Diesel Buggy Part 6 / Driveway Rescue Project 1

(ANNOUNCER)>> WHEN OUR TURBO DIESEL PULLED ALMOST 2,000 FOOT POUNDS ON THE DYNO, WE KNEW IT WAS TOO MUCH ENGINE FOR OUR ROCK CRAWLER. THE SOLUTION, TURN OUR TRAIL RIG INTO A MUD BUGGY. TODAY ON XTREME 4X4, A CUSTOM AIR INTAKE TO KEEP THE MUD OUT, UPDATED SUSPENSION, AND MORE. PLUS, WHEN YOU GET STUCK ON YOUR PROJECT, EVER WISH IAN COULD DROP IN AND HELP YOUR BUILD MOVE FORWARD. WELL NOW HE CAN.

(IAN)>> TODAY ON XTREME WE'VE GOT A PROJECT BACK IN THE SHOP THAT SOME OF YOU HAVE PROBABLY BEEN WONDERING WHERE IT'S BEEN AND OTHERS PROBABLY DON'T RECOGNIZE IT AT ALL. IT'S OUR DIESEL POWERED CURVY BUGGY. NOW THE REASON IT HASN'T BEEN IN HERE FOR A WHILE IS HONESTLY I JUST HIT A ROAD BLOCK WITH THIS PROJECT. AND LIKE YOU GUYS AT HOME, REAL LIFE GOT IN THE WAY.

I HAD OTHER STUFF TO WORK ON. SO I JUST STUFFED IT INTO THE CORNER AND LET IT SIT. BUT SO MANY OF YOU GUYS HAVE ASKED ABOUT THIS, IT'S TIME TO GET PAST THOSE ROAD BLOCKS, BRING IT BACK IN THE SHOP, AND GET IT CLOSER TO COMPLETION. NOW TODAY THAT'S EXACTLY WHAT WE'LL DO. WE'LL SHOW YOU ALL THE ROAD BLOCKS THAT WE HIT, HOW WE'RE GONNA GET PAST THEM. BY THE END OF TODAY WE'LL HAVE AIR CLEANER, CUSTOM EXHAUST, AND SITTING ON SOME SUSPENSION. PLUS WE'VE GOT A SPECIAL TREAT FOR YOU GUYS WHO ARE STUCK ON PROJECTS OF YOUR OWN. THE IDEA FOR THIS BUGGY STARTED WHEN WE TOOK DELIVERY OF A BRAND NEW TOOL, OUR BAILEIGH TUBING ROLLER. NOW WE DECIDED TO BUILD A BUGGY WITH NO STRAIGHT TUBES IN THE CHASSIS AT ALL. AFTER RUNNING A PILE OF INCH AND THREE QUARTER DOM THROUGH THE ROLLERS, WE HAD A PRETTY UNIQUE RIDE, AND THE OVER THE TOP ATTITUDE WASN'T GONNA STOP THERE. 54 INCH TALL MICKEY THOMPSON TTC CLAWS ON 20 INCH STASWORKS DOUBLE BEAD LOCKS.

