It's the moment of truth ... watch Rachael do the one thing she said she'd never do: wear a revealing Dancing with the Stars dress!

After Rachael promises to face her fear and wear a Dancing with the Stars dress, the show's costume designer gets to work on this glamorous creation! See how Randall Christensen gets the dress in shape from the sketch to sequins ... in just 65 hours!

What’s it like to wear those tiny *Dancing with the Stars* costumes? Former contestant Melissa Joan Hart gives Rach the lo-down on those sexy outfits!

Rachael was surprised to get a viewer e-mail from Dancing with the Stars costume designer Randall Christensen, who had issues with some of Rachael's comments about the dresses he designs for the show. Rachael explained that she's a huge fan of the show, but would never do the tango or a foxtrot because the costumes are too revealing. But after that on-air explanation prompted a second e-mail from Randall, Rachael decides to give him a call to make amends directly. Randall says he'll accept her apology under one condition: a promise from Rach to wear one of his dresses designed specifically for her! Will she do it?

In the show's five seasons, Rachael has never received an e-mail from a viewer like this! Wait 'til you hear who sent it and why Rachael is apologizing on air!