XOR - Xtreme Off-Road Builds

Parts Used In This Episode

Advance Adapters
Atlas Transfer Case
Dana Holding Corporation
Ultimate Dana 60™ Axles for the Jeep® JK and JL
Lincoln Electric
Lincoln Electric is the official welding supplier to XOR
Matco Tools
Matco Tools are the official tool supplier of XOR
Synergy Manufacturing
JEEP JK LONG ARM, REAR LOWER CONTROL ARM PAIR (8036)
Synergy Manufacturing
JEEP JK ADJUSTABLE REAR TRACK BAR 225.00 (8062)
Synergy Manufacturing
JEEP JK UNIVERSAL RIGHT/LEFT BRAKE HOSE ASSEMBLY rear (100.00 2.008066)
Synergy Manufacturing
JEEP JK FRONT LOWER SHOCK MOUNT RELOCATION/SKIDPLATE (8073)
Synergy Manufacturing
JEEP JK LONG ARM, REAR UPPER CONTROL ARM PAIR (8038)
Synergy Manufacturing
JEEP JK REAR BUMP STOP SPACER KIT - 2.0" LONG 50.00 (8058-20)
Synergy Manufacturing
JEEP JK REAR COIL SPRING STRETCH KIT (8032-06)
Synergy Manufacturing
JEEP JK REAR TRACK BAR BRACKET 135.00 (008056)
Synergy Manufacturing
JEEP JK/JKU REAR LIFT SPRINGS - 3.0" JK LIFT/2.0" JKU LIFT (PAIR) (8064-20)
Synergy Manufacturing
JK REAR STRETCH KIT (BRKTS ONLY) (8032)
The Industrial Depot
Tools, Hardware, and Shop Supplies

Episode Transcript

(NARRATOR)>> TODAY WE'RE BACK ON "PROJECT CREEP IT REAL". WE'RE FINISHING UP OUR SIX INCH LIFT. THEN GETTING OUR DANA 60 AXLES INSTALLED, ALONG WITH OUR NEW TRANSFER CASE. IT'S ALL RIGHT HERE ON XOR.

(JEREMY)>> HEY GUYS, WELCOME TO XOR. TODAY WE'RE BACK ON "PROJECT CREEP IT REAL", AND WHEN DANA HEARD ABOUT THE PROJECT THEY WANTED IN ON THE ACTION. SO BEFORE WE CAN GET THEIR AXLES UNDERNEATH THE JK ELIZA'S GOT TO FINISH UP THE REAR SUSPENSION.

(ELIZA)>> THIS, AND THAT, AND THIS ALL HAVE TO GO. [ torch cutting metal ]

(ELIZA)>> THE FIRST PIECE THAT HAS TO GO IS THE BRACKET FOR THE LOWER CONTROL ARM. NOW IT'S A PRETTY STOUT BRACKET BUT OUR LINCOLN TOMAHAWK 375 MAKES QUICK WORK OF IT. [ torch cutting metal ]

(ELIZA)>> ALL RIGHT, THAT ONE'S OFF. NOW GET THE REST OF THEM OFF. FOLLOWING THAT IS THE UPPER CONTROL ARM BRACKET, AND SINCE THIS ONE IS CLOSE TO THE FRAME I'M USING A CUTOFF WHEEL SO I DON'T DO ANY UNINTENTIONAL DAMAGE TO OUR FRAME. A LITTLE BIT CLOSER TO BEING DONE. AFTER THAT WE HAVE TO SECTION A PIECE OF THE BODY MOUNT BRACKET TO MAKE WAY FOR THE KIT'S MUCH BIGGER CONTROL ARM BRACKET. ALL RIGHT, NOW TIME FOR CLEAN UP. [ grinding metal ]

(ELIZA)>> YOU WANT TO MAKE SURE AND GRIND EVERYTHING SMOOTH FOR A GOOD, SQUARE FIT FOR THE NEW BRACKET. [ grinding metal ]

(ELIZA)>> WOO, A LOT OF WORK BUT IT IS GONNA BE WORTH IT. I CAN TAKE THAT OFF. THE BUMP STOP RUBBER SO THAT IT DOESN'T GET ALL MESSED UP WITH ALL THE SPARK.

