Ep 12. Bill's 1,500-HP Diesel Buggy

Bill's 1,500-HP Diesel Buggy is the twelfth episode of the fifth season of the hit show Texas Metal. In this episode, the team takes on one of their most challenging builds yet, pushing the limits of horsepower and engineering to create a custom-built diesel buggy.

The episode starts with Bill Hinton, a devoted off-road enthusiast, approaching the team at Ekstensive Metal Works with a unique request - a diesel-powered buggy. The challenge, however, is in the sheer power requirements of such a vehicle. Bill wants at least 1,500 horsepower, which means that the team has to find a way to fit a massive diesel engine into a compact buggy design.

The team takes on the challenge, first selecting a Cummins engine with a powerful Holset turbocharger that can generate the desired horsepower. They then get to work making modifications to the engine, reworking the fuel system and installing heavy-duty pistons and rods to accommodate the intense pressure that the engine will generate.

But the real challenge comes in designing and building the buggy itself. The team has to create a frame that can withstand the immense power of the engine while still being compact enough to fit a four-seater buggy body. They also need to make sure that the suspension system can handle the vehicle's weight and power, while keeping the ride smooth and responsive on even the roughest off-road terrain.

To create the buggy frame, the team uses a combination of square tubing and round chrome-moly tubing for added strength. They then weld the frame together and install a custom roll cage for added safety. For the suspension system, they opt for a full air suspension, which can be raised or lowered depending on the terrain.

The team then turns their attention to the buggy body, creating a sleek design that balances both form and function. They install rugged off-road tires and custom-built beadlock wheels, as well as a powerful LED lighting system for enhanced visibility on night rides. The finishing touch is a custom paint job, featuring a bright orange and black color scheme that gives the buggy a bold and eye-catching look.

As the build comes together, the team faces a number of challenges, including a stubborn engine that refuses to cooperate. However, they persevere through the setbacks, determined to create a buggy that can meet Bill's high expectations. Finally, after weeks of hard work and long hours, the finished buggy is revealed.

Bill is ecstatic with the final product, taking the buggy out for a spin on a nearby off-road course. The team watches as he puts the vehicle through its paces, hitting high speeds and making challenging turns with ease. Overall, the episode showcases the creativity, skill, and dedication of the Ekstensive Metal Works team, as they push the boundaries of what's possible in off-road vehicle design and engineering.