Willy’s Teardown & More Scout Upgrades!

(NARRATOR)>> TODAY ELIZA AND JEREMY ARE TEARING INTO THEIR '53 WILLYS TO BEGIN ITS CONVERSION INTO A 900 HORSEPOWER MUD SLINGER. THEY'RE REMOVING THE BODY AND GETTING RID OF THE DRIVETRAIN TO GET DOWN TO THE FRAME. THEN THEY'LL GET THE TANK INSTALLED AND RUN THE FUEL LINES ON THEIR "OVERLAND SCOUT". IT'S ALL TODAY HERE ON XOR.

(ELIZA)>> YOU CAN'T SELL THE BABY!

(JEREMY)>> HEY GUYS, WELCOME TO XOR. NOW WE THOUGH WE'D TAKE A BREAK FROM OUR OTHER PROJECTS TO START WORKING ON OUR 1953 WILLYS WAGON, THAT WILL EVENTUALLY HAVE SOMEWHERE NORTH OF 800 HORSE AND BE A PRETTY BIG MUD SLINGING TERROR, BUT WHEN WE FIRST BOUGHT THIS THING WE KNEW IT HAD A COUPLE OF ISSUES.

(ELIZA)>> THAT'S RIGHT, AS A MATTER OF FACT WHEN WE DECIDED TO ENGAGE OUR TRANSFER CASE INTO FOUR HIGH WE NOTICED THAT NOTHING UP FRONT WAS SPINNING. SO RATHER THAN BORE YOU GUYS WITH DRIVING A WOUNDED WAGON WE DECIDED WE'D TEAR IT APART AND BEGIN ITS TRANSFORMATION INTO ONE BAD MUDDER TRUCKER. [ drill spinning ]

(JEREMY)>> ALL RIGHT, WE'LL COME MY WAY WITH IT. FENDER... WILLYS HOOD! ONE OF THE GREAT THINGS ABOUT TEARING APART OUR WILLYS IS AT THE FACTORY THEY WERE ORIGINALLY ASSEMBLED USING SIMPLE TECHNIQUES. FOR EXAMPLE, THE FENDERS AND RUNNING BOARDS ARE ALL ONE UNIT AND HELD ON WITH JUST A COUPLE OF BOLTS.

ANOTHER EXAMPLE OF SIMPLICITY IS THE GRILL ASSEMBLY IS MOUNTED WITH TWO THREADED RODS THAT ARE CONNECTED TO THE FIREWALL AND ONE LOWER CENTERING BOLT THAT HOLDS IT TO THE CHASSIS.

OH, WE'VE GOT TRANS COOLER.

I GUESS WE'RE DOING IT THE EASY WAY.

MAKING A MESS!

OH WE'RE REALLY MAKING A MESS. AND SOMETIMES YOU NEVER KNOW WHAT YOU'RE GONNA FIND. THIS IS JONES, I THINK IT'S ALL NATURAL WATERED SODA, IT'S THE OVERFLOW IS WHAT IT IS.

(ELIZA)>> YUMMY!

(JEREMY)>> IT'S VERY CONVENIENT.

(ELIZA)>> LOOKS GREAT!

(JEREMY)>> UPPER HOSE OFF.

THAT'S AN EASY WAY TO CREATE YOUR OWN LOCKING NUT. IT WORKED!

(ELIZA)>> IT WORKS!

(JEREMY)>> THERE YOU GO. WE ALSO FOUND TWO HOMEMADE SUPPORTS HOLDING OUR ORIGINAL RADIATOR IN PLACE. OH GOT IT, IT'S ALL YOU!

YEAH, YOU CAN TAKE THAT TOO. WOW, WE'RE ACCOMPLISHING MAKING A MESS REALLY WELL.

(ELIZA)>> YES!

(JEREMY)>> IT CAN BE TRICKY TO FIND A WAY TO REMOVE THE BODY FROM THE CHASSIS. SO SOMETIMES AN UNCONVENTIONAL APPROACH IS NEEDED. SO BE CAREFUL AND TAKE YOUR TIME, AND LOOK FOR THE SIMPLEST WAY TO GET THE JOB DONE. ONE OF THE GREAT THINGS ABOUT THE WILLYS BODY IS THAT IN FACT IT IS VERY STURDY.

(ELIZA)>> YOU'RE DOING GOOD, JUST KEEP COMING STRAIGHT.

(JEREMY)>> IT HAS ENOUGH RIGIDITY THAT WE ARE NOT WORRIED ABOUT HURTING IT BY PICKING IT UP THIS WAY. THIS IS NOT AN APPROACH YOU WOULD WANT TO TAKE WITH A NEWER VEHICLE. WATCH YOUR FINGERS!