SO WHAT I'M GONNA DO IS I'M GONNA COME UP RIGHT ON THE INSIDE OF THE WELD SEAM SO THAT THAT WAY IT'S CLEAN AND WE CAN WELD IT OUT OVER HERE WHEN WE MOVE EVERYTHING BACK EIGHT INCHES. AGAIN I'M USING THE CUTOFF WHEEL BECAUSE IT GIVES ME THE MOST CONTROL FOR REMOVING A BRACKET LIKE THIS ONE THAT'S RIGHT UP AGAINST THE FRAME.

ALL RIGHT, NICE AND CLEAN, AND READY TO MOVE OVER ROUGHLY RIGHT ABOUT THERE.

AND JUST LIKE BEFORE, CLEAN UP IS IMPORTANT BECAUSE WE HAVE TO GET OUR NEW PART'S GEOMETRY ABSOLUTELY CORRECT.

SINCE WE'RE CUTTING THE BODY MOUNT I DIDN'T WANT TO CUT TOO MUCH. SO I'M USING THE SYNERGY CONTROL ARM BRACKET ITSELF AS A GUIDE TO SEE WHAT ELSE NEEDS TO COME OFF FOR A SNUG FIT.

WOO HOO, LOOK OUT! ALL RIGHT, LET'S TEST FIT THIS AGAIN. OH PERFECT FIT! THIS WELL THOUGHT OUT KIT IS DESIGNED TO UTILIZE THE EXISTING BODY MOUNT BOLT LOCATIONS TO SELF LOCATE THE BRACKET. THAT WAY YOU CAN'T GET IT WRONG, AND IT SAVES YOU A LOT OF TIME FROM REMEASURING, RETHINKING, AND SECOND GUESSING EVERYTHING.

[ welder crackling ]

(ELIZA)>> THIS PRETTY BLUE ARC IS WELDING THE TWO PIECES OF THE COIL MOUNT TOGETHER BEFORE IT GOES ON TO THE JEEP.

[ welder crackling ]

(ELIZA)>> WITH THE COIL MOUNT DONE, NOW WE CAN MOVE ON TO THE UPPER SHOCK MOUNT.

[ welder crackling ]

[ welder crackling ]

(ELIZA)>> ALL RIGHT, THAT'S TACKED IN PLACE. ALL RIGHT, WE'VE ALREADY MEASURED IT OUT. THIS HAS GOT TO GO CENTERED RIGHT THERE. THE WHEEL BASE STRETCH FROM THIS KIT PUSHES THE OLD BUMP STOP EIGHT INCHES BACK.

ALL RIGHT, THERE IT IS!

(NARRATOR)>> UP NEXT, WE'LL BUST OPEN A CASE OF NEW AXLES AND LATER, WE'LL INSTALL OUR TRANSFER CASE.

(ELIZA)>> HEY GUYS, WELCOME BACK TO XOR AND THE BUILD UP OF "PROJECT CREEP IT REAL". IT IS TIME TO GET OUR DANA 60'S UNDERNEATH OUR 2012 JK.

(JEREMY)>> DANA HAS GONE ABOVE AND BEYOND WHEN DESIGNING AND BUILDING THEIR AXLES, AND OUR ULTIMATE DANA 60'S SHOW JUST THAT. NOW THESE ARE DIRECT BOLT INS FOR OUR 2012 JK WITH ALL THE MOUNTS AND BRACKETS ALREADY ON THE HOUSINGS. SO THESE THINGS SHOULD GO IN OUR JEEP JUST LIKE THAT. THE FRONT HAS WARN LOCKOUTS, 35 SPLINED AXLE SHAFTS, AND A DETROIT ELOCKER. AND COUPLE THAT WITH 5.38 GEARS, THIS AXLE SHOULD TAKE EVERYWHERE WE NEED TO GO AND MORE. AND THE REAR IS A FULL FLOATING DESIGN WITH MASSIVE BRAKES, SPEED SENSORS ALL THE WAY AROUND, AN IMPRESSIVE CAST IRON DIFF COVER, AND 13-50 UJOINTS, THIS SHOULD HANDLE OUR 40 INCH TIRES WITHOUT ANY PROBLEMS. SO LET'S GET THESE UNDER OUR JEEP. HERE WE GO. IN 1904 DANA SPICER FOUND CLARENCE SPICER PATENTED HIS INVENTION OF AN ENCASED UNIVERSAL JOINT. HIS FIRST CUSTOMER WAS THE CARBON MOTOR COMPANY, AND SOON HE WAS SUPPLYING BUICK, OLDS, MACK TRUCKS, GALLEY SPRINGFIELD, AND AMERICAN MOTORS, AND THE REST IS HISTORY. WELL WE'RE GONNA PUT THE UPPER AND LOWER CONTROL ARMS ON AND THEY SHOULD BE PRESET CAUSE WE SENT THEM THE LENGTH ALREADY.

