DIY Shop Tools

(ANNOUNCER)>> THERE'S SOME SERIOUS FABRICATION GOING ON IN THE SHOP. TODAY ON XTREME OFF ROAD PROJECT LOCK JAW GOES FROM AN EMPTY FRAME TO A ROLLING CHASSIS. AND WE'LL BUILD A COUPLE OF OVER ENGINEERED TOOLS TO MAKE SUSPENSION WORK A BREEZE. PLUS INTENSE ULTRA FOUR ACTION FROM HOT SPRINGS, ARKANSAS.

(IAN)>> BY THE END OF THE DAY TODAY IN THE XTREME OFF ROAD SHOP WE HAVE A RATHER LOFTY GOAL PLANNED.

WE'RE GONNA HAVE PROJECT LOCKJAW BACK TO A FULL ROLLING CHASSIS. WE'RE GONNA HAVE THE ENGINE IN, TRANSMISSION, TRANSFER CASE, PAINT THE AXLES, MAYBE EVEN PAINT THE FRAME AND HAVE IT SITTING ON SOME TIRES AND WHEELS. MIGHT EVEN DROP THE CAB BACK ON, A HUGE MILESTONE FOR THIS PROJECT.

NOW WHEN YOU'RE BUILDING A RIG LIKE THIS YOU'RE

ALWAYS GOING TO BE USING A BUNCH OF SPECIALIZED TOOLS. AND THAT IS WHERE WE'RE GONNA START TODAY. WE'RE GONNA TAKE A LOOK AT SOME OF THOSE SPECIALIZED TOOLS. BUT NOT TOOLS THAT YOU CAN BUY. WE ARE GONNA BUILD SOME.

THIS AXLE ASSEMBLY STAND HAS BEEN KICKING AROUND THE XTREME SHOP FOR A LONG TIME. SO LONG IN FACT I COULDN'T TELL YOU WHERE I GOT IT. NOW I'VE LOOKED AROUND ONLINE AND I HAVEN'T FOUND

ONE SIMILAR TO THIS FOR SALE. SO TO GET ONE OF THESE IN YOUR SHOP THE BEST

OPTION IS TO BUILD IT. THE GOOD THING IS IF YOU'RE GONNA BUILD IT YOURSELF, YOU CAN MAKE SOME CHANGES TO IMPROVE ON THE DESIGN, AND THAT IS WHAT WE'RE GONNA DO. THE BASIC DESIGN WILL BE SIMILAR WITH TWO SETS OF LEGS IN A "V" AND A CROSS BRACE. UPPERS THAT WILL HOLD THE AXLE HOUSING IN PLACE, BUT I WANT TO ADD AN ADDITIONAL ADJUSTABLE ARM THAT WILL HOLD THE PINION AT AN ANGLE WHILE WORKING ON THE AXLE. THE BOTTOM LEGS ARE CUT FROM SOME TWO BY THREE

RECTANGULAR TUBING QUARTER INCH WALL THICKNESS. I'M USING THIS HEAVY WALLED STEEL TO ADD WEIGHT TO THE BOTTOM OF THE STAND FOR STABILITY. THE CROSS PIECE IS SOME TWO BY TWO OF THE SAME THICKNESS. OUR OLD AXLE STAND IS THREE FEET TALL, A GOOD WORKING HEIGHT WHETHER YOU'RE SITTING DOWN OR STANDING UP.

I'LL BUILD THE NEW STAND THE EXACT SAME HEIGHT. ON THE ORIGINAL STAND THE UPRIGHTS WERE ADJUSTABLE, BUT I REALLY ONLY NEED ONE TO BE ADJUSTABLE ON THIS NEWLY DESIGNED ONE. SO I CAN GO AHEAD AND WELD IN A FIXED UPRIGHT ON ONE END OF THE STAND. BUILDING THE ADJUSTABLE UPRIGHT TAKES A LITTLE MORE PLANNING. USING SOME FLAT PLATE I'LL MAKE A PINCH PLATE THAT WILL LOCK THIS SINGLE UPRIGHT INTO PLACE WHEN NEEDED.

