Build for Off Road Season 2 Episode 4
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Short filmTranscript
00:00Jeep right here is the best deal if you're looking for a base vehicle to turn into a hardcore off-road
00:07rig, and here's why. Two-door Jeep JKs right now, first generation, 07 to 11, you can pick them up
00:13for around $5,000. That's an acceptable price for something that you're going to chop up.
00:18Newer ones like this, second generation, 12 to 18, they're going to cost you somewhere around
00:23like that $10,000 mark. The nice thing is, is all the parts that are on this Jeep,
00:27they're still sought after. So even though you buy this Jeep, and maybe you drive it for a year and
00:32enjoy that life of the top off, doors off, you know, being cool owning a Jeep, you can then sell
00:37all those parts, recoup some of your money. When the JK first came out, I was not for it, and that's
00:43because it was so expensive to turn into a hardcore off-road rig. The two-door JK is the perfect base
00:49vehicle, like I said, because it's so cheap. That's what we're building today. Now this isn't my Jeep,
00:53this belongs to my buddy Ricky. I've been trying to get him to grow up and give up the side-by-side
00:58life for years and step into a real buggy. So that's what we're going to build them. We're
01:01going to build this Jeep into the perfect combination of hardcore Jeep and hardcore rock bouncer. So
01:08creature comforts inside, lots of horsepower underneath the hood, giant axles, and big old 42-inch tires.
01:15That's where we're going to end up. This is where we're starting. Step one, body comes off,
01:19and then we cut the frame in half. Twice. Oh, it's going to be a good day in the shop,
01:26because we're cutting things up in the Jeep world.
01:43Now, as I said before, if you want to basically maximize your profit potential,
01:49starting with a good Jeep, you're going to want to sell some of the parts. And if you're going to
01:53sell parts, the last thing you want to do is have a bunch of broken bolts on those parts,
01:57because that's just going to make the new owner somewhat upset. So when it comes to things like
02:02exhaust studs that we're working on right now for this little motor, you're going to want to get a
02:06good penetrating solvent like CRC knock or loose. What this will do is it basically sprays onto any
02:14rusted fasteners, and then it soaks into the threads. And because it's a penetrating solvent,
02:19it's going to dissolve the rust that's basically holding that nut on there,
02:22and then it will help lubricate it when it's time to take it off. Appears to have knocked it loose.
02:28One of the reasons why the JK is honestly such a good platform to start from is the frame.
02:41Back front axle. These frames are very good frames from the factory because they are hydroformed,
02:49fully boxed with four length front and rear from the factory. That's what kind of made the JK
02:53really a game changer when it first came out. We are going to use parts of this frame,
02:58because the whole point of this build is to make the ultimate throw down combination,
03:02rock bouncer slash jeep JK. So we're basically going to be cutting this frame somewhere in this
03:07area right here. But since we're going to do that, we need to go ahead and remove these motor mounts,
03:12because we're not reusing the motor. We're going to remove these coil mounts here. I don't know if I'm
03:16going to get all the way up to the actual coil mount. I think I'm just going to get the shock mount off.
03:20But I basically need an empty section of frame right here, because all that goes away.
03:35Now to convert this Jeep over to, as I said before, this ultimate off-roader that we're building,
03:40we basically are replacing the front half of the frame section. So this is a complete kit. It comes
03:46with two new frame rails, a new front bumper with an integrated hoop at the front, as well as a winch
03:50plate, and then a new crossover bar at the top. That's what this section is right here. That's
03:55going to integrate into two new coil over towers. Now this is obviously not a bolt-on suspension
04:01system. This is a lot of custom fab, but it did come with some templates that I marked on the frame
04:06to show me where to cut. So the first step here is going to be to cut this entire front frame section
04:11off. And then we're actually going to use the body mounts that are built into these frame rails
04:16to basically key into these old body mounts. So we'll put the body back on the frame to line
04:20everything up, line everything up, and then weld it in place. We'll cut this first.
04:34Boom!
04:36Pop off frame!
04:50Yeah, but you got to go that way.
04:59Well, let's throw a bolt at her. So we've made good headway on our deep JK that we're basically
05:04turning into a jeep slash rock bouncer type of shenanigans. The frame has now been completely
05:09stripped and prepped for all the new frame parts. The front frame section is on, and essentially what
05:14we've done here is we've used the jeep body as a jig. So even though we cut the frame off,
05:20right here according to the templates, to ensure that the front frame is still square,
05:25what we're doing is we're basically bolting it onto the factory body mounts. We bolted the jeep body
05:29back onto the rest of the body mounts on the frame, and then we basically just shoved everything on.