FINISH IT OFF WITH A REAR MOUNTED DURAMAX DIESEL ENGINE THAT WAS GIVEN A PILE OF UPGRADES FROM THE CREW AT FLEECE PERFORMANCE BEFORE TEARING UP THE DYNO CELL DOWN THE HALL AT THE HORSEPOWER SHOP. LAYING DOWN OVER 1,900 FOOT POUNDS OF TORQUE AT THE FLYWHEEL, AND THAT'S WHERE THE PROBLEMS BEGAN. IMAGINE THAT YOU'RE STRAPPED INTO THIS BUGGY AND YOU HAVE 1,900 POUND FEET OF TORQUE WITH TWIN TURBOS SPOOLING UP BEHIND YOU. THAT IS NOT A MOTOR THAT IS GONNA BE MANAGEABLE IN A ROCK CRAWLER AT ALL. AND THAT WAS OUR FIRST ROAD BLOCK. WE DON'T WANT TO GET RID OF THE TWIN TURBO DURAMAX BECAUSE IT'S JUST FLAT OUT COOL, BUT WHAT DO WE DO NOW. WE CAN'T RUN A ROCK CRAWLER WITH THIS CHASSIS. SO NOW WE'RE GONNA CHANGE IT ALL. A BIG MOTOR LIKE THAT YOU'LL FIND IN A MUD TRUCK ALL DAY LONG. THIS IS GOING TO BE OUR FIRST MUD BUGGY, AND THAT LEADS US TO OUR FIRST REAL ISSUE. YOU CAN'T HAVE AN OPEN AIR CLEANER ELEMENT ON A MUD BUGGY. WE NEED TO FIND A WAY TO GET FRESH AIR DOWN TO THE ENGINE AND NOT SUCK IN A BUNCH OF WATER AND DIRT. I'M GOING TO BUILD AN ENCLOSED AIR BOX FOR THREE FLAT PLATE STYLE SUMMIT RACING AIR FILTERS. THE BOX WILL BEGIN WITH A COMPLETE CARDBOARD MOCK UP MADE UP OF THREE KEY PARTS, THE FILTER MOUNT OR CENTER FILL PANEL, THE LOWER AIR BOX ASSEMBLY, AND THE UPPER AIR BOX THAT WILL ACT LIKE A HOOD SCOOP. ONCE THE ENTIRE AIR BOX IS BUILT OUT OF CARDBOARD, WE'LL CHECK THE FIT ON THE ROOF OF THE BUGGY, AND THEN BUILD THE ENTIRE THING OUT OF SOME .090 ALUMINUM SHEETS.

WITH THE UPPER HALF OF OUR ROOF BOX ASSEMBLY MOUNTED INTO THE ROOF, YOU CAN SEE THAT THE SCOOP ON THE TOP WILL ALLOW THE AIR TO BE DRAWN THROUGH THE THREE PLATE FILTERS. WE'LL SEAL OFF THE BOTTOM OF THE FILTERS WITH ANOTHER SCOOP TYPE ASSEMBLY, WELD IT IN PLACE, DRILL A HOLE ON THE BACK SIDE, AND THEN WE'LL CONNECT IT TO THE TURBO USING SOME OF THESE UNIVERSAL COLD AIR KIT ELBOWS THAT WE ALSO GOT FROM SUMMIT RACING. WE CAN CHANGE THE FILTERS OUT THROUGH THE TOP OF THE SCOOP SIMPLY BY LIFTING THEM OUT OF THE HOLE THAT WE CUT INTO THAT AIR BOX ASSEMBLY. NOW ONE THING THAT'S VERY IMPORTANT WITH THE DESIGN OF THIS UPPER AIR BOX IS WE'VE LEFT THE NOSE OF THE SCOOP OPEN.

THAT WAY IF ANY WATER GETS THROWN INTO THAT SCOOP FROM THE TIRE, IT'LL SIMPLY DRAIN OUT THE FRONT OF THE ROOF INSTEAD OF BEING PULLED IN THROUGH THE FILTERS AND INTO OUR TURBO CHARGER. NOW WHEN YOU'RE WORKING WITH THIS .090 ALUMINUM YOU DON'T WANT TO PUT TOO MUCH HEAT TO IT RIGHT AWAY. WE'VE JUST WELDED IT IN SHORT SECTIONS. WE'LL COME BACK LATER ONCE IT'S COOLED DOWN, FINISH WELD THE WHOLE THING, AND GRIND IT OFF FOR A NICE, CLEAN BRUSHED ALUMINUM LOOK.

(ANNOUNCER)>> UP NEXT, OUR FOUR BY FOUR PHYSICIAN CAN HELP YOU WITH YOUR PROJECT, AND HE EVEN MAKES HOUSE CALLS!

(ANNOUNCER)>> NEED HELP SOLVING A PROBLEM WITH YOUR PROJECT? HERE'S DRIVEWAY RESCUE BROUGHT TO YOU BY FOUR

WHEEL PARTS DOT COM.

(IAN)>> SOMETIMES IT'S NOT THE BIG JOBS THAT STOP A PROJECT IN ITS TRACKS, IT'S THE LITTLE THINGS, AND THAT'S WHAT WE'RE HERE TO HELP WITH TODAY.

