Max’s Roxor Build
- Thread starter Max A.
- Start date
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
Last week I pulled the old Roxor out for the first time in a while! I hate to even share the state of it. It’s been used and abused. A total of 16 rollover/side flops. 1400 of the roughest trail miles. I’ve even completely worn through the bottom of the front leaf spring u bolt plate from skidding across rocks on the trails. To the point where my leaf spring detached from the axle and sent leafs flying. You certainly cant say it didn’t get wheeled!
The reason for pulling it out is because Diesel freak was having a charity ride down at windrock in TN and I wanted to make sure Climax was there to support. The only problem was there is no way I’m showing up with my Roxor is such a dilapidated state.
To add to that at some point I lent out the transfer case to someone who had broken theirs and they called me asking if I could help.
I do have a spare transfer case that had built by Torque King using new intervals that where all sent out to be cryo-treated for added strength. Between that and upgraded bearings through out it is probably one of the strongest Roxor transfer cases anywhere.
After I got it installed I realized I much have had it put back together without the detent pill in the shift rails. This is what you want of your set up for twin stick…. Which mine is not.
With 3 days till leaving for TN I had to come up with something.
I ended up being able to use the original shift bracket and shift lever. I had to grind the factory lever pivot down slightly to allow me to slip in a new 1/4 inch plate I cut on the plasma table to act as the H/N/L lever in the bracket.
I then took a piece of 1/2 inch rod and bent a shift lever and a linkage piece to connect to the H/N/L shift rod. The factory lever was easily bent slightly to allow the factory linkage to bolt right up to the 2/4 selector rod.
Everything I’ve used here can be purchased at tractor supply for about the same price as 2 large pizzas. The only thing missing is some customs shift knobs made on the lathe. (Which I still haven’t done yet)
Sent from my iPhone using Tapatalk
The reason for pulling it out is because Diesel freak was having a charity ride down at windrock in TN and I wanted to make sure Climax was there to support. The only problem was there is no way I’m showing up with my Roxor is such a dilapidated state.
To add to that at some point I lent out the transfer case to someone who had broken theirs and they called me asking if I could help.
I do have a spare transfer case that had built by Torque King using new intervals that where all sent out to be cryo-treated for added strength. Between that and upgraded bearings through out it is probably one of the strongest Roxor transfer cases anywhere.
After I got it installed I realized I much have had it put back together without the detent pill in the shift rails. This is what you want of your set up for twin stick…. Which mine is not.
With 3 days till leaving for TN I had to come up with something.
I ended up being able to use the original shift bracket and shift lever. I had to grind the factory lever pivot down slightly to allow me to slip in a new 1/4 inch plate I cut on the plasma table to act as the H/N/L lever in the bracket.
I then took a piece of 1/2 inch rod and bent a shift lever and a linkage piece to connect to the H/N/L shift rod. The factory lever was easily bent slightly to allow the factory linkage to bolt right up to the 2/4 selector rod.
Everything I’ve used here can be purchased at tractor supply for about the same price as 2 large pizzas. The only thing missing is some customs shift knobs made on the lathe. (Which I still haven’t done yet)
Sent from my iPhone using Tapatalk
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
Next was fixing the appearance. I have build a pretty good relationship with a local powder coater so I dropped of all of the aluminum armor I had On The Rox make for me a while back. They did an amazing job getting everything turned round next day!!!! Blasted and coated insanely fast.
As you can see I borrowed a set of spare wheels and tires from the race car. Forged 17x9 Raceline beadlocks and 37/13.5r17 Maxxis Trepadors. A big step up from the 35s I’ve been running.
Next I worked on graphics to match the new Climax styling. I then sent everything out to the graphics guy that has helped me with the Roxor in the past. He still had the side templates and was easily able to print it out pre cut and ready to stick on.
I installed a 36 inch Corbeau rear seat. With car seat harness mounting points for the munchkin to be as safe as possible on the trails.
Lastly rattled canned all of the sliders bumpers and skid plates. They were all in much need of some TLC! Look at the battle scars on this skid plate.
