XOR - Xtreme Off-Road Builds

Parts Used In This Episode

Automotive Workwear
Official automotive workwear of Xtreme Off Road
Edwards Ironworkers
55 TON EDWARDS IRONWORKER with Hydraulic Accessory Pack option; 10 Ton Bender, 15 Ton Horizontal press,Tubing Roller and 40 Ton Shop Press.
ESAB
The Official Welding and Cutting Supplier of Xtreme Off Road, featuring the all-new Rebel 215 Multi-Process Welder
Holley
Holley LS Fest has become the go-to event for fans of GM's high performance do-it-all LS engine platform. For 2017, Holley is introducing an additional LS Fest event, LS Fest West, to be held at the world famous Las Vegas Motor Speedway just outside of Las Vegas, Nevada
Jimmy's 4x4
Custom Independent Front Suspension Set-Up
The Industrial Depot
INDUSTRIAL DEPOT - Fasteners, Hardware, And Shop Supplies

Episode Transcript

(NARRATOR)>> FOR YEARS THE LS FEST HAS BEEN A HUGE PARTY, CELEBRATING THE MUCH LOVED GM SMALL BLOCK, AND THIS TIME THE OFF ROAD COMMUNITY'S GETTING IN ON THE ACTION. TODAY ON XTREME OFF ROAD WE TAKE A VEGAS ROAD TRIP TO THE FIRST EVER LS FEST WEST, BRINGING YOU ALL THE HIGHLIGHTS AND HARD HITS OF THE OFF ROAD CHALLENGE. PLUS WE WORK ON OUR OWN DESERT RACER AS THE "BUCKIN' BRONCO" IS FITTED UP WITH A RACE READY IFS SUBFRAME.

(IAN)>> OUR BRONCO PROJECT HAS BEEN PUSHED TO THE SIDE FOR A LITTLE WHILE NOW AS WE TOOK CARE OF A COUPLE OF OTHER ITEMS, BUT WE'RE GONNA JUMP BACK ON THIS RIG TODAY. NOW WE'RE AT A PRETTY KEY POINT IN THE BUILD OF THIS RIG. THE CHASSIS IS ALMOST READY TO COME OFF OF THE TABLE AND SIT ON SOME JACK STANDS FOR THE FIRST TIME, BUT BEFORE WE DO THAT I WANT TO GET THE FRONT SUBFRAME LOCKED INTO PLACE FOR OUR INDEPENDENT FRONT SUSPENSION. I NEED TO GET IT IN THERE WITH THE CHASSIS ON THE TABLE JUST TO MAKE SURE EVERYTHING LINES UP CORRECTLY, AND I MAY END UP MOVING OUR MOTOR AROUND SLIGHTLY. I THINK I CAN COME FORWARD A COUPLE OF INCHES AND ACTUALLY DOWN FURTHER INTO THE BELLY TO GIVE US A LITTLE BIT BETTER WEIGHT TRANSFER. NOW WE'VE ALWAYS KNOWN THIS RIG WAS GONNA BE IFS, AND WHEN YOU'RE BUILDING AN ULTRA FOUR STYLE CRAWLER THERE'S ONLY ONE PLACE TO GO FOR THAT IFS ASSEMBLY. JIMMY'S FOUR BY FOUR IS A SHOP PIONEERING THE USE OF IFS IN ULTRA FOUR CARS. PROBABLY BEST KNOWN FOR LOREN HEALY'S "RED DRAGON", A SINGLE SEAT CAR THAT DOMINATES IN THE DIRT AND ON THE ROCKS. I KNEW THAT WHEN MY PLAN WAS IFS I WAS GONNA CALL THE CREW AT JIMMY'S FOUR BY FOUR, AND THEY BUILT ME THE UPDATED VERSION OF THE IFS SYSTEM UNDER THAT CAR. STARTING WITH A SPIDER TRAX NINE INCH IFS HOUSING, THE ENTIRE SUBFRAME IS JIG BUILT TO PROVIDE JUST OVER 18 INCHES OF FRONT WHEEL TRAVEL. BUILT USING A MIX OF PLATE STEEL AND TUBING, THE SYSTEM IS DESIGNED TO MINIMIZE CASTOR AND CAMBER CHANGE THROUGHOUT THE ENTIRE SUSPENSION TRAVEL.

