ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: Shredder on September 01, 2008, 02:49:02 PM
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My brother calls it a Trackota Wrangler because of the parts used. I am just glad to see it fanally coming together. It has been collecting dust in the garage for 2 years. I guess I just had to finally commit to doing it.
All in all it is coming along good. I would have been done by now if I just welded up what I needed to get the spring mounts on but I wanted it to be able to be duplicated and bolt on. I used CAD for all the parts I designed and made. Although you do need to cut off the old IFS brackets and crossmember and drill a few holes the rest is bolt on (with the option to weld for added strength). I took it apart to clean everything up but when I put it all back together I will shoot some pictures.
It is a Gen. 1 SWB with Toyota pickup axles and YJ springs front and rear. It will be interesting to see just how fast it can be installed when I put it all back together. I am going to clean the axles up and shoot some paint on them. Then I will put it all back together. I have a busy week ahead with the fire station but should be putting it back together next weekend. Here are the parts. I might have edit this as I remember more.
Parts List (I made):
2 Front spring hangers (bolt on)
2 Front spring shackle mounts (bolt on)
2 Rear spring hangers (bolt on)
2 Rear spring shackle mounts (bolt on)
4 Shackles (bolt on of course)
2 Front shock upper mounts (bolt on)
2 Front shock lower mounts (bolt on)
Other parts:
2 Toyota pickup axles F/R
4 YJ front springs (4 leaf), (YJ rears, 5 leaf, recommended for SPOA)
2 front shocks
2 rear shocks
3 weld on axle/spring perches for spring under aplication
4 New brake lines
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Well I got the chance to start work on the Trackota Wrangler. Here is a shot of it after cutting off the IFS and removing the rear suspension and axle. The YJ springs are also in this shot.
(http://www.boondox.net/ZukSAS_stands.jpg)
The Toyota axles waiting to be cleaned up.
(http://www.boondox.net/ZukSAS_axles.jpg)
Here are most the 1/4" pieces cut and bent before welding up to make the "kit".
(http://www.boondox.net/ZukSAS_pieces.jpg)
This shot shows most the parts ready to be bolted onto the Tracker frame.
(http://www.boondox.net/ZukSAS_Kit2.jpg)
This is a few hours later. The "kit" installed surprisingly fast. I had all the brackets on and the springs hanging in about 4 hours. Then I had to decide between spring over or spring under. Spring over was easy. I just rolled the axles under and bolted them up. It was too tall for the wimpy 31" tires I currently have on the Toyota rims so I decided on spring under. This shot shows it with the rear spring over while the front is spring under. Spring under did require the welding on of spring perches on the axle.
(http://www.boondox.net/ZukSAS_overunder.jpg)
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That is really cool. I like the "bolt on" idea, is that something you are going to produce? It may sell...
Nice job 8)
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that is awesome, i want it..lol if you ever decide to make one to sell , lots of us would love that kit...well i no i would!
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Here is a picture of it with the spring under option. It sit's pretty much how I hoped it would. It measures about 38" at the fenders on 31" tires. It has 16" under the frame rails and 18" at the rockers. About the same as a 6.5" suspension lift would be. No body lift.
This was done with new 4-leaf YJ springs F/R. I think 2-3" lift YJ springs would be nicer. I also tried with the springs over the axle which gave it about 21" under the frame rails but it looked silly with the 31" tires.
Overall I liked the "kit" however I am making a few simple changes to make it even better for the next one.
(http://www.boondox.net/ZukSAS_sideview.jpg)
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Looking good!
Have you thought about adding a piece to your spring hangers to act as a skid point. The way they are sitting now looks like you could have some snag points while sliding over obstacles.
Something like this.
(http://i49.photobucket.com/albums/f261/rellim87/ZukSAS_sideview.jpg)
Just my 2 coins worth
Amilla
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That's a good point and observation. Just may have to do that. Thanks.
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Any plans to sell the kit and or possible drawings for all of the bracketry so that I can make my own ;D ;
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It is being considered as a kit. I am making a few small changes in it to address any of the issues observed and to make it easier to manufacture. The prototype emptied my wallet (firefighters are underpaid). There is over $200 dollars in the 1/4" steel alone. Then there was the plasma cutting, bending, drilling 96 holes, welding, grinding and painting. There are a few machined parts in it also and over $75 in grade 8 and 10.9 hardware. Then I also had to build the jig to fit and hold the parts during welding.
