Big Rig Ram Diesel Complete

(ANNOUNCER)>> NOTHING BEATS THE FREEDOM OF DRIVING A BIG RIG DOWN THE OPEN ROAD, BUT THIS COMES PRETTY CLOSE. TODAY ON XTREME OFF ROAD WE OUTFIT OUR RAM 2,500 WITH BIG RIG INSPIRED EXHAUST, BUMPERS, AND MORE. PLUS CUSTOM BUILT HEADERS FOR OUR ROCK BOUNCER.

(IAN)>> TODAY IS THE DAY THAT YOU ALWAYS LOOK FORWARD TO WHEN YOU'RE BUILDING A CUSTOM ROCK BUGGY. TODAY WE'RE GONNA TEAR THIS RIG APART AND GET THE CHASSIS READY TO HEAD OUT FOR A CUSTOM POWDER COAT JOB.

BUT BEFORE WE DO THAT WE HAVE A COUPLE MORE ITEMS

THAT WE NEED TO TAKE CARE OF ON THE FABRICATION OF THIS RIG, AND IT'S GONNA START BY BUILDING SOME CUSTOM HEADERS. STARTING WITH A SUMMIT RACING HEADER EXHAUST FLANGE BOLTED ON TO OUR MOCK UP BIG BLOCK, THE PRIMARY TUBE IS BUILT USING SOME TWO INCH 16 GAUGE EXHAUST TUBING.

THEN EACH CYLINDER IS ROUTED TO THE SAME EXIT POINT ON THE CHASSIS USING MORE TWO INCH EXHAUST TUBING.

SINCE THERE'S NOT GONNA BE A FULL EXHAUST ON THIS BUGGY, I'M GONNA BUILD THESE HEADERS AS A MODIFIED SET OF ZOOMIES, WITH EACH PIPE EXITING JUST OUT THE SIDE OF THE CAR WITH SOME COOL TIPS. I'M NOT GONNA FINISH WELD OUR CUSTOM HEADER QUITE YET.

I WANT TO WAIT UNTIL THE ACTUAL MOTOR IS MOUNTED

INSIDE OUR FRESHLY POWDER COATED CHASSIS. I'LL TEST FIT IT, THEN I'LL FINISH WELD IT. THE REASON I WANT TO BUILD IT BEFORE ANY OF THAT HAPPENS IS BECAUSE OF ALL THE TACK WELDING YOU HAVE TO DO WHILE YOU BUILD THE HEADER. I DIDN'T WANT TO RISK DAMAGING OUR CUSTOM POWDER COAT. WHAT I HAVE TO DO NOW IS REMOVE IT FROM THE HEAD, MAKE SURE I CAN EASILY TAKE IT OUT OF THE BUGGY AND PUT IT BACK IN, AND THEN THE HEADERS WILL BE DONE.

OH YEAH! ONE PART OF A ROCK BOUNCER THAT NEEDS TO BE PROTECTED WELL IS THE FUEL CELL. EACH GALLON OF FUEL WEIGHS RIGHT AROUND SIX POUNDS, AND

THAT MEANS INSIDE A TYPICAL CELL THERE CAN BE CLOSE TO

75 POUNDS OF FUEL BEING THROWN AROUND. THAT MUCH WEIGHT HAS TO BE SECURE. WHEN THESE BOUNCERS ARE FLYING THROUGH THE AIR, ALL THE WEIGHT OF THAT FUEL IS SLOSHING INSIDE THAT CELL

AND IT CAN PUT A LOT OF STRESS ON JUST A TAB TYPE MOUNT AND EVEN A SET OF STRAPS. SO THE BEST WAY TO SECURE A FUEL CELL IN A ROCK BOUNCER IS TO FULLY ENCAPSULATE IT IN A BUNCH OF TUBING.

