More Blog Buggy Project Episodes

Xtreme 4x4 Builds

Parts Used In This Episode

A&A Manufacturing
Radius Tab Fits 1 1/4" Tubing
Miller Electric Manufacturing Co.
Miller Spoolmate 200 Spoolgun, 20 ft (6 m) cable, Extra contact tips and nozzle
Streetwerkz Custom Powder Coating
Streetwerkz is a state-of-the-art powder coating and media blasting facility in Columbus, Ohio Custom powder coated the Royal Purple Blog Buggy
Turbonetics Inc.
Turbocharger Head Unit,72MM GT-K 850, Aluminum, Black Chrome, Each
Woodward Fab
48" Metal brake
Woodward Fab
Throatless hand shear
Woodward Fab
Throatless rotary shear

Episode Transcript

(ANNOUNCER)>> THERE'S MORE THAN ONE WAY TO SKIN A CAT, OR A BUGGY. TODAY ON XTREME 4X4 WE SHOW YOU ALL THE TIPS AND TRICKS TO BUILD CUSTOM BODY PANELS FOR YOUR RIG, FROM MAKING THE TEMPLATE TO FINAL INSTALLATION, AND EVERYTHING IN BETWEEN. PLUS THE EXCITING NEW SERIES THAT'S BRINGING WEST COAST RACING TO THE EAST COAST.

