Parts Used In This Episode
Adventure Off Road Park
Adventure Offroad Park & Nature Center, South Pittsburg, TN
Edwards Ironworkers
55 Ton Edwards Ironworkers with Hydraulic Accessory Pack option; 10 Ton Bender, 15 Ton Horizontal press,Tubing Roller and 40 Ton Shop Press.
ESAB
The Official Welding and Cutting Supplier of Xtreme Off Road, featuring the all-new Rebel 215 Multi-Process Welder
The Industrial Depot
The Industrial Depot - Fasteners, Hardware, and Shop Supplies
Episode Transcript
(ANNOUNCER)>> EVERYONE
AGREES THAT HIGH DOLLAR OFF ROAD RIGS ARE FUN TO
DESIGN AND EVEN MORE FUN TO DRIVE, BUT SOMETIMES
THE FOUNDATION OF A GREAT BUILD IS A LITTLE MORE
MODEST, LIKE THIS 1981 DATSUN PICK UP, WHICH
WE'LL TURN INTO A DEDICATED TRAIL TRUCK
FOR ABOUT $10,000. PLUS WITH HUNDREDS OF
ACRES AND TRAILS RATED FROM MILD TO WILD, THERE'S
SOMETHING FOR EVERYONE AT ONE OF THE NEWEST OFF
ROAD PARKS AROUND.
(IAN)>> THERE'S DEFINITELY A TREND IN THE WORLD OF HARDCORE OFF ROADING, AND EVERYBODY WANTS A ONE OF A KIND RIG. THE PROBLEM IS HOW DO YOU DO THAT ON A BUDGET? I MEAN CUSTOM BUGGIES START AT $25,000, $30,000, CAN EASILY RUN UP TO $100,000 FOR A TRUE ONE OFF BUILD. CAN YOU HAVE A ONE OF A KIND CRAWLER FOR SOMEWHERE
AROUND, I DON'T KNOW, $10,000? WELL YEAH YOU CAN. THE KEY IS TO COME UP WITH A PLAN AND STICK TO IT, AND IT STARTS BY CHOOSING A VEHICLE THAT NOBODY ELSE WOULD PICK. I'VE CHOSEN THE 1981 DATSUN DIESEL PICK UP TRUCK.
WITH A STACK! [ ENGINE REVVING ]
(IAN)>> SO WHY DID I PICK THIS TRUCK? WELL IN ALL HONESTY IT'S JUST DIFFERENT. I REALLY AM GOING TO THROW AWAY MOST OF THE RIG BUT I'M GONNA KEEP A FEW KEY COMPONENTS. I WANT THE BODY STYLE BECAUSE YOU DON'T SEE A LOT OF THEM ON THE TRAIL. I WANT THE DIESEL MOTOR BECAUSE IT'S DEFINITELY SOMETHING DIFFERENT, AND I'M GONNA BE ABLE TO PULL A LITTLE BIT OF EXTRA POWER OUT OF IT. I WILL HAVE TO CONVERT IT OVER TO FOUR WHEEL DRIVE. SO THAT MEANS A NEW TRANSFER CASE, WE'RE GONNA HAVE TO COME UP WITH SOME AXLES, AND I WANT A BIG TIRE.
NO 37'S, NO 35'S, I MEAN ANYONE CAN DO THAT. I'M TALKING 40'S, 40'S ON A DATSUN DIESEL, THAT WILL TURN SOME HEADS.
[ ENGINE REVVING ]
(IAN)>> WITH A PLAN IN PLACE IT'S TIME TO GET THIS TRUCK INTO THE SHOP AND UP ON THE LIFT. FIRST ORDER OF BUSINESS A QUICK INSPECTION UNDERNEATH. THAT'S BAD! I KNEW IT WAS ROUGH BUT NOT THIS ROUGH. HANGER BEARING COMPLETELY SHOT, FRAME ROTTEN ON THE PASSENGER SIDE, LEAKS GALORE, BUT THE BIGGEST PROBLEM IS STILL THAT THIS TRUCK IS TWO WHEEL DRIVE WITH AARMS AND TORSION BARS UP FRONT. THERE IS A SOLID AXLE IN THE REAR, BUT THAT'S NOT GONNA HOLD UP TO 40 INCH OR TALLER TIRES. AND WITH TIRES THAT BIG WE'RE GONNA NEED
TO MAKE SOME ROOM. NOW THAT MEANS THE SHEET METAL HAS TO BE PULLED TO PREP FOR CUTTING.
TO REMOVE THE BED WE'LL USE THE GANTRY CRANE WE RECENTLY BUILT IN THE SHOP. IF YOU'RE WORKING ALONE, HAVING THE CRANE IS GREAT
BECAUSE IT MAKES A ONE MAN JOB OUT OF SOMETHING THAT NORMALLY REQUIRES TWO OR MORE PEOPLE. LOOK AT THAT BATTERY BOX!
BEFORE WE UNBOLT THE FENDERS A COUPLE OF THINGS NEED TO BE PULLED OUT OF THE ENGINE BAY.
THERE WE GO.
ONCE THE GRILL IS OUT THE FENDERS CAN BE REMOVED. THERE IS NO QUESTION THAT THE DIESEL ENGINE UNDERNEATH THE HOOD OF THIS TRUCK IS PRETTY COOL.
I'M SURE SOME OF YOU ARE WONDERING, WHY DID I BUY A TWO WHEEL DRIVE TRUCK TO TURN INTO A LOW BUDGET CRAWLER?
WELL IF I WAS TO JUST BUILD A FULL TUBE CHASSIS RIG AND THEN GO BUY THIS ENGINE AND TRANSMISSION,
WHEN IT CAME TIME TO FINISH OUT THE BUGGY, I WOULD NICKEL AND DIME MYSELF TO DEATH ON LITTLE THINGS LIKE BRAKE BOOSTERS, PEDALS, STEERING
COLUMNS, EVEN HOSES AND ALL THE WIRING. THAT STUFF WILL CHEW INTO YOUR BUDGET FAST. SO IF YOU'RE WORKING ON A BUDGET THIS IS A PERFECT EXAMPLE. START WITH THE MOST COMPLETE VEHICLE YOU CAN FIND, AND THIS IS THE ONE THAT I PICKED UP. I ALREADY TOLD YOU THAT WE'RE WORKING WITH $10,000 DOLLARS FOR THIS RIG AND IT BREAKS DOWN LIKE THIS. FOR THE TRUCK I BUDGETED $1,000 DOLLARS. ANOTHER $1,000 DOLLARS FOR AXLES, $500 BUCKS FOR TRANSFER CASE, $1,600 DOLLARS FOR MY NEW TIRES, $800 BUCKS FOR A NEW SET OF WHEELS, AND ABOUT $1,000 DOLLARS TO FOUR LINK THIS RIG FRONT AND BACK, $800 DOLLARS WORTH OF MISCELLANEOUS STEEL AND TUBING, $1,400 DOLLARS FOR COIL OVERS, ANOTHER $1,400 BUCKS FOR STEERING, AND I'M TOSSING $1,000 DOLLARS
IN THERE TO COVER ALL THE MISCELLANEOUS ODDS AND ENDS. THAT PUTS ME AT $10,500 DOLLARS FOR A FULL ON HARDCORE CRAWLER.
