BRODOZER

Monster Jam’s Latest Monster is Duramax Powered

In the Monster Jam world of Monster Trucks, big, loud, and blown methanol engines have ruled the roost for years, but there’s another force rising on the horizon. The BroDozer Monster Truck is the newest member of the Monster Jam family and since it was inspired by the original BroDozer that Dave Sparks (a.k.a. Heavy D from the Diesel Brothers TV show) and his crew built, it was appropriate that it would be powered by a diesel engine. The original BroDozer was a Ford truck with a Power Stroke diesel but the Monster Jam team turned to the crew at Wagler Competition Products to build a stout Duramax engine to power this monster.

Just moving a 13,000-pound truck with 66-inch-tall by 45-inch-wide BKT tires requires a ton of grunt, and putting a highly built Duramax engine into the chassis is just what the doctor ordered to help move this truck along. Feld Motor Sports VP of Operations, Bill Easterly, is a diesel guy at heart and knew that working with the right people, he could bring a diesel into the Monster Jam fold to compete on the big stage against the supercharged methanol-burning monster trucks. To bring it together he worked with the team at Sparks Motors including Diesel Dave and Dave “Heavy D” Sparks along with the teams at Wagler Competition Products and S&S Diesel Motorsport, who worked to develop and tune a Duramax engine combination that could keep up with the methanol-burning Monster Jam trucks without blacking out the stadium.

The Engine

After much design, testing, and evaluation, the engine team settled on a stock GM Duramax block that housed a Wagler Competition Products Race Series rotating assembly consisting of a Callies Ultra Billet crank shaft, WCP billet rods, and Ross pistons. The block is capped with a set of factory LBZ heads that the crew at Wagler ported and installed larger valves and PAC valve springs. A Wagler alternate-fire Street camshaft is used to actuate the valves through a set of WCP pushrods, while a WCP Street girdle and billet main caps work with ARP studs and fasteners to hold the package together from top to bottom.

Compression Duties

After trying a few combinations of forced induction, the team settled on a compound turbo arrangement using a Precision Turbo 6870 T4 divided high pressure stage turbo that’s perched upon a Wagler T4 divided Twisted Pedestal. A Precision 3×3.5 turbo draws in air from the atmosphere through a large K&N air filter element that’s shielded by an Outerwears cover. After the intake charge is compressed it’s channeled to a custom air-to-air intercooler that the WCP team fabricated in-house then down into the engine through a WCP Street intake manifold. On the exhaust side, custom tubular log-style headers were built to send the exhaust up to the 6870 with a pair of Precision PW46 wastegates to regulate pressure. Outlet from the 6870 is channeled to the 3×3.5 turbo then out and up through a small stack at the base of the rear edge of the cab when the body is installed.

Fueling

Of course, fuel requirements for the BroDozer would be high, so the team at S&S Diesel Motorsport built a pair of gear-driven 10mm CP3s that were installed in a billet WCP front cover. The high-pressure CP3s send the fuel to a set of S&S 200% over LBZ fuel injectors to deliver it into each cylinder. The S&S crew also handled the wire harnessing for the engine and configured and tuned the stand-alone Bosch Motorsport ECU that controls the Duramax. The package is said to deliver around 1,100 horsepower in its current trim and there’s more available when needed.

Transmission

Power from the monster Duramax is sent to a Coan Powerglide variant HD transmission that was specially built and tuned for the diesel monster truck application. It’s linked to the engine through a Coan torque converter and Browell bell housing. To get the power from the transmission to the axles, the BroDozer utilizes an SCS drop box transfer case. Custom axles get the power from the transfer case to the axles with shielded and strapped U-joints to prevent a broken shaft from flying into the stands. Pinion brakes are used to stop the truck on demand thanks to TBM Brakes F4 calipers and Revolution rotors.

Chassis & Suspension

The monster truck’s tube chassis isn’t only the safety cage for the driver. It’s also the support for the 4-link suspension as well as the engine, transmission, and bodywork. Large link arms keep the front and rear steering axles under the chassis as the truck twists, jumps, and bumps over and through obstacles in competition. Within the safety cage, the driver is cradled in an ISP full-containment racing seat and held securely in place with a set of Simpson harnesses. The hydraulic steering system uses two rams on each axle, with the front controlled by the steering wheel through an orbital valve while the rear steering is electronically controlled with a switch on a handle next to the wheel. The system is incredibly fast and responsive, allowing the driver to precisely drive the beast while doing incredible stunts like driving on two wheels and racing around a tight track with the 13,000-pound machine.

The Sky High Debut

In the BroDozer’s Monster Jam debut at the Nissan Stadium in Nashville, Tennessee, on June 23, 2018, it was a roaring success. The crowd loved seeing the truck at the pit party and was thrilled to see the diesel monster race around the stadium and fly through the air as Heavy D delivered some of the biggest jumps of the night. Despite putting up one of the quickest times in the practice session the day before the event, he stumbled in the racing on Saturday night losing in the first round to Brad Allen in Brutus. Sparks finished in 10th in the 2-Wheel Skills Challenge after delivering a great two-wheel bicycle, but faltered on his second trick with an attempted stoppie. Heavy D came to life in the freestyle round of competition, going out second. He laid down a great routine with high-flying jumps, miraculous saves, and a little diesel smoke to thrill the crowd. He finished freestyle with a score of 9.003 that stood as the high score for most of the night. With three trucks to go BroDozer was still in first place, but those three were monster truck legends Ryan Anderson, Adam Anderson, and Tom Meents, who took the top three spots and dropped Sparks to fourth place. But a fourth-place finish in both the truck and driver’s first Monster Jam competition is a great start to what we hope will be a long and happy diesel adventure that’ll likely continue to grow.

