Xtreme 4x4 Builds

Parts Used In This Episode

Airaid
Air Intake Kit, U-Build-It, Intake System, 4.00 in. Intake Tube, Air Filter, Universal, Kit
Crown Performance
Custom Steel Braided Brake Lines
DIY4X
14 Bolt Full Floating Disc conversion Kit
Factor 55
Uses your receiver as a recovery tow point, Lightweight precision CNC machined 6000 series aluminum
Hurst
Automatic Shifter, Quarter Stick, Chevy, Reverse Pattern, Powerglide, TH250, TH350, TH375, TH400, Each
Hurst Driveline Conversions
Shifter Cover, Plastic, Black, Quarter Stick, Each
Loctite
Threadlocker, 242, Medium-Strength, Blue, 36 ml, Each
Smittybilt
X2O 8 Comp - 8,000 lb. Winch - Comp Series with Synthetic Rope & Aluminum Fairlead
Summit Racing
Headers, Shorty, Steel, Painted, Chevy, GMC, Pickup. SUV, 4.8, 5.3L, Pair
The Industrial Depot
Industrial Depot - Fasteners, Hardware, and Shop Supplies
Trail Gear Inc.
Rock Defense Low Profile Front Bumpers
Trail Gear Inc.
Rock Defense?ув Toyota Rear Bumpers
Trick Flow Specialties
Engine Steam Line Plumbing Kit, All Four Corner Kit, Aluminum, Black Anodized, Chevy, Small Block LS, Kit

Episode Transcript

(ANNOUNCER)>> TO CREATE A TRUE HILL KILLING BUGGY YOU'VE GOT TO USE THE RIGHT PARTS. TODAY ON XTREME 4X4 OUR BUGGY IN A BOX RECEIVES A MODIFIED TRANNY SHIFTER, A DUAL BRAKE SYSTEM, AND A FULL SET OF ENGINE ACCESSORIES. PLUS WE'LL HELP ONE VIEWER WITH ALL HIS TRAIL RECOVERY NEEDS ON THIS WEEK'S DRIVEWAY RESCUE.

(IAN)>> TODAY WE ARE BACK UNDERNEATH OUR MEZZANINE IN OUR SIMULATED TWO CAR GARAGE SPACE HERE IN THE XTREME SHOP, WHERE WE'RE SHOWING YOU GUYS HOW TO BUILD A FULL ON THROW DOWN TUBE BUGGY USING ONLY A WELDER AND A GRINDER AS YOUR SPECIAL TOOL. NOW THE LAST TIME WE WORKED ON THIS RIG WE HAD JUST GOTTEN THE CHASSIS BACK FROM POWDER COAT. WE REBUILT OUR AXLES AND THEN THREW THEM UNDERNEATH THE RIG. THEN DROPPED IN OUR JUNKYARD ENGINE AND TRANSMISSION. TODAY WE'RE GONNA DEAL WITH OUR EXHAUST. WE'VE GOT THE SHIFTERS FOR OUR TRANSMISSION AND TRANSFER CASE, WE'LL INSTALL SOME OF OUR BRAKE COMPONENTS, AND THEN FINALLY GET THIS CHASSIS SITTING ON SOME TIRES AND WHEELS. NOW IF YOU GUYS REMEMBER, WHEN WE DROPPED THE CHASSIS OFF TO GET POWDER COATED WE LEFT A COUPLE OF ENGINE PARTS WITH THE GUYS AT STREET WORKS FOR THEM TO

HYDRO DIP AND COLOR AS WELL. AND NOW THAT THEY'RE BACK IN THE SHOP, YOU CAN SEE THAT OUR VALVE COVERS ARE NO LONGER RAW ALUMINUM. THEY HAVE THIS COOL CHARCOAL PAINT JOB WITH A CARBON FIBER INLAY WRAPPED ALL AROUND THE OUTSIDE. AND SINCE THEY'RE HERE, SHINNY, AND READY TO GO ON, WELL THAT'S THE FIRST THING WE'RE GONNA ADD.

BEFORE THE WATER PUMP CAN BE INSTALLED IT HAS TO BE MODIFIED. WE NEED TO DRILL, TAP, AND ADD A FITTING TO THE TOP SIDE OF THE PUMP FOR THE STEAM PORT TO BE ATTACHED TO.

