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Build for Off Road - Season 2 Episode 5 -
JK Southern Style Buggy - Part 2
JK Southern Style Buggy - Part 2
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03:19từ the very beginning the plan here is jeep slash rock bouncer and we talk about rock bouncer
03:24obviously we're going to talk about monster big heavy axles and that's exactly what we have here
03:30this is a 40 spline 14 bolt rear and then we have a 40 spline front dana 60 now i'm sure you're
03:40looking at these things and you're thinking those things look massive and they are we're talking a
03:44four inch axle tube and a giant knuckle on the end but the reason that we chose this particular front
03:52axle is because we plan to run a very specific axle shaft it's over there now the axle that i'm
04:01referring to is this bad boy right here now this is what is referred to as a big bell rcv now we're
04:07going to get to why we're using these in a second but we first need to talk about why are we going
04:12to put rcvs in anything i get asked all the time by people when i'm out on the trail and they see
04:17my rigs like why should i swap out my u-joints for a set of rcvs now i looked over the entire shop to
04:23try to find a set of axles with u-joints in them and honestly unfortunately i don't have any i've
04:27kind of thrown them all away but i do have this example right here this is a short side of a
04:32drive shaft and this is what you would normally see inside the knuckle of your axle shaft a u-joint
04:37a universal joint the problem is that it has four points of contact between essentially your carrier
04:45and the tire and wheel and when you turn this when you're off road it doesn't keep flowing in a
04:51constant motion because those four points of contact if you actually saw this in like high
04:55speed camera you'd see it actually almost work in an oblong movement that's why when you're on the
05:01trail and your tires start to spin in the front of your vehicle and often you'll see those vehicles
05:05the tires will start hopping up and down like this that's caused by the oscillation inside this u-joint
05:11inside an rcv is what's called a constant velocity joint we now have six points of contact throughout
05:18that entire turning circle and when the joint turns or the star on the inside turns it smooths
05:24out that motion so what happens is you have a smoother output of power down to the tire and wheel and i'm
05:29sure you kind of figured out by now that we're talking about breaking parts anytime you are jarring a
05:35suspension component or a driveline component that's when it breaks so if we can smooth out that
05:39action there's less chance that it's going to break the good news is is that if it breaks if you have an
05:45rcv you've got a lifetime warranty for your application so this is a jeep jl set of rcvs very popular
05:52application you can see that's big giant cv joint at the end this is going to be warrantied for up to a
05:5843 inch tall tire in your vehicle another option would be to step up to a set of one tons this is for an
06:0405 and up dana 60 super duty very popular upgrade this is warrantied up to a set of 47s what we're
06:11running as i said before is this 40 spline big bell this is the mac daddy of them all the biggest one
06:17they make there is no limit on tire size or horsepower for this bad boy right here so like i said from
06:24the very beginning we're building that jeep slash rock bouncer this is it but the best news is is no matter
06:30which set of rcvs you choose for your project it truly is a buy once cry once scenario because not
06:37only are they warrantied for life and built in the usa they are the strongest axles on the planet
06:44oh that's heavy okay so that cleared now we got to come off this
06:51this shaft combination is all 43 40 but if you're looking for the ultimate upgrade rcv offers all of
07:12shaft combinations available in 300 m material making them incredibly strong boom installated
07:19today in the shop we're working on our ultimate two-door jk and we're building a pretty serious
07:39throw down suspension to go with these monster axles but this is a perfect time to talk about
07:45probably one of the most asked questions i get when it comes to any type of off-road fabrication
07:50and that is when should i mig weld something versus tig weld something
07:55there are some very specific times when we would tig weld versus mig weld but a lot of the times in at
08:04least in the world of off-road fabrication it comes down to personal preference but i thought i'd go
08:09over a couple of reasons why you would switch between the two forms of welding in your shop so
08:14first we'll talk about mig welding mig welding is officially known as gas metal arc welding
08:18obviously we've covered this a lot you push that trigger the wire then comes out electricity is
08:24transferred from the contact tip to the wire when the wire meets the workpiece a short arc is created
08:31and that creates a arc which then creates the molten puddle and then the wire is fed from the machine
08:35down into the molten puddle that's your filler material now in most fab shops like i have here
08:41you're going to have a machine that has a set wire feed speed you set up the machine and the wire comes out
08:46if we were operating in a heavy fabrication environment like ship building or iron working
08:52you can step up to a more professional machine like an esob warrior now when it comes to tig welding or
08:58gas tungsten arc welding it's a little bit different because now what we're doing is the arc is being created
09:05uh being jumped between the tungsten and the work piece and i'm going to be feeding the filler wire or
09:11filler material with my spare hand uh the difference between the two is that i now have full control
09:17over how much filler how fast the filler is fed into the joint and also the amperage of the machine