WITH THE SHEET METAL OUT OF THE WAY, THE WELDING TABLE SURFACE PLATES ARE MOVED TO HOLD THE IFS SUBFRAME IN PLACE. [ impact drill spinning ]

(IAN)>> WE JUST SET OUR JIMMY'S FOUR BY FOUR IFS SUBFRAME ONTO THE CHASSIS TABLE TO SEE HOW MANY CHANGES I NEED TO MAKE TO THE FRONT OF THIS EXISTING BRONCO CHASSIS IN ORDER FOR IT TO WORK. NOW I ALWAYS KNEW THAT THESE TWO TUBES WERE GONNA GO. THEY WERE JUST BASICALLY PLACE HOLDERS TO LOCATE THIS FRONT GRILL SHELL BASED OFF SOME MEASUREMENTS THAT I GOT FROM THE GUYS AT JIMMY'S FOUR BY FOUR. NOW IT LOOKS LIKE IT'S SITTING REALLY HIGH RIGHT NOW BUT IT'S NOT. ALMOST ALL OF THESE IFS CARS, THE FRONT SUBFRAME ACTUALLY SITS LOWER THAN THE ACTUAL BELLY PAN OF THE REST OF THE RIG. JIMMY'S FOUR BY FOUR BUILDS THIS FRONT SUBFRAME ASSEMBLY WITH THIS INTEGRATED FRONT BUMPER, AND THEY WOULD THEN BUILD THE CHASSIS OFF OF THIS. WE ARE KIND OF DOING THIS A LITTLE BIT BACKWARDS. I'M BASICALLY TRYING TO MAKE THAT FIT INTO OUR EXISTING CHASSIS. MY PLAN IS TO BASICALLY MODIFY THAT FRONT BUMPER AND HAVE IT INTEGRATE INTO THE BOTTOM OF THIS LOWER GRILL SHELL HOOP. I NEED TO DROP IT DOWN BUT I NEED TO TAKE SOME MEASUREMENTS SO I CAN FIGURE OUT HOW MUCH.

WHEN BUILDING CUSTOM VEHICLES SOMETIMES YOU NEED TO BUILD THE TOOL THAT YOU'RE GONNA NEED.

TO RAISE THIS CHASSIS FOUR AND A HALF INCHES I'M BUILDING BRACKETS THAT WILL MOUNT TO THE FAB TABLE AND CRADLE THE LOWER TUBES ON OUR CHASSIS TO RAISE IT AND KEEP IT LOCKED IN THE CORRECT POSITION.

(NARRATOR)>> UP NEXT, WE GO FOR A JOY RIDE IN ONE SERIOUSLY BUILT BUG. PLUS IT'S THE FIRST ANNUAL LS FEST WEST.

(IAN)>> IF YOU'RE FAMILIAR WITH GM'S LS ENGINE THEN YOU'VE PROBABLY HEARD OF LS FEST. IT'S AN ANNUAL CELEBRATION OF ALL LS ENGINES PUT ON BY HOLLEY PERFORMANCE PRODUCTS. NOW NORMALLY IT'S IN BOWLING GREEN, KENTUCKY, AND THEY HAVE THINGS LIKE DRAG RACING, AND DRIFTING, AND SOME AUTO CROSSING, BUT THIS YEAR, JUST LIKE THE OLD SAYING GOES, THEY WENT WEST YOUNG MAN TO LAS VEGAS, NEVADA, CAUSE THEY KNEW THAT IF THEY BROUGHT THE LS FEST OUT HERE THE BOYS WHO LIKE TO PUT LS ENGINES IN THEIR DIRT MACHINES WOULD SHOW UP, AND THEY SHOWED UP INDEED. LS FEST IS THE PLACE FOR LOVERS OF ANY TYPE OF VEHICLE WITH AN LS BASED POWER PLANT, AND THE HOLLEY LS FEST WEST CELEBRATES THEM ALL, DRAG RACING, AUTO CROSSING, SHOW CARS, AND THIS YEAR FOR THE FIRST TIME AT ANY LS FEST OFF ROAD PRERUNNERS AND ULTRA FOUR CARS.

