Blog Buggy Part 6

(ANNOUNCER)>> FROM AN EMPTY CHASSIS TO A FULLY LOADED HILL KILLING BEAST. OUR VIEWERS DESIGNED THE BLOG BUGGY FROM THE GROUND UP. TODAY ON XTREME 4X4 ALL THAT HARD WORK PAYS OFF. WE'RE GONNA RED LINE THE ENGINE AND HEAT UP THE TIRES ON SOME OF THE NASTIEST TRAILS AROUND.

(IAN)>> TODAY IS THE DAY THAT ANYONE WHO'S EVER BUILT A CUSTOM TUBE CHASSIS ROCK CRAWLER ALWAYS LOOKS FORWARD TO. WHEN YOU BUILD THESE RIGS, YOU PUT THEM TOGETHER IN YOUR GARAGE, GET THEM 90 PERCENT OF THE WAY THERE. YOU ALMOST HAVE A FINISHED BUGGY. THEN YOU'VE GOT TO TEAR IT ALL APART SO YOU CAN SEND THE CHASSIS OUT FOR CUSTOM PAINT OR POWDER COAT. THEN YOU'VE GOT TO GET ALL THE PARTS AND PIECES BACK INTO YOUR SHOP TO PUT IT ALL BACK TOGETHER, AND THAT'S EXACTLY WHERE WE'RE AT TODAY. ON THIS SIDE OF THE SHOP IS OUR ROYAL PURPLE BLOG BUGGY CHASSIS, AND OVER HERE ALL THE PARTS AND PIECES WE NEED TO TURN THAT INTO A ROCK CRAWLER ONE LAST TIME.

PUSH IT FORWARD THERE.

(CHRIS)>> HERE WE GO!

(IAN)>> WHEN YOU PUT TOGETHER A TURBO MOTOR LIKE WE HAVE IN OUR BUGGY, YOU NEED TO MAKE SURE YOU HAVE A FUEL SYSTEM THAT CAN DELIVER ENOUGH PRESSURE TO THE FUEL RAILS WHEN THE TURBO CHARGER STARTS TO BUILD A LOT OF BOOST. AND FOR THAT YOU NEED A PRETTY SPECIFIC SETUP. NOW WE GOT EVERYTHING WE NEED FROM AEROMOTIVE PRODUCTS, AND IT STARTS RIGHT AT THE BACK OF OUR RIG WITH ONE OF THEIR 16 GALLON FUEL CELLS. THE FUEL'S GONNA LEAVE THE CELL, HEAD DOWN THROUGH A 10 MICRON FILTER ON TO THE BYPASS REGULATOR AND FINALLY UP TO THE FUEL RAILS AT THE ENGINE. NOW THE BYPASS REGULATOR IS KINDA LIKE THE BRAINS OF THE FUEL SYSTEM. IT DETERMINES HOW MUCH FUEL IS PUMPED FROM THE CELL UP TO THE MOTOR, AND IT DOES THAT BY MEASURING THE BOOST FROM THE TURBO CHARGER. IT'S PICKED UP RIGHT HERE AT THE SMALL NIPPLE ON THE SIDE OF THE REGULATOR. WHEN THE TURBO CHARGER STARTS TO BUILD BOOST IN THE ENGINE, IT'S BASICALLY COMPRESSING ALL THE OXYGEN, GETTING A LOT OF PRESSURE. YOU NEED MORE FUEL TO COMPENSATE FOR THAT. SO IT ALLOWS MORE FUEL BY, PUTS ENOUGH FUEL IN THE RAILS TO ALLOW US TO BUILD THAT EXTRA POWER. AND THE EXACT OPPOSITE IS TRUE. WHEN YOU LET OFF THE GAS, BOOST NUMBERS COME DOWN. WELL THE REGULATOR'S GONNA OPEN UP AND ALLOW THE FUEL TO BYPASS BACK DOWN THE RETURN LINE INTO THE TANK. NOW IN THE TANK THEY'VE MOUNTED ONE OF THEIR A-1,000 FUEL PUMPS, AND THEY PUT IT IN THE TANK FOR A PRETTY SPECIFIC REASON. IT'S THERE TO ELIMINATE VAPOR LOCK. VAPOR LOCK IS BASICALLY WHEN YOUR FUEL STARTS TO BOIL. NOW IT'S NOT LIKE A POT OF WATER ON THE STOVE WITH A WHOLE BUNCH OF BUBBLES JUST BOILING. WHAT HAPPENS IS THE FUEL IN THE FUEL LINE, IT CAN GET HEATED UP FROM THINGS LIKE THE EXHAUST, OR EVEN JUST OUT WHEELING ON A HOT DAY. SMALL LITTLE BUBBLES WILL START TO DEVELOP INSIDE THAT FUEL. ALL THOSE BUBBLES GET PICKED UP RIGHT AT THE FUEL FILTER AND BASICALLY CAUSE A BLOCKAGE. THE PUMP INSIDE THE TANK ELIMINATES THAT THE SAME WAY YOUR RADIATOR CAP DOES ON THE TOP OF YOUR RADIATOR. IT RAISES THE PRESSURE IN THE ENTIRE FUEL SYSTEM. WHEN YOU BRING THE PRESSURE UP ON ANY TYPE OF LIQUID, THE BOILING POINT GOES UP. WITH A PUMP INSIDE THE TANK, YOU VIRTUALLY ELIMINATE VAPOR LOCK. THE FUEL CELL IS MOUNTED TO THE CHASSIS USING TWO HOLD DOWN STRAPS TO KEEP IT SECURE. THE FUEL FITTINGS ARE AEROMOTIVE BILLET ALUMINUM FULL FLOW FITTINGS THAT ALLOW YOU TO SWIVEL A CONNECTION TO MAKE HOOKING THINGS UP A LOT EASIER. AND FINALLY WE'LL SECURE ALL OF THE DASH EIGHT BRAIDED LINE TO THE CHASSIS WITH SOME CUSHION CLAMPS.