NOW WE'RE ALL JUST GONNA PUT THIS STUFF ON HERE LOOSELY CAUSE WE'VE GOT TO MOVE THE SUSPENSION TO MAKE SURE IT DOESN'T BIND. SO I'M GONNA START WITH THAT. THEN ON TO THE LOWER CONTROL ARMS.

THAT ONE LINED RIGHT UP!

NOW WE'RE REUSING SOME OF THE STOCK HARDWARE TO INSTALL THE FRONT AXLE, AND WHEN YOU'RE DONE WITH THIS MAKE SURE YOU CYCLE THE SUSPENSION BEFORE YOU INSTALL THE SPRINGS AND SHOCKS JUST TO MAKE SURE THERE'S NO BINDING.

NOW THERE'S A LOT OF STORED ENERGY IN A SPRING THIS SIZE. SO TAKE YOUR TIME BEFORE YOU COMPRESS THE SUSPENSION, AND MAKE SURE IT'S SEATED IN THE UPPER AND LOWER MOUNTS CORRECTLY.

WHEN INSTALLING THE TRACK BAR REMEMBER, LEAVE IT LOOSE BECAUSE THIS IS WHAT IS GONNA ADJUST YOUR AXLE TO THE LEFT AND TO THE RIGHT AFTER YOUR SUSPENSION IS COMPLETELY INSTALLED. SAME GOES FOR THE DRAG LINK BECAUSE YOU'RE GONNA WANT THE TRUCK ALIGNED AFTER IT'S COMPLETELY FINISHED. AND THAT'S IT! THAT'S THE FRONT INSTALL. NOW WE'VE JUST GOT TO WRAP UP THE BACK.

(NARRATOR)>> WHEN WE COME BACK WE'LL FINISH UP THE REAR SUSPENSION, STAY TUNED!

(ELIZA)>> WELCOME BACK TO XOR. WITH OUR FRONT AXLE TAKEN CARE OF NOW IT'S TIME TO INSTALL THE REAR, BUT BEFORE WE CAN DO THAT I'VE GOT TO GET OUR NEW REAR TRACK BAR BRACKET MOUNTED UP.

UNLIKE THE FRONT THAT USES A STOCK TRACK BAR MOUNTING POINT, THIS NEW BRACKET IS NEEDED SINCE WE HAVE STRETCHED OUR WHEEL BASE BY EIGHT INCHES. AND JUST LIKE IN THE FRONT WE'LL NEED TO PRESET OUR UPPER CONTROL ARM LENGTH TO 26 AND THREEEIGHTHS.

THERE IT IS!

JUST LIKE IN THE FRONT WE ARE USING A COMBINATION OF STOCK AND NEW GRADE EIGHT HARDWARE.

THAT'S GONNA BE PRETTY SECURE. NOW TO GET THE UPPER. [ mallet banging ]

(ELIZA)>> ALL RIGHT, WELL PASSENGER SIDE IS IN. THEN WE'VE GOT TO DO THE EXACT SAME THING TO THE DRIVER'S SIDE. [ mallet banging ]

(ELIZA)>> WHEN DOING A JOB LIKE THIS HAVING AN ALIGNMENT PUNCH MAKES THE JOB A WHOLE LOT EASIER.

SYNERGY'S WELL THOUGHT OUT DESIGN MAKES ACCESS TO THE HARDWARE EASY, MAKING INSTALLATION A BREEZE.

FOR NOW WE'RE JUST BOLTING EVERYTHING IN PLACE TO MAKE SURE THAT WE HAVE PROPER GEOMETRY AND CLEARANCES. THERE IT IS.

