ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: Low Range on August 04, 2008, 10:28:54 PM
-
I might as well start from the beginning.
After the last wheeling trip I wanted to be able to take more people with us on our trips to Moab and local fun spots. I had my Samurai and with the wife and the 2 small dogs that doesn't leave much room for anyone else.
The Samurai was on the market within a week. Some of you might remember it from late last year.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P5100132.JPG)
I wanted to stay Zuk so at that point I was on the lookout for a Sidekick or Tracker with the following specs: Newer, White, Tan or Grey, 16v 1.6L, 4 Door, Automatic in good shape.
As you would guess it was not the easiest to find and I did not come up with much in Utah.
At it turned out, I sold my Samurai to a person in Washington near Tacoma and he paid us to deliver it to him. That began the search in the Seattle area.
We started the trip with a few leads on some in that neck of the world.
A few pics of the way up:
The Sami loaded and ready to go. My friend Javan went with us because he is from the area of Washington we went to and he wanted to see some family. Thankfully he bought a new Dodge Megacab the week before the trip. It made the trip nice! (It was a gasoline truck, you will want to know this for future reference.)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB140002.jpg)
Now for the entertainment of the trip. I don't know about any other state but good old Oregon has the dumbest law on the books in my opinion.
We had planned on driving strait through to Washington, about a 12-13 hour trip.
We stopped in La Grande, Oregon for some gas and a bathroom break at about 2am.
I get out, not knowing the law and started to open the filler on the side of the truck. All of a sudden some homeless looking guy walks up and says "you can't do that, I have to fill your truck." Um....Ok. Apparently you cannot fill your oun vehicle with gas in Oregon. News to me. So he start to "do his job."
Anyway I hope back in the truck for a sec to ask if anyone needs anything. Then I glance back out at the guy and notice the gas filler he was using was "GREEN"
You dumb|removethispart|@%$! This is a gas truck.
He pumped 7 gallons of diesel into my friends new Gas Truck.
Needless to say:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB150018.jpg)
The gas station put us up at the local hotel for the night, had to pay for the tow, a shop to pull the tank and drain it, the local Dodge dealership to reset the computer, a full tank of gas, and after our 8 hour intermission, we were back on the road. Never to stop in La Grande again.
That evening we made it to our destination and dropped off the Sami to its new home. Bye, Bye..... :( :'(
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB160033.jpg)
The next morning we headed out to look at a few Sidekicks and Trackers.
I fell in love with one in Everett and brought it home. It was all I wanted. A dark tan color, 4 door, auto, 16v 1.6L in good shape.
Wish I took some picks of it on the lot we got it from but it was pouring rain. It's Washington.
After we got home I pulled the Tcase for its first upgrade, 4.24:1 gears
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB250095.jpg)
Old gears:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB250113.jpg)
Trimming:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB260148.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB260152.jpg)
New gears:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB260198.jpg)
Ready to go back in, ohhh shiny:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB270225.jpg)
Then it was time for some lift and I wanted to try out the OME stuff.
For the rear I went with OME 955 rear coils and some 1.5" spacers along with some DT3000 Shocks. It ended up at about 3" of lift from fender down to center of the hub.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB270236.jpg)
For the Front I went with some OME 962 Front coils and OME Struts. It ended up at about 3" of lift from fender down to center of the hub to begin with.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB270244.jpg)
I added some 1.25" wheel spacers and some 30" BFG A/T's and it looked pretty good. I also put a mini spool in the rear. Its first run to Moab came quick that weekend and it was fun. It flexed pretty good.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PC010272.jpg)
In the middle of December I got the windows tinted and added some bling with the window visors. I think it looks good. ;D
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PC230037.jpg)
At the end of January the Shrockworks Front Bumper and Sliders came in and we got them on a couple day before the U4WD Winter convention in St George, Utah. I added in the Smittybuilt 8000 winch and replaced the cable with some winchrope and Spidertrax aluminum hawse fairlead. The front springs let down a bit under the extra weight so at that time I added on a set of 1.5" front coil spacers to bring it back up.
With only the 3" lift I "tested" those slider several times and I was glad I had them!
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P2020078.jpg)
The week after I picked up a front Toyota axle and started the teardown:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P2080114.jpg)
After a while:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P2090122.jpg)
And after some torching and grinding:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P2120123.jpg)
More to come.......
-
Looking awesome so far! Glad to see a Toyota front heading under it.
Were you planning to straight axle it all along? You gunna beef up the axle?
Cant wait to see more!
Amilla
-
The plan was to Toyota axle it all along, just had a few trips I wanted to lift it for untill I had the parts and money to do the axles.
I also had never done the OME springs to one and wanted to see what kind of ride it would have.