(IAN)>> NOW TODAY IS A DAY THAT WE'VE BEEN WAITING FOR A LONG TIME. WE FINALLY GOT OUR BLOG BUGGY CHASSIS BACK IN THE SHOP FRESH FROM THE POWDER COATER. WHILE IT WAS THERE, THE POWDER COATER TOOK A STAB AT OUR WHEELS. AS YOU CAN SEE, THEY ARE COMPLETELY DIFFERENT. HE WENT AHEAD AND DID A NICE SILVER METAL FLAKE POWDER COAT, AND THEN PUT TEFLON ON THE ROCK RINGS AS WELL AS THE BACK SIDE OF THE RIM TO KEEP STUFF FROM STICKING TO IT. NOW THESE WHEELS AND TIRES WILL REALLY FINISH OUT THIS RIG, BUT HOW DID IT ALL START? WELL LETS HAVE A LOOK. WE STARTED WITH A SIMPLE PLAN. LET YOU COMPLETELY DESIGN A BUGGY FROM TOP TO BOTTOM. AND AFTER WE ADD A COMPLETE ROLLING CHASSIS WITH ALL THE PARTS THAT YOU PICKED, WE TORE THE WHOLE THING APART AND SENT THE FRAME OUT TO GET POWDER COATED. THE ENGINE WE KEPT IN THE SHOP, COMPLETELY DISASSEMBLED IT, THREW A COUPLE OF UPGRADES AT IT, AND FINISHED IT OFF WITH A MONSTER TURBO CHARGER. NOW THE LAST TIME YOU GUYS SAW THIS CHASSIS, IT WAS 100 PERCENT BARE STEEL. SINCE THEN WE CARRIED IT UP TO THE GUYS AT STREET WORKS CUSTOM POWDER COATING IN COLUMBUS, OHIO. NOW THIS IS REALLY THE FIRST TIME WE'VE EVER BUILT KIND OF A THEME CRAWLER. AND THIS ONE BEING FOR ROYAL PURPLE, WE KNEW WE NEEDED TO HAVE SOMEBODY WHO COULD KNOCK THE WHOLE IDEA OUT OF THE PARK. AND THE GUYS THERE SPECIALIZE IN THIS TYPE OF HIGH END POWDER COAT FINISH, AND I THINK THEY REALLY NAILED THE WHOLE "I BLEED PURPLE" THEME WITH THIS SETUP. NOW THE WHOLE THING STARTED BY SAND BLASTING THE ENTIRE CHASSIS. THEN THEY PUT DOWN TWO LAYERS OF PRIMER POWDER COAT. NOW THAT DOES THE SAME THING THAT PRIMER IN A PAINT JOB DOES. JUST BASICALLY SEALS ALL THE METAL AND PREVENTS ANY IMPURITIES FROM POPPING OUT OF THE FINAL FINISH. NOW THIS IS A PURPLE CANDY COAT COLOR. SO THE NEXT STEP WAS A SILVER BASE. AND AFTER THE SILVER BASE WENT ON, THEY MASKED THE ENTIRE CHASSIS. NOW THAT MASK WAS THERE TO GIVE US OUR THEME. NOW THE "I BLEED PURPLE" THEME IS WHAT'S ON A LOT OF NEW ROYAL PURPLE PACKAGING. SO WE HAD THEM PUT A HEART ON TOP OF THE ENGINE PLATE AND THEN COVER THE ENTIRE CHASSIS WITH VEINS GOING THROUGHOUT THE ENTIRE RIG TO SORT OF GIVE THE WHOLE THING SORT OF LIKE AN EXPOSED SKELETON KIND OF LOOK. THEN IT WAS TIME FOR THE CANDY PURPLE, AND THE CANDY WITH POWDER COAT IS JUST LIKE PAINT, IT'S TRANSLUCENT. MORE COATS GO ON, THE DARKER IT'S GONNA GET. AND AFTER TWO COATS OF CANDY PURPLE, THE CHASSIS WAS CHECKED AND IT MATCHED THE BOTTLE PERFECTLY. SO IT WAS FINISHED OFF WITH TWO GOOD THICK COATS OF CLEAR AND THEN BUFFED TO A MIRROR FINISH. NOW THIS IS A PRETTY LABOR INTENSIVE PRODUCT. THERE'S OVER 900 HOURS IN THIS CHASSIS ALONE. AND I'M SURE A LOT OF YOU GUYS ARE WONDERING, WHY GO THROUGH ALL THAT WORK WITH CUSTOM POWDER COAT? WHY NOT JUST PAINT IT? WELL THE POWDER COAT REALLY SUITS ITSELF TO A TUBE CHASSIS DESIGN. IF YOU WERE GONNA PAINT THIS RIG YOU'D HAVE TO GET YOUR PAINT GUN INTO ALL THESE LITTLE NOOKS AND CRANNIES, AND THERE'S A GREAT CHANCE THAT YOU'RE NOT GONNA HAVE AS GOOD COVERAGE IN A LOT OF AREAS. POWDER FLOWS WHEN IT'S HEATED UP. IT KINDA TURNS TO LIQUID, GIVING THE CHASSIS 100 PERCENT COVERAGE. PLUS YOU'VE GOT TO REMEMBER, IT'S KINDA LIKE AN M&M WITH A HARD CANDY SHELL. IT'S GONNA BE A LOT STRONGER AND A LOT HARDER TO SCRATCH.

(CHRIS)>> STREET WORKS ALSO COVERED ALL THE BODY PANELS WITH THE SAME CANDY PURPLE POWDER COAT WITH THE LOGOS BURIED UNDERNEATH THE CLEAR TO GIVE IT THAT FINISHING TOUCH.

(IAN)>> THEN THEY FINISHED THE ENTIRE PACKAGE OFF BY COATING BOTH THE ROCK SLIDERS AND ALL OF THE SKID PLATES WITH A MILITARY SPEC WRINKLE TEFLON POWDER COAT. BUT THEY DIDN'T STOP THERE. THEY ACTUALLY ADDED CRUSHED GLASS TO THE POWDER TO GIVE IT JUST A LITTLE BIT OF A SPARKLE. NOW WE'VE ALREADY SHOWN YOU GUYS EVERY SINGLE ITEM THAT YOU PICKED FOR US TO BUILD THIS CRAWLER OUT OF, BUT ONE THING THAT WE'VE NEVER REALLY TALKED ABOUT HERE AT XTREME WAS HOW TO SKIN THE TUBE CHASSIS. AND AS YOU CAN SEE, WE'VE ALREADY BUILT ALL THE BODY PANELS FOR THIS RIG. THAT'S EXACTLY WHAT WE'RE GONNA DO TODAY. WE'RE GONNA TAKE YOU GUYS STEP BY STEP THROUGH THE PROCESS OF BASICALLY BUILDING BODY PANELS FOR YOUR TUBE CHASSIS. WE'LL ALSO LOOK AT FLOOR BOARDS, FIREWALLS, AND SKID PLATES. SHOW YOU ALL THE DIFFERENT MATERIAL OPTIONS YOU HAVE, AND SOME TOOLS THAT'LL MAKE THE JOB A LOT EASIER.