NOW WE'RE HERE TO GIVE JEFF HARDY A LITTLE BIT OF A HELPING HAND INSTALLING A SLIP YOKE ELIMINATOR AND NEW DRIVESHAFT IN THE BACK OF HIS TJ. WE SWUNG BY FOUR WHEEL PARTS AND PICKED UP EVERYTHING WE NEEDED. NOW WE'RE HERE AT HIS HOUSE. LETS HAVE A LOOK AT THAT JEEP. HOW ARE YOU DOING JEFF?

(JEFF)>> HEY IAN!

(IAN)>> GOOD TO MEET YOU.

(JEFF)>> YOU TOO.

(IAN)>> SO THIS IS THE JEEP RIGHT?

(JEFF)>> YES SIR.

(IAN)>> ALRIGHT, TELL ME A LITTLE BIT ABOUT IT.

(JEFF)>> IT'S A 2003. WE PICKED IT UP IN 2005. I'VE DONE A COUPLE OF LITTLE THINGS TO IT, LITTLE BUDGET BOOST, NEW WHEELS AND TIRES, AND ROCK SLIDERS, WINCH, AND WHEELED IT LIKE THIS.

(IAN)>> AND NOW BEFORE YOU PUT THE BIG LIFT ON YOU NEED SOME HELP WITH A SLIP YOKE ELIMINATOR AND A NEW DRIVESHAFT RIGHT?

(JEFF)>> YES SIR.

(IAN)>> ALRIGHT, WELL THE FIRST THING WE'RE GONNA DO IS WE'RE GONNA GET IT UP IN THE AIR A LITTLE BIT, PULL THAT SKID PLATE OFF.

(JEFF)>> SOUNDS GOOD.

(IAN)>> WE NEED SOME TOOLS FIRST.

(JEFF)>> FOR THE LONGEST TIME THIS WAS JUST A TOY. SO I TORE IT UP, IT WAS NO BIG DEAL. BUT NOW IT'S MY EVERYDAY DRIVER, SO I'VE GOT TO BE ABLE TO DRIVE TO WORK TOMORROW.

(IAN)>> ALRIGHT, LETS PULL THIS DOWN.

ALRIGHT, THE FIRST THING WE'RE GONNA DO IS DRAIN THE TRANSFER CASE, BUT THIS IS WHAT'S GOING ON THE BACK. WE'VE GOT AN ALL NEW FIXED YOKE OR SLIP YOKE ELIMINATOR

LIKE WE TALKED ABOUT. THIS IS FROM PRO COMP, AND THEN A BRAND NEW PRO COMP DRIVESHAFT. NOW THIS DRIVESHAFT WILL REPLACE THE ONE THAT WE TOOK OUT AND IT'S GOOD FROM NO LIFT UP TO FIVE INCHES OF LIFT. AND YOU SAID YOU WE'RE GONNA LIFT THE JEEP RIGHT?

(JEFF)>> YES, FOUR INCHES LATER.

(IAN)>> FOUR INCHES UP HIGHER, SO THIS WILL WORK WELL. THIS WILL JUST REPLACE THAT SHAFT, ALL THESE INTERNALS

WILL REPLACE EVERYTHING INSIDE THE TRANSFER CASE. ALL WE'VE GOT TO DO NOW IS DRAIN IT. WE'RE GONNA REBUILD THIS TRANSFER CASE ON A FOLDING TABLE IN JEFF'S DRIVEWAY. THE ONLY THING WE'LL HAVE TO BE CAREFUL OF IS MAKING SURE

THAT WE DON'T LOSE ANY PARTS. THE ONE GOOD THING, IF I MISS AND HIT MYSELF IN LIKE THE HAND OR SOMETHING, I'VE GOT A FIREMAN HERE TO STITCH ME BACK UP.

(JEFF)>> I'LL CALL 911!

(IAN laughing )

THIS IS THE OIL PUMP.

THIS IS THE ONLY TRANSFER CASE THAT HAS AN OIL PUMP. INSTEAD OF JUST LIKE THE GEARS SPLASHING AROUND IN THE OIL, THIS ACTUALLY DRAWS OIL UP FROM HERE. THIS IS YOUR LITTLE FILTER DOWN HERE. IT SUCKS IT UP AND LUBRICATES EVERYTHING.

