...the little devil.     A low stance, trail dedicated Samurai with minimal modifications. 

Modifications from stock...

Engine
-Weber Carb

Drivetrain
-4:1 T-case
-Reinforced Stock T-case arms

Suspension
-Rocky Road 3" Deaver Springs on all four corners. 
-Front axle moved forward 3/4"
-1" extended Rear Shackle

Wheels/Tires
-Samurai spoke wheels (5-1/2" wide) installed reversed and with the tire valve relocated to the now outer section
-1-1/4" wheel spacers
-31"x10.5" bias-ply TSL tires

Armor
-Diff Caps Front & Rear
-T-case Skidplate


I purchased this Samurai aka El Diablito around 5 years ago for $500.  From what I recall, a couple of owners prior to me had employed Diab on/off some farmland up north around the Kansas City rustbelt.  Those harsh years revealed themselves in the corroded, Swiss cheese-like sheetmetal, rust welded fasteners, and numerous questionable repairs.  For example, excess RTV oozed out of many mechanical components, the front axle was extremely bent (a few high jumps?), a booger-welded oil pan (caused by the diff hitting the oil pan after said jump?), and there were pieces of 2"x1/4" flat stock, mild steel added to all four spring packs (to help with the jump landing?).  The good news was that Diablito ran (somewhat) under its own power.

My initial buildup plan was to make this Samurai a simple SPOA trail beater primarily utilizing spare parts, which I had collected over the years.  Needless to say, I completed that plan around 5 years ago.    (Where has the time gone?)

First, I selected and rebuilt a straight front axle, welded on SPOA pads and trusses, and then added 5.12 Trackkick gears and a hybrid rear axle (Kick center/Samurai outer) with a spool.   Further additions were a 4:1 t-case, a Sky crossover steering system, a new exhaust system, and a weber carb to relieve the intermittent running issues.  The final touch was a set of 31" TSL Super Swampers mounted on reversed Samurai rims along with 1-1/4" wheel spacers.  After it was all assembled, I drove this Samurai around my local area, but for the most part over the years the vehicle just sat...and sat.  Every now I would spend an hour or two looking/working on it and maybe I would even start it up and drive it, but that was it.  Diablito simply did not excite me or inspire me to take him out to the trails.

I suppose Diablito was often overlooked because I already had a built up SPOA Samurai with a 16-valve engine, Front/Rear Lockers, 6:1 t-case etc.  I found that whenever I had a trail run, this built up rig was often my vehicle of choice, because it simply worked well.  However, this built up Samurai had recently started to show its age in all of the squeaks/groans, inverted leafs, etc.  It really needed some downtime to refit and retool. 

Therefore, several weeks ago after a local trail clean up run, my thoughts once again turned to Diablito.  As I was on the trail, which was not at all difficult with the dual lockers and a 90:1 crawl ratio, my thoughts drifted.... a mildly built, spring under Samurai could likely tackle this terrain.... albeit with maybe a few scrapes/dents.  It might be a challenge, but if I didn't really care about body damage, it could be a really fun challenge.   In addition, I have always thought that SPUA rigs were more fun to drive offroad, and tracked better (less wheel hop and a firmer grip on the terrain) without lockers than the taller SPOA configuration without lockers.

Thus, once I returned home my eyes landed once again on Diablito, which was mothballed in my back forty.  He had not run in maybe a couple of years at this point, and he would definitely need a lot of coaxing to move under his own power.   

As I dug around my spare parts stash I immediately identified and selected a set of used 3" lift Deaver Springs, a pair of 1" extended shackles and set of recently refurbished Samurai axles in the stock SPUA configuration.  Thus, I quickly developed a plan to transform Diablito into a SPUA Samurai with massaged wheelwells to fit the 31" TSLs.

First, I thought that the previous gearing setup, which had 5.12 diff gears and 4:1 t-case gears, was too low geared.  There was just too much shifting required at low speeds in both high and low range.  Therefore, I decided to just run the 4:1 t-case with the stock 3.73 diff gears. 

Second, I thought about running a traction device like a rear spool or locker, but I thought it would be more of a challenge if I just ran open diffs with the aggressive TSLs.  I was also very wary about potential scope creep.  This Samurai was supposed to be a simple, slightly modified rig.  Once I added one locker, then I would likely want to add a second one, upgraded axles, then power steering, etc etc.

So the only real initial mods were a Weber carb, Deaver leaf springs, and a 4:1 case.

Front Suspension

To fit the 31" tires in the front I knew that I would need to move the axle forward and likely hammer and/or trim some sheetmetal.  First, I re-drilled the spring pads and spring plates to move the front axle forward 3/4".  I chose 3/4" because I recalled that any additional distance forward would cause the stock steering setup to bind.  However, 3/4" also appeared to exactly center the wheel in the wheelwheel. 