AFTER THE RADIATOR SUPPORT IS UNBOLTED, THE FRONT SUSPENSION IS CUT FROM THE FRAME RAILS AS A COMPLETE UNIT.
[ DRILL SPINNING ] [ HAMMER BANGING ]
(IAN)>> STRUCTURAL STEEL IS CUT AND WELDED ONTO THE BOTTOM OF THE FRAME TO SET THE CHASSIS AT FULL COMPRESSION BELLY HEIGHT WHEN THE TRUCK IS LOWERED
OFF OF THE LIFT. WE'RE USING TWO INCH BY TWO INCH QUARTER WALL STRUCTURAL STEEL, WHICH IS THICK ENOUGH TO SAFELY SUPPORT THE WEIGHT OF THE TRUCK DURING HEAVY FABRICATION WORK. [ GRINDER SPINNING ] [ WELDER CRACKLING ]
(IAN)>> I'M PULLING THE DIESEL FUEL TANK BUT I'M GONNA SAVE IT TO REUSE IT TO HELP WITH THE BUDGET. AND JUST LIKE THE FRONT SUSPENSION, THE ENTIRE REAR SUSPENSION IS CUT OFF IN ONE PIECE AND ROLLED OUT OF THE WAY. [ SAW CUTTING ]
(ANNOUNCER)>> COMING UP WE CUT THROUGH THE RUST, GIVING OUR RIG A NARROWED REAR END AND AN EXOCAGE.
(IAN)>> SO AFTER A PILE OF WORK WE ARE FINALLY AT THE POINT WHERE WE CAN TURN OUR DISCOUNT DATSUN INTO A HARDCORE OFF ROAD CRAWLER. NOW JUST BECAUSE YOU'RE WORKING ON A BUDGET DOESN'T MEAN YOU CAN'T DO SOMETHING CRAZY LIKE CUT THE TRUCK IN HALF AND REBUILD A WHOLE NEW FRAME SECTION. IT'S JUST LABOR AND STEEL AND IT DOESN'T EFFECT THE BUDGET THAT MUCH. THE BEST PART IS BECAUSE I'M STARTING WITH A BLANK SLATE I WILL HAVE A GOOD PERFORMING CHEAP TRUCK. THE START OF THE NEW REAR FRAME SECTION WILL BE MADE WITH TWO BY FOUR QUARTER INCH WALL RECTANGULAR STEEL. IT FITS PERFECTLY INTO THE FACTORY FRAME WITH A LITTLE PERSUASION. I'VE GOT TO TAKE A BREAK, THAT HAMMER'S HEAVY!
[ WELDER CRACKLING ]
(IAN)>> FISH PLATES ARE CUT ON THE IRON WORKER AND WELDED ACROSS THE JOINTS TO ADD STRENGTH. [ WELDER CRACKLING ]
(IAN)>> THE FRAME RAIL ON THE PASSENGER SIDE OF THIS TRUCK IS COMPLETELY ROTTEN FOR THE BACK 10 INCHES PAST OUR CUT. NOW THAT IS WHY I MADE THIS SLEEVE PIECE SO LONG. I WANT TO GET PAST THAT INTO SOME GOOD STEEL.
NOW IF THIS WAS A STREET TRUCK WE WOULD HAVE TO REPAIR THIS FRAME, BASICALLY REPLACE IT, BUT BECAUSE THIS IS A CRAWLER WE DON'T HAVE TO DO THAT.
YOU'VE GOT TO REMEMBER, AN OFF ROAD TRUCK HAS MORE TUBING ADDED TO IT. WE'RE GONNA HAVE A ROCK SLIDER THAT'S GONNA COME OUT DOWN THE ROCKER, TIE INTO THE FRAME BACK AT THE FRONT WHERE THE STEEL IS STILL GOOD.
WE'LL ALSO HAVE AN EXOCAGE THAT GOES AROUND THE WHOLE OUTSIDE. IT WILL BASICALLY STIFFEN UP THIS ENTIRE SECTION OF FRAME. NOT ONLY DOES THIS SAVE US TIME BECAUSE I DON'T HAVE TO REPAIR IT, BUT IT WILL ACTUALLY BE STRONGER IN THE END THAN JUST REPAIRING THIS FRAME RAIL BECAUSE WE'VE GOT AN ENTIRE EXOSKELETON AROUND THE RIG.
THE PASSENGER SIDE IS IN VERY ROUGH SHAPE, AND EVEN WITH THE SLEEVE IN PLACE AND THE FISH PLATE, I NEED TO GET UNDER THE TRUCK AND WELD THE QUARTER INCH SLEEVE TO THE EXISTING TRUCK'S CROSSMEMBER FOR ADDITIONAL STRENGTH. A MOCK UP 14 BOLT AXLE IS DROPPED INTO PLACE ON SOME JACK STANDS JUST OVER 30 INCHES BACK FROM THE TRUCK'S CAB.
ONE INCH SQUARE TUBES ARE CUT 21 INCHES LONG TO SUPPORT THE TUBE THAT WILL BE THE MOUNTING POINT FOR THE REAR SHOCKS. [ WELDER CRACKLING ]
(IAN)>> INCH AND THREE QUARTER DOM IS CUT AND
NOTCHED TO FIT THE REAR CROSSMEMBER, AND THE FRAME EXTENSIONS ARE TRIMMED WITH THE PLASMA. THEN THE TUBE IS FULLY WELDED INTO PLACE. [ WELDER CRACKLING ]
(IAN)>> THERE REALLY ARE NO HARD AND FAST RULES WHEN YOU'RE BACK HALVING A TRUCK TO TURN INTO AN OFF ROAD RIG. IT REALLY DEPENDS ON WHAT TYPE OF SUSPENSION YOU'RE USING.