(ANNOUNCER)>> UP NEXT, HOW TO PICK THE RIGHT METAL FOR YOUR BODY PANELS AND THE BEST WAY TO CUT IT.

(IAN)>> TODAY WE'VE GOT OUR BLOG BUGGY CHASSIS FRESH BACK FROM THE POWDER COAT AND WE'RE USING IT TO SHOW YOU GUYS ALL THE STEPS THAT YOU NEED TO FOLLOW WHEN YOU'RE BUILDING CUSTOM BODY PANELS TO SKIN A TUBE RIG LIKE THAT. NOW YOU START BY MAKING A TEMPLATE. AND YOU'VE HEARD US SAY BEFORE THE BEST THING TO DO IS USE A PIECE OF CARDBOARD TO MAKE THAT TEMPLATE OUT OF. BUT YOU DON'T WANT TO USE CORRUGATED CARDBOARD LIKE A CARDBOARD BOX. WHEN YOU TRY TO BEND IT AT ANGLE, IT'LL TEND TO SNAP AND BREAK RIGHT IN THE VOID IN THAT CORRUGATED SECTION. THIS YOU'LL BE FIGHTING IT MORE THAN IT'S WORTH TO USE. WHAT YOU WANT TO GET IS WHAT'S CALLED HARD BOARD OR BRISTOL BOARD. IT'S ABOUT TWICE AS THICK AS NOTEBOOK PAPER. IT'S VERY EASY TO WORK WITH, BUT THE NICE THING IS IS WHEN YOU BEND IT AND MOVE IT, IT TENDS TO REACT VERY SIMILAR TO THE ALUMINUM THAT YOU'RE GONNA USE TO MAKE THE BODY PANELS OUT OF. NOW THE FIRST TOOLS YOU'RE GONNA NEED FOR THE JOB, BASICALLY A PERMANENT MARKER, A PAIR OF SCISSORS, AND A COUPLE OF RULERS. WITH THE TEMPLATE MATERIAL SECURED TO THE CHASSIS WITH SOME MASKING TAPE, WE'LL GET A ROUGH OUTLINE OF THE SHAPE OF THE PANEL. THEN CUT IT OUT, TRIM IT UNTIL IT FITS PERFECTLY, AND THEN MARK THE LOCATION OF ALL THE MOUNTING TABS. ONCE YOU HAVE YOUR TEMPLATE MADE, IT'S TIME TO DECIDE WHAT YOU'RE GONNA MAKE THE BUGGY SKINS OUT OF. NOW ONE POPULAR OPTION IS 090 ALUMINUM SHEET. IT'S VERY LIGHT WEIGHT, EASY TO WORK WITH, AND RESISTS CORROSION. YOU CAN GET IT IN A BUNCH OF DIFFERENT FINISHES. RAW, LIKE WE HAVE HERE, FULL POLISH IF YOU WANT THAT SHOW ROOM SHINE, OR EVEN PREPOWDER COATED IN COLORS LIKE BLACK AND WHITE THAT'S USED IN TRAILER MANUFACTURING. NOW IF YOU'RE TRYING TO PINCH A FEW PENNIES, YOU CAN USE JUST REGULAR OLE SHEET METAL THAT YOU GET FROM AN AUTO BODY SUPPLY PLACE. THE PROBLEM THERE IS IT'S A LITTLE BIT HEAVIER, A LITTLE BIT HARDER TO WORK WITH, AND OBVIOUSLY MORE PRONE TO RUSTING IF YOU GET A SCRATCH OR CHIP IN THE PAINT OR POWDER COAT. HECK I'VE EVEN SEEN GUYS SKIN THEIR BUGGIES USING EXPANDED METAL SHEETS. THE THEORY THEY IS THAT IT'S EASY TO KEEP THE BUGGY CLEAN CAUSE YOU JUST WASH THE INSIDE OUT, ALL THE MUD AND DIRT WILL JUST GO THROUGH ALL THE OPENINGS. THE DOWNFALL IS IF IT'S EASY FOR THE MUD AND DIRT TO GO OUT, IT'S JUST AS EASY FOR THE TIRES TO THROW IT RIGHT BACK IN. WHEN IT COMES TO CUTTING THE ALUMINUM, YOU HAVE A LOT OF DIFFERENT OPTIONS. A PLASMA CUTTER WILL MAKE QUICK WORK OF THE SKINS BUT YOU'LL HAVE A ROUGH EDGE THAT NEEDS TO BE CLEANED UP USING A GRINDER AND A FLAP WHEEL. ELECTRIC SHEARS WORK WELL, BUT CUTTING TIGHT CURVES CAN BE A LITTLE TRICKY. PLUS YOU DO WASTE SOME MATERIAL WHILE THE SHEARS MAKE THEIR CUT. A SET OF TIN SNIPS ALWAYS WILL GET THE JOB DONE. BUT IF YOU HAVE A LOT OF CUTTING TO DO, IT'S GONNA GET REAL OLD REAL FAST. FOR LONG STRAIGHT CUTS YOU CAN'T BEAT A LARGE FOOT SHEAR BUT THEY TAKE UP A LOT OF ROOM IN YOUR SHOP. A BENCH TOP SLITTING SHEAR IS A SMALLER OPTION FOR THOSE LONG STRAIGHT CUTS. AND FOR CURVES, A THROATLESS ROTARY SHEAR CAN FOLLOW COMPLEX LINES VERY EASILY.

