4x4 Off-Road UTV Build Ep.27 - Welding Differential, Changing Clutch, Test Drive

Welding differential in FWD gearbox, replacing clutch and test driving in mud.

This is part of a series of a four wheel drive utility vehicle build to lessen the work load on my trusty 2002 Honda Foreman Rubicon TRX500FA. This partially answers the question "Why?" but for those who want to ask "why don't you just buy a side-by-side instead of building one?" I just want to say - I'm not made of money. Side-by-sides are ridiculously expensive, even the car I drive around daily is worth less (not worthless though!), hell, it is even worth less than my 2002 Honda ATV.

"How much HP will it have?" - the 1.4 litre FWD petrol engine I'm planning on using has 55 kw and this will not change, but the torque will be tripled via the BMW differentials I'm using to transfer power to front and rear axles.

"It will be too heavy!" - this project just like the firewood processor project does not have to float. And a heavier vehicle will handle better anyway when hauling heavy loads.

Stay tuned for future episodes! Thanks for watching!

My other videos: seslow.info

Pomade - Silent Partner (SEslow Audio Library)

Welding equipment borrowed from Spetselektroodi AS, Estonia:
Fronius TransSteel 2700 welder
Optrel Crystal 2.0 Welding Helmet
Hypertherm Powermax 45 XP plasma cutter

Ladda ner



  • More fabrication videos on seslow.infovideos

    Donn DIYDonn DIYMånad sedan
    • #27

      [MÉHÉSZ] [MÉZESÁrpádZsigmond][MÉHÉSZ] [MÉZESÁrpádZsigmond]Månad sedan
    • why that motor on your left does not bother you ??!! :)) It has to be on your right !!

      x111x111Månad sedan
    • Can't remember if you have built in a handbrake,must rewatch for this but maybe consider a (old) Landrover style one? One single drum on the rear driveshaft.

      Pieter VercauterenPieter VercauterenMånad sedan
  • LOV IT !!

    Weld ONWeld ON6 timmar sedan
  • Wow nice assemble

    Noel TorremoroNoel Torremoro6 dagar sedan
  • 💖

    EBAA T.I.H.CEBAA T.I.H.C10 dagar sedan
  • put a metal cable tie around your CV boots or at least a thick plastic one.,

    MrBiddoMrBiddo10 dagar sedan
  • This channel is my favorit watching 👍

    osvaldo camoesosvaldo camoes14 dagar sedan
    • Thanks man!

      Donn DIYDonn DIY13 dagar sedan
  • Great job, are you done or are you going to do fairing and put on a windshield?

    Emmanuel DEmmanuel D14 dagar sedan
    • Not done, it needs firewall, hood, roof, skid plates, paint etc. 😉

      Donn DIYDonn DIY13 dagar sedan
  • Привет! Давно смотрю твои видео, очень круто! молодец! У меня вопрос: где вы берете деньги? Ведь на все эти материаллы нужны средства, и немалые. У нас в России если подобным заниматься нужно очень много работать чтобы были деньги. Но если очень много работать, то на остальное уже не хватит ни сил ни времени. Чем вы зарабатываете? Мечтаю о небольшом участке земли, где-нибудь подальше от мегаполиса, где можно будет заниматься любимым делом и никто рядом мешать на будет, такие как наши соседи

    Федя БаобабовФедя Баобабов14 dagar sedan
  • Torsen diffs would be way overkill for this build, but you've got to admit: They would be awesome. Very nice build btw! I like how you just go about "eyeballing" stuff, and it always comes out just right!

    Vegard CVegard C16 dagar sedan
    • Cheers man!

      Donn DIYDonn DIY15 dagar sedan
  • The USA seal teams have a diesel powered version of this over built unit, it holds 6 men and their equipment. The Israelis are selling a civilian version with diesel. It is heavy duty like the one you are building. I think the loaded unit I saw at a car show was selling for about $ 30,000 USD. It had a top speed of about 50 miles per hour.

    tim mayertim mayer16 dagar sedan
  • How about powder coating?

