Blog Buggy Part 2 / Low Dollar Wheeler 5

(ANNOUNCER)>> AFTER A LONG TIRING DAY DESIGNING OUR NEXT ROCK CRAWLER, IAN HAD A BRILLIANT IDEA.

(IAN)>> WHY NOT LET YOU DO IT FOR ME.

(ANNOUNCER)>> WE'LL CALL IT PROJECT BLOG BUGGY. TODAY ON XTREME 4X4 WE'LL KNOCK OUT THE TRANSMISSION, TRANSFER CASE, AND MORE!

(IAN)>> TODAY WE'RE JUMPING BACK ON OUR BLOG BUGGY PROJECT. NOW IF YOU GUYS REMEMBER, THIS IS THE RIG WHERE WE CHOSE THE CHASSIS, PUT A POLL UP ON OUR WEBSITE, AND LET YOU GUYS PICK EVERY OTHER PART OF THIS RIG. NOW LAST TIME WE SHOWED YOU THE ENGINE, TRANSMISSION, AND AXLE CHOICE AS WELL AS WHAT LOCKERS AND WHAT TIRES AND WHEELS. NOW TODAY WE'LL LET YOU KNOW WHAT TRANSFER CASE WAS THE WINNER, AS WELL AS DEAL WITH A BUNCH OF ODDS AND ENDS THAT HAVE TO BE TAKEN CARE OF WHEN YOU GET A CHASSIS THAT'S JUST BASICALLY A BARE ROLLER. WE'VE GOT A BUNCH OF TUBE WORK TO DO ON THIS MOTOR, A WINCH MOUNT UP FRONT, AND SOME STUFF IN THE BACK. BASICALLY WE'LL WORK FROM THE FRONT TO BACK KNOCKING OUT A BUNCH OF ODDS AND ENDS.

WE'RE GONNA START TODAY BY BUILDING AN ENGINE CAGE, WHICH DOES EXACTLY LIKE IT SOUNDS. PROTECTS THE TOP OF THE ENGINE IN CASE YOU FLOP THE BUGGY OVER, BUT JUST BECAUSE IT HAS A SIMPLE JOB DOESN'T MEAN IT CAN'T HAVE SOME STYLE. KEEPING WITH OUR PLAN TO MOVE FROM THE FRONT TO THE BACK ON THIS CHASSIS TODAY, WE'RE GONNA START BY INSTALLING OUR WINCH UP FRONT. NOW WE DID NOT GIVE YOU GUYS ANY OPTIONS WHEN IT CAME TO THE WINCH BECAUSE OBVIOUSLY WE'RE GONNA BE INSTALLING ONE ON THE RIG. AND FOR THIS BUGGY WE CHOSE THE BRAND NEW WORN CTI NINE POINT FIVE WINCH. NOW I'M SURE A LOT OF YOU THINK IT LOOKS VERY FAMILIAR TO THE CLASSIC 9,500 THERMO METRIC BUT WHERE IT'S CHANGED IS INSIDE THE ELECTRIC MOTOR. IT HAS A WHOLE NEW CONTACT ASSEMBLY INSIDE. NOW THAT ALLOWS YOU TO HAVE A LONGER DUTY CYCLE, OR THE LENGTH OF TIME THAT YOU WORK THE WINCH WHEN YOU'RE OUT IN THE FIELD. IT ALSO SPEEDS UP THE LINE PULL FOR THIS FIVESIXTEENTHS PRESPUN AIRCRAFT CABLE. NOW THIS WINCH CAN HANDLE 9,500 POUNDS WORTH OF PULLING, AND THE NEW PISTOL GRIP DESIGN REMOTE HAS AN INTEGRATED LED THAT WILL TELL YOU IF YOU DO GET NEAR THE MAXIMUM END OF THAT DUTY CYCLE.