(ELIZA)>> OKAY, GO AHEAD, ALL RIGHT!

(JEREMY)>> STILL GOOD?

(ELIZA)>> YOU'RE UP, YEP.

HOLD ON! [ hammer banging ]

(ELIZA)>> OKAY, FREE!

IT'S FINE!

(JEREMY)>> WE'RE JUST CAUGHT ON SOMETHING?

(ELIZA)>> I THINK WE SHOULD BE CLEAR THERE. YEP, WE'RE CLEAR.

(JEREMY)>> CAN I BACK OUT ELIZA?

(ELIZA)>> NO, YOU HAVE TO GO MAYBE ABOUT ANOTHER FOUR INCHES UP AND THEN TO YOUR LEFT.

(JEREMY)>> STILL NOT ENOUGH?

(ELIZA)>> YOU'RE OKAY HERE.

(JEREMY)>> OKAY, BACKING UP!

(ELIZA)>> OKAY, CAN YOU SWING IT OVER TO YOUR RIGHT JUST A LITTLE BIT? THERE YOU GO. YOU'RE CLEAR.

(JEREMY)>> 1953 WILLYS WAGON BODY FOR SALE. NO WAIT, WE'RE USING THIS.

(ELIZA)>> NO, NO, YOU CAN'T SELL THE BABY.

(JEREMY)>> GOING DOWN!

(NARRATOR)>> UP NEXT WE'LL GET THE DRIVETRAIN OUT, AND LATER WE'RE RUNNING OUR FUEL LINES UNDERNEATH THE SCOUT TO FEED OUR LS TWO, STICK AROUND!

(JEREMY)>> LET'S GO LOOK AT OUR CHASSIS.

(ELIZA)>> OH IT LOOKS SO SAD WITHOUT THE BODY.

(JEREMY)>> IT'S GONNA LOOK REALLY SAD SHORTLY. WE HAD ONE CASUALTY.

(ELIZA)>> WHAT'S THIS HERE?

(JEREMY)>> DO NOT TOUCH, DO NOT TOUCH! AND I CAN'T READ UPSIDE DOWN BUT I DON'T KNOW WHAT THAT SAYS. MAYBE SOMEBODY'S LAST NAME, NAPOLEON, OR SOMETHING LIKE THAT.

DOES THAT SAY VOODOO? IT'S PROBABLY CAUSE SOMEBODY KNEW WE NEED SOME VOODOO MAGIC TO PULL THIS THING OFF. AND THESE ARE AWESOME, YOU SEE THESE? EXHAUST!

(ELIZA)>> HEY, IT SAYS SOMETHING RIGHT THERE. FUN!

(JEREMY)>> WHAT DOES THAT MEAN?

(ELIZA)>> FUN!

(JEREMY)>> FUN! HAZINGA!

(ELIZA)>> VOODOO, WELL THE FRAME IS GOOD. IT'S STURDY, IT'S STOUT, IT'S A LITTLE HACKED UP IN THE FRONT WHERE THEY PUT IN STEERING BUT I MEAN IF WE BOX IT AND REINFORCE IT, IT'LL DO WHAT WE NEED IT TO DO.

(JEREMY)>> HERE'S ONE OTHER COOL THING THAT THEY CAME UP WITH. SOMEBODY DECIDED TO TAKE EXHAUST TUBING AND MAKE SOME BODY LIFT MOUNTS. THEY CUT EXHAUST TUBING AND PUT SOME WASHERS ON IT, AND IT PICKED THE BODY UP JUST ENOUGH TO CLEAR THE TIRES AND STUFF, BUT I GUESS ALL WE'VE GOT LEFT TO DO IS REALLY PULL THE ENGINE AND TRANSMISSION OUT OF IT AND SEE WHAT WE GOT FOR THE REST OF THE CHASSIS.

(ELIZA)>> GOT TO CLEAN HER UP, PRESSURE WASH HER.

(JEREMY)>> LET'S DO IT!

WE'RE GONNA CUT THE EXHAUST OFF NOW USING OUR TRUSTY TORCH. [ torch cutting metal ]

(ELIZA)>> IF YOU DON'T HAVE AN ACETYLENE TORCH YOU CAN MAKE JUST AS MUCH PROGRESS WITH A GOOD OLE SAWZALL. [ torch cutting metal ]

(ELIZA)>> THESE HOMEMADE SMALL BLOCK ENGINE MOUNTS WERE SIMPLY BOLTED ONTO A TAB THAT HAD BEEN WELDED ONTO THE FRAME, BUT FOR OUR NEW 632 THESE WILL HAVE TO GO.