WE'LL BUILD A DASH FOUR LINE OUT OF SOME BRAIDED HOSE AND A FITTING FROM SUMMIT RACING, AND ATTACH IT TO THE STEAM PORT FEED ON TOP OF THE CYLINDER HEAD. FOR OUR AIR INTAKE WE'RE GOING TO BE USING AN AIR AID YOU BUILT IT UNIVERSAL INTAKE KIT. IT COMES WITH A LARGE PIECE OF FLOW MOLDED PLASTIC. THEN YOU JUST CUT AWAY THE SECTIONS

THAT YOU DON'T NEED. HOOK IT UP TO THE INTAKE WITH THE SUPPLIED COUPLERS AND ROUTED IT TO AN AREA WHERE YOUR AIR FILTER IS SECURE. BECAUSE WE'RE USING A REFLASHED FACTORY ECU TO CONTROL OUR ENGINE, WE NEED TO INSTALL A FACTORY STYLE MASS AIR FLOW METER INTO OUR INTAKE TUBE. NOW THIS WILL MEASURE THE AMOUNT OF AIR THAT'S DRAWN INTO THE ENGINE AND ALLOW THE COMPUTER TO ADJUST THE FUEL AND TIMING CURVE TO GET IT TO PERFORM CORRECTLY. NOW WHEN YOU MOUNT THIS METER IS FAIRLY IMPORTANT. YOU DON'T WANT TO MOUNT IT REALLY CLOSE TO THE THROTTLE

BLADES BECAUSE THE TURBULENCE FROM AIR AS IT ENTERS THE INTAKE CAN CAUSE MISREADINGS. YOU DON'T WANT TO MOUNT IT REALLY FAR AWAY FROM THE AIR INTAKE BECAUSE IT WILL ACTUALLY CAUSE A VELOCITY DROP INSIDE THE AIR THAT'S TRAVELING THROUGH THE SENSOR. YOU WANT TO GET IT AS CLOSE TO A STOCK LOCATION AS YOU CAN. WE TOOK SOME MEASUREMENTS WHEN WE WERE AT THE JUNKYARD AND THAT PUTS IT RIGHT ABOUT IN THIS SECTION OF PIPE IN OUR INTAKE. AND ALL WE'LL HAVE TO DO IS CUT OUT THE SECTION, ADD SOME COUPLERS, AND MOUNT THIS AND THEN THE METER WILL BE ABLE TO PERFORM CORRECTLY. ANOTHER NICE FEATURE OF THIS AIRAID KIT IS THERE'S A BOSS MOUNTED INTO THIS SECTION RIGHT BY THE AIR FILTER THAT'LL ALLOW US TO MOUNT THE AIR INTAKE SENSOR, AND THAT'LL HAVE ALL OF OUR AIR SENSORS IN THE RIGHT SPOT, THIS ENGINE SHOULD RUN GREAT. IT'S ALWAYS A GOOD IDEA TO REPLACE A BUNCH OF STUFF WHEN YOU'VE PULLED AN ENGINE FROM A JUNKYARD. SO WE'LL DROP ON A NEW ALTERNATOR, A NEW THERMOSTAT, A NEW BELT, AND A NEW STARTER. NORMALLY WHEN IT COMES TIME TO BUILD HEADERS IN A TUBE

BUGGY, YOU GET A DO IT YOURSELF HEADER KIT. IT CONSISTS OF A BUNCH OF DIFFERENT BENDS, SOME FLANGES FOR YOUR MOTOR, AND SOME COLLECTORS. CARVE YOURSELF OUT ABOUT 16 HOURS OF YOUR TIME AND SPEND THE ENTIRE WEEKEND A SET OF CUSTOM HEADERS FOR YOUR RIG. BUT THE NICE THING ABOUT THE GOAT BUILT CHASSIS IS WHEN HE DESIGNED IT AROUND THAT LS FAMILY OF ENGINE, HE MADE SURE TO LEAVE ROOM FOR A SET OF OFF THE SHELF HEADERS. NOW THESE ARE FROM SUMMIT RACING AND THEY'RE FOR AN '04 CHEVY 1,500 PICK UP TRUCKS SAME YEAR, MAKE, AND MODEL THAT OUR ENGINE CAME OUT OF. THEY'RE A FACTORY REPLACEMENT STYLE HEADER,

SO THEY'RE A LITTLE BIT SHORT LIKE A MANIFOLD. AND NOT ONLY WILL THEY BOLT RIGHT UP TO OUR BLOCK, WE'LL HAVE THIS ENTIRE EXHAUST BUILT IN LESS THAN A COUPLE OF HOURS.