THE BIGGEST PROBLEM PEOPLE HAVE WHEN THEY PUT THESE BACK TOGETHER. SEE THAT LITTLE TINY LITTLE PIPE IN THERE?

(JEFF)>> YEAH.

(IAN)>> THEY WON'T GET THAT HOOKED UP AND THEN WHAT HAPPENS IS IT'LL LAST FOR 5,000 MILES AND THEN THE TRANSFER CASE IS GARBAGE. THIS IS A MACHINED SURFACE, SO YOU CAN'T LIKE STICK A SCREW DRIVER IN IT, BUT THERE WILL BE A COUPLE OF SPOTS.

JUST LIFT IT RIGHT OFF, SET THAT ASIDE. THAT'S THE OIL PUMP TUBE THAT I WAS TALKING ABOUT. AND IT'S EASY TO COME OUT OF THERE. SEE HOW IT'LL JUST POP OUT OF THERE? SO IF IT'S IN THERE LIKE THAT, IT'LL STARVE THAT CASE OF OIL.

HOLD IT DOWN LIKE THAT?

(JEFF)>> I SURE WILL.

(IAN)>> THIS TYPE OF SNAP RING USES A SNAP RING AS PART OF THE PIN AND IT'S JUST A LOT STRONGER. JUST LESS CHANCE THAT IT'S GOING TO FAIL.

OKAY, THIS IS PROBABLY THE TRICKIEST PART. THIS IS HOW THIS SHIFTS. SO THIS IS THE RAIL THAT MOVES UP AND DOWN AND IT ENGAGES THE COLLARS IN HERE. BUT WHAT WE HAVE TO DO IS WE'RE BASICALLY GONNA SLIDE THAT IN THERE AND LINE UP THAT COLLAR BUT WE HAVE TO DO THAT WHILE AT THE SAME TIME THIS WHOLE THING'S GOT TO GO IN AT ONE SHOT CAUSE ONCE THE CHAIN'S AROUND THIS IT CAN'T GET BACK IN THERE. OKAY, COME ON DOWN WITH IT. OH, UP A BIT!

THERE WE GO.

(JEFF)>> IT'S KIND OF OVERWHELMING TO TEAR APART A TRANSFER CASE IF YOU'VE NEVER DONE IT BEFORE. THERE'S A LOT OF LITTLE PARTS IN THERE. A LOT OF THE SMALL STEPS SUCH AS THE OIL PICK UP TUBE, WERE VERY HELPFUL. I WOULD FEEL VERY COMFORTABLE DOING THIS IN THE FUTURE.

(IAN)>> ONCE WE FILL THE CASE WITH SOME FRESH ATF, IT'S READY FOR US TO PUT IT BACK IN.

YEP, I'D SAY THAT'S TIGHT.

SO THERE YOU GO. IT WASN'T AS HARD AS YOU THOUGHT WAS IT?

(JEFF)>> NO, IT WAS FAIRLY EASY.

(IAN)>> AND NOW THAT YOU'VE DONE ONE YOU COULD PROBABLY DO 100 MORE.

(JEFF)>> I THINK SO.

(IAN)>> ALRIGHT, WELL HEY, THANKS FOR HAVING US OUT.

(JEFF)>> THANK YOU IAN.

(IAN)>> ALRIGHT, GET THIS THING ON THE TRAIL, SEND US A PICTURE.

(JEFF)>> SURE WILL.

(IAN)>> ALRIGHT, LOOKING FORWARD TO IT, YEAH!

(IAN)>> TODAY WE'RE DEALING WITH SOME ROADBLOCKS THAT BASICALLY STOPPED OUR CURVY BUGGY PROJECT IN ITS TRACKS.