(CHRIS)>> TO ATTACH THE PANELS YOUR BEST OPTION IS TO USE LIGHT WEIGHT BODY TABS FROM A&A MANUFACTURING. THEN YOU JUST SIMPLY BOLT THEM IN PLACE.

A FLAT WASHER AND A NYLOCK NUT INSURE THE BODY PANELS WON'T VIBRATE LOOSE WHEN YOU'RE ON THE TRAIL.

(ANNOUNCER)>> ON THE ROCKS, DOWN IN THE MUD, AND UP IN THE AIR, JUST AHEAD ALL THE ADRENALINE OF THE ECOURSE RACING SERIES.

(IAN)>> WE'RE ALL FAMILIAR WITH THE PHRASE CHAMPAGNE DREAMS AND A BEER BUDGET, AND IT CERTAINLY COMES UP WHEN YOU WANT TO GET INTO THE WORLD OF OFF ROAD RACING. WHAT DO YOU DO IF YOU WANT TO DRIVE A TROPHY TRUCK BUT ALL YOU'VE GOT IS A WORN OUT OLD JEEP CHEROKEE? WELL THE ANSWER'S SIMPLE, THROW YOUR RIG ON A TRAILER AND HEAD OFF TO YOUR LOCAL ECOURSE RACE. ON A BRISK TENNESSEE MORNING, AS THE SUN FILTERS THROUGH THE KUDZU, TIME RUNS SHORT FOR LAST MINUTE ADJUSTMENTS IN THE PITS. AND NOW THE FLAG DROPS ON THE LAST RACE OF THE SEASON. ROB KLINGER AND RON TOWERY FOUNDED THE EAST COAST OFF ROAD RACING SERIES IN 2009 FOR ONE SIMPLE REASON. THEY WANTED WEST COAST STYLE RACING ON THE EAST COAST.

