More 2-Car Garage Crawler Episodes

Xtreme 4x4 Builds

Parts Used In This Episode

150Tunes.com
Stand alone or conversion system for LSx swaps
Dupli-Color
Paint, Engine, Enamel with Ceramic Resin, Gloss, Black, 12 oz., Aerosol, Each
Monster Transmission and Performance
TH-400 SS Mega Monster Transmission Complete Rebuild Kit
Monster Transmission and Performance
TH350 / TH400 Torque Converter 1750 Stall Heavy Duty, 3 Lug
Monster Transmission and Performance
TH400 Full Manual Valvebody, Reverse Pattern
Off Road Designs
The Magnum Box, planetary gear reduction box that bolts to the front of an NP205 transfer case.
Streetwerkz Custom Powder Coating
Streetwerkz is a state-of-the-art powder coating and media blasting facility in Columbus, Ohio
Summit Racing
Valve Covers, Tall, Fabricated Aluminum, Natural, Plain, Chevy, 4.8, 5.3, 5.7, 6.0, 6.2, 7.0L, Pair
The Industrial Depot
Industrial Depot - Fasteners, Hardware, and Shop Supplies
TMR Customs
Transfer Case Support Kit - NP205 Side Mount with 1.75" Dia. Tabs
WD-40
WD-40 300042 Specialist Rust Remover Soak, 1 Gallon

Episode Transcript

(ANNOUNCER)>> WE TOOK ALL THE FANCY EQUIPMENT OUT OF OUR SHOP TO SEE IF WE COULD BUILD A FULL FEATURED TUBE BUGGY WITH JUST BASIC SHOP TOOLS. YOU'D BE SURPRISED AT WHAT YOU CAN ACCOMPLISH IN A SMALL TWO CAR GARAGE. TODAY ON XTREME 4X4, OUR TRANSMISSION AND TRANSFER

CASE GET SERIOUS PERFORMANCE BOOSTS. PLUS THE CUTTING EDGE IN POWDER COATING TECHNOLOGY.

(IAN)>> WE HAVE REACHED A PRETTY IMPORTANT MILESTONE WITH OUR TWO CAR GARAGE CRAWLER. TODAY WE'RE GONNA BLOW THIS ENTIRE RIG APART AND GET IT READY FOR A CUSTOM FINISH.

WE'LL THROW IT ON A TRAILER AND HAUL IT UP TO THE POWDER COATER, AND SHOW YOU EXACTLY WHAT IT TAKES TO TURN RAW METAL INTO THAT NICE, HIGH END POWDER COATED FINISH. BUT IT'S NOT JUST GONNA STOP WITH THE CHASSIS. WE'LL POWDER COAT AND DRESS UP SOME OF OUR ENGINE COMPONENTS,

REBUILD OUR TRANSMISSION, AND TEAR INTO OUR AXLES. BEFORE A CHASSIS IS POWDER COATED, ALL THE WELDING HAS TO BE FINISHED. FOR A BIG JOB LIKE THIS PICK UP A GOOD WELDING JACKET AND A PAIR OF MIG WELDING GLOVES BECAUSE A BUGGY CAN TAKE OVER EIGHT HOURS TO COMPLETELY FINISH WELD. NOW IDEALLY WHEN YOU'RE DOING ALL OF THIS FINISH WELDING YOU'D HAVE THE ENTIRE DRIVETRAIN IN THE CHASSIS JUST TO MAKE SURE YOU DON'T MISS ANY OF THE MOUNTS. BUT WE HAVE A PROBLEM. THE REDUCTION HOUSING THAT WE'RE USING TO ADAPT THE TURBO 400 TO OUR NP 205 TRANSFER CASE HASN'T SHOWN UP IN THE SHOP YET. NOW WE DID LUCK OUT WHEN IT CAME TO THE MOUNT FOR THE REAR TRANSFER CASE SUPPORT. WE KNOW THAT IT HAS TO BE EXACTLY 14 INCHES BACK FROM THAT TRANSMISSION FLANGE, WHICH PUTS IT DEAD CENTER IN THIS REAR BAR OF THE CHASSIS. SO ALL I HAVE TO DO IS ADD A COUPLE OF TABS. NOW THE TABS CAME IN OUR TRANSFER CASE REAR SUPPORT MOUNT KIT THAT WE GOT FROM TMR CUSTOMS. IT'S A COMPLETE LASER CUT ASSEMBLY BUILT SPECIFICALLY FOR THE NP 205. IT COMES APART LIKE THIS SO YOU CAN MODIFY IT, TRIM IT TO FIT YOUR APPLICATION, AND THEN FULLY WELD IT. ONCE I HAVE THESE TABS WELDED ONTO THE CHASSIS, IT'LL ALIGN WITH THAT REAR TRANSMISSION OUTPUT. LATER ON WHEN WE'RE ASSEMBLING THE BUGGY, I ONLY HAVE TO

