Dirt Cheap Locker Upgrade

(ANNOUNCER)>> WHO SAYS YOU'VE GOT TO HAVE DEEP

POCKETS TO BUILD A TRAIL RIG? TODAY ON XTREME OFF ROAD WE'LL FINISH UP OUR $5,000 DOLLAR TOYOTA AND CLIMB TO THE TOP OF THE HILL TO SEE HOW OUR RIG STACKS UP TO OTHER BUDGET FRIENDLY TRAIL TRUCKS.

(IAN)>> IT IS HARD TO BELIEVE THAT NOT TOO LONG AGO WE PULLED THIS TRUCK OUT OF A FIELD WITH WEEDS GROWING UP TO THE DOOR HANDLE. IT WAS DEFINITELY A VEHICLE THAT SOMEONE HAD JUST FORGOTTEN ABOUT.

BASICALLY ABANDONED, RUSTED OUT, AN ENGINE THAT WAS HALF PUT TOGETHER, JUST LEFT TO ROT. WE HAVE BROUGHT IT BACK TO LIFE AS A HARDCORE WHEELER. MORE IMPORTANTLY WE BROUGHT IT BACK TO LIFE WITH A VERY SMALL AMOUNT OF MONEY INVESTED, EMBRACING THE WORLD OF CHEAP OFF ROADING. NOW TODAY IS THE DAY YOU ALWAYS LOOK FORWARD TO WHEN YOU BUILD A TRUCK LIKE THIS. WE'RE GONNA TAKE IT DOWN TO OUR LOCAL OFF ROAD PARK, GET SOME DIRT ON THE TIRES, SEE HOW ALL THE MODIFICATIONS THAT WE MADE TO THIS TRUCK ARE GONNA PERFORM OFF ROAD. WE'RE GONNA HOOK UP WITH A BUNCH OF OTHER GUYS WHO ARE ALSO INTO THE WORLD OF CHEAP OFF ROADING. BUT BEFORE WE ROLL THIS TRUCK ONTO A TRAILER THERE'S STILL ONE MORE JOB THAT WE HAVE TO DO. BEFORE WE HIT THE DIRT WE NEED TO INSTALL LOCKERS IN BOTH OF OUR TRUCK'S AXLES. RIGHT NOW IT HAS TWO OPEN DIFFERENTIALS, WHICH IS NOT IDEAL FOR HARDCORE OFF ROADING. NOW THE PACKAGE THAT I PLAN TO INSTALL IS RIGHT HERE AND I GOT IT FROM TRAIL GEAR OFF ROAD. A SPOOL, GONNA GO IN THE FRONT AXLE, AND AN EATON MECHANICAL LOCKER INTO THE REAR. NOW SPOOLS ARE GREAT BECAUSE THEY PROVIDE 100 PERCENT TRACTION TO BOTH TIRES AT ALL TIMES. THE DOWNFALL IS THEY PUT A LOT OF LOAD ON THE AXLE SHAFTS. AND THAT'S WHY I WAS GONNA PUT IT IN THE FRONT AXLE. IF WE EVER HAD TO DRIVE ON THE ROAD, WE COULD JUST UNLOCK THE FREE WHEELING HUB. MECHANICAL LOCKER IS PERFECT FOR THE REAR BECAUSE IT GIVES US THE BENEFIT OF THE SPOOL LOCKING THE TWO AXLES TOGETHER WHEN THEY SENSE WHEEL SPEED, BUT WHEN WE'RE ON THE ROAD IT WILL GIVE US A LITTLE BIT OF DIFFERENTIAL ACTION ALLOW THE TIRES TO MOVE INDEPENDENTLY OF EACH OTHER. NOW WHY THE TWO DIFFERENT KINDS OF LOCKERS? WELL PRICE! TOGETHER THIS PACKAGE COMES IN RIGHT AROUND $1,000 DOLLARS. NOW IF YOU GUYS REMEMBER, WHEN WE FINISHED PAINTING