Moving a 13,000-pound truck with 66-inch-tall by 45-inch-wide BKT tires requires a ton of grunt.

Crew chief Daniel Crawford told us: “After the Nashville event, there were a few bugs to work out, but after those are resolved, the BroDozer Monster Jam truck is going to be a long-standing competitor in Monster Jam events.” Sparks added: “There’s still some lag… once the truck started to spool, the boost would jump from 12 lbs to 40+ lbs in a split second. It was like driving a rocket ship around that track.”

For more photos and details on the truck as well as additional on track action from BroDozer’s test session and Monster Jam debut, check out the December/January 2019 issue of our sister magazine Ultimate Diesel Builder’s Guide or online at DieselWorldMag.com. Until then, look for the truck to be attacking the course at a Monster Jam event near you—to see the schedule and even videos of the BroDozer in action with Sparks behind the wheel tune your browser to MonsterJam.com.

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FREQUENTLY ASKED QUESTIONS

 

What are the capabilities of modern monster truck engines?

Capabilities of Modern Monster Truck Engines

Modern monster truck engines are engineering marvels, designed to deliver immense power and withstand extreme conditions. Here are some of their key capabilities:

Impressive Dimensions and Weight

• Size: Approximately 10.5 feet tall, 12.5 feet wide, and 17 feet long.
• Weight: Around 12,000 pounds.

Extreme Power Output

• Horsepower: These engines can generate up to 1,500 horsepower, thanks to a blower system that forces air and fuel into the engine.
• Fuel Type: They run on methanol fuel, consuming up to three gallons per minute.

Advanced Suspension and Tire Design

• Suspension: Utilizes a four-link racing suspension with nitrogen-charged shocks, offering 30 inches of travel.
• Tires: Massive BKT tires that are 66 inches in diameter, 43 inches wide, and inflated to 16-20 psi, each weighing 645 pounds.

Reliability Over Raw Power

While engines are capable of producing substantial power, reliability is prioritized to ensure trucks consistently perform during shows. Instead of pushing engines to their absolute limits, the focus is on longevity and consistent performance.

Innovative Fluid Delivery Systems

• Oil Delivery: Unique challenges like standing on the nose or performing donuts require specialized oil pans with baffles and trap doors.
• Fluid Delivery Issues: These are common, particularly for the engine and transmission, leading to continuous innovation in fluid management systems.

Precision and Consistency

• Engine Assembly: Meticulous measurement and balancing of components like bearing clearances, ring gaps, and piston rocks are standard practices.
• Materials Inspection: Cranks and heads are regularly checked for cracks to ensure longevity.

Shift to Electronic Fuel Injection (EFI)

Transitioning to electronic fuel injection has notably increased engine life by providing a more consistent air/fuel mixture, thereby extending cylinder wall life.

Durability and Maintenance

Despite operating in harsh conditions, a significant number of these engines only require refreshment after one to two years. Parts like pistons and rods are commonly inspected and replaced due to wear and tear.

Quick Repairs and Testing

Crews are highly skilled, often completing complex repairs like transmission replacements in 15 minutes between show rounds. Continuous testing of new designs and technologies helps maintain top performance levels.

Modern monster truck engines represent a blend of raw power, advanced engineering, and consistent innovation, ensuring they deliver thrilling performances while enduring extreme conditions.

 

What is the process for assembling a monster truck engine?

The Process for Assembling a Monster Truck Engine

Building a monster truck engine is a meticulous task that demands precision and attention to detail. Here’s a breakdown of the key steps involved:

1. Measurement and Fitting
   • Every component, from bearing clearances to ring gaps, is measured precisely to ensure optimal performance.
   • Pistons are checked for movement, or “rock,” to confirm they fit correctly in the cylinder.
2. Inspection
   • Cranks and heads undergo thorough inspections for cracks or other potential issues before assembly.
   • This step is crucial to ensure the reliability and longevity of the engine under extreme conditions.
3. Balancing Components
   • Each part of the engine, including the crankshaft, is balanced meticulously. This step helps in reducing vibrations and enhances the efficiency and durability of the engine.
4. Precision Assembly
   • Following the inspections and measurements, the engine is assembled with an emphasis on precise alignment and fitment of all parts.

By following these steps, builders can ensure that a monster truck engine operates at peak performance and withstands the rigors of demanding environments.

 

What is the role of the crew members in ensuring the performance of monster trucks during shows?

The Role of Crew Members in Ensuring Monster Truck Performance During Shows

Crew members play a crucial role in the performance and success of monster truck shows. They work tirelessly behind the scenes to ensure the trucks are in top condition, often under challenging and high-pressure circumstances.

Intensive Maintenance and Repairs

Crew members tackle the intensive maintenance and repair tasks that are essential to keeping these massive vehicles operational. Imagine working on a grimy, oil-soaked truck with parts that are scorching to the touch. This is the reality for these dedicated professionals. They often have to deal with malfunctioning components and fluid leaks, fixing issues quickly and efficiently to prevent any disruptions during the show.