(BILL)>> IT LETS EVERYBODY JUST APPRECIATE THE SAME MOTOR AND SEE WHAT EVERYBODY ELSE DOES WITH IT. EVERY SOUND YOU HEAR OUT HERE YOU KNOW IT'S THE LS ENGINE SCREAMING, AND EVERYBODY APPRECIATES, AND IT'S JUST AWESOME.

(IAN)>> IN THE OFF ROAD WORLD WE HAVE BEEN LOVERS OF THE LS ENGINE FOR YEARS FOR GOOD REASON.

(JASON)>> GO TO THE JUNKYARD, GRAB A SIX LITER, THROW IT IN THERE, AND GO HAVE A GREAT CAR THAT YOU CAN REALLY MAKE RELIABLE WAS REALLY THE ONSET OF IT. THEN WE LEARNED WHAT THEIR POWER CAPABILITY WAS. YOU KNOW, THEIR HEAD DESIGN WAS AWESOME. THERE'S A LOT OF AFTERMARKET SUPPORT FOR IT, AND IT BECAME A COST EFFECTIVE MOTOR BUT IT WAS STILL RIGHT THERE WITH SOME OF THE TOP RACE ENGINES.

(RANDY)>> THE LS ENGINE IS SO VERSATILE. OFF IDLE DRIVABILITY IS GREAT. IT'S VERY TAME AND MANAGEABLE IN THE ROCKS, BUT YET YOU KNOW IT REVS TO 7,000 RPM, MAKES BIG HORSEPOWER ON TOP. YOU CAN'T BEAT IT.

(IAN)>> AND THE LS IS ALSO A FAVORITE FOR PRERUNNERS. PRERUNNERS ARE USUALLY TWO WHEEL DRIVE TRUCKS WITH HUGE AMOUNTS OF WHEEL TRAVEL FRONT AND REAR, DESIGNED TO PUNISH THE DESERT. THE CREW FROM DIRT ALLIANCE SHOWED UP IN FORCE, HAWKING TRUCKS OVER A WICKED TABLE TOP JUMP.

A PRERUNNER CAR THAT I HAVE ALWAYS LOVED IS THE CLASS ONE STYLE VW BUG OWNED BY BLAKE WILKEY FROM WILKEY WORKS.

(BLAKE)>> MY MOTHER'S FIRST CAR WHEN I WAS BORN WAS A BUG. SO WHEN I WAS BORN I WAS CRUISING IN A BUG. I WANTED SOMETHING THAT WAS STREET LEGAL, HAD WORKING DOORS, AND A COOL FACTOR. SOMETHING THAT WAS REALLY WIDE, LOT OF SUSPENSION, AND SOMETHING WE COULD GO GET CRAZY WITH.

(IAN)>> AND WHEN BLAKE OFFERED TO TAKE ME FOR A RIP THERE WAS NO QUESTION THAT I WAS READY FOR A RIDE. THIS REAR ENGINE SUPERCHARGED LS BASED BEAST IS ABLE TO CARRY THE FRONT TIRES OUT OF ANY CORNER THAT IT'S THROWN INTO. PLUS WITH THE MAJORITY OF THE WEIGHT BEING IN THE REAR, THE CAR LAUNCHES, FLIES, AND LANDS FLAT WITH HUGE KING SHOCKS ABLE TO SOAK UP ALL THE TRACK. TO SAY IT WAS FUN IS AN UNDERSTATEMENT. CONSIDERING THAT HE DRIVES LIKE A MAD MAN, WHEN HE'S OUT OF THE CAR HIS ATTITUDE INSTANTLY CHANGES TO THAT OF A TYPICAL SAN DIEGO SURFER DUDE.

(BLAKE)>> I HAD LONG HAIR FOR LIKE SEVEN, EIGHT YEARS NOW, AND I LOVE PIZZA. SOUTHERN CALIFORNIA, PRETTY MUCH GREW UP AND RAISED IN THE SAME AREA. KIND OF GET PROFILED AS A SAN DIEGAN.