05:34We'll go ahead and do some cross measurements to make sure that it's square,
05:36but at that point then we'll be ready to weld it in.
05:39For today's welding tip, we're going to talk about a couple of things. We're going to talk
05:53about some tips for welding stainless pipe, and then I'm also going to give you some updates on
05:58the ESOB Rebel and why you would add a water-cooled torch to that machine. Now I've told you before,
06:04and we've shown you how much I love the ESOB Rebel being a multi-process machine. You can make,
06:09you can TIG, and you can stick with it. It takes care of all the jobs inside your shop, but now
06:13you can add the new ESOB Cool Mini 2 to the bottom of your Rebel. What that does is allows you to add
06:20a water-cooled TIG torch to the entire package. Now the way a water-cooled TIG torch works is you
06:27basically have three lines coming up the torch. You have the line that carries the gas, like always,
06:32and then you have two additional lines, one that will take the coolant to the torch and one that
06:37returns it back to the small radiator and fan that sits underneath it, and that is what cools the torch
06:43head down. What a water-cooled torch does is it allows the torch body to get smaller and smaller and
06:49still operate at high amperage. This particular torch is rated for up to 250 amps, even though
06:54it is incredibly small. So if you're doing a lot of TIG welding and you need to get into super tight
06:58places and you want the torch as small as possible, it's a great time to upgrade to that water-cooled
07:02torch. So now let's talk about welding stainless. Now what I have here is a small set of stainless
07:08bellows that we're going to weld onto this pipe right here, and I think we'll just go through the
07:13process of how to set it up, how to weld it. So step one, whenever you're welding stainless,
07:18is going to be clean it up. For that, we use acetone. Most important part when TIG welding
07:26stainless is making sure that you keep the arc length as short as you can. So what I've done is
07:31I put this giant cup on here to allow me to stick the tungsten out really, really far. That also floods
07:38the area with the shielding gas and just ensures that the weld stays covered. When you stop welding,
07:45don't move anything. Make sure that you leave the torch alone. Keep that shielding gas flowing.
07:51That will ensure that you end up with that rainbow color that you want to get with stainless. Another
07:56thing that can help with this is back purging inside of the stainless, and for that you actually
08:02need another tool. This tool is pretty specific to automotive stainless exhaust. This is a heat sink
08:10and back purge valve that screws into the O2 sensor in your exhaust. So if I had an O2 sensor bung right
08:17here, this would simply screw into it. Then I use this quick connect, connect it, and then the other
08:23end goes into my double feed regulator that's on the back of the TIG welder. And what that will do is it
08:29will flow argon into the inside of this pipe. We want to plug either end with either tape or you
08:35can actually buy rubber plugs that plug it with a small little hole. And you basically fill the
08:39inside of this pipe with argon. That way, while you're welding it, the chromium doesn't boil up on
08:45the inside as well because it's also protected with that shielding gas. This is just a handy tool to have.
08:51Practice, practice, practice. Get a good quality welder. If you want that small torch, make sure you get a
08:55water cooler for it. Get the proper PPE, good helmet, good gloves, comfortable place to work,
09:00and then just spend time behind the hood. I like doing it every day.
09:18There's no way that we could take a Jeep and talk about turning it into a half Jeep,
09:22half-hardcore off-road rock bouncer and leave the V6 engine underneath the hood. So this is going
09:29underneath the hood of this truck. This is a pretty much brand new. It's 2024 Ram 6.4 liter
09:36Hemi engine with an 8 HP 75 behind it. This, in my opinion, when it comes to a Jeep JK,
09:44is probably one of the cleanest swaps that you can do. And we'll talk about why a little bit later.
09:49But whenever you are planning a project and you're going to use a used engine, make sure you get it
09:54from a reputable salvage yard. We were able to actually see video of this engine running in the
10:00truck before they pulled it, so we knew that it was good. And they did tell us that the water pump
10:06was bent, so we ended up going and replacing a brand new water pump on there. One thing that I think
10:11you should do before you swap in one of these is swap out the exhaust manifolds. This new manifold
10:16design has like a little bit of a kick to it, so we're going to try and take advantage of that
10:20to make it easier to get the exhaust out of the truck. But these manifolds showed up obviously
10:25bare cast. And yes, we could bolt them on and everything would be fine, but this is the time
10:30when we should paint these so they don't end up looking all rusty underneath the hood of our super
10:35cool Jeep. I'm going to paint these manifolds with this VHT flame-proof paint. This is specifically
10:42designed for exhaust components like manifolds, headers, turbo downpipes, or pretty much anything
10:48that sees a lot of heat. It's designed to handle that high temperature that exhaust sees. Once it's
10:53coated though, you do have to follow the curing procedure with VHT and there's instructions on the
10:58back. You want to heat the item up for about 10 minutes and then let it cool down, heat it up for
11:0220 minutes, let it cool down. That helps basically bake the paint onto the exhaust item. This will basically
11:09prevent these exhaust manifolds from rusting and it'll just keep it looking good underneath the hood.
