Build for Off Road S02E04 Southern Style Buggy Part 1080p DISC WEB AAC2 264 RAWR
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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
01:25because we're cutting things up in the Jeep world.
01:28Now, as I said before, if you want to basically maximize your profit potential, starting with a
01:49good Jeep, you're going to want to sell some of the parts. And if you're going to sell parts,
01:54the last thing you want to do is have a bunch of broken bolts on those parts because that's just
01:58going to make the new owner somewhat upset. So when it comes to things like exhaust studs that
02:03we're working on right now for this little motor, you're going to want to get a good penetrating
02:07solvent like CRC knock or loose. What this will do is it basically sprays onto any rusted fasteners
02:15and then it soaks into the threads. And because it's a penetrating solvent, it's going to dissolve the
02:20rust that's basically holding that nut on there. And then it will help lubricate it when it's time
02:25to 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 because the
02:59whole point of this build is to make the ultimate throwdown combination rock bouncer slash JK. So
03:04we're basically going to be cutting this frame somewhere in this area right here. But since we're
03:09going to do that, we need to go ahead and remove these motor mounts because we're not reusing the
03:13motor. We're going to remove these coil mounts here. I don't know if I'm going to get all the way up to
03:17the actual coil mount. I think I'm just going to get the shock mount off. But I basically need an empty
03:22section 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
03:51plate, 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 to
04:16basically key into these old body mounts. So we'll put the body back on the frame to line everything
04:21up and then weld it in place. We'll cut this first. Boom! Bye-bye frame!
04:36Yeah, 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 right here
05:21according to the templates to ensure that the front frame is still square, what we're doing is we're
05:26basically bolting it onto the factory body mounts. We bolted the Jeep body back onto the rest of the
05:30body mounts on the frame, and then we basically just shoved everything on. We'll go ahead and do
05:34some cross measurements to make sure that it's square. But at that point, then we'll be ready
05:38to weld it in.
05:49For today's welding tip, we're going to talk about a couple of things. We're going to talk about some
05:53tips for welding stainless pipe, and then I'm also going to give you some updates on the Aesop Rebel
05:59and 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 Aesop 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 Aesop 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
06:42torch head down. What a water-cooled torch does is it allows the torch body to get smaller and smaller
06:49and still operate at high amperage. This particular torch is rated for up to 250 amps, even though it is
06:55incredibly small. So, if you're doing a lot of TIG welding, and you need to get into super tight
06:59places, and you want the torch as small as possible, it's a great time to upgrade to that
07:02water-cooled torch. So, now let's talk about welding stainless. Now, what I have here is a small set of
07:08stainless bellows that we're going to weld onto this pipe right here, and I think we'll just go
07:13through the process of how to set it up, how to weld it. So, step one, whenever you're welding
07:18stainless is 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've put this giant cup on here to allow me to stick the tungsten out really, really far. That also
07:38floods the area with the shielding gas and just ensures that the weld stays covered. When you stop
07:45welding, don't move anything. Make sure that you leave the torch alone. Keep that shielding gas
07:50flowing. That will ensure that you end up with that rainbow color that you want to get with stainless.
07:56Another thing that can help with this is back purging inside of the stainless, and for that,
08:02you actually need another tool. This tool is pretty specific to automotive stainless exhaust. This is a
08:09heat sink and back purge valve that screws into the O2 sensor in your exhaust. So, if I had an O2 sensor
08:17bung right here, this would simply screw into it. Then I use this quick connect, connect it, and then
08:22the other end goes into my double feed regulator that's on the back of the TIG welder. And what that
08:28will do is it will flow argon into the inside of this pipe. We want to plug either end with either tape,
08:35or you can actually buy rubber plugs that plug it with a small little hole. And you basically fill
08:39the inside 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
08:50to have. Practice, practice, practice. Get a good quality welder. If you want that small torch,
08:54make sure you get a water cooler for it. Get the proper PPE, good helmet, good gloves, comfortable
08:59place to work, and then just spend time behind the hood. I like doing it every day.