THE TRUCK AND BUILDING THE EXOCAGE, WE LANDED RIGHT

ABOUT $4,300 DOLLARS WORTH OF MONEY INVESTED. SO WE DO HAVE $1,000 DOLLARS TO SPEND BUT I'M GONNA BE HONEST WITH YOU GUYS. A BUNCH OF LITTLE STUFF HAS COME UP SINCE THEN. I HAD TO BUY A BATTERY AND SOME BATTERY CABLES. IF YOU REMEMBER I DITCHED THE STOCK GAS TANK. SO I HAD TO GET A FUEL CELL AND AN EXTERNAL ELECTRIC FUEL PUMP FROM SUMMIT RACING. AND THEN I WAS ONLINE AND THE GUYS AT TRAIL WORTHY FAB WERE HAVING A SALE ON THEIR LED LIGHT BARS, AND I THOUGHT THAT THAT WOULD JUST LOOK AWESOME ON THE ROOF OF OUR DIRT CHEAP FUN WHEELER. SO I PICKED UP ONE OF THOSE. OUR BUDGET IS BLOWN. WE ARE RIGHT AT $5,000 DOLLARS, AND THAT'S GONNA HAPPEN WHEN YOU'RE TRYING TO BUILD A TRUCK ON A BUDGET. LITTLE STUFF IS ALWAYS GONNA COME UP AND JUST RUIN EVERYTHING.

NOW I COULD GO AHEAD AND JUSTIFY PUTTING THESE LOCKERS IN THERE AND SAYING YOU'VE GOTTA HAVE THEM.

YOU KNOW, IT'S WORTH SPENDING THE MONEY. BUT THERE IS A WAY TO LOCK THIS TRUCK UP FOR FREE.

TO REMOVE THE THIRD MEMBER FROM THE AXLE I HAVE TO UNBOLT BOTH AXLE SHAFTS, PULL THEM OUT OF THE CARRIER, AND DISCONNECT THE DRIVESHAFTS.

WITH THE THIRD MEMBER ON THE BENCH, THE BEARING CAPS ARE MARKED AND THE DIFFERENTIAL IS REMOVED. THE DIFFERENTIAL CARRIER IS THEN SPLIT TO EXPOSE THE SPIDER GEARS. THESE GEARS ALLOW EACH AXLE TO ROTATE INDEPENDENT OF EACH OTHER. AND BY WELDING THE SPIDER GEARS TO THE SIDE GEARS,

IT PREVENTS THIS FROM HAPPENING.

THE DIFFERENTIAL IS REASSEMBLED, AND WE NOW HAVE A FULLY LOCKED AXLE.

I'M SURE SOME OF YOU GUYS ARE WONDERING, IF YOU CAN JUST WELD UP THE SPIDER GEARS IN THE DIFFERENTIAL, WHY WOULD YOU EVEN GO AND BUY A SPOOL? WELL STRENGTH IS THE MAIN ISSUE. A WELDED DIFFERENTIAL IS DEFINITELY NOT AS STRONG AS A SPOOL. AND THERE IS A CHANCE THAT THOSE WELDS COULD BREAK ON THOSE SPIDER GEARS. THE PROBLEM IS WHEN THEY DO BREAK YOU'RE GONNA HAVE CHUNKS OF SPIDER GEAR AND WELD BEADS ROLLING AROUND

THE INSIDE OF YOUR AXLE, AND THAT CAN CAUSE A LOT OF COLLATERAL DAMAGE.

IT CAN TAKE OUT THE RING GEAR, DAMAGE THE PINION, AND DEFINITELY TEAR UP ALL OF THE BEARINGS. SO THE REPAIR AFTER ONE BREAKS IS A LOT MORE EXPENSIVE. THE OTHER THING IS IS IT'S LIKE A SPOOL. IT IS LOCKED 100 PERCENT OF THE TIME. SO IF YOU PUT A WELDED DIFFERENTIAL ON THE STREET,

YOU'RE GONNA BE PUTTING IT UNDERNEATH A LOT OF LOAD AND PROBABLY BREAK A LOT SOONER. BUT IF YOU'VE IN THE SITUATION THAT WE ARE WITH NO MONEY TO SPEND AND YOU NEED LOCKED AXLES TO GET OUT ON THE TRAIL, THIS IS A GREAT WAY TO GET BY UNTIL YOU'VE GOT ENOUGH MONEY TO REPLACE THEM WITH A MECHANICAL LOCKER OR A SPOOL.

(ANNOUNCER)>> COMING UP, FROM FLAT TIRES TO BENT TIE RODS, THIS GROUP OF OFF ROAD MACGYVER'S CAN HANDLE JUST ABOUT ANY TRAIL FIX.

