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IT BEGINS AS A FADED 25 YEAR OLD YJ, BUT WHEN WE'RE FINISHED IT'LL BE READY TO ROCK WITH A FOUR LINKS TUBE CHASSIS, ALUMINUM BODY, AND A HEAVY DUTY DRIVETRAIN. BEST OF ALL IT COULD BE YOURS!WE ARE READY TO KICK OFF ANOTHER YEAR HERE AT XTREME OFF ROAD. BEHIND ME I'VE GOT A PILE OF PARTS SITTING JUST OUTSIDE THE XOR SHOP. INSIDE, A BUNCH OF PROJECTS READY TO GET TURNED INTO THE ULTIMATE OFF ROAD MACHINES. WE'LL TAKE THIS WORN OUT JEEP YJ AND TURN IT INTO A TRAIL BEAST WITH FOUR LINK SUSPENSION, COIL OVERS, AND AN AMAZING DRIVETRAIN TO POWER IT UP THE HILL. WE'LL FINISH UP A BUNCH OF RIGS IN THE SHOP, LIKE OUR CRAWLER HAULER, OUR LOW BUDGET RALLY CAR, ANDPROJECT RAGING BULL, THE BIG BLOCK BEAST INSPIRED BY THE NEW GENERATION OF OVER THE TOP ROCK BOUNCERS. AND OF COURSE WE'LL GIVE YOU A FRONT ROW SEAT TO THE MOST INTENSE OFF ROAD EVENTS. WE'RE GONNA KICK THINGS OFF THIS YEAR WITH A PRETTY COOL PROJECT. I HAVE BROUGHT A PILE OF PARTS INTO THE XTREME SHOP TO TRANSFORM ONE OF THE LEAST DESIRABLE JEEPS INTOA TRUE OFF ROAD MACHINE IN A SHORT PERIOD OF TIME. SEE WHEN THESE YJ'S FIRST CAME OUT, GUYS WEREN'T REALLY SOLD ON THEM. THEY WERE BUILT A LOT LOWER, A LOT WIDER, AND NO ONE REALLY DUG THE SQUARE HEADLIGHTS UP FRONT. BUT TRUST ME, WHEN I AM DONE WITH THIS RIG, IT'S GONNA BE A HARDCORE CRAWLER. THIS 1990 JEEP YJ WILL BE THE BASE FOR A FULL ON THROW DOWN CUSTOM OFF ROAD RIG THAT'LL BE ABLE TO CRAWL LIKE A MONSTER AND KILL HILLS WHENEVER NEEDED. BUT EVEN BETTER THAN THAT, THIS JEEP CAN BE YOURS! YOU HEARD ME RIGHT, THANKS TO THE GUYS AT WD 40, YOU COULD ENTER TO WIN YOUR VERY OWN WD 40 SPECIALISTXTREME OFF ROAD MACHINE. SEE THE CREW AT WD 40 KNOWS THAT A LOT OF YOU GUYS AT HOME ARE WORKING HARD IN YOUR SHOPS, MAYBE EVEN BUILDING YOUR DREAM RIG OUT OF A JUNKYARD FIND LIKE THIS JEEP. AND TO MAKE THAT TRANSFORMATION YOU'RE GONNA NEED SOME SERIOUS TOOLS.SO WITH A PLAN IN HAND WE GOT A PALLET FULL OF WD 40 PRODUCT TO HELP WITH THIS BUILD.EVERYTHING FROM THE ORIGINAL MULTIUSE PRODUCT TO WD 40 SPECIALIST PENETRANT LONG TERM CORROSION INHIBITOR, AND WHITE LITHIUM GREASE. TO HELP WITH THE TEARDOWN, WD 40 BROUGHT IN MARK WHEELER, AN INSTRUCTOR AT THE NASCAR TECHNICAL INSTITUTE, AND UNIVERSAL TECHNICAL INSTITUTE GRAD TANNER SWINHART, WHO NOW SPENDS HIS DAYS WORKING AT MONSTER JAM.THERE IS NO BETTER FEELING THAN