Fonic Post Production is proud to announce its collaboration with Mattel in restoring the original 1983 pilot episode of Thomas the Tank Engine, bringing new life to a historic children’s television series.

Originally created as a proof-of-concept by Britt Allcroft and Clearwater Films, the pilot episode had remained unseen and untouched for over four decades. The rediscovery was made by Thomas & Friends series producer Ian McCue, who unearthed the 35mm film reels deep in the Mattel archives. “We uncovered film cans containing small, warped rolls of trims,” McCue told BBC News. “Elastic bands had deteriorated, leaving sticky residue. Significant restoration was needed to clean and scan the film in 4K.” Using the original script, the footage was meticulously stitched together to reconstruct the pilot as closely as possible.

Alongside the 35mm film, a sound effects and a voice-over track were also found. McCue was delighted to discover that the voice-over reel featured the voice synonymous to the original series, Ringo Starr himself, rather than a temporary placeholder recording. The only missing element was the music. To complete the restoration, McCue contacted Mike O’Donnell, co-composer of Thomas the Tank Engine’s iconic theme, who created a bespoke score for the pilot.

Christopher Swaine, who has edited sound for Thomas & Friends since 2010, led the audio assembly: “The original 35mm magnetic SFX track and Ringo Stars voice over were in pretty good condition. Mattel had digitised the reels and a rough sound-scape had been created. Using a variety of software and propriety assets, developed by Fonic over the years, we were able to enhance any areas that had degraded over time.”

Only a few new effects—such as the sound of a collapsing mine—were added, carefully crafted to match the original series’ aesthetic. Fonic also enriched the mix with subtle details, including children’s voices in the background and the ominous caw of a crow. Since Fonic is more accustomed to the soundscapes of later seasons, preserving the subtle but distinct character of the original series was essential. Swaine concluded: “Mike O’Donnell’s new score complemented the episode perfectly, and of course, working with Ringo Starr’s narration was a special highlight.”

Since its debut in 1984, Thomas the Tank Engine & friends—later renamed Thomas & Friends—has produced over 500 episodes, becoming one of the world’s most beloved children’s series. The restored pilot has already received enthusiastic responses from fans, some of whom have contacted Fonic with questions about the soundtrack. “We weren’t surprised to hear from fans,” said Barnaby Templer, Director of Fonic. “This restoration connects people to the magic of Sodor’s earliest days and celebrates the timeless storytelling that continues to resonate.”

Roberto Stanichi, Global Head of Mattel’s Infant and Preschool division, added: “The series has brought joy to generations, sharing timeless stories and valuable life lessons. This restoration honors that legacy beautifully.”

Fonic is honoured to have played a vital role in reviving this historic pilot. With 2025 marking the 80th anniversary of Reverend Wilbert Awdry’s creation of Thomas the Tank Engine, this restoration serves as a heartfelt tribute to a legacy that continues to inspire generations.