(IAN)>> SO MUCH SO THAT I ARRANGED FOR A DELIVERY TO BE MADE AFTER OUR RIDE. PIZZA DUDE! THAT'S ME ALL RIGHT THERE, THANKS MAN.

(BLAKE)>> PEPPERONI?

(IAN)>> YEAH, HERE, I GOT IT, TAKE THIS AND HOLD ON. THAT SHOULD COVER IT AND FOR YOU. THANKS MAN! THANKS FOR THE RIDE BLAKE.

(BLAKE)>> ANY TIME FELLA.

(IAN)>> BUT THIS TRACK WASN'T BUILT FOR PRERUNNER FUN. IT WAS BUILT FOR ULTRA FOUR RACING, AND NOW THAT WE'RE DONE HAVING FUN IT'S TIME FOR THE ULTRA FOURS TO GET TO WORK.

(NARRATOR)>> UP NEXT, HEAD TO HEAD ACTION AT THE OFF ROAD CHALLENGE ELIMINATIONS, AND WHEN BUILDING A DESERT RACER A LITTLE EXTRA PREP WORK GOES A LONG WAY.

(IAN)>> LS FEST IS THE PLACE WHERE IF YOU HAVE A VEHICLE WITH AN LS ENGINE YOU CAN FIND A SPOT TO HAVE FUN WITH IT. THERE'S EVEN A HUGE VENDOR AREA WHERE YOU CAN SHOP FOR PARTS TO MAKE IT BIGGER, STRONGER, AND FASTER, WITH A PILE OF COMPANIES OFFERING UPGRADES FOR THIS GM BASED POWER PLANT. NITTO TIRES WAS ONE OF THE SPONSORS OF THE OFF ROAD CHALLENGE EVENT, AND A BOOTH THAT MORE THAN A FEW PEOPLE PROBABLY STOPPED BY TO SHOP FOR TIRES AFTER THE CINCO DE MAYO TIRE DEFRYO EVENT FRIDAY NIGHT.

EVEN A FEW ULTRA FOUR RIGS GOT IN ON THE ACTION. [ engine revving ]

(IAN)>> BUT THESE ULTRA FOUR CARS WERE NOT HERE JUST FOR FUN. THEY WERE HERE TO DO WHAT THEY DO BEST, RACE! THE CREW FROM ULTRA FOUR RACING BROUGHT IN JOHN GOODBY TO TURN THE DIRT TRACK BESIDE THE DRAG STRIP INTO A SPLIT LANE OFF ROAD SHORT COURSE TRACK.

(JOHN)>> SO WHAT I DO IS I COME OUT TO THE SIDE AND I PREVIEW WHAT WE'RE GONNA DO. THEN I GO HOME AND I ETCHASKETCH ON A PIECE OF PAPER WHAT IT'S GONNA BE, WHERE THE JUMPS ARE GONNA BE, HOW THE TURNS ARE GONNA LAYOUT, AND THEN WE COME BACK OUT WITH EQUIPMENT AND WE MAKE IT HAPPEN.

(IAN)>> HOW LONG DID IT TAKE TO PUT THIS TRACK TOGETHER?

(JOHN)>> WE SPENT ABOUT FOUR DAYS HERE.

(IAN)>> AND THEN WHEN YOU'RE DONE WHAT DO YOU DO WITH IT?

(JOHN)>> WE'RE GONNA WIPE IT OUT IN A DAY.

(IAN)>> SHORT COURSE RACING IS NOT NEW TO THE WORLD OF ULTRA FOUR. THE ULTRA FOUR CLASS WAS DESIGNED AROUND A CAR THAT HAS TO BE ABLE TO DO EVERYTHING OFF ROAD.

(JASON)>> IT'S A CROSSOVER BETWEEN A DESERT TRUCK AND A ROCK CRAWLER, AND SO OUR WHOLE IDEA WITH THIS ONE WAS TO TRY TO TAKE EVERYTHING THAT WE COULD THAT WAS GOOD IN THE DESERT AND GOOD IN THE ROCKS, AND COMBINE THE TWO OF THEM.