(JEREMY)>> HMM, I GUESS YOU ONLY NEED THREE OF THEM. AND WITH THAT DISCONNECTED I'VE JUST GOT TO TAKE OUT THE TRANSMISSION CROSS MEMBER BOLTS AND THE REAR DRIVESHAFT, AND THEN WE'RE GONNA TRY TO PICK THE WHOLE ASSEMBLY UP AS ONE UNIT CAUSE IT'S JUST GONNA MAKE THINGS WAY EASIER.

HMM, DIDN'T EVEN MAKE A MESS.

(ELIZA)>> WE HAD SO MUCH SUCCESS LIFTING THE BODY WITH THE FORK LIFT THAT AGAIN, EVEN THOUGH IT'S AN UNCONVENTIONAL APPROACH, THIS MAKES IT EASY TO REMOVE THE DRIVETRAIN DUE TO ITS MANEUVERABILITY. COME ON IN.

A LITTLE BIT MORE. JUST ONE OVER, RIGHT THERE.

BEFORE LIFTING THE ENGINE OUT WE'RE GOING TO BE USING A HOSE CUTTER TO SEVER BOTH OF THE POWER STEERING PUMP LINES.

ALL RIGHT, WE ARE FREE.

(JEREMY)>> HOPEFULLY THE ENGINE AND TRANSMISSION, AND TRANSFER CASE ALL COME OUT SOMEWHAT SQUARELY IN ONE PIECE WITHOUT MAKING TOO BIG OF A MESS.

(ELIZA)>> THAT'S THE PLAN.

(JEREMY)>> OKAY?

(ELIZA)>> UP, YEP, COME ON UP.

(JEREMY)>> HEY LET'S JUST MOVE THE WHOLE CHASSIS.

(ELIZA)>> IT'S COMING, IT'S COMING.

ALL RIGHT, CAN YOU ADJUST A LITTLE BIT? YOU JUST COME UP A LITTLE BIT MORE SO YOU CAN CLEAR THE FRAME ON THE SIDE AND YOU START TO GO BACK. YOU CLEAR THERE? GO AHEAD AND MOVE BACK.

WOO, HOO!

(JEREMY)>> THAT IS ONE HEAVY ASSEMBLY.

(ELIZA)>> WELL NOW WE HAVE ROOM FOR A LOT OF ACTIVITIES. BIG BLOCK RIGHT HERE, YES!

(JEREMY)>> I GUESS WHAT WE'VE GOT LEFT TO DO IS GET RID OF CROSS MEMBER, DRIVESHAFT, WE'LL GET STEERING OUT OF THE WAY. EVENTUALLY I SUPPOSE WE'LL TEARDOWN TO AXLES AND STUFF, BUT WE'VE GOT ONE MORE THING THAT WE SHOULD DO.

(ELIZA)>> ALL RIGHT, IT IS BATH TIME. RUBBER DUCKY YOU'RE THE ONE, QUACK, QUACK!

(NARRATOR)>> AFTER THE BREAK WE'LL GET OUR MODIFIED FUEL TANK INSTALLED ON OUR SCOUT, STAY TUNED!

(JEREMY)>> HEY GUYS, LAST TIME YOU SAW US WE WERE PUTTING THE FUEL PUMP IN THE TANK FOR THE SCOUT. WELL SINCE THEN I WENT AHEAD AND TOOK CARE OF A COUPLE OF THINGS, LIKE THE WIRING AND PUTTING A COUPLE OF FITTINGS INTO PLACE, BUT THERE'S A COUPLE MORE THINGS THAT WE HAVE TO TAKE CARE OF YET, LIKE PUTTING THE VENT LINE ON AND ACTUALLY HOOKING UP SOME FUEL LINES FOR THE RETURN AND THE FEED LINE. NOW WE HAVE TO DO THAT BECAUSE YOU CAN'T ACCESS ANY OF THIS WHEN IT'S UNDERNEATH THE TRUCK. SO WE'LL ADD A COUPLE OF CHUNKS OF LINE HERE, SET EVERYBODY UP INTO PLACE, AND HOOK IT UP TO THE FUEL PRESSURE REGULATOR. ONCE WE'RE DONE WITH THAT WE'LL FINISH RUNNING EVERYTHING UP TO THE ENGINE.

