Off-road vehicle enthusiast Ian Johnson works on everything from upgrading a daily driving Jeep, to building a custom tube chassis rock crawler; he also shows how to tackle automobile concerns from "bolt-ons" to full fabrication.
Ian doesn't like spending money on new trucks, so he just builds what he wants; today, he starts working on a custom frame to sit under a classic Jeepster Commando and outfits the suspension, along with getting new one-ton axles underneath.
The Jeepster project is back, and Ian wants to focus on some of the drivetrain components; he pulls out a 3.5-liter Ecoboost engine and a 6-R-80 transmission from a Ford Expedition to help the old Jeep drive like a more modern one.
Ian loves the old International Scout body, but doesn't like the chassis underneath; he finds the right donor Scout body and fits it on a Jeep JK frame, with some modifications.
The new Bronco Raptor is expensive, so Ian is going to build his own; he takes an '80s box-style Bronco and adds a wider fiberglass body kit front and rear to give this classic Bronco a modern Raptor look.
Braptor Part 2
S5 E7
The body of the Bronco/Raptor project has been mocked up, and today Ian builds a custom chassis to go underneath; this will not be a standard tube chassis; this will be a plate-style chassis with a twin I-beam setup.
Ian brings in a Silverado for bumper and suspension upgrades, showing the difference between a lift kit and a suspension kit; he cuts out the stock crossmembers, installs a drop bracket for the front differential, and bolts on new tires and wheels.
If it has wheels and goes off road, Ian Johnson will work on it. From upgrading daily drivers to building a custom tube-chassis rock crawler, he takes you along on a do-it-yourself ride that tackles any kind of job.
Bomber Fab Pt. 1
S4 E1
Ian turns a stack of tubes into a shorter trail chassis and adds new axles.
Bomber Fab Pt. 2
S4 E2
Ian adds a motor and transmission to the build before turning to the axles.
Military Jeep Chassis Swap
S4 E3
Ian brings in a 1968 M715 to make it more reliable.
Since a TJ can be had for under 10K, Ian shows how to buy a Jeep on a budget and outfit it with everything needed to hit the rocks and still have money left over.
Budget Build TJ Part 2
S4 E6
The Budget TJ gets some more parts, including suspension and bumpers.
Ian brings back the Suzuki Samurai, this time for an old-fashioned engine swap; he's going to take out the mechanical four-cylinder diesel VW engine and upgrade it with a common rail VW diesel.
Ian's LJ Buggy has seen plenty of rocks and off-road tracks, and he already knows how to improve the vehicle. He rebuilds a dash, adds headlights, and redoes the steering and exhaust.
The JK stretch project is back from the body shop and is ready for an all-new suspension and axles; Ian will get some Dana 60s under the rig with 40-inch tires and see how it performs by hitting some rock hills.
Ian wants his Nissan Titan to tow his new Tracker side by side, so he needs to outfit it for towing; he bolts some off-road parts onto the side by side.
The RamCharger is ready for the trail with a new engine and drivetrain, but it needs to be outfitted for overlanding, so Ian builds out the interior for camping, adds a solar panel roof rack and builds a custom front bumper.
Ian needs a new FourWheeler shop truck, but he doesn't just buy new trucks, he builds them; he'll tear down a two-door Dodge Dakota and turn it into a custom tools-carrying monster.
Ian gets invited to ride in the 2020 Ultimate Adventure, where he and a group of off-road enthusiasts drive thousands of miles on-road and off-road, hitting the back roads and trails of America from Montana to Wyoming.
Ian begins assembly of a custom LJ chassis and builds a full Jeep out of a pile of metal tubs before he adds front and rear axles with cut-to-length control arms, and finishes off the build with coil-over suspension.
Larger tires on an off-road rig usually mean broken axles; a 1989 Dodge Ram Charger is in the shop; Ian shows how to swap out a semi-float axle for the more desirable full-float axle.
Ian doesn't want to fix a beat-up Polaris XP 900. He wants to turn it into a completely different rig. He decides to stretch the side by side and add longer suspension for more travel, but that's just the beginning.
An '80s Ramcharger is back in the shop for an engine swap; the owner wants a gas-powered Hemi, so Ian swaps the old, tired engine for one from a local junkyard.
Ian moves weight around on a Samurai to get more squat in the rear end, shifting the radiator and fuel cell and changing the rear end suspension geometry to help this rig better handle the rocks.
Ian goes on an adventure with some of his buddies, hitting a few off-road parks nearby, making some roadside repairs, and ending the trip with some Tennessee whiskey.