IF I WAS USING COIL SPRINGS OR LEAF SPRINGS I'D NEED TO HAVE THE FRAME RAIL RELATIVELY CLOSE TO THE AXLE. ANYWHERE BETWEEN 10 TO 12 INCHES, BUT BECAUSE MY PLAN IS TO LINK THE BACK OF THIS TRUCK AND USE EITHER A COIL OVER OR AN AIR SHOCK, I NEED ALMOST
20 INCHES OF ROOM TO FIT THAT SHOCK INTO PLACE. THAT'S WHY I'VE BROUGHT THIS FRAME RAIL ALL THE WAY UP TO THIS HEIGHT. THIS WILL BE THE MOUNTING BAR FOR THOSE SHOCKS WHEN WE FINISH OUT THE REST OF THE SUSPENSION. THE NEXT STEP IS JUST TO DECIDE ARE YOU GOING TO PUT ANY TYPE OF BED ON THE TRUCK, AND I DO WANT TO REUSE SOME OF THE FACTORY SHEET METAL. I THINK IT LOOKS PRETTY COOL, BUT I'LL JUST BE USING THE BED SIDE BECAUSE OBVIOUSLY THE BED FLOOR IS OF NO USE TO ME WITH ALL THIS TUBING COMING UP IN THE AIR. SO THAT IS THE NEXT STEP.
AND WITH THE HUGE AMOUNT OF RUST ON THIS TRUCK, THIS JOB IS PRETTY EASY.
[ DRILL SPINNING ] [ WELDER CRACKLING ] [ SAW CUTTING ]
(IAN)>> WITH THE NARROWED REAR END I'M ONLY
GONNA NEED PART OF THE TAILGATE. THIS TRUCK IS NO LONGER A DATSUN. IT WILL NOW BE AN ATSU!
(ANNOUNCER)>> UP NEXT WE CHECK OUT THE TRAILS AT ONE OF THE EAST COAST'S NEWEST OFF ROAD PARKS.
(IAN)>> WE'RE IN SOUTH PITTSBURG, TENNESSEE, JUST OUTSIDE CHATTANOOGA, AT ADVENTURE OFF ROAD PARK. WE'RE HERE JUST TO GO WHEELING WITH A BUNCH OF GUYS IN THEIR JEEPS BECAUSE TOM FROM TOM'S FOUR BY FOUR SUPERSTORE THOUGHT IT WAS GOOD IDEA TO NOT ONLY OWN AN OFF ROAD STORE, ALSO OWN AN OFF ROAD PARK WHERE EVERYONE CAN BREAK THEIR JUNK. WITHOUT A DOUBT THERE ARE PLENTY OF TRAILS AT AOP JUST WAITING TO PUSH YOUR SKILLS AND YOUR RIG TO THE LIMIT. THE PARK RECENTLY HOSTED A WICKED BOUNTY HILL SERIES WHERE 66 DRIVERS COMPETED FOR THE FASTEST TIME,
AND $25,000 DOLLARS WORTH OF PRIZE MONEY. THERE WAS NO SHORTAGE OF BIG AIR AND BREAKDOWNS.
BUT ADVENTURE OFF ROAD PARK'S 500 ACRES AND 120
TRAILS PROVIDE VISITORS WITH PLENTY OF OFF ROAD OPTIONS, DESIGNED FOR EVERYTHING FROM STOCK VEHICLES AND UTV'S TO HIGH END ROCK BOUNCERS. TRAILS ARE COLOR CODED BASED ON DIFFICULTY.
(THOMAS)> IT'S SET UP JUST LIKE A SKI RESORT, GREENS,
BLUES, BLACKS. EASY TRAILS ARE STOCK VEHICLES. A LOT OF SIDE TO SIDES USE THOSE. THEY USE A LOT OF THE MODERATES AS WELL, BUT SIDES TO SIDES, FOUR WHEELERS. TYPICALLY THE BLUE TRAILS, THE MODERATE TO DIFFICULT, ARE BUILT FOR MOST JEEPS THAT HAVE 35 INCH TIRES, WITH LOCKERS, WITHOUT LOCKERS, DEPENDING ON THE DRIVER ABILITY. HARDCORE TRAILS IS FOR YOUR JEEP. SO THE ONE TONS ALL THE WAY TO BUGGIES, AND WE HAVE EVERY RANGE OUT THERE. EACH CATEGORY HAS A WIDE RANGE. WE DON'T MAKE JUST A SIGNATURE STAMP, THIS IS A GREEN. THEY ALL HAVE A DIFFERENT RANGE.
(IAN)>> THE PARK HAS ALL THE NEEDED AMENITIES, WHETHER YOU'RE TRAVELING FROM JUST AROUND THE CORNER TO ACROSS THE COUNTRY.
(THOMAS)>> WE HAVE A FULL COMMUNITY PAVILION WITH RESTROOMS AND SHOWERS. WE ALSO HAVE R/V HOOK UPS. WE ALSO HAVE A CABIN AS WELL. SO THERE'S ANYTHING YOU WANT TO. THE GREAT THING ABOUT THE PARK IS WE'RE FIVE MINUTES FROM FIVE MAJOR HOTELS.
(IAN)>> WE ARE WHEELING TODAY WITH JEEPS AND WRENCHES, A LOCALLY BASED CLUB THAT ENJOYS GROUP TRAIL RIDES, WORKING ON EACH OTHERS JEEPS, AND INTRODUCING NEW JEEP OWNERS TO THE
OFF ROAD EXPERIENCE. (THOMAS G.)>> WHEN I FIRST GOT INTO OFF ROADING, IT'S VERY INTIMIDATING AT FIRST. SO IT'S NICE TO GO WITH A GROUP OF FOLKS THAT KNOW WHAT THEY'RE DOING. YOU LEARN A LOT WATCHING OTHER PEOPLE WHEEL. AND THEN IF ANYTHING BREAKS, YOU'VE GOT THE MAN POWER TO GET EVERYBODY HOME.
(JESSE)>> THIS IS MY FIRST TIME OUT WITH JEEPS AND WRENCHES. I'M PART OF THE FACEBOOK GROUP, WHICH ANYBODY CAN REQUEST TO BE A PART OF, BUT TODAY IS MY FIRST TIME ACTUALLY MEETING EVERYBODY AND NOTHING BUT GOOD THINGS TO SAY. MY DAD DOESN'T DO CARS, MY MOM DOESN'T DO CARS, NO ONE I KNOW DOES CARS. SO I HAD TO HAVE SOMEBODY TO GIVE ME EITHER GUIDANCE OR SHOW ME HOW THINGS ARE DONE, AND THE JEEP CLUB HAS GIVEN ME THAT, AND IT'S GIVEN ME
MORE THAN THAT TOO.
IT'S A FAMILY OUT HERE. YOU MAY NOT SEE EVERYBODY EVERYDAY BUT IT'S ONE OF THOSE THINGS THAT WHEN YOU COME OUT, EVERYBODY'S GONNA TAKE CARE OF EVERYBODY. (THOMAS G.)>> WE LOVE ADVENTURE OFF ROAD BECAUSE IT'S VERY OPEN. IT'S EASY TO WHEEL, IT'S WELL MARKED. YOU'RE NOT GONNA INTO ANYTHING YOU DON'T EXPECT. SO IF YOU WANTED A NICE, EASY DAY ON THE TRAILS THEY'VE GOT THE EASY TRAILS FOR YOU. IF YOU WANT TO GO THROUGH SOME CARNAGE THEY'VE GOT THE BLACK TRAILS TO CHALLENGE JUST ABOUT ANY RIG OUT THERE.