(ANNOUNCER)>> UP NEXT, YOU PROBABLY SHOULDN'T GO WHEELING WITHOUT BUMPERS AND A WINCH, AND NEITHER WILL JEREMY AFTER THIS WEEK'S DRIVEWAY RESCUE.

(ANNOUNCER)>> NEED HELP SOLVING A PROBLEM WITH YOUR PROJECT? HERE'S DRIVEWAY RESCUE, BROUGHT TO YOU BY FOUR WHEEL PARTS DOT COM.

(IAN)>> AN OFF ROAD RIG IS ARGUABLY NEVER FINISHED. EVERY TIME YOU TAKE IT OUT YOU'RE GONNA COME UP WITH A LIST IN YOUR HEAD OF THINGS YOU WANT TO FIX BEFORE ITS NEXT TRIP. NOW ON TODAY'S DRIVEWAY RESCUE WE HAVE A VIEWER. BEFORE HE TAKES HIS TRUCK OUT AGAIN, HE WANTS SOME HELP WITH SOME RECOVERY GEAR. FIRST STOP WAS TO OUR LOCAL FOUR WHEEL PARTS STORE TO HAVE A LOOK AT OUR OPTIONS OF DIFFERENT SIZES

OF SMITTYBILT WINCHES. AND SINCE JEREMY'S ROCKING A TOYOTA TRUCK, WE HAD THEM SPECIAL ORDER US IN A COUPLE OF TRAIL GEAR HEAVY DUTY OFF ROAD BUMPERS. THEN WE JUMPED IN THE DRIVEWAY RESCUE RIG AND HEADED ON OVER TO HIS HOUSE. HOW ARE YOU DOING JEREMY?

(JEREMY)>> HEY IAN, HOW'S IT GOING?

(IAN)>> IT'S GOING WELL, SO I SEE YOU'RE PULLING OFF YOUR ONE RECOVERY POINT NO HOOK ON HERE RIGHT?

(JEREMY)>> YEAH, IT'S THE ONLY PLACE OT HOOK TO WHEN I GET STUCK IN THE WOODS.

(IAN)>> TELL ME A LITTLE BIT ABOUT YOUR TRUCK, TELL ME ABOUT YOUR RIDE HERE.

(JEREMY)>> SO IT'S AN '87 TOYOTA FOUR RUNNER, FIRST GEN MODEL.

IT HAD A SOLID AXLE SWAP IN IT. I'VE BEEN RUNNING FACTORY GEARS FRONT AND REAR. IT IS LOCKED, AND THEN HAVING DOUBLER TRANSFER CASES IN IT AS WELL.

(IAN)>> NOW WHY'D YOU GO WITH A FOUR RUNNER INSTEAD OF A PICK UP?

(JEREMY)>> IT'S GOT LOTS OF SPACE. YOU KNOW, BE ABLE TO HAVE MY KIDS. THEY LIKE TO GO WHEELING AND CAMPING WITH ME. SO THERE'S PLENTY OF ROOM FOR THEM TO RIDE AS WELL AS

BRING THE COOLERS AND THE SLEEPING BAGS.

(IAN)>> OKAY, WELL SINCE YOU'RE DEALING WITH A FACTORY TOYOTA FRAME HERE, WHAT I DID IS I WENT AND PICKED UP BASICALLY AN AFTERMARKET FRONT BUMPER FOR IT, WHICH I'LL THINK WILL GIVE YOU EVERYTHING THAT YOU NEED. IF YOU GO AHEAD AND PULL THAT TOW HOOK OFF, I'LL GO GRAB THE BUMPER AND WE'LL HAVE A LOOK AT IT.

(JEREMY)>> HEY THAT SOUNDS GREAT.

