Two-Car Garage Crawler Part 8: Payoff

(ANNOUNCER)>> FROM OUR SMALL TWO CAR GARAGE SPACE TO THE GREAT OUTDOORS, OUR PREFAB BUGGY FINALLY HITS THE TRAIL. TODAY ON XTREME 4X4 WE GET WIRED WITH A CUSTOM ECU, GET IT ALL TOGETHER, AND GET GOING.

(IAN)>> NOW TODAY IS A PRETTY EXCITING DAY. WE'RE GOING TO BE FINISHING UP OUR TWO CAR GARAGE CRAWLWER, HAULING IT OUT TO OUR LOCAL OFF ROAD PARK, AND GIVING IT A THOROUGH BEAT DOWN TO PROVE THAT YOU CAN

BUILD A THROW DOWN TUBE BUGGY IN A SMALL TWO CAR GARAGE WITH JUST A WELDER AND A GRINDER. NOW IT'S HARD TO BELIEVE THAT LESS THAN A YEAR AGO A BOX OF TUBING SHOWED UP HERE THAT WOULD BE THE START OF THIS PROJECT. AND BEFORE LONG WE HAD A 100 PERCENT CUSTOM FOUR SEAT TUBE BUGGY CHASSIS. OUR DRIVETRAIN, WELL THAT MEANT A TRIP TO THE

JUNKYARD, AND WE BUILT A CUSTOM FRONT AXLE OUT OF TWO DONOR UNITS.

THEN WE CLEANED UP OUR JUNKYARD VEIGHT, REBUILT OUR AUTOMATIC TRANSMISSION, AND ONCE THE CHASSIS WAS BACK FROM POWDER COAT WE THREW IT ALL TOGETHER. NOW TODAY WE HAVE A BUNCH OF LITTLE JOBS TO DEAL WITH, SOME PLUMBING, SOME BODY PANELS, BUT MOST IMPORTANTLY

THE ONE THING THAT WE HAVE TO TACKLE FIRST IS GOING TO BE OUR WIRING. WE'LL START BY CHOOSING THE POSITION FOR OUR RTECH INDUSTRY BATTERY BOX SO WE KNOW WHERE ALL THE ELECTRICAL WIRES WILL BE RUN. ONCE WE HAVE THE HOLES DRILLED, WE CAN GIVE IT A COAT OF DUPLICOLOR HIGH BUILD PRIMER FOLLOWED BY SOME FLAT BLACK.

NOW THERE'S A COUPLE OF DIFFERENT WAYS TO WIRE UP A TUBE BUGGY. WE CAN WIRE IT UP LIKE A RACE CAR AND HAVE A BUNCH OF DIFFERENT SWITCHES, AND THAT IS WHY GOAT BUILT OFFERS THIS LARGE FLAT ALUMINUM PANEL DASH.

RACE CARS HAVE INDIVIDUAL CIRCUITS FOR ALL THE MAIN COMPONENTS. AND THEY HAVE SWITCHES AND CIRCUIT BREAKERS MOUNTED ON THE DASH TO CONTROL THEM. THINGS LIKE THE COOLING FAN, TRANSMISSION FAN, USUALLY THE FUEL PUMP, AND THEN A BACK UP FUEL PUMP AS WELL AS THE IGNITION. THAT WAY IF THERE IS A PROBLEM IN A RACE YOU SIMPLY HAVE TO DIAGNOSE ONE CIRCUIT UP UNDERNEATH THE DASH. NOW IN A FUN CAR LIKE THIS ITS HONESTLY A LOT EASIER JUST TO WIRE EVERYTHING UP WITH ONE MASTER SWITCH. WE'LL MOUNT IT UP IN THE DASH, TURN IT ON, AND LET IT ENERGIZE EVERYTHING, THE COMPUTER, THE FUEL PUMPS THE COOLING FANS, EVERYTHING BY UTILIZING A SET OF RELAYS. THAT WAY ALL WE HAVE TO DO IS JUMP IN THE CAR, SWITCH IT ON, AND WE'RE READY TO GO WHEELING. NOW THERE ARE SOME ADDITIONAL SAFETY FEATURES THAT YOU'LL WANT TO HAVE WHEN WIRING UP A CAR LIKE THIS. THE FIRST IS A WAY TO ISOLATE THE BATTERY FROM THE REST OF THE SYSTEM. AND THAT'S WHY WE'RE GONNA INSTALL THIS 100 AMP CIRCUIT BREAKER. WE'LL HOOK THE BATTERY UP TO ONE SIDE AND ALL THE POWER FEEDS ON THE OTHER. IF WE EVER NEED TO SHUT THE CAR DOWN, WE CAN JUST SIMPLY OPEN THE CIRCUIT BREAKER. THAT PREVENTS POWER FROM TRAVELLING THROUGH IT. IT ALSO HELPS KEEP THE BATTERY CHARGED WHEN THE CAR IS STORED. WE'RE READY TO GO WHEELING WE'LL JUST CLOSE THE CIRCUIT