NOW WITH THE FRONT OF THE BUGGY ALL TAKEN CARE OF, WE'RE GONNA SKIP OVER THE MIDDLE JUST FOR NOW AND MOVE TO THE REAR WHERE WE'LL INSTALL AN ALL ALUMINUM FUEL CELL AND RADIATOR THAT WE GOT FROM SUMMIT RACING. NOW THIS 15 GALLON FUEL CELL COMES WITH ALL THE PROVISIONS WE'RE GONNA NEED TO RUN OUR FUEL INJECTION ENGINE AS WELL AS THE SENDING UNIT ON THE TOP TO WORK HAND IN HAND WITH THE GAUGE. NOW WHEN I ORDERED IT, I ALSO MADE SURE TO ORDER THE FUEL CELL HOLD DOWN STRAPS THAT'LL SANDWICH THE CELL BOTH TOP AND BOTTOM, AND SUPPORT IT WHEN IT'S IN THE CHASSIS. NOW THE RADIATOR IS A UNIVERSAL FIT RADIATOR AND IT WORKS GREAT WITH THE THREETWOONE CHASSIS MOUNTING IT IN THE REAR. THE SIDE TANKS HAVE THESE SLOTS CAST INTO THE SIDE THAT ALLOW YOU TO RUN THESE SMALL TBOLTS, MAKING MOUNTING THIS RADIATOR EASY AS PIE.

(ANNOUNCER)>> OUR TRANSMISSION CASE LOOKS GOOD AT FIRST GLANCE, BUT YOU'D BE SURPRISED AT SOME OF THE HIDDEN DAMAGE AND OTHER NASTINESS LURKING INSIDE. UP NEXT, WHEN TO REBUILD AND WHEN TO REPLACE.

(IAN)>> TODAY WE ARE RIGHT IN THE MIDDLE OF OUR BLOG BUGGY CHASSIS. BEFORE I SHOW YOU GUYS WHAT TRANSFER CASE YOU PICKED FOR THIS PROJECT, WE NEED TO DEAL WITH THIS TRANSMISSION. NOW EVEN THOUGH THE GUY WHO SOLD US THIS 400 SWEARS THAT IT'S IN GREAT SHAPE, READY TO BOLT IN AND RUN, IT'S ALWAYS A GOOD IDEA IF YOU GET A JUNKYARD TRANSMISSION TO AT LEAST TAKE THE PAN OFF AND GO THROUGH IT BEFORE COMMITTING TO USING IT IN YOUR RIG. NOTHING'S WORSE THAN BUILDING THE ENTIRE BUGGY, HOOKING UP TRANSFER CASES AND DRIVE SHAFTS AND AXLES, JUMPING IN IT, FIRING IT UP AND DROPPING IT INTO GEAR, AND FINDING OUT THAT THE TRANSMISSION THAT YOU WERE TOLD WAS GOOD WAS ACTUALLY BURNED UP.

OH DEAR! THE FIRST STEP IS TO JUST CHECK THE CONDITION OF THE FLUID. THAT CAN TELL YOU A LOT ABOUT THE TRANSMISSION. IF IT'S BRIGHT RED AND DOESN'T SMELL LIKE BURNT TOAST OR CHARCOAL, THE INTERNALS ARE PROBABLY PRETTY GOOD. IF YOU'VE GOT A MILKY WHITE COLOR COMING OUT, IT'S SEEN SOME WATER.

NOW EVEN THOUGH WE HAVE SOME TELL TALE SIGNS OF WATER INSIDE THE TRANSMISSION, SPECIFICALLY ON THIS FILTER, THE REST OF THE FLUID LOOKED TO BE IN PRETTY GOOD SHAPE. WE COULD PROBABLY JUST SWAP OUT THE FILTER, FLUSH THE TRANSMISSION, AND WE'D BE GOOD TO GO. BUT WHEN IT COMES TO A HARDCORE OFF ROAD RIG, YOU'RE HONESTLY BETTER TO GO THROUGH THE ENTIRE TRANSMISSION FRONT TO BACK TO MAKE SURE ANY UPDATE THAT COULD POSSIBLY BE DONE INSIDE THE CASE IS TAKEN CARE OF. THAT WAY IT CAN HANDLE THE ABUSE OF SERIOUS OFF ROAD. THE NICE THING ABOUT THE 400 IS IT'S ONE OF THE EASIEST TRANSMISSIONS TO REBUILD.