USING INCH AND THREE QUARTER .120 WALL DOM AND THE FUEL CELL MOCKED INTO PLACE ON OUR CHASSIS, WE START BY BUILDING SOME BOTTOM TUBES TO SUPPORT THE CELL. [ welder crackling ]

(IAN)>> OUR REAR BAR IS THEN PUT IN PLACE, AND TUBES ON EITHER SIDE OF OUR 16 GALLON FUEL

CELL SECURE IT TO THE CHASSIS. SO WITH TUBING ON THE BOTTOM OF THE FUEL CELL FRONT AND BACK AND BOTH SIDES, ALL I HAVE LEFT TO DO IS ADD TWO SMALL LITTLE STRAPS ACROSS THE CELL AND IT WILL STAY PUT INSIDE THE CHASSIS AND WE DON'T HAVE TO WORRY ABOUT IT POSSIBLY FAILING IN THE EVENT OF A ROLL OVER. ONE WORD OF ADVICE THOUGH. IF YOU PLAN TO ENCAPSULATE A FUEL CELL LIKE THIS WITH TUBING, MAKE SURE BEFORE YOU WELD IT IN THAT YOU CAN EASILY REMOVE THE FUEL CELL AND PUT IT BACK IN. YOU DON'T WANT TO BASICALLY WELD A CAGE AROUND YOUR FUEL CELL SO TIGHT THAT YOU CAN'T TAKE IT OUT BEFORE YOU POWDER COAT THE CHASSIS. AND THAT'S EXACTLY WHERE I'M OUT RIGHT NOW. IT'S TIME TO GO OVER THIS WHOLE RIG, DO ALL THE FINISH WELDS, DRESS ALL THE TUBING, DISASSEMBLE THE ENTIRE RIG, AND TAKE THIS BUGGY OUT FOR SOME CUSTOM POWDER COATING.

(ANNOUNCER)>> UP NEXT, THE POWER OF A WINCH AND AN AIR COMPRESSOR IN ONE UNIT! PLUS A FULLY FEATURED TUNER FOR OUR RIG!

(IAN)>> WITH ALL OF OUR FABRICATION FINISHED UP ON OUR ROCK BOUNCER, WE'RE GONNA SPEND THE REST OF

TODAY FINISHING UP OUR BIG RIG RAM PROJECT. NOW WE'VE ALREADY TAKEN THIS 2,500 SERIES RAM PICK UP TRUCK AND TREATED IT TO A MILD SUSPENSION LIFT AND A

DUAL REAR WHEEL CONVERSION ALONG WITH A BRAKE UPGRADE. AND TODAY WE'RE GONNA START BY INSTALLING A COMPLETELY NEW EXHAUST SYSTEM. AND NOTHING SAYS BIG RIG MORE THAN A SET OF STACKS IN THE BED OF YOUR PICK UP. NOW THIS COMPLETE KIT IS FROM MBRP, AND IT'S WHAT'S CALLED THEIR SMOKER SERIES. WE OPTED FOR A SEVEN INCH ROUND, 36 INCH

TALL ANGLED CUT STACK. NOW THIS KIT COMES WITH EVERYTHING WE NEED TO DIVERT THE EXHAUST OUT OF OUR DPF FILTER AND UP INTO THE BED OF OUR PICK UP TRUCK. SO WE WILL HAVE TWO FUNCTIONING STACKS IN THE BACK OF OUR TRUCK. THAT SCREAMS BIG RIG RAM. WITH THE FACTORY TAIL PIPE REMOVED, A PIECE OF FLEXIBLE PIPE IS INSTALLED BEHIND THE DIESEL EXHAUST FILTER. AFTER MARKING AND DRILLING A PILOT HOLE THROUGH THE BOTTOM OF THE BED, A FOUR INCH HOLE IS

CUT USING A HOLE SAW. THE FULLY POLISHED STAINLESS STEEL ELBOW IS THEN INSTALLED ALONG WITH THE EXHAUSTY, AND THEN OUR STACKS ARE BOLTED INTO PLACE.