Rapid Problem-Solving

Time is always of the essence in the world of monster truck shows. Crew members frequently face situations where they have mere minutes to resolve mechanical problems. For instance, if a truck needs to be back in action within five minutes, the crew must act swiftly to diagnose and fix the issue without compromising safety or performance.

Pressure Management

Operating under immense pressure is part of the job. Whether it’s handling the heat from both the truck and the environment or dealing with urgent time constraints while someone is urgently demanding results, crew members must stay composed and focused. Their ability to perform under these conditions is essential for the smooth execution of the show.

Key Responsibilities of Crew Members:

• Mechanical Repairs: Addressing any mechanical failures quickly.
• Maintenance Checks: Regularly checking vehicle parts for wear and tear.
• Safety Assurance: Ensuring all repairs and maintenance meet safety standards.
• Efficiency: Performing tasks swiftly and accurately to minimize downtime.

In summary, crew members are the unsung heroes of monster truck shows, their hard work and quick thinking ensuring that every performance goes off without a hitch.

 

How often do monster truck engines need to be refreshed or rebuilt?

Monster truck engines operate under grueling conditions, often pushing the mechanical limits due to their high-performance demands. Typically, these engines experience a refresh or rebuild every 20 to 25 hours of operation.

Engine Refresh Cycle:

• Initial Freshen-up: After clocking in 20 to 25 hours, engines usually require attention. During this phase, minor clean-ups and adjustments are performed to ensure optimal performance.
• Bore Adjustments: For engines with a 4.500˝ bore, this initial refresh may expand the bore slightly to about 4.510˝ or 4.530˝, ensuring continued efficiency and durability.

Long-term Durability:

• Extended Lifespan: High-quality monster truck engines can last for several years if maintained properly, unless subjected to catastrophic failures like a rod breaking through the engine block.
• Major Overhauls: Despite the harsh conditions, about 75% of these engines survive the rigors for one to two years before they need a major overhaul.

This maintenance routine is critical for ensuring that these powerful machines remain competitive and reliable in their high-intensity environment.

 

Why is fiberglass used for the truck bodies?

Fiberglass offers a range of benefits that make it an ideal material for constructing truck bodies.

Durability and Strength

One of the main reasons fiberglass is chosen is its exceptional durability and strength. Unlike traditional metal bodies, fiberglass can withstand significant wear and tear without denting or corroding. This resilience ensures a longer lifespan for the truck body, which translates to lower maintenance costs and less downtime for repairs.

Lightweight

Fiberglass is considerably lighter than metal alternatives, which contributes to improved fuel efficiency. A lighter vehicle requires less energy to move, enabling better performance and reduced fuel consumption. This advantage is particularly beneficial in commercial applications where fuel costs can be a significant part of operational expenses.

Customizability

Fiberglass is highly customizable, allowing for more flexibility in design and construction. Truck bodies can be molded into various shapes and sizes to meet specific needs or preferences. This adaptability ensures that each truck body can be tailored to optimize its performance in different environments and tasks.

Corrosion Resistance

Unlike metal, fiberglass does not rust. This corrosion resistance is particularly valuable in regions with harsh weather conditions or where trucks are exposed to salt and chemicals. The long-term preservation of the truck body’s integrity ensures that it remains functional and aesthetically pleasing for many years.

Insulation Properties

Fiberglass naturally provides better insulation compared to metal, which can be advantageous for temperature-sensitive cargo. This feature helps maintain the interior temperature of the truck, protecting the cargo from extreme heat or cold and ensuring it arrives in optimal condition.

Conclusion

Fiberglass is employed for truck bodies due to its superior durability, lightweight nature, design flexibility, corrosion resistance, and excellent insulation properties. These factors combined make it a practical and cost-effective choice for truck manufacturers and operators alike.

 

How have monster truck shows evolved over the past 30 years?

Monster truck shows have transformed dramatically over the past three decades. Initially known for their loud engines and oversized tires, these events offered a straightforward thrill: big trucks crushing smaller cars and some rudimentary racing. The spectacle was simple yet captivating for fans who flocked to see the raw power on display.

Today, the evolution is unmistakable. Modern monster trucks, each boasting around 1,500 horsepower, are engineering marvels. Weighing up to 12,000 pounds, these behemoths defy gravity by soaring 40 feet into the air. Their stunts now include mind-boggling acrobatics, vastly outperforming their predecessors.

• Technological Advancements: Advances in engineering and technology have made today’s monster trucks more powerful and capable of performing complex maneuvers.
• Increased Safety Measures: Enhanced safety features protect both drivers and spectators, making the shows safer and more family-friendly.
• Entertainment Elements: Modern shows incorporate light displays, pyrotechnics, and high-energy music, elevating the overall entertainment value.
• Multi-Discipline Events: Today’s events often feature a mix of racing, freestyle stunts, and acrobatics, offering a more varied and dynamic experience.

A New Level of Spectacle

The modern incarnation of monster truck shows is a far cry from the simpler events of 30 years ago. Now, they offer an exhilarating blend of advanced technology, breathtaking stunts, and comprehensive entertainment, captivating audiences like never before.

 

What are some of the major events and shows organized by Feld Entertainment?