(IAN)>> ALRIGHT JEREMY, THIS IS WHAT I GOT FOR YOU. I SPECIAL ORDERED THIS FOUR WHEEL PARTS, THIS IS A TRAIL GEAR TOYOTA FOUR RUNNER SPECIFIC FRONT BUMPER. IT'S ALL DOM TUBING, AND IT GIVES YOU A WINCH PLATE MOUNT SO YOU CAN PUT A WINCH ON THE FRONT OF THE TRUCK AS WELL. NOW SINCE YOU'RE ASKING ABOUT RECOVERY POINTS, YOU NEVER WANT TO USE YOUR WINCH LIKE A TOW STRAP. YOU CAN ACTUALLY BREAK THE DRUM. SO WHILE I WAS THERE I PICKED UP ONE OF THESE FACTORY 55 HITCH LINKS CAUSE THE BUMPER HAS A RECEIVER HITCH IN THE FRONT. YOU JUST SLIDE IT IN, LOCK IT INTO THE PIN, YOU CAN HANG A DRING SHACKLE ON HERE. THAT'LL BE YOUR JUST DEAD TOW POINT.

(JEREMY)>> OKAY, GREAT!

(IAN)>> THAT WAY YOU CAN JUST USE YOUR WINCH FOR

WINCHING AND NOW YOU HAVE AN ACTUAL RECOVERY POINT ON THERE. NOW SINCE THIS IS DESIGNED TO BOLT RIGHT UP TO YOUR TRUCK, WE MAY HAVE TO MODIFY IT SLIGHTLY BECAUSE OF YOUR SOLID AXLE SWAP. BUT WE'LL PUT IT IN PLACE, CHECK IT, IF WE'VE GOT TO DO THAT WE CAN CUT ON IT CAUSE IT'S JUST RAW STEEL.

(JEREMY)>> GREAT!

(IAN)>> ALRIGHT SO GRAB THAT END, WE'LL SLIDE IT IN. SINCE YOU DON'T HAVE ANY OF THE FACTORY BOLTS, I BROUGHT SOME GOOD HEAVY DUTY GRADE EIGHT HALF INCH STUFF. AND WE'LL JUST DRILL OUT THOSE OLD BOLTS, GET A NUT IN BEHIND IT, AND BOLT IT FROM THERE.

AFTER A COUPLE OF TEST FITS, WE OPENED UP THE FACTORY HOLES AND BOLTED THE BUMPER INTO PLACE. ALRIGHT JEREMY, TO FINISH UP THE FRONT END OF YOUR TRUCK I'VE GOT THIS SMITTYBILT 8,000 POUND WINCH. IT'S PERFECT WEIGHT RATING FOR A TOYOTA RIG LIKE YOURS, AND IT'S A SYNTHETIC WINCH LINE WINCH. WHICH IS GREAT BECAUSE IT SHAVES A LITTLE BIT OF WEIGHT OFF THE FRONT END OF THE TRUCK, WHICH IS GOOD FOR STEEP HILL CLIMBS. BUT MORE IMPORTANTLY IT'S SAFE. IF THE WINCH DOES BREAK, IT DOESN'T HAVE THAT KINETIC

ENERGY THAT A CABLE DOES WHERE IT'S GOING TO WHIP BACK AND HURT SOMEBODY. IT'LL JUST FALL TO THE GROUND.

(JEREMY)>> GOOD FOR THE KIDS THEN.

(IAN)>> YEAH IT'S GREAT FOR A FAMILY WHEELER CAUSE IF YOU ARE WINCHING, YOU DON'T HAVE TO BE AS WORRIED ABOUT

WHEN PEOPLE ARE AROUND. AND THIS'LL BOLT RIGHT ONTO THAT BUMPER, AND THEN WE SHOULD BE DONE. WITH THE GRILL OUT OF THE WAY, THE WINCH DROPS ONTO

THE BUMPER AND IT'S WIRED UP TO THE BATTERY, AND WE FINISH IT OFF BY INSTALLING THE HOSS FAIR LEAD. ALRIGHT JEREMY, NOW YOU HAVE A GOOD BUMPER ON THE FRONT WITH A RECOVERY POINT, AND MORE IMPORTANTLY A GOOD NEW WINCH SO YOU CAN SELF RECOVERY, YOU DON'T HAVE TO RELY ON YOUR BUDDIES ALL THE TIME.

