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ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: MrBracket on February 12, 2011, 06:42:08 PM

Title: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 12, 2011, 06:42:08 PM
The adventure begins!! Picked up a nice moldy geo tracker today!! Thanks Eric.  It's a 1997 2wd 5spd with the snappy 16valve engine.  Got it home safe and sound despite the crazy winds on Interstate 5, saw a semi get pushed from the slow lane to the fast lane by the wind, SCARY!! But, that's a different story, this one is about the humble beginnings of a desert racing machine. 

Here it is!

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110212_165114.jpg)

She's not much to look at yet... well, she may never be, but I'm gonna be grinnin ear to ear despite the bugs in my teeth in a few months!!! Stay tuned as this little rig becomes race ready....

Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: BRD HNTR on February 13, 2011, 07:26:22 AM
That trailer looks big enough to haul two racers.  I am going to enjoy your build.  It's going to be a good year.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: prerunnerinidaho on February 13, 2011, 01:13:06 PM
Sweet looks like a clean start. Now I need to get busy on the lone Sammy. We got those same high winds out of the south west here in north Idaho last night.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on February 13, 2011, 05:38:04 PM
We gonna have a few cars this year! Very cool man. Glad to see so many people getting into this. I saw your post this morning and felt obligated to start ordering parts and go work on my car.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 14, 2011, 09:20:30 AM
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on February 14, 2011, 12:49:51 PM
Hmmm, should I be nice or competitive? OK I will be nice, Rethink the T-case. I can tell you that even with suspension and a 16v you will have a hard time without the low range option. I run the same size tires and found the power to be lacking. I could barley catch a 8 valve car that had a t-case on the straights. I put a T-case in for the next race and was able to catch and pass everyone within the 1st lap.

Also, test test test. It sucks to find the weakness of your car during the race. Mine was the axle(like yours) Although, it took quite a beating before it broke. I had won the 1st race, was in 1st place, and thought I would try to set a fast lap. A lot of full throttle over washboards and jumps, coupled with the t-case gears, is what led to my broken axle I think.

Anyway, just trying to pass what little experience I have along. Good luck and I look forward to the build. Don't forget to introduce your team and post a build thread in the Zukiworld Challenge section.
http://www.zukiworld.com/forum/race-team-introductions-information/ (http://www.zukiworld.com/forum/race-team-introductions-information/)

As for the fuel cell and apparel, I got my Fuel cell from Summit(cheap shipping) and all my apparel from www.saferacer.com (http://www.saferacer.com)

Your rear differential will accept the older axles. This is what I did when the axle broke. I even changed over the brake backing plates to retain the newer style brakes. I do not think you will need the bigger 4 door brakes, my car stops very quick.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 14, 2011, 07:31:42 PM
Thanks Bigzook! I can't wait to Test Test Test!! The main reason I think I can get away with no transfer case is the different format for the races this year... It sounds like tracks in the past were tight motorcross type tracks and this year it sounds more like wide open desert?? 

Do you cover the fuel cell intstall in your build thread? Curious to see what you did for the fuel pump??

Thanks again for bein nice, I expect you to be more competitive come race day!  ;)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on February 15, 2011, 09:23:27 AM
I have not installed my fuel cell yet, It is supposed to arrive Friday. For the fuel pump I just bought a after market in line pump. I wanted to use the factory pump in the cell but, due to budget constraints I could not. I will be taking my car to a local fabricator(Kustom Kreations) to do the Cell install as well as some other changes soon.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Drone637 on February 17, 2011, 10:10:14 PM
For the 4-door brake swap on the front all you need is the calipers and the rotors.  Another advantage, besides the larger brakes, is that the 4 door front rotors are vented.  I was able to feel quite a bit of brake fade as the race wore on, but that is probably part of my driving style and may have just been the brake fluid overheating.  So don't forget to get the high-temp brake fluid. 

Keep up the build notes.  :)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on February 18, 2011, 02:06:17 PM
Really? Well maybe I need to use my brakes more huh? ;D
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 19, 2011, 08:17:11 PM
I got a few hours to work on the racer today!!

Pulled it into the shop:

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110219_140354.jpg)

If you could see the mold..... YUCK!!

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110219_140458.jpg)

There was actually a rear seat under all that crap...

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110219_145218.jpg)

Removed about 687 pounds of wet carpet and moldy panels.... (just kidding, don't know the weight)

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110219_190401.jpg)

Looking better..

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110219_190423.jpg)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: KBC on February 19, 2011, 10:01:39 PM
Thanks Mike for telling me about this. Now you got me thinking about doing a build......
This sounds like a damn good time. Call or txt me when you need a hand.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 20, 2011, 08:49:53 AM
Thanks Mike for telling me about this. Now you got me thinking about doing a build......
This sounds like a damn good time. Call or txt me when you need a hand.
Ha Ha! Told you it looked fun!!!  I got to pop your Zukiworld Cherry, got your first post... LOL...

