Lock Jaw: Cage Fight

(ANNOUNCER)>> IT MAY LOOK LIKE AN OFF ROAD RAT ROD BUT TODAY ON XTREME OFF ROAD PROJECT LOCK JAW GETS TONS OF HIGH PERFORMANCE UPDATES, INCLUDING CLIMATE CONTROL AND MODERN ELECTRONICS.

PLUS DOES THIS ALWAYS SEEM TO HAPPEN WHEN YOU'RE MOVING AXLES? WE'VE GOT A FIX FOR THAT, AND HIGH FLYING, EARTH POUNDING, HEAD BANGING ACTION FROM THE METAL CLOAK STAMPEDE.

(IAN)>> EVERY NOW AND THEN HERE IN THE XTREME SHOP WE TEND TO HIT THE NAIL RIGHT ON THE HEAD WHEN IT COMES TO A PROJECT. THAT'S EXACTLY WHAT HAS HAPPENED WITH PROJECT LOCK JAW. YOU GUYS ARE LOVING THIS M-715 JEEP WE SAVED FROM THE WRECKING YARD. WE'RE PUSHING HARD TO FINISH THIS RIG UP, AND I'LL TELL YOU WHY A LITTLE BIT LATER. ANOTHER THING YOU GUYS ARE REALLY EXCITED ABOUT IS THE FACT THAT WE BUILT A FEW OF OUR OWN SHOP TOOLS. WELL I'VE GOT A COUPLE MORE TOOLS RATTLING AROUND IN THIS HEAD OF MINE. SO TODAY THAT'S WHERE WE'RE GONNA START WITH ONE MORE SHOP BUILT TOOL. LAST TIME WE BUILT TOOLS TO IMPROVE ON EXISTING DESIGNS.

TODAY I'M GONNA BUILD A TOOL TO SOLVE A PROBLEM. WHEN BUILDING A RIG, I FIND THE HARDEST PART IS ALWAYS GETTING THE AXLE IN AND OUT FROM UP UNDERNEATH THE FRAME. JACK IT UP BY THE PUMPKIN AND TRY TO PULL IT OUT. IT GETS OFF BALANCE AND BOOM, FALLS ON THE FLOOR. SO I'M GONNA BUILD AN ATTACHMENT FOR A FLOOR JACK THAT WILL STOP THIS FROM HAPPENING. I'M GONNA USE A FLOOR TRANSMISSION JACK AS THE BASE FOR THIS PROJECT BECAUSE IT HAS FOUR SWIVEL CASTORS UNDERNEATH IT, AND THAT MAKES LOCATING THE AXLE UNDER THE RIG A LOT EASIER.

THE ADAPTER IS BUILT USING TWO BY TWO EIGHTH INCH WALL SQUARE STRUCTURAL STEEL. TWO UPRIGHTS MOUNTED 24 INCHES APART WILL CLEAR ALMOST EVERY AXLE CENTER SECTION BUT NOT GET IN THE WAY OF ANY FUTURE LINK BRACKETS THAT ARE ADDED TO THE AXLE HOUSING.

TO HOLD THE AXLE IN PLACE THREEEIGHTHS INCH SOLID STEEL ROD IS BENT IN OUR PRESS AND WELDED TO EACH OF THE UPRIGHTS.

AN ADJUSTABLE PINION SUPPORT MADE USING TELESCOPING DOM TUBING WILL KEEP THE AXLE FROM

ROTATING WHEN IT'S JACKED UP.

THE UPRIGHT ASSEMBLY IS PLACED ON THE TRANSMISSION JACK, MARKED, AND THE MOUNTING HOLES ARE DRILLED.

WITH THE ASSEMBLY BOLTED INTO PLACE WE CAN TEST OUT OUR NEWEST SHOP TOOL.

