ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: johnnyairtime on December 06, 2011, 10:55:55 AM
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I found this one 1.5hrs away... towed my flatbed up to look at it (just in case). I kept thinking... it's got to be something I'm missing, or something wrong with it that the seller's not telling me (as all others I saw for $3500 range pricing were junk in my area). And he had lots of upgrades as you'll read (I'm sure I'm missing quite a few of the add-ons);
It's a 1992, with the following;
- Geo Tracker fuel injected 1.6L (3 speed auto)
- Geo Tracker power steering
- 3" Tach gauge
- SPOA Lift, with high steer, braided brake lines, large bump stops, boxed in spring plates...etc
- New Interior (front and rear seats, door panels)
- 33" Pro Comp Tires on 15x10 Progressive Alum wheels
- REAR Axle; Sidekick/Tracker axle, 4:56 gearing
- Rear end welded up, Locker (rear locker manual hubs, to take it out of full lock - per side)
- FRONT Axle; Stock Sammi Axle re-geared to 4:56 (no locker)
- Split H transfer case
- Two speed High/Low Doubler by OTT Industries "Kicker3"
- front and rear missing link
- front and rear disc brakes
- brand new soft top
- TomWood front cv driveline
- all new u-joints
- new stereo and two new speakers
- new procomp shocks.
- New 31" Spare M/T tire/wheel
- door "off" Mod to hinges
- All of the interior/dash is there, nothing missing.
Buyer was asking $4500, I gave'em $3800 cash.
... I also got a complete front and rear stock axle & springs, some stock wheels, stock fuel tank/sending unit, and spare tracker power steering unit thrown in with the deal.
Here it is loaded on my trailer, for the drive back home;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/Day1%20-%20sold/1d9a237d.jpg)
My immediate plans are;
- Add a Line Lock (which I found two, never connected under the hood!)
- Build a full interior roll cage - front to back
- Build rock sliders, and tubing side protection
- 7" IPF Headlamps, and 35W 4300K HID H4 Dual-Xenon lamps.
- front bumper mounted LED light bar
- diamond plate rear panels
- re-paint it back to grey (hood has black spray paint over flame decals) or semi-flat black, or even bed liner
- build new "road armor" type bumpers
(front specifically, not sure about the rear... I like stock with rubber end caps)
- Get door and gate lock cylinders replaced
- Add a CB (and Ham radio) for Geo-Caching events for the wife.
Near future thoughts;
- Pickup stock wheels, and mount 31 or 32" tires and re-gear for taller gearing.
... it tops out at 50 at 4000rpm as it sits currently, and I need it to be a comfortable 55mph (not for freeway, but surface streets) as a grocery getter from camp to town. It's a serious crawler, and I'm not sure I want to change it. We'll see once we use it some, and get used to it.
- If I build a rear-bumper; to add a swing out tire rack with high-lift/shovel/axe/fuel can mounts, LED backup light...etc.
- Front locker (not sure of what type just yet, ideas?)
I still have A LOT to learn about it.
I'm trying not to call the original owner back every day to ask questions... I'm writing them down, and will make a call a week until I get all the info I need going forward.
... I'll be taking it out within a week or so (our desert is only 1.5hrs away) to try it out.
I've already replaced the starter, and will be working on two of the larger dents this week. Then prepping it for my "lowrange" order coming in, which means I have to work on getting it sanded... some VERY mild rust repaired, and painted (still deciding on which color to use, and paint brand... or even to spray on liner instead of paint). I also have found a LOT of wires that I'll be re-running and re-wiring... soldering, and heat shrinking putting them back in looms. The previous owner was definitely NOT a wiring guy. AS I work through it, I'll also be cleaning up some of the welds, and taking a bit of the "rough" edges off.... I know I don't want it to be show quality (then I'll never want to scratch it!), but... I want it to be MY Sammi.
Updates and pictures will come, as I progress with the TO DO list. Stay tuned.
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It seems to be very clean. Hope full, get more pictures of your new toy soon ;)
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Wow ...Sounds like quite the score...Nice Zuke...The best advice I can give you is :Have fun...Take your time ....And RESURCH RESURCH RESURCH any decisions you make BEFORE YOU START TIRNING WRENCHES....Boxcar...
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Wow ...Sounds like quite the score...Nice Zuke...The best advice I can give you is :Have fun...Take your time ....And RESURCH RESURCH RESURCH any decisions you make BEFORE YOU START TIRNING WRENCHES....Boxcar...
I agree
With the way that is built, I say play with it and learn what you can, can't, and won't do before changing things around. Once you start using these off road, your wants seem to change a little.
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I too agree. I need to take it out and play around with it. And will be, in the next week or two.
However, tomorrow... I'll be getting the dings and dents removed, and some surface rust repaired (around the windshield). Then, I'll repair the hood latch areas on the hood itself (a bit of cracking from the hood brace coming loose from the hood). All of this, to prepare it for a Satin Black paint coming next week.
Today, I'll snap some "BEFORE" pictures of how I bought it. Dirty and all. Then, I'll be removing all of the needed items for a good thorough dent repair and prep for paint. I found a guy, who'll do good work... and get it all done in one day (tomorrow). I'm NOT a body guy, nor do I have those tools. But, I'll be welding up the mirror holes on the doors so he can flush them and assisting in making it straight (the mirrors are being relocated for when the doors come off during wheeling). So, between him and I... it should look pretty good, yet rough (primered spots) by end of day Friday.