AND FINALLY, THE AXLE HOUSING CRADLES WILL BE MADE FROM SOME FLAT PLATE BENT IN THE PRESS.

[ welder crackling ]

(IAN)>> NOW THIS IS THE PROBLEM WITH BOTH OF THESE STAND DESIGNS. IF I WANT TO HOLD THE AXLE IN A POSITION THAT'S SIMILAR TO HOW IT WOULD BE UNDERNEATH A RIG TO DO SOME WORK IT WON'T STAND BECAUSE IT ALWAYS WANTS TO ROLL DOWN BECAUSE OF THE WEIGHT OF THE PINION. SO I'M GONNA BUILD SOME TYPE OF PINION SUPPORT. NOW IT NEEDS TO BE ADJUSTABLE SO I CAN MOVE THE PINION UP AND DOWN, AND REMOVABLE SO I CAN STILL SWING THE PINION DOWN TO THE BOTTOM TO REBUILD THE GEAR SET. TO MAKE THE SUPPORT TELESCOPIC I CUT TWO PIECES OF DOM TUBING IN DIFFERENT DIAMETERS. AFTER CLEARANCING THE SMALLER INCH AND A HALF TUBE WITH THE BELT SANDER, IT EASILY SLIDES INTO THE INCH AND THREE QUARTER DOM. NOW I CAN FINISH BUILDING THE PINION SUPPORT.

AND WITH JUST A FEW HOURS WORK IN THE SHOP I'VE BUILT AN AXLE STAND THAT'S STRONGER AND MORE VERSATILE THAN THE STORE BOUGHT MODEL. THE NEXT TOOL I WANT TO BUILD IS OFTEN REFERRED TO AS A GANTRY CRANE. NOW YOU CAN BUY DIFFERENT TYPES OF GANTRY CRANES AT A BUNCH OF DIFFERENT TOOL MANUFACTURERS. THE THING IS IS THEY'RE REALLY TALL BECAUSE THEY'RE OFTEN USED IN PLACE OF AN ENGINE CRANE. IF YOU WANTED TO PULL THE MOTOR OUT OF A VEHICLE. BUT I DON'T NEED IT THAT TALL. I JUST NEED IT TALL ENOUGH SO I CAN HOOK ONTO THE FRONT OF A BUGGY AND FULLY EXTEND THE SUSPENSION FOR DOING THINGS LIKE SHOCK TUNING OR JUST CHANGING OUT SOME COIL SPRINGS. SO MINE WILL BE A LITTLE BIT SHORTER BUT BE ABLE TO HANDLE SIGNIFICANT WEIGHT. THE MAIN PORTION OF THE CRANE WILL BE BUILT BY USING TWO BY FOUR QUARTER INCH WALL STEEL. THE LEGS ARE WELDED TOGETHER. THEN I USE A FORK LIFT TO POSITION THE UPPER CROSS MEMBER IN PLACE. AFTER MAKING SURE EVERYTHING'S SQUARE, THE CROSS MEMBER IS WELDED UP. BRACES FROM TWO BY TWO THREESIXTEENTHS INCH WALL TUBING ARE THEN ADDED TO FINISH OUT THE STRUCTURE.

THE LIFTING DEVICE FOR MY GANTRY CRANE IS JUST THIS OLD CHAIN FALL THAT I HAD LAYING AROUND THE XTREME SHOP. IT ACTUALLY USED TO BE HUNG FROM THE CEILING. THAT'S WHY ALL THE CHAINS ARE SO LONG. AND I JUST LOOPED A PIECE OF CHAIN OVER THE TOP, BUT YOU COULD GO AS FAR AS BUILD SO SORT OF AN ELABORATE TROLLEY SYSTEM THAT WOULD SLIDE BACK AND FORTH OFF THIS MAIN BEAM JUST TO MAKE MOVING ITEMS AROUND A LOT EASIER. BUT HONESTLY NOW THAT I HAVE A GANTRY CRANE

I CAN'T WAIT TO USE IT.