(IAN)>> TOM PICKETT IS THE ARCHITECT OF ADVENTURE OFF ROAD PARK AND EDDIE MOSELY IS ONE OF THE BUILDERS.
(EDDIE)>> I HAVE CUT A LOT OF THESE TRAILS. A PORTION OF MOST OF THEM. I DON'T EVEN KNOW HOW MANY ARE HERE ANYMORE.
(IAN)>> EDDIE HAS CUT AND WHEELED SOME TOUGH TRAILS,
AND YET HE'S NOT AFRAID TO RUN THEM WITH A RATHER PRISTINE VEHICLE.
(EDDIE)>> THE JEEP I BROUGHT OUT, '07 JK,
BOUGHT IT BRAND NEW. WHEELED IT THE SECOND DAY I HAD IT, HAD IT ON THREE WHEELS THE SECOND DAY I HAD IT. A LOT OF PEOPLE USED TO SAY, WHAT IN THE WORLD ARE YOU DOING WITH A BRAND NEW JEEP OUT HERE IN THE WOODS? NOW YOU SEE THAT ALL THE TIME. I LOVE THE TECHNICAL CHALLENGES THAT WE'VE MANAGED TO BUILD INTO THIS PARK. I DON'T WANT TO JUST GO OUT AND PLAY IN THE MUD OR
SPIN AROUND IN CIRCLES.
I LIKE TO GO GET INTO SOMETHING THAT'S INTERESTING AND CHALLENGING, AND DOESN'T
HAVE TO BREAK MY JEEP TO DO IT.
(IAN)>> SO IF YOU'RE LOOKING FOR A PLACE TO GO WHEELING, TAKE IN AN OFF ROAD RACE, AND ENJOY THE SIGHTS AND SOUNDS OF THE TENNESSEE MOUNTAINS, CHECK OUT ADVENTURE OFF ROAD PARK.
(ANNOUNCER)>> COMING UP, WITH A PILE OF TUBING AND SOME TIME BEHIND THE WELDING TORCH, OUR DISCOUNT DATSUN IS REALLY STARTING TO TAKE SHAPE!
(IAN)>> WE'RE BACK ON XTREME CONVERTING OUR 1981 DIESEL DATSUN INTO A CAPABLE CRAWLER WITH A
BUDGET OF ROUGHLY $10,000, INCLUDING THE TRUCK. [ WELDER CRACKLING ]
(IAN)>> I WANTED TO DO SOME TYPE OF EXOCAGE ON THIS TRUCK BECAUSE CRAMMING A ROLL CAGE INSIDE OF THE CAB IS JUST GONNA MAKE IT REALLY TIGHT, BUT IT'S GONNA KINDA BE A HYBRID TYPE CAGE. IT'LL BE AN EXOCAGE AROUND THE CAB BUT ON THE
BACK OF THE TRUCK ALL THE TUBING WILL BE INSIDE THE SHEET METAL AND USED TO SUPPORT IT. I JUST THINK THAT WILL GIVE IT A LOT CLEANER LOOK. NOW TO DO THIS I DIDN'T RUN A MAIN HOOP AROUND THE TRUCK BECAUSE THIS WILL ALLOW ME TO KEEP THE TUBING A LOT CLOSER TO THE CAB. A HOOP WILL HAVE THE BEND ALL THE WAY UP GOOD AND HIGH. I'LL HAVE TO PUSH THIS TUBING OUT PRETTY FAR. I WANT TO KEEP EVERYTHING NICE AND TIGHT TO RETAIN THE LINES OF THE CAB. SO THE PLAN NOW IS I'M GONNA TAKE THIS PIECE OF TUBING, SET IT IN PLACE WHERE THE MAIN ROOF BAR WILL LAND. THEN I CAN MARK THIS TUBE, REMOVE IT AND NOTCH IT, AND THERE'LL BE A SLUG RIGHT AS WELL AS ANOTHER
TUBE THAT WE'LL WELD IN PLACE TO CREATE THAT MAIN HOOP. IT'LL JUST KEEP EVERYTHING A LOT CLEANER. THE EXOCAGE STARTS WITH BPILLAR TUBES THAT LOCK INTO THE FRAME EXTENSIONS. A PIECE OF INCH AND THREE QUARTER DOM IS SET IN AS A SPACER ALONG WITH A SHORT PIECE OF INCH AND A HALF DOM. THEN THE REAR KICKERS CAN BE WELDED INTO PLACE AND TUBING IS ADDED TO STRENGTHEN UP OUR NEW REAR FRAME SECTION. I THINK RIGHT NOW IS A GOOD TIME TO TAKE A BREAK AND FOR ME TO EXPLAIN EXACTLY WHAT I'VE GOT GOING ON AT THE TOP OF THIS PARTICULAR TUBE BECAUSE I'M SURE SOME OF YOU ARE THINKING IT LOOKS A LITTLE BIT WEIRD. SEE MY PERSONAL OPINION IS EXOCAGES ON CAB TRUCKS, IT'S HARD TO MAKE THEM LOOK COOL. BUT WHAT I THINK LOOKS COOL ON ANY PICK UP TRUCK
IS A CHASE RACK. SO I'M GONNA CREATE AN EXOCAGE THAT HAS THE STYLE OF A CHASE RACK THAT YOU'D SEE ON A PRERUNNER TRUCK. THIS TUBE RIGHT HERE ON BOTH SIDES OF THE TRUCK, THIS IS JUST A SPACER BECAUSE EVENTUALLY THIS TUBE WILL TRAVEL ALL THE WAY DOWN THE ROOF OF THE TRUCK, DOWN THE APILLAR, AND BEHIND THE FENDER, LIKE YOU'D SEE ON A TRADITIONAL EXOCAGE.
THIS KICKER THAT COMES UP THE BACK WILL COME UP AND
TRAVEL ABOVE THIS TUBE, AND THESE LITTLE PIECE OF INCH AND A HALF TUBING, THESE ARE THE SPACERS, AND THAT WILL CREATE THE APPEARANCE OF A TRADITIONAL BAJA BASKET THAT YOU'D SEE ON A CHASE TRUCK. SO YOU COULD STORE STUFF UP THERE. IT'LL BE GOOD AND STRONG BECAUSE THERE WILL BE SLUGS AT ALL THESE JOINTS AND EVENTUALLY I'LL HAVE TO ADD IN SOME MORE CROSS BRACING AND A TUBE ACROSS THE TOP WHEN I REPLACE THIS TUBE WITH THE ACTUAL PIECE. BUT BECAUSE I'M JUST WORKING ON THE BACK HALF OF THE TRUCK, I JUST WANT TO STOP EVERYTHING RIGHT HERE SO WE CAN FINISH OUT THE REST OF THE TUBING IN THE REAR. THAT'S WHY I JUST USED THESE SPACERS FOR NOW. BUT I HAVE TO SAY, SINCE WE DROVE THIS TRUCK INTO THE SHOP THIS MORNING AS A LOWERED MINI TRUCK AND NOW IT'S WELL ON ITS WAY TO BE A ONE OF A KIND TRAIL TRUCK WITH ONLY $120 DOLLARS INVESTED SO FAR, I'M PRETTY HAPPY!