... I'll take some in-progress pictures along the way between now and paint. Once it's painted, I'll do the interior with bed liner (even though it's not bad original grey paint) and color change the rest of the interior to satin black via paint added to rattle cans. I'm going to take it all apart to do the color change... AND learn about the rig. As well, I'll be tidying up ALL the wiring I can see not in wire loom or tied up neatly. AS well, get out the solder gun and repair a bunch of under hood stuff while I'm at it.
All of this, without changing how it "wheels" off-road.
... I've already ordered a bunch of usable stuff from LowRange. Things like Diff covers, body armor, etc. Will get door locks and such on order today. And then, once painted... I'll build my rock-sliders with outer tubing "body protection" and then when the "tire rack" hardware gets here... work on a back bumper and tire rack (also for gas, shovel, axe..etc). Once the back is done, I'll do a front bumper. I just need to work on "winch specs" so I can make the bumper winch friendly in case I, or a new owner ever wanted to add a winch.
I'll leave any gearing, tire/wheel change ideas to AFTER I take it out and play with it. I'm already pumped to go "play"!
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Haven't taken it out to "play" yet... too busy "fixing" stuff to my tastes.
Thus far, I've;
- repaired the rusted out lower rocker panels. (cut out the rust, and welded in new 16g steel)
- repaired all rust under seals/gaskets/moldings (around windshield, rear tail gate, etc)
- fixed the two corners that were dented in (stud welder and puller, with minor body filler)
- removed the door hinges and cleaned up the 'door off mod' someone else did.
- removed all the truss head phillips screws, to eventually replace them with torx or allen truss heads.
- sanded the entire body inside and out.
- removed the front 'custom' bumper the previous owner did.
- removed the rear stock bumper and hitch assembly, someone else made.
- ordered all new window rubber/felt and other gaskets/moldings.
- welded up all un-needed body holes (mirrors, tire carrier...) and filled, smoothed out for paint.
- welded in a new brace under the hood to tie in the hood brackets.
- welded in a new brace above the hood cowel to stiffen the bracket mounting area
- re-sealed/glued the hood itself to the interior hood X brace.
- repaired the stock holes, and dents in the fender flares. Sprayed them flat black.
- ... and more I can't remember.
This next week, I'll be using UPOL Raptor bed liner on the entire exterior and interior as my 'paint job'. After that, I'll be painting all the new bumpers and rock sliders, or things I build with flat black. This will give it some contrast.
Once the bed liner material is shot and dry, I'll be able to start re-assembling. Using all new stainless torx truss head machine screws in place of the phillips originals, and put on the new parts and protection I've been ordering/making for it.
Of course, I plan on using it... and getting some more dings/dents and scratches... but, they'll be from ME. Not someone else.
Santa is bringing me a Smittybuilt XRC8... so I'll incorporate that into my new bumper I'll build. Should be a FUN ride! ;)
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Here's some progress pictures, not in any order of progression... sorry... (they are clickable thumbnails);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a8a8452d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a8a8452d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0c7314f8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0c7314f8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_3e426bd8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/3e426bd8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_03b56ae3.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/03b56ae3.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_3dcd1733.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/3dcd1733.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_8e15073e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/8e15073e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_89e68393.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/89e68393.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_533bf30b.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/533bf30b.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_c0463fed.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/c0463fed.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_b4dbc3f7.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/b4dbc3f7.jpg)
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It's now ready for bed-liner to be sprayed on.
... All welding, dent pulling, and bracing is complete.
There's only a few things I'll need to tape off, and I'll have to hang the tail gate, doors, hood, and misc. brackets to make sure I get both sides. As I don't want to paint any of the brackets/hinges because they'll all be flat black with stainless hardware. So nice of Suzuki to use about 3 bolts sizes to secure the entire body. Makes hardware swaps quite easy.
Here's a few more;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_39310405.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/39310405.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_52e76f31.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/52e76f31.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_00091f76.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/00091f76.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_f2700425.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/f2700425.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_29ad3a71.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/29ad3a71.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_5650d0a2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/5650d0a2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0324f70f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0324f70f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_fdb8bd52.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/fdb8bd52.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_686cd5bf.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/686cd5bf.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_ab9435d8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/ab9435d8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0ac20ae7.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0ac20ae7.jpg)
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Today is a good day...
Got the Zuke washed, and ready for bed liner topcoat to be sprayed.
... finished the windshield body repairs, and it too is ready for bed liner topcoat.
My most exciting news today... Westfield Fasteners in the UK, has the flanged (truss head) button head socket screws and is shipping them DHL. I should have them by the 21st, and in perfect time to start re-assembling the Zuke. It'll sure be nice to replace the ugly phillips head screws with a stainless screw, that will hold it's luster for years to come.
Here's what they look like;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/3393684b.jpg)
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Looking good. :)
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Looking good. :)
Thanks Drone...
Tonight I was able to aaaaalmost finish the paint, or shall I say Top Coat? (since it's all bed liner).
The exterior of the zuke is done, yet I only did the interior portion of the doors, tail gate, top, hood...etc. Tomorrow, they'll get done and mounted by end of day Thursday. It'll start to look like a Samurai again.
I'm sure it'll look clean with all new stainless hardware, and flat black accents like the door hinges, fender flares...etc.
