Build for Off Road Season 2 Episode 5

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Transcript

00:00combination of jeep and rock bouncer now the reason it doesn't look like that is because it's

00:05just the frame last time we worked on this vehicle this is exactly what we worked on we basically got

00:11the drivetrain mocked up underneath the hood which is a monster six four hemi we love that

00:15and then did all the frame modifications to basically clear that engine and all the suspension

00:20that we have planned for this so before we put the body back on here and start chopping it up

00:25to fit a set of monster wheels and tires we're going to basically turn this into a complete

00:31rolling chassis that's step one so we're not starting by cutting something up for the first

00:36time we're actually going to put something together that feels weird down down down six four going down

00:43down down down six foot going down now it's stuck there we go that's my one up up up six

00:56bolt installed whenever you're moving an entire drivetrain like this around the shop it's great

01:03to have some type of engine lifting device or leveler like we have here at the front makes

01:07lifting the modern engines a lot easier but it's always a good idea just to keep a set of ratchet

01:11straps around because you can hook the back of the transmission and you actually use the ratcheting

01:15mechanism of the strap actually raise and lower it we recently picked up a bunch of these for the shop

01:20these are weathertech ratchet straps they have a working limit of 600 pounds so i don't need to

01:26worry about the weight of just the back of this transmission and they'll work great just securing

01:30cargo when we're out on the trail and stuff they have these cool little s hooks that have these little

01:34keepers on them that way you make sure they don't slip off and they come in a pack of two so when you

01:39buy them you're going to get two so they're just handy to have so if you're looking for some ratchet

01:42straps go ahead and look up these weathertech straps you'll never have too many ratchet straps

01:46that's a promise i make to you now that the engine transmission is in place as we talked about

01:51before when we mocked it up we've offset this entire package over to one side and now we can

01:56start working with our transfer case there's tons of transfer case options out there but when you're

02:01talking about hardcore heavy duty off-road what you really want is a full gear case that can handle

02:07the abuse and the power that we're going to throw at it and that's exactly what we have for this project

02:12this is set up for 14 10 cvs so monster u-joints up here at the transfer case which is perfect so now

02:19the transmission's in place i'm going to go ahead and mock up our transfer case get it set to the

02:24correct drop mark it for the studs and then we can basically mock into place because i need to build

02:29a custom transmission mount for the back of this transmission because you know custom that's what

02:34we do here there's no kits in this shop just like that boom mount next step in our rolling chassis is

02:47going to be to get the axles underneath of it now i said from the very beginning the plan here is jeep

02:52slash rock bouncer and we talk about rock bouncer obviously we're going to talk about monster big heavy

02:58axles and that's exactly what we have here this is a 40 spline 14 bolt rear and then we have a 40

03:06spline front dana 60. now i'm sure you're looking at these things and you're thinking those things

03:11look massive and they are we're talking a four inch axle tube and a giant knuckle on the end but the

03:19reason that we chose this particular front axle is because we plan to run a very specific axle shaft

03:27it's over there now the axle that i'm referring to is this bad boy right here now this is what is

03:34referred to as a big bell rcv now we're going to get to why we're using these in a second but we first

03:40need to talk about why are we going to put rcvs in anything i get asked all the time by people when

03:46i'm out on the trail and they see my rigs like why should i swap out my u-joints for a set of rcvs now

03:51i looked over the entire shop to try to find a set of axles with u-joints in them and honestly

03:56unfortunately i don't have any i've kind of thrown them all away but i do have this example

03:59right here this is a short side of a drive shaft and this is what you would normally see inside the

04:05knuckle of your axle shaft a u-joint a universal joint the problem is that it has four points of

04:11contact between essentially your carrier and the tire and wheel and when you turn this when you're

04:18off-road it doesn't keep flowing in a constant motion because those four points of contact if you

04:23actually saw this in uh like high-speed camera you'd see it actually almost work in an oblong

04:29movement that's why when you're on the trail and your tires start to spin in the front of your vehicle

04:34and often you'll see those vehicles the tires will start hopping up and down like this that's caused by

04:39the oscillation inside this u-joint inside an rcv is what's called a constant velocity joint we now have