I'm gonna tear into my wiring harness next so I will better understand it. 

Then it's time to get some seats and seatbelts ordered and build a cage!!!!!  ;D
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: KBC on February 20, 2011, 10:13:58 AM
Yep my cherry's poped! Im really excited, just need to find me a 4x4 2 or 4 door sidekick. I have to go look at a house this morn but I will come over after, and check out your beast.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Jluck on February 20, 2011, 04:21:06 PM
dare to be different....get a 4 door, thats what I am going to race if I get that far! ;D
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on February 20, 2011, 06:17:32 PM
Have fun with the wiring. Took me a few hours to figure everything out. Ack's Faq has a wiring diagram for a 96.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: BRD HNTR on February 20, 2011, 09:59:58 PM

Ha Ha! Told you it looked fun!!!  I got to pop your Zukiworld Cherry, got your first post... LOL...

I'm gonna tear into my wiring harness next so I will better understand it. 

Then it's time to get some seats and seatbelts ordered and build a cage!!!!!  ;D

I would suggest that you understand it before you tear into it. ???

On Drone637's Project: Trouble http://www.zukiworld.com/forum/build-diaries-how-to-diy/project-trouble/30/ (http://www.zukiworld.com/forum/build-diaries-how-to-diy/project-trouble/30/)
is a description on how we built his roll cage.  It may help.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: BRD HNTR on February 20, 2011, 10:07:57 PM
dare to be different....get a 4 door, thats what I am going to race if I get that far! ;D

Don't look to hard, prospective race cars are just waiting to be found.  Then you can spend your time working on them instead of working on YOUR build.  They are such time HOG'S.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 21, 2011, 08:02:21 AM
Thanks for the input guys. I'm sure my cage will closely resemble the others on here.  I just want to get all my bases covered when it comes to the basics, then I can get creative with the suspension  ;D

My goal with the wiring, is to make a simple control panel of all the necessary functions using marine grade switches.  This will never be my only project and my shop is only so big..... This thing is gonna have to sit outside from time to time without any glass... I'll cover it, but blue tarps only keep so much moisture out of things.... 

My son and I drove the little racer around after it was all gutted out, sitting on a block of wood with no seatbelt was fun, LOL..  definately need to add some weight to the rear tires, no traction will all that 16valve power!!!! ;)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: kreator on February 21, 2011, 11:10:54 AM
hey if you get the front windshield out in one piece I will take  it off of your hands also the drivers door window regulator.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 21, 2011, 01:08:23 PM
hey if you get the front windshield out in one piece I will take  it off of your hands also the drivers door window regulator.

Are you local??  If so, come on by and remove it yourself for free, all I ask is that you take all the black goo off my window frame too  :)  Sorry, the window regulator was toast.....

I ordered Seats and seatbelts today! Gonna have to wait a week or two to order the fuel cell...  
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: kreator on February 21, 2011, 03:22:53 PM
I AM IN SALEM, WHERE ARE YOU AT?
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on February 21, 2011, 03:30:46 PM
I AM IN SALEM, WHERE ARE YOU AT?
I'm in springfield, south of you about 45mins... sending you a pm.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on March 02, 2011, 09:54:28 AM
Didn't get much done this last weekend... It was so damn cold!! I really need to insulate my shop so I can run a heater.... 

Got the dash tore out...

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110226_174246.jpg)

And the wiring harness all out...

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110227_122043.jpg)

I'm gonna move the battery to the rear of the vehicle as well as make a box to house the computer and all fuses.  I want to have everything in one place to make trouble shooting easier on the fly. 

My Seats arrived too  ;D

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110225_163015.jpg)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on March 02, 2011, 09:56:10 AM
I'm a big boy, so you'll notice the seat on the right is a wide version... Co-pilot is gonna have to be a lightweight, so they get a skinny seat.. LOL...  ;)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: ebewley on March 02, 2011, 10:58:50 AM
Nice seats...

-Eric
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Jluck on March 02, 2011, 12:06:26 PM
x2 on the seats.....in my younger years I had small buckets in my pick-up. it was my motto if you can fit in 'em you dont ride in 'em. (pissed off a few ladies) ;)

build is looking good.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on March 07, 2011, 12:40:30 PM
Got very little done this weekend, between family events and my sons basketball games.... yada yada yada, excuses excuses, I know... lol..

Laid out the wiring harness..

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110305_064144.jpg)

And started trimming it down..

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110305_101427.jpg)

Got the Airbag wiring out, that was easy. Removed the Daytime Running Light circuit trimmed out as well.  Still have some work to do on it.....  I'm learning as I go, and I really enjoy that!!  I prefer doing things myself when I can, If I was at all trying to make a profit at this, it would be way cheaper to buy a harness... But this is a hobby for me  ;D
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on March 27, 2011, 11:59:31 AM
Finally spent some more time on the DezKick project!!  ;D

Here is a shot of the finished wiring harness and the PILE of crap removed from it!!