Here's a couple in progress;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9f764cc4.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9f764cc4.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_5b627bbb.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/5b627bbb.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_2beb4a30.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/2beb4a30.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_76c2a8ea.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/76c2a8ea.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_2cc33d22.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/2cc33d22.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_75a73dec.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/75a73dec.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a1c88213.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a1c88213.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_63b3f122.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/63b3f122.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_6f40d5f0.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/6f40d5f0.jpg)
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Super slow going today, and the last few days as my lower back (sacroilac to be specific) is giving me some serious pain.
Got some more parts in today;
.... the much needed Truss Head Socket button head screws!! As well as my rotopax fuel cans (to add to my tire rack I've not built yet). Tomorrow, I get some more goodies....
None-the-less, it's coming together.
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a781eb4c.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a781eb4c.jpg)
I've decided to take the windshield back off, to cut the 'zuk support bra' and add a light tab. You can see where I noted to cut, since the support bra isn't allowing me to tilt the windshield forward as it was intended. And you can see how the light won't match up to the pre-existing hole (mirror is in the way). It's even a small PIAA.
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_6f725ef6.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/6f725ef6.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_2098c005.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/2098c005.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_5d30d1ab.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/5d30d1ab.jpg)
Tomorrow, I'll cut and weld the support bra and re-spray it (touch up). As well, might hang my doors and tail gate to get them off my garage floor before they get banged up. I'm now looking into a pre-fab roll cage as I'm not sure I can bend one up without my back giving out. As it is, I'm in pain all day and more so as the day goes on. Sadly, I've got an awesome bender... and might have to bite the bullet and pay someone else to do the majority of the fab work. Once the cage is done, I'll start putting the interior back in and finishing that kind of "easy" stuff.
The bumpers, and rock sliders will come soon... But I've got to give my back time to heal, and I'm going to visit the Doc again this next week. I've got to get something done with me, before I can finish the Zuke.
EDIT:
Here's the fix to the window, done. If I had a smaller off-road light, the window could still come down. However, I'll simply remove the whole window rather than ever sit it on the hood (if I ever want it removed - which the plan is not to, but to have it available. Good resale perc too!). I had to bend out the mirror tabs quite a bit so they'd clear the hood/fender area;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_85a0c874.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/85a0c874.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_13cb31f2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/13cb31f2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_19ef1f28.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/19ef1f28.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_392ade04.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/392ade04.jpg)
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That is turning into a mean looking Zuk.
Too bad about the back, and bending over to work or get things doesn't help it. I found that if I stand at arm's length from a counter, put hands on counter and with arms straight, bend belly forward as far as possible. Don't bounce, just bend belly as far forward (arching back backward) and hold 30-40 seconds. After doing three of those it does seem to feel better.
And a trip for a good massage can do wonders. My Butt muscles were pinching nerves which caused swelling and locking up the muscles, which caused pain and immobility. A good massage and I was feeling great (for an old man).
You are doing a good work.
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That is turning into a mean looking Zuk.
Too bad about the back, and bending over to work or get things doesn't help it. I found that if I stand at arm's length from a counter, put hands on counter and with arms straight, bend belly forward as far as possible. Don't bounce, just bend belly as far forward (arching back backward) and hold 30-40 seconds. After doing three of those it does seem to feel better.
And a trip for a good massage can do wonders. My Butt muscles were pinching nerves which caused swelling and locking up the muscles, which caused pain and immobility. A good massage and I was feeling great (for an old man).
You are doing a good work.
Thanks!! I know it's not a huge build up (like some people, who get crazy... and have big wallets), but I'm trying to take pride in each and every thing I do. Gets a bit overwhelming at times. Baby steps for sure.
Just got an XRC-8 (winch) for Christmas, so I'll be integrating that into my front bumper build. But, today... I should have a roll cage on it's way to me (craigs list seller, who copied petroworks design) already pre-bent. It'll save me time, and pain. Then, I'll work on rock sliders, skidplates, and bumpers. I've got a trip for 1-7 planned to use it... so, it'll be fun (done or not).
Here's it's current status (waiting on cage to put the interior back in);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/e895caa0.jpg)
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what thickness of material will your bumpers be made of??
I'm trying to plan to build a set soon, I was thinking 2x6 rectangle but not sure how thick
I want to keep them super simple.
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are you planning on puttin a winch on ? front bumper is my next. my mind hasnt figured out what i want to build yet. just wondering why so much great body work. just to scrap it on the trails? hopfully your trails are bigger then ours in northwest.
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what thickness of material will your bumpers be made of??
I'm trying to plan to build a set soon, I was thinking 2x6 rectangle but not sure how thick
I want to keep them super simple.
The main portion of the bumper will be 6" C channel (square tube is too heavy, and not needed). The outer edges will taper down to 4" C, and then to 2" (thats the plan anyway, subject to change). I'll first mount my XR-C8 winch (X-Mas present), to the frame (instead of using the bumper as a winch mount) behind the front bumper. And build around it. The rear, similar... with 6" C Channel, tapering down to 4, then wrapping around to the fender flare (similiar to a shrockworks back bumper)
are you planning on puttin a winch on ? front bumper is my next. my mind hasnt figured out what i want to build yet. just wondering why so much great body work. just to scrap it on the trails? hopfully your trails are bigger then ours in northwest.
Yup... winch! Thanks to the in-laws!! Love them!!