04:46six points of contact throughout that entire turning circle and when the joint turns or the star on the

04:52inside turns it smooths out that motion so what happens is you have a smoother output of power

04:58down to the tire and wheel and i'm sure you kind of figured out by now that we're talking about

05:02breaking parts anytime you are jarring a suspension component or a driveline component that's when it

05:08breaks so if we can smooth out that action there's less chance that it's going to break the good news is

05:13is that if it breaks if you have an rcv you've got a lifetime warranty for your application so this

05:20is a jeep jl set of rcvs very popular application you can see a big giant cv joint at the end this is

05:26going to be warrantied for up to a 43 inch tall tire in your vehicle another option would be to

05:32step up to a set of one tons this is for an 05 and up dana 60 super duty very popular upgrade this is

05:37warrantied up to a set of 47s what we're running as i said before is this 40 spline big bell this is the

05:46back daddy of them all the biggest one they make there is no limit on tire size or horsepower for

05:52this bad boy right here so like i said from the very beginning we're building that jeep

05:56slash rock bouncer this is it but the best news is is no matter which set of rcvs you choose for

06:02your project it truly is a buy once cry once scenario because not only are they warrantied

06:09for life and built in the usa they are the strongest axles on the planet oh okay so that cleared now we

06:20got to come off this look at that right there

06:26this shaft combination is all 43 40 but if you're looking for the ultimate upgrade rcv offers

06:41all of their shaft combinations available in 300m material making them incredibly strong boom installated

06:56today in the shop we're working on our ultimate two-door jk and we're building a pretty serious

07:09throw down suspension to go with these monster axles but this is a perfect time to talk about probably one

07:15of the most asked questions i get when it comes to any type of off-road fabrication and that is when

07:21should i mig weld something versus tig weld something there are some very specific times

07:30when we would tig weld versus mig weld but a lot of times in at least in the world of off-road fabrication

07:36it comes down to personal preference but i thought i'd go over a couple of reasons why you would switch

07:41between the two forms of welding in your shop so first we'll talk about mig welding mig welding is

07:46officially known as gas metal arc welding uh obviously we've covered this a lot you push that

07:51trigger the wire then comes out electricity is transferred from the contact tip to the wire

07:57when the wire meets the workpiece a short arc is created and that creates a arc which then creates

08:03the molten puddle and then the wire is fed from the machine down into the molten puddle that's your

08:07filler material now in most fab shops like i have here you're going to have a machine that has a set

08:13wire feed speed you set up the machine and the wire comes out if we were operating in a heavy

08:18fabrication environment like ship building or iron working you can step up to a more professional

08:24machine like an aesop warrior now when it comes to tig welding or gas tungsten arc welding it's a

08:31little bit different because now what we're doing is the arc is being created uh being jumped between the

08:37tungsten and the workpiece and i'm going to be feeding the filler wire or filler material with my spare

08:43hand uh the difference between the two is that i now have full control over how much filler how fast

08:49the filler is fed into the joint and also the amperage of the machine because i actually control

08:54the amperage output at the end of the piece of tungsten by a foot pedal on the floor so when would

09:01you choose them and why would you jump back and forth well this is a perfect example right here this

09:06is a bracket right here has a whole bunch of mig welding on it this is for the suspension on this jeep jk

09:12and this is a perfect example of when mig welding works great it's fast it's quick it's strong it's

09:18fine but this little captured nut plate that we're going to add to hold the bolt keep it from turning

09:23if we come in here and mig weld it we could do that but it's so small it is better for us to

09:29tig weld it and i'll show you why

09:34you can see on a joint like this where we just want to basically lock this washer into place

09:39using the tig welder ends up with a much cleaner and much more low profile weld than if we went in

09:45and mig welded it if we make welded this edge material onto this base material considering how

09:49thick this base material is we'd end up with a really fat weld that might cause undercut on the

09:54top of this washer and also wouldn't look very good another time where you see a lot of people switch

10:00from mig welding to tig welding believe it or not is on sheet metal

10:03you can see down here where i tig welded the exact same butt joint on this 18 gauge

10:13i was able to essentially melt this mig welding tack that i had started with and basically draw it