ONE OF THE COOLEST THINGS ABOUT SEMI TRUCKS IS HOW THE BRAKES WORK. THEY USE HEAVY DUTY SPRINGS TO ALWAYS APPLY THE BRAKES ON THE TRUCK. AND THEN WHEN YOU FIRE THE RIG UP, AN AIR COMPRESSOR

WILL BUILD UP AIR PRESSURE TO RELEASE THOSE SPRINGS SO YOU CAN DRIVE DOWN THE ROAD. THAT'S WHY WHEN YOU HEAR A BIG RIG STOP AND PARK,

IT RELEASES ALL THAT AIR. IT GOES PSSSSHHH! AND THAT ACTUALLY APPLIES THE BRAKES. THAT MEANS 18 WHEELERS ALWAYS HAVE SOME TYPE OF ON BOARD AIR AT THEIR DISPOSAL. WE WANTED SOMETHING SIMILAR FOR PROJECT BIG RIG RAM.

ONE OF THE EASIEST WAYS TO ADD ON BOARD AIR IS WITH

ONE OF THESE WARN POWER PLANT SERIES WINCHES. NOW THE BOTTOM HALF OT HE WINCH IS A STANDARD WARN 12,000 POUND WINCH WITH 80 FEET OF THREEEIGHTHS INCH AIRCRAFT CABLE JUST IN CASE WE EVER HAVE TO USE OUR WORK TRUCK FOR WORK. THE TOP HALF HAS AN INTEGRATED SMALL AIR COMPRESSOR. YOU REMOVE A PANEL ON THE SIDE, AND YOU CAN HOOK UP AN AIR HOSE. FLIP A SWITCH ON THE FRONT AND IT WILL USE THE SAME POWER FROM THE BATTERY THAT'S USED TO POWER THE WINCH TO RUN AN AIR COMPRESSOR. AND THAT WAY WE'LL BE ABLE TO AIR UP TIRES OR EVEN RUN SOME AIR TOOLS AROUND THE HOUSE, OR WHEN WE'RE IN THE FIELD. THE DOWNFALL TO THE POWER PLAN IS IT'S A LARGE FRAME. IT'S A BIG BODIED WINCH, AND MOUNTING ON THE FRONT OF A FULL SIZE TRUCK HAS ALWAYS BEEN TRICKY.

BUT BUCK STOP BUMPERS HAS DESIGNED A COMPLETE LINE OF REPLACEMENT BUMPERS FOR A BUNCH OF DIFFERENT FULL SIZE TRUCKS THAT ARE SPECIFICALLY DESIGNED TO HOUSE THE POWER PLANT WINCH.

IT GIVES YOU GOOD ACCESS TO ALL THE CONTROLS AND AN AREA UP TOP SO YOU CAN EASILY HOOK UP THE AIR HOSE. NOW I'VE ALREADY GONE AHEAD AND LOADED UP THESE BUMPERS

WITH SOME LIGHTS THAT WE GOT FROM ORACLE, AND ALL I

HAVE TO DO NOW IS BOLT THEM ONTO OUR TRUCK. THE FACTORY BUMPERS ARE REMOVED FROM THE TRUCK TO EXPOSE THE STOCK FRAME RAIL.

[ air ratchet spinning ]

THE WARN POWER PLANT WINCH DROPS INTO THE WINCH POCKET ON THE FRONT BUMPER, AND THE FAIR LEAD IS BOLTED INTO PLACE. EACH BUCK STOP BUMPER IS BUILT USING A COMBINATION OF QUARTER INCH AND THREESIXTEENTHS INCH STEEL WITH ROLLED UPPER EDGES TO COMPLIMENT THE ROUNDED DESIGN OF MODERN PICK UPS. WE HAD OUR BUMPERS COATED BY STREET WORKS CUSTOM COATINGS WITH AN EXACT PAINT MATCH FOR OUR DODGE BUT IN THE STRENGTH OF A HIGH QUALITY POWDER COAT FINISH. TO FINISH THINGS OFF THE ORACLE ROUND LED LIGHTS ARE MOUNTED USING THE INTEGRATED BUCK STOP MOUNTING BUCKETS AND THE LIGHTS ARE WIRED UP.

(ANNOUNCER)>> UP NEXT, WE'RE ROLLING IN STYLE WITH UPDATED LIGHTING, RETRACTING RUNNING BOARDS, AND MORE!

(IAN)>> WE ARE RIGHT IN THE MIDDLE OF CONVERTING OUR 2013 TRADESMAN PICK UP INTO PROJECT BIG RIG RAM.