HAVING 75,000 SCREAMING FANS YELLING FOR YOUR TRUCK.UNIVERSAL TECHNICAL INSTITUTE HAS 11 CAMPUSES NATIONWIDE FEATURING PROGRAMS IN AUTOMOTIVE, COLLISION REPAIR, AND DIESEL AND INDUSTRIAL. IN ADDITION, UTI HAS PARTNERED WITH OVER 30 BRANDS TO OFFER FACTORY SPECIFIC TRAINING AND CREDENTIALS.SO THEY CAN EARN SEVEN, 10, 12, 15 DIFFERENT CREDENTIALS FOR DIFFERENT MANUFACTURERS, WHICH WOULD TAKE THEM YEARS AND YEARS TO GET TO IN THE FIELD.THE WD 40 COMPANY IS PROUD TO BE ASSOCIATED WITH UTI, WHO HAS TRAINED OVER 180,000 TECHNICIANS OVER THE LAST 50 YEARS.AND THE AUTO INDUSTRY TO THIS DAY STILL NEEDSQUALIFIED TECHNICIANS, AND WD 40 COMPANY ALONG WITH UTI IS COMMITTED TO PROVIDING A SOLUTION.BEFORE ANY TEARDOWN BEGINS IT'S ALWAYS A GOOD IDEA TO DEGREASE THE VEHICLE WHERE YOU'RE GOING TO BE WORKING. IT'LL MAKE TEARDOWN A LOT CLEANER AND ALLOWS YOU TO VISUALLY INSPECT SOME OF THE KEY PARTS.VEHICLES ARE WAY EASIER TO WORK ON WHEN THEY'RE CLEAN. I MEAN YOU SEE ALL OF THE GREASE, AND GRIME, AND GUNK THAT'S COMING OFF OF THIS THING AS WE KEEP SPRAYING IT. THE GREASE AND GRIME CAN DEFINITELY HIDE PARTS THATARE BROKEN, YOU KNOW, SEALS THAT ARECRACKED OR LEAKING.AFTER A GOOD COAT OF THE WD 40 SPECIALIST MACHINE AND ENGINE DEGREASER FOAMING SPRAY, WE LET IT SIT FOR ABOUT FIVE MINUTES, AND THE PRESSURE WASHER PEELS OFF 20 YEARS WORTH OF OIL, DIRT, AND GRIME.FIRST STOP, WHOLE JEEP, I WANT FIVE PARTS. I WANT THE HOOD, WINDSHIELD FRAME, FRONT GRILL, AND THAT BRAKE MASTER CYLINDER, THEN THE STEERING COLUMN. THAT'S ALL WE'RE AFTER. ARE YOU READY?YES SIR.ARE YOU READY?READY!HE'S READY! FIRST STOP, HOOD HINGE BOLTS, AND THE HOOD IS REMOVED AND PLACED OUT OF THE WAY. THE JEEP'S HALF CAB SOFT TOP IS PULLED BACK AND THE WINDSHIELD HINGES ARE UNBOLTED FROM THE BODY. IT IS VERY COMMON FOR THE CAPTURED NUTS INSIDE THE JEEP'S BODY TUB TO SPIN. WHEN THAT HAPPENS, THE BEST OPTION IS TO SIMPLY DRILL OUT THE HEADS OF THE FACTORY TORQUE BOLT.THE GRILL SHELL AND STEERING SHAFT, ALONG WITH THE MASTER CYLINDER, ARE REMOVED. TO CLEAN THE STEERING SHAFT WE'LL DROP IT IN WD 40 RUST REMOVER SOAK FOR ABOUT THREE HOURS. THE PARTS THAT WE WILL NOT BE USING ALL ROLLED OUT THE DOOR TOGETHER AND THE NEW AQUALU ALUMINUM JEEP BODY IS CARRIED INTO THE SHOP. THIS REPLACEMENT TUB IS MADE FROM 5052 MARINE GRADE ALUMINUM ALLOY THAT'S FIVETHIRTYSECONDTHS OF AN INCH THICK.A GREAT REPLACEMENT JEEP TUB