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110327_113359.jpg)

Here is a shot of the control box. The computer and all fuses and relays are in this plastic battery box.  Should be nice to have it all in one place should something go wrong during a race.  I plan to mount it such that I can reach it while in the drivers seat.

(http://i250.photobucket.com/albums/gg246/mrbracket12/Project%20DezKick/IMG_20110327_112309.jpg)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: kreator on March 27, 2011, 01:53:27 PM
Nice job on the wiring, buy doing it your self you know there was no short cuts. I am going to cut my windshield out this week and see if I think I can get the windshield out of yours in one piece I did my daughters this week.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on March 27, 2011, 06:59:58 PM
Fyi, after last year my cluster only had 1 working guage. Nice job on the wiring.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Jluck on March 27, 2011, 09:49:01 PM
nice use of the battery box. are you going to dust proof it any?
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Soupy on March 27, 2011, 11:35:39 PM
Are you going to put the dash back in? If not,I'd like to see if it will fit in my 95 sidekick 4 door.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on March 28, 2011, 07:12:59 AM
Thanks guys, it was a lot of work, me eyes went crossed a few times reading the schematics... LOL..

MX5Man, I will usee the dash, it is required by the rules. I just gutted everything out of it.

Jluck, I haven't thought of dust proofing it. Got any ideas on doing that???
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on April 22, 2011, 08:01:28 PM
It's looking doubtful that I'll get to finish the DezKick project. at least not this year...  :(  I got laid off from my job a few weeks ago.. I have found another one, but I took a huge cut in pay... I can't wait for this economy to recover!!  Argggh!

Anyways, I'm not sure if I'll just sit on the project for a while or try and sell it...  Gonna re-think all my projects....... I'll keep you posted... 
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Bigzook on April 23, 2011, 07:35:09 AM
Awww crap. I am really sorry to hear that. I was looking forward to another car on the track. I am glad you found another job so quick. I have been lucky so far to work in the construction trade and not lose my job yet.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Drone637 on April 24, 2011, 10:03:50 AM
That's a shame, it looked like a good start to the build as well.  Next year though right?  For the Oregon track at least.  :)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Jluck on April 24, 2011, 10:11:54 AM
I might be able to help a little bit with stock parts. if you need any "HD" four door parts let me know.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: prerunnerinidaho on April 25, 2011, 10:13:30 PM
That sucks but at least you got back to work quick. Unlike my 9 month ride on the couch. My build is on hold due to the Sammy being used as work rig 150 miles a day round trip.
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on January 03, 2012, 11:32:54 AM
Hey guys! Been forever since I've posted on here....  couple jobs later and no money for this project... I've started my own business building trailers and hitch carriers for dirt bikes, check out my website at www.moto-mule.com (http://www.moto-mule.com) if you get a chance. 

Anywhooo, I'm going to be moving in May to a smaller place, trying to downsize and get ahead.  I really don't have the money to finish the DezKick in the near future.  I'd love to build and race in the Zukiworld challenge but it's just not in the cards for me right now.  So, I am regretfully offering the DezKick for sale for $1500 OBO.  I'd love to see someone finish this thing and have a ball racing it! Ok, honestly I'd be a bit jealous, but much better than just parting it out.

Here are some pics of it as it sits now.  Basically it's just a gutted out 1997 Geo Tracker with a 138,000 mile 16valve engine, power steering, and very new 235/75-15 tires.  If you look at the previous posts, you'll see I simplified the wiring harness and put all the fuses, relays, and the computer in a battery box.  I also started making flared front fenders for it.  My plan was to build a long travel front suspension that was wider than stock.  Obviously none of that got done, the fenders can easily be removed and replaced with stock ones.  They could also be finished, but be prepared for a lot of fiberglass and bondo work!

It has been sitting for over a year, but it has been kept indoors and still fires right up and drives.

(http://www.moto-mule.com/geo01.jpg)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: MrBracket on January 03, 2012, 11:35:13 AM
Here are more pics:

(http://www.moto-mule.com/geo02.jpg)

(http://www.moto-mule.com/geo03.jpg)

(http://www.moto-mule.com/geo04.jpg)

(http://www.moto-mule.com/geo05.jpg)

(http://www.moto-mule.com/geo06.jpg)

(http://www.moto-mule.com/geo07.jpg)

(http://www.moto-mule.com/geo08.jpg)
Title: Re: Project * DezKick * Zukiworld Challenge Desert Racer
Post by: Drone637 on January 05, 2012, 10:25:44 AM
It's a shame you won't be out running with us this year.  The battery box setup looks good though!