11:14If you wanted to dress it up even further underneath the hood, Duplicolor has a full range of engine
11:19enamel. Now this paint is specifically designed to paint under the hood engine components and engine
11:25blocks so it can handle the heat as well as the chemicals that are underneath the hood. They have
11:29them in 34 different colors. I had them send me some of this hemi orange because I may just
11:33do a couple touch-ups on the block here and there because you know, hemi, hemi orange, it's gotta happen.
11:38And basically, so if you wanted to make the truck look even fancier, you can go ahead and coat the
11:42block like that. To start with right now, I'm gonna go ahead and just spray these with the flat black
11:46and then bolt them on the motor. First step is to clean any of oils or impurities off the cast.
11:53I'm using this Duplicolor foaming prep spray. I'm gonna spray it on there and then wipe it off.
11:59So we're gonna apply two light coats and one medium coat. You want to apply all those coats within
12:08one hour and give yourself about 10 minutes between each coat.
12:28That's probably pretty darn close.
12:30Now, the engine is in between the frame rails. Obviously, it's just mocked up into place and that
12:36is because fitting these hemi engines into the JK engine compartment is a little bit tight. Even more
12:41so with the truck engine because the intake is so tall. Misunderstanding a lot of times when it comes
12:47to engines is that they have to be in the center of the frame and that's actually not true, especially
12:52an off-road vehicle. Even from the factory, some of these engines are offset to the passenger side or
12:57driver's side depending on where the front drive shaft goes. In this particular vehicle,
13:02the front drive shaft is on the driver's side. So we're going to be offsetting this engine probably
13:06one to one and a half inches towards the passenger side of the vehicle to give me more room. It's also
13:11going to give me more room for the front pumpkin on the axle. But before we can even figure out if
13:16this engine's in the right spot, we got to drop the body back down. Body down. Body's going down.
13:23Down, down, down. For an initial installation, I'm pretty happy with where we're at. The one thing
13:30that you have to watch out for with these hemi's is the fact that the cylinder heads are so large,
13:35they don't necessarily fit into this sort of like recess in the firewall. So the head is really close
13:41on that passenger side at the bottom, but I'm probably going to just hammer the firewall in a
13:46little bit there. I think that'll solve that problem. I can then slide this engine back,
13:50I think maybe about an inch. That's what I'm after. My concern is how close the throttle body
13:54is to the radiator because I still need to fit a fan down inside of there. But I think another
13:59solution for that is going to be to basically raise this engine up a little bit. That will
14:03basically pull the throttle body up and back at the same time. I've already closed the hood and
14:08checked that there is still plenty of room there. So I think if we basically come up and back,
14:13I think that'll be the finished spot for this engine. You do need to watch out for a couple other
14:17things. In this particular vehicle, we are going to be running an actual steering gear. So there will
14:22be a steering gear over here mounted to the frame rail. There's provisions for it on our frame rail
14:26kit right here. So it's going to bolt on and there is a shaft that has to run down from the obviously
14:31steering wheel down to there. So we've got to make sure that clears by the cylinder head as well.
14:35But the Jeep engine bay is fairly large. So putting these V8s in here is not that hard. You just kind
14:40of got to fine tune them around back and forth and then we can start making some mounts. Right now,
14:44the body comes back off. Up, up, up. Jeep body going up.
14:55Let's try this.
15:08Quite often when I'm building mounts, I'll just go ahead and cut the holes on the plaza table, but that's
15:13when it's for a very common size fastener and I can run a reamer through it that I have.
15:18These mounts, because I'm reusing the engine side mounts from the Hemi, it uses a weird metric size
15:23bolt. So what I've done is I've matched that up with one of my drill bits and I'm just going to drill
15:28the hole through it to make life a lot easier. I'm using my new Woodward Fab bench top drill press.
15:34I kind of like these bench top drill presses because they don't take up a whole bunch of space in the shop.
