Defender 90: Axles

(NARRATOR)>> IF YOU'RE DOING THE MATH FOR YOUR EXPEDITION RIG REMEMBER THE THREE "R'S", RUGGED, READY, AND RELIABLE. THIS WEEK ON XTREME OFF ROAD OUR DEFENDER GETS UPGRADED AXLE ASSEMBLIES, DUAL PURPOSE SUSPENSION, AND MORE. PLUS "BUCKIN' BRONCO" RECEIVES RACE READY BYPASS SHOCKS ALONG WITH SOME STYLISH CUSTOM SHOCK MOUNTS, AND WE CHECK OUT ONE KILLER FLAT BED TRAILER.

(IAN)>> NOT TOO LONG AGO WE SHOWED YOU GUYS OUR LATEST PROJECT, THIS LAND ROVER D-90. WE TOOK IT OUT FOUR WHEELING, THEN BROUGHT IT INTO THE SHOP, COMPLETELY STRIPPED IT OF ALL OF ITS LAND ROVER DRIVETRAIN AND DROPPED IT ONTO A JEEP WRANGLER FRAME. NOW BEFORE I FULLY COMMIT TO THE LOCATION OF THE BODY ON THAT FRAME I WANT TO TURN IT INTO A TRUE ROLLING CHASSIS, AND FOR THAT IT'S GONNA NEED SOME NEW AXLES, AND THAT IS WHAT IS ON THIS PALLET. I'M TURNING THIS INTO A ONE TON ROVER.

THE ONE TONS FOR THIS D-90 ARE A HIGH PINION DANA 60 FRONT AXLE OUT OF A 2012 FORD F-250 SUPER DUTY, AND A 10.25 STERLING REAR AXLE OUT OF A 2000 FORD SUPER DUTY. A GREAT COMBO FOR ANY PROJECT, AND AS USUAL IT ALL STARTS BY STRIPPING THE REAR TO BARE TUBES TO PREP FOR A SET OF TRUSSES. OH YEAH! [ metal grinding ]

(IAN)>> ONE OF THE ADDED BENEFITS TO SWAPPING A JK FRAME UNDERNEATH OUR D-90 IS THE POPULARITY OF THAT MODEL OF WRANGLER. THERE'S TONS OF AFTERMARKET SUPPORT FOR THAT PARTICULAR VEHICLE, INCLUDING ONE TON AXLE SWAP KITS FROM RTECH INDUSTRIES. NOW THIS IS A COMPLETE TRUSS ASSEMBLY SYSTEM WITH A TRUSS THAT BRIDGES OVER THE CENTER SECTION, AND MOUNTS FOR THE COIL SPRINGS, UPPER AND LOWER LINK MOUNT, AND EVEN THE PAN HARD BAR, AND THEY USE THESE UNIQUE ALIGNMENT GAUGES TO MAKE SURE THAT EVERYTHING IS IN THE FACTORY LOCATION ONCE IT'S UNDERNEATH YOUR RIG, AND THEY THINK OF EVERYTHING, EVEN A SMALL RELIEF CUT IN THIS UPPER LINK MOUNT, TO MAKE SURE THAT YOU CAN STILL UTILIZE THE EMERGENCY BRAKE ON THIS REAR STERLING AXLE. NOW I'VE GOT ONE OF THESE KITS FOR THE REAR AXLE AS WELL AS THE FRONT, AND ONCE THEY'RE TACKED INTO PLACE BOTH OF THESE ONE TON AXLES WILL BE BOLT IN READY FOR OUR RIG. [ welder crackling ]

(IAN)>> THE RTECH TRUSS ASSEMBLY BEGINS BY PREPPING THE AXLE WHERE THE TRUSS WILL REST ON THE CENTER SECTION. EACH BRACKET IS PLACED ONTO THE TUBE USING THE INCLUDED ALIGNMENT JIG, AND TACKED IN PLACE. [ welder crackling ]

(IAN)>> WITH THE REAR AXLE COMPLETED IT CAN GO AWAY AND THE FRONT CAN GO ONTO THE STAND.

FACTORY BRACKETS ARE CUT OFF.

[ hammer tapping ] [ metal grinding ]

(IAN)>> THE CENTER SECTION IS TRIMMED TWO INCHES NARROWER PER THE RTECH INSTRUCTIONS.