(CHRIS)>> TO HELP COOL THE REAR MOUNTED RADIATOR WE'RE GONNA BE INSTALLING TO HAYDEN 14 INCH ELECTRIC FANS MOUNTED TO THE BACK SIDE OF THE RADIATOR TO DRAW IN THE COOL AIR FROM INSIDE THE PASSENGER COMPARTMENT.

(IAN)>> WITH ALMOST EVERYTHING BOLTED BACK ON TO OUR CHASSIS, WE'RE READY TO SLING SOME AXLES UNDERNEATH IT AND HAVE IT SITTING ON ITS TIRES AND WHEELS ONE LAST TIME. BUT BEFORE WE DO THAT WE HAVE TO PUT TOGETHER OUR SUSPENSION LINKS. AND WE KNEW FROM THE VERY BEGINNING THERE'S NO WAY WE'RE RUNNING RUN OF THE MILL STEEL LINKS ON THIS RIG. SO WE HAD BRANIK MACHINE PUT TOGETHER ONE OF THEIR ALUMINUM BUGGY LINK PACKAGES FOR US. IT'S A TWO INCH UPPER AND A TWO AND A QUARTER INCH LOWER, AND THEY'RE ALL MADE OUT OF SOLID 7075 ALUMINUM ALLOY. NOW WE USE THIS TYPE OF ALUMINUM NOT JUST BECAUSE IT LOOKS GOOD. IT HAS TO DO WITH THE PROPERTIES OF THE MATERIAL. SEE 7075 WILL ALWAYS WANT TO RETURN BACK TO ITS MACHINED SHAPE. SO WHEN YOU'RE OUT WHEELING WITH THE BUGGY AND YOU PUT THE ENTIRE WEIGHT OF THE RIG ON ONE SUSPENSION LINK, YOU'RE GONNA SEE IT DEFLECT SLIGHTLY. BUT ONCE YOU'RE OFF THAT ROCK AND THE WEIGHT IS REMOVED, IT'LL RETURN BACK TO ITS NATURAL SHAPE. NOW BRANIK CAN PRETTY MUCH ENGRAVE ANYTHING YOU WANT IN YOUR LINK, SO WE HAD THEM PUT ROYAL PURPLE IN THE LOWERS AND THE I BLEED PURPLE INTO THE UPPERS, AND THEN FINISHED OFF EITHER END WITH SOME WRENCH FLATS TO HELP MAKE KEEPING THE HEIM JOINTS TIGHT A LOT EASIER. NOW FOR THOSE HEIM JOINTS WE GOT SOME INCH AND A QUARTER ONES FROM ROD AND SUPPLY, INCREDIBLY BIG AND INCREDIBLY STRONG. SOME HIGH MISALIGNMENT SPACERS WILL HELP STEP IT DOWN TO A THREE QUARTER INCH BOLT THAT'S A LOT EASIER TO WORK WITH.