( drill spinning )

(IAN)>> WELL!

ANY GOOD TRANSMISSION REBUILD ALWAYS BEGINS WITH A GOOD THOROUGH INSPECTION OF THE TRANSMISSION CASE. NOW THE FIRST AREA THAT WE NOTICED WHEN WE TORE IT DOWN WAS THAT THE BOLT FOR THE CENTER SUPPORT WAS BROKEN AND WE REMOVED IT WITH THAT EASY OUT. NOW THAT MEANS WE MAY HAVE PROBLEMS INSIDE THE TRANSMISSION, BUT THERE'S A COUPLE OF THINGS OUTSIDE THAT JUMPED OUT AT US RIGHT AWAY. AT THE BACK SOMEONE HAS BROKEN ONE OF THE MOUNTING HOLES OFF FOR THE ADAPTER. THEY SIMPLY WELDED IT ALL UP AND RETAPPED IT. NOW THAT IS NOT THE END OF THE WORLD AS LONG AS IT DOESN'T LEAK FLUID. WE HAVE ANOTHER PROBLEM ON THE OTHER SIDE WHERE ONE OF THE FREEZE PLUGS WAS TAPPED INTO THE CASE TO BLOCK OFF A FACTORY MODULATOR. YOU CAN SEE THAT A HAIRLINE CRACK HAS STARTED TO OPEN UP. THAT IS PROBABLY JUST GONNA CONTINUE ALL THE WAY INTO THE TRANSMISSION AND START A LEAK RIGHT THERE. NOW WHEN WE LOOKED INSIDE WHERE THAT CENTER SUPPORT BOLT WAS BROKEN, WE CAN SEE A COUPLE OF HAIRLINE CRACKS. NOW WE'RE NOT SURE IF THEY'RE CASTING FLANGE ISSUES OR IF THE CASE ITSELF IS STARTING TO BREAK, BUT AT THIS POINT IN TIME THE FACT THAT WE'VE SEEN THREE PROBLEMS WITH THIS CASE, WE KNOW RIGHT AWAY WE'VE GOT TO FIND ANOTHER ONE. NOW SOMEONE HAS ALREADY BEEN IN THIS TRANSMISSION. THAT'S NOT THE END OF THE WORLD. YOU CAN TAKE A TRANSMISSION APART MANY TIMES THAT'S BEEN REBUILT BEFORE, BUT OCCASIONALLY YOU'LL SEE THINGS THAT YOU QUESTION WHY PEOPLE EVEN BOTHER. IN THE CASE OF THIS TRANSMISSION, THE SHIFT LEVER RIGHT HERE NORMALLY HAS COTTER PIN THAT HOLDS IT IN PLACE. OBVIOUSLY WHOEVER REBUILT THIS TRANSMISSION DIDN'T HAVE ANY COTTER PINS BECAUSE THEY PUT IN AN ACTUAL NAIL NORMALLY USED IN THE WOOD SHOP. THAT IS PROBABLY NOT A GOOD IDEA. THEY COULD HAVE AT LEAST CUT THE END OFF TO MAKE IT NOT LOOK LIKE A NAIL ANY MORE. JUST LIKE THE CASE, EVERYTHING INSIDE THE TRANSMISSION MUST BE DISASSEMBLED AND INSPECTED AS WELL. THE MAIN WEAR ITEM YOU'RE KEEPING YOUR EYES ON ARE THE CLUTCH PACKS. IF ANY OF THEM ARE BURNT UP, YOU HAVE TO FIGURE OUT WHY. YOU CAN SEE INSIDE THIS TRANSMISSION, EVERYTHING STILL LOOKS GOOD AS NEW. CONSIDERING HOW MUCH WORK IT IS TO REBUILD YOUR AUTOMATIC TRANSMISSION, THE BEST THING YOU CAN DO FOR HARDCORE WHEELING IS TO UPGRADE AS MUCH AS YOU CAN IN ONE SHOT. AND THE EASIEST WAY TO DO THAT IS WITH A MONSTER IN THE BOX KIT FROM MONSTER TRANSMISSION. NOW IT COMES WITH EVERY CONCEIVABLE UPGRADE FOR THE MODEL OF TRANSMISSION THAT YOU ARE REBUILDING. AND IN THE TURBO 400, NOT ONLY DOES IT REPLACE SOME OF THE HARD PARTS, IT REPLACES SOME OF THE STOCK WEARABLE COMPONENTS WITH ITEMS THAT CAN HANDLE MORE ABUSE. PERFECT EXAMPLE OF THAT ARE THE CLUTCH DISCS. THESE MAY LOOK EXACTLY LIKE THE CLUTCH DISCS THAT WE TOOK OUT OF THE TRANSMISSION, BUT THEY'RE NOT. THESE ARE RED ALTO CLUTCH DISCS. THE MATERIAL THAT THEY'RE MADE FROM IS DESIGNED TO HANDLE HIGHER HEATS BEFORE IT STARTS TO BREAK DOWN. YOU CAN EASILY SEE THAT THE STEELS ARE COMPLETELY DIFFERENT. THEY'RE BLACK INSTEAD OF SILVER. NOW THAT BLACK IS ACTUALLY A TEFLON COATING DESIGNED TO LET THE CLUTCH PACKS SLIP A LITTLE BIT EASIER WHEN THEY'RE NOT ENGAGED. BY ALLOWING THEM TO SLIP EASIER KEEPS THE TEMPERATURE DOWN AND WILL EXTEND THE LIFE OF THE ENTIRE CLUTCH PACK ITSELF. NOW IN THE 400 WE'RE GONNA REPLACE THE ENTIRE DRUM ASSEMBLY WITH A NEW UNIT WITH A HEAVY DUTY SPRAG ON THE FRONT OF IT. AND WHILE WE'RE INSIDE THE TRANSMISSION, WE'RE GONNA UPGRADE EVERY SINGLE BUSHING. BECAUSE OF THE WATER WE FOUND IN THE PAN, ANY RUST ON ANY OF THESE BUSHINGS COULD LEAD TO FUTURE FAILURES.

