everything gets checked
0:51:47 > 0:51:49before it's ready to go out onto the line.
0:51:49 > 0:51:54I'll be at the top, checking the lag dampers on the rotor heads,
0:51:54 > 0:51:57just checking the irons, just a general inspection.
0:51:57 > 0:51:59Make sure they are clean and undamaged.
0:51:59 > 0:52:02As I'm looking in, I'm just making sure there's nothing
0:52:02 > 0:52:06that can obstruct, there's no leaks from these here,
0:52:06 > 0:52:11which are the brake cables, and make sure it all looks good, basically, nothing's interfering.
0:52:11 > 0:52:16Obviously, the environment we're in now is a flight environment, so the aircraft's going to be
0:52:16 > 0:52:20going for a flight, so if anything spotted, we can prevent an accident.
0:52:20 > 0:52:23There's people's lives at stake. It's going to be the air crew.
0:52:23 > 0:52:27It's a big machine to be flying around in if something gets missed.
0:52:27 > 0:52:30I'm quite nervous. This is my first proper servicing.
0:52:30 > 0:52:34I've only just been trained up to do this, so quite nervous.
0:52:49 > 0:52:54Everyone on the Chinook project knows their skills and efforts are about to be put to the test.
0:52:55 > 0:52:58Once you see it flying, you look up and see it and think,
0:52:58 > 0:53:01"I had a part in that. Some of my work's flying out there".
0:53:01 > 0:53:03Yeah, it's good. At the end of the day,
0:53:03 > 0:53:07it's a little bit of self-satisfaction in the job you do,
0:53:07 > 0:53:10what you're putting together and the quality of the job.
0:53:10 > 0:53:13Being ex-service, I understand where they're going to
0:53:13 > 0:53:16and, obviously, the importance of them and how much they're needed.
0:53:16 > 0:53:21So, yeah, in a way it'll be good to see them out there actually doing what they've been built for.
0:53:26 > 0:53:30And for Si Jones, this is the most important day of the year.
0:53:33 > 0:53:37For the delivery of Aircraft Four, it's one of the most important days,
0:53:37 > 0:53:42because this is the day we prove the aircraft flies and we've actually achieved the goal of the reversion.
0:53:42 > 0:53:48All the hard work that's gone on over the last many months has obviously culminated in actually getting
0:53:48 > 0:53:52this aircraft in the air and making it a safe and airworthy aircraft. That's the key.
0:53:52 > 0:53:56It'll be good to see it in the air - the culmination of a lot of hard work.
0:53:59 > 0:54:03The pilots and ground crew have spent hours meticulously planning the test flight.
0:54:04 > 0:54:05I'll just keep an eye open
0:54:05 > 0:54:11for any torque fluctuations or any problems on the PTIT.
0:54:11 > 0:54:15I'll keep an eye on the instruments. You do control and I'll do engines.
0:54:15 > 0:54:17OK. And if there's a problem, just say "abort"
0:54:17 > 0:54:22- and rather than slam the controls down, I'll just ease them down.- OK.
0:54:22 > 0:54:25If we're going to have a problem, I'd like to have it at six inches,
0:54:25 > 0:54:27not 10-15 feet. It's just much easier.
0:54:47 > 0:54:52It's taken hundreds of people almost a year to rebuild,
0:54:52 > 0:54:56and now the aircraft is in the hands of just two men.
0:54:59 > 0:55:04All day, I've been going through what if scenarios and thinking about
0:55:04 > 0:55:09"OK, what if this happens, what if that fails, what have I got to do if I see this?"
0:55:09 > 0:55:15Ordinarily on a typical flight, you don't typically do that until you sit in the airplane.
0:55:15 > 0:55:19But when you have a first flight, first programme, I start thinking about that very early.
0:55:19 > 0:55:25I was a US Marine for 23 years, retired, was in the first Gulf War,
0:55:25 > 0:55:29actually with a ground unit. I know exactly who the customer is.
0:55:29 > 0:55:32The customer is the young enlisted man, the young officer
0:55:32 > 0:55:36who's leading foot patrols, who's on a truck tour or a truck patrol.
0:55:36 > 0:55:40Getting him off those roads and up in a helicopter moving
0:55:40 > 0:55:43from point A to point B is absolutely the most important thing.
0:55:43 > 0:55:48I'm really proud to be part of the process that's getting these aircraft
0:55:48 > 0:55:52there as quickly as possible, in the best possible condition they can be in.
0:56:29 > 0:56:34Batteries on, APU is off, compass is set two zero zero.
0:56:34 > 0:56:38OK, one-zero-one-two is set and I have two-one-zero.
0:56:47 > 0:56:49OK, I have the first brake check.
0:56:52 > 0:56:54Power's coming in now.
0:57:02 > 0:57:04There's no going back now.
0:57:26 > 0:57:29The quality and the level of work put in by the guys is superb.
0:57:29 > 0:57:33A lot of dedication from the ground crew, air crew and the whole team.
0:57:33 > 0:57:36If there'd been any real problems, it would have been on the ground
0:57:36 > 0:57:39straight away, so it seems to be going well.
0:57:46 > 0:57:50With its first flight a success, this Chinook will now face
0:57:50 > 0:57:54a full month of further testing, before being ready for active duty.
0:57:54 > 0:57:58But for Britain's Secret Engineers, the clock is still ticking.
0:57:58 > 0:58:02Tomorrow, they'll begin work as usual,
0:58:02 > 0:58:07ensuring that the next helicopters are delivered to the frontline as quickly as possible.
0:58:36 > 0:58:39Subtitles by Red Bee Media Ltd
0:58:39 > 0:58:42E-mail subtitling@bbc.co.uk