Major Events and Shows Organized by Feld Entertainment

Feld Entertainment is renowned for orchestrating a variety of large-scale, traveling performances that captivate audiences of all ages. Below are some of the key events and shows managed by this industry leader:

• Monster Jam: A high-adrenaline motorsport event featuring massive trucks performing jaw-dropping stunts and races.
• Disney on Ice: A family favorite that brings beloved Disney characters to life on the ice with spectacular skating performances and magical storytelling.
• Supercross: An exhilarating off-road motorcycle racing series that attracts thousands of enthusiasts to its high-speed competitions.
• Marvel Universe Live: An action-packed live show that immerses fans in the thrilling universe of Marvelsuperheroes with impressive stunts and special effects.
• Sesame Street Live!: A delightful stage show featuring the iconic characters from Sesame Street, combining educational themes with fun musical numbers.
• Jurassic World Live Tour: An adventure-filled live show that transports audiences into the world of dinosaurs, complete with lifelike animatronics and engaging storytelling.

These events showcase Feld Entertainment’s unparalleled ability to create unforgettable experiences for diverse audiences across the globe.

 

How many monster trucks and engines does Feld Entertainment own for Monster Jam?

Feld Entertainment possesses an impressive collection for Monster Jam, managing over 50 monster trucks. Additionally, they maintain a fleet exceeding 100 blower engines.

 

What specific challenges do monster truck engines face due to their unique performance demands?

Just moving a 13,000-pound truck with 66-inch-tall by 45-inch-wide BKT tires requires a ton of grunt, and putting a highly built Duramax engine into the chassis is just what the doctor ordered to help move this truck along. Feld Motor Sports VP of Operations, Bill Easterly, is a diesel guy at heart and knew that working with the right people, he could bring a diesel into the Monster Jam fold to compete on the big stage against the supercharged methanol-burning monster trucks.

However, the unique performance demands of monster trucks present specific challenges that go beyond just engine power. One of the most significant issues faced by these behemoths is fluid delivery. Traditional engine placements often result in oil starvation during stunts like wheelies. When the truck lifts its front end, the oil pump pickup can be left out of the oil, starving the engine and leading to potential damage.

To counteract this, many trucks have their engines placed backwards in the chassis. This repositioning allows the oil pump pickup to remain submerged during rear wheelies, but introduces new challenges when tricks are performed on the front wheels. Engineers have explored various solutions, including v-shaped oil pans and even the possibility of switching to dry sump systems, to ensure consistent oil delivery no matter the stunt.

Additionally, the punishing conditions these trucks endure can wreak havoc on engine components. Pistons and rods are frequent casualties, yet the resilience of these machines is remarkable. Despite the harsh operational environment, a significant portion of trucks are ready for a freshen-up after just one to two years of use.

Moreover, the physical stresses involved are immense. The 12,000 to 13,000-pound trucks land with such force that the g-forces generated can break parts off the engine. This constant cycle of high-impact stunts and the need for powerful, reliable engines showcases the incredible engineering behind these monster machines.

 

What are some of the innovative solutions used to address common issues in monster truck engines?

“After trying a few combinations of forced induction, the team settled on a compound turbo arrangement using a Precision Turbo 6870 T4 divided high pressure stage turbo that’s perched upon a Wagler T4 divided Twisted Pedestal. A Precision 3×3.5 turbo draws in air from the atmosphere through a large K&N air filter element that’s shielded by an Outerwears cover. After the intake charge is compressed, it’s channeled to a custom air-to-air intercooler that the WCP team fabricated in-house then down into the engine through a WCP Street intake manifold. On the exhaust side, custom tubular log-style headers were built to send the exhaust up to the 6870 with a pair of Precision PW46 wastegates to regulate pressure. Outlet from the 6870 is channeled to the 3×3.5 turbo then out and up through a small stack at the base of the rear edge of the cab when the body is installed.

However, forced induction wasn’t the only innovative solution the team implemented to address common issues in monster truck engines. Fuel management is critical, especially given the extreme conditions these trucks operate under. To tackle fuel delivery problems, the team incorporated a cutting-edge fuel management system that ensures consistent fuel flow even during aggressive maneuvers. This system is especially effective at maintaining fuel pressure when the vehicle is at steep angles or during sudden movements, common scenarios in monster truck events.

Moreover, the switch from traditional mechanical fuel injection to advanced electronic fuel injection (EFI) systems has been a game-changer. Mechanical fuel injection systems, while effective at high speeds, often struggled at idle or low engine speeds. By adopting EFI, the team achieved:

• Reduced fuel consumption: Nearly halved compared to mechanical systems.
• Improved emissions: Cleaner exhaust output.
• Consistent air/fuel ratio: Enhanced engine performance across all RPM ranges.
• Extended engine life: More consistent air/fuel curves reduced wear and tear on critical engine components.

These innovations not only enhanced performance but also contributed significantly to the longevity and reliability of the engines, ensuring that the trucks could handle the rigors of competitive events with greater efficiency and less downtime.”

 

How does the design and placement of the engine affect a monster truck’s performance?

An 1,100+ horsepower 6.6L Duramax engine built by the team at Wagler Competition Products is mounted in the middle of the custom tube frame chassis behind the cab, facing rearward. Notice the custom exhaust headers used to expel burned gasses from the reworked factory GM heads.