FOR ANY WORN OUT RIG, OR IN OUR CASE, THE START OF THE WD 40 SPECIALIST XTREME OFF ROAD MACHINE.COMING UP, THE TUB MEETS THE TUBING AND THE PIECES START FALLING INTO PLACE. PLUS 42 INCHES OF SUBSTANCE AND STYLE.WELCOME BACK TO THE XOR SHOP WHERE WE ARE BUILDING THE WD 40 SPECIALIST XTREME OFF ROAD MACHINE. A CUSTOM JEEP YJ CRAWLER THAT YOU CAN OWN. AND TO MAKE THIS RIG TRULY ONE OF A KIND, A NEW CHASSIS FROM WIDE OPEN DESIGN IS BROUGHT INTO THE SHOP. DESIGNED TO REPLACE THE FACTORY FRAME AND SUSPENSION ON JEEP YJ'S AND CJ'S, THE CHASSIS ARRIVES FULLY WELDED WITH DRIVETRAIN AND SUSPENSION MOUNTS IN PLACE. SET UP FOR AN LS BASED POWER PLANT, TURBO 400 TRANS, FOUR LINKS FRONT AND REAR, AND 14 INCH COIL OVERS. MADE FROM A COMBINATION OF .188 AND .120 WALLED DOM TUBING, THIS CHASSIS WILL SAVE US TONS OF TIME.SO YOU'RE GONNA PRETTY MUCH BE ABLE TO TAKE A BODY OFF OF YOUR JEEP FRAME, SET IT RIGHT ON THIS THING, AND GO TO WORK FROM THERE.BELIEVE IT OR NOT, THIS CHASSIS WAS ONLY OUTSIDE FOR ONE NIGHT AND IT'S ALREADY BECOMECOVERED IN SURFACE RUST. WIPING IT DOWN WITH SOME WD 40 MULTIUSE PRODUCT WILL REMOVE THIS SURFACE RUST AND KEEP IT FROM COMING BACK. THE FIREWALL ON OUR JEEP BODY IS MARKED FOR THE BRAKE MASTER CYLINDER AND STEERING COLUMN, AND CUT OUT USING THE PLASMA CUTTER. THE CHASSIS HAS RAISED REAR COIL OVER MOUNTS THAT REQUIRE SOME TRIMMING OF THE FACTORY WHEEL TUBS IN ORDER TO REACH MAXIMUM ARTICULATION OF THE REAR SUSPENSION. WE'LL DROP THE BODY ONTO THE CHASSIS TO CHECK THE FIT. A LITTLE TRIMMING IS ALL WE'LL NEED TO GET EVERYTHING INTO PLACE.ONCE THE TUB DROPS DOWN IT CAN SLIDE ANYWHERE.ONCE CUT OUT, THE CAGE IS LOWERED INTO PLACE TO LINE UP WITH THE CHASSIS MOUNTS. WE'RE AT AN INCH AND CHANGE, AND NOWWE'RE GETTING CLOSER. I'LL JUST MARK IT AND THEN WE'LL TAPE IT AND CHECK IT.TO CHECK THE CLEARANCE AT THE TOP OF THE CAGE THE WINDSHIELD FRAME IS DROPPED INPLACE ON OUR TUB. THE WINDSHIELD HINGES WERE IN GOOD SHAPE BUT THE PIVOT POINTS ARE PACKED WITH RUST. TO FREE THEM UP, A LITTLE BIT OF TIME IN THE WD 40 RUST REMOVER SOAK ALONG WITH SOME WD 40 SPECIALIST RUST RELEASE PENETRANT AND THE HINGES ARE FREE AGAIN.IT PENETRATES RUST 50 PERCENT FASTER THAN THE LEADING PENETRANT COMPETITOR. SO IT'S GONNA BE USED ON EVERY RUSTED NUT AND BOLT THROUGHOUT THE PROCESS.TO GET A FINAL LOOK AT THE MOCK UP OF THIS JEEP, THE HOOD AND GRILL SHELL ARE PUT IN