    Minh VuMinh Vu16 dagar sedan
  • 8:26 firewood totes in the background - please show how you made them

    Jason WierengaJason Wierenga17 dagar sedan
    • Yes, homemade firewood totes/baskets. I'll think about making a video of it. 🙂

      Donn DIYDonn DIY17 dagar sedan
  • mis seisma seal mudas ei jäänud? :D

    TaaviDaTaaviDa18 dagar sedan
  • You can ask, where is the offroad?  You can ask, where is the offroad?🤷‍♂️

    Baba YgaBaba Yga18 dagar sedan
  • I have been following your all fabrication work , you have good hand ✋ I like the work👍

    Moselo mikaMoselo mika19 dagar sedan
    • Thank you!

      Donn DIYDonn DIY18 dagar sedan
  • Бедный ( не может найти бездорожье, привезите его в Россию

    Tum GoTum Go20 dagar sedan
  • Prouder and prouder!

    Rancillin MontgomeryRancillin Montgomery20 dagar sedan
  • One seat?

    John ZufallJohn Zufall21 dag sedan
  • How much cnc Plasma Cutter paid

    Mikko mäkeläMikko mäkelä22 dagar sedan
  • keep getting in that mud puddle and you will get a better coaster :D

    buder5buder524 dagar sedan
  • Kuule, peaaegu poolteist nädalat ilma videota? Kuna uus video?

    Erik KersnaErik Kersna24 dagar sedan
  • tõsine sõiduk igaks olukorraks nii suvel kui talvel

    Marek KüngasMarek Küngas25 dagar sedan
    • 🤘 Maainimesele abivahendiks.

      Donn DIYDonn DIY25 dagar sedan
  • 12:53 could be a spongebob time card lol

    DoctorWhoRoblox1935DoctorWhoRoblox193526 dagar sedan
  • Honestly best bang for your buck is getting a pair of torsen limited slip diffs. I’m almost positive bmw used them in one of the z3 models. They are great in every condition and won’t cause undue damage to turf or the drive terrain on hard surfaces

    shawn danahershawn danaher26 dagar sedan
  • Coool

    Abbas MoezziAbbas Moezzi27 dagar sedan
  • What country/next big city is that youre living?

    TheFastStangTheFastStang27 dagar sedan
  • This is a well built UTV. in the future you may want to weld the rear differential to be on the safe side. Again a very nice well built UTV.

    Eddie PattersonEddie Patterson28 dagar sedan
  • Ilus vaadata sellist tööd! Nii mõnigi sõber-tuttav tunnustab ka.

    raiko1981raiko198129 dagar sedan
    • Tänud!

      Donn DIYDonn DIY26 dagar sedan
  • Love your stuff man you are a genius!

    mattmax85mattmax8529 dagar sedan
  • Those alignment tools are only a couple dollars was there a reason you had to make one, don't get me wrong if you made it just to make it and have a better one than you can buy I'm all for it I'm just curious

    tim wegmantim wegman29 dagar sedan
  • Great stuff Donn, keep on keeping on 💪🏻u rock, n inspire me brotherman

    jrbob37jrbob37Månad sedan
  • Please move your content to Rumble I am deleting my SEslow account due to SEslow silencing those who do not support leftist, anarchists’ and Biden voters. Please put your great channel on Rumble where the 1st Amendment is honoured and I can still watch your excellent content.

    DavidDavidMånad sedan
  • Welded diff rocks, open diff sucks on terrain

    automoto95automoto95Månad sedan
  • Amazing... so much that I don't have words for this. Cool idea and the final effect! :) Cheers.

    CJWarlockCJWarlockMånad sedan
  • Собери уже РУССКОГО ШЕРПА И МОЗГИ НЕ Е;;;И!!!

  • В настоящее болото загони свовой джип

  • Show de bola

    PericlesPericlesMånad sedan
  • It might just be me but does the suspension move?