[ WELDER CRACKLING ]
Show Full Transcript
(IAN)>> THERE'S DEFINITELY A TREND IN THE WORLD OF HARDCORE OFF ROADING, AND EVERYBODY WANTS A ONE OF A KIND RIG. THE PROBLEM IS HOW DO YOU DO THAT ON A BUDGET? I MEAN CUSTOM BUGGIES START AT $25,000, $30,000, CAN EASILY RUN UP TO $100,000 FOR A TRUE ONE OFF BUILD. CAN YOU HAVE A ONE OF A KIND CRAWLER FOR SOMEWHERE
AROUND, I DON'T KNOW, $10,000? WELL YEAH YOU CAN. THE KEY IS TO COME UP WITH A PLAN AND STICK TO IT, AND IT STARTS BY CHOOSING A VEHICLE THAT NOBODY ELSE WOULD PICK. I'VE CHOSEN THE 1981 DATSUN DIESEL PICK UP TRUCK.
WITH A STACK! [ ENGINE REVVING ]
(IAN)>> SO WHY DID I PICK THIS TRUCK? WELL IN ALL HONESTY IT'S JUST DIFFERENT. I REALLY AM GOING TO THROW AWAY MOST OF THE RIG BUT I'M GONNA KEEP A FEW KEY COMPONENTS. I WANT THE BODY STYLE BECAUSE YOU DON'T SEE A LOT OF THEM ON THE TRAIL. I WANT THE DIESEL MOTOR BECAUSE IT'S DEFINITELY SOMETHING DIFFERENT, AND I'M GONNA BE ABLE TO PULL A LITTLE BIT OF EXTRA POWER OUT OF IT. I WILL HAVE TO CONVERT IT OVER TO FOUR WHEEL DRIVE. SO THAT MEANS A NEW TRANSFER CASE, WE'RE GONNA HAVE TO COME UP WITH SOME AXLES, AND I WANT A BIG TIRE.
NO 37'S, NO 35'S, I MEAN ANYONE CAN DO THAT. I'M TALKING 40'S, 40'S ON A DATSUN DIESEL, THAT WILL TURN SOME HEADS.
[ ENGINE REVVING ]
(IAN)>> WITH A PLAN IN PLACE IT'S TIME TO GET THIS TRUCK INTO THE SHOP AND UP ON THE LIFT. FIRST ORDER OF BUSINESS A QUICK INSPECTION UNDERNEATH. THAT'S BAD! I KNEW IT WAS ROUGH BUT NOT THIS ROUGH. HANGER BEARING COMPLETELY SHOT, FRAME ROTTEN ON THE PASSENGER SIDE, LEAKS GALORE, BUT THE BIGGEST PROBLEM IS STILL THAT THIS TRUCK IS TWO WHEEL DRIVE WITH AARMS AND TORSION BARS UP FRONT. THERE IS A SOLID AXLE IN THE REAR, BUT THAT'S NOT GONNA HOLD UP TO 40 INCH OR TALLER TIRES. AND WITH TIRES THAT BIG WE'RE GONNA NEED
TO MAKE SOME ROOM. NOW THAT MEANS THE SHEET METAL HAS TO BE PULLED TO PREP FOR CUTTING.
TO REMOVE THE BED WE'LL USE THE GANTRY CRANE WE RECENTLY BUILT IN THE SHOP. IF YOU'RE WORKING ALONE, HAVING THE CRANE IS GREAT
BECAUSE IT MAKES A ONE MAN JOB OUT OF SOMETHING THAT NORMALLY REQUIRES TWO OR MORE PEOPLE. LOOK AT THAT BATTERY BOX!
BEFORE WE UNBOLT THE FENDERS A COUPLE OF THINGS NEED TO BE PULLED OUT OF THE ENGINE BAY.
THERE WE GO.
ONCE THE GRILL IS OUT THE FENDERS CAN BE REMOVED. THERE IS NO QUESTION THAT THE DIESEL ENGINE UNDERNEATH THE HOOD OF THIS TRUCK IS PRETTY COOL.
I'M SURE SOME OF YOU ARE WONDERING, WHY DID I BUY A TWO WHEEL DRIVE TRUCK TO TURN INTO A LOW BUDGET CRAWLER?
WELL IF I WAS TO JUST BUILD A FULL TUBE CHASSIS RIG AND THEN GO BUY THIS ENGINE AND TRANSMISSION,
WHEN IT CAME TIME TO FINISH OUT THE BUGGY, I WOULD NICKEL AND DIME MYSELF TO DEATH ON LITTLE THINGS LIKE BRAKE BOOSTERS, PEDALS, STEERING
COLUMNS, EVEN HOSES AND ALL THE WIRING. THAT STUFF WILL CHEW INTO YOUR BUDGET FAST. SO IF YOU'RE WORKING ON A BUDGET THIS IS A PERFECT EXAMPLE. START WITH THE MOST COMPLETE VEHICLE YOU CAN FIND, AND THIS IS THE ONE THAT I PICKED UP. I ALREADY TOLD YOU THAT WE'RE WORKING WITH $10,000 DOLLARS FOR THIS RIG AND IT BREAKS DOWN LIKE THIS. FOR THE TRUCK I BUDGETED $1,000 DOLLARS. ANOTHER $1,000 DOLLARS FOR AXLES, $500 BUCKS FOR TRANSFER CASE, $1,600 DOLLARS FOR MY NEW TIRES, $800 BUCKS FOR A NEW SET OF WHEELS, AND ABOUT $1,000 DOLLARS TO FOUR LINK THIS RIG FRONT AND BACK, $800 DOLLARS WORTH OF MISCELLANEOUS STEEL AND TUBING, $1,400 DOLLARS FOR COIL OVERS, ANOTHER $1,400 BUCKS FOR STEERING, AND I'M TOSSING $1,000 DOLLARS
IN THERE TO COVER ALL THE MISCELLANEOUS ODDS AND ENDS. THAT PUTS ME AT $10,500 DOLLARS FOR A FULL ON HARDCORE CRAWLER.
AFTER THE RADIATOR SUPPORT IS UNBOLTED, THE FRONT SUSPENSION IS CUT FROM THE FRAME RAILS AS A COMPLETE UNIT.