... of course, if I scratch it, dent it, or damage it... it's on me. And now that it's done (body work wise), it'll be tough to swallow on the first few dents/scratches... but, I'm not too worried about it. I'll make sure to build things to help curb "dents", and well... the bed liner won't scratch too easily (unless body meats rock). Point is, I can't work on the rest of it and make it look good... without first taking care of the core issue (OCD Much?!?! ::))
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Yesterday, under the influence of pain meds (due to my back killing me)... I was able to clean up the engine bay wiring. It was full of scotch locks, 110V wire nuts, exposed wiring, exposed wire connections, a tupperware type container, 2 bridged circuit breakers trying to make a 30amp breaker (done wrong), .... you name it, it was there and wrong. Amazing this thing hasn't caught fire or that something didn't short out.
BEFORE:
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_144ff45f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/144ff45f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_070b5ce0.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/070b5ce0.jpg)
AFTER:
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_37e512c1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/37e512c1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0f7b4a78.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0f7b4a78.jpg)
Now to tackle the interior, under the drivers dash;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_fb51645b.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/fb51645b.jpg)
And to lower the auto tranny shifter mechanism, that stood super tall (hindered reaching the radio knobs) and was an ugly beast. I'll lower it and set it below the tunnel hump, so that I can add a shift boot and it'll look more "factory";
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9b2280ef.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9b2280ef.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_e2da4d67.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/e2da4d67.jpg)
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That was a lot of crimp connectors!
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That was a lot of crimp connectors!
Yup... and now, I've got a partially non-working instrument cluster! :-[
http://www.zukiworld.com/forum/technical-discussion-performance-modify/samurai-electrical-fuel-and-temp-gauges-not-working-no-idiot-lights/ (http://www.zukiworld.com/forum/technical-discussion-performance-modify/samurai-electrical-fuel-and-temp-gauges-not-working-no-idiot-lights/)
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Got the shifter lowered today, and just about done with the wiring.
Now I'm able to put a shifter boot onto the mechanism, so it looks more "factory" finished. The mechanism was too tall and bothersome, and looked fugly. OF course it works great, and allows me to now access the stereo controls without issue. I'll touch up the sheet metal I installed with bed liner, when I've got it mixed up for other touch-ups.
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_791cd460.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/791cd460.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0b3087b1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0b3087b1.jpg)
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Nice work cleaning up PO's handi work. After all that work it is going to be tough when the dents come, but after the first one it doesn't hurt as much.
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Got the wiring all done the other day... spent some time on a "cluster" problem, but did a work-a-round by supplying the cluster with it's own 12V Switched and Ground. Something was awry in the wire loom, not sure... but, it's done and buttoned up.
That allowed me to start on the roll cage. I was going to buy one from a Craigs List seller who's selling copy weld-in Petroworks cages. Complete cage, for $350. The darn steel cost me $150 today and I already had a good portion of the rear size. Not sure how he does that price, with it pre-bent and notched... but, it was to save me a bunch of bending and notching. The deal didn't come through for whatever reason (he was 3hrs away from me) and I had to start building it myself.
I started on the back first, and thought to remove the bow and use the cage as support for the soft top. However, once I got to the point of the rear upper cage, I decided to just use the bow... and let it do it's job.
Here's the cage in progress (EARLY stages for sure), and tomorrow I'll finish the entire back with cross-bracing and tubing gussets in the critical corners. I'm going to leave the back open for ease-of-access into that area, and I'm going to keep as much tubing away from rear-seat occupants heads... Yet, If this ever went over, I want the occupants as safe as possible.
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_72f9d936.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/72f9d936.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_5439c358.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/5439c358.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_fd5f2872.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/fd5f2872.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_32e7548c.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/32e7548c.jpg)
Tomorrow, I'll finish the back and get started on the front. Should be almost done by end of day. Happy New Year!
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good looking ride, you should put some shields under the spot lights to keep the glare off of the hood.
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good looking ride, you should put some shields under the spot lights to keep the glare off of the hood.
Thanks! ... I have a feeling I won't be using anything up on the hood area. I've heard the glare is ridiculous. The other thought was to aim them up a tad, and use them as "hill lights". We'll see. I'll have two bumper mounted 75W HID Hella Rally 4000 Off-Road lights paving the way so not much other light will be needed. These suckers are amazingly bright. (I convert standard halogen to HID, and then use a 75W Ballast to power the H1 bulb - amazing).
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Not a lot to update... Got more of the cage done, will be 100% done tomorrow (yet, will need to pull it for final welding and paint).
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_2ded64c8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/2ded64c8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_29d599da.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/29d599da.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a4df33b2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a4df33b2.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9d767c2e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9d767c2e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_f8dc13e1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/f8dc13e1.jpg)
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Cage is finally done....
We (my wife and I) pulled it, finish welded it, removed the old cage brace connectors, and prepped it for paint. Then, got some primer on it before she went to get dinner..... tonight, I'll throw some color on it. We decided to go with Rust-Oleum's HAMMER paint in grey. Almost went blue... to add some real color, but the grey will match the interior.
Some pics;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9c705a6f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9c705a6f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9060369e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9060369e.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_5708f74d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/5708f74d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_771f956a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/771f956a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_d82476fd.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/d82476fd.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_d5d299da.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/d5d299da.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0392c48d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0392c48d.jpg)
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That's a pretty sweet looking cage 8), nice work. What size of tubing did you use? 1", 1.5" and 1.75"?
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That's a pretty sweet looking cage 8), nice work. What size of tubing did you use? 1", 1.5" and 1.75"?
Thanks Jordan... It's 3/4" for the handles, 1" and 1.25" for some of the supports, and 1.5/1.75" for the main cage. I had a 20' stick of 1.75 in the garage... so, I used it for the back half (no other reason really), and all the tubing is .090 wall thickness (the stock cage is more like .065). I didn't use DOM or Chrom-oly ... I used mild-steel or as it's called "HREW" (hence a few more braces). I don't think it's necessary to use the much more costly DOM on such a light (under 3500#), slow vehicle (my personal opinion of course!).