Metal is expensive so I need to do a CAD layout for the laser cut so all the pieces nest for minimal scrap. The laser will also be able to "drill" the holes at the same time for less man-hours. Not to mention less drill bits. I'm working out price structure for it now. So you just might see an actual kit soon. ;) It's hard to find time to do all this when you are a firefighter 24/7 but I have had alot of requests for this.
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This kit will be great!
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Are you using the stock sidekick steering box? What did you do for steering?
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Yes the stock Tracker steering box was retained. The steering linkage used on the axle was stock toyota. For a temporary set-up we tried a driver side tierod on the passenger side with a shortened crossover. A custom draglink between that tierod's stabilizer mount and the pitman arm connected the two. This is going to be changed to an aftermarket hi steer setup to allow for spring over axle also. I'll post some pics of it once the change is completed.
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Is this the Boondox kit that has been in developement?
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Is this the Boondox kit that has been in developement?
I guess you could call it that since I am the only one left at Boondox. I run it on the side (real job = fire fighter/first responder) from my garage/basement and do what I can to keep customers happy but it isn't easy with my schedule. Development of this kit stalled for over a year but I finally made some time to get to it.
Boondox will soon be moving to Denver where the new owner has some good plans to make things better. I'll still be connected with them in R&D work though which is cool.
BTW- Sorry I am so hard to get hold of to any of you reading this. It is hard to take a call when you are fighting a fire. :police:
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Shredder do you have an estimate of customer cost this is exactly what I would like to do to a tracker.
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Boondox will soon be moving to Denver where the new owner has some good plans to make things better. I'll still be connected with them in R&D work though which is cool.
Well thats it.....no more shopping around. If theres going to be a (semi) local shop, I just gotta support 'em. ;) Thats Great!
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Any more development on this?
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I'm running this kit on my tracker. I have almost 2000 miles on it already.
From what I hear they are making a few slight changes on the kit. I was talking with Steve from Boondox yesterday and hopes are to have the kit available soon.
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Is there an estimated price yet??????
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Soon
Still working everything out to make it a good deal
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subscribed!
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I'm really interested in the cost of this kit. please PM me with an estimate, High ball it if need be. This may make or break me getting a jeep instead of a 4 door track/kick.
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waiting with popcron a nd beer... anone have any feedback on avail and price yet?
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Soon
Still working everything out to make it a good deal
Hello is this kit allready available?
a curious firefighter from Holland
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The wait may be over! I'm working with Sky at Sky's Offroad Design on a ZUKIWORLD project vehicle that is going to be leaf-sprung Toyota solid axle equipped. He is prototyping in the shop right now and we'll be featuring the vehicle as soon as it's ready. As of now, he is planning on selling this kit.
Below is a sneak peak with it on rollers.
-Eric
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Man, that looks great. What are you doing for gearing? Are you going the Kicker route? Are those 33's or 35's?
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Man, that looks great. What are you doing for gearing? Are you going the Kicker route? Are those 33's or 35's?
Well, that part is open at the moment. I'm weighing options on power/gearing. A couple of proposed ideas are to run Stock 16 valve engine with a Samurai case behind the Sidekick transmission w/o the Sidekick case & 5.29:1 gears. Another idea is 5.29, stock Sidekick case w/XL7 V6. Another idea is Samurai case, Mercedes 300SD w/manual transmission & 4.10:1 gears. Maybe run a 1.9 TD VW engine with stock t-case and tranny & 4.10 gears.
The tires on it are 35 inchers...
Something like that. :)
-Eric
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cool. thanks for the update. Let us know what you decide to go with for the gearing.
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No plans for a review of the Trail Tough Undertaker box? :)
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No plans for a review of the Trail Tough Undertaker box? :)
There are plans.
-Eric
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Sounds like the perfect setup.
If you really need some help reviewing it you can send it my direction. It would probably go great in the new race truck. :D
Looking forward to the solid axle setup, is Sky planning on using YJ or Toyota springs?
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Sounds like the perfect setup.
If you really need some help reviewing it you can send it my direction. It would probably go great in the new race truck. :D
Looking forward to the solid axle setup, is Sky planning on using YJ or Toyota springs?
YJ.
-Eric
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I'm somewhat interested.
Dont know how there is over $200 in 1/4" steel alone tho, I just got a 4'x4' piece of 3/16 from the local steel place and it was $52.xx. For a 4'x4' piece of 1/4" it should be around $70-80 and there's no way you have 4'x4' of steel in those brackets.
Regardless, I'm interested and would like to hear more about the "kit" and what all is required.
Any issues with moving the front axle setup forward 1.5-2" and the rear back about an inch?