15:37You can simply move them out of the way when you're not using it. This one has a 450 watt motor. It's
15:43variable speed, which is nice. It has a half inch chuck, so it fits pretty much all the large size
15:48drill bits. And the nice thing is, is it has a readout to tell you the speed that the drill is
15:54actually turning at, so you can set it for the size that you're drilling. And then it also has this
15:57little laser guide so you know exactly where it's going to punch the hole.
16:07Tip for you. You know that the drill is running at the correct speed and the correct pressure
16:14when the chips that come off make these small little spikes. When you get that, perfect speed,
16:19perfect pressure. Huzzah! All right, now I gotta build the other side.
16:39Over my time of building custom vehicles, I've swapped many engines into many vehicles that they
16:44weren't in there before. I think I've put LSs in basically everything. I've put Toyota engines in
16:49things. I've put Jeep engines in Toyotas. I've done all those things. I've even put
16:53an LS engine in a BMW for my kid. Even made it a manual transmission. Don't be a bad dad. Teach your
16:59kid how to drive a stick. But the hardest part about getting an engine to work inside a modern vehicle
17:05is the communication between the engine and the rest of the car. And that is because modern vehicles
17:12use a lot of CAN bus communication. So it's not like the old days where you just
17:16turn the key and 12 volts goes down to the starter and it starts the motor. It doesn't work that way
17:20anymore. Everything goes through the powertrain control module or ECU or whatever you want to call
17:26it. Basically, the computer. So when it comes to dealing with one of these modern Jeeps and you
17:32want to get a Hemi underneath the hood, which in my opinion is the best swap and it's because of that
17:36communication, the best place to call is Hotwire Auto. Hotwire Auto will build you a completely new
17:44wiring harness with all new OEM style connectors. They will reflash the computer to work with your
17:50vehicle. They can even take care of the TCU in the transmission. And the key to all of this
17:55is the fact that they will build this harness, flash the computer and set it all up so everything
18:00inside that Jeep works like it did from the factory. They can build you a harness like this
18:06in a hot rod setup. I have that in a couple other of my vehicles. That basically means you just hook
18:11it up to like a 12 volt power and a ground and you just switch the key and you can run the vehicle.
18:15But when you want everything to work inside the Jeep, gauges, AC request, all that stuff,
18:22you need to have a harness and more importantly, a company that understands how to make that
18:26communication work. And Hotwire can do that for you. Plus, on top of that, they offer great phone
18:31support either before, during, or after the install. So if you're planning a project like this,
18:37honestly, the first call you need to make is you call Hotwire. You tell them,
18:40hey, I got a Jeep. I'm going to put a Hemi in it. They will tell you what motor to buy,
18:44what transmission to get, what computer to choose from. They'll steer you right,
18:48right from the very beginning. And the best part is in this application, 100% plug and play.
18:53When you're trying to combine basically a Jeep and a rock bouncer, you'd think that the right
19:09decision would be to go with full hydraulic steering. But if it's going to be a dual purpose
19:15vehicle like this, it is nice to have a mechanical connection between the steering wheel and the
19:20axle. So that means that you're going to be wanting to use some type of steering gear.
19:24The good news is, is you can get upgraded steering gears like this bad boy right here,
19:28often referred to as a big bore box, because it's much larger in size than a traditional JK
19:34steering box and a lot stronger. So this way, we're going to get that mechanical connection
19:38between the steering wheel and the axle, thanks to the steering shaft, through the sector shaft,
19:42down to the pitman arm, and then a drag link down to the front axle. But at the same time,
19:46we're going to get all the additional power of a full hydraulic steering system,
19:49because the box has more power, and we're going to be adding a cylinder assist cylinder
19:53down to the axle. The frame already has provisions to bolt us into place,
19:57and the last thing we want to check before we make sure that the motor mounts
20:01are where they're going to be.
20:11So we accomplished a lot today by driving this two-door Jeep JK into the shop, completely disassembling
20:29it, cutting it into multiple pieces, and now it's completely unusable in any way, which is okay,
20:34because that is always the first step in building the perfect off-road vehicle, basically making
20:39it completely unusable for a certain period of time while you throw parts at it and a whole
20:43bunch of money. But the drivetrain's in. 6.4 Hemi, 8-speed automatic, our new frame suction,
20:48our suspension's ready to go in. After this, we're ready to sling some serious axles underneath it,
20:53and get this bad boy sitting on some 42-inch tall tires. But that is what we'll do next time. Having the
20:59CX-4 under the hood, all ready to be plugged in with all the wiring, that is a milestone in itself.
21:05If I had a running Jeep, I could go vroom vroom, but I don't. Vroom.
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