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AT XTREME OFF ROAD THE ONLY THING WE LIKE BETTER THAN WORKING ON PROJECTS IS PLAYING WITH THEM. FROM A DIRT CHEAP PICK UP WITH WELDED DIFFS TO A JEEP ROLLING ON RACE READY SUSPENSION, AND EVERYTHING IN BETWEEN. WE'VE TAKEN THEM TO THE LIMIT, AND TODAY WE'LL LET YOU KNOW HOW THEY HANDLE OUR FIELD TEST. PLUS, THE ACCESSORIES YOU NEED FOR SAFE, COMFORTABLE MIG WELDING.IT IS HARD TO BELIEVE THAN AN ENTIRE YEAR HAS PASSED WITH US HANGING OUT HERE IN THE XTREME OFF ROAD SHOP. AND WHAT A YEAR IT HAS BEEN. WE'VE BUILT SOME PRETTY COOL PROJECTS THIS YEAR, HELPED OUT A COUPLE OF WHEELERS IN NEED, AND BASICALLY JUST HAD A TON OF FUN ATTACKING THE DIRT WHENEVER WE COULD. SO I THOUGHT, WHY NOT SPEND TODAY TAKING A LOOK BACK AT SOME OF MY FAVORITE MOMENTS.I OFTEN SAY THAT CAR GUYS STARTED RECYCLING BEFORE IT WAS COOL. AND STICKING WITH THIS MANTRA, I WANTED TO BUILD A RIG FOR LESS THAN $5,000 TO TAKE WHEELING. AND AFTER PULLING A TOYOTA MINI TRUCK OUT OF A FIELD, TORE IT DOWN TO A BARE FRAME.STARTING WITH A SIMPLE REBUILD KIT, THE MOTOR WAS FRESHENED UP AND CLEANED UP.THAN THE FUN STARTED BY CUTTING THE ENTIRE FRONT HALF OF THE TRUCK'S FRAME OFF AND REBUILDING IT TO PERFORM A SOLID AXLE SWAP.OUT BACK I DID THE SAME AND TREATED THE TRUCK TO A CUSTOM FOUR LINK SUSPENSION.BUILT SOME BEAD LOCKS, TOSSED ON A SET OF 35 INCH TIRES, PAINTED THE CAB WITH A RATTLE CAN, ANDBUILT AN EXO CAGE TO PROTECT US WHEN WE'RE ON THE TRAIL. WELDING THE THIRD'S WILL LOCK UP THE AXLES FRONT AND REAR. THEN A HIGH STEER KIT FINISHED IT ALL UP. AND WITH JUST AT $5,000 IN THIS TRUCK, I CALLED A FEW OF OUR LOW BUCK WHEELING BUDDIES AND HEADED INTO THE WOODS. LIKE US, THEY BUILT THEIR RIG ON A SHOESTRING BUDGET. ( )>> SOMEWHERE AROUND $4,500 DOLLARS. ( )>> CLOSE TO $5,000.ABOUT $3,900 DOLLARS.WHEN YOU'RE BUILDING ON A BUDGET, YOU END UP RUNNING A LOT OF STOCK PARTS. AND LIKE THIS STEERING ROD, SOMETIMES THEY JUST DON'T HOLD UP TO HARDCORE WHEELING.I HAD AN ISSUE WITH A STEERING. I BENT MY CROSS TIE ROD. IT WAS STILL A FACTORY THIN PART. WE ENDED UP SLEEVING IT WITH A HIGH LIFT JACK AND BEEN RIDING THE REST OF THE DAY.THAT KIND OF DO IT YOURSELF INVENTIVENESS RUNS IN THE BLOOD OF BUDGET WHEELERS.WHETHER THEY'RE IMPROVISING A TRAIL FIX OR DESIGNING THEIR LATEST PROJECT. ANDY SAVED SOME MONEY AND CREATED A UNIQUE RIDE WHEN HE COMBINED THE CHASSIS OF A TOYOTA WITH THE BODY OF A KIA.I ACQUIRED A TOYOTA TRUCK THAT THE BODY WAS SHOT BUT THE