(ROB)>> WELL A COUPLE OF YEARS AGO WE ALL HAD AN IDEA TO PUT ON A RACE. WE FIGURED IT'D BE A ONE TIME THING. IT CAUGHT ON LIKE WILDFIRE AND HERE WE ARE TODAY. WE'VE TRIPLED IN SIZE AND RACERS, AND KEEP GOING EVERY SINGLE RACE.

(RON)>> I MEAN WE WERE HANGING OUT IN BAJA A COUPLE YEARS AGO SITTING AROUND AND JUST EVERYBODY WAS TALKING WHAT A GREAT TIME IT WAS AND HOW MUCH FUN WE WERE HAVING. AND YOU KNOW, WE LOOK AROUND, THERE'S 20 GUYS SITTING AROUND A CAMP FIRE THAT HAVE DRIVEN 2,000 MILES ACROSS THE COUNTRY TO WATCH SOME RACING. SO WE FIGURED IF WE COULDN'T GO OUT THERE EVERY WEEK, YOU KNOW, TRY TO DO SOMETHING LOCAL.

(IAN)>> AFTER THEY RETURNED HOME, THEY CREATED A RACING SERIES WITH A BALANCE OF DRIVING STYLES.

(ROB)>> THE WHOLE GOAL IS TO NOT LET ANY ONE TYPE OF VEHICLE DOMINATE. SO EVERY COURSE HAS GOT A MIXTURE OF ROCKS, TECHNICAL, HIGH SPEED. SO YOU KNOW, IT REALLY TESTS THE DRIVER.

(IAN)>> FOUR WHEEL DRIVE VEHICLES COMPETE IN THREE CLASSES, DESIGNED TO APPEAL TO A WIDE RANGE OF RACERS.

(ROB)>> MOST OF IT'S GRASS ROOTS BUT IT'S GROWING. WE'VE GOT A LOT MORE PROFESSIONAL, A LOT MORE SEMI PRO GUYS OUT HERE RACING.

(IAN)>> CLASSA CONSISTS OF PRETTY MUCH STOCK SUV'S AND TRUCKS WITH VERY LITTLE MODIFICATIONS.

(ROB)>> IF A GUY'S NOT SURE IF HE WANTS TO DROP THE MONEY. FOR A VERY LOW DOLLAR AMOUNT HE CAN JUMP IN, JUMP IN THE SPORT, COME OUT AND COMPETE AND HAVE FUN.

(IAN)>> CLASSB ALLOWS YOU TO MODIFY YOUR RIG A LITTLE BIT, BUT STOPS YOU WITH A LIMIT ON YOUR TIRE SIZE AT 40 INCHES. CLASSC, UNLIMITED, PERFECT FOR CUSTOM TUBE BUGGIES, AFTERMARKET DRIVETRAINS, AND UNLIMITED BUDGETS. PLUS THERE'S A UTV CLASS FOR THE GROWING SIDE BY SIDE MARKET. THESE GUYS HAVE A LOT OF FUN AND CATCH A LOT OF AIR. FOR EACH CLASS THE BIGGEST CHALLENGE IS MUD. EVERY RAINFALL LEADING UP TO THE RACE CREATED STANDING WATER, SLIPPERY DIRT, AND OBSTACLES TO AVOID OR FACE HEAD ON. DRIVER'S RACE IN ECOURSE FOR MANY REASONS. KEITH DOUGLAS RACED MOTORCYCLES UNTIL A KNEE INJURY SIDELINED HIM, BUT HE'S FOUND A WAY TO EXPERIENCE THE ADRENALINE RUSH OF COMPETITION WITH AN EXTRA MEASURE OF SECURITY.

(KEITH)>> I'M INSIDE A CAGE HERE. I'M PRETTY PROTECTED COMPARED TO GOING 60, 80 MILES AN HOUR THROUGH THE WOODS ON A MOTORCYCLE. I PLAN ON DOING THIS UNTIL THEY CARRY ME OUT.

