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Project Zuk 3.0 (rows of seats) - 2003 XL7

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #53 on: April 04, 2019, 09:20:30 PM »
And here's a 2 1/2 minute long video of part of the drive out in the morning, which was a piece of cake compared to the drive in because we weren't breaking trail, plus the temperature was below 0 again compared to around +15C the afternoon before.
https://www.youtube.com/watch?v=BVD_c2XEpbA
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #52 on: April 04, 2019, 09:12:30 PM »
I put in a late, late night last Thursday so I could take the Zuk up the mountain on Friday. I'm still planning on finishing it with some rocker guard and maybe some matching paint, but other than that it's done and it works. I decided not to add more tubing for side protection because it didn't look good and adds a significant amount of weight. I may still make some pieces at the bottom of the flares but I don't think it's worth the effort involved, might just have to get used to the slightly unfinished look...tell me what you think, guys!


On to the winter camping pics. First things went pretty well, nice hard frozen snow with lots of traction and flotation.




Then I found the soft spot at the bottom of the hill.


With the help of several guys pushing at the back plus these awesome ATV loading ramps that matched my wheelbase exactly, it took about 2 hours to get up this 100 foot long hill. Just makes me think how nice it would have been to have a winch and not be eating dinner at 10:00 After getting the Zuk up.we spent a bit of time trying to coax my friends 1994 Land Cruiser up the same hill, but it sank almost instantly and we said forget it. All items needed at camp were loaded into the Suzuki and it went the rest of the distance into camp. Not without some more difficulty, but with 2 big boys to push on the front bumper to help me back up onto the crust every time I broke through, I managed to make it all the way to the lake, which was the idea because I had all the firewood in the trunk.




The backside of Hudson Bay Mountain as viewed from the frozen Dennis Lake
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #51 on: March 23, 2019, 09:08:49 PM »
These are 3x4x3/16" tubing. Any slimmer than that in either direction and they won't fit right...it's basically exactly 3" from the pinch seam at the bottom to the part of the door sill that is vertical (in theory the strongest part) and if they are less than 4" wide then they would be recessed inside your doorsills. Even at 4" wide, the front and rear ends are pretty much flush, because the body tapers out towards the fenders. This mod is really popular on BC Suzuki Club with all the older Sidekicks that are now 20+ years old and rotting away, so I basically just modified the idea to work on mine. I've also done this on my old 97 Kick as well as an 89 FJ62. Some guys on BC Zuks say they wish they did 6" wide tubing to add more sideways protection. I have a pair of old 2x2 rock sliders from my old Tacoma that I was thinking about adding as s side step...just weighing the pros and cons of doing that:

Pros: added side protection, ease of access to roof rack, maybe a step for the kids, deals with the "missing pieces" look by the bottoms of the flares effectively
Cons: added weight (guessing 20 lbs per side), possibly annoying ankle-biter when getting in and out, more leverage on welds on sheetmetal

In the meantime, I've since tackled the driver's side, mostly. Just need another evening or two to finish it up. Hoping to take it out next weekend and do a little early spring camping in the snow, but we'll see if I manage to finish it up enough to take outside...
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline JollyZuk

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #50 on: March 16, 2019, 03:39:40 AM »
What tubing did you use for your sliders?  So far I have just built a driver side for my ‘Kick, but I incorporated a full length step into mine.  It sure helps the little ones be able to get inside.

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #49 on: March 12, 2019, 07:06:31 PM »
Oh yeah, flat landing for sure! That's a far cry from my neck of the woods. Calgary is borderline acceptable as far as terrain goes...at least it's only an hour's drive to the Rockies from there. But an hour seems pretty far when I've got an 8500 foot peak looming right over my town!

I spent about a day working on the passenger side rock slider doorsill. It's basically done except for the final finish which I will do at the same time as the other side, which is completely undone at this point. It's a fair bit of work but it is turning out nicely.

Clearance check at full compression. Had to do some more hammering and trimming at the front.Still not sure if it's going to be completely rub free, but I think I've fixed the metal rib inside the fender which was slicing the outboard tread off my tires!


Sizing things up:


Before putting a cap on the back:


After. I smeared seam sealer all over this later too.


Before capping the front, which was more work because the top of the tube is also open:


So I had to cap the end and the top, using a rectangle and a triangle and a whole shwack of seam sealer.


I'm happy with how it turned out, but might add some details by the bottom of the fender flares because it looks like something's missing there. Or maybe I'll add another tube that sits out a few inches to provide protection from sliding sideways into stuff, and allows the slider to be used as access for the roof rack. Each one only weighs 38 pounds after I got 40% of the tube removed by plasma cutter to fit around the side impact protection in the body...prior to that they came in at 58 so it is considerable savings, so I could afford to add a bit again, but I am trying to avoid adding unnecessary weight so we'll see.
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #48 on: March 03, 2019, 03:42:06 PM »
Olija - I spent most of it Saskatchewan, but I was iaround Edmonton and Calgary often also. I had a Jeep Wrangler as a rental, most of the tie I was there. I would hang out with Flatland 4x4,moatly camping and wheeling on Crown land.