SO FAR WE'VE COMPLETELY CHANGED DIRECTIONS

WITH THIS RIG. WE ARE NO LONGER PUTTING TOGETHER AN OVER THE TOP ROCK CRAWLER. WE'RE BUILDING OUR FIRST EVER MUD BUGGY. NOW ONE AREA THAT DEFINITELY NEEDS TO BE ADDRESSED

NOW IS THE SUSPENSION. IF YOU GUYS REMEMBER, WE HAD A VERY COMPLICATED CANTILEVER STYLE SUSPENSION DESIGN SET UP FOR THIS RIG, WITH A PIVOT POINT ON THE CHASSIS AND SOME COIL OVER SHOCKS MOUNTED TRANSVERSELY ACROSS THE HOOD. NOW THERE'S DEFINITELY A BENEFIT TO THAT WHEN YOU'RE ROCK CRAWLING BECAUSE IT CAN INCREASE THE WHEEL TRAVEL WHEN YOU'RE OUT IN THE TRAILS. BUT WHEN YOU'RE TALKING ABOUT A MUD BUGGY, WHEEL TRAVEL IS NOT THAT IMPORTANT.

YOU JUST NEED TO ABSORB SOME SHOCKS THAT YOU'LL FIND WHEN YOU'RE IN THE PIT. SO WE'RE GONNA COMPLETELY REMOVE ALL OF THAT AND JUST GO BACK TO A TRADITIONAL SET OF COIL OVERS MOUNTED JUST LIKE EVERY OTHER RIG WE'VE BUILT.

THE FIRST STEP IN REDESIGNING OUR SUSPENSION WILL BE TO COMPLETELY REINSTALL ALL OF OUR FOUR LINK SUSPENSION BARS. THEN WE'LL SET THE AXLE AND THE CHASSIS AT THE HEIGHT THEY'LL SIT WHEN THE SHOCK IS FULL COMPRESSED.

NOW WE ARE ABLE TO REUSE THE SHOCKS THAT WE HAD PUT

IN WITH OUR PREVIOUS SUSPENSION DESIGN. THEY ARE BILSTEIN 9,100 SERIES TWO AND A HALF INCH COIL OVER

SHOCKS WITH 12 INCHES OF STROKE. NOW IF YOU GUYS REMEMBER, WHEN WE WERE BUILDING THIS AS A ROCK CRAWLER, 12 INCHES OF STROKE DOESN'T SOUND LIKE A

LOT, BUT WE WERE INSTALLING THEM WITH A CANTILEVER SUSPENSION SYSTEM TO GIVE US ALMOST 20 INCHES OF WHEEL TRAVEL.

NOW WE DON'T NEED TO WORRY ABOUT THAT MUCH WHEEL TRAVEL NOW BECAUSE NOW A MUD BUGGY. AND JUST HAVING A GOOD COMPACT SETUP LIKE THIS 12 INCH SHOCK WILL WORK PERFECTLY. WE ARE GONNA LEAVE IN PLACE THE SLIDER STOPS AND DUAL RATE KIT SO WE CAN INSTALL TWO DIFFERENT RATES OF SPRINGS ONTO THE SHOCK TO BE ABLE TO CONTROL THE SUSPENSION TRAVEL. REMEMBER WE GOT 1,900 POUND FEET OF TORQUE PUSHING THIS BUGGY, AND JUST LIKE A LOT OF MUD TRUCKS, THEY'VE GOT A LOT OF HORSEPOWER, A LOT OF WHEEL SPIN, AND THE BEST CASE SCENARIO, THEY PICK UP A LOT OF SPEED IN THAT MUD PIT. WHEN THEY POP OUT OVER THE BACK END OF THE MUD PIT, THEY TEND TO GET A LOT OF SUSPENSION TRAVEL AND SOMETIMES END UP CATCHING A LITTLE BIT OF AIR. BY BEING ABLE TO FINE TUNE THE SUSPENSION WITH OUR DUAL RATE KIT, WE'LL BE ABLE TO KEEP THE BUGGY IN CONTROL WHEN WE'RE

COMING OUT OF THE DIRT.

(ANNOUNCER)>> IF IT TAKES A FORK LIFT AND A SAWZALL TO

INSTALL YOUR ENGINE, YOU MUST BE DOING SOMETHING RIGHT!

(IAN)>> THERE WE GO.

(IAN)>> THE FINAL ROAD BLOCKS THAT WE HAVE TO DEAL WITH ON OUR BUGGY ALL REVOLVE AROUND THE ENGINE. IT'S CHANGED A LOT SINCE WE ORIGINALLY BUILT OUR CURVY BUGGY CHASSIS, AND I'M SURE THAT WE'RE GONNA HAVE SOME PROBLEMS WHEN WE DROP THIS TWIN TURBO DURAMAX BACK IN.