[ DRILL SPINNING ] [ HAMMER BANGING ]
(IAN)>> STRUCTURAL STEEL IS CUT AND WELDED ONTO THE BOTTOM OF THE FRAME TO SET THE CHASSIS AT FULL COMPRESSION BELLY HEIGHT WHEN THE TRUCK IS LOWERED
OFF OF THE LIFT. WE'RE USING TWO INCH BY TWO INCH QUARTER WALL STRUCTURAL STEEL, WHICH IS THICK ENOUGH TO SAFELY SUPPORT THE WEIGHT OF THE TRUCK DURING HEAVY FABRICATION WORK. [ GRINDER SPINNING ] [ WELDER CRACKLING ]
(IAN)>> I'M PULLING THE DIESEL FUEL TANK BUT I'M GONNA SAVE IT TO REUSE IT TO HELP WITH THE BUDGET. AND JUST LIKE THE FRONT SUSPENSION, THE ENTIRE REAR SUSPENSION IS CUT OFF IN ONE PIECE AND ROLLED OUT OF THE WAY. [ SAW CUTTING ]
(ANNOUNCER)>> COMING UP WE CUT THROUGH THE RUST, GIVING OUR RIG A NARROWED REAR END AND AN EXOCAGE.
(IAN)>> SO AFTER A PILE OF WORK WE ARE FINALLY AT THE POINT WHERE WE CAN TURN OUR DISCOUNT DATSUN INTO A HARDCORE OFF ROAD CRAWLER. NOW JUST BECAUSE YOU'RE WORKING ON A BUDGET DOESN'T MEAN YOU CAN'T DO SOMETHING CRAZY LIKE CUT THE TRUCK IN HALF AND REBUILD A WHOLE NEW FRAME SECTION. IT'S JUST LABOR AND STEEL AND IT DOESN'T EFFECT THE BUDGET THAT MUCH. THE BEST PART IS BECAUSE I'M STARTING WITH A BLANK SLATE I WILL HAVE A GOOD PERFORMING CHEAP TRUCK. THE START OF THE NEW REAR FRAME SECTION WILL BE MADE WITH TWO BY FOUR QUARTER INCH WALL RECTANGULAR STEEL. IT FITS PERFECTLY INTO THE FACTORY FRAME WITH A LITTLE PERSUASION. I'VE GOT TO TAKE A BREAK, THAT HAMMER'S HEAVY!
[ WELDER CRACKLING ]
(IAN)>> FISH PLATES ARE CUT ON THE IRON WORKER AND WELDED ACROSS THE JOINTS TO ADD STRENGTH. [ WELDER CRACKLING ]
(IAN)>> THE FRAME RAIL ON THE PASSENGER SIDE OF THIS TRUCK IS COMPLETELY ROTTEN FOR THE BACK 10 INCHES PAST OUR CUT. NOW THAT IS WHY I MADE THIS SLEEVE PIECE SO LONG. I WANT TO GET PAST THAT INTO SOME GOOD STEEL.
NOW IF THIS WAS A STREET TRUCK WE WOULD HAVE TO REPAIR THIS FRAME, BASICALLY REPLACE IT, BUT BECAUSE THIS IS A CRAWLER WE DON'T HAVE TO DO THAT.
YOU'VE GOT TO REMEMBER, AN OFF ROAD TRUCK HAS MORE TUBING ADDED TO IT. WE'RE GONNA HAVE A ROCK SLIDER THAT'S GONNA COME OUT DOWN THE ROCKER, TIE INTO THE FRAME BACK AT THE FRONT WHERE THE STEEL IS STILL GOOD.
WE'LL ALSO HAVE AN EXOCAGE THAT GOES AROUND THE WHOLE OUTSIDE. IT WILL BASICALLY STIFFEN UP THIS ENTIRE SECTION OF FRAME. NOT ONLY DOES THIS SAVE US TIME BECAUSE I DON'T HAVE TO REPAIR IT, BUT IT WILL ACTUALLY BE STRONGER IN THE END THAN JUST REPAIRING THIS FRAME RAIL BECAUSE WE'VE GOT AN ENTIRE EXOSKELETON AROUND THE RIG.
THE PASSENGER SIDE IS IN VERY ROUGH SHAPE, AND EVEN WITH THE SLEEVE IN PLACE AND THE FISH PLATE, I NEED TO GET UNDER THE TRUCK AND WELD THE QUARTER INCH SLEEVE TO THE EXISTING TRUCK'S CROSSMEMBER FOR ADDITIONAL STRENGTH. A MOCK UP 14 BOLT AXLE IS DROPPED INTO PLACE ON SOME JACK STANDS JUST OVER 30 INCHES BACK FROM THE TRUCK'S CAB.
ONE INCH SQUARE TUBES ARE CUT 21 INCHES LONG TO SUPPORT THE TUBE THAT WILL BE THE MOUNTING POINT FOR THE REAR SHOCKS. [ WELDER CRACKLING ]
(IAN)>> INCH AND THREE QUARTER DOM IS CUT AND
NOTCHED TO FIT THE REAR CROSSMEMBER, AND THE FRAME EXTENSIONS ARE TRIMMED WITH THE PLASMA. THEN THE TUBE IS FULLY WELDED INTO PLACE. [ WELDER CRACKLING ]
(IAN)>> THERE REALLY ARE NO HARD AND FAST RULES WHEN YOU'RE BACK HALVING A TRUCK TO TURN INTO AN OFF ROAD RIG. IT REALLY DEPENDS ON WHAT TYPE OF SUSPENSION YOU'RE USING.
IF I WAS USING COIL SPRINGS OR LEAF SPRINGS I'D NEED TO HAVE THE FRAME RAIL RELATIVELY CLOSE TO THE AXLE. ANYWHERE BETWEEN 10 TO 12 INCHES, BUT BECAUSE MY PLAN IS TO LINK THE BACK OF THIS TRUCK AND USE EITHER A COIL OVER OR AN AIR SHOCK, I NEED ALMOST
20 INCHES OF ROOM TO FIT THAT SHOCK INTO PLACE. THAT'S WHY I'VE BROUGHT THIS FRAME RAIL ALL THE WAY UP TO THIS HEIGHT. THIS WILL BE THE MOUNTING BAR FOR THOSE SHOCKS WHEN WE FINISH OUT THE REST OF THE SUSPENSION. THE NEXT STEP IS JUST TO DECIDE ARE YOU GOING TO PUT ANY TYPE OF BED ON THE TRUCK, AND I DO WANT TO REUSE SOME OF THE FACTORY SHEET METAL. I THINK IT LOOKS PRETTY COOL, BUT I'LL JUST BE USING THE BED SIDE BECAUSE OBVIOUSLY THE BED FLOOR IS OF NO USE TO ME WITH ALL THIS TUBING COMING UP IN THE AIR. SO THAT IS THE NEXT STEP.