DRIVETRAIN WAS GOOD. SO I NEEDED SOMETHING TO PUT IT IN AND HAPPENED TO CROSS A CRAIG'S LIST ADD FOR A $600 DOLLAR KIA SPORTAGE. IT'S GOT TOYOTA DRIVETRAIN, MOTOR, TRANSMISSION, TRANSFER CASE, AND AXLES. THREE LINK FRONT AND REAR OUT OF FACTORY JK LINKS WITH AN AIR BAG SYSTEM.AS FOR OUR TOYOTA, THE PERFORMANCE WAS DEFINITELY HIGHER THAN THE PRICE, EASILY CLIMBING ITSWAY THROUGH THE ROCKS AND MUD. FOUR LINKING THE BACK OF THIS TRUCK WAS DEFINITELY WORTH THE EXTRA MONEY. THE REAR AXLE CAN EASILY FLEX OVER THE ROCKS IN THE TRENCH, KEEPING BOTH WHEELS ON THE GROUND AND US MOVING FORWARD.THE EXOCAGE DOES A GREAT JOB PROTECTING THE CAB AND FRONT SHEET METAL FROM DAMAGE WHEN ON THE TRAIL. IN SERIOUS OFF CAMBER TRAILS LIKE THIS ONE, THE ROOF BARS AS WELL AS THE MAIN HOOP DO THEIR JOB. DITCHING THE IFS IN FAVOR OF THE SOLID AXLE WAS THE RIGHT CHOICE. THE TRAIL GEAR LEAF PACKS ALLOW THE FRONT END TOFLEX WHEN WE NEEDED SERIOUS ARTICULATION. ALL IN ALL A GREAT DAY ON THE TRAIL WITH A GREAT GROUP OF WHEELERS. TODAY PROVES THAT YOU DON'T NEED TO HAVE SIX FIGURES IN THE BANK TO HAVE FUN OFF ROAD. YOU JUST NEED A GOOD GROUP OF FELLOW OFF ROADERS AND THEIR CHEAP WHEELERS.UP NEXT, EVEN THE MOST CAPABLE UTV CAN BENEFIT FROM THE XTREME OFF ROAD TREATMENT. PLUS WE GO BACK TO SCHOOL TO LEARN THE INS ANDOUTS OF RALLY RACING.SINCE FINISHING UP PROJECT DIRT CHEAP FUN'S JUST BEEN KICKING AROUND THE SHOP. NOW I HAVE ANOTHER SET OF UPGRADES PLANNED FOR IT. SO YOU'LL SEE IT BACK AGAIN NEXT YEAR.BUT DON'T WORRY, THEY'LL BE DONE ON THE CHEAP. BUT PROBABLY THE MOST FUN I HAVE HAD ALL YEAR HAS BEEN WITH A PROJECT THAT SURPRISED EVEN ME, AND THAT WAS WHEN POLARIS ASKED ME IF I WANTED TO CHECK OUT THEIR LATEST RAZOR 1,000 SIDE BY SIDE. I PICKED IT UP FROM THE DEALER AND WENT STRAIGHT TO OUR LOCAL OFF ROAD PARK JUST TO SEE WHAT ALL THE BUZZ WAS ABOUT WITH THESE RIGS. THERE IS NO QUESTION THAT SIDE BY SIDES ARE POPULAR, AND AFTER SPENDING A GOOD DAY WHEELING IT, I CAN SEE WHY. EVEN THOUGH THE RIG IS FUN, NO VEHICLE IS LEFT UNTOUCHED ONCE IT ENTERS THE XOR SHOP. SO AFTER ADDING SOME ADDITIONAL ACCESSORIESFROM POLARIS, FRONT BUMPER, ROCK SLIDER, REAR BUMPER, AUDIO SYSTEM, AND A ROOF, THE SUSPENSIONWAS TAKEN CARE OF NEXT. UPGRADED TIE RODS FRONT AND REAR, SUSPENSIONSTIFFENING PLATES ON ALL FOUR CORNERS, A SET OF BOMBPROOF AXLES TO TURN LARGER, MORE AGGRESSIVE TIRES, AND BACK INTO THE DIRT WE WENT. BACK AT OUR LOCAL OFF ROAD PARK, AND RIGHT AWAY THE RAZOR FEELS MORE AGGRESSIVE. THE NEW