BREAKER AND AWAY WE GO. NOW WE'RE ALSO GONNA MOUNT THE STARTER BUTTON CLOSER TO THE CENTER OF THE DASH THAN ON THE FAR DRIVER'S SIDE. THAT WAY IF YOU'RE EVER ON A TRAIL AND THE ENGINE DIES AND YOU'RE TRYING TO KEEP THE BUGGY UNDER CONTROL, THE

PASSENGER CAN JUST REACH OVER, HIT THE STARTER BUTTON, AND KICK THE ENGINE OFF, GET THE VEHICLE RUNNING AGAIN.

NOW ONE SAFETY FEATURE THAT WE NEVER HOOK UP IN A TUBE BUGGY IS ACTUALLY THE PARK AND NEUTRAL START SWITCH ON THESE SHIFTERS. SEE THEY HOOK UP A SMALL MICRO SWITCH IN THESE

SHIFTERS SO IT WILL ONLY START WHEN YOU HAVE THE BUGGY IN PARK OR NEUTRAL. BUT IF YOU'RE CLIMBING A BIG HILL AND HIT A BUMP AND GET A LITTLE HICK UP IN THE FUEL LINE AND THE VEHICLE STALLS, THE LAST THING YOU WANT IS TO HAVE TO STOP THE RIG, FIND PARK OR NEUTRAL, AND THEN RESTART IT. YOU JUST WANT TO HIT THAT STARTER AND GO.

IT DOES MEAN THAT YOU HAVE TO HAVE YOUR WITS ABOUT YOU EVERY TIME YOU CLIMB IN, JUST MAKING SURE THE RIG'S IN PARK BEFORE YOU START IT, BUT IT'S WELL WORTH THE TRADE OFF. THE CIRCUIT BREAKER GETS MOUNTED TO THE LID OF OUR RTECH BATTERY BOX. FOUR RELAYS ARE ATTACHED TO THE DASH BAR TUBE, ONE FOR THE FUEL PUMP, ONE FOR THE TRANSMISSION FAN, ONE FOR THE COOLING FANS ON THE RADIATOR, AND ONE FOR OUR MAIN IGNITION.

THEN POWER FEEDS FOR THE COOLING FANS AND OUR FRONT LED BAR AND RAN TO THE FRONT OF THE BUGGY. WITH OUR ELECTRICAL WIRES RAN, WE CAN GO AHEAD AND INSTALL OUR RADIATOR. AND THIS IS THE ONE CUSTOM PIECE THAT YOU HAVE TO GET FOR ONE OF THESE GOAT BUILT STYLE CHASSIS. WE HAD OURS BUILT BY PERFORMANCE ROD AND CUSTOM. NOW THIS IS ONE OF THEIR HEAVY DUTY ALUMINUM RADIATOR AND ELECTRIC FAN COMBO KITS, WHERE THE FANS ARE MOUNTED ON THE GRILL SIDE OF THE RADIATOR WITH SOME SHROUDING BUILT IN. NOW THIS PARTICULAR CORE IS WHAT'S CALLED A DUAL PASS CORE. THE INLET AND THE OUTLET ARE ON ONE SIDE OF THE RADIATOR. THE COOLANT WILL ENTER THE CORE, TRAVEL ACROSS IT, THROUGH THE OTHER TANK, AND BACK ACROSS THE RADIATOR BEFORE BEING PULLED BACK INTO THE ENGINE. BASICALLY COOLING THE ENGINE TWICE, BUT MORE IMPORTANTLY IT'S THE IDEAL SETUP FOR THIS LS STYLE ENGINE. NOW YOU COULD ALSO ADD ANY TYPE OF MOUTH THAT YOU WANT AND WE HAD THEM PUT ON THESE TWO WINGS ON EITHER SIDE THAT WILL LINE UP PERFECTLY WITH THE TUBE SIN OUR CHASSIS.