(IAN)>> WE'RE OUT HERE AT WOOLEY'S OFF ROAD PARK WITH A BUNCH OF OTHER GUYS WHO HAVE EMBRACED THE LIFESTYLE OF CHEAP WHEELING. PROJECT DIRT CHEAP FUN IS ALL FINISHED UP AND READY TO HIT THE TRAILS. BUT BEFORE WE GET ANY MUD ON THESE TIRES, LETS TAKE A LOOK BACK AND SEE WHERE THIS ALL BEGAN. IT ALL STARTED WHEN WE WANTED TO BUILD A

LOW BUCK TRAIL RIG. WE SET A BUDGET OF $5,000 AND FOUND AN '86 TOYOTA TURBO TRUCK FOR SALE LOCALLY. THE TRUCK WAS PRETTY RUSTY, BUT THE CAB AND THE FRAME LOOKED GOOD AND SOLID. IT WAS OURS FOR THE TAKING. ONCE BACK AT THE SHOP, WE STRIPPED THE TRUCK DOWN TO A BARE FRAME. WE DIDN'T KNOW WHAT SHAPE THE ENGINE WAS WHEN WE POPPED THE HOOD AT THE SALVAGE YARD. BUT CONSIDERING IT DIDN'T EVEN HAVE A VALVE COVER, IT MADE SENSE TO REBUILD IT. IT DIDN'T TAKE LONG TO FIND TROUBLE. THAT CLUTCH IS TOAST. BUT THE MORE WE TORE INTO THE MOTOR THE BETTER IT LOOKED, ESPECIALLY IT THE CYLINDERS. ACTUALLY IT LOOKS REALLY GOOD. I MEAN IT'S DIRTY, NO RUST AT THE END OF THE CYLINDERS. FEEL THE LIP, THERE'S NOT A LOT OF RIDGE IN IT. IF IT WAS RUNNING BAD THERE'D BE A BIG CARBON LIP ON THERE, BUT THERE'S NOT. LETS SEE IF IT ROLLS OVER. WE THEN FRESHENED UP THE ENGINE WITH A COMPLETE REBUILD KIT AND GAVE IT A FACELIFT WITH A COAT OF PAINT.

NEXT UP WE TACKLED THE SUSPENSION, FIRST BY CUTTING OFF THE IFS AS A WHOLE UNIT, AND REPLACING IT WITH A SOLID AXLE SITTING ON SOME LEAF SPRINGS.

OUT BACK A COMPLETELY REDESIGNED FOUR LINK SUSPENSION WAS BUILT TO PROVIDE MAXIMUM ARTICULATION.

TIRES ARE KEY TO GOOD PERFORMANCE OFF ROAD, BUT A GOOD SET OF BEAD LOCKS ARE JUST AS IMPORTANT. KEEPING THE BUDGET IN MIND, THE FACTORY TOYOTA WHEELS WERE TREATED TO A DIY BEAD LOCK CONVERSION.

FOR ROCK CRAWLING YOU NEED A LOT OF TORQUE. AND BY REBUILDING OUR TRANSFER CASE WITH A SET OF FOUR POINT SEVEN TO ONE LOW RANGE GEARS WE WOULD HAVE ALL THE TORQUE WE WOULD NEED TO GET THROUGH THE ROCKS. EVEN THOUGH WE WERE WORKING ON A BUDGET, WE STILL WANTED THIS RIG TO LOOK COOL. SO AFTER PREPPING THE CAB, SPRAYED IT WITH TWO COATS OF DUPLICOLOR RATTLE CAN PAINT. AND A SET OF FIBERGLASS FENDERS WERE ADDED FOR EXTRA FLARE. TO PROTECT THE CAB AND THE OCCUPANTS WHILE WHEELING, A TUBE BED AND EXOCAGE WERE BUILT USING INCH AND FIVEEIGHTHS DOM TUBING.

SO HOW DID OUR BUDGET FARE DURING THIS REBUILD?