(ANNOUNCER)>> COMING UP, WE'RE READY TO ROCK AND ROLL WITH CUSTOM TUNED SHOCKS. PLUS A BUDGET FRIENDLY WAY TO TURN YOUR RIDE INTO AN EXPEDITION RIG.

(CHRIS)>> WE'RE BACK ON XTREME DOING THE FINAL ASSEMBLY ON OUR BLOG BUGGY. ONCE WE HAVE THE AXLES UNDERNEATH THE CHASSIS, THIS RIG WILL BE A ROLLER AGAIN.

(IAN)>> THIS ENTIRE BUGGY HAS BEEN PUT TOGETHER WITH ANSWERS THAT YOU GUYS GAVE TO A POLL THAT WE PUT UP ON OUR WEBSITE, AND SO FAR WE'VE SHOWN YOU EVERY SINGLE OPTION THAT YOU CHOSE EXCEPT FOR ONE, AND THAT WAS THE SUSPENSION. NOW YOU HAD THREE CHOICES. YOU COULD HAVE WENT WITH A CLASSIC AIR SHOCK. YOU COULD HAVE GONE WITH A MORE RACE TYPE SETUP WITH A COIL CARRIER AND A SET OF BYPASS SHOCKS. BUT IN THE END YOU GUYS CHOSE THE CLASSIC COIL OVER SETUP BOTH FRONT AND REAR. NOW THESE ARE BILSTEIN 9,100 SERIES SHOCKS, AND YOU'VE SEEN US USE THESE IN A LOT OF CRAWLERS. NORMALLY WE ORDER THEM WITH A VERY SPECIFIC DIGRESSIVE ROCK CRAWLING VALVING STACK, BUT THIS TIME WE WERE ABLE TO DO SOMETHING A LITTLE BIT DIFFERENT. NOT TOO LONG AGO THE GUYS FROM BILSTEIN MADE A TRIP OUT HERE AND SPENT THE DAY WITH US SHOCK TUNING ON A BUGGY THAT WAS ALMOST EXACTLY THE SAME AS OUR ROYAL PURPLE BLOG BUGGY. THEY WERE ABLE TO REALLY DIAL IN THE VALVING ON THAT TRIP AND THEY PUT THESE SHOCKS TOGETHER FOR US WITH THAT EXACT VALVING SETUP AND EXTERNAL RESERVOIR PACKAGE. NOW AT THE SAME TIME WE'RE ABLE TO GET REAL CLOSE ON THE SPRING RATE. SO WE CALLED UP SUMMIT RACING AND WE ORDERED ALL THE COIL SPRINGS. NOW THE FRONT IS GONNA BE A 175 LOWER WITH A 150 UPPER ON TOP OF IT. AND OUT BACK AN 80 UPPER WITH A 100 LOWER. NOW THIS'LL GET US CLOSE, BUT AS USUAL, THE BEST WAY TO TUNE IT IN IS TO SPEND SOME TIME IN THE DIRT AND SWAPPING OUT SPRINGS IF YOU NEED TO. SO WE CALLED SUMMIT RACING AND HAD THEM SEND US A BUNCH OF EXTRA SPRINGS SO WE COULD DIAL IT IN.