It's going back in the Sammi today, so I can start re-assembling everything! I'm excited, as it'll finally look like a Zuke!
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Nice looking Zuk.... I think the Hammered look will be SHARP... on the rollcage. Keep up the GREAT work!
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Thanks Tux... The hammered look is pretty cool, yet... looks better if you can paint something all in on shot. Meaning, too much overspray from when you start the front of a cage and get to the back. The front is already drying, and any overspray somewhat ruins the hammered look. It still turned out well.
We shot the last coat this AM, and ... me ... being impatient, we put the cage in at about 2pm. Had the entire Zuke back together by 6pm. And that was with many small touch ups, re-aligning some bolt holes, installing a new poly window and seal, the entire interior, and a few other little things. My wife rocks!
Also, ... I've got three tubes that I forgot to measure before I welded them up... and, you really don't notice 1 of them, just the 2 if your standing perfectly in the back, or front... Problem is, I NOTICE! I also had a problematic ground lug on my welder's clamp. I didn't notice until I was nearly done. I fixed it, and boy oh boy... welds came out sweet (like they used to) after that. Made me want to re-do almost all of it. The welds on this are some of the worst I've done... so, I'm a bit happier it wasn't me (so much).
Here's some shots before it got dark, I'll get more tomorrow (in the day light). Time to start the rock sliders!!!
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_1753c92a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/1753c92a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_33e41fe1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/33e41fe1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_d94db1cc.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/d94db1cc.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_1aba6e20.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/1aba6e20.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_de841588.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/de841588.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_31f0693a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/31f0693a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_1d9519d1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/1d9519d1.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_3c4f4ade.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/3c4f4ade.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_e09c4992.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/e09c4992.jpg)
The two dreaded tubes (running front to back);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_d7691e37.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/d7691e37.jpg)
My lovely wife helping out (one of the very last things to put on tonight - rear view mirror);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0005fb44.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0005fb44.jpg)
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VERY nice job.
Nothing like a bad ground to bugger up a weld, and adjusting speed and temp just doesn't seem to help. I ground out 1/4 of the welds on first cage and covered them with the grossest welds ever before I found the ground wire almost gone.
Your rig is looking great.
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VERY nice job.
Nothing like a bad ground to bugger up a weld, and adjusting speed and temp just doesn't seem to help. I ground out 1/4 of the welds on first cage and covered them with the grossest welds ever before I found the ground wire almost gone.
Your rig is looking great.
Thanks MUCH!! ... and, I didn't realize it was the ground until I looked over at the clamp and saw the insulation smoking! DRAT!
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very nice.
might consider a diagonal on the b hoop
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very nice.
might consider a diagonal on the b hoop
B hoop? as in the stock roll bar section? ... thought about it, yet... it'll hamper access in/out of the vehicle. If I go and put race seats and harnesses in, I'll then be adding the diagonal and a cross brace (for the shoulder harnesses).
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Little bit today... as I had to hunt down some Plasma Cutter consumables before I got busy today.... which, took me a long time and by then I was nearly out of day light. Got the plasma going again... and, well... only got the winch mount welded up.
But, before that... took a couple pictures with the top on, and it waiting for me to get to work!
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_0cafaff0.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/0cafaff0.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a1d388bf.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a1d388bf.jpg)
Extended the frame 6" and added a 3/16" steel plate for the winch to sit on. Tomorrow, I'll cut out mud/water drains and drill holes for the winch itself. I've got more bracing to do, and to feather in the frame additions. I'll also taper the bottom of the frame extension once I get rolling on the bumper build (next week);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_f667fde5.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/f667fde5.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_ab94a3fe.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/ab94a3fe.jpg)
Tomorrow, I'm going to start a belly pan (skidplate) and my rocker panel - rock sliders. It should go fairly smooth now that my plasma is up and running. I've changed my design in my head a few times and now I'm down to a clean workable solution. It'll tie in my sliders with the belly skid plate and make this thing slide right over any obstacle. Then, Saturday... we're heading out with a large group.
Here's some video of the area we'll be wheeling (I don't know anyone in the video, just borrowed it for your amusement);
Heart Attack Hill Anza Borrego Jeep Trip (http://www.youtube.com/watch?v=_bScAe7rjsU#)
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Not a whole lot to update from Wednesday, as all I did was run around picking up bolts and getting steel and alum for today's project. Which was, to start on the center (belly) 1/4" alum. skid plate, which meant making frame brackets... and in process, I started the rocker panel guards/sliders and am incorporating a 1/4" alum. skid plate into them too... which, will tie in the rocker panel to the lower edge of the frame.
I was able to get the passenger rocker panel assembly done fairly quick and got started on the drivers side (cutting lengths, etc). Once I made the rocker panel assembly, I made brackets to the frame... so it's all removable. Only 9 bolts! Then I made the frame skids which are welded to the frame, and are the base for the transfer case/belly skid plate. Once I got it all welded in, I finished the pass. rocker skid plate... and, threw myself a learning curve. However, got it done (no pictures as I got done past dark).