(JEREMY)>> ABSOLUTELY, REALLY APPRECIATE ALL THE TIME AND ENERGY ON THAT.

(IAN)>> HEY NO PROBLEM, NOW I WOULD SUGGEST WHEN THE WIND DIES DOWN A LITTLE BIT, GO AHEAD AND GIVE THIS BUMPER A COAT OF PAINT. EITHER MASK IT OFF AND PAINT ON THE TRUCK OR PULL IT OFF AND PAINT IT. AND I LIKE TO LEAVE A LITTLE BIT OF WORK FOR YOU GUYS TO DO. SO I GOT YOU A MATCHING REAR BUMPER FOR THE TRUCK, AND IT HAS A RECEIVER HITCH IN IT AS WELL FOR YOUR RECOVERY POINT. GO AHEAD, GET IT ON, GET THEM PAINTED, GET THE SHOTS OF THIS TRUCK ON THE TRAIL, YOU AND YOUR FAMILY HAVING FUN.

(JEREMY)>> ABSOLUTELY, WILL DO.

(IAN)>> ALRIGHT MAN, I APPRECIATE IT, THANK YOU VERY MUCH.

(ANNOUNCER)>> COMING UP, A DRIVELINE THAT'S READY FOR ANY TERRAIN.

(IAN)>> NOW WE DIDN'T INSTALL OUR TRANSFER CASE ASSEMBLY WHEN WE PUT IN THE REST OF THE DRIVETRAIN BECAUSE WE WEREN'T SURE HOW WE WERE GOING TO SHIFT IT. BUT NOW THAT THE TRANSMISSION IS IN PLACE,

WE KNOW THAT A GOOD SET OF FLOOR SHIFTERS LIKE THIS PACKAGE FROM OFF ROAD DESIGNS WILL WORK GREAT IN OUR CHASSIS. THERE WILL BE THREE LEVERS IN TOTAL, A TWIN STICK KIT FOR THE 205 AND A SINGLE SHIFTER FOR THE FRONT MAGNUM RANGE BOX MOUNTED ON THE FRONT OF IT. NOW THE NICE THING ABOUT THIS OFF ROAD DESIGN SETUP

IS IT COMES WITH EVERYTHING THAT WE'RE GONNA NEED. ALL THE SHIFT LINKAGES AS WELL AS SPHERICAL ROD ENDS TO CONNECT THE SHIFTERS TO THOSE LINKAGES. NOW YES, THE 205 IS ARGUABLY ONE OF THE EASIEST TRANSFER CASES OUT THERE TO SHIFT. BUT BUY USING THOSE ROD ENDS AT BOTH CONNECTION POINTS, IT JUST THE SHIFTER A LOT SMOOTHER TO THE TOUCH. THE LINKAGE INDEX OFF OF THE 205'S FRONT BEARING OUTPUT

AND ARE SECURED WITH A LITTLE BIT OF LOCTITE ON ALL THE FASTENERS.

THEN THE TRANSFER CASE IS INSTALLED INTO THE BUGGY, AND THE HOLES FOR BOTH THE SHIFTERS ARE CUT INTO THE PLATE BETWEEN THE SEATS. NOW THE LOCATION OF ALL THE TRANSFER CASE SHIFTERS IS KINDA DECIDED FOR US BY THE DRIVE TRAIN. THE TWIN STICKS FOR THE 205 NEED TO BE ON THE SAME SIDE AS THE OUTPUT SHAFT TO LINE UP WITH THE SHIFT RAIL.

SO THEY'RE OFFSET TO THE DRIVER. NOW THE SHIFTER FOR THE RANGE BOX NEEDS TO BE ON THE

OPPOSITE SIDE SO IT CAN LINE UP WITH THE LEVER THAT ENGAGES THAT REDUCTION HOUSING.