PLACE AND THEN BOOM, WE'VE GOT A JEEP AGAIN.UP NEXT, A JUNKYARD FIND IS THE FOUNDATION FOR A SET OF HARDCORE AXLES AND LONG TRAVEL COIL OVERS. PLUS, TO HANDLE ALL OUR UPGRADES WE'RE GONNA NEED A COUPLE OF EXTRA CYLINDERS.JUST LIKE THE JEEP, THE AXLES NEED TO BE DEGREASED BEFORE ANY WORK ON THEM CAN BEGIN. AND AFTER A GOOD COATING OF THE DEGREASER AND SOME TIME WITH THE PRESSURE WASHER, THE AXLE IS BROUGHT BACK INTO THE SHOP AND TORN DOWN TO A BARE HOUSING.THESE AXLES ARE OUT OF THE SAME MODEL OF TRUCK BUT DIFFERENT YEARS. THE REAR IS AN EARLY '90'S FORD SUPER DUTY. THAT'S A STERLING REAR, IT'S A 10.5 INCH RING GEAR FULL FLOAT REAR AXLE ASSEMBLY. UP FRONT WE HAVE A NEWER '04 AND UP FORD SUPER DUTY AXLE, AND IT IS A SUPER 60. NOW THE REASON THAT WE LIKE THE 60'S ON THE FRONT OF THE NEWER FORDS IS BECAUSE THE REVERSE ROTATION, OR HIGH PINION.JUST GIVES US A BETTER DRIVELINE ANGLE ON OUR FRONT DRIVESHAFT. JUST LIKE THE REST OF THE JEEP THOUGH, WE'RE REALLY ONLY USING A FEW COMPONENTS OFF OF BOTH OF THESE AXLES. THE REAR WE USED A FULL HOUSING ALL THE WAY TO THE END OF THE WHEEL MOUNTS. OUT FRONT WE'RE REALLY ONLY GOING TO USE THE CENTER SECTION AND THE TUBES. EVERYTHING ELSE IS GETTING REPLACED.THE WIDE OPEN DESIGN CHASSIS KIT COMES WITH AXLE TRUSSES AND LINK MOUNTS. WITH THE TRUSS TACKED IN PLACE, THE AXLE IS PLACED UNDERNEATH OUR JEEP, AND THE TABS FOR THE HEIM JOINTS ARE TACKED INTO PLACE. [ welder crackling ]THE CHASSIS THAT WE INSTALLED UNDERNEATH OUR JEEP BODY IS DESIGNED TO TAKE A VERY SPECIFIC HARDCORE SUSPENSION SYSTEM. NOW IT COMES WITH ALL THE BRACKETS AND TABS YOU NEED TO INSTALL IT, AND IT USES SOME PRETTY UNIQUE PIECES. IT STARTS WITH A SET OF HEAVY DUTY INCH AND A QUARTER HEIM JOINTS. WE GOT THESE FROM RUSTY'S OFF ROAD. THEY'RE AN INCH AND A QUARTER SHANK, ALL CHROMOLY AND HEAT TREATED CONSTRUCTION, AND TAKE A ONE INCH GRADE EIGHT THROUGH BOLT. NOW THE SHOCK PACKAGE IS COIL OVERS ALL THE WAY AROUND. WE OPTED FOR THE FOX TWO AND A HALF INCH COIL OVERS WITH REMOTE RESERVOIRS. THESE ARE A 14 INCH TRAVEL SHOCK, THEY HAVE A SEVENEIGHTHS INCH ROD, AND THE VALVING PACK INSIDE IS ALREADY SETUP SPECIFIC FOR OUR VEHICLE. IT'S WHAT'S CALLED THEIR TRAIL RIDING VALVE PACKAGE. AND IT'LL BE PERFECT FOR SOME MILD ROCK CRAWLING, AND EVEN SOME SERIOUS HILL KILLING. LASER CUT BRACKETS, LIKE THESE SHOCK MOUNTS, AREOFTEN TIGHT ON THE HEAD OF THE FASTENER. AFTER