Here's the rocker panel, bolted up;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_a8066b00.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/a8066b00.jpg)
Then, I made the brackets to the frame, and bolted them up (take a good look at the frame here);
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_4d431889.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/4d431889.jpg)
Here, the frame skids are done and welded up, as well as the bracing/mounts for the alum. rocker skid plate;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_66faad8d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/66faad8d.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_d7c276dd.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/d7c276dd.jpg)
Then I put on the tubing rocker guard, and will weld it up off the Zuke;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_9ec084fd.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/9ec084fd.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_2a7677c6.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/2a7677c6.jpg)
Tomorrow, I'll finish up... (and take some pictures of the side alum. skidplate) ... remove it all, weld it all up... and if I have time, rattle can it flat black. If not, it goes back on... raw steel for Saturday's adventure.
Tomorrow, I also have my diff. guards to weld on, and a simple axle brace/truss for the front.
.... going to be a busy day! Another early one.
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Got the rock sliders/belly pan done. Yet, don't have any completed pictures of the full setup... just, the passenger side rock slider and skid plate (I was too busy working, trying to utilize my day of light)....
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_b678617f.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/b678617f.jpg)
Then later, I broke a bolt on the drivers side rock slider skid plate... and, had to do some magic to get it out and re-tap the threads. Once I was done... it was then about 9PM. We had to be up at 4AM, to meet some people for breakfast. UPS showed up late, which also left me with still a "fuel tank skidplate, axle truss, diff. cover, and to relocate my steering stabilizer" left to do that night. I didn't HAVE TO... but, wanted to... get it all done. I was cleaning up the garage about 11pm, ate dinner (hadn't eaten ANYTHING all day), and was in bed by 11:30. What a day.
Here's a shot of the diff cover and truss welded up, and steering stab moved higher up;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_29187da8.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/29187da8.jpg)
AND... this AM, we went out and did 70miles of fun!!!
Here's us dropping into what they call "heart attack hill" (yes, I'll fix my squeakers soon enough!)
http://www.smugmug.com/gallery/20937458_cFjGjr# (http://www.smugmug.com/gallery/20937458_cFjGjr#)!i=1663221136&k=TkqW5pK&lb=1&s=A
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That aluminum looks really good 8), I was going to use 1/8" steel, but I'll have to check the price on 1/4" aluminum.
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That aluminum looks really good 8), I was going to use 1/8" steel, but I'll have to check the price on 1/4" aluminum.
Gracias! ... I contemplated 10gauge steel instead of alum. But it would have required more bracing behind it, and the savings was about $80 less (alum to 10g) not counting the additional bracing that would have been needed to keep the steel from bending. In fact, I contemplated IN the steel yard... for about 30min, doing my own (NASA Calibrated) bend tests. Ya know, push on it with the knee on a 4 x 4' piece. hahaha.... The alum. is definitely worth the extra $$. Especially because I can hold it and screw it into place. No need for a jack, and some wood to hold it up for you.
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Ya, anther plus with the aluminum is you don't have to paint it to keep it from rusting!
Just watched the video, looks like a pretty steep decent! The sami looks awesome too 8)
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Wow, you have... I uh... that cage is.... and the sliders...... I have nothing to add, I'm just going to copy you verbatum, very nice work sir, very nice indeed.
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Thanks fellas... all in due time, right?! It just takes patience (I have none) to get things done. Now if I could just cut out eating, soda breaks, and ... oh, I normally don't eat breakfast and lunch... so, CHECK. Now, cut out my soda breaks and drink water more often... don't answer the phone, and avoid my yard and lawn. Oh, wait... lawns haven't been mowed in weeks, and the wife pulled weeds in the front yard... woo hoo, so... as you see, my priorities are all about the Sammi (again)!
... yesterday, ran to the wrecking yard to get myself a CS130 alternator. Found an 11' clocked 105amp, and rushed home to hit O'Reillys and get a 3 wire pigtail. DONE. This AM, woke to pull the stocker (from my tracker motor) and found the 55amp alt has a CAST metal lower mount! UGH!
Per this thread, I need to cut and re-weld!
http://www.zukikrawlers.com/showpost.php?p=26493 (http://www.zukikrawlers.com/showpost.php?p=26493)
... but can't due to the cast metal bracket.
FIRST PROBLEM; Cast metal bracket. I had to remake a completely new one (no time to order one).
SECOND PROBLEM; 105amp junkyard alt was bad. No bueno! So I annied up and bought a new one for $94.00 from O'Reilly.
THIRD PROBLEM; Old pulley didn't fit onto new alternator. Too small diameter hole. I drilled it out, and used a teardrop grinder to get it perfect for the new alternator.
FOURTH PROBLEM; The tension bracket was too short and in the wrong place to be "correct". I lengthened it just over an inch and moved it out in front of the alternator where it should be.
FIFTH PROBLEM; The tension bracket has a brace, that now wouldn't work with the longer more angled tension bracket. So I remade a new brace (easy peezy).
... with those problems out of the way and the new 105amp alternator mounted up, I'm eager to wire it up and get'er running tomorrow morning.
Here's my thread on Zukicrawlers; http://www.zukikrawlers.com/showpost.php?p=743587&postcount=395 (http://www.zukikrawlers.com/showpost.php?p=743587&postcount=395)
And my pictures;
The lower, or main bracket completely remade;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_66c2c778.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=66c2c778.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_55cda948.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=55cda948.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_7d3d1668.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=7d3d1668.jpg)
The adjuster/tension bracket was lengthened about 1.25" in total;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_37d58905.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=37d58905.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_7a587e86.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=7a587e86.jpg)
The adjuster/tension bracket's brace was completely remade too;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_247bd472.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=247bd472.jpg)
Installed;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_be8e0440.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=be8e0440.jpg)
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Looks so clean in there!