It was great for what I did with it. Now its time for more.
Sean
-
You going to be keeping this build with coils?
Whats the tire size you are going for?
Amilla
-
think i saw you heading down I84 not to long ago . you passed me in my little white 2 door side kick .
-
Never had a white 2 Door.
Must have been a customer of mine. ;D
It will be the Trail-Slayer kit with a couple of mods.
Sean
-
no no LOL
how long ago did you make your trip .
I had a guy pass me heading west on I84 with a sami on a Trailer , heading west dont remember if it was between boise Idaho and Nampa or caldwell and ontario OR. was earlier i think maybe a few months back ?
but i remember thinking when it went buy about lifting my sidekick .
i was heading home to payette in a white stock 89 2 door side kick doing 65 in a 75 LOL .
if it wasnt you then there was another trailerd sami on its way west through La Grand .
there is more then a few around here thouh so it may not have been you .
-
I understand now, it was us back in early November 07
-
Got some more good pics of the rig before the tear-down again
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040034.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040033.JPG)
Then I broke down and spent the money and got this:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/ttcoilkit.jpg)
The next step was the start of the rear axle setup with this:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/rahousing.jpg)
And this, it isn't the right one for the suspension kit but I measured up and we are not far off from the one Brent supplies and the joints would be at angles instead of straight so I decided to go with it:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/rearulinkmount.jpg)
At the time you could not order it setup for the Toyota Elocker setup and the diff flange looked like this:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/housing2.jpg)
So out came the cut off wheel, welder, drill and tap:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_4942.JPG)
In this picture you can see the truss installed and the final setup for elocker:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_4989.JPG)
The axle mounts for the links are made to mount up to the factory Toyota IFS axle so we took measurements off a stock housing. Then we strapped the housing to the jackstands so it wouldn't turn on us. Leveled it up and started figuring out angles and widths:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_4992.JPG)
Got them welded on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_5003.JPG)
More to come............
-
Man, that's nice stuff.
-
Those are some purdy welds.
-
Got most the welding done:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_5005.JPG)
Next I pressed out the wheel bearing retainer off the old drum brake backing plate and bead blasted it. I am going to run the disk brake setup so that was all I needed. I also went with the new Chromo shafts and got new wheel studs (yes I am completely overbuilding this, yes I know I would not break the stock ones):
(http://www.zuwharrie.com/gallery/albums/userpics/11769/IMG_5024%7E0.JPG)
Then there was a period where I just plain forgot to take pics.
During that time, I got the Factory Rear Toyota Elocker Diff Rebuilt with 5.29 Trail Creeper gears and added a Elocker skid
I got the GM Metric Disk Brake setup using the Sky-Mfg kit. I went with the ebrake calipers and will see if I can get them hooked up later. I also picked up some hard lines from the local parts store. Bent them all up and re-flared everything
Ordered in two 33"x12.5 Goodyear Wrangler MTR tires and a pair or 15x10 ProComp rims.
We also ran a wire wheel on it one more time and painted it all up.
Here are a few finished pics of the axle, don't know if I want to eat off it or put it under the Tracker:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040027.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040023.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040020.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040010.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040017.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040018.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040015.JPG)
More to come.........
-
Very very nice. You should really consider building offroad parts..... and selling them....... maybe start a 4x4 shop......
:P :laugh:
-
Very very nice. You should really consider building offroad parts..... and selling them....... maybe start a 4x4 shop......
:P :laugh:
He does have a 4x4 shop. Go to www.lowrangeoffroad.com to check it out. I've bought from him and they are good prices. I don't think he makes his own stuff to sell but its top notch, the sami was awesome.
Looks good Sean. Thanks for posting it here. Excited to see the rest.
-
???
Very very nice. You should really consider building offroad parts..... and selling them Uh, sarcasm anyone?
-
That rig is gonna be AWESOME! Now all it needs is a custom turbo setup!
-
Finally got time to pull the Tracker in on the hoist and pulled the rear stock axle:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040044.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8040043.JPG)
More to come......
-
On Wednesday I got more time to work on it.
Here is the picture of the crossmember assembled and ready to go in:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8060015.JPG)
Here it is in in place. It took the pogo stick and some hits with the rubber hammer to get it in place and ready to drill the holes:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8060022.JPG)
Here it is after the holes were drilled:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8060024.JPG)
Got the upper coil pocket in and the coil spring hung, you can see the park brake cable hanging over the frame on the left in this picture:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8060030.JPG)
This morning I was able to get the axle hung. To do so I rolled that axle under the Tracker, lowered it down and bolted it to the coils. Then I lifted it up and attached each link one at a time. I also bolted in the shocks and the driveline:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090014.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090012.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090010.JPG)
I then noticed that the stock park brake cable looked like it would go right into the ebrake hole on the GM calipers and it snapped right in:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090018.JPG)
It looks like I will just have to cut it, pull the small stock spring and add in a new end somehow. We will figure it out some other time but I was surprised how easy its going to be make it work together:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090022.JPG)
To get the cable to stretch far enough I unbolted it from above the crossmeber (you can see the stock location at the top of the picture) and rerouted it under the crossmember. I flipped the mounting bracket and bolted it into an existing hole on each side.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8090029.JPG)
More to come......