ALL RIGHT, TRACK BAR'S IN. GOING DOWN! JUST LIKE UP FRONT, WE NEED TO CYCLE THE REAR SUSPENSION TO MAKE SURE THAT WE'RE NOT BINDING ANYWHERE.

(JEREMY)>> IT LOOKS GOOD SO FAR.

(ELIZA)>> SAME OVER HERE, NOTHING'S BINDING.

(JEREMY)>> KEEP GOING. PERFECT! I DON'T THINK IT'S GONNA COMPRESS ANY MORE THAN THAT.

(ELIZA)>> I DON'T THINK SO. PUT IT BACK UP.

(JEREMY)>> YEAH THAT'S GOOD, PERFECT.

(ELIZA)>> NOW WE CAN MOVE ON TO INSTALLING OUR SPRINGS AND SHOCKS, AND THAT STARTS WITH REUSING OUR STOCK SPRING GUIDES.

LET'S LOWER IT DOWN A BIT. NOW OUR REAR SHOCKS HAVE THE SAME REMOTE RESERVOIR DESIGN AS IN THE FRONT. WE GOT OURS FROM SUMMIT RACING DOT COM.

AFTER INSTALLING THE PASSENGER'S SIDE SHOCK, AND WITH EVERYTHING IN PLACE, WE'LL GO BACK AND MAKE SURE THAT WE HAVE ALL OUR WASHERS AND LOCK NUTS INSTALLED, AND THEN WE'LL TORQUE EVERYTHING TO SPEC.

(NARRATOR)>> AFTER THE BREAK IT'S TIME FOR A NEW TRANSFER CASE, STICK AROUND.

(ELIZA)>> HEY GUYS, WELCOME BACK TO XOR AND THE BUILD UP OF "PROJECT CREEP IT REAL". WE'VE GOT OUR SYNERGY SUSPENSION HUNG AND OUR DANA 60 INSTALLED.

(JEREMY)>> THAT'S RIGHT. WITH EVERYTHING UNDERNEATH THE JEEP WE NEED TO GET RID OF ONE MORE THING, AND THAT'S THE STOCK TRANSFER CASE. SO WE'RE GONNA REPLACE THAT WITH SOMETHING WAY MORE SUITABLE FOR OUR JK. AND THAT IS THIS ADVANCED ADAPTERS ATLAS TRANSFER CASE. NOW UNLIKE OUR STOCK TRANSFER CASE THIS IS A GEAR DRIVEN, VERSUS THIS ONE'S A CHAIN DRIVEN CASE. PLUS IT ALMOST DOUBLES OUR GEAR RATIO, 2.71 TO ONE VERSUS 4.3 TO ONE.

AND THERE'S SOME ASSEMBLY REQUIRED, AND THAT STARTS WITH THE BRACKET THAT HOLDS THE SHIFTER CABLES IN PLACE.

ALSO IN THE KIT IS A GUIDE FOR THE TK SHIFTER CABLES, AND THAT'S AS SIMPLE AS A PIECE OF ALL THREAD AND A STEEL STAND OFF TUBE.

AND A LITTLE MEDIUM STRENGTH PERMATEX THREAD LOCKER HELPS KEEP EVERYTHING IN PLACE.

NOW WE'VE ALREADY FILLED OUR TRANSFER CASE WITH 75-90 SYNTHETIC GEAR OIL, AND THERE'S A UNIQUE AND EASY WAY OF CHECKING THE OIL'S LEVEL OVER TIME AND IT ONLY REQUIRES YOUR EYES, AND THAT IS A SIGHT TUBE SO WE KNOW HOW MUCH FLUID WE HAVE. WE DON'T HAVE TO EVER CHECK BY DROPPING ONE OF THE PLUGS. WE CAN JUST CRAWL UNDERNEATH THE JK, TAKE A PEAK, MAKE SURE THE FLUID'S JUST FINE.