WITH OUR NEW ADAPTER BOLTED ONTO THE JACK I NOW HAVE A VERY STABLE PLATFORM FOR REMOVING OR INSTALLING AXLES. YOU CAN SEE EVEN WITH A BIG HEAVY AXLE LIKE THIS 14 BOLT, THE AXLE MAY MOVE AROUND A LITTLE BIT BUT IT'S NOT GONNA FALL OFF THE JACK ONTO THE FLOOR. NOW I DID MAKE THIS PINION SUPPORT ADJUSTABLE BY USING THIS BOLT THROUGH THESE TWO PIECES OF TELESCOPIC TUBING. BUT ONE OF THE NICE THINGS ABOUT USING THE

TRANSMISSION JACK IS IT HAS ADJUSTMENTS ALREADY BUILT INTO IT.

I CAN EITHER PITCH THE AXLE SIDE TO SIDE OR MOVE IT FORWARD AND BACKWARD CAUSE THAT'S WHAT THE JACK IS DESIGNED TO DO. NOW WHAT IF YOU DON'T HAVE A TRANSMISSION JACK, ARE YOU OUT OF LUCK WHEN YOU WANT TO BUILD A BRACKET LIKE THIS? NO, YOU CAN ADAPT IT TO A REGULAR FLOOR JACK, AND IT'S EASIER THAN YOU THINK. THE SADDLE ON MOST FLOOR JACKS IS REMOVABLE.

IT PIVOTS ON A SOLID PIECE OF STEEL THAT'S CAST INTO THE SADDLE ITSELF. BY CUTTING A PIECE OF TUBING TO FIT INSIDE THIS PORTION OF THE JACK AND BOLTING A PLATE ON TOP OF THE JACK, WE NOW HAVE A BASE FOR OUR NEW AXLE MOUNT BRACKET.

THERE ARE SOME BENEFITS TO USING A COMMON FLOOR JACK FOR THIS TYPE OF AXLE STAND. IT SITS A LOT LOWER, SO IT'LL BE EASIER TO GET THE AXLES IN AND OUT OF THE RIG. AND IT'S A LOT MORE STABLE BECAUSE IT'S BOLTED TO THE SINGLE PAD. THE TRANSMISSION JACK SITS HIGHER. AND BECAUSE IT HAS ALL THOSE FINE TUNE

ADJUSTMENTS IN THE PAD, THE AXLE, IT'S GONNA GET A LITTLE BIT WOBBLY. SO I THINK FOR NOW I'M GONNA LEAVE THIS BOLTED JUST TO THIS FLOOR JACK. I'VE GOT TO SAY, HAVING THIS IN THE SHOP READY TO GO AT A MOMENTS NOTICE, WELL THAT'S GONNA MAKE MY LIFE A LOT EASIER.

(ANNOUNCER)>> UP NEXT EVERYTHING'S COMING TOGETHER NICELY FOR PROJECT LOCK JAW. PLUS THERE'S A REASON THEY CALL THIS RACE THE STAMPEDE.

(IAN)>> WITH THE CAB SITTING BACK ON THE FRAME FOR PROJECT LOCK JAW, THE NEXT STEP IS TO JUMP INSIDE, FINISH OUT THE FLOORS, AND BUILD A ROLL CAGE. BUT THERE'S ONE THING THAT'S BEEN BUGGING ME ON THIS RIG EVER SINCE WE PICKED IT UP, AND THAT IS THE ROOF LINE. I LIKE THE HEIGHT OF THIS SIDE WINDOW. I DON'T LIKE HOW THE FRONT WINDSHIELD KINDA JUMPS UP A GOOD THREE OR FOUR INCHES AND GOES ACROSS THE TOP. SO BEFORE I START ON THE CAGE, THE FIRST THING I'M GONNA DO IS CHOP THE TOP. THE FIRST STEP, GET THE WINDSHIELD FRAME OFF OF THE TRUCK AND ONTO A TABLE.

THE ORIGINAL GLASS IS CRACKED AND NO GOOD. SO IT HAS TO GO.

THEN THREE AND A HALF INCHES ARE CUT OUT OF THE FRAME.

THE SIDES OF THE FRAME ARE AT AN ANGLE. SO THE TOP WILL GET WIDER WHEN IT'S CUT DOWN. THE CENTER IS STRETCHED TO THE NEW WIDTH.