-
Does it need a panhard bar for that set up? Or does the four link stop the side to side movement? This is the trail tough kit right?
-
Does it need a panhard bar for that set up? Or does the four link stop the side to side movement? This is the trail tough kit right?
With the 4 link and the 2 center bars diagonally mounted it will not move side to side.
This is the TT kit with a few mods along the way.
Sean
-
Well I had more time to work on it on Sunday night. I got the brakes bled, readjusted all the links, tightened everything down, got the wheels on and took it for a spin around the block. Here are a few pics of what it looked like after I pulled it back in:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8100036.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8060038.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8100035.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8100034.JPG)
It was a nice drive, felt good. Since I had to remove the exhaust right after the cat, it was a bit loud but not horrible. I was just happy to be able to turn a corner without the tires dragging since the old axle had a spool.
I think I might try a set of 3000 series shocks eventually. These 8000 series seem to be a little stiff for me.
I was a nice drive, felt good. Since I had to remove the exhaust right after the cat, it was a bit loud but not horrible. I was just happy to be able to turn a corner without the tires dragging since the old axle had a spool.
I think I might try a set of 3000 series shocks eventually. These 8000 series seem to be a little stiff for me.
On Monday night I put the Sliders back on and drove it home. Here is a couple pics of how the Shrockworks sliders mounted up next to the crossmember. Real close:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120008.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120010.JPG)
Here is a couple pictures of it as of today in the driveway:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120004.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120001.JPG)
Next comes:
-Finish up a few loose ends on the rear: hook up breather tube, cut and mount the park brake cables, sleeve park brake cable with some tube where it lays on the frame.
-Install Gas tank Skid that is at powdercoat now.
-Continue building front axle. I was using a front out of a 83 model Toyota with the short truss and have since then aquaired an 85 axle with the long truss and will continue to build it. Pictures will be posted along the way.
- Pulled the Clutch fan last week and ordered in a 16" Flex-a-Lite electric fan that is not here yet, hopefully see it soon and then show the install on that.
-I also want to figure out a intake setup for the 16v that uses a K&N cone filter and get rid of the box.
-I will also be installing the Stainless Steel 16v Header and have the exhaust shop install a new 2" exhaust system.
-Final step will be the Rear bumper and tire carrier that we will be looking for from ZOR.
More to come........
-
Looks great. I'd like to come see it some time if I can.
-
Them are some bling bling rims you got going there.
How wide is that rock assault rear end? Same width as the 86+ rear ends?
Would you by any chance be doing the IFS hub swap on your 85 front end? Get an extra 3" out of it, and not have to run a wheel spacer in the front to match the rear end.
I built my whole front end up and when i was done i realized i should have just coined up and done it.
Amilla
-
Looks great. I'd like to come see it some time if I can.
PM sent ;D
-
Them are some bling bling rims you got going there.
How wide is that rock assault rear end? Same width as the 86+ rear ends?
Would you by any chance be doing the IFS hub swap on your 85 front end? Get an extra 3" out of it, and not have to run a wheel spacer in the front to match the rear end.
I built my whole front end up and when i was done i realized i should have just coined up and done it.
Amilla
It is the IFS width 86+
I had not thought about the widening kit but I might not go a full 1.5" spacer either. Maybe just an inch. I dont know. Now you have me thinking! I hate that.
Sean
-
A few parts came in today ;D
Here is what we had before:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120009-1.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120006-1.JPG)
After removing the stock exhaust manifold I found I had a crack in it and didn't even know, it doesn't look like its bad though because there is no black stuff around it:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150029.JPG)
Here is the old downpipe and cat, it measures about 2" going in and the end is 1.75". We will be going to 2" with a high flow cat:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150019.JPG)
Before I installed the new header I test fit the flange on the end of the downpipe to see if I could cut it off and give it to the exhaust shop to mate up to the header. It will work great:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150022.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150035.JPG)
Here is the new Thorley Header installed, bling, bling:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150013.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150017.JPG)
I ordered in a K&N cone filter and drilled a 13/32" hole in the rubber lip and threaded in the temp sensor. It was nice and tight and should seal nicely:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150024.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150023.JPG)
Here it is all installed:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8150026.JPG)
More to come.........