MODIFY THE TRANSFER CASE BRACKET. I DON'T HAVE TO WORRY ABOUT CUTTING AND GRINDING ON OUR FRESHLY POWDER COATED CHASSIS.

SO WITH ALL THE MOCK UP COMPLETE, IT'S TIME TO TEAR THIS BUGGY APART. NOW WE'LL GO AROUND AND CHECK ALL THE JOINTS AND FINISH WELD ANY THAT NEED IT.

WE'LL ROLL THE CHASSIS ONTO ITS SIDE, AND ONTO ITS ROOF TO MAKE SURE THAT WE'VE COVERED IT ON EVERY SINGLE ANGLE. THEN IT'S TIME TO CLEAN IT UP USING A WIRE WHEEL ON A GRINDER. FINISH IT OFF WITH A FINE GRIT FLAT WHEEL.

NOW WE'RE NOT JUST GONNA CARRY THE CHASSIS UP TO OUR POWDER COATERS. IF YOU'LL REMEMBER WE PULLED THIS FIVE POINT THREE ENGINE OUT OF A JUNKYARD AND IT' STILL LOOKS THAT WAY. WE WANT TO CLEAN IT UP BEFORE WE DROP IT INTO A FRESHLY POWDER COATED CHASSIS. THE PARTS WE'RE GONNA TAKE WITH US WILL BASICALLY BE OUR ENGINE COVER, OUR FRONT ACCESSORY DRIVE, WE'LL DO

SOMETHING SPECIAL WITH THE VALVE COVERS AND WE'LL EVEN PULL THE OIL PAN OFF. THEN THE REST OF THE LONG BLOCK, WE'LL JUST CLEAN THAT

UP, GIVE IT A COAT OF PAINT.

AFTER A GOOD SPRAY WITH SOME ENGINE DEGREASER, THE BLOCK IS

WIPED DOWN, ALL THE EXHAUST PORTS AND INTAKE PORTS ARE STUFFED WITH RAGS, AND WE SHOOT IT WITH A COAT OF DUPLICOLOR FLAT BLACK PAINT. I PULLED THE WATER PUMP OFF OF THE ENGINE BECAUSE IT NEEDS TO BE MODIFIED BEFORE IT GOES BACK INTO THE BUGGY. THE WIRING HARNESS FOR OUR FIVETHREE, WELL WE'LL BOX THIS UP AND SEND IT OFF TO WAYNE AND THE GUYS AT 150 TUNES.COM. THEY'LL GO AHEAD AND CUT IT DOWN AND REFLASH OUR FACTORY PCM TO MAKE THE ENTIRE ASSEMBLY 100 PERCENT STAND ALONE. NOW WE TOLD YOU WE'RE GONNA DO SOMETHING SPECIAL WITH THIS FRONT ACCESSORY DRIVE, AND WHILE WE'RE AT IT WE THOUGHT WHY NOT DO SOMETHING WITH THESE FULLY FABRICATED ALUMINUM VALVE COVERS THAT WE GOT FROM SUMMIT RACING. YEAH SURE, WE CAN DROP THEM ON THE ENGINE RIGHT NOW WITH THIS NICE, FULL POLISH FINISH, BUT WHY NOT TAKE THEM WITH US TO THE POWDER COATERS, SEE WHAT YOU CAN DO WITH THEM.