09:18There's no way that we can take a Jeep and talk about turning it into half Jeep, half hardcore
09:23off-road rock bouncer, and leave the V6 engine underneath the hood. So this is going underneath
09:29the hood of this truck. This is a pretty much brand new, it's 2024 Ram 6.4 liter Hemi engine
09:37with an 8 HP 75 behind it. This, in my opinion, when it comes to a Jeep JK, is probably one of the
09:45cleanest swaps that you can do. And we'll talk about why a little bit later. But whenever you are
09:51planning a project and you're going to use a used engine, make sure you get it from a reputable
09:56salvage yard. We were able to actually see video of this engine running in the truck before they
10:01pulled it. So we knew that it was good. And they did tell us that the water pump was bent. So we
10:07ended up going and replacing a brand new water pump on there. One thing that I think you should do before
10:12you swap in one of these is swap out the exhaust manifolds. This new manifold design has like a little
10:17bit of a kick to it. So we're going to try and take advantage of that to make it easier to get
10:20the exhaust out of the truck. But these manifolds showed up obviously bare cast. And yes, we could
10:27bolt them on and everything would be fine. But this is the time when we should paint these so they don't
10:32end up looking all rusty underneath the hood of our super cool Jeep. I'm going to paint these
10:38manifolds with this VHT flame proof paint. This is specifically designed for exhaust components like
10:44manifolds, headers, turbo downpipes, or pretty much anything that sees a lot of heat. It's designed to
10:50handle that high temperature that exhaust sees. Once it's coated though, you do have to follow the
10:55curing procedure with VHT and there's instructions on the back. You want to heat the item up for about
11:0010 minutes and then let it cool down. Heat it up for 20 minutes at a cool down. That helps basically
11:05bake the paint onto the exhaust item. This will basically prevent these exhaust manifolds from
11:11rusting and it'll just keep it looking good underneath the hood. If you wanted to dress it up even
11:15further underneath the hood, Duplicolor has a full range of engine enamel. Now this paint is
11:21specifically designed to paint under the hood engine components and engine blocks so it can
11:26handle the heat as well as the chemicals that are underneath the hood. They have them in 34 different
11:30colors. I had them send me some of this hemi orange because I may just do a couple touch-ups on the
11:35block here and there because you know hemi, hemi orange, it's got to happen. And basically so if you
11:39wanted to make the truck look even fancier, you can go ahead and coat the block like that. So start with
11:44right now I'm going to go ahead and just spray these with the flat black and then bolt them on
11:47the motor. First step is to clean any of oils or impurities off the cast. I'm using this Duplicolor
11:54foaming prep spray. I'm just going to spray it on there and then wipe it off.
12:02So we're going to 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. Now the engine is in between the frame rails obviously it's just
12:34mocked up into place and that is because fitting these hemi engines into the JK engine compartment
12:39is a little bit tight. Even more so with the truck engine because the intake is so tall.
12:46Misunderstanding a lot of times when it comes to engines is that they have to be in the center of
12:50the frame and that's actually not true. Especially an off-road vehicle even from the factory some of
12:55these engines are offset to the passenger side or driver's side depending on where the front drive
13:00shaft goes. In this particular vehicle the front drive shaft is on the driver's side so we're
13:04going to be offsetting this engine probably one to one and a half inches towards the passenger side
13:09of the vehicle to give me more room. It's also going to give me more room for the front pumpkin
13:13on the axle. But before we can even figure out if this engine's in the right spot we've got to drop
13:18the body back down. Body down. Body's going down. Down, down, down. For an initial installation I'm
13:27pretty happy with where we're at. The one thing that you have to watch out for with these
13:32hemis is the fact that the cylinder heads are so large they don't necessarily fit into this sort
13:37of like recess in the firewall. So the head is really close on that passenger side at the bottom
13:44but I'm probably going to just hammer the firewall in a little bit there. I think that'll solve that
13:48problem. I can then slide this engine back I think maybe about an inch. That's what I'm after.
13:52My concern is how close the throttle body is to the radiator because I still need to fit
13:56a fan down inside of there. But I think another solution for that is going to be to basically
14:01raise this engine up a little bit. That will basically pull the throttle body up and back at
14:06the same time. I've already closed the hood and checked it. There is still plenty of room there.
14:10So I think if we basically come up and back I think that'll be the finished spot for this engine.
14:16You do need to watch out for a couple other things. In this particular vehicle we are going to be
14:20running an actual steering gear. So there will be a steering gear over here mounted to the frame rail.
14:24There's provisions for it on our frame rail kit right here. So it's going to bolt on and there
14:28is a shaft that has to run down from the obviously steering wheel down to there. So we got to make
14:33sure that clears by the cylinder head as well. But the Jeep engine bay is fairly large. So putting
14:38these V8s in here is not that hard. You just kind of got to fine tune them around back and forth
14:42and then we can start making some mounts. Right now body comes back off. Up, up, up. Jeep body going up.