09:23because i actually control the amperage output at the end of the piece of tungsten by a foot pedal on the floor
09:29so when would you choose them and why would you jump back and forth well this is a perfect example
09:35right here this is a bracket right here has a whole bunch of mig welding on it this is for the
09:40suspension on this jeep jk and this is a perfect example of when mig welding works great it's fast
09:46it's quick it's strong it's fine but this little captured nut plate that we're going to add to hold
09:52the bolt to keep it from turning if we come in here and mig weld it we could do that but it's so
09:57small it is better for us to tig weld it and i'll show you why
10:01you can see on a joint like this where we just want to basically lock this washer into place
10:09using the tig welder ends up with a much cleaner and much more low profile weld than if we went in
10:15and mig weld it if we mig welded this edge material onto this base material considering how thick this base
10:20material is we'd end up with a really fat weld that might cause undercut on the top of this washer and
10:25also wouldn't look very good another time where you see a lot of people switch from mig welding to
10:31tig welding believe it or not is on sheet metal you can see down here where i tig welded the exact same
10:41butt joint on this 18 gauge i was able to essentially melt this mig welding tack that i had started with
10:47and basically draw it across the entire joint all the way down only having to add a very small amount
10:53of filler and i have a good fusion weld this right here honestly is ready for a little bit of metal
10:58finishing and you are ready to go from there so it removes a step in the process which is why you see
11:04a lot of high-end sheet metal fabricators will prep their joints and tig weld them instead of mig welding
11:10but you can see the benefits of having both machines at your fingertips in the shop at any given time which
11:17is why it's great to have a multi-process machine like the esob rebel now this is actually the rebel
11:23acdc so not only can it mig weld it can stick weld it can tig weld it can also ac tig so i can do things
11:31like aluminum and most importantly it's equipped with the cool mini 2 so i have a water cooled torch
11:37so i have an incredibly small torch to fit into tight places one machine to tackle any job in the shop
11:44before we sling the front axle underneath the frame i went ahead and tacked on these shock towers
11:51now when i'm building custom suspension like this on an off-road vehicle i like to build it at full
11:56compression so that means the suspension is fully compressed and the axle is basically at full bump
12:01that's where you're going to have any interference issues when it comes to vehicles like this
12:05now that these are tacked in place look at the front axle underneath there and then we can start
12:09figuring out some suspension links
12:10when you're choosing shocks for a project like this rock bouncer slash jk there's lots of different
12:38options now i always have thought that when we're dealing with rock bouncers you can get incredibly
12:44complicated when it comes to the shocks you can have coilovers and bypasses and uh three tube bypasses
12:51five tube bypasses but i don't really think you need that because rock bouncing is kind of like a drag race
12:57versus desert racing is kind of like a marathon so for this vehicle what we decided to choose is a set of
13:03internal bypass shocks what that means is that we have full adjustment of compression and rebound
13:08right on the reservoir and what that allows us to do is fine tune how the shock reacts whether we're
13:14on or off-road when you're mounting your shocks you really should plan to upgrade the fasteners as well
13:21now arp makes fasteners any size any length that you can imagine and they are perfect for an application
13:29like this these shocks are going to see a lot of abuse off-road and all that abuse transitions through
13:35the upper and lower shock bolt arp bolts are 20 stronger than grade 8 they're 100 made in the usa
13:42and they're available in either a black oxide or a stainless finish the threads are rolled after heat treat
13:50which helps the strength stay in that fastener after it's been made it's a perfect upgrade for your
13:57project when you have a critical fastener like these shock bolts while we're back here at the corner
14:01i think i'll go ahead and start mounting up the brake lines now the jk is a little bit different than
14:07let's say a buggy a buggy we'd think about running the brake line off the caliper down the axle tube and
14:12maybe up one of the links but because we're going to keep this vehicle just as much jk as is hardcore
14:19off-roader we're going to have hard lines going to all four corners because we're leaving the abs intact so
14:24we're going to need good long flex lines for every single corner because we've got so much wheel
14:29travel and whenever i'm looking for custom flex lines i only go to one place i call crown performance
14:35crown performance can make you a flex line any length you want i've ordered 10 foot long flex lines
14:41for projects they are 100 made in the usa they are a multi-layer design they come in many different
14:49colors they are incredibly strong i always tell the story about how i had a flex line on a project like
14:54this and it was attached to the caliper and i was racing in an ultra four race and a tree root came
15:00up and caught the flex line on the axle and when it ripped it off the flex line didn't fail it actually
15:05pulled the banjo bolt right out of the caliper and the flex line was still good all we had to do was
15:11put a new banjo bolt back in and we were back on the trail so that's how strong these things are
15:15now when you're ordering your crown lines make sure to get a hold of crown performance in california