(IAN)>> THE RACE WOULD CONSIST OF TWO LAPS AROUND THE TRACK. EACH CAR WOULD START RIGHT BEFORE THE TABLE TOP JUMP, MAKE ONE LAP THROUGH THE WHOOP SECTION INTO A COUPLE OF HIGH BANK TURNS, BEFORE EXCITING ONTO THE FRONT STRAIGHT SECTION OF THE OVAL DIRT TRACK, HAVING TO AVOID THE WALL AS WELL AS A WELL PLACED TIRE BARRICADE BEFORE DUMPING BACK INTO THE TABLE TOP AND AROUND THE TRACK ONE LAST TIME. UP FIRST, THE LIMITED CLASS CARS. THESE ARE BASED MORE OFF PRODUCTION VEHICLES, HAVE RECTANGULAR FRAME RAILS, LIMITED SUSPENSION TRAVEL, AND 37 INCH TALL TIRES. EVEN THOUGH THEY ARE CONSIDERED THE ENTRY LEVEL CLASS, THEY PUT ON A GREAT SHOW. THE RACE WAS BUILT AROUND A SERIES OF BRACKETS, WORKING OUR WAY DOWN FROM ABOUT 20 CARS TO THE FINAL TWO, AND THERE WAS NO SHORTAGE OF ACTION IN THE DIRT DURING THE RACE.

I'VE KNOWN RANDY SLAWSON FOR OVER A DECADE, A TRUE BUILDER/RACER. HE RACES EACH ONE OF THE BOMBER CARS THAT HE BUILDS HIMSELF. THE BOMBERS PROVE THAT SOLID AXLE CARS CAN HANDLE HIGH SPEED OFF ROAD RACING.

(RANDY)>> THE DAY WE PUT IT IN THE TRAILER I THREW SOME DIFFERENT SPRINGS ON IT, LOWERED IT DOWN A LITTLE BIT, PUT SOME 37'S ON IT, AND TRIED TO TURN IT INTO A SHORT COURSE CAR. WITH SOME REALLY GOOD SHOCK TUNING THE THING COULD BE A WEAPON ON THE SHORT COURSE I GUARANTEE YOU.

(IAN)>> IN THE END IT WAS RANDY SLAWSON AND HIS BOMBER, AND JASON SCHERER IN HIS IFS SINGLE SEATER, AND WHEN THE FLAG DROPPED IT WAS A GREAT RACE.

(JASON)>> THERE'S EVERYBODY OUT HERE, AND TO SEE ALL THE DIFFERENT PEOPLE RUNNING IT, AND REALLY THE TOP PERFORMANCE GUYS OUT HERE ARE SHOWING OFF WHAT THEY CAN DO WITH THIS LS MOTOR. SO I'M LEARNING THINGS FROM DIFFERENT PEOPLE, AND ALSO YOU'RE REALLY ENJOYING A GOOD SHOW.

(IAN)>> SCHERER WOULD TAKE THE CHECKERED FLAG AND THE WIN AT THE FIRST EVER LS FEST WEST OFF ROAD CHALLENGE. SO IF YOU LIKE THE LS ENGINE IN ANY TYPE OF CAR, BUT IF YOU REALLY LIKE IT WHEN THEY'RE DOING WORK IN THE DIRT, I EXPECT TO SEE YOU AT LS FEST WEST NEXT YEAR. I KNOW I PLAN TO BE THERE.

(IAN)>> WE'RE RIGHT IN THE MIDDLE OF INSTALLING OUR JIMMY'S FOUR BY FOUR IFS SUBFRAME ASSEMBLY INTO OUR CLASSIC '66 BRONCO TUBE CHASSIS. NOW I'VE ALREADY GOT THE CHASSIS RAISED UP ON OUR FRAME TABLE TO THE CORRECT HEIGHT. SO NOW I CAN START TO SURGICALLY MODIFY THE FRONT BUMPER ON THIS ASSEMBLY SO IT WILL INTEGRATE CORRECTLY WITH OUR GRILL HOOP. THE FRONT BUMPER ON OUR SUBFRAME ASSEMBLY IS TWO INCH 120 WALL TUBING. SINCE THE GRILL SHELL IS INCH AND THREE QUARTER DOM, I CAN CUT A RELIEF CUT INTO THE FRONT BUMPER THAT WILL FIT PERFECTLY AROUND THE GRILL SHELL TUBE. IT'LL NEED TO BE CLEARANCED FOR THE CENTER BARS, BUT WITH SOME CLAMPS AND SOME HAMMER PERSUASION, IT FITS NEATLY INTO PLACE.