OH YEAH!

AND THE TRUSS IS DROPPED INTO PLACE. [ welder crackling ]

(IAN)>> SUSPENSION BRACKETS ARE TACKED ONTO THE HOUSING, INCLUDING THE NEW UPPER LINK MOUNTS.

[ welder crackling ]

(IAN)>> YOU MIGHT THINK THAT WILL ALL THE CUSTOM TOUCHES THAT ARE GOING ON WITH OUR D-90 WE'D BE LOOKING TO BUILD A 100 PERCENT CUSTOM SUSPENSION SYSTEM BUT THAT IS NOT THE BEST DECISION FOR THIS RIG. THIS IS AN EXPEDITION TRAVEL RIG. SO WE HAVE TO THINK ABOUT MAINTENANCE AND PART AVAILABILITY ANYWHERE IN THE WORLD, AND THAT'S WHY THE BEST OPTION FOR OUR D-90 IS TO USE A 100 PERCENT BOLT ON SUSPENSION SYSTEM FROM JKS MANUFACTURING. NOW THIS THEIR JSPEC TWO DOOR JEEP JK KIT, AND IT COMES WITH HEAVY DUTY CONTROL ARMS FOR BOTH THE FRONT AND THE REAR, HEAVY DUTY TRACK BARS FOR BOTH AXLES, AND FOX ADVENTURE SERIES SHOCKS. THE COIL SPRINGS ARE A DUAL RATE COIL SPRING. NOW THIS WILL GIVE US GOOD ON ROAD MANNERS AND GOOD FLEX WHEN WE'RE OFF ROAD. IF YOU WERE PUTTING TOGETHER WHAT WOULD BE CONSIDERED A DUAL PURPOSE JEEP JK THIS WOULD BE THE KIT THAT YOU WOULD CHOOSE.

(NARRATOR)>> UP NEXT WE TURN OUR DEFENDER INTO A ROLLING CHASSIS. PLUS WE SPEND A DAY AT ONE OF THE MOST CHALLENGING OFF ROAD PARKS IN THE SOUTH.

(IAN)>> WE ARE BACK ON XTREME CONVERTING OUR DEFENDER 90 OVER TO A ONE TON ROVER. NOW WITH OUR AXLES PREPPED, THE NEXT STEP IS TO INSTALL THEM ONTO THE SUSPENSION UNDERNEATH THE FRAME.

THE JKS KIT USES ALL THE FACTORY SUSPENSION MOUNTS AND EACH CONTROL ARM IS INSTALLED INTO THE FRAME, AS WELL AS INTO THE NEW BRACKETS ON OUR RTECH TRUSS ASSEMBLIES. FOX SHOCKS AND THE COIL SPRINGS FINISH UP THE FRONT.

THE REAR AXLE IS THE SAME PROCESS. UPPER AND LOWER CONTROL ARMS GO IN, PAN HARD BAR, SHOCKS, AND SPRINGS. THEN THIS D-90 NOW HAS A SET OF ONE TON AXLES UNDERNEATH IT.

JUST EYEBALLING THE AXLES UNDERNEATH OUR TRUCK AND HAVING IT ACTUALLY SIT ON A SET OF TIRES AND WHEELS ARE TWO VERY DIFFERENT THINGS, AND I DEFINITELY WANT TO GET A TIRE AND WHEEL PACKAGE INTO THE WHEEL WELL OF OUR PROJECT BEFORE I COMMIT ON THE LOCATION OF THE BODY ON THAT FRAME. NOW FOR OUR TIRES I CHOOSE A SET OF BF GOODRICH MUD TERRAIN KMTWO TIRES. NOW THIS IS A GREAT DUAL PURPOSE TIRE. IT'S BEEN TORTURE TESTED ALL OVER THE WORLD, ON EXPEDITIONS AS WELL AS OFF ROAD RACES LIKE THE BAJA 1,000. IT'S AN AGGRESSIVE OPEN SELF CLEANING TREAD DESIGN WITH EDGE SCOOPS AND SHOULDER SCALLOPS TO PROVIDE GOOD TRACTION, AND IT'S BUILT WITH A MIX OF NYLON, POLYESTER, AND STEEL BELTS. NOW I OPTED FOR A 37 INCH TALL TIRE BECAUSE IT WILL GIVE US PLENTY OF GROUND CLEARANCE FOR OUR ONE TON AXLES BUT STILL KEEP THE VEHICLE VERY STABLE ON LONG HIGHWAY DRIVES, WHICH IS PERFECT FOR AN XTREME EXPEDITION RIG. WE'RE GONNA WRAP THESE TIRES AROUND A SET OF FUEL OFF ROAD ANZA ONE PIECE BEAD LOCK WHEELS. THESE FORGED WHEELS ARE SPECIFICALLY DESIGNED FOR SERIOUS OFF ROAD VEHICLES, AVAILABLE IN MANY CUSTOM FIT AND COLOR COMBINATIONS. WE WENT WITH A MATTE GRAY FINISH.