WELL WE SPENT $500 BUCKS ON OUR ENGINE REBUILD, $1,100 DOLLARS ON SUSPENSION UPGRADES, $500 DOLLARS TO GET LOW GEARS INTO THE CASE, $480 BUCKS ON PAINT AND TUBING, A $350 DOLLAR HIGH STEER KIT, AND $1,500 BUCKS FOR THE TIRES AND WHEELS. TOSS ON AN ADDITIONAL $600 DOLLARS FOR MISCELLANEOUS ITEMS AND WE'VE SPENT $5,030 BUCKS!

(ANNOUNCER)>> COMING UP. ( )>> TURN THE CELL PHONE OFF, GO OUT IN THE WOODS, AND FORGET ABOUT WORK AND RELAX.

(ANNOUNCER)>> THE PERFECT DAY ON THE TRAIL!

(IAN)>> FOR OUR TOYOTA'S FIRST TRAIL RIDE WE DECIDED TO BRING ALONG A FEW FRIENDS. LIKE US, THEY BUILT THEIR RIGS ON A SHOESTRING BUDGET.

(NATHAN)>> SOMEWHERE AROUND $4,500 DOLLARS.

(RHYN)>> CLOSE TO $5,000 IN IT WHEN IT'S ALL SAID AND DONE.

(ANDY)>> ABOUT $3,900 DOLLARS.

(DANIEL)>> I'M RIGHT AT $5,000 DOLLARS.

(IAN)>> RIGHT AWAY WE NOTICED OUR TRUCK WAS SMOKING MORE THAN A FRESHLY REBUILT ENGINE SHOULD. WE HAVE SINCE FIGURED THIS OUT TO BE A STICKING VALVE IN THE HEAD OCCASIONALLY FLOODING OUR EXHAUST WITH UNBURNT FUEL.

THAT TELLS US THAT THE NEW HEAD WE GOT WITH OUR TRUCK MAYBE WASN'T ALL THAT NEW. BUT THESE THINGS ARE GONNA HAPPEN WHEN YOU BUILD ON A TIGHT BUDGET. THE TRUCK IS NOT GONNA BE PERFECT, BUT IT IS SOMETHING WE'LL HAVE TO FIX BEFORE OUR NEXT TRIP OUT. FOR TODAY IT ISN'T KEEPING OUR TRUCK FROM CONQUERING THE TRAILS.

WHOOPS! WHAT DID STOP US ON THE TRAIL WAS DRIVER ERROR. I AIRED DOWN THE TIRES JUST A LITTLE TOO MUCH AND THE

INSIDE BEAD CAUGHT A ROCK, POPPED OFF THE RIM. THIS CAUSED THE VALVE STEM TO BE PULLED OUT

OF THE RIM AS WELL. NOT A PROBLEM! WHEN YOU'RE WHEELING WITH GUYS WHO PRIDE THEMSELVES ON

RIDING CHEAP, EVERYONE IS WILLING TO GET DIRTY TO GET YOU BACK ON THE TRAIL. AND LIKE A BAND OF BROTHERS, WE PULLED THE WHEEL AND TIRE OFF, POPPED IN A NEW VALVE STEP AND AIRED IT BACK UP.

WHEN YOU'RE BUILDING ON A BUDGET, YOU END UP RUNNING A LOT OF STOCK PARTS. AND LIKE THIS STEERING ROD, SOMETIMES THEY JUST DON'T HOLD UP TO HARDCORE WHEELING.

(ANDY)>> I HAD AN ISSUE WITH THE STEERING, I BENT MY CROSS TIE ROD. IT WAS STILL A FACTORY THIN PART. WE ENDED UP SLEEVING IT WITH A HIGH LIFT JACK AND BEEN

RIDING THE REST OF THE DAY.

(IAN)>> THAT KIND OF DO IT YOURSELF INVENTIVENESS RUNS

IN THE BLOOD OF BUDGET WHEELERS, WHETHER THEY'RE IMPROVISING A TRAIL FIX OR DESIGNING THEIR LATEST PROJECT.

(DANIEL)>> IF YOU THINK IT'S EXPENSIVE IT'S REALLY ONLY AS EXPENSIVE AS YOU MAKE TO AN EXTENT. BUT IF YOU TAKE YOUR TIME AND BE SMART WHEN YOU WHEEL IT CAN BE VERY AFFORDABLE.

(ANDY)>> GET USED TO WORKING. YOU'VE GOT TO BE WILLING THE TIME TO BUILD IT INSTEAD OF THE MONEY.