AND WITH THE HUGE AMOUNT OF RUST ON THIS TRUCK, THIS JOB IS PRETTY EASY.
[ DRILL SPINNING ] [ WELDER CRACKLING ] [ SAW CUTTING ]
(IAN)>> WITH THE NARROWED REAR END I'M ONLY
GONNA NEED PART OF THE TAILGATE. THIS TRUCK IS NO LONGER A DATSUN. IT WILL NOW BE AN ATSU!
(ANNOUNCER)>> UP NEXT WE CHECK OUT THE TRAILS AT ONE OF THE EAST COAST'S NEWEST OFF ROAD PARKS.
(IAN)>> WE'RE IN SOUTH PITTSBURG, TENNESSEE, JUST OUTSIDE CHATTANOOGA, AT ADVENTURE OFF ROAD PARK. WE'RE HERE JUST TO GO WHEELING WITH A BUNCH OF GUYS IN THEIR JEEPS BECAUSE TOM FROM TOM'S FOUR BY FOUR SUPERSTORE THOUGHT IT WAS GOOD IDEA TO NOT ONLY OWN AN OFF ROAD STORE, ALSO OWN AN OFF ROAD PARK WHERE EVERYONE CAN BREAK THEIR JUNK. WITHOUT A DOUBT THERE ARE PLENTY OF TRAILS AT AOP JUST WAITING TO PUSH YOUR SKILLS AND YOUR RIG TO THE LIMIT. THE PARK RECENTLY HOSTED A WICKED BOUNTY HILL SERIES WHERE 66 DRIVERS COMPETED FOR THE FASTEST TIME,
AND $25,000 DOLLARS WORTH OF PRIZE MONEY. THERE WAS NO SHORTAGE OF BIG AIR AND BREAKDOWNS.
BUT ADVENTURE OFF ROAD PARK'S 500 ACRES AND 120
TRAILS PROVIDE VISITORS WITH PLENTY OF OFF ROAD OPTIONS, DESIGNED FOR EVERYTHING FROM STOCK VEHICLES AND UTV'S TO HIGH END ROCK BOUNCERS. TRAILS ARE COLOR CODED BASED ON DIFFICULTY.
(THOMAS)> IT'S SET UP JUST LIKE A SKI RESORT, GREENS,
BLUES, BLACKS. EASY TRAILS ARE STOCK VEHICLES. A LOT OF SIDE TO SIDES USE THOSE. THEY USE A LOT OF THE MODERATES AS WELL, BUT SIDES TO SIDES, FOUR WHEELERS. TYPICALLY THE BLUE TRAILS, THE MODERATE TO DIFFICULT, ARE BUILT FOR MOST JEEPS THAT HAVE 35 INCH TIRES, WITH LOCKERS, WITHOUT LOCKERS, DEPENDING ON THE DRIVER ABILITY. HARDCORE TRAILS IS FOR YOUR JEEP. SO THE ONE TONS ALL THE WAY TO BUGGIES, AND WE HAVE EVERY RANGE OUT THERE. EACH CATEGORY HAS A WIDE RANGE. WE DON'T MAKE JUST A SIGNATURE STAMP, THIS IS A GREEN. THEY ALL HAVE A DIFFERENT RANGE.
(IAN)>> THE PARK HAS ALL THE NEEDED AMENITIES, WHETHER YOU'RE TRAVELING FROM JUST AROUND THE CORNER TO ACROSS THE COUNTRY.
(THOMAS)>> WE HAVE A FULL COMMUNITY PAVILION WITH RESTROOMS AND SHOWERS. WE ALSO HAVE R/V HOOK UPS. WE ALSO HAVE A CABIN AS WELL. SO THERE'S ANYTHING YOU WANT TO. THE GREAT THING ABOUT THE PARK IS WE'RE FIVE MINUTES FROM FIVE MAJOR HOTELS.
(IAN)>> WE ARE WHEELING TODAY WITH JEEPS AND WRENCHES, A LOCALLY BASED CLUB THAT ENJOYS GROUP TRAIL RIDES, WORKING ON EACH OTHERS JEEPS, AND INTRODUCING NEW JEEP OWNERS TO THE
OFF ROAD EXPERIENCE. (THOMAS G.)>> WHEN I FIRST GOT INTO OFF ROADING, IT'S VERY INTIMIDATING AT FIRST. SO IT'S NICE TO GO WITH A GROUP OF FOLKS THAT KNOW WHAT THEY'RE DOING. YOU LEARN A LOT WATCHING OTHER PEOPLE WHEEL. AND THEN IF ANYTHING BREAKS, YOU'VE GOT THE MAN POWER TO GET EVERYBODY HOME.
(JESSE)>> THIS IS MY FIRST TIME OUT WITH JEEPS AND WRENCHES. I'M PART OF THE FACEBOOK GROUP, WHICH ANYBODY CAN REQUEST TO BE A PART OF, BUT TODAY IS MY FIRST TIME ACTUALLY MEETING EVERYBODY AND NOTHING BUT GOOD THINGS TO SAY. MY DAD DOESN'T DO CARS, MY MOM DOESN'T DO CARS, NO ONE I KNOW DOES CARS. SO I HAD TO HAVE SOMEBODY TO GIVE ME EITHER GUIDANCE OR SHOW ME HOW THINGS ARE DONE, AND THE JEEP CLUB HAS GIVEN ME THAT, AND IT'S GIVEN ME
MORE THAN THAT TOO.
IT'S A FAMILY OUT HERE. YOU MAY NOT SEE EVERYBODY EVERYDAY BUT IT'S ONE OF THOSE THINGS THAT WHEN YOU COME OUT, EVERYBODY'S GONNA TAKE CARE OF EVERYBODY. (THOMAS G.)>> WE LOVE ADVENTURE OFF ROAD BECAUSE IT'S VERY OPEN. IT'S EASY TO WHEEL, IT'S WELL MARKED. YOU'RE NOT GONNA INTO ANYTHING YOU DON'T EXPECT. SO IF YOU WANTED A NICE, EASY DAY ON THE TRAILS THEY'VE GOT THE EASY TRAILS FOR YOU. IF YOU WANT TO GO THROUGH SOME CARNAGE THEY'VE GOT THE BLACK TRAILS TO CHALLENGE JUST ABOUT ANY RIG OUT THERE.
(IAN)>> TOM PICKETT IS THE ARCHITECT OF ADVENTURE OFF ROAD PARK AND EDDIE MOSELY IS ONE OF THE BUILDERS.
(EDDIE)>> I HAVE CUT A LOT OF THESE TRAILS. A PORTION OF MOST OF THEM. I DON'T EVEN KNOW HOW MANY ARE HERE ANYMORE.