WITH THE TIRES MOUNTED ONTO THE WHEELS AND THE WHEELS MOUNTED ONTO THE AXLE, THE TRUCK IS LOWERED DOWN TO CHECK THE FIT OF OUR 37 INCH TALL TIRES AND THE BODY. THE FRONT END IS SITTING A LITTLE HIGH BECAUSE OF NO DRIVETRAIN IN THE FRAME, BUT THESE AXLES AND THIS FRAME FIT THE D-90 PERFECTLY.

(NARRATOR)>> THE FOUNDATION OF A GOOD DAY WHEELING, A GREAT TRAILER.

(IAN)>> WE'RE ABOUT TO HIT THE ROAD AND TAKE OFF TO AN OFF ROAD PARK TO SPEND A DAY FOUR WHEELING, BUT BEFORE I DO THAT I'VE GOT TO GET PROJECT LOCKJAW UP ON THE TRAILER. A JOB MADE A LOT EASIER THANKS TO OUR NEW H&H TRAILERS' SPEED LOADER GOOSE NECK. CONSTRUCTED USING AN EIGHT INCH HIGH TENSILE STRENGTH STEEL CHANNEL FRAME, FOUR WHEEL DISC BRAKES, AND TANDEM EIGHT LUG AXLES. THE SPEED LOADER HAS A UNIQUE TILT BED FEATURE THAT SPEEDS UP LOADING AND UNLOADING. NO MORE RAMPS!

THE TRAILER HAS FULL DOT COMPLIANT LED LIGHT PACKAGE, TWIN DROP LEG JACKS, AND A FULL TWO BY EIGHT TREATED WOOD FLOOR. THE TRAILER ITSELF IS POWDER COATED WITH A SMOOTH TOP DESIGN. WE OPTED FOR THE 30 FOOT VERSION OF THE TRAILER BECAUSE IT'LL GIVE US THE MOST HAULING OPTIONS, AND IT COMES WITH EIGHT OF THESE HEAVY DUTY SWIVEL ATTACHMENT POINTS IN THE DECK OF THE TRAILER, AND THESE JUST AREN'T ATTACHED TO THE WOOD. THERE'S ACTUALLY A METAL BACKING PLATE THERE MAKING THEM INCREDIBLY STRONG. ALSO HAS A FULL RUB RAIL DOWN BOTH SIDES WITH A COMPLETE SET OF STAKE POCKETS, AND THESE STAKE POCKETS ARE THREESIXTEENTHS OF AN INCH, SOME OF THE THICKEST STAKE POCKETS IN THE INDUSTRY, AND OF COURSE I'M SECURING MY PROJECT TO THE TRAILER WITH A COMPLETE SET OF MAX CUSTOM TIE DOWN RATCHET STRAPS BECAUSE WHEN IT COMES TO HOLDING YOUR RIG ONTO YOUR BRAND NEW TRAILER YOU WANT A GOOD QUALITY RATCHET STRAP. TODAY WE'RE HEADING TO GOLDEN MOUNTAIN PARK JUST OUTSIDE OF COOKEVILLE, TENNESSEE, IN THE SMALL TOWN NAMED SPARTA. GOLDEN MOUNTAIN HAS HUNDREDS OF ACRES WITH CLOSE TO 50 LISTED TRAILS FROM EASY TO DIFFICULT WITH GREAT AMENITIES FOR SPENDING THE WEEKEND IN THE WOODS. PAVILIONS, PRIMITIVE CAMP SPOTS, AND EVEN MULTIPLE RV HOOKUPS.