(ANNOUNCER)>> COMING UP, WE'RE ON THE ROCKS WITH THE GUY WHO DESIGNED OUR CHASSIS AND HIS TWO SEATER.

(IAN)>> NOW ALTHOUGH OUR PLAN IS TO KEEP THE CHASSIS WIRING HARNESS IN OUR BUGGY INCREDIBLY SIMPLE, WHEN IT COMES TIME TO GET A JUNKYARD ENGINE LIKE OUR FIVETHREE TO RUN IN A PROJECT LIKE THIS, WELL THINGS CAN GET A LITTLE BIT TRICKY. NOW THERE'S A COUPLE OF OPTION FOR YOUR. NOW WE CHOSE TO HAVE OUR FACTORY HARNESS CUT DOWN AND OUR ECU REFLASHED BY WAYNE AND THE GUYS AT 150 TUNES DOT COM. THEY SIMPLY TAKE THE ENTIRE FACTORY WIRING HARNESS APART AND REMOVE ANY UNNEEDED WIRES TO TURN IT INTO A TRUE TWO WIRE HOOK UP, ONE IGNITION WIRE AND ONE MAIN BATTERY FEED. THEN THEY CLEAN EVERYTHING UP, CHECK ALL THE CONNECTORS, AND LABEL EVERYTHING TO MAKE IT EASY TO REINSTALL ONTO THE ENGINE, AND THEN LOAD THE ECU WITH A PROGRAM TO MAKE IT SUITABLE FOR WHATEVER YOU WANT WITH YOUR RIG. NOW ONE OF THE NICE THINGS ABOUT THE SERVICE THAT WAYNE AND THE GUYS AT 150 TUNES OFFER IS THEY PROVIDE LIFETIME REFLASHES OF THAT ECU IF YOU EVER WANT TO CHANGE SOMETHING. MAYBE YOU WANT THE COOLING FANS TO COME ON A LITTLE BIT SOONER OR THE ENGINE TO FIRE UP A LITTLE BIT QUICKER. ALL YOU'VE GOT TO DO IS PACK UP YOUR ECU AND SHIP IT TO THEM, AND HE'LL REFLASH IT FOR YOU NO CHARGE AT ALL. THE BEST PART IS IS WAYNE'S A WHEELER. SO YOU COULD RUN INTO HIM AT EVENTS LIKE KING OF THE HAMMERS OR EVEN EASTER JEEP SAFARI. AND IF HE'S THERE WITH HIS LAPTOP HE'LL REFLASH YOUR UNIT FOR YOU RIGHT THERE. BECAUSE WE'RE DEALING WITH THE HARNESS THAT CAME OFF THIS ACTUAL MOTOR, ALL THE CONNECTIONS ARE EASY TO PLUG IN.