(ANNOUNCER)>> COMING UP, AN IN DEPTH LOOK AT THE LATEST IN CUSTOM COATING TECHNIQUES.

(IAN)>> WITH OUR CHASSIS LOADED UP AND A FEW EXTRA PARTS TO GO WITH IT, WE TOOK THE DRIVE UP TO COLUMBUS, OHIO, HOME TO STREET WORKS CUSTOM COATINGS.

NOW YOU'VE SEEN THEIR WORK BEFORE ON XTREME WHEN THEY KNOCKED IT OUT OF THE PARK WITH A TRUE CUSTOM PURPLE CANDY COAT FINISH ON OUR ROYAL PURPLE CRAWLER. WHERE THEY BURY GRAPHICS UNDERNEATH THE CUSTOM COATING TO REALLY DELIVER THE ROYAL PURPLE THEME. ( )>> THERE WE GO, TEAM WORK, PEOPLE POWER, AND BLAH!

(IAN)>> I'M SURE YOU'RE WONDERING, A TWO CAR GARAGE CRAWLER WITH CUSTOM POWDER COATING. WELL BELIEVE IT OR NOT, IT'S NOT AS EXPENSIVE AS YOU THINK.

(JOSHUA)>> POWDER COATING TYPICALLY IS MORE AFFORDABLE THAN PAINT IS. FOR INSTANCE, YOU'RE CHASSIS, IF WE WERE TO WET SPRAY PAINT THAT, NOT ONLY WOULD IT NOT BE AS DURABLE AS POWDER COATING, BUT THE MATERIAL COSTS ALONE WOULD COST MORE THAN WHAT I'M GONNA GIVE YOU A FINISHED PRODUCT FOR IN POWDER COATING.

(IAN)>> AND WITH HUNDREDS OF COLOR CHOICES TO CHOOSE FROM, THE SKY'S THE LIMIT. STREET WORKS ACTUALLY STARTED OUT AS A HIGH END HOT ROD SHOP, BUT WITH MORE AND MORE POWDER COATING JOBS COMING THROUGH THE DOOR, JOSH KNEW THAT HIS FUTURE WAS IN SPRAYING COLOR.

(JOSH)>> THE DEMAND FOR POWDER COATING VERSUS HOT RODS GREW, SO WE WENT WITH WHAT WAS WORKING FOR THE BUSINESS AT THE TIME AND WE'VE NOT TURNED BACK.

(IAN)>> THE PROCESS IS NOT AS DIFFICULT AS YOU THINK.

(JOSH)>> WE START OFF BY DEGREASING EVERYTHING, IF THERE'S GREASE. THEN WE MEDIA CLEAN IT. YOU RUN IT THROUGH A PHOSPHATE WASH TO SEAL AND PROTECT THE SURFACE.

(IAN)>> THEN IT'S RINSED AND HUNG ON A RACK WHERE THE POWDER IS APPLIED.

(IAN)>> FINALLY IT'S IN TO THE BAKE OVER JUST LIKE A BATCH OF COOKIES.

NOW DON'T THINK THAT YOU HAVE TO GET A FULL ON CUSTOM POWDER COAT JOB LIKE WE ARE FOR OUR CRAWLER. STREET WORKS HAS POWDER COATING PROCESSES FOR ALL TYPES OF BUDGETS.

(JOSH)> WE HAVE A GOOD, BETTER, BEST PROGRAM WHERE YOU CAN GET THE GOOD, WHICH IS YOUR BASIC COATING. BETTER, WHICH IS ALL THE AFOREMENTIONED STEPS OF POWDER COAT, PRIMER, AND THEN A COATING. AND THEN BEST WHERE WE JUST GO CRAZY AND DO PRIMER, COLOR, CLEAR, COLOR SANDING, BUFFING, ETCETERA.