APPLYING SOME WD 40 MULTIUSE PRODUCT, EACH TAB IS OPENED UP WITH A REAMER TO MAKE SHOCK INSTALLATION A LOT EASIER. JUST LIKE THE REAR AXLE, THE ENGINE FRONT DANA 60 IS GUTTED TO A BARE HOUSING. THE OUTERC IS CUT FLUSH FROM THE TUBE AND THE GEARS AND CARRIER ARE REMOVED FROM THE HOUSING. THE TRUSS IS TACKED INTO PLACE, AND THE HOUSING ISTHEN PLACED UNDER THE FRONT OF THE JEEP. MOCK UP LINKS ARE MADE FROM SOME DOM TUBING, AND THEN THE AXLE TABS ARE TACKED INTO PLACE ALONG WITH THE LOWER SHOCK MOUNTS. NOW THE CHASSIS COMES WITH THE MAJORITY OF TUBING NEEDED TO MAKE THE JEEP A ROLLER BUT WE WANT TO ADD A COUPLE EXTRA PIECES JUST TO MAKE IT GOOD AND STRONG. THE FIRST WILL BE AN ADDITIONAL BRACE TO THE TOP OF THIS SHOCK HOOP. NOW THEY'RE ALREADY BRACED SIDE TO SIDE BUT WE WANT TO TIE THEM INTO THE CAGE INSIDE OF THE JEEP. SO WE'LL RUN A PIECE OF TUBING FROM THE TOP OF THE SHOCK HOOP, THROUGH THESE TABS THAT COME WITH THE CHASSIS, AND THEN ANOTHER PIECE OF TUBING ON THEINSIDE THAT WE'LL TIE INTO THE CAGE JUST TO MAKE EVERYTHING GOOD AND STRONG. INCH AND A HALF DOM IS NOTCHED TO FIT THE UPPER SHOCK HOOP AND ATTACHED TO THE INCLUDED FIREWALL PLATES.UP NEXT, A STRONG, RELIABLE FIVE POINT THREE POWER PLANT, AND SOME BOMB PROOF BEAD LOCKS.THE STRAIGHT SIX ENGINE THAT'S UNDERNEATH THE HOOD OF OUR YJ FROM THE FACTORY WOULD BE OKAY FOR SOME MILD OFF ROADING, BUT WE'RE TRYING TO BUILD AN XTREME OFF ROAD MACHINE. SO I DECIDED THE BEST OPTION WOULD BE TO GET A VEIGHT UNDERNEATH THE HOOD. NOW THIS IS A FIVE POINT THREE LS BASED TRUCK ENGINE THAT WE PICKED UP FROM POWERTRAIN PRODUCTS. NOW POWERTRAIN PRODUCTS DOES THINGS ALITTLE BIT DIFFERENTLY. THEY DON'T JUST REBUILD THAT ENGINE, THEY DO WHATTHEY CALL REENGINEER IT. THEY GO IN AND FIX ANY COMMON FAILURE POINTSINSIDE THAT ENGINE BEFORE THEY CRATE IT UPAND SHIP IT TO YOU. THE NICE THING IS IT'S GONNA COME WITH A FULL WARRANTY EVEN WHEN WE INSTALL IT IN AN OFF ROAD VEHICLE LIKE OUR JEEP. PLUS IT'S GONNA GIVE US A PILE OF HORSEPOWER UNDERNEATH THE HOOD.THE FIVE POINT THREE IS A TIGHT FIT WITH THE BODY ON THE CHASSIS, BUT A LITTLE WORK WITH THE MATCO TOOLS ENGINE TILTER AND IT SLIDES UNDERNEATH THE FRONT HOOP AND RESTS ON THE ENGINE PLATES. LIKE ALL HARDCORE OFF ROAD RIGS, THE ENGINE DRIVETRAIN IN THIS JEEP WILL BE SOLID MOUNTED. BEFORE I PULL ANY TUBE THROUGH THE TUBE SHARK, I ALWAYS LIKE TO COAT THE FOLLOWER