NOW IT'S TIME FOR SOME COSMETIC GOODIES. OUT BACK A SET OF LED TAIL LIGHTS THAT WE GOT FROM SUMMIT RACING. UP FRONT, ALSO FROM SUMMIT RACING, A SET OF PROJECTOR BEAM BLACKED OUT HEAD LAMPS AND AN ALL MESH BLACK GRILL. EVEN THOUGH WE ONLY INSTALLED A THREE INCH LIFT ONTO OUR RAM, THAT TRUCK SITS PRETTY HIGH STRAIGHT FROM THE FACTORY. AND CLIMBING INTO AFTER A LONG DAY OF WORK WILL BE A LOT EASIER WITH SOME TYPE OF A STEP. BUT I DON'T WANT TO RUIN THE LINES OF THE TRUCK. I REALLY LIKE HOW HIGH IT SITS AND HOW MEAN IT LOOKS. THAT'S WHERE A SET OF BESTOP POWER BOARDS ARE GOING TO COME INTO PLAY. THEY USE A SMALL ARTICULATING ARM AS WELL AS THESE ELECTRIC MOTORS TO BASICALLY HIDE THE STEP UP BEHIND THE ROCKER PANEL. WHEN YOU OPEN THE DOOR, IT LOWERS IT DOWN SO YOU CAN GET IN THE TRUCK. CLOSE THE DOOR ONCE YOU'RE INSIDE AND IT PULLS IT UP OUT OF VIEW AGAIN. BUT WHAT'S REALLY UNIQUE IS HOW EASY THIS SYSTEM IS TO

INSTALL BECAUSE IT USES WIRELESS TECHNOLOGY. THERE'S JUST A SMALL SENSOR THAT MOUNTS INSIDE EACH DOOR, AND A MAGNET THAT MOUNTS ON THE DOOR JAMB. WHEN THOSE TWO ARE SEPARATED IT SENDS A SIGNAL TO THE WIRELESS CONTROLLER TO LOWER THE STEP DOWN.

NOW THE KIT COMES WITH EVERYTHING WE NEED TO INSTALL IT SPECIFIC FOR OUR DODGE, AND THE FIRST STEP IS PUTTING IN THE SENSORS. EACH SENSOR MOUNTS ONTO THE BPILLAR OF THE TRUCK, AND THE MAGNETS ARE LOCATED ON THE DOORS. THE ARMS MOUNT TO THE INSIDE EDGE OF THE ROCKER PANEL USING NUTSERTS AND AN ANCHORING PLATE. WITH THE FUSE REMOVED FROM THE WIRING HARNESS, THE WIRES ARE HOOKED UP TO THE BATTERY AND RAN DOWN TO THE MOTORS. THE FUSE IS THEN REINSTALLED AND THE SYSTEM IS TESTED.

THE FINAL COSMETIC UPGRADE WE WANT TO MAKE TO OUR BIG RIG RAM IS TO INSTALL THIS 50 INCH BLACK NIGHT LIGHTING LED LIGHT BAR ALONG THE TOP OF OUR WINDSHIELD. NOW IT'S NO SECRET THAT TRUCKERS LOVE TO ADD LIGHTS TO THEIR BIG RIG. SO IT'S GONNA FIT WITH THE THEME OF OUR TRUCK, BUT IT'S ALSO GOING TO BE FUNCTIONAL. THIS LIGHT BAR WILL THROW TONS OF LIGHT OUT THE FRONT OF THE TRUCK WHEN WE'RE HEADING DOWN THOSE DARK WINDING ROADS TO THOSE OFF ROAD PARKS IN

THE MIDDLE OF NOWHERE. NOW NORMALLY INSTALLING A LIGHT BAR THIS BIG ON A BRAND NEW TRUCK LIKE OURS REQUIRES A LOT

OF CUSTOM FABRICATION. BUT THE GUYS AT SOCAL SUPER TRUCKS HAVE SOLVED THAT PROBLEM FOR US. THEY OFFER THESE UNIQUE LED LIGHT BAR BRACKETS SPECIFICALLY FOR THE DODGE RAM TRUCK. THEY'RE FULLY LASER CUT AND THEY'RE ALL TIG WELDED.