10:18across the entire joint all the way down only having to add a very small amount of filler

10:23and i have a good fusion weld this right here honestly is ready for a little bit of metal finishing

10:28and you are ready to go from there so it removes a step in the process which is why you see a lot

10:34of high-end sheet metal fabricators will prep their joints and tig weld them instead of mig welding but

10:41you can see the benefits of having both machines at your fingertips in the shop at any given time which

10:47is why it's great to have a multi-process machine like the esob rebel now this is actually the rebel acdc

10:54so not only can it mig weld it can stick weld it can tig weld it can also ac tig so i can do things

11:01like aluminum and most importantly it's equipped with a cool mini too so i have a water cooled torch

11:07so i have an incredibly small torch to fit into tight places one machine to tackle any job in the shop

11:16before we sling the front axle underneath the frame i went ahead and tacked on these shock towers

11:22now when i'm building custom suspension like this on an off-road vehicle i like to build it at full

11:26compression so that means the suspension is fully compressed and the axle is basically at full

11:30bump that's where you're going to have any interference issues when it comes to vehicles

11:34like this now that these are tacked in place we'll get the front axle underneath there and then we'll

11:38start figuring out some suspension links

12:01when you're choosing shocks for a project like this rock bouncer slash jk there's lots of different

12:08options now i always have thought that when we're dealing with rock bouncers you can get incredibly

12:14complicated when it comes to the shocks you can have coilovers and bypasses and uh three tube bypasses

12:21five tube bypasses but i don't really think you need that because rock bouncing is kind of like a drag

12:26race versus desert racing is kind of like a marathon so for this vehicle what we decided to choose is a set of

12:33internal bypass shocks what that means is that we have full adjustment of compression and rebound

12:39right on the reservoir and what that allows us to do is fine tune how the shock reacts whether we're

12:44on or off-road when you're mounting your shocks you really should plan to upgrade the fasteners as well now

12:51arp makes fasteners any size any length that you can imagine and they are perfect for an application

12:59like this these shocks are going to see a lot of abuse off-road and all that abuse

13:03transitions through the upper and lower shock bolt arp bolts are 20 stronger than grade 8 they're 100

13:11made in the usa and they're available in either a black oxide or stainless finish the threads are rolled

13:19after heat treat which helps the strength stay in that fastener after it's been made it's a perfect

13:26upgrade for your project when you have a critical fastener like these shock bolts while we're back

13:31here at the corner i think i'll go ahead and start mounting up the brake lines now the jk is a little

13:36bit different than let's say a buggy a buggy we think about running the brake line off the caliper

13:41down the axle tube and maybe up one of the links but because we're going to keep this vehicle just as

13:47much jk as is hardcore off-roader we're going to have hard lines going to all four corners because we're

13:53we're leaving the abs intact so we're going to need good long flex lines for every single corner

13:58because we've got so much wheel travel and whenever i'm looking for custom flex lines i only go to one

14:03place i call crown performance crown performance can make you a flex line any length you want i've

14:09ordered 10 foot long flex lines for projects they are 100 made in the usa they are a multi-layer design

14:17they come in many different colors they are incredibly strong i always tell the story about how

14:22i had a flex line on a project like this and it was attached to the caliper and i was racing in an

14:27ultra four race and a tree root came up and caught the flex line on the axle and when it ripped it off

14:34the flex line didn't fail it actually pulled the banjo bolt right out of the caliper and the flex line

14:39was still good all we had to do was put a new banjo bolt back in and we were back on the trail so that's

14:44how strong these things are now when you're ordering your crown lines make sure to get a hold of crown

14:50performance in california you can talk to all their experts on the phone they'll spec out the

14:55perfect line for you they have a multiple end options if you talk to them you'll get exactly what

15:00you want every single time it's a big tire but i'm strong

15:15with the rolling chassis all mocked up before we start building suspension we want to test fit the

15:19body to make sure everything clears so i'm gonna have ricky go get a jeep body from the shop next door

15:25i'm gonna go grab some lunch one of my pickups of course before i hit the road i want to upgrade

15:30my truck with some parts from weathertech whether it's protecting the outside or the inside there are

15:35no drill mud flaps bolt right on weathertech has you covered let's hit the dirt and put these parts to