(ELIZA)>> THE GREAT THING ABOUT USING AN FITTINGS IS ATTACHING THE HOSE IS VERY SIMPLE. JUST TWIST THE HOSE INTO THE FITTING SOCKET UNTIL IT BOTTOMS OUT. AFTER THAT BACK IT OFF ABOUT AN EIGHTH OF AN INCH.

THEN WHEN YOU TIGHTEN THE SOCKET ONTO THE OTHER FITTING THE EXTENSION PROTRUDING FROM THE END IS FORCED INTO THE HOSE'S TEFLON LINER TO CREATE A LEAK PROOF SEAL.

ON TOP OF OUR NEW PUMP THERE ARE THREE PORTS. A VENT LINE TO RELIEVE ANY PRESSURE IN THE TANK, AN OUTLET PORT, WHICH SENDS FUEL TO THE ENGINE, AND A RETURN FOR UNUSED FUEL COMING BACK FROM THE PRESSURE REGULATOR. WE'RE USING EARL'S PRO LITE 350 BRAIDED HOSE. NOT ONLY IS IT EASY TO CUT TO LENGTH, IT'S TOUGH AND ABRASION RESISTANT. AND GIVEN SOME OF THE RUGGED TERRAIN WE'LL BE WHEELING OUR SCOUT THROUGH THAT'S A GOOD THING.

IT'S IMPORTANT TO UTILIZE GAPS IN THE FRAME AND GAPS IN THE BODY TO RUN FUEL LINES. AS TOUGH AS THESE LINES ARE A LITTLE EXTRA PROTECTION CERTAINLY IS A SMART APPROACH.

(JEREMY)>> ALL RIGHT, YOU WANT TO PULL THOSE FRONT LINES FORWARD.

(ELIZA)>> THERE YOU GO!

(JEREMY)>> AND THEN HOLD IT RIGHT THERE.

(ELIZA)>> DID IT FALL OUT?

[ ratchet twisting ]

(ELIZA)>> HERE AT XOR WE'RE GONNA BE PULLING IN A LOT OF PROJECTS TO GET THEM TRAIL READY. NOW WHETHER THAT MEANS SETTING UP SUSPENSION, FABBING UP ROLL CAGES, OR JUST GETTING THEM READY TO HIT THE TRAIL, ONE OF OUR MOST IMPORTANT TOOLS HERE AT THE SHOP IS OUR MIG WELDER. NOW BEFORE WE CAN GET TO ANY OF OUR PROJECTS WE NEED TO HAVE OUR WELDER SETUP. SO TODAY WE'RE GONNA WALK YOU THROUGH THE PROCESS OF GETTING YOUR POWER MIG 210 SETUP AND READY TO GO. NOW FIRST THINGS FIRST, WE WANT TO DETERMINE WHAT IT IS THAT YOU'RE GONNA BE WELDING. IF YOU'RE GONNA BE PATCHING UP PANELS THEN YOU WANT TO RUN POINT ZEROTWOFIVE THE WAY WE DID WHEN WE WERE PATCHING UP OUR SCOUT. NOW TODAY WE'RE GOING TO BE RUNNING POINT ZEROTHREEZERO SO THAT WE CAN WELD UP A THICKER GAUGED MILD STEEL. NOW IF YOU'RE RUNNING AXLE BRACKET SUSPENSION OR ANY KIND OF FRAME WORK YOU'RE GOING TO WANT TO RUN YOUR POWER MIG 256. THAT WILL ALLOW YOU TO RUN A POINT ZERO FOURFIVE WIRE FEED. NOW FOR WHAT WE'RE DOING OUR POWER MIG 210 WILL BE JUST FINE. THE FIRST STEP IS TO FLIP DOWN THE TENSION ADJUSTOR. THEN RAISE THE TOP DRIVE ROLL PRESSURE ARM. REMOVE THE OUTER GUIDE SO YOU CAN ACCESS YOUR LOWER DRIVE ROLL. MAKE SURE YOU HAVE THE CORRECT SIZE CHOSEN FOR YOUR WIRE AND REINSTALL THE LOWER DRIVE ROLL. CUT AND UNROLL THE FIRST SIX INCHES OF THE WIRE FROM YOUR SPOOL AND DO NOT LET THE END OF THE WIRE GO SO IT WON'T UNSPOOL OFF OF THE ROLL. FEED IT THROUGH THE WIRE DRIVE INLET ALONG INNER THROUGH, OVER THE DRIVE ROLL, AND THROUGH THE OUTLET ON THE GUN SIDE.

POWER UP YOUR MACHINE AND SQUEEZE THE TRIGGER ON YOUR GUN TO BEGIN FEEDING WIRE DOWN THE LENGTH OF THE GUN LINER UNTIL IT COMES OUT THE END OF THE GUN SEVERAL INCHES.