Engine Placement and Performance

Weight Balance and Stunt Execution:For weight balance reasons and to enable the truck to perform wheelies across the floor on the back wheels, the engine is mounted backward. This setup helps in distributing weight more evenly, which is crucial for executing high-impact stunts. The oil pump pickup is strategically placed in the front of the engine to ensure continuous oil flow, but when performing tricks on the front wheels, this becomes a challenge as the oil pickup can be out of oil again.

Forced Induction System

After trying a few combinations of forced induction, the team settled on a compound turbo arrangement using a Precision Turbo 6870 T4 divided high-pressure stage turbo that’s perched upon a Wagler T4 divided Twisted Pedestal. A Precision 3×3.5 turbo draws in air from the atmosphere through a large K&N air filter element that’s shielded by an Outerwears cover. After the intake charge is compressed, it’s channeled to a custom air-to-air intercooler that the team fabricated in-house, then down into the engine through a WCP Street intake manifold.

Oil Management Concerns

Given the engine’s backward orientation and the truck’s ability to perform varied stunts, there’s an ongoing discussion about optimizing the oil system. The team has considered v-shaped oil pans to keep the oil pickup submerged during different maneuvers. Ultimately, transitioning to a dry sump system may be the solution to ensure the engine remains lubricated under all conditions.

Exhaust and Wastegate Configuration

On the exhaust side, custom tubular log-style headers were built to send the exhaust up to the 6870, with a pair of Precision PW46 wastegates to regulate pressure. The outlet from the 6870 is channeled to the 3×3.5 turbo, then out and up through a small stack at the base of the rear edge of the cab when the body is installed.

By intricately designing and placing the engine and its components, the team has managed to create a monster truck that is not only powerful but also capable of performing an array of stunts. This attention to detail ensures that the truck remains competitive and reliable in various performance scenarios.

 

What measures are taken to ensure the reliability of monster truck engines?

“Of course, fuel requirements for the BroDozer would be high, so the team at S&S Diesel Motorsport built a pair of gear-driven 10mm CP3s that were installed in a billet WCP front cover. The high-pressure CP3s send the fuel to a set of S&S 200% over LBZ fuel injectors to deliver it into each cylinder. The S&S crew also handled the wire harnessing for the engine and configured and tuned the stand-alone Bosch Motorsport ECU that controls the Duramax. The package is said to deliver around 1,100 horsepower in its current trim and there’s more available when needed.

Ensuring this power is consistently reliable, the team takes several additional measures. They prioritize reliability over squeezing out every possible horsepower. This approach ensures the trucks can consistently perform during shows without unexpected breakdowns.

Before introducing any new components like pushrods, rockers, or cams, they undergo rigorous field testing. This prevents untested parts from causing failures during live events. Extensive and costly testing is a hallmark of their process, where they might test new ramp designs, camshafts, or fuel injection setups for weeks before deployment.

These thorough reliability measures ensure that while the BroDozer has the potential to deliver immense horsepower, it can also maintain consistent performance and longevity, making every show a guaranteed spectacle for the fans.”

 

What are some common issues faced by monster truck engines?

“After the Nashville event, there were a few bugs to work out, but after those are resolved, the BroDozer Monster Jam truck is going to be a long-standing competitor in Monster Jam events. Sparks added: ‘There’s still some lag… once the truck started to spool, the boost would jump from 12 lbs to 40+ lbs in a split second. It was like driving a rocket ship around that track.’”

Fluid delivery has hands down been the number one problem both for the engine and the transmission. There’s been a lot of innovation from that and a lot of new things that were tried. Some worked, some didn’t work, but it always continues to evolve.

Case in point, years and years ago, all the engines used to be in the front of the trucks. However, when you did a wheelie across the floor, the oil pump pickup was out of the oil and you starved the engine for oil. For weight balance reasons and for the idea that the truck is going to do a wheelie across the floor on the back wheels, the oil pump pickup is in the front of the engine and the engine is in the truck backwards. They run a drop-style transfer case, and obviously, the truck goes forward when you put it in drive, but the engine and transmission are in there backwards on most of the trucks. However, now that they’re doing tricks on the front wheels too, the oil pump pickup is out of the oil again. We’ve talked about v-shaped oil pans, and ultimately, it may end up going to dry sump.

While the fluid delivery issues are some of the most common things seen, there are some parts such as pistons and rods that are usual suspects for damage. However, despite the harsh operating conditions of monster trucks, three quarters of them come back after one to two years ready for a freshen up.

The 12,000-lb. Trucks land with enough g-forces to sometimes break parts off the engine. This means constant vigilance and innovation are key to keeping these behemoths roaring.”

 

How does the fuel system of a monster truck engine work?

Of course, fuel requirements for the BroDozer would be high, so the team at S&S Diesel Motorsport built a pair of gear-driven 10mm CP3s that were installed in a billet WCP front cover. The high-pressure CP3s send the fuel to a set of S&S 200% over LBZ fuel injectors to deliver it into each cylinder. The S&S crew also handled the wire harnessing for the engine and configured and tuned the stand-alone Bosch Motorsport ECU that controls the Duramax. The package is said to deliver around 1,100 horsepower in its current trim and there’s more available when needed.