NOW THE TRANSMISSION SHIFTER WE CAN MOUNT WHEREVER WE WANT BECAUSE WE'RE GONNA BE USING THIS CABLE STYLE

SHIFTER THAT WE GOT FROM SUMMIT RACING. NOW THIS IS OFTEN REFERRED TO A PRO STICK BECAUSE YOU'LL FIND IT IN A LOT OF DRAG CARS BECAUSE IT CAN QUICKLY MOVE FROM GATE TO GATE TO ENGAGE DIFFERENT GEARS IN THE TRANSMISSION. THE PROBLEM IS IT CONTAINS WHAT'S CALLED A REVERSE LOCK OUT. NOW THE DRAG RACERS LIKE THAT SO THEY DON'T ACCIDENTLY SHIFT IT INTO REVERSE FROM THIRD GEAR WHEN THEY'RE DRIVING DOWN THE TRACK. BUT OFF ROADERS HATE THAT BECAUSE WHEN YOU'RE CLIMBING THOSE BIG LEDGES AND THE CAR IS ABOUT TO ROLL OVER BACKWARDS, YOU WANT TO BE ABLE TO SLAM IT INTO REVERSE

AS FAST AS YOU CAN. REVERSE LOCK OUT MEANS THAT YOU HAVE TO TAKE YOUR HANDS OFF THE WHEEL, AND PUSH THIS LITTLE LEVER AS WELL AS PUSH THE SHIFTER FORWARD. NOW THAT MEANS WE HAVE TO MODIFY THIS SHIFTER BEFORE WE INSTALL IT SO WE DON'T HAVE THAT LOCKOUT MECHANISM ENGAGED. WITH THE SHIFTER ON THE BENCH, THE SIDE COVER PLATE IS REMOVED AND THE REVERSE LOCKOUT LEVER DISCARDED.

THEN THE GATE IS GROUND SMOOTH USING A DIE GRINDER WITH A CARBIDE BIT, UNTIL THE HANDLE EASILY MOVES FROM FIRST TO REVERSE. WITH THE SEAT IN PLACE, THE LOCATION OF THE SHIFTER IS MARKED, DRILLED, AND IT'S BOLTED INTO THE CHASSIS. THEN THE SHIFTER CABLE IS INSTALLED ONTO THE SHIFTER HANDLE, AND ATTACHES TO THE MANUAL LEVER ON THE SIDE OF THE TRANSMISSION. NOW THE POSITION OF THE SHIFTER IS FAIRLY

CRITICAL WHEN YOU MAKE THIS MODIFICATION.

YOU WANT TO GET YOUR SEAT INTO THE CHASSIS, AND PUSH YOURSELF INTO THE BACK OF IT CAUSE IF YOU'RE TIGHTLY BELTED WITH A FIVE POINT HARNESS. AND THEN MAKE SURE THAT YOU CAN EASILY REACH DOWN, FIND THE SHIFTER FOR THOSE QUICK FIRST TO REVERSE SHIFTS THAT PREVENT THE BUGGY FROM ROLLING OVER BACK WARDS ON THOSE STEEP HILL CLIMBS. IF WE HAD MOUNTED THE SHIFTER ANY FURTHER FORWARD, WHEN I WAS PINNED BACK INTO THE SEAT I'D BE REACHING FOR IT AND POSSIBLY MISS THAT SHIFT. NOW THE TRANSFER CASE SHIFTERS, YOU JUST WANT TO MAKE SURE THAT THEY DON'T CONTACT THE SEATS OR GET IN THE WAY OF THE AUTOMATIC TRANSMISSIONS SHIFTER ONCE THEY'RE INSTALLED, CAUSE YOU'RE ONLY GOING TO BE SHIFTING THOSE IN BETWEEN TRAILS. NOW TO FINISH OUT THIS INSTALLATION I WENT AHEAD AND PICKED UP THIS PLASTIC COVER FROM SUMMIT RACING FOR OUR QUARTER STICK SHIFTER. IT SIMPLY DROPS DOWN OVER THE TOP AND FINISHES OUT THIS INSTALLATION.

(ANNOUNCER)>> UP NEXT A DUAL BRAKING SETUP WILL GET OUR FOUR SEATER THROUGH THE TIGHTEST OF TRAILS.