(IAN)>> BEYOND THE THRILL OF RACING, HE ENJOYS THE FRIENDSHIP OF THE FELLOW COMPETITORS.

(KEITH)>> IF THEY SEE YOU OFF THE SIDE OF THE TRAIL, ASK YOU IF YOU NEED PARTS OR TOOLS? IT'S A REALLY GREAT CAMARADERIE. WE'RE ALL RACING AGAINST EACH OTHER BUT WE'RE ALL HAVING A GOOD TIME. WE'RE ALL LOOKING OUT FOR EACH OTHER'S SAFETY.

(IAN)>> THE UNLIMITED CLASS ROUNDS OUT A DAY OF HARD RACING. AFTER 10 LAPS AND TWO AND A HALF HOURS BEHIND THE WHEEL, SHAWN FISHER TAKES THE CHECKERED FLAG FOR CLASSC. [ siren ]

(IAN)>> HIS WINNING STRATEGY?

(SHAWN)>> I DIDN'T OVERDRIVE THE CAR. YOU GET SO EXCITED IN THE GO FAST YOU WANT TO PUSH THE HARDCORE CRAWLING HARD. SO YOU END UP OVER DRIVING THE CAR AND BREAKING EVERYTHING YOU HAVE. SO I JUST KEPT IT AT A GOOD 75 TO 80 PERCENT, MADE SURE THE CAR FINISHED. WORDS CAN'T DESCRIBE. I MEAN I EAT, SLEEP, AND BREATHE THIS STUFF. SOME OF THE FIRST WORDS MY CHILDREN HAVE EVER SAID WERE BUGGY. SO WHAT DOES IT MEAN, IT MEANS EVERYTHING.

(IAN)>> ALUMINUM ISN'T JUST USED TO SKIN THE BODY OF OUR BUGGIES. WE ACTUALLY USE IT TO MAKE SKID PLATES AND PARCEL TRAYS, LIKE THIS ONE THAT'LL REST UNDERNEATH OUR FUEL CELL. THE DIFFERENCE IS WE DON'T USE THE THIN 090 ALUMINUM. WHAT WE USE IS A LOT THICKER, 5052 MARINE GRADE ALUMINUM. AND HOW YOU WORK WITH IT IS A LITTLE BIT DIFFERENT. WE WENT AHEAD AND PREMADE ALL OF THE INTERIOR PANELS FOR THIS BUGGY OUT OF THE THICKER MARINE GRADE ALUMINUM. NOW THERE'S A REASON THAT WE LIKE THE 5052 ALUMINUM OVER THE 6061, AND IT MAINLY HAS TO DO WITH THE PRICE. IT COSTS US ABOUT A THIRD AS MUCH WHEN WE BUY IT IN FULL SHEETS. IT WORKS VERY SIMILAR TO THE 6061. IT'S EASY TO WELD AND EASY TO FINISH OUT. IT ALSO RESISTS CORROSION. THAT'S WHY IT'S CALLED MARINE GRADE. IT'S MAINLY USE IN PRODUCTION OF BOAT HULLS AND FUEL TANKS. THE ONE DOWNFALL IS THAT IT'S NOT AS MALLEABLE OR BENDABLE AS THE 6061. SO IF YOU WANT TO DO COMPLEX CURVES IT MAKES IT A LOT HARDER. BUT WHEN YOU'RE USING A THICKER SHEET LIKE THIS, THERE'S BENEFITS FOR IT IN OTHER AREAS.

(CHRIS)>> BECAUSE THE SHEETS ARE THREESIXTEENTHS OF AN INCH THICK, YOU CAN MOUNT THINGS DIRECTLY TO THEM LIKE AN ORBITAL VALVE, BRAKE PEDAL ASSEMBLY, YOUR SHIFTER, AND EVEN A BATTERY BOX. IT MAKES FINISHING THE INTERIOR THAT MUCH EASIER.