ONCE THE HARNESS IS LAID OUT, EVERYTHING CAN ONLY BE

HOOKED UP A CERTAIN WAY. NOW OUR ENGINE IS EQUIPPED WITH A DRIVE BY WIRE THROTTLE BLADE ASSEMBLY. THAT MEANS THERE'S NO CABLE CONNECTING THE GAS PEDAL TO THE ENGINE. SO WE HAD TO GET A COUPLE OF EXTRA THINGS WHEN WE WERE OUT AT THE JUNKYARD. THE FIRST IS A COMPLETE PEDAL ASSEMBLY OUT OF A 2005 CHEVY PICK UP TRUCK. IT HAS A SENSOR ON THE SIDE OF IT THAT MEASURES THE LOCATION OF THE THROTTLE PEDAL WHEN YOU PRESS IT DOWN. AND ON TOP OF THAT WE HAD TO GET WHAT'S CALLED A TACH MODULE. THE TACH MODULE CONVERTS THE SIGNAL FROM THE THROTTLE PEDAL INTO A SIGNAL THE ECM CAN UNDERSTAND, AND THEN IN TURN DRIVES THE ENGINE. NOW SOME PEOPLE AREN'T A FAN OF THE DRIVE BY WIRE THROTTLE BODIES CAUSE THERE'S USUALLY A LITTLE BIT OF PEDAL LAG IN THAT THROTTLE WHEN YOU FIRST GET INTO IT.

BUT WHEN THE RETUNED OUR ECU, THEY WERE ABLE TO REMOVE THAT AND GIVE US A NICE, TIGHT THROTTLE RESPONSE. SO REALISTICALLY YOU'RE NOT EVEN GONNA BE ABLE TO TELL THAT YOU DON'T HAVE A CABLE HOOKED UP TO THE GAS PEDAL.

WITH THE PEDAL MOUNTED ONTO THE FIREWALL, WE'LL RUN ALL THE ELECTRONICS ONTO THE ENGINE SIDE OF THE CHASSIS. WE'LL MOUNT THE COMPUTER, TACH MODULE, AND THE FUSE BLOCK ONTO A PIECE OF ALUMINUM PLATE THAT'S BOLTED TO THE BUGGY. NOW THE LAST ITEM WE WANT TO DEAL WITH BEFORE WE THROW ON OUR FUN TIRES, FIRE THIS THING UP, AND HEAD TO THE TRAIL IS TO INSTALL SOME BODY PANELS. NOW DREW HAD THE GUYS AT MEREDITH MACHINE WORKS CUSTOM BUILD THIS JK INSPIRED HOOD SPECIFICALLY FOR THIS CHASSIS. NOW THE PACKAGE ALSO INCLUDES A NARROWED GRILL SHELL THAT HAS SOME PROVISION FOR SOME OFF ROAD LIGHTS IF YOU WANT TO ADD THEM TO JUST FINISH OUT THE JEEP LOOK. NOW BOTH PIECES ARE INCREDIBLY LIGHT WEIGHT

FIBERGLASS CONSTRUCTION AND THEY'LL BASICALLY JUST MOUNT OFF OF THE EXISTING TUBES THAT WE HAVE ON THE CHASSIS. ONCE WE HAVE THESE ON, WELL THIS BUGGY'S READY FOR THE TRAIL. WE'LL ATTACH A SMALL SHEET METAL LBRACKET TO THE CHASSIS, MARK THE LOCATION OF THE HOOD PIN ON THE BOTTOM OF THE HOOD, AND THEN DRILL A HOLE

THROUGH THE FIBERGLASS. AND WE'LL DROP IT INTO PLACE AND INSTALL THE HOOD PIN. THE SIDE PANELS, THEY JUST BOLT ONTO THE TABS THAT WE WELDED ONTO THE CHASSIS BEFORE WE SEND IT OUT TO POWDER COAT. THEN ALL WE'VE GOT TO DO IS TAKE CARE OF A BUNCH OF LITTLE THINGS. WE'LL RUN AND INSTALL ALL OF OUR BRAKE LINES, MOUNT UP OUR TIRES AND WHEELS, AND WE'RE READY TO GO WHEELING.

(ANNOUNCER)>> UP NEXT THE GOATS OF MAYHEM OFF ROAD PART. NOT THOSE GOATS, THESE GOATS!