-
Holy hell! Did you polish that header out after you got it in?! Defiantly bling for your engine! All you need now is a polished intake tube!
You get anymore progress on your front axle?
After seeing how you did up your rear axle i cant wait to see your front axle.
Amilla
-
good stuff :)
i remember when i first did my intake sensor mod 3 years ago
-
Ah this brings back memories of building my trailslayer kit! Keep up the pictures and let me know what you decide to do to the track bar mount in the front to keep the frame from being comprimised...
Maybe I should just slow down and quite jumping my truck...
Hutch
-
YEH SURE LIKE THAT WILL HAPPEN
-
Ah this brings back memories of building my trailslayer kit! Keep up the pictures and let me know what you decide to do to the track bar mount in the front to keep the frame from being comprimised...
Maybe I should just slow down and quite jumping my truck...
Hutch
Here's what I did to help with that.
-Eric
-
I decided to change out the timing belt since it has 147000 miles on it an I do not know when or if it was ever changed. Here are a few pics.
I pulled the original fan and shroud:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8120008-1.JPG)
With the new belt and timing tensioner pulley on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8160014.JPG)
The old timing cover was not in the greatest shape:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8160016.JPG)
All back together with a new timing cover and new belts:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8160017.JPG)
More to come........
-
After I got the timing belt all squared away I went in with the new 16" Flex-a-lite Fan:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8180024.JPG)
Mounted it up with the through core ties but the bottom of the fan sits nicely on the bottom lip of the radiator so it will not be pulling down at all if the vehicle wants to leave the ground. There is only about a 1/2" of open core above the fan so it will cool well:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8180025.JPG)
Mounted the temp sensor through the core right under the top inlet and the adjustable relay right next to it using one of the a/c line tie screws:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8180022.JPG)
I ran it up and down the street this morning through a few fan cycles to make sure it all worked and adjusted it a few time to get it set right.
I got the gas tank skid back from the powdercoaters yesterday so I will be going in with it in the next few days.
More to come..........
-
Hows the Tracker coming along?
any updates?
Amilla
-
Did you notice much power gain switching to the electric fan?
You got a really nice rig.
-
Did you notice much power gain switching to the electric fan?
You got a really nice rig.
I have a flex-a-lite E fan on my samurai...set up the same way Sean has his.
It felt peppier when i put it on, but I'm sure its a placebo effect.
Amilla
-
Yeah, thats what I was wondering. I think I will do it anyway. What can it hurt(other than my wallet) 8)?
-
I did the fan at the same time as the header and the intake and the jump to the Toyota's on 33" tires so I will never know if it made a big difference or not by itself.
I do know that a bunch of customers have told me that it make a big difference by itself.
More updates coming, been real busy lately.
Sean
-
Ok, time for some updates.
I got the Gas tank skid from the powdercoaters
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8190004.JPG)
Here is a shot of the stock skid
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P8190005.JPG)
Got it installed. After install I shot the bolts with a little black paint.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA210001.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA210004.jpg)
-
Whats the thickness of that skid?
Everything is looking so purdy!
Cant wait to see her done.
Amilla
-
It is 10 gauge sheet so basically 1/8" thick. Could be stronger but the only thing out on the market and have not had any issues with them yet.
-
Finally got some time to clean the garage and get the Tracker in on Sunday night.
I put it up on jackstands and snapped a few pics:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA190175.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA190176.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA190178.jpg)
Didn't get much time the first night so I got the tires, spacers, calipers, and hubs off:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA190179.jpg)
Here is were it is as of this morning after a few more hours of work:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA210214.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA210219.jpg)
-
I also got in some rocker switches that fit nicely in the dash for the E-Lockers. I will have to do a little sanding on the bottom of the switch cover so I can push it all the way down but they will look and work great:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA210015.jpg)
Now I just need to get the rear wired up.
MORE TO COME............
-
are those wranglers m/t tires? do you plan on using those? i was considering to buy them but they dont looks aggressive like my baja claws
-
Yep, Goodyear MTR's.
I love them. My dad runs 35" on his Samurai, my brother runs 37" on his Toyota, and I ran 33" on my Samurai and now on this Tracker.
To me they are a great all around tire for what we do in Utah and they have a low load rating so they squash down at low PSI with a lesser weights of the Suzuki's and Toyota's.
-
hmm i wonder how they are in the mud. online they say there a good off road tire.
p.s. hows that add to cart buttons going on the website. need to buy a soft top lol
-
Luv my MTR"S Great tire!!!!
-
I really like the color! Oh theres a lot more to like also :laugh:, but what color is it?