It all came together in just a few days to make an old Roxor look new/ish again!
Then it was off to Windrock!
Sent from my iPhone using Tapatalk
As you can see I borrowed a set of spare wheels and tires from the race car. Forged 17x9 Raceline beadlocks and 37/13.5r17 Maxxis Trepadors. A big step up from the 35s I’ve been running.
Next I worked on graphics to match the new Climax styling. I then sent everything out to the graphics guy that has helped me with the Roxor in the past. He still had the side templates and was easily able to print it out pre cut and ready to stick on.
I installed a 36 inch Corbeau rear seat. With car seat harness mounting points for the munchkin to be as safe as possible on the trails.
Lastly rattled canned all of the sliders bumpers and skid plates. They were all in much need of some TLC! Look at the battle scars on this skid plate.
It all came together in just a few days to make an old Roxor look new/ish again!
Then it was off to Windrock!
Sent from my iPhone using Tapatalk
txroadkill
Well-known member
- Joined
- Oct 28, 2018
- Messages
- 1,305
- Points
- 113
- Location
- Texas
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2498
happy to see all the Roxor updates shared over here. Been watching them on Facebook. The refresh turned out great. So about them travel plans, we gonna have a Roxor run out west sometime?
- Joined
- Jun 13, 2019
- Messages
- 435
- Points
- 63
- Location
- Prescott, AZ, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 02776
WOW!!!! That's Outstanding!!!
Noticed something missing. Clock velcro to the dash. If I was in the area I'd be happy to help you with that. 🤣🤣🤣
Glad you're back.
Noticed something missing. Clock velcro to the dash. If I was in the area I'd be happy to help you with that. 🤣🤣🤣
Glad you're back.
- Joined
- Mar 10, 2019
- Messages
- 2,291
- Points
- 113
- Location
- Hurricane, WV, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2507
Well done Max.
- Joined
- Mar 10, 2019
- Messages
- 2,291
- Points
- 113
- Location
- Hurricane, WV, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2507
Are you doing the coal crawl this year?
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
Great to hear from you guys. some of you have been around since the beginning!
Roxsauras... My apologizes for not calling you back the other day. I honestly meant to, i guess it slipped my mind. Im not sure if there will be a coal crawl this year. It started off strong and numbers have been dwindling. I think it's mostly because Wade has been hosting 2 different Roxor get togethers the last couple years.
I would love to do a Moab get together at some point maybe 2026?
Roxsauras... My apologizes for not calling you back the other day. I honestly meant to, i guess it slipped my mind. Im not sure if there will be a coal crawl this year. It started off strong and numbers have been dwindling. I think it's mostly because Wade has been hosting 2 different Roxor get togethers the last couple years.
I would love to do a Moab get together at some point maybe 2026?
I am glad to see that you are back also. I had just mentioned in the last couple weeks on someones post that I wish you were back working with Roxors again. I had also been thinking about starting over on your build post and going through it all again.
I have been seriously considering the Twin Stick Conversion. A buddy of mine has a few old CJ's rounded up. He says that he can spare the Twin Stick parts off of one. I wish that Mahindra would use the Twin Stick set up on factory Roxors. It would sure make using Low Range much handier. With how I use my 2024 Roxor I would use 2 WD Low Range a lot just poking around on trails. Especially some rough trails that do not require Four Wheel Drive, just driving slow.
Condensing your build post would take some work as long as it is. If you just condensed it to the Build Information it would shorten it a lot. I have read it all over the years, just never all at one time.
My build is tame compared to yours. Mainly I am just making my Roxor more use-able, with no plans for Rock Crawling ever. Bumpers, Tires, Winch, Bow Shackles, Hooks on the Frame Horns, Reese Hitch, Roof, Windshield, The Rear Bulkhead has been very handy for Hangers, mounting a Gun Rack, D's to secure my Sprayer Tank, etc. Still in the works are Doors and a Heater. My latest Tame Mod was getting rid of the under seat storage locks.