(JOHN)>> 2,000 FOOT POUNDS IN A BUGGY?

(IAN)>> RIGHT AWAY WE FOUND A COUPLE OF PROBLEMS, BUT IT'S NOTHING A GOOD SAWZALL WON'T FIX.

THERE WE GO!

BEFORE WE START MAKING THE REQUIRED CHANGES TO OUR

BUGGY'S CHASSIS, I WANT TO FINISH OUT THE FULL EXHAUST SYSTEM JUST TO MAKE SURE NONE OF IT WILL GET IN THE WAY OF THE TUBING THAT WE'RE GONNA ADD TO THE RIG. NOW FOR OUR EXHAUST WE'RE GONNA BE USING A 100 PERCENT STAINLESS STEEL UNIVERSAL FIT EXHAUST KIT THAT WE GOT FROM MAGNAFLOW. NOW ONE OF THE NICE THINGS ABOUT THIS KIT IS IT'S MADE OUT OF MONSTER FIVE INCH STAINLESS STEEL PIPE THAT IS BENT USING A PROCESS CALLED MANDREL BENDING, WHICH MEANS THAT ALL THE INSIDE CURVES OF THE EXHAUST ARE SMOOTH. THERE'S NOT THE KINKS THAT YOU'LL FIND WHEN YOU BEND A PIECE OF PIPE WITHOUT A MANDREL. NOW THE REASON THAT'S IMPORTANT IS EACH ONE OF THOSE KINKS CAN ACTUALLY CAUSE TURBULENCE IN THE EXHAUST FLOW. NOW TURBULENCE NOT ONLY SLOWS DOWN THE EXHAUST AND CAUSES YOU TO LOSE A LITTLE BIT OF POWER, ON A DIESEL IT'S MORE CRITICAL CAUSE THE LONGER THAT EXHAUST IS IN THAT PIPE THE HEAT WILL ACTUALLY SOAK INTO THE PIPE, RAISE YOUR EGT'S, AND ALL THAT HEAT CAN ACTUALLY GET BACK RIGHT INTO THE TURBO CHARGER ITSELF. NOW WE'RE JUST GONNA BE DOING A STRAIGHT PIPE EXHAUST ON THIS RIG BECAUSE WELL, IT'S A MUD BUGGY. AND WE COULD LEAVE IT RAW, YOU COULD HAVE IT CERAMIC COATED, BUT OUR PLAN IS PRETTY COOL. WE'RE GONNA GO AHEAD AND POLISH THE EXHAUST JUST LIKE THE MAGNAFLOW MUFFLERS. GET IT TO THAT MIRROR SHINE. THAT WAY IT'LL JUST BE ONE LITTLE EXTRA PIECE OF BLING ON THIS OVER THE TOP RIG.

THE EXHAUST WILL SIMPLY START AT THE TURBO OUTLET CONNECTING TWO 45 DEGREE PIECES TO CREATE A 90 AND A 45 TO TUCK UNDER THE REAR BAR. FINISH IT OFF WITH THE MAGNAFLOW MONSTER EIGHT INCH FULL POLISH TIP. YOU KNOW, I'VE GOT TO SAY, GETTING THE CURVY BUGGY BACK IN THE SHOP AND KNOCKING OUT A BUNCH OF THESE ROAD BLOCKS REALLY HAS ME ENERGIZED FOR THIS PROJECT AGAIN. I CAN'T WAIT TO FINISH IT UP, GET THESE TIRES SLINGING SOME MUD OUT IN THE MUD PIT. NOW FOR YOU GUYS AT HOME THAT ARE MAYBE STUCK ON ONE OF YOUR PROJECTS, DON'T WORRY ABOUT IT. IT HAPPENS TO THE BEST OF US. IF YOU'RE REALLY STUCK, GO AHEAD AND CALL ONE OF YOUR FRIENDS OVER. GET A FRESH SET OF EYES ON THE PROJECT.

HECK, EVEN IF YOU HAVE TO CUT IT IN HALF TO MOVE FORWARD, THAT IS JUST PART OF THE PROCESS.