-
hmm i wonder how they are in the mud. online they say there a good off road tire.
p.s. hows that add to cart buttons going on the website. need to buy a soft top lol
Top page should be ready to go this week.
Sean
-
Here is the install of my New Warn XD9000i Winch.
This was the Smittybilt 8000 I installed last year and I didn't put a cover on it over the winter so it didn't look to good. I wanted to replace it with something that looked a little better.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PA230035.jpg)
Had to do a little trim, trim on the grill:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB010002.JPG)
All installed with a new Winchline 125 foot synthetic rope and Safety Thimble, and Shrockworks anodized fairlead:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB010004.JPG)
Here is the grill opening for the winch:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB010006.JPG)
And here is the lesson I learned from last time:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB010011.JPG)
MORE TO COME........
-
Got a few more odds and end done, the front top shock mounts bolted in, seem like a quick job but with all the crap over the top of the passanger side strut mount it takes a while:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030015.JPG)
Then I started to figure out frame plates for the drivers side. Most have had issues with frame tearing with the Trail-Slayer kits between the panhard and the steering gear box in the crump zones. I am just doing some preventative plating so I don't have to worry about it in the future
Here is the outside before:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030002.JPG)
Here is the cardboard template I made, the black spots are the planned rosette welds and we will weld around the sides as well.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030012.JPG)
Here is the inside before:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030009.JPG)
Here is the templet with planned rosette welds:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030011.JPG)
What do you all think???
-
Hey Sean, I notice you have the older style panhard mount there in your pictures. You may want to talk to Brent and have a look at their new design as it may work better for you. In my latest build it was actually worse (V6 swap interference) but it may be something your looking for. I like your plating ideas; that will help a lot.
-Eric
-
Plate idea is looking good Sean, you should throw some flare onto it. Put like an LR or something ;D
Amilla
-
Shop Truck ..... :D You will get out what you put in. Nice rig
-
Well I called TT and traded the old panhard mount setup for the new one. I am sure glad I didnt weld on the old axle, and frame mounts yet.
THANKS ERIC!!!
-
I figured I would change out the Master cylinder to avoid having issues and Brake fluid all over once the front axle was in.
I did a bunch of research and basically that nobody knew what would fit the Trackers for sure so I went with what works on the Samurai and we will give it a try. I found a 1-1/16" Subaru Forester 1998 in the local yard and went and picked it up for $20.00
Here is the factory Master and ABS mess on the Tracker:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB030023.JPG)
I pulled everything out:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB080256.jpg)
Here is what the Subaru 1-1/16"(left) and Original Tracker 15/16"(right) master cylinders look like together, I also picked up a few o-rings from the parts store to seal up the new cylinder:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB130267.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB130268.jpg)
I took some time to measure up all the differences between the Cylinders. and here is what I found:
-The Subaru Cylinder has 1mm more throw or movement than the Tracker one.
-The pushrod in the Tracker one starts at 24.5mm into the booster from the bolt flange.
-The pushrod in the Subaru starts 4.5mm inside the cylinder from the bolt flange.
With that info, the 1mm throw difference I am not going to worry about. I also needed a 29mm longer pushrod. I took a trip down to Fastal with the original one. I picked up a bolt that will do the trick:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB130265.jpg)
I also had to take a big drill bit and bevel the inside holes a bit for it to fit right on the booster:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB130269.jpg)
Here is the completed setup with a proportioning valve from the rear chamber to the rear disk brakes. I had to do alot of pipe bending and flaring to get it all done. I also used the factory Tracker line splitter to divide the front chamber to the two front brakes:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB130270.jpg)
No way to test things our yet with no front axle but I don't see why it will not work.
More to Come.....
-
Looks good. :)
-
cant wait to see the finish project. its going to a bad suzuki >:D
-
Got the Front High Pinion Elocker Diff back from the shop with new 5.29's, solid spacer and triple Drilled flange a few days ago:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190032.JPG)
I took apart the Toyota hubs, bead blasted them, cleaned them all up, painted them and put them back together today:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB200039.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB200043.JPG)
I have been working on the front axle a bunch and will post pics soon......
-
how hard was it to put the lockers all back together?
i wouldn't mind cleaning mine up.
-
how hard was it to put the lockers all back together?
i wouldn't mind cleaning mine up.
You mean the elocker? It not to complicated, mostly just a regular diff with a shifter fork and pintle. They just hold together with a pin you punch out. Just take it apart and put it back together in reverse order.
Sean
-
i meant the hubs. guess i should of said hub locker :-\ my mad dude
-
Same deal, just watch how you take them apart and turn the dial a few times. Once you know how they work you can figure out how to put them back together.
