Ep 39. Boon Duggy Dune Bug Surprise!

As the title suggests, this episode of Roadkill Garage season 4, "Boon Duggy Dune Bug Surprise!", features a unique build: a dune buggy that combines elements of the classic VW Beetle and a Jeep-style off-roader. The hosts, David Freiburger and Steve Dulcich, start by introducing the "Boon Duggy" project, which is a backyard creation from one of their friends. The vehicle was built using a shortened VW Beetle chassis, a homemade roll cage, and a body that resembles a Jeep CJ.

The hosts explain that the Boon Duggy was originally powered by a Volkswagen engine, but it was too underpowered for off-road use. To address this issue, they've decided to replace it with a more powerful engine - a 5.3-liter V8. Steve shows off the custom engine mount he's fabricated, which allows the V8 to bolt onto the Beetle's transaxle.

Once the engine is in place, the hosts move onto the suspension. They've decided to use Jeep YJ leaf springs, which will provide more travel and durability than the original VW suspension. To fit the springs, they need to modify the Boon Duggy's frame and install new shock mounts. Steve demonstrates how to use a plasma cutter to make precise cuts in the metal.

With the suspension sorted, the hosts move onto the brakes. They're upgrading the Boon Duggy with larger disc brakes from a Chevy truck, which will provide more stopping power off-road. David demonstrates how to install the new brakes and bleed the system.

Finally, it's time to take the Boon Duggy on a test drive. The hosts head to the desert to see how the modified dune buggy handles off-road terrain. The V8 engine roars to life and the Boon Duggy surges forward with surprising speed and power. As they drive over sand dunes and rocky terrain, the hosts note how well the new suspension and brakes perform. The Jeep-style body provides plenty of clearance and protection, making it a true off-road machine.

Overall, this episode of Roadkill Garage showcases the ingenuity and creativity of backyard builders. The hosts demonstrate how to take a classic VW Beetle and turn it into a one-of-a-kind off-road machine. With their expert fabrication skills and a few key modifications, the Boon Duggy is ready to take on any challenge.