IT'LL BE SO MUCH EASIER TO CHANGE COIL SPRINGS AND SET UP SHOCKS IN A BUGGY. I'LL JUST HAVE TO LIFT IT UP WITH A CHAIN FALL. I DON'T HAVE TO ALWAYS PUT IT ON THE LIFT. PLUS BUILDING TOOLS LIKE THIS IS A GREAT WAY TO PRACTICE YOUR WELDING.

(ANNOUNCER)>> UP NEXT, RAIN PLUS STEEP OFF CAMBER HILLS EQUALS ONE EXCITING ULTRA FOUR RACE.

PLUS PROJECT LOCKJAW BECOMES A ROLLING CHASSIS.

(IAN)>> IN THE HILLS OF HOT SPRINGS, ARKANSAS, ADDED TO THE BABBLE OF SPLASHING STREAMS IS THE SOUND OF FLOWING FUEL AS OVER 40 ULTRA FOUR TEAMS GATHER TO QUALIFY FOR THE FIRST RACE OF THE SEASON. BUT THIS IS NO WARM UP EVENT.

THE 1,200 ACRES OF HOT SPRINGS ORV PARK CONTAIN SOME OF THE STEEPEST HILLS AND TOUGHEST ROCKS IN THE EASTERN HALF OF THE UNITED STATES. IT'S A PLACE WHERE YOU CAN GO FROM BEING COMPLETELY IN CONTROL OF YOUR VEHICLE TO FLIPPED ON YOUR LID IN AN INSTANT.

(CLAY)>> THE TERRAIN, IT'S BRUTAL. IT'S LIKE THE HAMMERS WITH JUST ALL ROCKS.

IT'S GOT MAJOR ROCKS, GOT MAJOR LEDGES, AND

IT RAINED YESTERDAY. IT RAINED ABOUT AN INCH YESTERDAY.

SO EVERYTHING'S WET. SO WATER PLAYS A BIG PART OUT HERE IN HOT SPRINGS. ALL THE LEDGES AND STUFF HAVE GOT WATER RUNNING DOWN THEM. SO IT'S GONNA MAKE IT INTERESTING.

(IAN)>> ADDING TO THE DIFFICULTY, MUCH OF THE COURSE IS SINGLE TRACK. SO EVEN IF YOU'RE RUNNING AT TOP SPEED, PLACES TO

PASS THE COMPETITION ARE FEW AND FAR BETWEEN. RACERS MUST COMPLETE FIVE LAPS, EACH SIX AND THREE QUARTER MILES LONG. QUITE A CHALLENGE KEEPING A RIG TOGETHER FOR ALMOST 34 MILES OF DECIDEDLY HARSH ENVIRONMENT.

(TOM)>> IT'S REALLY TIGHT WOODS RACING. IT'S DEFINITELY GOING TO BE A DAY TO MINIMIZE YOUR MISTAKES, AND DON'T LET YOUR ATTENTION DOWN, AND DON'T HIT ANY TREES. THERE'S TOUGH ROCKS HERE. IT'S REALLY COOL WHEELING. IT'S A LOT DIFFERENT THAN THE HAMMERS, IT'S A LOT DIFFERENT THAN THE WEST COAST. BUT I GREW UP ON THE EAST COAST ORIGINALLY. SO IT'S NICE BEING CLOSER BACK TO THE EAST COAST, BUT IT'S ALSO FUN TO MAKE THE EFFORT TO COME BACK HERE AND GO RACING AND SEE GUYS THAT YOU DON'T GET TO RACE ALL SEASON UNTIL MAYBE NATIONALS OR UNTIL KING OF THE HAMMERS. SO PRETTY EXCITED TO GET BACK HERE.

(IAN)>> RAIN, MUD, AND OFF CAMBER HILLS HAMPERED THE RACERS ALL DAY LONG, LEAVING MAY RIGS WHEELS UP ON THE TRAIL. TO STAY IN THE HUNT, GOING HARD IN THE FLAT SECTIONS BECAME CRUCIAL, HOWEVER.

(LOREN)>> THEY HAD ABOUT A MILE OF BAD STUFF LAST YEAR AND THEY TOOK THAT OUT OF THE COURSE.