NOW THE WINDSHIELD CAN BE TACKED UP, BUT FIRST IT NEEDS SOME EXTRA SUPPORT FROM A PIECE OF ONE INCH SQUARE STEEL TO KEEP IT GOOD AND STRAIGHT. A QUICK TEST FIT ONTO THE TRUCK TO CHECK THE HEIGHT, AND IT CAN BE REMOVED TO FULLY WELD, GRIND AND SMOOTH, AND HIT EACH WELD WITH SOME OD GREEN PAINT. THE NEXT PIECE OF BODY WORK I HAVE TO DO TO THIS TRUCK IS FINISH MY FLOOR REPLACEMENT. NOW IF YOU REMEMBER, WHEN WE HAD THE CAB UP OFF THE FRAME, I WENT AND BUILT ALL NEW FLAT FLOOR SECTIONS ON BOTH SIDES OF THE TRUCK BECAUSE THE STOCK FLOOR HAD ROTTED COMPLETELY AWAY. NOW SINCE THEN I'VE BUILT THE TOP OF THE TRANSMISSION AND TRANSFER CASE TUNNEL. AND I BUILT IT THE SAME AS THE FLOOR, USING THIS ONE INCH COLD ROLLED ELECTRIC WELD SQUARE TUBING AND CAPPED IT WITH SOME 16 GAUGE STEEL.

I NOW NEED TO MAKE THE SIDES FOR THIS TUNNEL, AND THEN I CAN GO AHEAD AND WELD EVERYTHING IN PLACE, SEAM SEAL ALL THE JOINTS, PULL THE CAB BACK OFF THE FRAME, AND GET IT READY FOR A GOOD COAT OF PAINT.

THE REMAINDER OF THE FLOORS ARE ALSO 16 GAUGE STEEL. AND ONCE CUT TO FIT, THEY ARE PUT INTO PLACE AND WELDED EVERY EIGHT TO 10 INCHES USING A STITCH WELDING TECHNIQUE. THIS SERIES OF TACK WELDS LIMITS THE HEAT INPUT INTO THE MATERIAL AND HELPS ELIMINATE WARPAGE IN THE PANELS. THE WELDS ARE THEN GROUND SMOOTH AND THE TUBE STRUCTURE THAT WAS ORIGINALLY ADDED TO SECURE OUR CAB'S SHAPE CAN FINALLY BE REMOVED.

THE CAB IS PULLED OFF THE CHASSIS AND SET ON ITS BACK TO FINISH UP THE UNDERSIDE OF THE FLOOR.

EXCESS FACTORY FLOOR IS CUT OFF AND THE SEAMS ARE ALSO STITCH WELDED. NOT ALL OF THE BODY WORK THAT I HAVE TO DO WITH OUR CAB HAS TO DO WITH RUST. THERE'S ONE SECTION OF THE FIREWALL THAT I NEED TO REPLACE BECAUSE AT SOME POINT IN TIME SOMEONE CUT A HOLE, OR RATHER HALF OF A HOLE, INTO THE FIREWALL. FOR WHAT REASON WE'LL NEVER KNOW. THE REASON I NEED TO FIX IT IS BECAUSE I WANT TO MOUNT SOMETHING IN THE LOCATION OF THAT HOLE. THIS IS A SMALL UNIVERSAL HEATER SYSTEM FROM SUMMIT RACING. NOW IT ACCEPTS TWO HEATER HOSES FROM THE ENGINE THAT'LL PUMP WARM ENGINE COOLANT THROUGH A SMALL HEATER CORE INSIDE.

IT HAS TWO OUTLETS THAT'LL BLOW NICE WARM AIR INTO THE CABIN OF OUR M-715 PICK UP TRUCK WHEN WE'RE OUT ON THE TRAIL. NOW IT'S UNIVERSAL FIT AND JUST MOUNTS ONTO A FLAT FIREWALL.

SO I NEED A PLACE TO MOUNT IT, AND I NEED THIS BECAUSE WHERE WE PLAN TO TAKE THIS TRUCK ON ITS MAIDEN VOYAGE, WELL IT COULD BE CHILLY.

ONCE THE HEATER IS MEASURED AGAINST THE FIREWALL, IT'S AS EASY AS CUTTING AND PATCHING WITH SOME 16 GAUGE STEEL.

(ANNOUNCER)>> UP NEXT!