(IAN)>> EDDIE HAS CUT AND WHEELED SOME TOUGH TRAILS,
AND YET HE'S NOT AFRAID TO RUN THEM WITH A RATHER PRISTINE VEHICLE.
(EDDIE)>> THE JEEP I BROUGHT OUT, '07 JK,
BOUGHT IT BRAND NEW. WHEELED IT THE SECOND DAY I HAD IT, HAD IT ON THREE WHEELS THE SECOND DAY I HAD IT. A LOT OF PEOPLE USED TO SAY, WHAT IN THE WORLD ARE YOU DOING WITH A BRAND NEW JEEP OUT HERE IN THE WOODS? NOW YOU SEE THAT ALL THE TIME. I LOVE THE TECHNICAL CHALLENGES THAT WE'VE MANAGED TO BUILD INTO THIS PARK. I DON'T WANT TO JUST GO OUT AND PLAY IN THE MUD OR
SPIN AROUND IN CIRCLES.
I LIKE TO GO GET INTO SOMETHING THAT'S INTERESTING AND CHALLENGING, AND DOESN'T
HAVE TO BREAK MY JEEP TO DO IT.
(IAN)>> SO IF YOU'RE LOOKING FOR A PLACE TO GO WHEELING, TAKE IN AN OFF ROAD RACE, AND ENJOY THE SIGHTS AND SOUNDS OF THE TENNESSEE MOUNTAINS, CHECK OUT ADVENTURE OFF ROAD PARK.
(ANNOUNCER)>> COMING UP, WITH A PILE OF TUBING AND SOME TIME BEHIND THE WELDING TORCH, OUR DISCOUNT DATSUN IS REALLY STARTING TO TAKE SHAPE!
(IAN)>> WE'RE BACK ON XTREME CONVERTING OUR 1981 DIESEL DATSUN INTO A CAPABLE CRAWLER WITH A
BUDGET OF ROUGHLY $10,000, INCLUDING THE TRUCK. [ WELDER CRACKLING ]
(IAN)>> I WANTED TO DO SOME TYPE OF EXOCAGE ON THIS TRUCK BECAUSE CRAMMING A ROLL CAGE INSIDE OF THE CAB IS JUST GONNA MAKE IT REALLY TIGHT, BUT IT'S GONNA KINDA BE A HYBRID TYPE CAGE. IT'LL BE AN EXOCAGE AROUND THE CAB BUT ON THE
BACK OF THE TRUCK ALL THE TUBING WILL BE INSIDE THE SHEET METAL AND USED TO SUPPORT IT. I JUST THINK THAT WILL GIVE IT A LOT CLEANER LOOK. NOW TO DO THIS I DIDN'T RUN A MAIN HOOP AROUND THE TRUCK BECAUSE THIS WILL ALLOW ME TO KEEP THE TUBING A LOT CLOSER TO THE CAB. A HOOP WILL HAVE THE BEND ALL THE WAY UP GOOD AND HIGH. I'LL HAVE TO PUSH THIS TUBING OUT PRETTY FAR. I WANT TO KEEP EVERYTHING NICE AND TIGHT TO RETAIN THE LINES OF THE CAB. SO THE PLAN NOW IS I'M GONNA TAKE THIS PIECE OF TUBING, SET IT IN PLACE WHERE THE MAIN ROOF BAR WILL LAND. THEN I CAN MARK THIS TUBE, REMOVE IT AND NOTCH IT, AND THERE'LL BE A SLUG RIGHT AS WELL AS ANOTHER
TUBE THAT WE'LL WELD IN PLACE TO CREATE THAT MAIN HOOP. IT'LL JUST KEEP EVERYTHING A LOT CLEANER. THE EXOCAGE STARTS WITH BPILLAR TUBES THAT LOCK INTO THE FRAME EXTENSIONS. A PIECE OF INCH AND THREE QUARTER DOM IS SET IN AS A SPACER ALONG WITH A SHORT PIECE OF INCH AND A HALF DOM. THEN THE REAR KICKERS CAN BE WELDED INTO PLACE AND TUBING IS ADDED TO STRENGTHEN UP OUR NEW REAR FRAME SECTION. I THINK RIGHT NOW IS A GOOD TIME TO TAKE A BREAK AND FOR ME TO EXPLAIN EXACTLY WHAT I'VE GOT GOING ON AT THE TOP OF THIS PARTICULAR TUBE BECAUSE I'M SURE SOME OF YOU ARE THINKING IT LOOKS A LITTLE BIT WEIRD. SEE MY PERSONAL OPINION IS EXOCAGES ON CAB TRUCKS, IT'S HARD TO MAKE THEM LOOK COOL. BUT WHAT I THINK LOOKS COOL ON ANY PICK UP TRUCK
IS A CHASE RACK. SO I'M GONNA CREATE AN EXOCAGE THAT HAS THE STYLE OF A CHASE RACK THAT YOU'D SEE ON A PRERUNNER TRUCK. THIS TUBE RIGHT HERE ON BOTH SIDES OF THE TRUCK, THIS IS JUST A SPACER BECAUSE EVENTUALLY THIS TUBE WILL TRAVEL ALL THE WAY DOWN THE ROOF OF THE TRUCK, DOWN THE APILLAR, AND BEHIND THE FENDER, LIKE YOU'D SEE ON A TRADITIONAL EXOCAGE.
THIS KICKER THAT COMES UP THE BACK WILL COME UP AND
TRAVEL ABOVE THIS TUBE, AND THESE LITTLE PIECE OF INCH AND A HALF TUBING, THESE ARE THE SPACERS, AND THAT WILL CREATE THE APPEARANCE OF A TRADITIONAL BAJA BASKET THAT YOU'D SEE ON A CHASE TRUCK. SO YOU COULD STORE STUFF UP THERE. IT'LL BE GOOD AND STRONG BECAUSE THERE WILL BE SLUGS AT ALL THESE JOINTS AND EVENTUALLY I'LL HAVE TO ADD IN SOME MORE CROSS BRACING AND A TUBE ACROSS THE TOP WHEN I REPLACE THIS TUBE WITH THE ACTUAL PIECE. BUT BECAUSE I'M JUST WORKING ON THE BACK HALF OF THE TRUCK, I JUST WANT TO STOP EVERYTHING RIGHT HERE SO WE CAN FINISH OUT THE REST OF THE TUBING IN THE REAR. THAT'S WHY I JUST USED THESE SPACERS FOR NOW. BUT I HAVE TO SAY, SINCE WE DROVE THIS TRUCK INTO THE SHOP THIS MORNING AS A LOWERED MINI TRUCK AND NOW IT'S WELL ON ITS WAY TO BE A ONE OF A KIND TRAIL TRUCK WITH ONLY $120 DOLLARS INVESTED SO FAR, I'M PRETTY HAPPY!
[ WELDER CRACKLING ]