I really like reading about your build, but my idea of a good Rock Crawling Adventure would be driving to Flat Nasty with a Cooler of Peak Tea, and Lawn Chairs to watch other people tear their stuff up. I plan for Rocky to be my last Side By Side, UNLESS they make a new Roxor with a Twin Stick, A Mechanical Speedometer that you can see, and Conventional Gage's that are use-able. Then I would probably trade mine in, and start over on perfection.
I am now posting under Bob R1, I was originally just Bob R starting around 2019. I had to set up a new account over the years.
Glad You Are Back.
Bob R
I have been seriously considering the Twin Stick Conversion. A buddy of mine has a few old CJ's rounded up. He says that he can spare the Twin Stick parts off of one. I wish that Mahindra would use the Twin Stick set up on factory Roxors. It would sure make using Low Range much handier. With how I use my 2024 Roxor I would use 2 WD Low Range a lot just poking around on trails. Especially some rough trails that do not require Four Wheel Drive, just driving slow.
Condensing your build post would take some work as long as it is. If you just condensed it to the Build Information it would shorten it a lot. I have read it all over the years, just never all at one time.
My build is tame compared to yours. Mainly I am just making my Roxor more use-able, with no plans for Rock Crawling ever. Bumpers, Tires, Winch, Bow Shackles, Hooks on the Frame Horns, Reese Hitch, Roof, Windshield, The Rear Bulkhead has been very handy for Hangers, mounting a Gun Rack, D's to secure my Sprayer Tank, etc. Still in the works are Doors and a Heater. My latest Tame Mod was getting rid of the under seat storage locks.
I really like reading about your build, but my idea of a good Rock Crawling Adventure would be driving to Flat Nasty with a Cooler of Peak Tea, and Lawn Chairs to watch other people tear their stuff up. I plan for Rocky to be my last Side By Side, UNLESS they make a new Roxor with a Twin Stick, A Mechanical Speedometer that you can see, and Conventional Gage's that are use-able. Then I would probably trade mine in, and start over on perfection.
I am now posting under Bob R1, I was originally just Bob R starting around 2019. I had to set up a new account over the years.
Glad You Are Back.
Bob R
Last edited:
- Joined
- Mar 10, 2019
- Messages
- 2,291
- Points
- 113
- Location
- Hurricane, WV, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2507
I plan on going back to Moab again every year. I'm definitely in. If you do a coal crawl let me know and I'll help spread the good word, and attend.
Do you still have the FC150?
txroadkill
Well-known member
- Joined
- Oct 28, 2018
- Messages
- 1,305
- Points
- 113
- Location
- Texas
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2498
I’m definitely down for a Moab run.
- Joined
- Mar 10, 2019
- Messages
- 2,291
- Points
- 113
- Location
- Hurricane, WV, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2507
Well anyone else thinking the same as me? The jeeps have their week ( don't get me wrong I love my CJ), why don't we start a Moab madness for Roxors? I'm gonna reach out to MANA tomorrow.
txroadkill
Well-known member
- Joined
- Oct 28, 2018
- Messages
- 1,305
- Points
- 113
- Location
- Texas
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2498
They have a full size invasion. Toyota or Nissan or maybe both have events there too. back in my Jeep days I went out there for a yearly forum run. The __ annual jeeps unlimited Moab run. We had to do it on the down low to avoid permit issues. It was an unorganized ride “Officially“. We picked a week usually in May. Sometimes June. And we all met there. No official trail itinerary or registration. Just show up and we’ll decide what trails that morning. Every morning meet at city market and break off into small group. One night we’d have a potluck supper at lions park. Can’t see why we couldn’t do the same.
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
30 Roxors gathered and we raised over $12,000 dollars for a fellow Roxor owner who is battling breast cancer. The Roxor community is amazing. The trails were great, not too muddy, everyone got a bit of a challenge if they wanted to. HardCabs provided 2 great meals. And of course it was great catching up with everyone! I think I counted 12 long travel kits in the bunch! So cool seeking my parts in action! Looking forward to the next gathering.
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
- Joined
- Mar 10, 2019
- Messages
- 2,291
- Points
- 113
- Location
- Hurricane, WV, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 2507
Looks like it was an awesome time.