[ welder crackling ]

(IAN)>> THIS IS A PERFECT EXAMPLE AS TO WHY IT IS SO IMPORTANT TO PUT A CHASSIS TOGETHER LIKE THIS ON SOME TYPE OF SETUP TABLE. I CAN QUICKLY DETERMINE THAT OUR JIMMY'S FOUR BY FOUR FRONT IFS ASSEMBLY IS PERFECTLY IN LINE WITH THE REST OF OUR CHASSIS JUST BY TAKING A FEW MEASUREMENTS OFF OF THE TABLE. NOW IT'S EASY JUST TO KEY IT INTO THE GRILL SHELL. WE ALWAYS KNEW THAT THAT WAS GONNA LINE UP FINE, BUT MAKING SURE THAT IT'S SITTING RIGHT ON TOP OF THIS TABLE ALSO ENSURES THAT EVERYTHING IS SQUARE WITH THE REST OF OUR CHASSIS. NEXT STEP IS TO BASICALLY ADD MORE TUBING TO GIVE IT MORE STRENGTH. SO WE HAVE AN UNSUPPORTED JOINT RIGHT HERE. I'LL PROBABLY PULL IT BACK OVER HERE TO THIS FENDER BAR, AND THAT'LL PROBABLY PULL OVER HERE TO OUR WINDSHIELD BAR. WE DO NEED TO PLAN FOR THE ENGINE TO BE REMOVED THROUGH THE HOOD OF THIS TRUCK, NOT THROUGH THE BOTTOM LIKE WE DO WITH SOME BUGGIES. SO AS I'M ADDING TUBING I NEED TO MAKE SURE THAT I DON'T PUT A PIECE OF TUBING RIGHT OVER TOP OF THIS ENGINE OR IT'LL MAKE GETTING THAT MOTOR OUT A LOT HARDER.

TO ANCHOR THE SUBFRAME TUBING IS CUT, NOTCHED, AND GROUND TO FIT WITH THE FENDER BAR AND LOWER BRACE, AND FINALLY TACKED INTO PLACE.

MASKING TAPE IS THEN USED TO LAY OUT THE REST OF THE TUBING.

AT THIS POINT FOR THE FRONT OF OUR CHASSIS IT'S JUST LIKE WASHING YOUR HAIR. IT'S LATHER, RINSE, REPEAT. IT'S CUT A PIECE OF TUBE, NOTCH IT, GRIND IT TO FIT, AND THEN TACK IT INTO PLACE. USING MASKING TAPE CAN HELP YOU VISUALIZE WHERE THE TUBES ARE GONNA LAND AND LET YOU KNOW IF IT'S GONNA "A", LOOK GOOD, AND "B", WORK. IN THIS CASE I KINDA GOT AHEAD OF MYSELF. I THOUGHT THESE TWO TUBES WOULD WORK WELL CAUSE THEY'D TIE OFF THESE TWO NODES AND TIE BACK INTO OUR WINDSHIELD TUBE, BUT I CAN'T DO THAT BECAUSE IF YOU REMEMBER THERE'S GONNA BE A HOOD SITTING ON TOP OF THIS BRONCO. SO INSTEAD I NEED TO MOVE THEM. NOW THERE'S A COUPLE OF EASY PLACES TO PLACE THEM. I'VE CREATED AN "X" RIGHT HERE THAT'LL STRENGTHEN UP THIS WHOLE SIDE OF OUR CHASSIS SO I CAN PULL THIS NODE BACK DOWN INTO THIS JOINT, AND THEN I THINK ON THIS FRONT ONE WE'LL ACTUALLY JUST KICK STRAIGHT DOWN AND STRENGTHEN UP OUR FRONT IFS SUBFRAME. I REALLY WON'T PROBABLY WORK ON THIS PIECE OF TUBING UNTIL I HAVE OUR SHOCK PACKAGE IN PLACE BECAUSE THEY LAND SOMEWHERE IN THIS AREA RIGHT HERE, BUT AT THIS POINT I JUST HAVE A WHOLE LOT OF TUBING TO CUT.