SO WE'RE IN ROCKS ALL DAY LONG AND TREES WE CAN BARELY FIT THROUGH. AND WE'RE GONNA BE IN FIRST GEAR PUSHING HARD ALL DAY.

(IAN)>> LOREN HEALY, LAST YEAR'S WINNER, FINISHED IN 13TH PLACE AFTER HIS CAR GOT STUCK ON A ROCK DURING QUALIFYING, LEAVING HIM NEAR THE BACK OF THE PACK ON RACE DAY. THIS YEAR'S WINNER, CHICKY BARTON, CLAIMED HIS FIRST ULTRA FOUR WIN, PUSHING HIS CAR RIGHT TO THE EDGE WITHOUT BREAKING IT.

(CHICKY)>> JUST GOTTA WATCH OUT FOR THOSE TREES. I MEAN THE WHOLE COURSE IS LINED WITH TREES. I SMACKED ACTUALLY ONE AND BENT AN AARM TAB. LUCKILY ENOUGH IT HELD TOGETHER THE REST OF THE RACE AND GOT ME ACROSS THE CHECKERED FLAG.

(ANNOUNCER)>> COMING UP WE'LL TURN PROJECT'S LOCKJAW'S FRAME FROM RUSTED TO RENEWED, AND FILL IT WITH SOLID AXLES AND A POWERFUL DRIVETRAIN.

(IAN)>> THE FIRST STEP TO GETTING LOCKJAW BUILT UP AS A FULL ROLLING CHASSIS IS ACTUALLY TO TEAR IT DOWN TO A BARE FRAME. I'VE GOT A LITTLE BIT MORE FAB WORK TO DO TO THIS RIG

BEFORE I CAN PAINT IT AND START FINAL ASSEMBLY.

THE STEERING SYSTEM FOR THIS PROJECT IS FROM PSC STEERING. NOW IT'S FOR A JEEP BUT NOT FOR OUR PARTICULAR MODEL. WE'RE GONNA ADAPT IT TO FIT. IT'S FOR A JEEP TJ WITH A HEMI IN IT. NOW IT STARTS WITH AN ALL NEW HEAVY DUTY STEERING GEAR. IT'S BEEN COMPLETELY REBUILT AND DRILLED AND

TAPPED FOR RAM ASSIST. A NEW PUMP THAT'LL GO ONTO OUR HEMI AS WELL AS A PULLEY, NEW RESERVOIR, ALL THE HOSES, AND FITTINGS, AND BRACKETS TO INSTALL EVERYTHING.

THE RAM WILL MOUNT DOWN ONTO THE AXLE. AND WHILE I HAD THEM PUTTING THE KIT TOGETHER, I HAD THEM INCLUDE ONE OF THEIR HEAVY DUTY FLAT YOU DRILL IT PITMAN ARMS. SO THIS IS A HEAVY DUTY FORGED UNIT, AND ALL I HAVE TO DO IS FIND A LOCATION FOR THE TIE ROD AND DRILL IT AND APPLY THE TAPER TO IT. BUT FIRST THINGS FIRST, I NEED TO FIND A WAY TO MOUNT THIS BOX ONTO THE FRAME. USING SOME THREESIXTEENTHS INCH PLATE, HOLES FOR THE STEERING GEAR ARE PUNCHED USING THE IRON WORKER, AND TUBE STAND OFFS ARE ADDED. [ welder crackling ] USING OUR NEW STEERING BOX PLATE AS A GUIDE, DRILL THROUGH THE EXISTING FRAME RAIL AND ADD SOME SPACERS ON THE INSIDE OF THE PLATE TO

PREVENT THE FRAME RAIL FROM COLLAPSING WHEN THE GEAR IS BOLTED UP. [ welder crackling ] THE PLATE IS THEN TACKED INTO PLACE, THE GEAR IS TEST FIT, AND IT'S FINISH WELDED. TO BUILD THE LINKAGE FOR THE STEERING SYSTEM I'M USING HEAVY DUTY TIE ROD ENDS FROM TMR CUSTOMS. THESE ARE GENERAL MOTOR'S ONE TON TIE ROD ENDS, AND ONE HAS A MOUNTING HOLE CAST INTO IT TO CREATE A YTYPE STEERING LINKAGE.