14:54Let's try that.
15:08Quite often when I'm building mounts I'll just go ahead and cut the holes on the plasma table but
15:13that's when it's for a very common size fastener and I can run a reamer through it that I have.
15:17These 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
15:28drill the hole through it to make light a lot easier. I'm using my new Woodward Fab bench top
15:33drill press. I kind of like these bench top drill presses because they don't take up a whole bunch of
15:37space in the shop. You can simply move them out of the way when you're not using it. This one has a
15:41450 watt motor. It's variable speed which is nice. It has a half inch chuck so it fits pretty much
15:47all the large size drill bits. And the nice thing is is it has a readout to tell you the speed that
15:53the drill is actually turning at so you can set it for the size that you're drilling. And then it also
15:57has this little laser guide so you know exactly where it's going to punch the hole.
16:00Tip for you. You know that the drill is running at the correct speed and the correct pressure
16:13when the chips that come off make these small little spikes. When you get that, perfect speed,
16:19perfect pressure.
16:26Huzzah! Alright, now I've got to build the other side.
16:38Over 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
16:49and things. I've put Jeep engines in Toyotas. I've done all those things. I've even put an LS engine
16:54in 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 turn the key
17:17and 12 volts goes down to the starter and it starts the motor. It doesn't work that way anymore.
17:21Everything, it goes through the powertrain control module or ECU or whatever you want to call it.
17:26Basically, the computer. So when it comes to dealing with one of these modern Jeeps
17:31and you want to get a Hemi underneath the hood, which in my opinion is the best swap
17:35and it's because of that communication, the best place to call
17:39is Hotwire Auto. Hotwire Auto will build you a completely new wiring harness with all new
17:45OEM style connectors. They will reflash the computer to work with your vehicle. They can
17:50even take care of the TCU in the transmission. And the key to all of this is the fact that they
17:56will build this harness, flash the computer and set it all up so everything inside that Jeep works
18:02like it did from the factory. They can build you a harness like this in a hot rod setup. I have that
18:08in a couple other of my vehicles. That basically means you just hook it up to like a 12 volt power
18:12and a ground and you just switch the key and you can run the vehicle. But when you want everything
18:17to work inside the Jeep, gauges, AC requests, all that stuff, you need to have a harness and more
18:24importantly, a company that understands how to make that communication work. And Hotwire can do that
18:28for you. Plus on top of that, they offer great phone support either before, during, or after the
18:34install. So if you're planning a project like this, honestly, the first call you need to make
18:38is you call Hotwire. You tell them, Hey, I got a Jeep. I'm going to put a Hemi in it. They will tell
18:43you what motor to buy, what 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 decision
19:10would be to go with full hydraulic steering. But if it's going to be a dual purpose vehicle like this,
19:16it is nice to have a mechanical connection between the steering wheel and the axle. So that means that
19:21you're going to be wanting to use some type of steering gear. The good news is, is you can get
19:25upgraded steering gears like this bad boy right here, often referred to as a big bore box because
19:30it's much larger in size than a traditional JK steering box and a lot stronger. So this way,
19:36we're going to get that mechanical connection between the steering wheel and the axle, thanks to
19:40the steering shaft, through the sector shaft, down to the pitman arm, and then a drag link down to the
19:44front axle. But at the same time, we're going to get all the additional power of a full hydraulic
19:49steering system because the box has more power. And we're going to be adding a cylinder assist
19:53cylinder down to the axle. The frame already has provisions to bolt us into place. And the last
19:58thing we want to check before we make sure that the motor mounts are where they're going to be.
20:02So we accomplished a lot today by driving this two-door Jeep JK into the shop, completely disassembling it,
20:29cutting 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 it
20:40completely unusable for a certain period of time while you throw parts at it and a whole bunch of
20:43money. But the drivetrain's in. 6.4 Hemi, 8-speed automatic, our new frame suction, our suspension's
20:49ready to go in. After this, we're ready to sling some serious axles underneath it and get this bad
20:54boy sitting on some 42-inch tall tires. But that is what we'll do next time. Having the CX 400 of the
20:59hood all ready to be plugged in with all the wiring, that is a milestone in itself. If I had a running
21:06Jeep, I could go vroom, vroom, but I don't. Vroom.
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