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Did some more shopping today...
Picked up a 2nd Battery, and a switchover as well as some connectors and wiring.
With a new Hold Down on the main battery position (there was no battery hold-down at all when I bought it. The battery was just sitting there), I made a base for the second battery out of 16g Stainless I had lying around. Then I used the same type of hold down on the #2 battery.
Pretty simple once the alternator was done yesterday.
Here's the setup installed and complete;
(http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_b66f028a.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=b66f028a.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_b8505575.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=b8505575.jpg) (http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/th_89949a3a.jpg) (http://smg.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/PROGRESS/?action=view¤t=89949a3a.jpg)
... I must have all the luck however. As I was putting on the last prefab'd battery cable onto the battery terminal, it snapped in half! It seriously was the very last item to call it "done". And without over tightening... it just snapped. So, thankfully it was a pre-fab'd end that slipped over the top of the battery terminal. I had the separate battery terminals with a stud (they are labeled as "marine terminals"), so I used yet another one on that battery post. In doing that, it allowed me to crimp on a new connector and tie down the battery cable. Otherwise, it'd have been too short by an inch or two (and there was no slack, plus it was all routed and zip tied in).
Tomorrow comes the lock-lines so I have a temp parking brake when out wheelin'.
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Looks so clean in there!
Yes it does, and very neat. His fab work seems to be detailed pretty good also. Has some 16 ga. SS just laying around, must not throw the small stuff away either. He seems to work at a pretty good pace too.
I enjoy following your build. Your alternator bracket looks much better than my converted one.
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If you ever want to get that intake air back on the cold side of the motor, I have an extra Honda intake housing like this for sale. Scoured ebay and the internet looking for one and ended up winning two on bids.
This one is not mine but an example of what the intake can look like when its all polished up. Pretty sweet I think!
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So whats your review on that "bed-liner" so far? I have been wanting to do that for some time on my rig, but was looking into a product from SEM. But I think I like this product better.
From the looks of it you sprayed it on right? I plan on rolling it on. I wonder if rolling will still look nice. Did you end up spraying a top coat enamel to protect it from sun fade?
TWO THUMBS UP!
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So whats your review on that "bed-liner" so far? I have been wanting to do that for some time on my rig, but was looking into a product from SEM. But I think I like this product better.
From the looks of it you sprayed it on right? I plan on rolling it on. I wonder if rolling will still look nice. Did you end up spraying a top coat enamel to protect it from sun fade?
TWO THUMBS UP!
Love the stuff. And yes, it's sprayed on. Comes with a sprayer in the "kit".
My advice... DON'T ROLL ON any brand bedliner. It doesn't spread evenly, and looks like a DIY job. I did an 18' trailer floor and took it up 18" on the sides (interior of course) and it looks "just okay". My buddy sprayed his trailer, and it looks professional. Similar to the Samurai's spray job.
No UV protection needed with this product.
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[/quote]
Love the stuff. And yes, it's sprayed on. Comes with a sprayer in the "kit".
My advice... DON'T ROLL ON any brand bedliner. It doesn't spread evenly, and looks like a DIY job. I did an 18' trailer floor and took it up 18" on the sides (interior of course) and it looks "just okay". My buddy sprayed his trailer, and it looks professional. Similar to the Samurai's spray job.
No UV protection needed with this product.
[/quote]
WORD!
So "what kit" do I buy? :) You know since you already figured it out! 8)
I am impressed with your results. Looks professional... oh wait, it is professional ;)
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WORD!
So "what kit" do I buy? :) You know since you already figured it out! 8)
I am impressed with your results. Looks professional... oh wait, it is professional ;)
UPOL Raptor #ME-820
As an example;
http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html (http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html)
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WORD!
So "what kit" do I buy? :) You know since you already figured it out! 8)
I am impressed with your results. Looks professional... oh wait, it is professional ;)
UPOL Raptor #ME-820
As an example;
[url]http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html[/url] ([url]http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html[/url])
Awesome!
So were you pretty picky about the body work or will this fill in "minor" dents?. Part of me wants to make everything FLAT, but then I think, what the heck, its an off road machine and doesn't need to be perfect.
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WORD!
So "what kit" do I buy? :) You know since you already figured it out! 8)
I am impressed with your results. Looks professional... oh wait, it is professional ;)
UPOL Raptor #ME-820
As an example;
[url]http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html[/url] ([url]http://www.tptools.com/p/2600,233_U-Pol-Raptor-Spray-On-Truck-Bed-Liner-Kit.html[/url])
Awesome!
So were you pretty picky about the body work or will this fill in "minor" dents?. Part of me wants to make everything FLAT, but then I think, what the heck, its an off road machine and doesn't need to be perfect.
I was picky... simply because, it's a lot of work to go through to "paint a turd" if ya know-what-I-mean. Best to make it look good, because if your not good at putting down the liner... it'll look like crap once all said-and-done. It'll cover pretty good scratches the heavier you put it on... but dents? No way. Take the time to do it right... and it'll come out like new. PLUS, I only did one light coat. If I did it again, I'd do two-three (light) coats waiting 2-3 days in between. AND, you can tell the difference in my doors to the body panels... simply because I painted them separately. So once the doors are mounted, the grain and texture is a bit off (and noticeable).
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Gotcha.
Did the one light coat use up the gallon?
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Gotcha.
Did the one light coat use up the gallon?