GIBSON EXHAUST GIVES US A LITTLE BIT OF EXTRA POWER, AND THE SOUND THAT A MONSTER LIKE THIS NEEDS. RCV AXLES AND RACER TECH UPGRADED SUSPENSION COMPONENTS MEANT THAT WE COULD PUSH THIS RAZOR INTO SOME SERIOUS WHEELING SITUATIONS AND NOT WORRY ABOUT BREAKING. PLUS THE NEW BODY PROTECTION OF THE ROCK SLIDERS ALLOW US TO CRAWL OVER SOME SERIOUS ROCKS. SO IF YOU'RE LOOKING FOR AN EASY WAY TO GET INTO THE DIRT AND HAVE SOME FUN, MAYBE THERE'S A RAZOR IN YOUR FUTURE. THE RAZOR WASN'T THE ONLY BRAND NEW VEHICLE TO MAKE ITS WAY INTO THE XTREME OFF ROAD SHOP. I NEEDED A NEW SHOP TRUCK. AND AFTER LOOKING LONG AND HARD, I FOUND WHAT I NEEDED IN THIS 2,500 RAM TRADESMAN EDITION. AND JUST LIKE THE SIDE BY SIDE, STOCK WAS NOT GONNA DO. SO A COMPLETE REDESIGN OF THE RAM WAS NEEDED. A NEW SUSPENSION SYSTEM, FOLLOWED BY A TIRE AND WHEEL UPGRADE THAT INCLUDED 10 LUG ADAPTERS,22 INCH WHEELS, AND A BODY CONVERSION TO CHANGE IT FROM SINGLE REAR WHEEL TO DUALS.BUMPERS, WINCH, AND LIGHTS FINISHED IT UP. THEN PROJECT BIG RIG RAM WAS COMPLETE. NOW I BASICALLY PICKED THIS TRUCK UP FROM THE DEALERSHIP AND BROUGHT IT STRAIGHT TO THE XTREME SHOP TO START WORKING ON IT. AND SINCE THEN I'VE PUT ALMOST 18,000 MILES ON IT.MOST OF THAT WITH A TRAILER HOOKED UP OUT BACK. AND I HAVE TO SAY, I AM STILL IN LOVE WITH THIS TRUCK. IT TURNS HEADS EVERYWHERE IT GOES.PULLS LIKE A BEAST, AND WHEN YOU SEE THOSE SPIKES DRIVING DOWN THE HIGHWAY, NOBODY TRIES TO MERGE INTO MY LANE AT ALL. PROBABLY THE MOST COMMON QUESTION I GET ASKED ABOUT THIS PARTICULAR PROJECT HAS TO DO WITH FUEL MILEAGE. I'LL THROW SOME NUMBERS AT YOU BEFORE AND AFTER ALL THE MODIFICATIONS. IN STOCK FORM THIS TRUCK COULD AVERAGE BETWEEN 19 AND 20 MILES PER GALLON ROLLING DOWN THE HIGHWAY UNLOADED.NOW AFTER I MADE ALL THE CHANGES, DRIVING IT AROUND WITH NO TRAILER OR NOTHING IN THE BED, I'M GETTING 16, 17 MILES PER GALLON. SO A LOSS OF A COUPLE MILES PER GALLON, WHICH ISN'T BAD CONSIDERING ALL THE CHANGES THAT WE MADE AND CONVERTED IT OVER TO A DUAL REAR WHEEL. ALL THE EXTRA ROTATIONAL LOAD. PUT A TRAILER ON THE BACK AND THAT'S WHEN EVERYTHING CHANGES. AN OPEN TRAILER WITH A JEEP ON IT REALLY ONLY KNOCKS ABOUT ONE MILE OFF MY MILES PER GALLON. GET ME DOWN AROUND 15 MAYBE 16, I PUT A BIG LOAD ON THE BACK OF THIS TRUCK. I'M TALKING ENCLOSED TRAILER, 12,000 POUNDS, EXTRA TALL HEIGHT, BASICALLY PULLING A BIG SAIL DOWN THE INTERSTATE. I'VE SEEN 11-12 MILES PER GALLON, WHICH ISN'T BAD CONSIDERING THE WEIGHT THAT I'M PULLING. ALL