(IAN)>> ANDY SAVED SOME MONEY AND CREATED A UNIQUE RIDE WHEN HE COMBINED THE CHASSIS OF A TOYOTA WITH THE BODY OF KIA.

(ANDY)>> I ACQUIRED A TOYOTA TRUCK THAT THE BODY WAS SHOT BUT THE DRIVETRAIN WAS GOOD. SO I NEEDED SOMETHING TO PUT IT IN AND HAPPENED TO CROSS A CRAIG'S LIST AD FOR A $600 KIA SPORTAGE.

IT'S GOT TOYOTA DRIVETRAIN, MOTOR, TRANSMISSION, TRANSFER CASE, AND AXLES. THREE LINK FRONT AND REAR OUT OF FACTORY JK LINKS WITH AN AIR BAG SYSTEM. I AM RUNNING A GROOVED SET OF 35 INCH TSL'S.

ABOUT THE ONLY TREAD ON THEM IS WHAT I GROOVED INTO THEM. THESE TIRES WERE ACTUALLY WORE DOWN PAST THE WEAR LINES. THEY WERE TOO SMOOTH TO RUN ON THE STREET ANYMORE. THAT'S HOW I GOT THEM CHEAP. AND I TOOK A GROOVER AND ALL THIS, ALL THESE TREADS

ARE ALL CUT IN THERE.

(IAN)>> WE'VE SEEN MANY UNASSUMING SAMURAIS ZIP RIGHT UP THE TRAIL WITH EASE, AND NATHAN WHITEAKER'S

ZUK IS NO EXCEPTION.

(NATHAN)>> IT HAS TOYOTA AXLES, FOUR LINK REAR SUSPENSION, AIR SHOCKS. THE AXLES ARE PRETTY MUCH STOCK, JUST WELDED DIFFERENTIALS. IT HAS A LOWER GEAR TRANSFER CASE. CUT IT OFF IN THE BACK AND ADDED SOME TUBING TO MAKE IT LOOK A LITTLE BETTER AND A LITTLE SAFER. MY FIRST VEHICLE WAS A SUZUKI SAMURAI, AND OF COURSE BEING MY FIRST VEHICLE, I DISCOVERED EARLY THAT THEY WERE REALLY TOUGH CAUSE I WASN'T PLEASANT WITH IT. IT DOES CLIMB WELL AND A LOT OF ITS WEIGHT, THEY'RE A LOT LIGHTER THAN OTHER VEHICLES AND SOMETIMES I THINK HAVING LESS POWER ALMOST HELPS. YOU DON'T BREAK AS MUCH. AND SOMETIMES IT MAY HELP YOU GET A LITTLE MORE TRACTION. IT'S ALWAYS GREAT WHEN YOU SEE SOMEBODY TRY, AND TRY, AND TRY IN SOMETHING THAT THEY'VE GOT $40,000, $50,000 DOLLARS IN AND I PULL UP IN SOMETHING THAT LOOKS LIKE YOU DRUG IT OUT OF A FENCE ROLL AND YOU

CLIMB RIGHT UP IT. ALSO DOESN'T MAKE THEM VERY HAPPY EITHER. UP NEXT, AN IN DEPTH LOOK AT OUR TOYOTA'S PERFORMANCE.

(IAN)>> WE'RE BACK ON XTREME OFF ROAD WHEELING WITH A BUNCH OF TRUCKS THAT COST $5,000 OR LESS. NOW BEFORE WE HEAD INTO SOME TIGHTER TRAILS WE'LL TAKE A LITTLE PRECAUTION WITH OUR BODY PANELS. TOO MANY CLOSE CALLS WITH THESE FENDERS TODAY. WE'LL PULL THEM OFF BEFORE WE HIT THE NEXT TRAIL. WITH THE FENDERS OFF THE FEAR OF BODY DAMAGE WAS GONE. SO ROLLING THROUGH THE TIGHT TRAILS WITH A LITTLE SPEED IS NO PROBLEM.