(IAN)>> POWDER COATING IS IDEAL FOR A ROCK CRAWLER.

BELIEVE IT OR NOT IT'S ACTUALLY A LOT STRONGER THAN PAINT, AND CAN EASILY HANDLE THE ABUSE THAT THIS RIG WILL SEE ON THE TRAIL.

(JOSHUA)>> THE SIMPLEST EXPLANATION I CAN GIVE IS WHEN IT'S FULLY CURED IT'S A LOT MORE FLEXIBLE. YOU CAN ALMOST BEND A POWDER COATED PART, DEPENDING ON ITS THICKNESS, 90 DEGREES BEFORE YOU'LL HAVE DELAMINATION.

(IAN)>> THE EXTRA PARTS THAT WE BROUGHT ALONG WITH OUR CRAWLER WE'RE NOT GETTING THEM POWDER COATED AT ALL. WE'RE TAKING ADVANTAGE OF A BRAND NEW PROCESS AVAILABLE AT STREET WORKS. IT'S CALLED HYDRO DIPPING.

(JOSH)>> YOU LAY A FILM ON THE TOP OF THE SURFACE OF THE WATER, ACTIVATE IT WITH A CHEMICAL, PUSH THE PART THROUGH THE IMAGE SO THAT YOU CAN GET 360 DEGREE COVERAGE OF AN IMAGE ON THE PART. BEFORE YOU WEREN'T ABLE TO HAVE A REAL PRECISE INTRICATE

GRAPHICS ADDED ONTO POWDER COATING, WHERE NOW WE CAN POWDER COAT A PART, DIP IT IN HYDROGRAPHIC GRAPHIC, SAY FLAMES, OR SKULLS, OR CAMOUFLAGE, AND THEN ADD A POWDER COAT CLEAR ON TOP OF IT.

(IAN)>> SO WITH THE WORK THAT JOSH HAS DONE FOR US IN THE PAST AND THE NEW IDEAS HE HAS READY FOR OUR BUGGY, WE KNOW WE'RE GONNA GET BACK ONE HECK OF A FINISHED CRAWLER.

(ANNOUNCER)>> UP NEXT, IF YOU'VE NEVER OVERHAULED A TRANSMISSION BEFORE, THE TURBO 400 IS THE PERFECT PLACE TO START.

(IAN)>> NOW EVEN THOUGH THE MAJORITY OF OUR PROJECT IS OUT OF OUR TWO CAR GARAGE, IT DOESN'T MEAN WE HAVE TO STOP WORKING ON IT. LOTS OF UPGRADES THAT WE STILL NEED TO TAKE CARE OF ON THE DRIVETRAIN AND ESPECIALLY NOW THAT WE HAVE ALL THIS OPEN SPACE, IT MAKES IT A LOT EASIER. NOW WE DECIDED TO RUN A TURBO 400 IN THIS RIG FOR A COUPLE DIFFERENT REASONS. IT'S A GOOD, STRONG, THREE SPEED AUTOMATIC THAT ONCE WE UPGRADE IT WE'LL BE ABLE TO HANDLE ALL THE ABUSE WE COULD THROW AT IT IN THE DIRT. BUT MORE IMPORTANTLY, IT IS A VERY EASY AUTOMATIC TRANSMISSION TO REBUILD IN A SMALL TWO CAR GARAGE. YOU DON'T NEED ANY SPECIAL TOOLS TO COMPLETELY OVERHAUL THIS UNIT. AND IF YOU'VE NEVER REBUILT AN AUTOMATIC TRANSMISSION BEFORE,

