Hey everybody, I build cars for off road events and cheap car road trips. I figured i should share some of the info that I have!

This build started with a 1992 Chevrolet Beretta 2.2L that i bought fort $190 and drove it 1hr home. It was in pretty awful condition.

The first steps were a complete tune up from top to bottom, and the engine checked out good on compression. I also removed the TCC lockup plug from the transmission to avoid future issues.

 

someone before us did some interesting work on the thermostat housing/ water outlet block. The bolts were stripped and help in by silicon, so i removed the block to repair it. You can see that I found some nasty stuff inside.... lots of JB weld. Coolant can get into the intake and exhaust system through this block when it is damaged from using tap water. I searched every junkyard around for a good housing, and finally got lucky with a replacement.

 

I replaced all kinds of gaskets and every fluid on the car as preventative work, because you never know how people maintained their vehicle.

The next step was to start making a way to lift this thing!! The front struts are a difficult job because they are directly attached to the steering system, where as most steering racks attach to the spindle/knuckle. I was stuck using the stock struts for time limits. I didnt have time to come up with a new strut/steering system.

The rear was alot easier. I used coil springs from a late 90's Cadillac coupe fwd v8, because they have the nearly the same measurements, but much higher progressive springs rate. The shocks I used were from a 2015 dodge charger or challenger. They more or less bolt in using a modified Corsica upper shock mount.

The rear springs had to be heated to get the proper height. I only heated a few coils until we had the proper rate and height. I also welded the top and bottom coils to the perches because we would be doing full extension off jumps

 

The engine mounts were all toast, and causing issues with sub frame clearance. I replaced them all, and got some wheel spacers to accommodate the new tires. We used 28.8inch maxxis mud tires, and still had to beat the floors in with a 8lb sledge hammer to clear under full steering lock.

Alot of the original electronics were not working, we we bypassed them instead of repairing them. Manual cooling fan controller, analog temp gauge, IAC bypass etc.

The outer door handles were broken and hard to find/ expensive, so i just ditched the doors and welded support bars instead. We also skinned the hood for looks.

A harbor freight winch was added with internal and external controls.

My partner made a nice roof rack, and we were more of less done!

I am sure i left out alot of info, so ask questions!

 

I spray painted red where we had to push the wheel wells/ floors in. I used a cut off wheel to cut all the supports and make 1inch wide strips 2-6 inches long in the metal that made it easier to moosh.

 

The trip for this was was a little over 500 miles around south/central texas. I posted day one's GPS coordinates for day one's event.