FOUR LINKING THE BACK OF THIS TRUCK WAS DEFINITELY WORTH THE EXTRA MONEY. THE REAR AXLE CAN EASILY FLEX OVER THE ROCKS IN THE TRENCH KEEPING BOTH WHEELS ON THE GROUND AND US MOVING FORWARD. YOUR REALLY NOTICE A WELDED FRONT DIFF

WHEN IT'S THIS MUDDY. THE TRUCK TENDS TO WANT TO PULL STRAIGHT AHEAD AND EVEN

WHEN THE WHEELS ARE TURNED. BUT THIS TRADE OFF IS WELL WORTH THE EXTRA TRACTION WE NOW HAVE. THE EXOCAGE DOES A GREAT JOB PROTECTING THE CAB AND FRONT SHEET METAL FROM DAMAGE WHEN ON THE TRAIL. IN SERIOUS OFF CAMBER TRAILS LIKE THIS ONE, THE ROOF BARS AS WELL AS THE MAIN HOOP DOING THEIR JOB.

THIS TYPE OF TERRAIN IS IDEAL FOR THE PIT BULL ROCKER.

THE LARGE TREAD BLOCKS DIG INTO THE MUD.

DITCHING THE IFS IN FAVOR OF THE SOLID AXLE WAS THE RIGHT CHOICE. THE TRAIL GEAR LEAF PACKS ALLOW THE FRONT END TO FLEX WHEN WE NEEDED SERIOUS ARTICULATION. HAVING THE FOUR POINT SEVEN TO ONE GEARS IN OUR CASE MEANS WE WOULD EASILY PICK DIFFERENT GEARS FOR DIFFERENT PARTS OF THE TRAIL. FIRST GEAR FOR MAXIMUM TRACTION, SLOW SPEED CRAWLING, BUT IF WE NEED TO WE COULD REV UP AND DUMP THE CLUTCH IN THIRD TO GET SOME WHEEL SPEED, HOP

UP OVER SOME LEDGES. TRY THIS WITH A SET OF FACTORY GEARS AND THE ENGINE WOULD JUST STALL OUT. NOW WE WEREN'T THE ONLY TOYOTA ON THE TRAIL. RHYN BROGDEN AND HIS SON ALEX BROUGHT ALONG THEIR PICK UP TOO.

(RHYN)>> IT'S A 1983 TOYOTA. I PUT LEAF SPRINGS ON IT, PUT A LOCKER IN THE FRONT END.

I WELDED THE REAR END. BOUGHT A DOUBLE TRANSFER CASE, BUCKET SEATS, INTERIOR ROLL CAGE, BOBBED THE BED, BOUGHT THE WHEELS AND TIRES USED, AND WE RIDE IT A LOT.

(IAN)>> RHYN BOUGHT HIS FIRST TRAIL TRUCK, A JEEP, BACK WHEN HE WAS 16. WHEELING'S BEEN PART OF HIS LIFE EVER SINCE. WE ASKED HIM TO DESCRIBE A GOOD DAY ON THE TRAIL.

(RHYN)>> TURN THE CELL PHONE OFF, GO OUT IN THE WOODS, AND FORGET ABOUT WORK AND RELAX. AND IT'S A CHALLENGE TOO. I ENJOY KNOWING I MADE IT UP THE HILL.

(IAN)>> OF ALL THE VEHICLES ON TODAY'S TRAIL RIDE, DANIEL WILLIS'S WRANGLER LOOKS THE LEAST LIKE A BUDGET RIG. HE GOT A DEAL ON IT BECAUSE IT WAS DAMAGED IN AN ACCIDENT.

(DANIEL)>> THE REAR END, THE COVER, ALL THE COVER BOLTS WERE BROKEN OFF INTO THE REAR END FLUSH. ALL THE RING GEAR BOLTS WERE PULLED OUT OF IT, AND THE TRANSFER CASE, THE PUMP HAD COME DISCONNECTED IN THE TRANSFER CASE.

(IAN)>> AFTER A $5,000 DOLLAR INVESTMENT AND MANY LONG HOURS IN THE SHOP, DANIEL HAS A FULL FLEDGED TRAIL MACHINE. ALL IN ALL A GREAT DAY ON THE TRAIL WITH A GREAT GROUP OF WHEELERS. TODAY PROVES THAT YOU DON'T NEED TO HAVE SIX FIGURES IN THE BANK TO HAVE FUN OFF ROAD. YOU JUST NEED A GOOD GROUP OF FELLOW OFF ROADERS AND THEIR CHEAP WHEELERS.