Fuel Delivery Challenges

Monster trucks face unique challenges when it comes to fuel delivery. The extreme impacts and g-forces during jumps and landings can cause significant issues. Traditional metal tanks are prone to bursting under such conditions, so a poly tank is utilized for its resilience. The fuel sloshing around in the tank adds another layer of complexity, making consistent fuel delivery a critical concern.

Innovations in Fuel System

To address these issues, one of the most innovative solutions introduced is the HydraMat. Acting like a fuel-wicking diaper, the HydraMat ensures continuous fuel pickup even when the fuel sloshes away from the pickup point. This has been rigorously tested on the dyno, demonstrating zero drop in fuel pressure during extreme conditions. However, engineers found that the HydraMat could fold into itself when the truck went upside down, a problem that has since been resolved, making it a reliable component in the fuel system.

Transition to EFI

Another significant advancement in monster truck fuel systems is the transition from mechanical fuel injection to Electronic Fuel Injection (EFI). Mechanical systems were effective when the truck was on flat terrain but struggled at idle or low engine speeds. Switching to EFI has brought numerous benefits, including:

• Reduced Fuel Consumption: The trucks now use roughly half the fuel as before.
• Improved Emissions: Cleaner emissions thanks to a more consistent air/fuel ratio.
• Engine Efficiency: EFI systems are leaner at lower RPMs, improving engine health and efficiency.
• Increased Engine Life: The consistent air/fuel curve provided by EFI has been shown to extend engine life.

Expert Insights

These advancements aren’t just theoretical. Real-world testing and expert insights confirm the benefits. The transition to EFI, for example, was found to increase engine life, thanks to a more consistent and efficient air/fuel mixture. This is a significant improvement over the mechanical systems, which were less reliable in maintaining optimal performance conditions.

By combining high-pressure CP3s and advanced EFI technology, the BroDozer’s fuel system not only meets the demands of high-performance monster truck engines but also ensures reliability and efficiency under extreme conditions.

 

How does the crew handle repairs and maintenance during Monster Jam events?

“After the Nashville event, there were a few bugs to work out, but after those are resolved, the BroDozer Monster Jam truck is going to be a long-standing competitor in Monster Jam events,” Sparks added. “There’s still some lag… once the truck started to spool, the boost would jump from 12 lbs to 40+ lbs in a split second. It was like driving a rocket ship around that track.”

When it comes to maintaining these high-performance machines, the crew’s work is nothing short of astonishing. “If somebody loses a transmission in round two of racing, it has happened before where they’ve had it back out on the floor for round three of racing 15 minutes later,” Sparks noted. “It’s a pretty amazing feat to watch. They have what they call the crash box, which is a toolbox with all of the emergency tools. They’ll pull the damaged truck to the crash area and there’s a team of guys waiting. If it slung a driveshaft out of it or has a broken axle shaft or whatever the issue is, they’ll tend to it, quickly.”

He continued, “The part that a lot of people don’t get to see is the crew guys. In between rounds or in between shows, the crew guys have the toughest job out there. They’re working on a dirty, nasty, muddy truck with oil running out of it. Everything is hot to touch and hot to work on and somebody is screaming at them that the truck has to be back on the floor in five minutes, but they get that work done.”

This combination of rapid, high-pressure maintenance and fine-tuning is what keeps the BroDozer and other Monster Jam trucks at the top of their game, ready to perform at their peak in every event.”

 

What are the different types of stunts performed at Monster Jam events?

“Despite putting up one of the quickest times in the practice session the day before the event, he stumbled in the racing on Saturday night losing in the first round to Brad Allen in Brutus. Sparks finished in 10th in the 2-Wheel Skills Challenge after delivering a great two-wheel bicycle, but faltered on his second trick with an attempted stoppie. Heavy D came to life in the freestyle round of competition, going out second. He laid down a great routine with high-flying jumps, miraculous saves, and a little diesel smoke to thrill the crowd.

Monster Jam events are known for a variety of stunts that push the limits of what these powerful machines can do. The categories include:

• Racing: Speeding head-to-head on a track.
• Two-Wheel Skills: Performing tricks like bicycles and stoppies.
• Donuts: Spinning the truck in tight circles.
• Freestyle Stunts: Combining jumps, flips, and other daring maneuvers.

In the freestyle round, Heavy D’s routine exemplified the essence of these categories with high-flying jumps and miraculous saves, adding a little diesel smoke to thrill the crowd even more.”

 

How do crews prepare for emergencies and unforeseen issues during monster truck shows?

“After the Nashville event, there were a few bugs to work out, but after those are resolved, the BroDozer Monster Jam truck is going to be a long-standing competitor in Monster Jam events,” Sparks added. “There’s still some lag… once the truck started to spool, the boost would jump from 12 lbs to 40+ lbs in a split second. It was like driving a rocket ship around that track.”

When it comes to maintaining these high-performance machines, the crew’s work is nothing short of astonishing. Their rapid response to emergencies during events is a testament to their preparation and skill.

“If somebody loses a transmission in round two of racing, it has happened before where they’ve had it back out on the floor for round three of racing 15 minutes later,” Sparks noted. “It’s a pretty amazing feat to watch. They have what they call the crash box, which is a toolbox with all of the emergency tools. They’ll pull the damaged truck to the crash area and there’s a team of guys waiting. If it slung a driveshaft out of it or has a broken axle shaft or whatever the issue is, they’ll tend to it, quickly.”