THIS IS A GREAT ONE TO BE YOUR FIRST OFFICIAL OVERHAUL. NOW WE'RE GONNA UPGRADE EVERYTHING IN THE CASE WITH AN ENTIRE PACKAGE FROM MONSTER TRANSMISSION. THIS IS THERE MONSTER IN A BOX KIT AND IT'S ALL THE POPULAR UPGRADES IN ONE SPOT. HEAVY DUTY BAND, RED ALTO CLUTCH DISCS, COLEEN STEELS, NEW ONE WAY CLUTCHES, AND A NEW HEAVY DUTY DRUM. NOW WE DID ADD ONE UPGRADE TO THE KIT AND THAT WAS TO INCLUDE A FULL REVERSE PATTERN MANUAL SHIFT VALVE BODY. NOW WHAT THAT MEANS IS BASICALLY FIRST GEAR AND REVERSE ARE A LOT CLOSER TOGETHER ON THE SHIFTER THAT'S IN THE RIG. WHEN YOU START CLIMBING UP THAT STEEP HILL AND YOU FEEL THAT FRONT SUSPENSION UNLOADING AND IT'S GONNA ROLL BACK ON ITSELF, YOU JUST HAVE TO SLAP THE SHIFTER FORWARD AND IT'LL AUTOMATICALLY ENGAGE REVERSE AND YOU CAN BACK DOWN THE HILL. NOW IF YOU ARE WORKING IN A SMALL TWO CAR GARAGE SPACE, PICK YOURSELF UP ONE OF THESE LITTLE PLASTIC FOLDING TABLES. THEY'RE REALLY INEXPENSIVE, GIVE YOU LOTS OF WORK SPACE.

THERE'S NOT A CHANCE YOU'RE GONNA LOSE ANY

OF YOUR SMALL PIECES. AND BEST OF ALL, YOU CAN FOLD IT UP AND PUT IT AWAY. YOU DON'T NEED TO BUY A HEAVY DUTY BENCH. WE'VE SHOWN YOU COUNTLESS TURBO 400 REBUILDS BEFORE, BUT WHEN YOU'RE DEALING WITH A REVERSE MANUAL VALVE BODY WITH ENGINE BRAKING, THERE'S SOME SPECIFIC STEPS THAT YOU HAVE TO FOLLOW. WE DO HAVE SOME RUST ON OUR INPUT DRUM ASSEMBLY, AND THIS IS A PERFECT OPPORTUNITY TO USE THE NEW WD 40 RUST SOAK. THE PART CAN SOAK IN THE FLUID, AND THE RUST WILL BE REMOVED WITHOUT DAMAGING THE BASE MATERIAL. THE MIDDLE TEFLON SEALING RING ON THE CENTER SUPPORT NEEDS TO BE REMOVED AND DISCARDED FOR THE VALVE BODY TO WORK CORRECTLY.

THE DIRECT DRUM IS TORN DOWN AND THE NEW MONSTER TRANSMISSION PIECE IS REBUILT USING A HEAVY DUTY ONE WAY CLUTCH, ALL NEW LIP SEALS ON THE PISTON, AND THE MATCHING SPRINGS FOR OUR VALVE BODY.

THEN ALL THE CLUTCHES ARE SOAKED IN FLUID AND INSTALLED AND THE CLEARANCES CHECK ABOVE THE DIRECT CLUTCHES TO MATCH THE VALVE BODY SPECIFICATIONS. THEN THE ENTIRE ASSEMBLY IS DROPPED INTO THE CASE AND THE REST OF THE TRANSMISSION REASSEMBLED.

AND WE'LL FINISH IT OFF WITH THE PUMP.

INSIDE THE VALVE BODY THE SEALING RINGS ARE REMOVED AND DISCARDED FROM THE ACCUMULATOR PISTON.

THEN A SINGLE CHECK BALL IS INSTALLED.

NEXT THE SPACER PLATE, GASKET, AND THE NEW REVERSE MANUAL VALVE BODY ARE INSTALLED, FOLLOWED BY THE FILTER AND A NEW CHROME PAN.

(ANNOUNCER)>> JUST AHEAD, EXTRA GEAR REDUCTION FOR OUR JUNKYARD TRANSFER CASE.