NOW WE'VE ALREADY TAKE ALL THE MEASUREMENTS FOR THE SHAFTS FOR BOTH THE FRONT AND REAR HOUSING, AND RIGHT NOW OUR CV IS CUTTING THOSE SHAFTS AS WELL AS PUTTING TOGETHER ONE OF THEIR HEAVY DUTY C/V ASSEMBLIES FOR THE FRONT, AND THEY'LL BE HERE IN NO TIME AT ALL. BUT WE WANT TO GO AHEAD AND FINISH ASSEMBLING THIS FRONT AXLE SO WE CAN GET THE BUGGY DOWN SITTING ON ITS TIRES AND WHEELS JUST TO DOUBLE CHECK THE LOCATION OF THESE SHOCK TABS, CYCLE THE SUSPENSION WITH THE NEW SUSPENSION LINKS IN IT, AND JUST HAVE A GOOD LOOK AT EVERYTHING BEFORE WE WELD IT IN FOR GOOD. NOW IN ORDER TO FINISH OUT THIS HOUSING WE HAVE TWO MORE UPGRADES THAT WE'RE GONNA THROW AT IT. THE FIRST IS A SET OF REID RACING HEAVY DUTY CHROMOLY KNUCKLES. NOW THIS IS A FACTORY KING PIN REPLACEMENT KNUCKLE BUT MADE OUT OF A STRONGER CHROMOLY STEEL. THE NICE THING IS IS THE FACTORY STEERING ARM IS LEFT CAST INTO THE KNUCKLE. WHICH MEANS IF YOU WANTED TO PUT THIS ON A FACTORY AXLE AND USE THE STOCK STEERING YOU COULD. BUT THE REASON WE LIKE IT HAS TO DO WITH OUR HIGH STEER ARMS. THESE HIGH STEER ARMS ARE FROM RTECH INDUSTRIES, AND THEY KEY OFF THE TOP OF THE KNUCKLE LIKE ALMOST ALL OF THE HIGH STEER ARMS OUT THERE. BUT THE NICE THING IS THEY'VE ADDED THIS SMALL LITTLE PIECE THAT'S BEEN MACHINED INTO THE ARM. THAT LINES UP PERFECTLY WITH THIS FACTORY STEERING MOUNT. THAT ALLOWS US TO USE THIS LONG BOLT INCLUDED IN THE KIT AND MOUNT ALL OF THE STEERING ON THIS BUGGY IN DOUBLE SHEER. THAT WILL SHARE ALL THE LOAD THAT'S PUT INTO THE STEERING ON BOTH THE HIGH STEER ARM AND THE KNUCKLE, JUST MAKING IT A LOT STRONGER. IT ALSO ALLOWS YOU TO MOVE THE LOCATION OF THE RAM UP AND DOWN ON THE AXLE TO FINE TUNE THAT ANGLE AND GET EVERYTHING RUNNING IN A NICE, STRAIGHT LINE. NOW THE NEXT THING WE'RE GONNA DO IS UPGRADE THE ACTUAL BUSHING ITSELF. NORMALLY ON A KING PIN YOU INSTALL ONE OF THESE SMALL NYLON BUSHINGS JUST RIGHT ON TOP OF THE CONE. NOW THEY'RE FINE FOR EVERY DAY WHEELING AND MAYBE EVEN SOME MILD WHEELING, BUT WHEN YOU'RE READY TO TAKE THINGS TO THE NEXT LEVEL, YOU WANT TO SWAP THEM OUT FOR A SET OF THESE REED RACING BRONZE INSERTS. THEY FIT IN THE SAME SPOT AS THE NYLON ONES BUT BECAUSE IT'S MADE OUT OF BRONZE, THERE'S NO CHANCE THAT THAT'S GONNA BREAK AND LEAVE YOU STRANDED OUT ON THE TRAIL. [ air ratchet spinning ]

(ANNOUNCER)>> UP NEXT WE PUT THE BLOG BUGGY TO THE TEST!