(ANDREW)>> SHORT COURSE SCARES ME MORE THAN SPIDERS, AND SNAKES, AND COCKROACHES.

(IAN)>> THE METAL CLOAK STAMPEDE HAS BECOME ONE OF THE LARGEST RACES IN THE ULTRA FOUR SERIES. SECOND ONLY TO KING OF THE HAMMERS.

THOUSANDS OF FANS COME OUT TO BRAVE TRIPLE DIGIT TEMPERATURES AND WATCH SOME SERIOUS SHORT COURSE ACTION. THIS TIME THEY WERE ALSO TREATED TO A COME FROM BEHIND VICTORY FROM A DRIVER WHO REFUSED TO QUIT.

(TOM)>> WE'RE HERE AT THE METAL CLOAK STAMPEDE, WHICH IS THE FIRST WEST COAST NATIONAL IN ULTRA FOUR SERIES.

(IAN)>> THE DICTIONARY CALLS STAMPEDE A SUDDEN FRENZIED RUSH OF PANIC STRICKEN ANIMALS.

COULD THERE BE A BETTER WAY TO DESCRIBE THIS RACE.

(ANDREW)>> SHORT COURSE SCARES ME TREMENDOUSLY, MORE THAN SPIDERS, AND SNAKES, AND COCKROACHES. GOING TIRE TO TIRE WITH THESE THINGS AND THIS MUCH POWER, IT'S HONESTLY INCREDIBLE.

(TOM)>> A LITTLE MORE OF A SPRINT RATHER THAN AN ENDURANCE RACE, LIKE KING OF THE HAMMERS. THE LONGER RACES, MORE ENDURANCE RACE, SO YOU HAVE TO PACE YOURSELF A LITTLE BIT MORE. THESE RACES ARE FULL ON SPRINT.

(IAN)>> WITH ALMOST 70 ULTRA FOUR RACERS REGISTERED FOR THE MAIN EVEN, FRIDAY'S PRELIMINARY HEATS WOULD BE ABOUT ONE THING, THINNING THE HERD.

IN EACH OF THESE FIVE PRELIMS ONLY THE TOP THREE FINISHERS ARE GUARANTEED A SPOT IN THE FINAL RACE ON SATURDAY.

(DARREN)>> IT CAN BE A LITTLE BIT NERVE RACKING.

YOU GET A LOT OF PEOPLE THIS CLOSE TO EACH OTHER, EVERYBODY'S IN A HURRY TO CROSS THE FINISH LINE. IT CAN GET A LITTLE NERVE RACKING OUT THERE. START BANGING SOME DOORS, RUBBING SOME TIRES.

(IAN)>> IN QUALIFYING, WITH EACH DRIVER RACING ALONE AGAINST THE CLOCK, EVERYONE FACED THE SAME OPPONENTS, A DEMANDING COURSE AND THE SEARING HEAT. TOM WAYS EARNED THE FASTEST LAP DURING

FRIDAY'S QUALIFIERS, BUT MECHANICAL ISSUES FRUSTRATED HIS ATTEMPTS TO SECURE A SPOT IN SATURDAY'S MAIN EVEN. SHANNON CAMPBELL AND LOREN HEALY ENDED THE DAY AT THE HEAD OF THE PACK, WITH LOREN SITTING IN POLE POSITION FOR THE FINAL. THE CARS HEADED INTO A SERIES OF WHOOPS, ROCK GARDENS, AND JUMPS THAT GAVE BOTH SKILL AND SUSPENSION A GOOD WORKOUT.

FOR THE NEXT 45 MINUTES RACERS HAMMERED THEIR WAY THROUGH THE DUST AND ALL KINDS OF OBSTACLES, PUNISHING BOTH MAN AND MACHINE ALONG THE WAY. DURING THE FIRST HALF OF THE FINAL TOM WAYES WAS NOWHERE TO BE FOUND AMONG THE RACE LEADERS. JUST MINUTES BEFORE THE ULTRA FOUR FINAL STARTED

HE MANAGED TO SECURE THE FINAL SLOT BY MEANS OF THE

LAST OF THE LAST CHANCE QUALIFIERS. BUT IT WOULD MEAN HE WOULD START DEAD LAST, 25TH OUT OF 25 RACERS. NONE THE LESS HE DROVE LIKE A MAN POSSESSED. IN FRONT OF HIS FELLOW RACERS AND A CROWD OF THOUSANDS WAYES MADE WHAT SEEMED IMPOSSIBLE

POSSIBLE, OVER COMING THE ODDS, WINNING THE METAL CLOAK STAMPEDE AND HIS FIRST ULTRA FOUR CHECKERED FLAG.