THEY'LL ANCHOR IN OFF THE RAIN GUTTERS AND MOUNT THIS BAR RIGHT AT THE TOP OF OUR WINDSHIELD. USING THE SUPPLIED TEMPLATE, THE ROOF MOLDING

IS CUT TO LENGTH. THE ROOF IS DRILLED, AND NUTSERTS ARE INSTALLED. SOME SILICONE WILL HELP THE RUBBER GASKET SEAL, AND THE LIGHT IS INSTALLED ONTO OUR ROOF.

(ANNOUNCER)>> JUST AHEAD A SIDE BY SIDE COMPARISON TO FIND OUT IF WE'VE CAPTURED THAT CLASSIC BIG RIG STYLE. PLUS WE'LL TEST OUR UPGRADED SUSPENSION ON THE ROAD.

(IAN)>> THERE IS NO QUESTION THAT OUR 2,500 RAM TRADESMAN HAS UNDERGONE A SERIOUS TRANSFORMATION. IT'S REALLY STARTING TO LOOK LIKE A BIG RIG TRUCK. NOW THERE'S STILL A FEW THINGS WE WANT TO TAKE CARE OF BEFORE WE TAKE IT OUT ON A TEST DRIVE, AND THESE ITEMS WILL BE TO HELP US USE THE TRUCK FOR WORK HERE AROUND THE XTREME SHOP. IT'S GONNA START BY PULING A LITTLE BIT EXTRA POWER OUT OF OUR DIESEL. AND THE EASIEST WAY TO DO THIS IS GONNA BE WITH A TUNER. WHEN IT COMES TO TUNERS FOR BRAND NEW MODELS OF TRUCKS LIKE OUR RAM, THE GUYS AT BULLY DOG PRIDE THEMSELVES ON HAVING THEIRS AVAILABLE FIRST THANKS TO AN EXTENSIVE R&D DEPARTMENT. FOR OUR RAM WE'RE GONNA USE THE BULLY DOG G/T TUNER. NOW IT DOES MORE THAN JUST ADD THREE DIFFERENT POWER LEVELS THAT WE CAN ADJUST ON THE FLY. IT HAS A SET OF FULLY CUSTOMIZABLE GAUGES THAT ALLOW US TO MONITOR A BUNCH OF DIFFERENT PARTS OF OUR ENGINE WHILE WE'RE DRIVING. IT HAS A DRIVING COACH SET UP INSIDE OF IT THAT'LL HELP US KEEP AN EYE ON OUR FUEL MILEAGE WHILE WE'RE DRIVING THE TRUCK, AND IT HAS FULL DIAGNOSTICS BUILT INTO IT. SO IF WE EVER IN THE FUTURE PITCH UP A TROUBLE CODE IN OUR TRUCK, WE'RE NOT GONNA HAVE TO TAKE IT TO THE DEALER TO HAVE IT CHECKED OUT TO FIND OUT WHAT'S WRONG. THE TUNER PLUGS INTO THE OBD TWO PORT ON THE TRUCK, AND THE WIRE IS ROUTED SECURELY UP TO

THE TOP OF THE DASH. THEN ALL I HAVE TO DO IS FOLLOW THE PROMPTS ON THE G/T TUNER TO INSTALL OUR TUNE INTO THE FACTORY ECU, CHOOSE OUR CUSTOM GAUGE SETUP, AND ADJUST FOR OUR NEW TIRES SIZE. THE LAST TWO ITEMS DEFINITELY HAVE TO DO WITH WORK. IF YOU'VE INSTALLED A LIFT IN YOUR TRUCK AND PLAN TO PULL A TRAILER, YOU HAVE TO HAVE SOME TYPE OF DROP HITCH. I LIKE THESE HEAVY DUTY ALUMINUM UNITS. THEY'RE NICE AND LIGHT WEIGHT, AND KEEP THE TRAILER TUCKED UP NICE AND CLOSE TO THE BACK BUMPER, MAKING IT EASY TO MANEUVER AROUND THE OFF ROAD PARK. FINALLY SOME TYPE OF PROTECTION FOR THE BED WHEN WE'RE HAULING STUFF. I LOOKED AT ALL THE OPTIONS AND I CHOSE ONE OF THESE RUBBER BED MATS. THE COOL THING IS THIS ONE'S ACTUALLY FOR AN '09 TO '11 MEGA CAB, CAUSE THOSE BEDS WERE A LITTLE BIT SHORTER, AND THAT'LL COMPENSATE FOR THE BED SPACE WE LOST WITH OUR EXHAUST STACK COVER.