    Pork ChopPork ChopMånad sedan
  • Beautiful Job, Donn!! Well Donn..I mean Well Done!! ;-)

    jlucasoundjlucasoundMånad sedan
  • That thing is a beast! 👍🏻

    PAfarmboyPAfarmboyMånad sedan
  • I'm a bit late to the party this week! Great stuff Donn. Are you going to make a cover for the instrument cluster? It looks vulnerable to the elements! Love ya work. Cheers from Sydney Australia 🇦🇺🦘🐨🇦🇺

    paul martinpaul martinMånad sedan
  • Why don't you make the rear wheels turn also?? It would be great to see that from you!!

    ORESORESMånad sedan
  • Today is such a big payoff for all the hard work.....you looked like you were enjoying it.....bravo.....after you finish it I would love to know a total weight....it is so well built and heavy duty, but I'm curious how much weight it actually added I'm guessing about 1400 lbs

    Fabrication NationFabrication NationMånad sedan
  • Your going to destroy the field just trying to make a mudhole big enough to stop it......love it

    Fabrication NationFabrication NationMånad sedan
  • COOL RIG!!! Just one question... why engine on Left side and not on the Right side of the vehicle?

    JTLJTLMånad sedan
  • Какие-то совсем детские препятствия для такой крутой машинки, она явно может намного больше.

    Андрей ШевченкоАндрей ШевченкоMånad sedan
  • You spoke of welding the front and rear differentials as well as the center I believe? I would be tempted to do the rear first then a bit of a "torture test". Leaving the front open _should_ help with steering at slow speed. If you still need to, you can always weld the front diff later after all! Definitely looking forward to your PTO driven trailer at some time in the future.

    Michigan EngineerMichigan EngineerMånad sedan
  • I wouldn't weld the axle differentials as it will cause massive understeer by not allowing the tires to travel at different speeds while turning. Maybe use limited slip differential or possibly a selectable locker. Or you could possibly modify the differentials and make them locking. I learned this by welding the diffs on my 68 Ford mud bogger. My solution is to drive around with the driver's side lockout in free and locking it in when I need more traction.

    David GreenDavid GreenMånad sedan
  • I am really happy with you…you are the best youtuber…this is 4x4???

    Next Level GarageNext Level GarageMånad sedan
  • Just so you know, you didn't need subtitles - your english is very good. Hello from Australia

    SalSalMånad sedan
  • Goes well by the looks, now you'll probably have to dismantle it to get it painted.

    Douga57Douga57Månad sedan
  • Next time on Donn diy i build a fusion powered tank with rail gun and PDC.

    Rickard nilssonRickard nilssonMånad sedan
  • Well done, my friend!! Five giant stars for you! Art

    Art SzaboArt SzaboMånad sedan
  • It’s cool and all but not sure why one would build a single seater heavy machine with virtually no suspension like that when there are plenty of side by sides with better suspension, lighter, set up right out of the box.

    Dean VignaDean VignaMånad sedan
    • It's a low geared tractor built for working and emphasis on the word "utility" in the UTV, not a speedy jumping buggy.

      Donn DIYDonn DIYMånad sedan
  • Who’s the guy that engineered this 😂😂

    Bryan PyneBryan PyneMånad sedan
  • You made it great! But the next could be a solid axles project?

    As it Should BeAs it Should BeMånad sedan
  • I almost sure.. i've seen him smiling 😁

    As it Should BeAs it Should BeMånad sedan
  • Склад ума!!! Very good 💪!!!

    ФЕРМЕР161ФЕРМЕР161Månad sedan
    • Thank you! Spasibo!

      Donn DIYDonn DIYMånad sedan
  • One of the best homemade projects on you tube.

    Alex AltrichterAlex AltrichterMånad sedan
    • Cheers man!

      Donn DIYDonn DIYMånad sedan
  • I see you got the idea of a PTO from my suggestion to remake the ATV mower

    DoctorWhoRoblox1935DoctorWhoRoblox1935Månad sedan
  • Awesome job !.. We need you for the Zombie apocolapse..