(IAN)>> WE ARE RIGHT IN THE MIDDLE OF REASSEMBLING OUR TWO CAR GARAGE CRAWLER. WE'RE READY TO MEASURE FOR OUR HYDRAULIC STEERING AND BRAKE HOSES. BUT BEFORE WE DO WE NEED TO MOUNT A FEW MORE ITEMS ONTO THE CHASSIS. IT'S GONNA START UP FRONT WITH A SET OF MASTER CYLINDERS, TWO INDEPENDENT MASTER CYLINDERS AND TWO INDEPENDENT BRAKE PEDALS. NOW WE DO THIS FOR A COUPLE OF DIFFERENT REASONS. IT GIVES US FULL CONTROL OVER EITHER AXLE WHEN WE'RE OFF ROAD AND ALLOWS US TO DO WHAT'S CALLED FRONT OR REAR DIGS WITH THE BUGGY. BUT MORE IMPORTANTLY, IF FOR SOME REASON WE HAVE A BRAKE

LINE FAILURE WHILE WE'RE OUT ON THE TRAIL, WE WON'T LOSE BRAKES COMPLETELY INSIDE THE RIG BECAUSE WITH TWO DEDICATED MASTER CYLINDERS WE HAVE TWO DEDICATED HYDRAULIC CIRCUITS. WITH THE FIREWALL IN PLACE, WE'LL USE THE PEDAL

ASSEMBLIES AS A TEMPLATE TO MARK THE LOCATION OF ALL THE HOLES. THEN WE'LL CUT AND DRILL THEM, AND BOLT EVERYTHING IN PLACE.

BOTH THE BRAKE AND STEERING LINES WE'RE GONNA HAVE MADE BY CROWN PERFORMANCE. THESE ARE A COUPLE OF EXAMPLES OF THEIR WORK FOR A DIFFERENT PROJECT. THE BRAKE LINES WILL BE A FULL BRAIDED KIT, TEFLON LINED, AND THEN COVERED IN A COLORED COATING OF OUR CHOICE. THE STEERING LINES WILL BE A STAINLESS STEEL BRAIDED LINE PRECRIMPED DASH SIX FEED AND RETURN FOR THE ENTIRE STEERING SYSTEM. NOW IN ORDER TO MEASURE THE LENGTH OF THOSE LINES WE NEED TO DETERMINE WHERE THEY'RE GOING TO GO TO GET FROM THE MASTER CYLINDER DOWN ONTO THE AXLES. AND I LIKE TO RUN THEM DOWN THE UPPER SUSPENSION LINK, AND THEN SECURE THEM USING SOME TYPICAL WORM GEAR CLAMPS. THAT WAY THEY'RE NICE AND TIGHT, OUT OF THE WAY OF THE SUSPENSION MOVEMENTS, AND THEY WON'T BE DAMAGED WHEN WE'RE ON THE TRAIL. NOW ONE OF THE EASIEST WAYS TO MEASURE THE LINES IS JUST TO USE AN OLD PIECE OF SCRAP WIRE.

YOU CAN JUST FEED IT INTO THE MASTER CYLINDER, FEED IT EVERYWHERE IT WANTS TO GO. THEN TAKE IT OFF AND MEASURE THE LENGTH.

NOW THE REASON I HAVEN'T PAINTED THIS REAR AXLE YET

IS BECAUSE I WASN'T SURE IF I WAS GONNA USE A BOLT ON OR WELD ON REAR DISC BRAKE CONVERSION. AND NOW THAT EVERYTHING IS IN PLACE, I CAN TELL THAT

THE PERFECT SOLUTION IS THIS BOLT ON BRACKET THAT WE GOT FROM DIY FOUR BY. NOW IT'S ANOTHER REASON WHY I LIKE TO RUN A FULL BRAIDED BRAKE LINE KIT ON A TUBE BUGGY.

SEE THESE REAR DISC BRAKE CONVERSION, THEY JUST USE A SET OF FACTORY REPLACEMENT FRONT CALIPERS JUST MOUNTED ON THE BACK. AND EVEN THOUGH IT'S ON A FIXED AXLE POSITION, WHEN YOU HIT THE BRAKES THAT CALIPER STILL MOVES SLIGHTLY. IF YOU HAD A HARD LINE BOLTED ONTO THAT CALIPER, IT WOULD EVENTUALLY BECOME LOOSE OR AT WORST BRAKE. BY RUNNING A BRAIDED BRAKE HOSE IT JUST GIVES YOU A LITTLE BIT OF FLEX AND ALLOWS THAT CALIPER TO MOVE. WHILE I BUILD ALL THE MOUNTS FOR OUR MOCK UP BRAKE LINES, WHY DON'T YOU HEAD ON OVER TO POWERBLOCK TV DOT COM.
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