THAT'S WHERE I, UH OH! [ laughing ]

(IAN)>> THE NICE THING ABOUT GOLDEN MOUNTAIN IS THERE'S TRAILS FOR EVERY KIND OF VEHICLE. I MEAN LOCKJAW'S A WELL BUILT RIG BUT IT'S NOT A TUBE BUGGY, IT'S NOT A ROCK BOUNCER BY ANY MEANS. LEAF SPRINGS ALL THE WAY AROUND AND A VEIGHT ENGINE. NOW I CAN COME AND SPEND A WEEKEND AT GOLDEN MOUNTAIN AND HAVE JUST AS MUCH FUN AS EVERYBODY ELSE. YOU ACTUALLY CAN COME OUT HERE AND WHEEL IN A STOCK JEEP AND YOU'LL HAVE PLENTY OF TRAILS TO RIDE ON FOR MANY, MANY DAYS.

WE'VE BROUGHT A BUNCH OF PROJECTS TO GOLDEN MOUNTAIN OVER THE YEARS, FROM EXPEDITION TRAVEL RIGS, TRAIL TRUCKS, HILL KILLERS, AND MOST RECENTLY IT WAS A STOP ON OUR ANNUAL XTREME OFF ROAD ADVENTURE.

(GREG)>> YOU KNOW WHAT THE MOST AMAZING THING TO ME IS HOW ALL THE TRAILS ARE CUT THROUGH THE TREES. THE TREES ARE SO DENSE HERE, AND THEN ALL OF A SUDDEN THERE'S A TRAIL THAT HEADS OFF TO THE RIGHT, OR HEADS OFF TO THE LEFT. IT REALLY ENCOMPASSES EVERYTHING ABOUT TENNESSEE, AND ABOUT GETTING OUT HERE IN THE WOODS AND HAVING FUN.

(IAN)>> IF YOU'RE LOOKING FOR A GREAT PARK TO HIT WHILE IN TENNESSEE, MAKE SURE TO PUT GOLDEN MOUNTAIN ON YOUR LIST. IT IS A DEFINITE MUST WHEEL PARK IN THE SOUTH.

(NARRATOR)>> WE'VE ALWAYS ADMIRED THOSE REALLY COOL SHOCK MOUNTS YOU SEE ON DESERT RACERS. SO WE'RE BUILDING OUR OWN.