IN ALL VERY HAPPY WITH THIS RIG.COMING UP, THE LATEST AND GREATEST WELDING ACCESSORIES. AND A RIG BUILD RIGHT FOR ONE DESERVING SOLDIER.NOW SHOP TIPS FOR STRONGER, SAFER WELDS.HOPEFULLY BY NOW YOU GUYS HAVE SPENT SOME TIME TUNING YOUR WELDER, EXPERIMENTING WITH DIFFERENT TYPES OF WELDING WIRE AND SHIELDING GAS, AND PRACTICING AT DIFFERENT WELD JOINT SETUPS WITH DIFFERENT POSITIONS OF THE TORCH TO OBTAIN A GOOD QUALITY WELDING BEAD. NOW I'VE BEEN WELDING FOR OVER 25 YEARS, AND TODAY I'M GONNA SHARE WITH YOU SOME OF THE TIPS AND TRICKS, AND PRODUCTS THAT WILL MAKE YOU MORE COMFORTABLE WHILE YOU'RE WELDING. BECAUSE IF YOU'RE COMFORTABLE WHILE YOU'RE BURNING IN AN ARC, THE WELDING BEAD WILL ALWAYS BE BETTER QUALITY. IF YOU'RE GONNA WELD A LOT, PICK YOURSELF UP A GOOD WELDING JACKET. THESE JACKETS ARE MADE FROM LEATHER, FLAME RESISTANT MATERIAL, OR A MIXTURE OF BOTH, AND THEY'LL PREVENT WELDING SPARKS OR SLAG FROM HITTING YOUR SKIN. A GOOD SET OF GLOVES ARE IMPORTANT FOR THE SAME REASON. MIG WELDING GLOVES HAVE AN EXTRA THICK HEAT RESISTANT PADDING ON THE BACK OF THE HAND BECAUSE OF ITS PROXIMITY TO THE WELDING ARC. THE GLOVES AND THE JACKET ARE AN OBVIOUS SAFETY ITEM, BUT THEY ALSO IMPROVE THE QUALITY OF YOUR WELD. REMEMBER, A GOOD WELD BEAD REQUIRES GOOD TORCH POSITION AND A NICE, EVEN TRAVEL SPEED. IF YOU'RE WELDING WEARING JUST A TSHIRT AND ONE OF THE ARCS BOUNCES UP AND HITS YOU IN THE ARM, IT'S JUST COMMON NATURE FOR YOUR BODY TO FLINCH. NOW WHEN YOU FLINCH WHEN YOU'RE WELDING, WELL THATCAN RUIN A GOOD WELD. ANOTHER HANDY ITEM IS A WELDING PILLOW. THIS SMALL PILLOW IS MADE FROM FLAME RESISTANT MATERIAL AND WILL HELP SUPPORT YOUR FORE ARMS AND INSULATE YOU FROM THE HEAT OF A FINISHED WELD. AUTO DARKENING HELMETS ARE VERY POPULAR NOWADAYS, AND THE BENEFITS ARE PRETTY OBVIOUS. THE HELMET DOESN'T DARKEN DOWN UNTIL YOU STRIKE THE ARC, AND THAT ALLOWS YOU TO GET THE TORCH INTO THE PERFECT POSITION BEFORE YOU START WELDING. THE BEST ADVICE I CAN GIVE YOU WHEN SHOPPING FOR AHELMET IS GET THE BEST HELMET THAT YOU CAN AFFORD. THE MORE MONEY THAT YOU SPEND USUALLY MEANS THE VIEWING AREA IS GONNA BECOME LARGER. HIGH QUALITY PROFESSIONAL HELMET LIKE THIS HAS A LARGE VIEWING AREA THAT JUST GIVES YOU A GOOD OVERALL VIEW OF THE AREA THAT YOU'RE WELDING. NOW RECENTLY MILLER'S COME OUT WITH A NEW ACCESSORY FOR THEIR WELDING HELMET LINE, AND I THINK IT'S GREAT. IT'S CALLED THE COOL BAND WELDING HELMET COOLER. IT REPLACES THE HEAD GEAR IN THE WELDING HELMET WITH