(IAN)>> NOW WHEN IT COMES TIME TO CUT THE THICKER ALUMINUM, YOU REALLY ONLY HAVE A FEW OPTIONS. BECAUSE IT'S SO THICK, YOU CAN'T USE ANY OF THE HAND TOOLS THAT WE USED ON THE BODY SKINS. NOW TIN SNIPS OR FOOT SHEARS FOR THIS STUFF. NOW WE'VE EXPERIMENTED WITH A BUNCH OF DIFFERENT WAYS TO SEVER THESE SHEETS AND WE'VE COME UP WITH A COUPLE THAT WORK. IF YOU'RE GONNA DO JUST A SIMPLE CUT, A PLASMA CUTTER WORKS OKAY. THE PROBLEM IS IS IT LEAVES THIS SPATTER ALL ALONG THE EDGE. AND IF YOU'RE GONNA WELD, THIS EDGES YOU'RE GONNA HAVE TO GRIND IT A LOT AND GET RID OF ALL OF THAT OR YOU'LL END UP CONTAMINATING THE ALUMINUM WELD. THE BAND SAW WORKS REALLY WELL BUT THE PROBLEM THERE IS IF YOU'RE GONNA DO A LONG STRAIGHT CUT LIKE ON THE BACK OF THIS SHEET, THE BLADE CAN TEND TO WANDER AS YOU'RE CUTTING IT AND ONCE AGAIN YOU'LL SPEND A LOT OF TIME FINISHING IT WITH A GRINDER. BELIEVE IT OR NOT, THE BEST WAY WE'VE FOUND TO CUT THIS 5052 ALUMINUM IS WITH A CIRCULAR FRAMING SAW AND A METAL CUTTING BLADE YOU CAN GET AT YOUR LOCAL HARDWARE STORE. THE NEW BLADE INSTALLS ONTO THE SAW LIKE ANY OTHER CIRCULAR SAW BLADE. AND THEN A GUIDE IS CLAMPED ON TO OUR ALUMINUM SHEET TO MAKE SURE THE SAW TRACKS STRAIGHT. USING THE CIRCULAR SAW IS NICE AND LOUD, SO BE SURE TO WEAR SOME HEARING PROTECTION. THE CIRCULAR SAW LEAVES US WITH AN EDGE THAT'S BASICALLY READY TO WELD, BUT THERE'S A TIP THAT I WANT TO SHARE WITH YOU WHEN IT COMES TO STICKING THESE ALUMINUM PIECES TOGETHER. IF YOU'RE GONNA DO A JOINT WITH THIS THICK ALUMINUM LIKE THIS, YOU END UP WELDING ON THE EDGE OF BOTH PIECES OF MATERIAL. NOW THE PROBLEM THAT HAPPENS HERE IS YOU HAVE A TENDENCY FOR THE HEAT TO RUN INTO EITHER EDGE AND CAUSE IT TO MELT QUICKER. NOW THERE'S AN EASIER WAY TO WELD THESE TWO TOGETHER, AND IT MEANS WELDING IT TWICE. START BY WELDING THE BACK SIDE OF THE JOINT WITH A MIG WELDER AND A SPOOL GUN. THE MIG WELD IS STRONG BUT IT DOES NOT LOOK GOOD. ON THE FRONT SIDE OF THE JOINT YOU FINISH IT OFF WITH A GOOD LOOKING TIG WELD. SO NOW YOU GUYS ARE ALL CAUGHT UP TO WHERE WE'RE AT WITH OUR ROYAL PURPLE BLOG BUGGY. NOW THE NEXT TIME WE'VE GOT THIS RIG BACK IN THE SHOP, WE'LL TURN IT BACK INTO A FULL ROLLER, SLIDE THE AXLES, TIRES AND WHEELS UNDERNEATH IT AND GET THE DRIVETRAIN BACK INTO THE CHASSIS. FOR DETAILS ON ANY OF THE PRODUCTS SEEN IN TODAY'S EPISODE, HEAD ON OVER TO POWERBLOCK TV DOT COM.
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