Sean
-
The first time i took a hub apart to clean it up i got a little stuck on how the spring was held it. Just messed around with it, but it would of defiantly been easier if i had seen how it was before i just ripped it apart.
Amilla
-
Time for some pics on the axle housing build
Just to remind you what I started with, here is the axle when I got it:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P2080116.JPG)
On this pics you can see the added flange material on the right, the cut out for the locking fork, the left 4 holes are newly drilled and tapped as well:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB150003.JPG)
Because of the elocker pintle cover and motor I had to cut a bunch out of the passanger side bracket:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB150007.JPG)
Steering stops before:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB160009.JPG)
Then here is a gussets ready to be welded on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB160010.JPG)
Diff Guard ready to be welded on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB160013.JPG)
-
Here is the inside of the birfield cup ground down to make room for the Longfields:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190024.JPG)
Got the center link mount welded on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190026.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190030.JPG)
And the diff cover welded on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190031.JPG)
Got the brackets all ready to weld on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190027.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190029.JPG)
And here it is at 1:30am Thursday morning:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB190036%7E0.JPG)
-
Panhard mount ready to weld to the frame:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB210002.JPG)
Crossmember from Drivers side:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB210006.JPG)
Crossmember from Passanger side:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB210005.JPG)
More to come......
-
Thats looking good :) you can sure put some good welds down.
p.s. i just talked to you called and ordered all those parts. 1.6 adapter kit, fuel pump, new softtop, etc. kid from new jersey. Rob K. :P
i didn't realize it was you until i saw your name posted.
-
I actually have my brother Chris do my welding. His welds look far better than mine, ;D
Sean
-
No knuckle ball gussets?
Good thinking on girding the knuckle ball for longs, that is one thing i wish i would of done while the axle was all apart.
Looking real good keep up the good work!
Amilla
-
No knuckle ball gussets?
All of my Toyota friends (yea I admit to having Toyota friends :P ) HIGHLY recommended them when I was ordering parts for my Toy axles (and they are prety cheap too).
Zig
-
Iv seen a few bent axles due to knuckle balls giving up the ghost.
Amilla
-
Here is the last of the front axle build.
On Friday night we got it all welded up, I also put in the Diff stud eliminator kit and the elocker studs. This is right before I dropped in the diff, the RTV silicone is ready to go:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB210010.JPG)
My brother was rebuilding his Toyota Engine in the shop on Saturday so I was not able to paint it inside. With time running out I resorted to using some scaffolding laying around and strapped it up out back in the grass. Here it is after a couple coats of primer:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220011.JPG)
After the paint dried I put in the Creeper Breather:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220015.JPG)
Pressed in the kingpin bearing races:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220013.JPG)
Installed the Marlin HD Inner Axle Seals:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220014.JPG)
At that point the paint on the knuckles was dry so I put them together. New ARP upper knuckle studs, new lower OEM studs, and new spindle studs on the other side you can't see:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220019.JPG)
I then put together the spindle parts. New front wheel studs, vented rotors, and bearings:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220021.JPG)
Here is what I came up with to press in the rear bearing races and seal. I used an old Toyota rim (front up), and a wheel spacer. It worked out nice:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220022.JPG)
-
Passanger side knuckle installed with Rockring felt protectors and button head allen bolts:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220024.JPG)
View from the outside:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220023.JPG)
Longs:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220028.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220030.JPG)
Spindle bolted on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220031.JPG)
All together:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220032.JPG)
IFS Calipers:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220034.JPG)
That was about as far as I made it Saturday night, it was actually about 2am Sunday morning and about 40 degrees outside.
The next morning got the other side done:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220036.JPG)
Used more shims then I expected to get the right adjustment on the knuckles:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB220038.JPG)
-
Here we are going in on Sunday night:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB230041%7E0.JPG)
It finished the install and bleed the brakes Monday morning. Then took it to the exhaust shop.
When I got it back I took it for a test drive and played around for a minute in the field out back, when I flexed it I found I had a bit of rubbing to fix:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB230045.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB230044.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB230042.JPG)
On Monday night I took out the front wheel spacers I had put in to match the rear IFS width. That is what was causing the rubbing in the front. I also shortened the lower rear control arms to get a little better pinion angle and get away from the rear bumper a little more. I also installed the new rim rings and took out the ABS lights from the dash.
On Tuesday I wired up the front locker:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB250046.JPG)
Here is the locker switches installed with both lockers locked in. When they lock, the light turns on:
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB250050.JPG)
After that it was just touch up the paint, make a few more adjustments and load it up on the trailer. It was off for Moab on Wednesday morning.
-
We had alot of fun in Moab.