THIS SMALL ELECTRIC VAN THAT WILL CIRCULATE CLEAN, FRESH AIR FROM THE BACK OF THE HELMET DOWN TO THE FRONT. NOW THIS WILL PREVENT WELDING SMOKE AND GAS FROM BUILDING UP INSIDE THE HELMET, AND IT WILL ALSO KEEP YOU COOL WHEN YOU'RE WELDING ON A HOT DAY. IT'S ALWAYS A GOOD IDEA TO KEEP A WELDING CAP HANDY. SO IF YOU HAVE TO DO ANY OVERHEAD WELDING, THE TOP OF YOUR HEAD WILL BE PROTECTED. I LIKE TO KEEP A TUBE OF WELDING PASTE, OFTEN REFERRED TO AS TIP DIP IN THE SHOP AS WELL.IF I'M GOING TO BE WELDING A LOT ON DIRTY MATERIAL, I'LL DIP THE TIP TO PREVENT AN EXCESSIVE SLAG BUILD UP FROM HAPPENING. GRAB YOURSELF A ROLL OF SPARK PAPER FROMTHE WELDING SUPPLY STORE AS WELL. THIS LOW TACK PAPER WILL PREVENT WELDING SPARKS FROM DAMAGING GLASS OR OTHER COMPONENTS THAT YOU NEED TO PROTECT WHILE WELDING AROUND THEM. DIFFERENT SIZED NOZZLES FOR THE WELDER COME IN HANDY TOO. LARGER ONES PRODUCE A LARGER SHIELDING GAS CLOUD TO PROTECT THE PUDDLE. BUT THE SMALLER NOZZLE WILL ALLOW YOU TO GET THE TORCH INTO TIGHTER AREAS. THIS IS ESPECIALLY IMPORTANT WHEN YOU'RE DOING A LOT OF TUBE WORK. NEXT YOU WANT TO HAVE A GOOD LOOK AT WHERE YOU'RE GONNA PERFORM MOST OF YOUR WELDING.YOU WANT TO HAVE A GOOD WELDING BENCH. NOW IT DOESN'T HAVE TO BE 10 FEET LONG LIKE THIS ONE IS. IT CAN BE A LOT SMALLER, AND YOU CAN EVEN WELD SOME CASTORS UNDERNEATH IT TO MAKE IT MOBILE IN A SMALL SHOP SPACE. BUT YOU WANT TO MAKE SURE THAT THE TOP OF THE BENCHIS BARE STEEL, NO PAINT OR POWDER COAT. THAT WAY YOU CAN SIMPLE GROUND THE WELDER TO THE BENCH, AND WHAT YOU'RE WORKING ON WILL BE GROUNDED THROUGH THE TOP OF THE BENCH. NOW THIS IS A GREAT INTRODUCTORY FABRICATION PROJECT BECAUSE YOU'RE GONNA HAVE A BUNCH OF DIFFERENT TYPES OF MATERIAL AND MANY DIFFERENT TYPES OF WELDING JOINTS. BUT WHEN YOU'RE READY TO STEP UP TO THE NEXT LEVEL, IT'S TIME TO GET OFF THE BENCH AND ONTO A TABLE. HAVING A TRUE SETUP TABLE LIKE THIS ONE FROM STRONG HAND TOOLS, WILL HELP YOU PRODUCE QUALITY FINISHED PRODUCTS. THE CLAMP SYSTEM WILL HOLD THE MATERIAL STABLE DURING THE WELDING AND COOLING CYCLE OF THEFABRICATION PROCESS.UP NEXT, THREE DAYS OF INTENSE RALLY TRAINING AT THE FIRM.EVEN THOUGH WE'VE FINISHED UP A PILE OF RIGS THIS YEAR, THERE'S STILL SOME IN THE SHOP THAT NEED OUR ATTENTION. PROJECT HOCUS FOCUS IS ONE OF THEM. YEAH, THE CAGE IS IN, SEATS ARE IN, WE'RE EVEN SITTING ON OUR RACE TIRES. THIS CAR IS READY TO COMPETE IN ITS FIRST RALLY RACE, OR SO I THOUGHT UNTIL WE HEADED DOWN TOTHE FIRM FOR A COUPLE DAYS