(ANNOUNCER)>> COMING UP, WE REPLACE OUR BEAT UP TRANSMISSION CASE WITH A GENTLY USED MODEL, AND THEN CUT THAT SUCKER UP!

(IAN)>> ALL OF OUR NEW UPGRADED PARTS ARE INSTALLED ONTO OUR TRANSMISSION INTERNALS AND THEY'RE READY TO BE DROPPED INTO OUR NEW CASE. NOW FOR THAT NEW CASE I JUST RAN DOWN TO A LOCAL TRANSMISSION SHOP AND PICKED UP THIS GOOD USED TURBO 400 TRANSMISSION CASE THAT BELIEVE IT OR NOT IS A TWO WHEEL DRIVE VERSION FOR A PONTIAC CAR. NOW THE NICE THING IS IS IT'S A LOT CHEAPER TO BUY ONE THAT'S TWO WHEEL DRIVE INSTEAD OF FOUR WHEEL DRIVE. AND BECAUSE IT'S OUT OF A PONTIAC, IT PROBABLY WAS NOT ABUSED AS MUCH AS A FOUR WHEEL DRIVE TRUCK UNIT. NOW THE ONE THING I'M SURE A LOT OF YOU GUYS ARE WONDERING IS HOW ARE YOU GOING TO ADAPT A PONTIAC BELL HOUSING TO BOLT UP TO OUR CHEVY MOTOR. WELL WE'RE GONNA DO THAT AND UPGRADE THE BELL HOUSING ALL AT THE SAME TIME. IF THE TURBO 400 HAS ONE DRAWBACK, IT'S IN THE BELL HOUSING ITSELF. CAST RATHER THIN AND CAN CRACK VERY EASILY. BUT THE NICE THING IS BECAUSE OF THE POPULARITY OF THIS TRANSMISSION FOR DRAG RACING APPLICATIONS, YOU CAN UPGRADE THE BELL HOUSING LIKE WE ARE HERE. WE'RE GONNA BE USING A HEAVY DUTY BELL HOUSING THAT WE GOT FROM SUMMIT RACING THAT IS SFI APPROVED. ONCE BOLTED TO THE FRONT OF THIS TRANSMISSION, IT SHOULD BE BOMB PROOF. NOW THE LAST UPGRADE WE'RE GONNA THROW AT THIS TRANSMISSION HAS TO DO WITH THE VALVE BODY ITSELF. WE'RE GONNA REPLACE IT WITH THIS UNIT THAT WE ALSO GOT FROM SUMMIT RACING. IT IS A FULL MANUAL REVERSE PATTERN VALVE BODY THAT WILL BOLT INTO THE BOTTOM OF THE TRANSMISSION AND REPLACE THE VALVE BODY THAT WE TOOK OUT. NOW NOT ONLY DOES IT CHANGE HOW THE TRANSMISSION SHIFTS, IT ACTUALLY CHANGES THE LOCATION OF EACH GEAR. WHEN YOU PULL THE TRANSMISSION OUT OF PARK, IT'LL GO PARK, REVERSE, NEUTRAL JUST LIKE NORMAL. THEN WHEN YOU PULL IT DOWN ONE MORE LEVER YOU WON'T GET DRIVE, YOU'LL GET FIRST GEAR. ONE MORE LEVER AGAIN YOU GET SECOND GEAR, AND ONE MORE YOU GET THIRD. THIS TRANSMISSION IS NO LONGER AN AUTOMATIC TRANSMISSION. THINK OF IT AS A HEAVY DUTY STANDARD TRANSMISSION WITHOUT A CLUTCH.