I had two boxes (2 gallons, or 8 containers) and used 7 of the containers. Doing inside and out of vehicle.
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Thanks for your info. Excellent job on your project.
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Thanks for your info. Excellent job on your project.
No problem. Always eager to share... especially if it helps make your project, one step easier or for you not to have to do all the research! My Pops always told me; "Work smarter, not harder"
And thank you. It's on a long hold right now... funds have temporarily dried up.
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Amen!
I hear you on the budget. I'm in the same boat. A little at a time.
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Nice job .I like to se zukes built without Hacking the body all to sh.t.
Will keep following the thread...Boxcar...
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Yes exactly. I'm all about building my rigs to be just as functional as OEM, but with more perks. I think you have more then doubled your investment here.
I wonder how much of a challenge it would be to get a soft top to zip around this puppy. Would be sweet to have the piece of mind of going anywhere, anytime knowing mother nature can't spoil the trip.
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i noticed you said you put your windshield in yourself or did i read that wrong? is this a complicated procedure of is it fairly easy to install?
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Yes exactly. I'm all about building my rigs to be just as functional as OEM, but with more perks. I think you have more then doubled your investment here.
I wonder how much of a challenge it would be to get a soft top to zip around this puppy. Would be sweet to have the piece of mind of going anywhere, anytime knowing mother nature can't spoil the trip.
I am building my sport cage to replace the soft top frame in my tracker, and it appears that it will.
(https://lh6.googleusercontent.com/-1hjzgX-yyBo/TzXxo_1FWQI/AAAAAAAAJ9k/DhHkS7oUp6Y/s800/DSCF0685.JPG)
I haven't finished, so it is not road tested.
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i noticed you said you put your windshield in yourself or did i read that wrong? is this a complicated procedure of is it fairly easy to install?
I installed my own windshield on my SJ when I installed the plexiglas. Wasn't that hard at all but it helps to have two people.
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i noticed you said you put your windshield in yourself or did i read that wrong? is this a complicated procedure of is it fairly easy to install?
I installed my own windshield on my SJ when I installed the plexiglas. Wasn't that hard at all but it helps to have two people.
Sorry, haven't logged in for awhile... but yes, TWO People!!
Being I had added the bed liner material all around the window opening, it made the re-install of the plexiglass much harder then a stock window or stock metal frame. I should have shaved a MM off the plexiglass to make it easier... and I used all the tricks in the book I knew to make it easier. Still a tough job.
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I wanted to also note...
I didn't use the "bow" for the soft top. It makes the top just too hard to snap the back closed. Almost near impossible unless it's out in the sun (the top is recently new, and SUPER tight). So, I made sure the cage took up some of the slack, and supported the back of the soft top. A little bit of flap at freeway speeds, but the thing isn't anything close to quiet anyway. Who notices some wind flap noise?!
Also, I've got all the parts to do my brake stuff, which is to move the proportioning valve to inside the cab. And to add two loc-lines for when we're on the trail, and need a bit of help holding it in place. Once I do all that plumbing, I'm going to re-do the brake rotors (resurface them, or replace them) and get new pads. We should be 100% here pretty soon.
Funds are still dried up, but I'm going to bite the bullet here pretty soon and make my front and rear bumpers. I've got high-lift jack, Rotopax gas cans, and other stuff sitting in the garage waiting to find a home on the Zuke. Plus, the in-laws just picked up a new Rubicon... Wow... nice rig. And they've nearly finished it's upgrades before I'm done. DRAT!
.... updates to come. Just don't hold your breath. ;D
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On the plus side, it will make you feel really good when you are able to out wheel them. :D
For the flapping, I had a YJ that had that issue. Just get a piece of pipe insulation the right size and put it on your roll bar. No more noise and it takes up the bit of slack. :D
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Great job on your Samurai!!Also great picture gallery!Maybe a bit of overkill on some build points though...ok,maybe I'm a teeny teeny bit jealous...OK? ;)
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............... (update) I'm going to re-do the brake rotors (resurface them, or replace them) and get new pads. We should be 100% here pretty soon.......
Removed the wheels yesterday to see why my rear brakes were squeaking so bad. Come to find out, they had no friction goo between pad and caliper, plus they needed to be replaced anyway. I rounded off a stuck bolt in the process, and had to use my acetylene torch to heat up the axle caliper mount to get the bolt to loosen. Once removed, I ran over to Autozone and was able to get replacement pads and 4 new bolts (M12-1.25). Pads were from a early 90 Geo Tracker "Front". Probably because I have a hybrid rear axle from a track/kick. And 4 bolts and all pads was only $25. Cool! No more squeak, and I have new pads (no need to resurface anything either).
Next month, I'm going to finish this thing. No matter what it takes!! (Mortgage can wait - ;))
On the plus side, it will make you feel really good when you are able to out wheel them. :D
For the flapping, I had a YJ that had that issue. Just get a piece of pipe insulation the right size and put it on your roll bar. No more noise and it takes up the bit of slack. :D
Good idea. I just don't like what the foam insulation looks like. Flapping doesn't bother me too much, as it's rare that my Sammi is going fast enough to cause the issue. haha!
Great job on your Samurai!!Also great picture gallery!Maybe a bit of overkill on some build points though...ok,maybe I'm a teeny teeny bit jealous...OK? ;)
LOL... thanks. And I like to overbuild. It's not much more work, and better then underbuilding. :D
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who wouldn't be jealous in this? I envy it too. haha
great work. awesome ride you got there.