(IAN)>> WE'RE AT THE POINT WITH OUR "BUCKIN' BRONCO" BUILD WHERE IT'S TIME TO START LOOKING AT SOME SHOCKS FOR OUR REAR TRAILING ARM SUSPENSION. NOW WHENEVER YOU TALK ABOUT AN ULTRA FOUR STYLE CAR THERE ARE CERTAIN THINGS THAT YOU'RE DEFINITELY GONNA WANNA HAVE. OF COURSE TRAILING ARMS ARE ONE OF THEM, SWAY BARS ANOTHER, AND WE INSTALLED THAT LAST TIME, BUT THE SHOCK PACKAGE IS GOING TO BE VERY UNIQUE. WE NEED A SHOCK THAT CAN ALLOW US TO ROCK CRAWL WHEN WE'RE IN SOME SERIOUS TRAILS BUT ALSO A SHOCK THAT'S ABLE TO CONTROL THE WHEEL MOVEMENT WHEN WE'RE TRAVELING AT A HIGH RATE OF SPEED OVER ROUGH TERRAIN. NOW THE ONLY WAY TO DO THAT IS WITH A GOOD QUALITY COIL CARRIER AND BYPASS SHOCK PACKAGE. ADS RACING SHOCKS IS A WELL KNOWN SHOCK SUPPLIER FOR RACE CARS AND HEAVY DUTY WEEKEND WHEELERS. NOW WHAT THEY LIKE TO DO IS REALLY GET TO KNOW THE END USER OF THEIR SHOCK AND THE RIG, AND PUT TOGETHER A PACKAGE SPECIFIC FOR YOU. NOW WHEN I TOLD THEM THAT I WAS BUILDING AN ULTRA FOUR STYLE BRONCO THEY KNEW EXACTLY WHAT I NEEDED BECAUSE THIS SAME PACKAGE IS ON A BUNCH OF RIGS COMPETING IN EVENTS LIKE KING OF THE HAMMERS. NOW IT ALL STARTS WITH A TWO AND A HALF INCH THREADED BODIED COIL OVER SHOCK. NOW THIS SHOCK IS A HEAVY DUTY HARDENED STEEL BODY THAT'S BEEN PRECISION HONED WITH A LIGHTWEIGHT AIRCRAFT QUALITY RESERVOIR MADE OUT OF ALUMINUM. IT HAS A HARDENED STEEL SHOCK SHAFT THAT'S ATTACHED TO A BILLET 70-75 SHOCK PISTON WITH PRECISION GROUND VALVING ON EITHER SIDE. IT HAS A BILLET ADJUSTOR WITH A PINCH BOLTS AND DUAL RATE ADJUSTORS ON THE SHOCK BODY AS WELL AS TEFLON LINED SPHERICAL ROD ENDS AT EITHER END FOR MOUNTING IT. NOW IN OUR BRONCO THE COIL OVER IS BETTER DESCRIBED AS A COIL CARRIER BECAUSE ITS PRIMARY JOB IS NOT AS A COIL OVER SHOCK. IT'S JUST SIMPLY TO HOLD THE COIL SPRINGS AND CONTROL HOW THEY REACT IN THE SYSTEM. THE ACTUAL SHOCK ABSORPTION IN OUR BRONCO WILL BE TAKEN CARE OF BY THIS ADS RACING THREE INCH BYPASS SHOCK. YOU CAN SEE THAT IT'S SIMILAR IN CONSTRUCTION TO THE COIL OVER EXCEPT THE RESERVOIR IS HARD MOUNTED TO THE SHOCK AND IT'S FINNED FOR EXTRA COOLING. THE MOST OBVIOUS DIFFERENCE THOUGH ARE ALL THESE TUBES ON THE OUTSIDE OF THE SHOCK, AND EACH ONE IS EQUIPPED WITH A HARDENED STEEL STEM, CHECK BALL, AND SPRING INSIDE, BUT WHAT DO THESE TUBES DO? WELL THEY'RE ACTUALLY VERY IMPORTANT. EVERY SHOCK ABSORBER WORKS USING THE VERY SAME TECHNOLOGY. INSIDE THE BODY IS A COLUMN OF OIL. ATTACHED TO THE SHOCK'S SHAFT IS A VALVE. THAT VALVE IS USUALLY A ROUND PIECE OF STEEL OR ALUMINUM WITH A BUNCH OF HOLES, OR ORIFICES, IN IT. THE VALVES ARE ACTUALLY FLAT PLATES ON THE TOP AND THE BOTTOM, AND AS THE VALVE IS PUSHED THROUGH THE OIL, THE PLATES DEFLECT, ALLOW THE FLUID THROUGH THE ORIFICE, AND THAT'S WHAT PROVIDES YOU THE DAMPENING IN THE SYSTEM. NOW ANY HIGH END SHOCK ABSORBER CAN BE REBUILT. YOU CAN TAKE IT APART AND CHANGE THE VALVING, OR THOSE FLAT PLATES, INSIDE THE SHOCK TO CHANGE HOW IT REACTS, MAKE IT STIFFER OR SMOOTHER. THE PROBLEM IS WHEN YOU MAKE THOSE CHANGES IT EFFECTS THE SHOCK THROUGH ITS ENTIRE TRAVEL. THAT IS WHERE A BYPASS SHOCK CHANGES EVERYTHING. THESE TUBES ON THE OUTSIDE OF THE SHOCK, THEY'RE BASICALLY JUST WHAT THE NAME IMPLIES. THEY ARE BYPASS TUBES. AS THE SHOCK VALVE MOVES THROUGH THE OIL INSTEAD OF ALL THE OIL HAVING TO TRAVEL THROUGH THE VALVES AND THE ORIFICES, IT'LL ACTUALLY PUSH OIL THROUGH THE BYPASS TUBE, ESSENTIALLY GOING AROUND THE PISTON. THAT ALLOWS US TO FINE TUNE HOW THE SHOCK REACTS IN DIFFERENT PARTS OF THE TRAVEL. YOU CAN SEE ON THIS PARTICULAR SHOCK, WITH THE TWO COMPRESSION ADJUSTORS HERE, WE CAN CHANGE HOW THE SHOCK REACTS IN THIS SECTION OF THE SHOCK, MAKE IT VERY LOOSE, VERY SOFT, STIFFEN IT UP IN THIS TOP PART OF THE TRAVEL WHERE THE SHOCK IS ALMOST FULLY COLLAPSED, AND THEN WHEN GET PAST THIS LAST TUBE WE CAN HAVE A SET OF VALVES INSIDE THE SHOCK THAT BECOME VERY STIFF TO ABSORB THAT SERIOUS ABUSE. SAME THING HAPPENS ON REBOUND, OR AS THE TIRE AND WHEEL FALL AWAY. WE CAN ADJUST HOW FAST OR HOW SLOW THAT HAPPENS WITH THE BYPASS TUBES ON THE OUTSIDE OF THE SHOCK. YOU CAN SEE THAT WHEN YOU'RE TALKING ABOUT A VEHICLE THAT'S DESIGNED TO TRAVEL VERY QUICKLY OVER ROUGH TERRAIN BEING ABLE TO FINE TUNE HOW THE SUSPENSION REACTS AT DIFFERENT PARTS OF ITS TRAVEL CAN BE VERY IMPORTANT.