Thursday was pouring rain all day long. We started out on Hell's Revenge to test things out and found my weakness pretty fast. We did not weld enough around the panhard mount on the axle and it bent over.
We winched the front bumper into the bed of a Chevy truck that was with us and he drug me off the trail.
We found a nice Moab resident in that welded me back up on Thanksgiving night and we were ready for the next day. Never had any trouble the rest of the weekend.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB280084.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB280090.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB280087.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/PB290142.JPG)
My plans for the near future are:
-Find some 16" coils with a little bit stronger spring rates for the front and rear. I have 14" - 175 pound coils all the way around now and they are not enough for me with the heavy front bumper and winch and the rear bumper and tire carrier for the rear I will have. I have 2 - 1" spacers in the rear and a 1" in the front and I want about 2" more lift.
-Install a Rear Bumper and Tire carrier and somehow mount up a highlift as well. After thatmove the rear axle back about 1/2" - 1" to get the tire a bit more away from the fender. It rubbed on the plastic trim a bit on flex.
-Make a tool box to mount to the inside of the rear door.
MORE TO COME.........
-
Very nice work! I wish i had some E-lockers.
With a nice run under your belt with the tracker, are you happy with it?
I'm not sure how hardcore you got with it, but does it seem stable?
How is the suspension? Are your gears nice and low, or do you want lower?
Sorry for all the questions, one of my buddies is looking into this set up when his kicks IFS gives up.
Just trying to get some 1st hand knowledge.
Amilla
-
With a few trails under the belt I am happy.
The Low Range gearing is more them enough with the 5.29 diffs and 4.24:1 tcase and I love the Automatic.
I would like a bit more height and need to loose the rear bumper, it rubbed pretty bad but I knew it would.
I will eventually have to replace the control arms as I already tweaked one a bit. Might sleeve what I have.
All in all, I love the setup and glad I did it.
Could use a bit more ponies under the hood ;D
-
Hmmm i hear a supercharger will get ya up and going a little bit quicker ;D
That's good to hear that everything is working out pretty solid.
Ever think about some duel T-cases?! You could be walking the tracker!
Amilla
-
I do not need any more gearing, it has all the gearing I need. Just can't get out of its own way on the road.
Sean
-
I see I missed a lot when I was on vacation. :(
Truck looks great and its awesome that you had fairly good luck with first time out.
When you were putting your front axle together, is that similar how to a samurai axle rebuild?
-
I see I missed a lot when I was on vacation. :(
Truck looks great and its awesome that you had fairly good luck with first time out.
When you were putting your front axle together, is that similar how to a samurai axle rebuild?
The samurai axle is the same but smaller parts ;D
-
I do not need any more gearing, it has all the gearing I need. Just can't get out of its own way on the road.
Sean
Is it pretty slow on road?
Pretty much the only difference between a Samurai and Toyota axle (other than size) is the steering and they way the knuckles are.
Amilla
-
Is it pretty slow on road?
Pretty much the only difference between a Samurai and Toyota axle (other than size) is the steering and they way the knuckles are.
Amilla
I can do 65 easy, its just getting there takes a second.
Sean
-
Great work! If you dont mind me asking what do you have in to that bad boy? ???
-
Great work! If you dont mind me asking what do you have in to that bad boy? ???
I would say 13 if your counting retail prices and I'm not gone yet.
-
VERY NICE!!! Now you've got me itching even worse to get mine back...
Zig
-
I'm jealous
-
Ok, time for some updates.
We have had a few outings since the last time I posted and things have done well.
I have swapped out to heavier duty 18" front coils for the front and 16" coils in the rear as well as 3000 series Doetsch Shocks. By far a better ride and taller.
I also got the Rear bumper on and done before our May Arizona Zukapalooza Trip.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010103.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010170.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010179.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010180.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010225.JPG)
This trip helped me to see a few things needed to be done:
-Rear end was making noise, thought it was the brakes but soon found out it wasn't just the brakes
-I needed better steering as the little sidekick pump didn't want to turn the 33's with a locker in.
-Needs more Power!
-
I started the changes by adding in one of these:
(http://www.lowrangeoffroad.com/images/samurai/engine/cam.jpg)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/SSPX0117.jpg)
We will see how much it helps after we get it up on all fours again.
Also also wanted to get Hydro Assist on it so I pulled the steering box to get it drilled and tapped.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/SSPX0116.jpg)
I also order in the following parts:
(http://www.pscmotorsports.com/images/medium/Coolers/DER-13253-sm_MED.jpg) (http://www.spidertrax.com/core/media/media.nl?id=1551&c=407909&h=2505ebc24e6f8570c725) (http://www.pscmotorsports.com/images/medium/Tie%20Rod%20Clamps/SC-CL09_MED.jpg)
(http://www.pscmotorsports.com/images/medium/126_small_MED.jpg) (http://www.pscmotorsports.com/images/medium/Cylinders/SC-2206-sm_MED.jpg)
(http://www.lowrangeoffroad.com/images/samurai/steering/tcpump.jpg)
Now I just need to figure out how to make it all work.