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Man, that looks great. What are you doing for gearing? Are you going the Kicker route? Are those 33's or 35's?
Well, that part is open at the moment. I'm weighing options on power/gearing. A couple of proposed ideas are to run Stock 16 valve engine with a Samurai case behind the Sidekick transmission w/o the Sidekick case & 5.29:1 gears. Another idea is 5.29, stock Sidekick case w/XL7 V6. Another idea is Samurai case, Mercedes 300SD w/manual transmission & 4.10:1 gears. Maybe run a 1.9 TD VW engine with stock t-case and tranny & 4.10 gears.
The tires on it are 35 inchers...
Something like that. :)
-Eric
Just let me know when you need the 1.9 TD
:)
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Picking up an 84 SFA Toyo axle from bend this weekend.....oh boy. 5 hour drive in a diesel........for one axle. To get that. What pack are you gonna use on this project? 4/5?
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Picking up an 84 SFA Toyo axle from bend this weekend.....oh boy. 5 hour drive in a diesel........for one axle. To get that. What pack are you gonna use on this project? 4/5?
Hey minmatar, do you play eve online?
Sorry to post off topic, just had to know ;)
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I did.....4 years is more then enough time spent on one game........
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I did.....4 years is more then enough time spent on one game........
Hehe, yup, well I still do but not as active as I used to ;)
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Amusing as I just started playing...
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yeah I was i stopped playiing full time after TCT corp / LV alliance broke.
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Ok im gonna start spaming this topic until i get an answer on kit prices....... >=l I refuse to let this subject get any lower on the totem pole of DIY.
Sky
Boon
LETS GET SOME PRICES!
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Ok im gonna start spaming this topic until i get an answer on kit prices....... >=l I refuse to let this subject get any lower on the totem pole of DIY.
Sky
Boon
LETS GET SOME PRICES!
Did you call them?
-Eric
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hey i have my 84 front axle for the kicker and am doing the leaf lift as well, its less parts to break... curious though kinda new to this, but bolt on? i have been gathering parts and luckily i didn't buy the shackles and hangers yet, but can you show how the front frame got extended, i didn't want to weld that because of the fear of weakening the frame, but that is the only struggle i have right now.
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I did the Toyota axles on mine, and used leafsprings, I did not need to extend the frame at all.
I will try to get some pics up soon.
I am running one of BOONDOX's protype sas kits.
Hopefully the kit will be on the market soon, I love it and have been running it for over a year now, with no issues
I know Steve at Boondox would have liked to have the kit on the market by now, but some things came up, that took priority over his business, so the kit got put on the backburnner
I started with the spring under version, but I think I am going to go spring over soon
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Picking up an 84 SFA Toyo axle from bend this weekend.....oh boy. 5 hour drive in a diesel........for one axle. To get that. What pack are you gonna use on this project? 4/5?
how much is the axle? if you dont mind me asking
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I got a set(front & rear) of 84 toyota pickup axles from a junk yard for $300, then rebuilt them.
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that is the best price I have found them at too.
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Ok im gonna start spaming this topic until i get an answer on kit prices....... >=l I refuse to let this subject get any lower on the totem pole of DIY.
Sky
Boon
LETS GET SOME PRICES!
Did you call them?
-Eric
Call who? I dont see any numbers to call........Im sitting on cash to spend and the zuki just blew a thermostat. Full close for 2 miles = plastic radiator bezzle shot. =( major over heat and id rather buy the lift and think of a new power plant.
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Ok im gonna start spaming this topic until i get an answer on kit prices....... >=l I refuse to let this subject get any lower on the totem pole of DIY.
Sky
Boon
LETS GET SOME PRICES!
Did you call them?
-Eric
Call who? I dont see any numbers to call........Im sitting on cash to spend and the zuki just blew a thermostat. Full close for 2 miles = plastic radiator bezzle shot. =( major over heat and id rather buy the lift and think of a new power plant.
Aren't you posting a question to Sky, to give you a price? I replied to that request saying "call them..." He doesn't frequent this board but I'm sure he'll be able to answer your questions about the kit he is developing. So, that's the who to call. :)
-Eric
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Ok im gonna start spaming this topic until i get an answer on kit prices....... >=l I refuse to let this subject get any lower on the totem pole of DIY.
Sky
Boon
LETS GET SOME PRICES!
Did you call them?
-Eric
Call who? I dont see any numbers to call........Im sitting on cash to spend and the zuki just blew a thermostat. Full close for 2 miles = plastic radiator bezzle shot. =( major over heat and id rather buy the lift and think of a new power plant.