WHEN I SIMULATE THE ANGLE OF THE TRANSFER CASE LIKE IT SITS IN THE JEEP YOU CAN SEE THE OIL LEVEL CLEARLY. JEEPS ARE SO COMPUTERIZED NOW THAT ADVANCE ADAPTERS KNOWS YOU CAN'T JUST INSTALL THEIR TRANSFER CASE WITHOUT COMMUNICATING WITH THE ELECTRONICS THAT CONTROL THE TRANSMISSION. THESE SWITCHES ARE JUST GOING TO TRICK OUR PCM INTO THINKING THAT THE STOCK TRANSFER CASE IS IN THE TRUCK SO IT SHIFTS PROPERLY. ON THE BACK OF THE TRANSMISSION THE STOCK COUPLER HAS TO COME OFF THE OUTPUT SHAFT. THEN WE CAN INSTALL THE FLAT FLANGE FROM THE KIT.

AND A LITTLE THREAD LOCKER HELPS SECURE THE NEW SUPPLIED NUT IN PLACE. [ drill spinning ]

(JEREMY)>> FOLLOWING TORQUEING, THE INPUT SHAFT ADAPTER GOES ON AND IS SECURED WITH FOUR BOLTS AROUND ITS PERIMETER.

WE'RE APPLYING A LITTLE PERMATEX GASKET MAKER ON THE BACK OF THE TRANSMISSION JUST TO KEEP OUT ANY DIRT AND DEBRIS. WHEN INSTALLING YOUR ATLAS IT'S IMPORTANT TO PAY ATTENTION TO HOW THE STOCK TRANSFER CASE WAS CLOCKED ON THE BACK OF THE TRANSMISSION. THAT WAY YOU CAN INSTALL THE ATLAS IN THE EXACT SAME POSITION. IT'S HEAVY, BUT IT'S IN THERE. FOR MORE INFORMATION ON ANYTHING ON TODAY'S SHOW GO TO POWERNATION TV DOT COM.

NOW WHEN WE WERE LOOKING FOR BUMPERS FOR OUR JK WE WENT STRAIGHT TO ARIES. THIS IS THEIR ROCK CRUSHER SERIES BUMPER, AND ARIES BUMPERS ARE SO AFFORDABLE YOU CAN USE THEM STOCK OR MODIFY THEM TO FIT. WE'RE GONNA BE ADDING ABOUT EIGHT INCHES OF LENGTH HERE. SO WE'RE GONNA GO AHEAD AND CUT THIS SIDE OFF SO WE DON'T HIT ANYTHING.

ARIES BUMPERS ARE MADE FROM FORMED QUARTER INCH PLATE STEEL. SO IT TAKES A LITTLE BIT OF HORSEPOWER TO CUT THROUGH. WE'RE USING OUR LINCOLN TOMAHAWK PLASMA CUTTER TO GET THE BALL ROLLING. [ torch cutting metal ]

(JEREMY)>> WE'RE CUTTING THE BUMPER RIGHT NEXT TO THE REENFORCED PORTION THAT THE DRING MOUNT IS WELDED TO. I WANTED MY LINE TO BE PERFECTLY STRAIGHT. SO I SWITCHED OVER TO A CUTOFF WHEEL FOR A MORE PRECISE CUT. [ saw cutting metal ]

(JEREMY)>> AND BACK TO THE PLASMA TORCH WHERE I JUST COULDN'T REACH WITH THE CUTOFF WHEEL. [ torch cutting metal ]

(JEREMY)>> WE'RE GONNA BE USING THE END CAP FROM THE PIECE THAT I JUST CUT OFF. SO WE'RE GONNA USE A CUTOFF WHEEL TO GET THAT REALLY PRECISE CUT.

[ saw cutting metal ]

(JEREMY)>> SINCE THE BUMPER'S WELDED ALL THE WAY AROUND I JUST NEED TO CLEAN OFF WHAT'S LEFT OF THE WELDS. [ grinding metal ]

(JEREMY)>> WE NEED TO TAKE THE BEND OUT OF OUR END CAP. SO USING OUR EDWARDS 40 TON SHOP PRESS AND A LITTLE BIT OF LOVE COMES OUT PRETTY CLEAN.

ARIES SEND THEIR BUMPERS IN A POWDER COATED FINISH. SO I JUST NEED TO GET RID OF THAT SO I CAN WELD ON THE END CAP. [ grinder spinning ]

(JEREMY)>> AND NOW IT'S AS SIMPLE AS ALIGNING THE CORNERS, PUTTING A COUPLE OF TACKS IN, AND THEN BURNING IT ALL HOME. [ welder crackling ]
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