THE SUPER DUTY KNUCKLES NEED TO BE REAMED OUT FOR THE NEW TIE ROD END. THIS REQUIRES THE USE OF A HALF INCH PER FOOT REAMER UNTIL THE TIE ROD END FITS CORRECTLY. THE ACTUAL TIE ROD IS CUT FROM INCH AND A HALF QUARTER WALL DOM TUBING. AND I'LL FINISH IT OUT BY INSTALLING THE PSC HYDRAULIC RAM.

NEXT STEP IS TO MOUNT SOME BUMP STOPS TO THE FRAME. NOW I ONLY WANT ABOUT FOUR OR FIVE INCHES OF UP TRAVEL IN THIS FRONT SUSPENSION.

SO I PICKED UP SOME THESE UNIVERSAL BUMP STOPS FROM DAYSTAR PRODUCTS. NOW THEY'RE GOOD AND SOFT, AND THEY'RE PROGRESSIVE. THAT MEANS IT'LL ACTUALLY SLOW THE SUSPENSION DOWN

BEFORE STOPPING AND ELIMINATE THAT HARD HIT YOU SOMETIMES FEEL WITH FACTORY BUMPS. ALL I HAVE TO DO NOW IS BUILD THE MOUNT.

BUMP STOP MOUNTS ARE CUT, PUNCHED, AND BENT, AND THEN TACKED INTO PLACE ON OUR JEEP'S FRAME.

[ welder crackling ] PERFECT! AND THIS CHASSIS IS FINALLY READY TO BE FINISH WELDED AND PREPPED FOR A GOOD COAT OF PAINT.

(ANNOUNCER)>> UP NEXT, SOFT RUBBER AND HARDCORE WHEELS FOR PROJECT LOCKJAW.

(IAN)>> WITH ALL THE WELDING FINISHED I'VE BASICALLY SPOT PAINTED THIS FRAME. ANYWHERE WHERE I GROUND DOWN TO BARE STEEL OR ADDED NEW METAL TO IT. I WANT TO BLACK OUT THIS ENTIRE FRAME TO MAKE IT LOOK GOOD AND NEW BUT I DON'T WANT TO PAINT OVER THIS SURFACE RUST. IT WON'T STOP IT FROM RUSTING. IT'LL JUST KEEP RUSTING UNDERNEATH THAT PAINT. SO I'M GONNA TREAT THE FRAME. I'M GONNA USE THIS LOCTITE EXTEND RUST TREATMENT. THIS WILL BASICALLY ENCAPSULATE THE RUST. IT WILL PREVENT OXYGEN FROM GETTING TO IT. IT WILL STOP THAT RUSTING PROCESS. IT'S A PRIMER COAT.

SO ONCE IT'S IN PLACE I CAN THEN GO AHEAD AND PAINT RIGHT OVER IT AND THIS FRAME WILL BE GOOD AS NEW. THE TREATMENT IS A THIN LIQUID. SO IT COVERS THE FRAME VERY EASILY USING A BRUSH. AFTER LETTING IT DRY FOR 24 HOURS, VHT EPOXY PAINT IS APPLIED. IT IS RUST AND SALT RESISTANT TO KEEP OUR

CHASSIS LOOKING GOOD FOR YEARS TO COME. ASSEMBLY STARTS WITH THE BDS SUSPENSION LEAF SPRINGS AND BOTH AXLES ARE THEN SLID INTO PLACE UNDER OUR FRAME.