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
How about some 40s!
I don't plan to take it wheeling with 40s but I was pretty surprised at how well they fit. Zero rubbing up, front steering lock to lock, but as you can see the tires do stuff into the rear bumper.
I don't plan to take it wheeling with 40s but I was pretty surprised at how well they fit. Zero rubbing up, front steering lock to lock, but as you can see the tires do stuff into the rear bumper.
Last edited:
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
Get your popcorn ready!
Let’s get back to some actual building!
I have a few weekends coming up with very little planned so now is a good time to take on the major renovation I’ve been planning on for 2 plus years.
Remember the red Roxor I had for a few months? The one I was going to use the chassis for the FC body swap and then the red body was going to be used to mak a 4 door Roxor. Well I ended up selling that to Wade LaLone when life got a bit busy a few years back.
Now that things have settled down for a bit I’m back on the mission of making my 4 door wheeler a reality.
Yes I know Wade recently welded 2 Roxors together to make a ridiculously long Roxor limo (that I think is awesome!) but this one will be done diffrent. I still plan to wheel the absolute crap out of it so it will need to be a bit more functional for trail use.
Why because I refuse to play the duck game with a newer jeep
. But also we wheel as a family now and I gave up all of my storage to add a corbeau rear seat for my daughter.
I’d like to add the gear rack I built a while back behind the rear seats.
Let’s get this build started with stripping it down. And unfortunately ruining the brand new wrap.
Sent from my iPhone using Tapatalk
Let’s get back to some actual building!
I have a few weekends coming up with very little planned so now is a good time to take on the major renovation I’ve been planning on for 2 plus years.
Remember the red Roxor I had for a few months? The one I was going to use the chassis for the FC body swap and then the red body was going to be used to mak a 4 door Roxor. Well I ended up selling that to Wade LaLone when life got a bit busy a few years back.
Now that things have settled down for a bit I’m back on the mission of making my 4 door wheeler a reality.
Yes I know Wade recently welded 2 Roxors together to make a ridiculously long Roxor limo (that I think is awesome!) but this one will be done diffrent. I still plan to wheel the absolute crap out of it so it will need to be a bit more functional for trail use.
Why because I refuse to play the duck game with a newer jeep
. But also we wheel as a family now and I gave up all of my storage to add a corbeau rear seat for my daughter. I’d like to add the gear rack I built a while back behind the rear seats.
Let’s get this build started with stripping it down. And unfortunately ruining the brand new wrap.
Sent from my iPhone using Tapatalk
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
I started by drawing out the rough shape of the rear doors, minus 10 inches of length. I left the corners angular for now but I plan to give them some curve later. For now I just want to make it as easy as possible to build the new body panels and get doors drawn up for the plasma table.
Sent from my iPhone using Tapatalk
Sent from my iPhone using Tapatalk
Max A.
Well-known member
- Joined
- Nov 4, 2019
- Messages
- 629
- Points
- 93
- Location
- Baltimore, MD, USA
- Roxor Ownership
- Roxor Owner
- Roxor #
- 00168
After getting the door cuts made I got the Roxor in the air and started to disconnect all of the harness plugs. Brake lines and drive shaft. Then use a laser level to draw a line across the floor, about 1.5 inches in front of the rear floor seam. The plasma cutter made short work of slicing through the floor and bedliner.
Next was the frame. I chose to cut right in between the roll bar tie in and the spring hanger. The frame rails are parallel for about a foot in that area. That should make it easier to add 10 inches of box steel then fish plate over it for extra strength.
At this point I face palmed a bit…. Boy am I glad I added a flex section into the exhaust.
Sent from my iPhone using Tapatalk
Next was the frame. I chose to cut right in between the roll bar tie in and the spring hanger. The frame rails are parallel for about a foot in that area. That should make it easier to add 10 inches of box steel then fish plate over it for extra strength.
At this point I face palmed a bit…. Boy am I glad I added a flex section into the exhaust.
Sent from my iPhone using Tapatalk