MORE TO COME......
-
Truck looks awesome 8) I'd be interested in some more info on those springs as I'm having a hard time getting mine sprung right. I did the pressure increase mod to my stock pump and I can turn my 36's locked without too much trouble.
http://bbs.zuwharrie.com/content/topic,82835.0.html
-
Very, very nice. And nice write up of it all too. Thanks!
-
Truck looks awesome 8) I'd be interested in some more info on those springs as I'm having a hard time getting mine sprung right. I did the pressure increase mod to my stock pump and I can turn my 36's locked without too much trouble.
[url]http://bbs.zuwharrie.com/content/topic,82835.0.html[/url]
We can get longer coils in different rates. PM sent.
Sean
-
Hey Sean,
Did you and your crew fab up that rear bumper?
-Eric
-
Its a 2 door Calmini Rear with allot of mod to get it on. We had to add about 1.5" to each side to make it wider. We also had to rework the latch and some steel to the top on the sides under the lights and around the corner and build brackets to get the bumper mounted on. Then had it re-powdercoated.
I also used a ZOR hitch under it.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/untitled1.JPG)
-
That's cool... I've been contemplatin' doing the same thing for a 4-door buildup I'm working on... I'm curious, why a hitch?
-Eric
-
That's cool... I've been contemplatin' doing the same thing for a 4-door buildup I'm working on... I'm curious, why a hitch?
-Eric
Basically for the d-ring you see, no other tow point or strap-to-trailor point in the rear and I'm anal and I do not want to strap on the axle tube.
Sean
-
That's cool... I've been contemplatin' doing the same thing for a 4-door buildup I'm working on... I'm curious, why a hitch?
-Eric
Basically for the d-ring you see, no other tow point or strap-to-trailor point in the rear and I'm anal and I do not want to strap on the axle tube.
Sean
Ah, I see...
-Eric
-
great job! I wish I could pull that off on mine right now.
-
reinforce the frame while you have that steering box off. you'll regret it later if you dont
-
What brand of muffler did you use on your exhaust system?? Also could you maybe post a picture of the full exhaust system?
Thanks
-
It is a round 4 or 5 inch magnaflow. It is loud and I need them to add in a resonator or something.
-
Amazing Tracker man... I've been looking for inspiration for mine, and I think i just found it.
AND WHY DOES EVERYONE HAVE SUCH A NICE BACKYARD! :'(
-
Ok, finally have time for a few updates.
I took the stock power-steering Bracket and chopped it a bit, cut off the bottom front tab that mounts to the front of the stock pump.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010094.JPG)
Then I cut the 1.6L TC Pump bracket we sell in half.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010098.JPG)
Then welded them them together after several hours of fitment and making sure it was all right. The belt had to be aligned right, the fittings on the pump could not interfere with anything else and the A/C brackets and compressor had to fit right. I had to clearance the A/C bracket a little to make it work but I got it all in. The belt may be a 1/32" off but it works close enough.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010103%7E0.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010107.JPG)(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010106.JPG)
Here is the mounting point before the bracket
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010130.JPG)
With bracket
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010133.JPG)
With Pump
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010135.JPG)
With A/C bracket, you can see the front corner is trimmed
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010136.JPG)
With A/C compressor
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010138.JPG)
-
I mounted the reservoir using a stock Air filter box mount, it jams itself into the padding on the grill and is very solid
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010110.JPG)
Rebuilt, drilled and tapped the box for the hydro assist. The other hydro fitting is on the top front corner of the box
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010113.JPG)
I mounted the heat sink between the bumper and A/C fan on a cross-member. I just used self tapping hex head bolts to mount it in. Worked great.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010115.JPG)
I also had a custom panhard made to get rid of the Tie Rod Ends that are used in the Trail Slayer kits and used Heim Joints. I had to drill the FJ80 tapered holed out to 5/8" and machine down the misalignment spacers to get it were I wanted it.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010125.JPG)
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010124.JPG)
Here is a picture of the ram mounted in the axle side only. Here it is mounted between the 2 tabs provided on the upper link bracket but I ended up mounting it above the top tab to get the ram level once mounted onto the tie rod bracket.
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010128.JPG)
-
Here is a picture of the hose routing
(http://www.zuwharrie.com/gallery/albums/userpics/11769/P1010140.JPG)