IT ALL STARTS BY ADDING A PIECE OF INCH AND A HALF DOM TUBING THAT WILL ACT AS THE BACK BONE FOR OUR SHOCK MOUNT, TYING THE BELT BAR TO THE REAR PART OF THE CHASSIS TOGETHER. [ saw cutting metal ]

[ welder crackling ]

(IAN)>> THIS TUBE IS HONESTLY JUST HERE TO LOCATE OUR SHOCKS WHILE I WORK ON THE SHOCK MOUNTS. NOW THE EASY WAY TO MOUNT UP THIS SHOCK PACKAGE WOULD BE TO BURN IN THIS PIECE OF TUBING, AND THEN GO AHEAD AND JUST ADD A TAB FOR THE FRONT COIL OVER AND A SET OF TABS FOR THE REAR BYPASS, BUT ONE THING THAT I HAVE ALWAYS LIKED ON A WELL BUILT TRAILING ARM CAR IS THE REAR SHOCK MOUNTS. THEY'RE USUALLY LARGE PIECES OF PLATE THAT TIE IN THE CENTER OF THE CHASSIS TO THE TOP OF THE CHASSIS. THEY'RE BASICALLY WELDED UP PIECE OF ART, AND I'VE ALWAYS WANTED TO BUILD ONE. SO THAT IS WHAT OUR BRONCO'S GETTING. IT ALL STARTS AT THE COMPUTER. THE SHOCK MOUNT BEGINS WITH A FLAT PLATE DESIGN IN FAST CAM. THIS PLATE STYLE UPPER MOUNT WILL NOT ONLY LOCATE THE BYPASS AND COIL CARRIER, IT WILL ALSO STRENGTHEN THE BPILLAR OF THE CHASSIS. EACH SIDE OF THE MOUNT IS MADE FROM THREESIXTEENTHS INCH PLATE BUT TO LIGHTEN UP THE OVERALL WEIGHT OF THE MOUNT A LARGE WINDOW IS CUT INTO THE BRACKET.

IT'LL BE BENT AT THE TOP TO TIE IN TO THE TOP RAIL OF OUR BRONCO'S CHASSIS.

46!

THE BRACKET IS THEN GROUND TO FIT PERFECTLY AND TACKED INTO PLACE. FILLER PLATES ARE ADDED...

...AND A LARGE GUSSET IS USED TO BRACE THE UPPER MOUNT LATERALLY INTO THE SIDE OF THE CHASSIS. BOTH SHOCKS ARE REINSTALLED TO CHECK THE FIT, AND THE SHOCK MOUNT IS DONE WITH A TOTAL OF 26.5 INCHES OF TOTAL WHEEL TRAVEL IN THE REAR OF THIS RIG.