Thomas soon finds Percy down the line, having broken down while delivering the goods to Farmer McColl. He cries out for Thomas to help, who can only beg him to keep going. Acting as animation supervisor was Jeff Bailey who had held similar positions prior to this production. Spencer draws ahead while Thomas struggles up a hill with his load. Being that she's written screenplays before for this franchise, it's acceptable to a point. He asks Percy to deliver the machines for him while he goes to help Hiro.
Percy shows up and Thomas tells him everything. When he arrives with the Duke and Duchess, Thomas tells him all about Hiro. As Thomas heads to Hiro's Hideout, Spencer appears, wondering why Thomas is not working on his Branch Line. Spencer races along with James and Toby whistling behind him, just as Thomas arrives in front of Spencer, blocking his way. Eventually, Hiro knows he cannot go on and comes to a stop. On top of that the rights to the show transferred to different hands, leading to new ideas being added. However this is the first time Edward, Emily, Spencer, Mavis, Rocky, the Fat Controller and the Duke and Duchess have been individually voiced.
Before he leaves, he talks to Thomas and Percy one more time. Thomas encourages Hiro to puff away from Spencer on his own. It turns out that he is staying for the summer to help the Duke and Duchess build their summer house. Together they chased the mighty Spencer down the track and away from Hiro. Thomas promises that he will find them, but he knows this means he will not be able to help Hiro. The animation was also quite the departure from past features.
One particular engine lives there, named Victor, a kind and enthusiastic engine. At the same time, Gordon sneaks along and delivers more parts for Hiro. This is because both characters were meant to be voiced by Kerry Shale during the original cut. Thomas is beyond grateful and rushes to the Steamworks. That night, Hiro confesses to Thomas that despite everything, he has become very homesick. The Fat Controller tells them that there is a lot of hard work in the morning, so they need to be up early and he tells Thomas not to rush around with heavy trucks for no reason; he wants Really Useful Engines - not Really Broken Engines, which makes Thomas worry more about Hiro.
This scene was never shown in the special. Percy is nervous about Hiro at first, but when Hiro complements him, the two become fast friends. Hiro is very grateful and Thomas heads off, only to run into Spencer who chases him. When Hiro is completed, all of the engines are there and they are amazed at how wonderful he looks. Voicing Spencer is Glenn Wrage. Needless to say, nobody is pleased with the news, especially when Spencer rushes around with his work, teasing the other engines.
All of which give their roles life and something unique to hear. All Hiro needs is one more part before he is completed, so the other engines promise to guard Hiro until Percy delivers the last part. Kevin then drives clumsily over to Thomas and Victor. Then Hiro goes to rescue and clean Spencer. Spencer then challenges Thomas to a race to take place at dawn the next day. Victor tells Thomas he will have something for him later and the two engines rush off.
The engines whistle at him and he whistles back. Spencer ends up under a chute and his funnel gets filled with slate. When Spencer finds James and Toby, the player uses James to chase Spencer away. Then the player plays a game of snap. Thomas and Spencer are coupled to their heavy loads and Edward whistles to announce the start of the race.
Gordon wins the race and who should step out of the was the Fat Controller and the Duke and Duchess. The Fat Controller scolds Spencer for playing around with Percy's mail coaches and orders him to give them back at once. The Duke and Duchess absolutely love their nice new summer house. Much of it is well done when taking it all in. Other places like Tidmouth Sheds, Knapford Station, Gordon's Hill, and Brendam Docks are remarkably kept intact. Hiro is miserable, knowing that he will soon be sent for scrap. Just then, he finds Percy's mail coaches in a siding and whistles loudly believing that Thomas had been hiding them.
As they do so, Spencer watches from the siding, determined to find out what they are up to. There is a new area to be featured though and that's the Sodor Steamworks lead by two new characters. Thomas waits a while before seeing Hiro again. The two are excited, until they suddenly hear Spencer's whistle. Hoping to help Hero, it's up to Thomas and his friends to help put Hiro back together. Percy's mail coaches have mysteriously vanished and nobody can find them.