The crew’s readiness is crucial. In between rounds or shows, the crew guys have one of the toughest jobs. They work tirelessly under challenging conditions.

“They’re working on a dirty, nasty, muddy truck with oil running out of it. Everything is hot to touch and hot to work on and somebody is screaming at them that the truck has to be back on the floor in five minutes, but they get that work done,” he continued.

This combination of rapid, high-pressure maintenance and fine-tuning is what keeps the BroDozer and other Monster Jam trucks at the top of their game, ready to perform at their peak in every event. The crew’s ability to resolve unforeseen issues swiftly ensures these mechanical beasts are always race-ready, showcasing their dedication and expertise.

 

What is the organizational structure of the crew during emergencies?

During emergencies, a team of crew members is strategically positioned in the crash area, ready to tackle the issues as soon as the truck arrives.

 

What is the physical environment and working condition for the crews?

The crews work under tough conditions, dealing with dirty, muddy vehicles that are leaking oil, and everything is extremely hot to the touch.

 

How quickly are crews expected to resolve issues?

Crews are expected to perform repairs rapidly, often getting the truck ready to return to the track for the next round in just 15 minutes.

 

What are some specific mechanical issues crews might face during a show?

Crews may encounter problems like a lost transmission, a driveshaft that has come loose, or a broken axle shaft, among other potential mechanical failures.

 

How does the suspension system of a monster truck function?

The monster truck’s tube chassis isn’t only the safety cage for the driver. It’s also the support for the 4-link suspension as well as the engine, transmission, and bodywork. This four-link racing suspension system is crucial for high-performance maneuverability, featuring four main bars that link the front and rear axles to the frame. Large link arms keep the front and rear steering axles under the chassis as the truck twists, jumps, and bumps over and through obstacles in competition.

The truck rides on clusters of nitrogen-charged shocks, providing an impressive 30˝ of travel in the suspension. This setup ensures the vehicle can absorb significant impact while maintaining speed and stability over rugged terrain. Within the safety cage, the driver is cradled in an ISP full-containment racing seat and held securely in place with a set of Simpson harnesses.

The hydraulic steering system uses two rams on each axle, with the front controlled by the steering wheel through an orbital valve while the rear steering is electronically controlled with a switch on a handle next to the wheel. The system is incredibly fast and responsive, allowing the driver to precisely drive the beast while doing incredible stunts like driving on two wheels and racing around a tight track with the 13,000-pound machine.

 

What type of shocks are used, and what is their travel capability?

The vehicle utilizes shocks that are charged with nitrogen, and these shocks provide an impressive 30 inches of travel, allowing for smooth handling of rough terrain.

 

How are the suspension components connected to the truck?

The suspension system includes four primary bars that connect the front and rear axles directly to the truck’s frame, ensuring solid support and alignment.

 

What type of suspension does the monster truck use?

The truck is equipped with a racing suspension that features a four-link design, offering enhanced stability and performance.

 

What makes the original BroDozer monster truck unique compared to other brodozers?

What sets the original BroDozer monster truck apart from others in the “brodozer” category is its trailblazing approach and distinctive features. Unlike typical monster trucks that rely on nitromethane for power, BroDozerpowers through with its diesel engine, a rarity in the monster truck arena. This unique fuel choice gives BroDozer a signature, roaring thunder akin to an out-of-control Peterbilt, coupled with dramatic bursts of black smoke as it soars over jumps.

Adding to its standout appeal is its striking, construction-inspired yellow paint job, reminiscent of a Tonka truck, which has captured the attention of Monster Jam enthusiasts everywhere. The creation by the Diesel Brothers truly defies expectations by breaking traditional rules, establishing its own formidable presence among competitors.

 

How much can it cost to build a brodozer or show truck?

Building a brodozer or show truck can be a significant investment, often reaching six figures. Enthusiasts pour substantial resources into customizing these vehicles, with costs for components like wheels, tires, and paint quickly adding up.

Here’s a simplified breakdown of potential expenses:

• Wheels and Tires: Premium choices can easily reach $10,000 to $15,000.
• Paint and Custom Finishes: Unique and intricate designs might set you back $20,000 to $30,000.
• Lift Kits: Expect to spend between $5,000 and $10,000, depending on size and quality.
• Bed and Body Kits: These enhancements can range from $10,000 to $20,000.
• Bumpers and Additional Accessories: Adding custom bumpers and other details could cost another $5,000 to $15,000.

When you add up all these elements, the total investment can easily surpass $100,000, reflecting the dedication and passion owners have for transforming their trucks into distinctive, eye-catching masterpieces.

 

Which brands are most popular for creating brodozers or show trucks?

When it comes to crafting show trucks or brodozers, Ford is often at the forefront, particularly with their F-250 and F-350 models. These trucks are favorites because they offer a wide range of aftermarket customization options. Additionally, many of them are equipped with powerful diesel engines, like the Power Stroke V8s, making them ideal for heavy-duty enhancements.

However, Ford isn’t the only player in the game. Other heavy-duty trucks from brands like Ram, Chevrolet, and GMC are also popular choices among enthusiasts. These brands offer robust models that can be transformed into impressive brodozers, thanks to their durability and performance capabilities.

 

What is a “brodozer” truck and why are they considered show trucks?