Aren't you posting a question to Sky, to give you a price? I replied to that request saying "call them..." He doesn't frequent this board but I'm sure he'll be able to answer your questions about the kit he is developing. So, that's the who to call. :)
-Eric
Doesn't he understand we're the best of the best? >=l HMMM???!!!!!
Im still not sure who im suppose to be calling from sky.....
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I called SKY and they still have no prices in mind. They're still "working the kinks" out. =( this makes me sad. If i could even buy the prototype id be stoked...... Im glad i looked at their gallery. 9 Pics of the kit are up some are action shots ;)
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Is the back of that Sky kit using yj springs also or a coil kit? Are slip yoke eliminators needed for the Sky and Trail tough kit? If so, I can see the use of the sammy tcase.
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Is the back of that Sky kit using yj springs also or a coil kit? Are slip yoke eliminators needed for the Sky and Trail tough kit? If so, I can see the use of the sammy tcase.
Sky kit is leafed all around if you go to their site you can see the suspension setup. Looks like the rear is pushed out 3 1/4" with a shackle mount coming off the outside of the frame.I like this idea due to everyone on the 4 doors running their springs into the gas tank. (nice move in my opinion) Looks sturdy.
I believe a sammy T case is ideal (especially if you do the rear off set axle like the samurai guys)
Question is if you wanna get rid of the Tracker T Case all together and run only the sammy case? |removethispart|@ 6 to 1. Would it be enough 2wd for free way and around town.
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I looked at the sky setup and noticed the shacle is in the bace and not the front like most are. that is different.
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Just an update. Just called SKY and they said we could see this kit out as soon as 3-4 weeks!!!!!!! start saving cause fathers day is right around the corner!!!
Any dad with a sidekick that would like to see some axles under it, making it the size of a Ford Diesel........mind u. Would love this kit!!!!
I know my dad would love me, to buy this for me, on fathers day! ha!
Lets not limit this to Fathers day now. Mothers day. Anniversaries, guys, does your little lady hate your sidekick cause everyone can see in as they drive past? NOW YOU CAN LOOK DOWN ON THEM! No longer will you be hassled by that ricer or old school American muscle guy.
Single? The sky kit can help you there too!!! See a nice looking girl you would like to talk to on the road? Run her |removethispart||removethispart|@$$ over and swap insurance! Always a good ice breaker.
Can ya tell the coffee is working?
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from the pictures it looks like it will be a weld on setup and not just bolting stuff up. what size tire do you think it could run?
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I've got a set of 35's already to go. Not the best choice but ill work with them until i figure out its characteristics. Ill be running a 1.5" spacer front and back. Unless i can find a full floating rear end. 5.29's and im looking into a sammy t-case. Ill prob drop the sidekick t case all together. and mach up a truss bracket. Ill keep it locked in the rear for now not much for rock crawling around here in the PNW.
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I am planning on making a home made setup for my toy axles, but my DD broke down and can figure out how I am supposed to cut it up and rebuilt if I still need to drive it. I have some 33's if you want to trade minmatar. I am in Portland too. maybe we could get to gether and help each other out.
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from the pictures it looks like it will be a weld on setup and not just bolting stuff up. what size tire do you think it could run?
Yes, it'll be a weld in kit. The prototype 4-door in the pictures has 35" tires on it.
-Eric
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Are those billstein 5125's? Those are pretty stiff.....
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Are those billstein 5125's? Those are pretty stiff.....
Um, what application and valving?
-Eric
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when do you think the kit will be on the market?
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My best guess is the month of march. I have no clue to what it will cost either. Lets not hope its anywhere near the trail slayer kit....... id rather have a second sidekick then pay that much....id stick 2 ifs and sell my axle.
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Are those billstein 5125's? Those are pretty stiff.....
Um, what application and valving?
-Eric
I know the 5125 goes to 170/60 but i've seen them as high as 366/240 way over kill
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hey what did you do for a drive line? did you use a spacer or had one made
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I wonder if they are using kick or toy driveshafts? Kick shafts can be used to keep it cheap, but need a slip yoke elimintor to have lots of travel. But if using a sammy tcase, then front sammy driveshafts could be shortened for that apllication, or common aftermarket sammy driveshafts.
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I wonder if they are using kick or toy driveshafts? Kick shafts can be used to keep it cheap, but need a slip yoke elimintor to have lots of travel. But if using a sammy tcase, then front sammy driveshafts could be shortened for that apllication, or common aftermarket sammy driveshafts.