    DadwithallthecoolDadwithallthecoolMånad sedan
  • I always thought that US Army mules used back in the 60s would be a simple vehicle for gathering and hauling firewood out of the woods. That is a very useful and resilient Ute, you've built. Great job. Regards, Solomon

    Life After WorkLife After WorkMånad sedan
    • 💪👍

      Donn DIYDonn DIYMånad sedan
  • It seems to pretty well in the mud! I want to see how fast it can go!

    Aaron bambergAaron bambergMånad sedan
  • Pane vints ette

    Kristo krKristo krMånad sedan
  • Yeah, she's a climber. Niiiice, Donn. Can't wait to see how you make the trailer.

    camgreercamgreerMånad sedan
    • 🤘🤘

      Donn DIYDonn DIYMånad sedan
  • Kõik mis sa ehitad tuleb sul väga hästi välja.

    Jako ArrasJako ArrasMånad sedan
    • Suured tänud!

      Donn DIYDonn DIYMånad sedan
  • Какая природа! Дом у озера! Это просто мечта! Убраться из города, от его суеты и злобы! Автор просто красавчик с золотыми руками! Так держать!

    Андрей КаАндрей КаMånad sedan
  • No próximo vídeo é o n° 28

    Leonardo Batista RochaLeonardo Batista RochaMånad sedan
  • It would be great to have manual dif locks..😉 but - I know, for non-solid surfaces it doesn't matter. Respect, nice to see such of great job done.

    Martin N.Martin N.Månad sedan
  • Looks like Yamaha Rhino 700! Good job!

    angus johnsonangus johnsonMånad sedan
  • Love your work, but the adverts are starting to get out of control.

    ozdatmanozdatmanMånad sedan
  • ok I gata ask where did u get the rtv in a can?

    Laymon PhelpsLaymon PhelpsMånad sedan
  • Nice 👍

    James KilleenJames KilleenMånad sedan
  • Using the dif sideways to drive both the front and back wheels is so dumb that it's possibly the most brilliant thing I've heard in weeks. Also, while very immature, I have to ask to see how fast it goes :)

    Effortless WebEffortless WebMånad sedan
  • Get a job and have enough of his wife to sit on checkers.

    Дмитрий НовиковДмитрий НовиковMånad sedan
  • I learned a lot from watching your videos. My father and I have been working on my tracked vehicle together and its been a great time.

    Midwest Tempest ApocMidwest Tempest ApocMånad sedan
    • Very cool!

      Donn DIYDonn DIYMånad sedan
  • Congrats, have followed the build from the start!!!

    Honeycutt RacingHoneycutt RacingMånad sedan
    • Cheers!

      Donn DIYDonn DIYMånad sedan
  • Entry and exit angles are very good.

    TFTaussieTFTaussieMånad sedan
    • That's what I had in mind when designing the frame and stance.

      Donn DIYDonn DIYMånad sedan
  • Great work 👍. Well done 👏

    Gunnar ForsbergGunnar ForsbergMånad sedan
  • 👏👏👏👍👍👍

    Владимир БелоноговВладимир БелоноговMånad sedan
  • 👍👍👍

    Питерский ГаражПитерский ГаражMånad sedan
  • Hello, I have subscribed to your channel for more than a year and it would be good if you activated the French subtitles. keep it up

    jacques mesrinesjacques mesrinesMånad sedan
  • Wah mantep cah gone..👍😅

    H.I __ WOODH.I __ WOODMånad sedan
  • ta des gros testicules! lol jamais j'oserai ouvrir une boite. j'ai celle de mon jumper citroen qui est hs et je vais la changer complete. j'ai la 3 eme et la 5eme vitesse qui siffle. continue, tu fais du bon travail. j'ai envie de construire un buggy comme le tient, j'ai sur mon terrain un opel frontera comme donneur de pieces. je ferai ca quand j'aurai plus de temps, j'ai beaucoup de choses a faire et peu de temps pour les loisirs en plus de la santé qui est pas tres bonne. bon courage a toi.