In the Monster Jam world of Monster Trucks, big, loud, and blown methanol engines have ruled the roost for years, but there’s another force rising on the horizon. The BroDozer Monster Truck is the newest member of the Monster Jam family and since it was inspired by the original BroDozer that Dave Sparks (a.k.a. Heavy D from the Diesel Brothers TV show) and his crew built, it was appropriate that it would be powered by a diesel engine. The original BroDozer was a Ford truck with a Power Stroke diesel but the Monster Jam team turned to the crew at Wagler Competition Products to build a stout Duramax engine to power this monster.

But what exactly is a “brodozer” truck, and why are they turning heads both in arenas and on the streets?

Brodozers are towering show trucks, often with a cab so high you can’t help but wonder how to climb in. These vehicles are less about utility and more about making a statement—an art form in the automotive world. Just like lowriders that bounce on hydraulics and super-low sports cars that struggle over speed bumps, brodozers aren’t built for practicality. They’re designed to grab attention and showcase their owners’ creativity and craftsmanship.

Most brodozer enthusiasts prefer the term “show trucks.” They pour significant time and money into transforming standard trucks into these eye-catching giants. It’s not uncommon for owners to invest upwards of $100,000 on enhancements like wheels, tires, paint, bed kits, lift kits, and bumpers. This level of customization turns each brodozer into a rolling art project, a testament to the dedication and passion of its owner.

In essence, brodozers are a vibrant subculture within the automotive scene, celebrating the artistry and individuality of their builders. While some may critique the trend, there’s no denying the impact these trucks have on both fans and casual observers alike.

 

What is the cultural perception of brodozers?

Brodozers are part of a niche automotive subculture, admired by enthusiasts for their uniqueness and craftsmanship, while also facing criticism from others who view them as impractical.

 

What is involved in creating a brodozer?

Creating a brodozer involves a substantial investment in upgrades such as specialized wheels, tires, custom paint jobs, and various lift and bed kits.

 

What is the purpose of a brodozer?

The main purpose of a brodozer is to provide a fun, eye-catching presence on the road, drawing attention with their towering height and bold aesthetics.

 

Why are they called show trucks?

They are referred to as show trucks because their primary purpose is to exhibit their impressive and extravagant modifications, rather than serve practical uses.

 

What is a ‘brodozer’ truck?

A brodozer truck is a highly modified, oversized pickup truck designed to showcase its size and style, often becoming more of an art piece than a functional vehicle.

 

What features and modifications are common in a brodozer or show truck?

The monster truck’s tube chassis isn’t only the safety cage for the driver. It’s also the support for the 4-link suspension as well as the engine, transmission, and bodywork. Large link arms keep the front and rear steering axles under the chassis as the truck twists, jumps, and bumps over and through obstacles in competition. Within the safety cage, the driver is cradled in an ISP full-containment racing seat and held securely in place with a set of Simpson harnesses. The hydraulic steering system uses two rams on each axle, with the front controlled by the steering wheel through an orbital valve while the rear steering is electronically controlled with a switch on a handle next to the wheel. The system is incredibly fast and responsive, allowing the driver to precisely drive the beast while doing incredible stunts like driving on two wheels and racing around a tight track with the 13,000-pound machine.

Beyond the raw power and engineering marvel of a monster truck, there’s a vibrant world of customization that echoes in the realm of show trucks, also known as brodozers. These trucks take customization to extraordinary heights with features that are as much about show as they are about go.

Key Features of Show Trucks:

• Lift Kits: Just like the monster’s towering stance, show trucks often feature giant lift kits, some reaching a foot or more, elevating the truck’s presence to an awe-inspiring level.
• Wheels and Tires: Massive wheels and tires dominate the landscape, designed to impress rather than engage in off-road antics.
• Custom Paint and Lighting: Much like the monster truck’s bold appearance, show trucks boast paint jobs that can cost as much as a small SUV. They often incorporate modern LED lighting, adding a custom flair that turns heads.
• Bumpers and Grilles: Custom bumpers with integrated lights and grilles are common, enhancing the truck’s aesthetic appeal and aggressive look.

In the world of show trucks, owners often prefer to get hands-on, modifying their vehicles with personal touches. Just as a monster truck is built for performance stunts, a show truck is crafted for visual impact and individuality. This culture of customization reflects a passion similar to that found in the monster truck arena, where every detail contributes to a unique, jaw-dropping spectacle.

 

How do the costs associated with show truck modifications compare to standard vehicles?

The costs for custom paint jobs on show trucks can be substantial, often exceeding the price of an average vehicle like a Toyota RAV4, reflecting the high level of detail and craftsmanship involved.

 

What role does lighting play in the customization of a show truck?

Lighting is crucial for customization, with modern LED lights being used to enhance the truck’s appearance and complement its paint scheme for a unique and cohesive look.

 

What is the cultural mindset or approach of show truck owners towards customization?

Show truck owners typically embrace a hands-on, do-it-yourself attitude, preferring to personally undertake the customization work rather than hiring others.

 

What are typical modifications made to a show truck?

Common modifications include installing massive lift kits, custom bumpers with built-in lights, distinctive grilles, and, for diesel trucks, oversized exhaust systems.

 

What are common aesthetic features of a show truck?

Show trucks often boast extravagant features, including elaborate custom paint jobs, large wheels with intricate detailing, and vibrant LED underglow lighting to create a striking visual impact.

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