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #47 on: March 02, 2019, 09:29:55 PM »
Started another fairly big project on the XL7. Been putting off rock sliders for about 2 summers now...it's time to get some on before I do something I regret! I didn't want to put frame-mounted sliders on because you lose a fair bit of clearance with those compared to chopping out the rockers and welding tubing to the body, plus I needed to do some work at the fenders to get the tires to fit properly, and there was a bit of rust starting at the rear of the rockers. So, I started by making a surgical incision:
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #46 on: January 01, 2019, 09:29:35 PM »
Cool Ridjobradi, whereabouts in this vast country were you working?

We were visiting down in the lower mainland of BC last month and got out to Vedder Mountain with an old friend with his Land Cruiser and my brother in law with his Xterra. This is a neat mountain to play on as there is a main logging road going around the perimeter and many trails criss-crossing over it and around the botttom as well. Unfortunately, since I moved away from this area almost a decade ago, it's been logged a few times and some of the old trails are now just gravel roads and some of the old forests have been completely clear cut. Progress I guess. But the good news is there is plenty of wilderness to go around in the rest of BC outside the lower mainland, and this was a good reminder of why I don't miss living down there anymore!

The cruiser didn't quite fit where the Suzuki easily did:


Hang Glider's Point, the top of the mountain. Visibility was good enough to see the Pacific Ocean from here.


A challenging climb where I found out one of my front hubs has been improperly installed for the last 12 months and finally didn't lock in all the way, causing me to spin out in 2wd before figuring out the problem and correcting it. The Xterra had no issues since he had a front locker...makes me think maybe I should invest in one someday....






And here is a video my nephew put together from the day. Nothing too exciting but you get a better idea of some of the terrain:
https://www.youtube.com/watch?v=flElLrrswAM
Happy 2019 to all my fellow Zookers!

« Last Edit: January 01, 2019, 09:33:31 PM by olija »
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #45 on: December 08, 2018, 08:41:06 PM »
Olija - Another great pic. I spent several months working Canada, a few years ago. The countryside pics are awesome. I have several pics of old farmsteads that are still some of my favorite photos.

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #44 on: November 28, 2018, 09:56:41 PM »
Went for a little outing yesterday. There is an old road that existed before the current bridge was built across the Skeena River at Kitwanga, called the Hazelton-Kitwanga Backroad. Off the road a short ways is a beautiful little lake called Keynton Lake. It's not possible to get to the lake from Hazelton anymore because many years ago the road washed out 15km from Hazelton, but people have been squeezing around the gate with their quads and bikes for years. I thought it would be neat to see if the same could be done in a Suzuki. The short answer was no, but we found a very interesting quad trail that would have taken us to the lake if we hadn't turned around for fear of having to back up forever if there was a tree down. No pics of the trail but I will definitely be back to finish it off next year probably. Instead, here's a shot at the bottom of the trail by the Skeena River.

97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #43 on: November 21, 2018, 09:53:05 PM »
Added a Night Rider S20 LED bar last week. This is a street-legal 20" single-row "driving light" LED. I got a chance to try it out last week as well when I took my family and some visitors out on a 700km round trip to some hot springs and back. The whole way back was pitch black and the road was wet, and this is where a light like this is worth it's weight in gold. The stock headlights were pretty much useless in these conditions which is exactly why I had been looking for a light like this. The bonus is that with some careful fabrication, I was able to mount it fairly discretely between my bumper and my skid plate where I had a bit of a gaping hole for sticks and stones to bust up my rad. Win-win!

I also swapped out the rear shocks for the proper-length ones for my lift.The old ones were from when I started out with a 3" lift and the new ones are for a 4.5" lift. For some reason Alter Ego neglected to tell me that, nor did I think of it, when they gave me a set of their A-arms to try to bump up my front lift. Should be a little more flexible out there now, but haven't had a chance to try it out yet.
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline JollyZuk

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #42 on: October 13, 2018, 07:43:56 AM »
Olin’s, that is awesome!  My jealousy of your beautiful surroundings is making it hard to think nice thoughts though!!!

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #41 on: September 30, 2018, 09:18:10 PM »
Got out this evening and did the Dome Mountain Loop. It's got some minor challenges, more when it's wet and soggy, but a great view from the top, and it's not too long so the kids don't get bored.











97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #40 on: September 03, 2018, 10:05:25 PM »
Did a day trip with a friend up to the Telkwa Range as approached from Houston, BC. Was neat because neither myself, my wife, nor my friend's wife had ever been up there and it was quite nice. I didn't get any pics of the challenging stuff on the way up to the alpine, but I know he did so maybe I'll post them later.








97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper

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Offline olija

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Re: Project Zuk 3.0 (rows of seats) - 2003 XL7
« Reply #39 on: August 24, 2018, 09:58:26 PM »
I know it's a long shot, but it'd sure be something to have the next Zukfari around here!
97 Sidekick 4door 5 speed, 1.5 spacer lift, 2" body lift, CJ rims, locked rear, 31's, 4:1 low <SOLD>
01 Vitara 2.0L 5 speed, 2.5" Calmini lift, 2" body lift, Sidekick rims, locked rear, 31's, 4:1 low, 5.13 diffs <SOLD>
03 XL7 2.7 5 speed, 3" AE lift with OME springs, 2" AE body lift, 5.13 diffs, 235/80R17 BFG AT's on Ultra 17x8 with 1" spacers, skid plates, Balmer Fab front bumper