THEN TURN YOUR MACHINE OFF AND INSTALL THE CORRECT CONTACT TIP, FOLLOWED BY THE CORRECT NOZZLE FOR SOLID WIRE OR FLEX CORE.

NOW THAT WE GOT ALL THIS SETUP WE'RE GONNA GO WITH OUR RECOMMENDED WELD SETTINGS AND WE'RE GOING WITH THE 14 GAUGE.

WE ARE SELECTING ZEROTHREEZERO DIAMETER WIRE, AND A METAL THICKNESS OF 14 GAUGE.

WELL IT'S A LOT EASIER THAN IT LOOKS AND MAKES WELDING A BREEZE.

[ welder crackling ]

(NARRATOR)>> WHEN WE COME BACK WE'LL GET OUR LS PLUMBED IN FOR FUEL, DON'T GO AWAY!

(ELIZA)>> HEY GUYS, WELCOME BACK TO XOR AND THE FUEL SYSTEM INSTALL ON OUR "OVERLAND SCOUT". WE'VE DECIDED TO MOUNT OUR FUEL PRESSURE REGULATOR ON THE FRAME JUST IN FRONT OF OUR REAR AXLE, BUT FIRST WE NEED TO GET RID OF MORE THAN 30 YEARS OF ROAD GRIME. [ grinding metal ]

(JEREMY)>> NOW SINCE OUR FUEL PRESSURE REGULATOR DIDN'T COME WITH A MOUNT WE'RE GONNA HAVE TO MAKE ONE, AND IT'S AS SIMPLE AS CUTTING UP SOME EXHAUST TUBING AND SOME SQUARE TUBING AND WELDING THEM TOGETHER. WE CHOSE A PIECE OF SCRAP EXHAUST TUBING THAT HAS THE SAME INNER DIAMETER AS THE OUTSIDE DIAMETER OF THE FUEL PRESSURE REGULATOR. THAT WAY IT FITS SNUGLY. THE SQUARE TUBING WILL SERVE AS A SPACER AND GIVE US A MOUNT TO WELD TO THE FRAME. THE EASIEST WAY TO MARK A STRAIGHT LINE ON A PIECE OF ROUND TUBING IS TO LAY A PIECE OF ANGLE IRON ON TOP AND MARK YOUR LINE.

THE BELT SANDER JUST CLEANS OFF ANY BURRS AND SHARP EDGES.

[ welder cracking ]

[ welder crackling ]

(ELIZA)>> TO SECURE OUR REGULATOR TO OUR NEW MOUNT WE ARE SIMPLY USING TWO HOSE CLAMPS.

NOW YOU CAN USE A REGULAR PAIR OF SCISSORS, BUT A GOOD HOSE CUTTER MAKES FOR A MUCH CLEANER CUT.

YOU DON'T HAVE TO INVEST IN A SET OF AN WRENCHES FOR THESE DASH SIX FITTINGS. A REGULAR SET OF WRENCHES WILL GET THE JOB DONE, JUST BE CAREFUL NOT TO STRIP THE ALUMINUM THREADS.

THERE ARE SEVERAL ADVANTAGES TO MOUNTING OUR FUEL PRESSURE REGULATOR HERE. FIRST IT KEEPS IT AND THE HOSES OUT OF THE TRAVEL OF OUR SUSPENSION. SECOND IT'LL BE CLEAR OF ANY HEAT GENERATED BY THE EXHAUST, AND LAST AND MOST IMPORTANTLY, SINCE IT HAS A BUILT IN FILTER IT'LL BE EASILY ACCESSIBLE FOR SERVICE. OUR HOLLEY REGULATOR IS INTERNALLY PRESET TO PROVIDE OUR FUEL INJECTION SYSTEM WITH 59.5 POUNDS OF PRESSURE, WHICH IS PERFECT FOR OUR NEW 460 HORSE LS POWER PLANT.

(JEREMY)>> AND LAST BUT NOT LEAST WE'LL RUN ONE UP TO THE FRONT, HOOK UP TO OUR FUEL RAILS.

(ELIZA)>> FOR MORE INFORMATION ON WHAT YOU'VE SEEN ON TODAY'S SHOW, OR FOR DETAILS ON OTHER XOR PROJECTS, JUST HEAD ON OVER TO POWERNATION TV DOT COM.

AND WITH THAT THE TOP SIDE OF THE ENGINE IS DONE. JUST A COUPLE OF QUICK CONNECTIONS.