(IAN)>> NOW I KNOW WHAT YOU GUYS ARE THINKING. I JUST SAW THAT BUGGY A FEW MINUTES AGO AND IT WAS NOWHERE NEAR THIS COMPLETE, AND YOU'RE RIGHT! IT'S BEEN A COUPLE OF WEEKS SINCE WE'VE HAD THIS RIG IN THE SHOP. AND IN THAT TIME WE KNOCKED OUT A BUNCH OF LITTLE THINGS. AND ALTHOUGH THEY'RE IMPORTANT, IT'S STUFF THAT WE'VE SHOWN YOU MANY TIMES BEFORE.

(CHRIS)>> THE FLUID LINES FROM CROWN PERFORMANCE, THE DASH SIX STEERING LINES, AND THE BRAIDED BRAKE LINES WERE INSTALLED ONTO THE CHASSIS. THE RCV AXLES AND CONSTANT VELOCITY JOINTS WERE SLID INTO THE HOUSING, AND THE JE REEL DRIVELINES WERE CONNECTED FROM THE TCASE TO THE FRONT AND REAR AXLES. WITH THE RIG FINISHED UP, IT'S TIME TO SEE IF THIS BUGGY WORKS AS GOOD AS IT LOOKS.

AHH!

(IAN)>> HA, HA, HA, WHOO! THAT'S CRAZY MAN! WHEN IT WANTS TO GO I CAN'T EVEN STOP IT FROM REVVING UP. AS SOON AS THAT TURBO GOES IT GOES, AHHHHH! AND ALTHOUGH OUR BUGGY HAS A JUNKYARD FIVE POINT THREE, THE NEW CAM SHAFT AND OUR TURBONETICS TURBO GAVE US ALL THE POWER THAT WE NEEDED WHEN WE HAD TO GIVE OUR RIG THAT SOUTHERN BUMP.

WE INVITED BILL MCCLISTER, A FELLOW WHEELER WHO ALSO ROCKS AN EOR THREETWOONE BUGGY OUT FOR OUR TRAIL RIDE AT MAYHEM OFF ROAD PARK. IT TAKES A SERIOUS RIG TO CONQUER THESE TRAILS, AND ONE WITH LOTS OF MUSCLE.

(BILL)>> I'M FINDING WHERE WE RIDE THAT IT'S MOSTLY HORSEPOWER. YOU WOULDN'T THINK SO BECAUSE IT IS DRY, BUT THE ROCKS ARE STILL SLICK AND IT'S STEEP, AND REQUIRES QUITE A BIT OF MOMENTUM TO GET WHERE YOU NEED TO GO.

(IAN)>> THE OTHER PART OF THE EQUATION IS TRACTION. THE 42 INCH PIT BULL ROCKERS ARE BRED FOR THIS TYPE OF WHEELING, EASILY CONFORMING TO THE ROCKS AND DIGGING LIKE A SET OF PADDLE TIRES IN THE DIRT. THEY PROVIDE EXCELLENT GROUND CLEARANCE, AND TOGETHER WITH OUR SHAVED 14 BOLT EASILY CLEAR THE ROCKS ON THE TRAIL.

(CHRIS)>> BEING ABLE TO PICK FROM A PILE OF GEAR RATIOS THANKS TO OUR FOUR SPEED ATLAS AND A MANUAL VALVE BODY IN THE TURBO 400 MEANT WE CAN CRAWL WHEN WE NEED TO, OR GET SOME GOOD WHEEL SPEED WHEN WE WANT IT.

(IAN)>> EVERY SINGLE ITEM ON THIS CHASSIS WAS CHOSEN BY YOU GUYS AT HOME. AND I HAVE TO ADMIT, YOU DID A GREAT JOB. MIXING JUNKYARD PARTS LIKE THE FIVETHREE, TURBO 400, AND FRONT AND REAR AXLES, BUT ADDING SOME GREAT OPTIONS LIKE THE FOUR SPEED ATLAS, COIL OVERS FRONT AND REAR, AND THE CUSTOM POWDER COAT, YOU GUYS BUILT AN AWESOME RIG.

