Cop Car Workshop - Season 1

In the first episode, engineering genius John Heussi, finds himself in need of a new riot van. He starts the process by treating his team to a bit of stress relief, otherwise known as beating the living daylights out of an old Riot Van, before throwing himself headlong into a spot of riot training. These ‘research' experiences help him design a new one, and it's just as well because just minutes into its first shift the van is attacked by firework wielding teenagers - hell bent on creating mischief. Throw into the mix a trashed beat car, a forensic accident investigator and crime car damage by a feathered friend and you have entered the world of Cop Car Workshop.

Head of Cheshire Constabulary's Fleet Services, John Heussi, is preparing himself for two weeks of well-earned sunshine and adventure. With 57 builds currently in progress John wants to make sure nothing gets missed and hands over what proves to be a busy fortnight for the team at the Vehicle Maintenance Workshop.

Dave has a BMW X5 armed response vehicle build to oversee and ensure is completed by the time John gets back. He also has to repair the dive team's truck and a crime car damaged during a high-speed chase as well as preparing for a last-minute visit from the local MP.

Will John return to chaos at the Vehicle Maintenance Workshop, or will Dave have it all under control?

The day begins at Cheshire Constabulary's vehicle maintenance unit with Darren discovering a broken key to a gun safe in an armed response vehicle. Meanwhile, Head of Fleet Services, John Heussi, and his team are redesigning the vehicles that transport the dog units, turning a humble Ford Mondeo into a Dog Van.

Cheshire Constabulary's motorbike fleet gets a run out as they escort a 370-ton electrical transformer across the county. Capable of hitting 125mph the fleet struggles with the 10mph top speed of the abnormal load.

The North-West Underwater Search and Marine Unit covers six police forces from the bottom of Scotland to the bottom of North Wales. When their police boat is crushed in an incident, Inspector Dave Corcoran calls on his best mate, John Heussi, to turn what looks like a tug boat into a police vessel. John is only too happy to accept the challenge.

Meanwhile, back at the Vehicle Maintenance Unit, the team have to fix up a beat car whose tyres were slashed whilst on duty, John's favourite vehicle is returned in a less-than-pristine condition, and there's an ongoing investigation into Darren's facial hair.

It's another busy day at Cheshire Constabulary's vehicle maintenance unit as the usual array of bangs, prangs and scrapes present themselves for fixing in order to ensure 96% of the police's fleet are on the road.

John Heussi, Head of Fleet services, is on a mission to redesign the force's beat car, including a newly designed light bar to prevent the amount of speeding tickets posted through his letterbox, and incorporating a loud hailer.

Meanwhile, an old beat car turns up in the middle of a forest in the Czech Republic, but why is it there and how did it get there? And with the imminent opening of the Mersey Gateway, Tracy has her work cut out to provide 670 toll exemption stickers across the fleet.

Head of Cheshire Constabulary's Fleet Services, John Heussi, takes to the track to experience first-hand the force's TPAC (tactical pursuit and containment) manoeuvre. Meanwhile, nine of the fleet's unmarked BMW 330 crime cars have reached the end of the road and Dave has been despatched to ensure replacements are on the way. Back at the vehicle maintenance unit there's a car parking crisis that John and Dave are trying to fix by getting rid of unwanted skips and trailers, which are home to some unusual objects. And emergency repairs are required to get two police scrambler bikes back out on the road.

The rural crime unit of Cheshire Police have requested two 4x4 vehicles to help them scale the steep tracks of the Peak District in order to stamp out farm machinery theft, poaching and environmental damage. They need them as quickly as possible so John Heussi concocts a plot to meet the demand, but he's left with a headache when it doesn't go to plan.

Cheshire Police's specialist off-road motorcyclists join the fight against the illegal and anti-social use of mini-motos and off-road bikes as part of Operation Scrambler. Meanwhile John, Dave and Ros get an excuse to show off their knowledge of the second-hand police car market when end of service vehicles are put up for auction.

It's Friday at the Vehicle Maintenance Unit - or Fat Friday as it's commonly known to those in the workshop. But things haven't got off to a good start. A shortage of staff sees Dave manning the phones, an unpleasant whiff from a Riot Van warrants further investigation and after 105,000 miles on the clock it's game over for a marked Interceptor.

Beneath all the cop car modifications, the Interceptor is a high-performance BMW 330. Having one of these mean machines off the road is a major headache for Sergeant Andy Jones of the Road Policing Unit. Working hard and fast, John Heussi and his team need to be quick off the mark to replace the powerhouse.

It's another day of repairs, rebuilds and write-offs at the Vehicle Maintenance Unit at Cheshire Constabulary.

John Heussi embarks on a complete redesign of Cheshire Constabulary's fleet of outdated forensic vans. Elsewhere, not for the first time, a crime car comes in with a faulty wailer, but the fault remains elusive.

Cheshire Police Sergeant Rob Simpson and PC Rick Walker are responsible for investigating Cheshire's rural crime. They currently cruise up and down dales and through rivers in an ageing 4x4 vehicle. But with their vehicle coming to the end of its life there is increasing pressure to get them a new one.

Meanwhile, the vehicle maintenance unit's Pete Shepley is opening the workshop for the final time in his 42-year career.