15:22you can talk to all their experts on the phone they'll spec out the perfect line for you they
15:27have a multiple end options if you talk to them you'll get exactly what you want every single time
15:32it's a big tire but i'm strong
15:42with the rolling chassis all mocked up before we start building suspension we want to test fit the
15:49body to make sure everything clears so i'm going to have ricky go get a jeep body from the shop next
15:54door and i'm going to go grab some munch in one of my pickups of course before i hit the road i want
16:00to upgrade my truck with some parts from weathertech whether it's protecting the outside or the inside
16:05their no drill mud flaps bolt right on weathertech has you covered let's hit the dirt and put these
16:11parts to the test
16:12let's go off-roading brought to you by weathertech
16:19driving up the hill
16:21what's sunny up here
16:24i think the best vehicle for overlanding or you know car camping as we used to call it
16:32is full-size truck i mean the reality is you're not going to hit any super hardcore trails
16:37but you got so much room for your stuff in a full-size truck you got a bed in the back you can put a
16:44rack on the back you can add a rooftop tent to it still have room for all of your friends and you can
16:49get to some of the mild trails or like just mild off-road sections like we are here and get to some
16:55pretty remote campsites with just a well-built mid-size or full-size pickup truck
17:02this is 2010 silverado it's not a huge investment they're not very expensive v8 power you know it's
17:09ifs so it rides comfortable on the highway a little bit of lift and you can fit larger wheels and tires
17:14this one's got a locker in the back and it's open up front so you can do some mild off-roading you're
17:19not going to throw it up any hardcore trails but when you're looking to get into like remote campsites
17:24it's got everything that you need this is why overlanding has become so popular you can get
17:30out in nature still have all the creature comforts of home on your rig and when you need to get back
17:35to civilization you just jump in your truck and head out myself i've got to get back to the shop
17:40because i've got a jeep to cut up jeeps choppy choppy grinding wheels lots of welding
17:46whenever i go out on the trail i always like to carry some type of coolant stop leak and for over
17:5550 years iron tight all weather seal has been the choice of professionals for coolant stop leaks and
18:02that is because it chemically bonds with the cooling in the system so it stops the current leak as well
18:08as stays in place to stop leaks in the future you don't have to flush the coolant system at all so you
18:14simply pour it in and it works fast the perfect place to use iron tight all weather seal would be
18:20if you had a leak at this junction right here this is a crossover through the intake where the coolant
18:26flows sometimes you end up with a small seat or small leak right here or possibly a pinhole
18:32in your radiator you simply pour it in it acts quickly and you are back on the trail
18:50okay let's get the plumb bobs today in the build for off-road shop we're working on our two-door jk that's
18:57it's a combination between a jeep jk and a rock bouncer and the body is finally going back onto
19:03our rolling chassis but because of our rear shock towers we need to clearance the body because we've
19:09essentially done what's often referred to as frenching in these coilovers on any jeep the best
19:16thing you can do is move the shock into the frame and that's exactly what our suspension kit did but
19:21because of that we need to cut out this wheel well so this shock tower can fit
19:42since we're trying to keep a lot of the creature comforts of this jk even though we've slid a hardcore
19:48off-road chassis underneath it in the old days we just cut these holes in the tub and leave it we
19:53don't want to do that i'm basically going to build some type of interior panel structure to cover it up
19:58we'll seam seal it with some seam sealer just like the rest of the body and then we will coat it using
20:03this dupli-color truck bed coating now you've seen me use this in the past when i've been lining truck beds
20:09but the nice thing about the dupli-color truck bed coating is that it's universal you can use it anywhere
20:14you want this is a perfect application for this it's a durable impact resistant black vinyl textured
20:22polymer so it gives me a really nice textured finish when i'm done it's dry to the touch in about an hour
20:28and then you can actually start moving or using around it in two hours so it's perfect for an
20:34application like this i like it because it's quick easy to apply and made for the diy crowd whether
20:42you're applying it with a roller spray gun or just grabbing an aerosol can it's a great all-around
20:47protective coating that you can use on truck beds inner fenders tailgates bed rails step areas and even
20:55running boards that's a wrap for today on our two-door jk build we got a pile done we now have a full
21:02rolling chassis with the drivetrain in place all of our axles are mocked up as well as our shocks are
21:08locked into position the next thing we're going to do is start working on of all the suspension
21:12links we'll cycle the suspension make sure everything looks good and then we'll weld that
21:16in for good next time you see this truck back here in the shop we're going to be dealing with
21:20all the things that are obviously not done we have to do something with these front fenders
21:24that new rear opening for the rear tire is not going to cut it so you got to deal with that
21:28and it's going to need something better than a factory cage for the throw down four-wheel and
21:33and this truck is going to see in its life but that is next time right now that is a cool-looking jeep
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