    chris patchris patMånad sedan
  • This thing riding smoothly as hell! 👍🍻

    AFH ProjectsAFH ProjectsMånad sedan
    • Thanks buddy! 🍻

      Donn DIYDonn DIYMånad sedan
  • السيارة التي مرت أمامك انا كتت فيها

    الباشاالباشاMånad sedan
  • Looks like it is working really well. I was watching and thinking "he should weld the rear diff too, eh, I'm sure he is already thinking about that" 5 seconds later the words appear on screen lol. Did you make some kind of power take off on the front too? I don't remember that in the other videos but may have missed it. Did you have any problems at all yet? Seems like it has went very smoothly since you started driving it.

    blperocblperocMånad sedan
    • No problems so far surprisingly, works pretty well.

      Donn DIYDonn DIYMånad sedan
    • I wanted to make an engine driven PTO on the front but the room got tight and now I'm not so sure anymore. If I can fit a PTO clutch at the front then I'll build it. It would be very useful for different implements at the front.

      Donn DIYDonn DIYMånad sedan
  • My brain still gets confused when it hears french van but sees awesome UTV. 😆 You're doing an awesome job! Very impressive 👍

    Roger GustafssonRoger GustafssonMånad sedan
    • @Donn DIY I've had mostly french cars and I like them. Reliable and affordable to buy and maintain. My wife has a Citroën Cactus and myself a partner van. Love that van. So easy to work on and extremely practical!

      Roger GustafssonRoger GustafssonMånad sedan
    • Haha, yes, I don't care what People say, I personally like French cars and car parts. And they serve me well.

      Donn DIYDonn DIYMånad sedan
  • Сколько терпения, старания и упорства!!!

    Дмитрий РожновскийДмитрий РожновскийMånad sedan
  • Не перестаю восхищаться! Одна зима, .. и новое транспортное средство. Есть буксировочный крюк. Теперь будет на чем дрова возить в зимний период.

    Дмитрий РожновскийДмитрий РожновскийMånad sedan
  • I'm surprised that you didn't build a 3 point hitch for it lol excellent video your creativity is always wonderful to watch

    J OtooleJ OtooleMånad sedan
    • I can always build a 3 pt hitch for it later. After all, it is a tiny tractor. 😀

      Donn DIYDonn DIYMånad sedan
  • By seeing this I remember the vehicle used in video game " farcry 1 ". Awesome

    I'm what I'mI'm what I'mMånad sedan
  • Уже на третьей минуте поставил лайк. Ты гений!

    Дмитрий РожновскийДмитрий РожновскийMånad sedan
    • Spasibo!

      Donn DIYDonn DIYMånad sedan
  • That is a seriously capable off-roader, Donn! Well done!

    N1RKWN1RKWMånad sedan
    • Cheers man!

      Donn DIYDonn DIYMånad sedan
  • Covert it to 6x6 utv....

    Brian WindamBrian WindamMånad sedan
  • Covert it to 6x6 utv....

    Brian WindamBrian WindamMånad sedan
  • great job, i think you can have more traction if you turn the tires around

    duane gloverduane gloverMånad sedan
    • Yup, but depends mostly on the surface.

      Donn DIYDonn DIYMånad sedan
  • Usually, when the gearbox fits easyly, its because you forgot the push bearing

    Te lo explicoTe lo explicoMånad sedan
    • The thrust bearing is in there for sure. 🤘😁

      Donn DIYDonn DIYMånad sedan
  • Look at that climb angle! People pay a lot for vehicles that don’t come close.

    Matt FieldsMatt FieldsMånad sedan
  • Instead of sheet metal body panels, try using waterproof canvas. Like the stuff used for old military tents. It looks cool, it’s light weight and it’ll never rust! I imagine just regular canvas with a coat of Flex Seal/Plasti-Dip would work great too.

    Matt FieldsMatt FieldsMånad sedan
    • @Donn DIY well that works too!

      Matt FieldsMatt FieldsMånad sedan
    • I'll probably use some plastic.

      Donn DIYDonn DIYMånad sedan