(ANNOUNCER)>> COMING UP, RUGGED RELIABLE ELECTRONICS AND LIGHTING FOR OUR JEEP.

(IAN)>> WITH ALL THE FAB WORK FINISHED UP ON OUR CAB, BEFORE I DROP IT ONTO THE FRAME FOR GOOD AND START FINAL ASSEMBLY, I WANT TO GIVE IT A COAT OF BED LINER BOTH UNDERNEATH AND INSIDE ON OUR NEW FLOORS. NOW I'M GONNA USE A PRODUCT CALLED RAPTOR LINER. AND IT USES THIS SIPHON TYPE SPRAY GUN OFTEN

REFERRED TO AS A SHUTZ GUN. NOW IT'S A PROFESSIONAL TYPE PRODUCT. SO YOU GET IT AT AN AUTOMOTIVE SUPPLY HOUSE. AND BECAUSE IT'S A PROFESSIONAL TYPE PRODUCT THERE ARE SOME FUMES INVOLVED WITH IT. SO MAKE SURE THAT YOU'VE GOT GOOD PERSONAL PROTECTION, RUBBER GLOVES, GLASSES, RESPIRATOR, AND WORK IN A WELL VENTILATED AREA.

OR IF YOU HAVE IT, FIRE UP YOUR PREP BOOTH. TO SPRAY THE LINER IT'S AS SIMPLE AS ADDING THE HARDENER TO THE BOTTLE AND SHAKE FOR TWO TO THREE MINUTES TO INSURE FULL ACTIVATION. THE SIPHON GUN IS THEN ATTACHED ONTO THE BOTTLE AND IT'S TIME TO START SPRAYING. A LINER PROVIDES GOOD COVERAGE AND THE TEXTURED COATING GIVES A NICE FINISHED SURFACE. ONCE THE BOTTOM OF THE CAB AND FIREWALL ARE COMPLETELY COVERED, I MOVE ONTO THE INTERIOR FLOOR, AND LASTLY GIVE THE INSIDE OF THE BED A COAT AS WELL. AND THE BED AND CAB ARE DROPPED BACK ONTO OUR CHASSIS FOR THE LAST TIME. BEFORE THE FRONT SHEET METAL GOES ON, THIS IS THE PERFECT TIME TO TAKE CARE OF A FEW ODDS AND ENDS, MAINLY THE WIRING. THAT WAY I'M NOT LEANING OVER THE FENDERS, STANDING ON MY HEAD TRYING TO HOOK THINGS UP. NOW FOR THE MAIN WIRING HARNESS FOR PROJECT LOCK

JAW I DON'T WANT A FACTORY REPLACEMENT HARNESS. I DON'T NEED THAT. I NEED SOMETHING A LITTLE BIT MORE UNIVERSAL. NOW I GOT THIS UNIVERSAL EXTREME DUTY OFF ROAD HARNESS FROM SUMMIT RACING. NOW IT ONLY HAD 10 CIRCUITS IN IT, BUT INSIDE THE WATER RESISTANT FUSE BLOCK THERE'S ALSO FOUR RELAYS ALREADY WIRED UP AND ALREADY MOUNTED. NOW THE NICE THING ABOUT THIS IS IT'S GONNA GIVE US JUST ENOUGH CIRCUITS FOR EVERYTHING WE

NEED ON THIS TRUCK. THINGS LIKE OFF ROAD LIGHTS, OUR COMPRESSOR IN THE BACK, AND THE POWER WE'LL NEED TO RUN OUR ENGINE.