WHEN IT CAME TIME FOR YOU GUYS TO CHOOSE THE TRANSFER CASE FOR THIS RIG, SO MANY OF YOU CHOSE THIS ONE RIGHT HERE WE'RE NOT EVEN GONNA TALK ABOUT THE OTHER TWO OPTIONS. OVER 80 PERCENT OF YOU WANTED TO SEE A FOUR SPEED ATLAS TRANSFER CASE INSTALLED IN THIS BUGGY. NOW THE WAY THIS WORKS IS RATHER UNIQUE. ON THE BACK HALF IT'S BUILT VERY SIMILAR TO A TRADITIONAL ATLAS TRANSFER CASE WITH HEAVY DUTY HELICAL CUT GEARS, TRUE ROLLER BEARINGS, AND HEAVY DUTY OUTPUTS BOTH FRONT AND REAR. BUT INSTEAD OF JUST BOLTING UP TO THE TRANSMISSION, THERE'S AN ADDITIONAL REDUCTION BOX MOUNTED TO THE FRONT OF THE TRANSFER CASE. NOW INSIDE HERE WE HAVE A TWO POINT SEVEN TWO TO ONE PLANETARY GEAR SET. NOW THAT GIVES US FOUR DIFFERENT RATIO OPTIONS TO CHOOSE FROM. WE CAN CHOOSE A ONE TO ONE HIGH. WE CAN ENGAGE THE TWO POINT SEVEN TWO REDUCTION OF THE FRONT RATIO BOX ALONE. WE CAN COMBINE THAT WITH THE TRANSFER CASE OPTION, WHERE IN THIS CASE WE HAVE A THREE POINT EIGHT. SO WE HAVE A ONE TO ONE, TWO POINT SEVEN TWO, THREE POINT EIGHT, OR THE ULTIMATE LOW OF 10.34 TO ONE. NOW WHAT MAKES THAT A GOOD BENEFIT IS IT GIVES YOU LOTS OF DIFFERENT OPTIONS WHEN IT COMES TO CHOOSING YOUR RING AND PINION. YOU CAN CHOOSE A SENSIBLE RING AND PINION FOR JUST CRUISING AROUND THE TRAILS OR EVEN HIGH SPEED DESERT RACING. BUT WHEN YOU NEED TO SLOW THE RIG DOWN FOR SOME SERIOUS STOPPING POWER, YOU CAN EASILY ENGAGE THAT ULTIMATE LOW.

(ANNOUNCER)>> MICHELANGELO WORKED IN MARBLE, REMBRANDT USED OILS, BUT IAN PREFERS RATTLE CANS! IT'S A CUSTOM CAMO PAINT JOB ON THE CHEAP!