WITH EVERYTHING FINISHED UP ON PROJECT BIG RIG RAM, LETS COMPARE OUR PICK UP TO AN ACTUAL BIG RIG. OUR AMERICAN FORCE 10 LUG WHEELS LOOK JUST LIKE AN 18 WHEELER, MAYBE EVEN A LITTLE BIT BETTER. TWO SEVEN INCH SMOKER STACKS FROM MBRP, AND JUST ABOVE THE CAB, JUST LIKE THE BIG RIG DOES. THE HEAVY DUTY BUCK STOCK BOSS FRONT BUMPER LOOKS MEAN AND GIVES THE TRUCK AN AGGRESSIVE FRONT END. NOT AS BIG AS A SEMI, BUT STILL PRETTY MENACING TO SEE IN YOUR REAR VIEW MIRROR. AND OF COURSE LIGHTS ACROSS THE ROOF. TRUCKERS LOVE LIGHTS, AND THAT'S WHY WE INSTALLED THIS 50 INCH LED BAR. THE SEMI WILL OBVIOUSLY HAVE A HIGHER TOW RATING THAN OUR TRUCK, BUT OUR DUALLY CONVERSION INCREASED OUR TOWING CAPACITY BY ABOUT 26 PERCENT UP TO JUST OVER 22,000 POUNDS. BEFORE WE TORE THIS TRUCK DOWN, I PUT ABOUT 5,000 MILES ON IT, AND I'M HAPPY TO SAY THAT THE BDS SUSPENSION STILL RIDES JUST LIKE A FACTORY TRUCK. AND NOW WE HAVE A STANCE THAT'S ACCEPTABLE FOR AN XOR SHOP TRUCK. THE FOX SHOCKS DAMPEN THE RIDE EASILY, AND PROGRESSIVE COIL SPRINGS CAN COMPENSATE FOR THE TRANSITION FROM SMOOTH ROAD TO ROUGH ROAD IN AN INSTANT. ONE OF THE NICE THINGS ABOUT HAVING A MANUAL TRANSMISSION IN THIS RIG IS IT WASN'T A BIG DEAL TO NOT CHANGE THE GEAR RATIO WHEN WE UPPED THE TIRE SIZE. A LOT OF THE TIME THE REASON THAT YOU HAVE TO CHANGE THE GEARS IN THE AXLE IS WHEN YOU STEP UP A TIRE SIZE

IS SO THE AUTOMATIC TRANSMISSION ISN'T CONSTANTLY HUNTING FOR THE RIGHT GEAR TO BE IN. BECAUSE I'VE GOT A STICK, I CHOOSE WHAT GEAR I'M IN, I DON'T LET THE TRANSMISSION CHOOSE IT FOR ME.

NOW THE TRUCK ALWAYS HAD A PILE OF TORQUE RIGHT OFF IDLE, AND YOU COULD EASILY PULL AWAY FROM

STOP IN SECOND GEAR. NOW WITH OUR 35 INCH TALL TIRE I'M FINDING I'M JUST PULLING AWAY IN FIRST GEAR, SHIFTS ARE A LITTLE BIT SMOOTHER, THE RPM RANGE IS WORKING WELL. AND I MEAN ALL IN ALL, THIS TRUCK WITH 35'S, IT'S THE PERFECT PACKAGE, PERFECT. I'VE GOT TO SAY, I THINK WE'VE ACHIEVED OUR GOAL. WE TOOK A THREE QUARTER TON PICK UP THAT WAS ALREADY A GREAT TRUCK AND MADE IT BETTER. AND NOW WE'VE GOT RIG THAT'S READY TO WORK, OR TAKE OUR FAVORITE TOYS TO THE TRAIL.