BUT NOT ALL THAT EXTRA STUFF THAT YOU'D FIND WITH A PREMADE HARNESS BECAUSE I DON'T NEED THINGS LIKE CRUISE CONTROL. LOCK JAW DON'T GOT IT. THE FUSE BOX AND CIRCUIT BREAKERS ARE ATTACHED TO THE FIREWALL. AND THE HARNESS IS ROUTED TO THE INSIDE OF THE CAB AS WELL AS FEEDS LEFT UNDER THE HOOD FOR THE ENGINE. I'M JUST LOOSELY RUNNING THE MAIN HARNESS AROUND TO DIFFERENT SPOTS ON THE TRUCK SO IT CAN HOOK UP TO ALL THE ITEMS WE NEED TO MAKE LOCK JAW RUN. ONE OF THOSE MAIN ITEMS IS GONNA BE A COMPLETE ENGINE WIRING HARNESS AND COMPUTER. NOW I GOT THIS SETUP FROM HOT WIRE AUTO, AND IT IS ACTUALLY THE FACTORY WIRING HARNESS THAT WAS ON OUR ENGINE WHEN IT CAME FROM THE JUNKYARD. HOT WIRE TOOK IT, COMPLETELY CLEANED IT ALL UP, ADDED NEW CONNECTORS WHERE NEEDED, AND THEN

SHEATHED IT ALL WITH NEW WIRE LOOM COATING. NOW THIS IS WHAT'S CALLED THEIR HOT ROD HARNESS. THEY'VE BASICALLY COMPLETELY REMOVED ANY FACTORY VEHICLE SETTINGS ON IT AND IT CAN BE HOOKED UP TO JUST A CONSTANT POWER, A SWITCHED POWER, AND SOME GROUNDS AND IT WILL RUN. NOW THE KEY TO THAT IS REFLASHING THE FACTORY ECU. NOW THIS IS THE COMPUTER THAT CAME WITH OUR ENGINE. IT HAS EVERYTHING WE NEED TO MAKE OUR ENGINE RUN. AND MORE IMPORTANTLY, ALSO HAS THE CONTROLS IN PLACE FOR OUR FULLY ELECTRONIC AUTOMATIC TRANSMISSION. NOW THERE WILL JUST BE A FEW CONNECTIONS MADE FROM THIS HARNESS INTO OUR TRUCK'S MAIN HARNESS. AND THEN THIS ENGINE WILL BE READY TO ROLL. THE HARNESS IS FULLY PLUG AND PLAY. EACH SENSOR IS CLEARLY MARKED AND THE ECU IS MOUNTED UNDER THE DASH ON THE PASSENGER'S SIDE OF THE TRUCK. NOW THE FRONT CLIP CAN BE INSTALLED AND WE'LL PULL THE WEAK STOCK HEADLIGHTS OUT FOR A COUPLE OF UPGRADES. EVERYTHING ABOUT LOCK JAW IS OLD AND WORN OUT ON THE

OUTSIDE WITH MODERN TECHNOLOGY UNDERNEATH

WHERE IT COUNTS. AND THE LIGHTING IS NOT GOING TO BE ANY DIFFERENT. I GOT A WHOLE BUNCH OF STUFF HERE, ALL FROM FIREWIRE LED. ONE OF THEIR LARGE 50 INCH DUAL COMBO SPOT AND FLOOD LED BARS. WE'LL MOUNT THAT UP ON THE WINDSHIELD. A SET OF THEIR ALUMINUM WATER RESISTANT ROCK LIGHTS. THESE HAVE THREE ONE WATT LED'S INSIDE OF THEM. WE'LL MOUNT THEM UP ABOVE EACH TIRE AND WHEEL. AND WE'RE GONNA DITCH THOSE WORN OUT SEALED

BEAMS UP FRONT, AND UPGRADE IT USING AN LED LIGHT CONVERSION KIT WITH NEW HOUSINGS.

AND NOW WE'VE GOT BRIGHT LIGHTS FOR SOME SERIOUS WHEELING. WE'VE TEASED YOU FOR A WHILE NOW AND NEXT WEEK YOU'RE GONNA SEE IT.

WE'RE HAULING LOCK JAW OUT TO THE MOST ICONIC JEEP EVENT IN THE WORLD, THE EASTER JEEP SAFARI, DEEP IN THE RED ROCKS OF MOAB, UTAH.