(IAN)>> OUR TWO CAR GARAGE CRAWLER IS OUT AND READY TO GO WHEELING. NOW IF YOU GUYS REMEMBER, THE WHOLE POINT OF THIS RIG

WAS TO PROVE THAT YOU COULD PUT TOGETHER A FULL ON THROW DOWN ROCK CRAWLER IN YOUR GARAGE WITH JUST A WELDER AND A GRINDER AS YOUR SPECIAL TOOL. NOW WE'RE OUT HERE AT MAYHEM OFF ROAD PARK, THE TRUE STOMPING GROUNDS FOR HARDCORE OFF ROAD RIGS. NOW YOU MAY NOTICE THE CAR LOOKS A LITTLE BIT DIFFERENT THEN THE LAST TIME YOU SAW IT. WHEN WE WERE NUT AND BOLTING IT WE THOUGHT THE GLOSS BACK ON THE BODY PANELS JUST DIDN'T GO WELL WITH THE POWDER. SO I WENT AHEAD AND GAVE IT A NICE COAT OF THIS TEXTURED GRAPHITE METALLIC FROM DUPLICOLOR. NOW THE TRUCK IS ALL NUT AND BOLTED AND READY TO HIT

THE DIRT, BUT WHO WANTS TO GO ALONE? SO WE INVITED DREW AND HE BROUGHT HIS TWO SEATER.

(DREW)>> THE FEW DIFFERENCES ARE OBVIOUSLY IT'S A TWO SEATER, BUT I HAVE AN OPTIONAL REAR SPARE TIRE CONFIGURATION IF YOU WANT TO CARRY A SPARE, OR IF YOU'RE RACING AND WANT A SPARE.

DRIVETRAIN, IT'S A GM SIX LITER FROM A CADILLAC,

IT'S AN LQ NINE. IT'S GOT A TURBO 400, ATLAS TRANSFER CASE. AXLES, IT'S GOT A ROCK JOCK FRONT 60, A JUNKYARD 60 REAR. SUSPENSION WISE IT'S GOT MY STANDARD FOUR LINK FRONT AND

REAR, IT'S GOT FOX TWO INCH COIL OVERS, AND FOX TWO AND A HALF EXTERNAL BYPASS SHOCKS, CURRIE NRX SWAY BARS.

(IAN)>> BY COMPARISON OUR RIG HAS TWO EXTRA SEATS, A FRONT AXLE THAT WE BUILT OUT OF A COUPLE OF JUNKYARD PIECES. ORI AIR STRUTS ON ALL FOUR CORNERS, AND 42 INCH TALL PIT BULL TIRES. WE'RE RUNNING THE SAME SUSPENSION AS DREW, BUT OURS USES LINKS FROM BRANNICK MACHINE MADE OUT OF 7075 ALUMINUM. SO WHAT DOES DREW THINK OF OUR FOUR SEATER?

(DREW)>> IT'S GOOD TO SEE DIFFERENT TAKES ON IT CAUSE I HAVE MY POINT OF VIEW OR MY IDEAS, AND THEN SOMEBODY MIGHT HAVE A COMPLETELY OTHER IDEA.

(IAN)>> BUT WE'RE NOT HERE FOR A CAR SHOW. WE'RE HERE TO TEAR INTO SOME ROCKS. PILE INTO OUR BUGGIES, STRAP IN, HEAD INTO THE WOODS. THE FIRST TRAIL OF THE DAY IS A CREEK BED TRAIL. IT'S A GOOD WARM UP TRAIL WITH JUST LOTS OF ROCKS

SCATTERED THROUGHOUT THE TRAIL. OUR CRAWLER HANDLED IT GREAT FLEXING OVER THE BIG STUFF AND BUMPING UP OVER SOME STEEP LEDGES.

THIS IS DREW'S FIRST WHEELING TRIP TO THE SOUTH,

BUT QUICKLY FINDS A GOOD LINE. THERE'S A LOT OF WATER ON THE TRAIL, MAKING THE

ROCKS GOOD AND SLICK. MEANING WE HAVE TO TAKE MULTIPLE HITS TO CLEAR EACH LEDGE. BUT ONCE WE FOUND THE RIGHT LINE, WE'LL GET OVER TO THE TOP.

THEN IT WAS DREW'S TURN. SLOWLY BUT SURELY HE WAS ABLE TO HEAT UP HIS TIRES AND FOLLOW OUR LEAD.