(ANNOUNCER)>> XTREME'S LOW DOLLAR WHEELER IS BROUGHT TO YOU BY FOUR WHEEL PARTS, YOUR TRUCK AND JEEP ACCESSORY SUPER STORE ONLINE AT FOUR WHEEL PARTS DOT COM.

(IAN)>> WE ARE JUST ABOUT FINISHED UP WITH OUR LOW DOLLAR WHEELER AND WE'VE SPENT EXACTLY $5,000 DOLLARS. THIS JEEP CHEROKEE IS READY TO HIT THE TRAIL, BUT BEFORE WE TAKE IT OUT WE WANT TO DEAL WITH ONE LAST THING AND THAT IS THIS WORN, FADED, SAD LOOKING WHITE FACTORY PAINT JOB. NOW IF YOU WANT TO PAINT YOUR RIG ON A BUDGET, THE EASIEST WAY TO DO IT IS WITH A SPRAY CAN. BUT IF YOU WANT TO MAKE IT NOT LOOK LIKE YOU SPRAYED IT WITH A SPRAY CAN, THE BEST ANSWER THERE IS CAMOUFLAGE. JUST BECAUSE WE'RE SPRAYING THIS TRUCK ON THE CHEAP DOESN'T MEAN WE DON'T WANT IT TO STILL LOOK GOOD. SO WE'LL MASK OFF EVERYTHING THAT WE DON'T WANT TO GET PAINT ON LIKE THE GRILL, THE WINDOWS, AND WE'LL EVEN RIP OFF THE STOCK FENDER FLARES TO MAKE SURE THAT WE GET GOOD COVERAGE UP INTO THE FENDER WELLS.

PAINTING A TRUCK CAMOUFLAGE IS HONESTLY VERY EASY. START WITH YOUR DARKEST COLOR, LIKE A BLACK, AND LAY DOWN A BUNCH OF DIFFERENT SHAPES. THEN SLOWLY LIGHTEN IT UP WITH SOME BROWN, SOME OLIVE GREEN, AND FINISH IT OFF WITH A COUPLE OF TAN HIGHLIGHTS. BUT HONESTLY THE BEST PART IS YOU CANNOT SCREW UP A CAMO PAINT JOB. JUST KEEP SPRAYING UNTIL IT LOOKS RIGHT TO YOU. EVEN THOUGH WE HAVE A FOUR AND A HALF INCH LIFT ON OUR CHEROKEE, THE TIRES ARE STILL CONTACTING THE FENDERS AT FULL LOCK. AND CONSIDERING WE JUST SUNK A HEFTY $25 BUCKS AND AN HOUR AND A HALF INTO THAT CUSTOM PAINT JOB, WE DON'T WANT TO RUIN IT. SO WE'RE GONNA SOLVE THAT PROBLEM BY OPENING UP THE FENDER WELLS AND INSTALLING A SET OF BUSHWHACKER FLAT STYLE FENDER FLARES. NOW THEY'LL NOT ONLY GIVE US THAT CLASSIC FLAT STYLE FENDER THAT'LL GO REALLY WELL WITH OUR CAMOUFLAGE PAINT JOB. IT'LL ALSO ALLOW US TO OPEN UP THE BOTTOM OF THE WHEEL WELLS, GIVE US MORE CLEARANCE FOR OUR 33'S.

AND OUR LOW DOLLAR WHEELER IS FINALLY 100 PERCENT DONE, AND I'LL BET YOU GUYS WILL AGREE THAT A JEEP CHEROKEE IS A GREAT VEHICLE TO BUILD A BUDGET CRAWLER ON. WE HAVE LESS THAN $5,500 BUCKS IN THIS TRUCK BUMPER TO BUMPER, AND WE'VE CONVERTED A WORN OUT OLD MALL CRAWLER INTO A TRUCK THAT'S NOT ONLY READY TO PERFORM OFF ROAD. NOW IT LOOKS GOOD TOO. FOR DETAILS ON ANY OF THE PRODUCTS SEEN IN TODAY'S EPISODE, HEAD ON OVER TO POWERBLOCK TV DOT COM!