15:42the test let's go off-roading brought to you by weathertech driving up the hill but sunny up here

15:55i think the best vehicle for overlanding or you know car camping as we used to call it is full-size

16:03truck i mean the reality is you're not going to hit any super hardcore trails but you got so much room

16:09for your stuff in a full-size truck you got a bed in the back you can put a rack on the back you can

16:15add a rooftop tent to it still have room for all of your friends and you can get to some of the mild

16:21trails or like just mild off-road sections like we are here and get to some pretty remote campsites

16:27with just a well-built mid-size or full-size pickup truck this is 2010 silver auto it's not a huge

16:36investment they're not very expensive v8 power you know it's ifs so it rides comfortable on the highway

16:41a little bit of a lift and you can fit larger wheels and tires this one's got a locker in the

16:45back and it's open up front so you can do some mild off-roading you're not going to throw it up any

16:50hardcore trails but when you're looking to get into like remote campsites it's got everything that you

16:55need this is why overlanding has become so popular you can get out in nature still have all the

17:02creature comforts of home on your rig and when you need to get back to civilization you just jump in

17:06your truck and head out myself i've got to get back to the shop because i've got a jeep to cut up

17:13jeeps choppy choppy grinding wheels lots of welding

17:19whenever i go out on the trail i always like to carry some type of coolant stop leak and for over 50 years

17:26iron tight all weather seal has been the choice of professionals for coolant stop leaks and that is

17:32because it chemically bonds with the cooling in the system so it stops the current leak as well as stays

17:39in place to stop leaks in the future you don't have to flush the coolant system at all so you simply pour

17:45it in and it works fast the perfect place to use iron tight all weather seal would be if you had a leak

17:51at this junction right here this is a crossover through the intake where the coolant flows sometimes

17:57you end up with a small seat or small leak right here or possibly a pinhole in your radiator you simply

18:03pour it in it acts quickly and you are back on the trail

18:20okay let's get the plum bobs today in the build for off-road shop we're working on our two-door

18:26jk that's a combination between a jeep jk and a rock bouncer and the body is finally

18:32going back onto our rolling chassis but because of our rear shock towers we need to clearance the body

18:38because we've essentially done what's often referred to as frenching in these coilovers on

18:44any jeep the best thing you can do is move the shock into the frame and that's exactly what our

18:50suspension kit did but because of that we need to cut out this wheel well so this shock tower can fit

19:05since we're trying to keep a lot of the creature comforts of this jk even though we've slid a

19:17hardcore off-road chassis underneath it in the old days we just cut these holes in the tub and leave

19:23it we don't want to do that i'm basically going to build some type of interior panel structure to cover

19:27it up we'll seam seal it with some seam sealer just like the rest of the body and then we will coat it

19:32using this duplicolor truck bed coating now you've seen me use this in the past when i've been lining

19:38truck beds but the nice thing about the duplicolor truck bed coating is that it's universal you can

19:44use it anywhere you want this is a perfect application for this it's a durable impact resistant black vinyl

19:52textured polymer so it gives me a really nice textured finish when i'm done it's dry to the touch in about

19:58an hour and then you can actually start moving or using around it in two hours so it's perfect

20:03for an application like this i like it because it's quick easy to apply and made for the diy crowd

20:12whether you're applying it with a roller spray gun or just grabbing an aerosol can it's a great all-around

20:17protective coating that you can use on truck beds inner fenders tailgates bed rails step areas and even

20:25running boards that's a wrap for today on our two-door jk build we got a pile done we now have a full

20:32rolling chassis with the drivetrain in place all of our axles are mocked up as well as our shocks

20:38are locked into position the next thing we're going to do is start working on all the suspension links

20:42we'll cycle the suspension make sure everything looks good and then we'll weld that in for good

20:47next time you see this truck back here in the shop we're going to be dealing with all the things

20:50that are obviously not done we have to do something with these front fenders that new rear opening for

20:55the rear tire is not going to cut it it's got to deal with that and it's going to need something

21:00better than a factory cage for the throw down four wheel and this truck is going to see in its life but

21:04that is next time right now that is a cool looking jeep

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