SO WITH THE FIRST TRAIL UNDERNEATH OUR BELT, IT'S TIME TO TAKE THESE RIGS DEEPER INTO THE PARK AND FIND SOMETHING A LITTLE MORE CHALLENGING.

(ANNOUNCER)>> SOMETIMES TO MAKE IT TO THE TOP YOU'VE GOT TO DRIVE ANGRY.

(IAN)>> WE'RE BACK ON XTREME AND DEEP IN THE WOODS AT MAYHEM OFF ROAD PARK WITH DREW AND

TIM FROM GOAT BUILT.

THROWING SOME DIRT ONTO OUR TIRES AND SEEING HOW OUR BUGGIES PERFORM.

ALRIGHT DREW, WHAT DO YOU THINK OF TENNESSEE WHEELING SO FAR?

(DREW)>> IT'S GREAT, IT'S A LITTLE SLIPPERY BUT IT'S PRETTY IMPRESSIVE.

(IAN)>> WELL THAT LITTLE CREEK BED TRAIL, A LITTLE WARM UP. THIS IS REALLY WHAT MAYHEM IS MORE KNOWN FOR, THESE

BIG, NASTY, LONG HILL CLIMB SECTIONS. SO THIS IS ACTUALLY THE ONE THAT WHENEVER THEY HAVE A RACE OUT HERE THEY USE THIS.

THE RECORD'S LIKE 126 ALL THE WAY TO THE TOP.

WE WON'T TRY TO BEAT THAT.

WE'LL JUST CRAWL UP IT AND HAVE SOME FUN.

(DREW)>> LET'S DO IT!

(IAN)>> ALRIGHT LETS GO!

RIGHT AWAY THE FIRST OBSTACLE IS A BIG, STEEP LEDGE. IT TAKES A FEW TRIES AND A COUPLE OF DIFFERENT ANGLES TO GET SET UP CORRECTLY. THEN AFTER HEATING UP THE TIRES OUR FOUR SEATER HOPS RIGHT OVER. JUST HAD TO WARM UP THE TIRES A LITTLE BIT, WHAAAA! NOW SO FAR OUR FOUR SEATER LOVES THE ROCKS AT MAYHEM OFF ROAD PARK. THIS IS THE FIRST BUGGY WE'VE EVER BUILT WITH ORI AIR STRUTS. I'M VERY IMPRESSED AT HOW WELL THE AXLE CAN DROOP OUT

AND ARTICULATE AS WELL AS SOAK UP HARD HITS TO THE FRONT END WHENEVER YOU'RE ROLLING UP ON SOME LARGER ROCKS.

NOW IT'S DREW'S TURN TO ASSAULT THE HILL. SO FAR THE TRAILS THAT WE'VE RUN ARE MORE ABOUT PICKING THE RIGHT LINE BUT ON HIGHWAY 52 YOU JUST NEED A

WHOLE LOT OF SKINNY PEDAL.

WITH OUR FIRST SERIOUS TRAIL UNDER OUR BELT, IT'S TIME TO HEAD OVER TO A GREAT TRAIL TO END THE DAY, THE SKY LIFT

TRAIL, A STEEP SERIES OF LEDGES AND ROCKS THAT RUNS RIGHT UP BESIDE THE TAKE OUT ROAD.

OUR FOUR SEATER WAS DEFINITELY UP TO THE TASK. OCCASIONALLY WE HAD TO PIN THE THROTTLE AND BOUNCE OFF SOME ROCKS, BUT WE EVENTUALLY CLAWED OUR WAY TO THE TOP.

THERE WE GO!

AFTER FINISHING THE TRAIL IN OUR FOUR SEATER, I WANTED TO JUMP INTO THE PASSENGER SIDE ON DREW'S RIG TO SEE HOW WELL HE'S ADAPTED TO SOUTHERN TENNESSEE WHEELING. OH NOW YOU'RE FEELING LIKE YOU'RE IN TENNESSEE, I HEARD A REV LIMITER. YEAH, THAT'S IT!

ALL IN ALL WE HAD A GREAT DAY IN THE WOODS WITH BOTH OF OUR GOAT BUILT RIGS.