WHENEVER YOU'RE WORKING WITH TUBING A DIFFICULT AREA IS ALWAYS A COMPLICATED TUBE JOINT. YOU WANT A NICE, TIGHT FITTING NOTCH WHERE THE TUBES INTERSECT. THINK OF IT LIKE PAINT AND BODY. SPEND A LOT OF TIME ON THE PREP AND YOU'LL END UP WITH A HIGH QUALITY PAINT FINISH. SAME HOLDS TRUE WITH TUBE JOINTS. SPEND A LOT OF TIME GETTING YOUR FIT UP PERFECT AND YOU'LL HAVE A HIGH QUALITY AND STRONG WELD HOLDING YOUR CHASSIS TOGETHER. NOW THERE'S NOTHING THAT'S GONNA REPLACE JUST TIME WITH THE TUBE GETTING IT TO FIT PERFECTLY, BUT THERE ARE SOME TOOLS THAT CAN MAKE THE JOB A LOT EASIER. THERE ARE MANY WAYS TO CUT A NOTCH. TWO POPULAR ONES ARE A GOOD QUALITY HOLE SAW STYLE NOTCHER OR A PLASMA CUTTER. BOTH OF THESE SHOULD BE CONSIDERED AS THE INITIAL CUT JUST TO FIT THE TUBING. YOU'RE GONNA WANT A HAND GRINDER WITH A SELECTION OF FLAT DISCS. I PREFER A 40 GRIT FOUR INCH DISC. THESE MAKE QUICK WORK CLEANING UP THE NOTCH. A GOOD PAINT PEN CAN BE USED TO MARK THE LOCATION OF A NOTCH ON A TUBE BY HOLDING IT AGAINST THE TUBE AND USING IT AS A GUIDE. PAINT PENS WORK BEST BECAUSE THEY ARE NOT EFFECTED BY THE HEAT OF THE GRINDER OR THE PLASMA CUTTER. A SELECTION OF CARBIDE BURRS, A DIE GRINDER, AND A SMALL AIR POWERED CUTOFF WHEEL WILL HELP CUT TACKS TO REMOVE THE TUBE. YOU CAN BUY PROFILE GAUGES THAT SLIDE OVER THE TUBING TO HELP WITH COMPLICATED NOTCHES. TUBE NOTCHING IS A COMPLICATED PROCESS. PLAN TO TAKE MULTIPLE TRIPS BETWEEN YOUR CHASSIS AND YOUR BENCH WITH YOUR HAND GRINDER FINE TUNING THAT NOTCH UNTIL IT FITS PERFECT. ANOTHER TIP I CAN GIVE YOU IS ALWAYS START WITH THE MOST COMPLICATED NOTCH. ON THIS CHASSIS FOR THIS TUBE IT INTERSECTS TWO PIECES OF TUBING. SO I RAN THE TUBE LONG AND JUST SPENT TIME FINE TUNING THIS NOTCH. THIS ONE'S MORE COMPLICATED THAN THIS SIMPLE NOTCH UP AT THE GRILL SHELL. IF I'D STARTED HERE THERE IS A CHANCE THAT BY THE TIME I HAD THIS END FITTING CORRECTLY MY TUBE MAY HAVE BEEN TOO SHORT. IF THAT HAPPENS DON'T GET MAD, DON'T JUST TACK IT IN AND PLAN TO JUMP THE GAP, OR MAYBE CHANGE THE ALIGNMENT OF THE TUBE. SET IT ASIDE. YOU WILL USE IT SOMEWHERE ELSE IN YOUR CHASSIS, I PROMISE. EVEN IF IT'S JUST A SHORT PIECE OF TUBE FOR A GUSSET. ALSO, GRIND OFF THE MILL SCALE CAUSE IT'LL JUST CLEAN UP THE FINISH WELDS CAUSE YOU'RE NOT WELDING ON DIRTY TUBING.
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