(IAN)>> WITH OUR TURBO 400 COMPLETELY REBUILT AND EQUIPPED WITH THIS REVERSE MANUAL VALVE BODY AND NEW

TORQUE CONVERTER, IT'S READY TO BOLT UP BEHIND OUR FIVE POINT THREE LITER VEIGHT. NOW WE SIMPLY FRESHEN THIS MOTOR UP WITH A COAT OF PAINT

AND WE'RE WAITING ON THE VALVE COVERS AND ACCESSORY DRIVE TO COME BACK FROM THE POWDER COATER. BUT ONE PART OF THE DRIVETRAIN THAT WE HAVEN'T SHOWN YOU YET IS WHAT TRANSFER CASE WE'RE GONNA USE IN THIS PROJECT. WELL WE OPTED TO USE THE NP 205 CASE. AND THIS PARTICULAR MODEL WE GOT FROM A LOCAL JUNKYARD. IT'S OUT OF A FULL SIZE FORD PICK UP TRUCK. NOW THE NICE THING ABOUT THE 205 IS IT'S 100 PERCENT CAST IRON CONSTRUCTION WITH A LARGE CASE, HOLDS A LOT OF FLUID. AND IT IS ALL GEAR CONSTRUCTION, MAKING IT INCREDIBLY STRONG. THE ONE DOWNFALL OF THE 205 IS IT WAS NEVER OFFERED BEHIND

A TURBO 400 TRANSMISSION. YOU ALWAYS HAVE TO GET AN ADAPTER PLATE TO CONNECT THE TWO OF THEM TOGETHER. NOW THE GUYS AT OFF ROAD DESIGNS HAVE BEEN WORKING WITH 205'S FOR YEARS, AND THEY'VE TAKEN ADVANTAGE OF THAT PROBLEM TO CREATE THE NEW MAGNUM SERIES RANGE BOX. THIS WILL ADAPT THE TURBO 400 TO THE 205, BUT IT ALSO HAS AN ADDITIONAL PLANETARY GEAR SET MOUNTED INSIDE IT TO GIVE US

ONE EXTRA RATIO OF LOW RANGE OPTION.

THAT BASICALLY MEANS THAT WE HAVE A FOUR

SPEED TRANSFER CASE.

WE CAN RUN THE 205 IN HIGH FOR A ONE TO ONE, SLIP IT INTO LOW FOR A TWO TO ONE, ENGAGE THE RANGE BOX ALONE FOR A TWO POINT SEVEN TO ONE, OR COMBINE THE TWO OF THEM TOGETHER TO GET A MASSIVE FIVE POINT FOUR TO ONE LOW RANGE RATIO, WHICH WILL BE GREAT FOR SOME SLOW SPEED CRAWLING. NOW WE DO HAVE TO TEAR INTO THE 205 TO INSTALL A NEW INPUT SHAFT THAT COMES WITH THE OFF ROAD DESIGNS' KIT THAT'LL ADAPT THE 205 INTO THE RANGE BOX.

WITH THE CASE DISASSEMBLED, THE INPUT GEAR IS REMOVED.

THE NEW INPUT SHAFT ASSEMBLY SLIDES INTO PLACE AND THE SHIFT COLLAR IS INSTALLED. THE OUTPUT SHAFT IS PUT BACK IN, FOLLOWED BY THE SPEEDOMETER HOUSING.

AND THE REAR BEARING SUPPORT.

AND NOW OUR TRANSFER CASE IS READY TO BOLT UP TO OUR REDUCTION BOX, AND THE ENTIRE DRIVETRAIN FOR OUR BUGGY IS PREPPED AND READY TO INSTALL. NOW THE NEXT TIME WE'RE BACK IN OUR SMALL TWO CAR GARAGE SPACE THAT'S EXACTLY WHAT WE'LL DO. WE'LL HAVE THE CHASSIS BACK FROM POWDER COAT, ASSEMBLE THE ENTIRE BUGGY INTO A ROLLING CHASSIS.
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