(IAN)>> EVERY NOW AND AGAIN WE PUT A PROJECT TOGETHER HERE AT XTREME THAT A LOT OF YOU GUYS JUST FALL IN LOVE WITH, AND THAT'S EXACTLY WHAT HAPPENED WITH OUR EXPEDITION WJ. YOU GUYS FLOODED US WITH QUESTIONS ABOUT HOW TO BUILD A RIG LIKE THIS, AND WHY WE MADE CERTAIN DECISIONS WHEN WE PUT IT TOGETHER. BUT BELIEVE IT OR NOT, THE MAJORITY OF THE EMAILS THAT HAVE COME INTO THE XTREME SHOP HAVE ALL REVOLVED AROUND THE TRAILER. DO I REALLY NEED ONE IF I WANT TO GO EXPEDITION TRAVELING, AND IF I DON'T WHAT RE MY OTHER OPTIONS. THERE'S NO QUESTION THAT WITH THE TRAILER BEHIND YOUR RIG, YOU'RE GONNA BE ABLE TO HAUL A LOT MORE GEAR. BUT WHAT IF YOU LIVE IN A STATE THAT LIMITS YOUR SPEED LIMIT WHEN YOU'RE ON THE HIGHWAY HAULING A TRAILER? THAT CAN MAKE LONG TRIPS EVEN LONGER, AND IT CERTAINLY DOES MAKE HAULING THE RIG THROUGH THE WOODS A LITTLE BIT MORE DIFFICULT. BUT CAN YOU GET A PLACE TO SLEEP WITHOUT THE TRAILER? YOU SURE CAN! THIS IS AN ARB ROOF TOP TENT. IT'S VERY SIMILAR IN DESIGN TO THE ONE THAT'S ON THE TOP OF OUR EXPEDITION TRAILER. YOU CAN MOUNT THIS TO SMALL CARS, MID SIZE SUV'S, OR EVEN PICK UP TRUCKS. IT'LL GIVE YOU A COVERED PLACE TO SLEEP THAT'S UP OFF THE GROUND SO YOU DON'T LOSE A LOT OF BODY HEAT IN THOSE COLD CAMPING ADVENTURES. THE NICE THING IS IS IT INSTALLS IN JUST A COUPLE OF MINUTES. WITH THE MATTRESS REMOVED FROM INSIDE THE TENT, THE EXTRUDED ALUMINUM STRIPS ARE BOLTED TO THE TENT BASE. THEN IT'S SLID ONTO THE ROOF RACK ON THE CHEROKEE, AND HELD DOWN WITH THE MOUNTING CLAMPS. THE LAST STEP IS TO INSTALL THE LADDER.

AND THAT'S ALL IT TAKES. NOW YOU HAVE A PURPOSE BUILT EXPEDITION VEHICLE, THAT IF YOU'RE JUST GOING BY YOURSELF YOU CAN JUST JUMP IN THE TRUCK AND GO. IF A BIG GROUP OF YOU IS GOING ON A TRIP, THROW THE TRAILER BACK ON THE BACK AND YOU HAVE PROVISIONS TO SLEEP FOUR ADULTS COMFORTABLY. NOW THERE'S ONE THING YOU NEED TO BE AWARE OF BEFORE YOU RUN OUT AND PUT A ROOF TOP TENT ON YOUR RIG. YOU NEED TO SPEC THE ROOF RACK FOR THE TENT. YOU HAVE TO LOOK UP THE WEIGHT OF YOUR ROOF RACK IN THE OWNER'S MANUAL AND THE WEIGHT THAT TENT THAT YOU BUY NEEDS TO BE ABLE TO SUPPORT. THEN YOU CAN GO AHEAD AND GET IT AFTER MARKET ROOF RACK TO COMBINE THE TWO. ON OUR JEEP WE JUST GOT SOME YAKIMA CROSS BARS THAT ARE RATED TO HOLD THE WEIGHT OF THE TENT ONTO OUR JEEP. AND AFTER THAT WE'RE READY TO GO CAMPING, READY! FOR DETAILS ON ANY OF THE PRODUCTS SEEN IN TODAY'S EPISODE, HEAD ON OVER TO POWERBLOCK TV, DOT COM. COMING DOWN!