THE NEXT STEP IN PUTTING TOGETHER OUR ROLLING CHASSIS IS GONNA BE TO DROP THE DRIVETRAIN INTO PLACE. AND WITH NO BODY IN THE WAY THE EASIEST WAY TO DO THAT IS TO BOLT THE ENGINE AND TRANSMISSION TOGETHER AND LOWER THEM INTO THE FRAME. NOW THIS IS THE TRANSMISSION THAT WAS BEHIND OUR FIVE POINT SEVEN LITER HEMI WHEN WE PULLED IT FROM THE JUNKYARD. AND AT THE VERY LEAST BASED ON THE AMOUNT OF WORK WE'RE DOING TO THIS RIG, I DEFINITELY WANT TO TEAR INTO THIS TRANSMISSION, HAVE A LOOK AT IT, MAYBE GIVE IT A QUICK REBUILD. BUT THERE IS A BETTER OPTION. INSTEAD OF USING THIS TRANSMISSION, I GOT A NEW CRATE TRANSMISSION FROM POWERTRAIN PRODUCTS. NOW THIS TRANSMISSION IS WHAT THEY CALLED REENGINEERED, NOT JUST REBUILT, AND WHAT THAT MEANS IS THEY GO IN AND PERFORM ANY AND ALL REQUIRED UPDATES TO THE TRANSMISSION WHEN THEY'RE REBUILDING IT.

AND THAT'S A BIG DEAL. SEE WHEN MANUFACTURERS ARE BUILDING VEHICLES, IF THEY FIND A PROBLEM IN A TRANSMISSION, EVEN IF IT'S MID MODEL YEAR, THEY'LL MAKE THE CHANGE IN THE

TRANSMISSION FROM THAT POINT ON. NOW YOU WON'T KNOW THAT IF YOU'RE JUST USING A JUNKYARD TRANSMISSION. SO BY GETTING A COMPLETELY REENGINEERED ONE FROM POWERTRAIN PRODUCTS WE KNOW THAT ALL THE UPDATES HAVE BEEN DONE. AND IT COMES WITH A PRETTY GOOD WARRANTY.

THE TRANSMISSION IS BOLTED TO THE BACK OF OUR HEMI AND DROPPED INTO PLACE.

THE TRANSFER CASE IS BOLTED UP TO THE BACK OF THE TRANSMISSION AND THE CROSS MEMBER LOCKS IT ALL TOGETHER. IN ORDER FOR OUR CHASSIS TO TRULY BE A ROLLING CHASSIS WE NEED SOME TIRES AND WHEELS. NOW I WASN'T SURE WHAT WHEEL AND TIRE PACKAGE I WAS GONNA CHOOSE FOR THIS PROJECT. SO I FOUND A WEBSITE CALLED RIMS ONE ONLINE, AND THEY HAVE EVERY TIRE AND EVERY WHEEL ALL IN ONE

PLACE SO YOU CAN MIX AND MATCH AND PUT TOGETHER THE PACKAGE THAT'S PERFECT FOR YOU. I WANTED SOMETHING CLASSIS BECAUSE THIS IS AN OLD SCHOOL MILITARY TRUCK, AND THIS IS WHAT I FOUND.

THIS IS THE BF GOODRICH KX CRAWLER. NOW WHAT MAKES THIS TIRE PERFECT IS THAT IT'S A HARDCORE, AGGRESSIVE OFF ROAD TIRE BUT

YOU HAVE TO REMEMBER. THE CRAWLER IS THE TIRE THAT STARTED THE DEDICATED ROCK CRAWLING TIRE MOVEMENT. BFG LAUNCHED THIS TIRE YEARS AGO AND THEY WERE USED ON COMPETITION VEHICLES ALL OVER THE WORLD. WHAT MAKES THIS TIRE SPECIAL IS THAT IT'S WHAT'S CALLED A RED LABEL TIRE. AND THAT MEANS THAT THE COMPOUND IS EXTRA SOFT, MEANING THAT WE'LL HAVE TONS OF TRACTION WHEN WE'VE GOT THIS RIG UP ON THE ROCKS. NOW THE WHEELS, WELL THEY'RE PRETTY SPECIAL TOO. THESE ARE ATX SLAB WHEELS, A HEAVY DUTY ALUMINUM BEAD LOCK IN A NICE FLAT BLACK POWDER COAT FINISH. THE BEAD LOCK RING HAS A SERRATED EDGE TO HELP KEEP OUR TIRE HELD IN PLACE WHEN WE'RE AIRED DOWN.

ONCE THESE ARE BOLTED UP TO OUR AXLES, WE FINALLY

HAVE A FULL ON ROLLING CHASSIS.