OF RALLY TRAINING.SQUISH BRAKES, NOW LOOK FOR THE APEX, LOOK FOR IT, NO, TOO EARLY, TOO EARLY, NOW IT'S PUSHED YOU OUT TO THE GREEN.I HEAR YOU, OKAY, YES.I KNOW YOU WANT TO GET TO THE DIRT EARLY BUT WE'RE NOT DOING IT HERE, OKAY?WE SPENT THREE DAYS AT THE FIRM LEARNING THE INS AND OUTS OF RALLY RACING IN MANY DIFFERENT TYPES OF CARS. FROM TWO WHEEL DRIVE STOCKERS ALL THE WAY UP TO FULLY UNRESTRICTED STI RALLY RACING MACHINES. MY INSTRUCTOR HAD SPENT YEARS RACING A FOCUS. AND AFTER DRIVING HIS PERSONAL ONE FOR A COUPLE OF LAPS, I HAD A LIST OF CHANGES I WANTED TO MAKE TO THE XOR RALLY RACER. SO OUR LITTLE FORD FOCUS IS GOING BACK UNDERNEATH THE KNIFE. I'M GONNA TAKE YOU GUYS STEP BY STEP THROUGH THE PROCESS OF CONVERTING THIS AUTOMATIC FRONT WHEEL DRIVE CAR TO A MANUAL TRANSMISSION. THEN I'LL INSTALL A HYDRAULIC HAND BRAKE AND WE'LL BE READY TO RACE.NOW THERE IS NO QUESTION THAT THIS HAS TO BE ONE OF THE COOLEST JOBS IN THE WORLD. I GET TO BUILD A BUNCH OF DIFFERENT RIGS AND JUST ATTACK THE DIRT AS MANY TIMES AS WE CAN, ALL IN THE NAME OF FUN. BUT THIS YEAR WE BUILT THIS JEEP CHEROKEE. NOT FOR FUN, FOR A VERY SPECIAL CAUSE. WE PUT IT TOGETHER FOR ERIC, A SOLDIER WHO DESERVED A HARDCORE RIDE. ERIC GODFREY DROPPED HIS JEEP XJ OFF AT AN OFF ROAD SHOP BEFORE HE DEPLOYED OVERSEAS. ALL HE WANTED WAS A SET OF ONE TON AXLES UNDERNEATH IT. WHEN HE GOT BACK, WHAT HE GOT WAS A MESS. XTREME OFF ROAD WAS NOT GONNA LET THAT STAND.PILES OF VOLUNTEERS POURED INTO THE SHOP, GUTTING THE XJ OF ALL ITS STOCK SUSPENSION IN FAVOR OF A CUSTOM FOUR LINK FRONT AND REAR. SOLDIERS INVADED AS WELL TO INSTALL NEW BUMPERS,A WINCH, COLD AIR KIT, AND BUILT SOME CUSTOM BEADLOCKS. COIL OVER HOOPS, 12 INCH TRAVEL SHOCKS, A NEW TRANSFER CASE, AND CUSTOM TUBE WORK, FULLY FABRICATED NINE INCH AXLES WITH NEW GEARS AND LOCKERS, ALUMINUM SUSPENSION LINKS, ANDERIK'S XJ WAS READY FOR HIM. HE HAD THE RIG HE ALWAYS WANTED.THIS TIME BUILT RIGHT!THIS REALLY IS POINT AND SHOOT, MAN. THAT WAS EFFORTLESS!YES!THIS THING IS KILLER. MY OLD JEEP WOULD HAVE NEVER MADE IT OVER THAT, EVER. THEY REALLY HAVE MY DEEPEST GRATITUDE. I NEVER EXPECTED THAT THAT MANY PEOPLE WOULD STEP UP AND HELP OUT, AND IT REALLY BLOWS MY MIND. I HOPE ONE DAY I CAN FIND A WAY TO PAY THEM FOR IT.NOW WE HAVE A FEW PROJECTS STILL KICKING AROUND THE XTREME OFF ROAD SHOP. SO STICK AROUND, YOU'RE GONNA GET TO SEE THIS ROCK BOUNCER FINISHED UP, TAKEN OUT TO KILL A COUPLE OF HILLS. PLUS I'VE GOT A FEW OTHER PROJECTIDEAS UP MY SLEEVE.