To be honest id go with custom drive lines Suzuki 2 Toyota. = UJ 2 CV. I think it would be my best bet after turning the front axle 15 deg counter clock wise. Pointing the 3rd member to the offset samurai T case.
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Are you planning on cutting and rotating the knuckle balls?
The 1st and 2nd generation Toyota drivelines fit up to a Samruai T-cases quite well.
Amilla
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Are you planning on cutting and rotating the knuckle balls?
The 1st and 2nd generation Toyota drivelines fit up to a Samruai T-cases quite well.
Amilla
Yeah Ill cut them with a 4" pipe cutter. And rotate them myself. Im going to take them to a shop to be welded correctly though. I dont have that much faith in my welding skills. I'll leave that to the pro's. Im fine with welding other items.
Im sure ill get a ton of welding time in with this kit though.
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Sad to say that sky is so backed up this kit has been put on the back burner. Looks like ill be making my own kit. Really sad to hear that but 6 months out does not work for me.
Broke my heart.....
Looks like we might have a new thread on SAS SOA coming soon. Just need to find out what direction to take with the mounting points for the leaf's.
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Are you planning on cutting and rotating the knuckle balls?
The 1st and 2nd generation Toyota drivelines fit up to a Samruai T-cases quite well.
Amilla
Yeah Ill cut them with a 4" pipe cutter. And rotate them myself. Im going to take them to a shop to be welded correctly though. I dont have that much faith in my welding skills. I'll leave that to the pro's. Im fine with welding other items.
Im sure ill get a ton of welding time in with this kit though.
for some reason I have never thought about having to cut the knucles if I rotate the third member to grt a better driveline angle. does anyone have any more info on how to do this???
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Are you planning on cutting and rotating the knuckle balls?
The 1st and 2nd generation Toyota drivelines fit up to a Samruai T-cases quite well.
Amilla
Yeah Ill cut them with a 4" pipe cutter. And rotate them myself. Im going to take them to a shop to be welded correctly though. I dont have that much faith in my welding skills. I'll leave that to the pro's. Im fine with welding other items.
Im sure ill get a ton of welding time in with this kit though.
for some reason I have never thought about having to cut the knucles if I rotate the third member to grt a better driveline angle. does anyone have any more info on how to do this???
Here ya go This is my guide on rotating the knuckles
http://www.4x4wire.com/toyota/tech/rotated_housing/]
[url]http://www.4x4wire.com/toyota/tech/rotated_housing/ (http://[url) [/url]
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sounds easy, but my axles are fj55 axles, so I don't know if they are built the same. with the way the knuckle goes into the axle housing.
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Im sure its the same since toyota has always favored birfields. Sad to say this kit is on the back burner which will drive me to get the calmini lift......for now im just referbishing the axles im keeping and gathering parts and saving money for a second zuk
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I have got a couple nice zuks for you
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Do you have a 2d soft top? Kinda would like a new daily driver....
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I have:
1989 2dr convertible body and frame.
1990 2dr tintop
1991 4dr needs some tuning
1994 4dr might need to rebuild the motor
1995 4dr in the middle of doing the head gasket
1995 2dr 4.3 GM V6 700r4 but I dont raelly want to get rid of it
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Well if you ever get a 2 door soft top in. Nice and clean let me know. Im in the market.
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Any updates on these kits?
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i need info for this kit to!!!
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I've recently talked with Low Range about converting my front end- it sounds like they are very close to having a kit ready and I will be starting on the swap this weekend. It is made for a samurai axle but can use a samurai to toyota axle kit.
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hi i just purchased a 93 tracker an want to put yota straight axles under her do u have a number i can reach u at just want to ask some questions in reguards to your build im new to the tracker world took me along time find one than was in good enough shap to be worth messing with
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I guess Im helping to revive a year old thread. But this is good stuuf. Im in the market for this kit. The slayer is still pretty pricy but this kit I would pay good money for... Any updates? Is sky still going to carry the kit or low range? Any info would be greatly apreciated.
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Just call Low Range Off Road- they have everything you need for the swap. I've been running mine for quite a while now and it has been great.
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Low Range has it for the Samurai not the tracker, anyone know where I can get brackets for the Tracker???
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yj springs are about 6" longer than sammy springs and will stick out further in the front hindering your approach angles. The mounting kit for the toyota axles is available for both yj or sammy springs but if you want to mount yj springs on your tracker front end you will have to build your own mounts out in front of the bumper. I think they stick out too far and when you add the shackles, there is a real loss of clearance and approach. I am running Trail Gear rear sammy springs with 3" of lift for my front swap and they are working good.