DYE WITH A GOOD AMOUNT OF WHITE LITHIUM GREASE. IT JUST PREVENTS THE TUBE FROM GETTING HUNG UP IN THE BENDER AND POSSIBLY KINKING. NOW NORMALLY I'VE GOT TO PULL THAT FOLLOWER DYE OUT AND PAINT THE WHITE LITHIUM ON THERE. AND IT IS EASIER TO USE A SPRAYWHITE LITHIUM GREASE. NOW THE WD 40 SPECIALIST CAN ACTUALLY MAKES THIS A LOT EASIER. IF YOU HAVE A DYE THAT IT'S EASY TO GET TO, YOU CAN JUST SPRAY IT NORMALLY. ON THE TUBE SHARK IT'S BURIED IN THERE.THAT'S WHERE THE STRAW COMES IN HANDY BECAUSE I CAN GET RIGHT TO THE VERY BACK OF THE DYE AND GIVE IT A GOOD COATING OF WHITE LITHIUM GREASE. THE DOM TUBING IS BENT AND NOTCHED TO CLEAR THE FRONT OF THE ENGINE OIL PAN, LOCKING THE ENGINE MOUNT TUBES TOGETHER FOR EXTRA STRENGTH. SO FAR EVERYTHING WE'VE DONE TO OUR JEEP HAS BEEN TURNING IT INTO A HARDCORE OFF ROADER. WE'RE NOT GONNA STOP WITH THE TIRES. FOR THIS RIG I'VE CHOSEN A SET OF PIT BULL ROCKERS, 42 INCHES TALL WITH A 15 INCH CROSS SECTION. NOW THE ROCKER IS A VERY AGGRESSIVE OFF ROAD TIRE THAT'LL GIVE US TONS OF TRACTION IN THE DIRT. THE SIDE WALLS ARE MULTIPLE PLIES AND INCREDIBLY THICK TO PREVENT THEM FROM CUTTING WHEN WE'RE ON THE TRAIL. NOW THESE ARE SET UP FOR A 17 INCH WHEEL, AND FOR THOSE WHEELS WE'VE GOT SOMETHING PRETTY SPECIAL. THESE 17 INCH TRAIL GEAR WHEELS ARE HEAVY DUTY ALUMINUM BEAD LOCKS THAT HAVE BEEN TORTURE TESTED IN SOME OF THE MOST HARDCORE OFF ROAD RACINGEVENTS IN THE COUNTRY.AND TRAIL GEAR OFFERS A UNIQUE OUTER RING THAT IS SEGMENTED AROUND THE WHEEL. STREETWORKS CUSTOM COATINGS TOOK THESE PIECES AND APPLIED A CUSTOM POWDER COAT FINISH THAT SCREAMS WD 40.IT IS HARD TO BELIEVE THAT THAT QUICKLY OUR MOCK UPIS ALMOST 100 PERCENT DONE. OUR SUSPENSION IS IN, SHOCKS ARE MOUNTED, MOTOR IS DONE. WE EVEN HAVE A TRANSMISSION MOUNT IN PLACE. WE ARE ALMOST READY TO COMPLETELY BLOW THIS RIG APART, PAINT SOME PIECES, AND THEN START FINAL ASSEMBLY. WE'RE NOT DONE BUILDING THIS JEEP YET.A HARDCORE OFF ROADER LIKE THE WD 40 SPECIALIST XTREME OFF ROAD MACHINE STILL NEEDS MORE. NEXT TIME THE AXLES WILL GET COMPLETELY REBUILT, ENGINE AND TRANSMISSION WILL GET A HOST OF AFTERMARKET GOODIES, AND THE BODY WILL RECEIVE A CUSTOM TREATMENT THAT YOU WON'T BELIEVE.THE WD 40 SPECIALIST XTREME OFF ROADMACHINE IS GOING TO ONE LUCKY WINNER. YOU CAN ENTER THE SWEEPSTAKES BY GOING TO POWERNATION TV DOT COM OR WD 40 DOT COM. SO GOOD LUCK TO ALL YOU VIEWERS.