When I first setup Diablito for the SPOA lift, I had lowered the front bumpstop 1-1/2" inches, and forward about an inch, via some square tubing that I welded on.  I also notched the stock bumpstop mount for shock clearance.  This bumpstop modification also worked out well for the new SPUA configuration, and still allowed around 2" of uptravel on the front suspension. 

Finally, I hammered all of the wheelwell sheetmetal and seams flat.  During testing at full compression, I discovered that the TSL lugs did not rub at all.   

I thought I might have to add a small 3/4" driveshaft spacer to the front driveshaft, but that did not turn out to be the case.  The driveshaft still appears to have plenty of splines for compression and elongation.

For the front shocks, I reused the same set of cheap Monroe shocks (rear of a Chevy Chevette) that I had used for the SPOA setup.

Rear Suspension

For the rear suspension it was even more straight forward.  Of course, the fixed ends of the springs were rust welded, but 15 minutes with an angle grinder/cut off wheel made short order of them.  Then, I installed new bushings, fasteners, and the Deaver Springs.  I also added 1" extended shackles to the pivot end for a little more lift, and a slight rake stance when unloaded.
Finally, the cheap Red Ryder shocks (FJ40 application) from the SPOA were bolted into their stock location. 

At this time I still need to add (weld) bumpstop extensions to the rear.  Likely, I will drop them 1-1/2" as that appears to be the amount of uptravel still left when the tire is nearly stuffed. 

While Diablito is not a flex monster (or a looker ), I am quite happy with the amount of flex available.  Especially, for a simple SPUA rig.

Other focus areas
-This past weekend I replaced the structurally deficient and contaminated fuel tank/skid plate as well as the ethanol devoured fuel filler hose.  The replacement tank was the earlier type with a drain bung, so that I could easily drain fuel if Diablito was likely to sit any length of time.  I sourced a new fuel filler hose from Petroworks, and I also replaced the fuel filter and rubber feed lines. It's amazing how well the engine runs with fresh, clean gas.   

-I checked the valve timing, timing belt, and crank keyway.  All of those areas looked good, so I reassembled everything.  However, as I torqued the crank pulley back to 90-ft lbs, I noticed that the driver's side motor mount was out.  Thus, I sourced a good, used motor mount from my parts stash.  Then with the help of a maple tree limb and a ratchet strap, I replaced the motor mount.      Engine no more floppy.

The next trail run/clean up (Gruber ORV park) is another weekend away, so I am working on various loose ends to ensure Diablito will be ready.  I am looking forward to testing his mettle. 

Kind of cool It sounds like a bigger tired version of what I wanted for mine.

Actually, I had thought about creating a similar rig years ago based around 29" Super Swamper TSLs, ala Zukiworld's GI Jane.

http://www2.zukiworld.com/feature_gijane-3/


However, since I already had the 31" TSLs, I thought I would make them work.  Plus, Diablito has a lot of fender rust with large gaps between inner the fenders and vertical sheetmetal.  During the repair of the fender arches I will open them 1-2" more ("virtual lift") for larger tires.  I can foresee running 33" TSLs after the 31" TSLs have worn out.

The engine is running smoother everyday. 


https://m.youtube.com/watch?sns=fb&v=iL6cjiiJo7I

watched the video you shared. good to know its running smoothly now. anyway, any feedback on the Super Swamper tires? been comparing it to Duratracs i've seen on a vitara.

Replacing the old fuel tank made a fast improvement in regards to engine performance.  I cannot recall any fuel tank that I have peered inside that looked any more disgusting.  It had black tar like deposits clinging to the entire interior or tank.  I do not know if that was due to ethanol breaking down rubber fuel filler hose or possibly the previous owners just filling it up with suspect fuel or a combination of both factors.  Since the deposits were all over, and the filler hose was mostly intact, but just soft in a 1" spot, I think Diablito saw a lot of bad fuel over the years. 

My thoughts on the SAM-12, 31"x10.5" Bias-Ply Super Swamper TSLs.
http://www.intercotire.com/tires.php?id=10&g=1

Pros:
-Excellent offroad traction and likely superior offroad traction when compared to any radial tire.  (The Samurai literally walked up that log in the flex shot.  No lockers required.)  I think the superior traction is not only due to the tread design, but the soft rubber compound along with the heavy weight of the tires.  The heavy weight keeps the tires firmly planted.
-6 ply tread and 4 ply sidewall construction makes the TSL tough as nails offroad.  Punji sticks will not penetrate the tread or sidewall.


Cons
-Poor choice for a daily driver due to the bias construction.  The tires develop flat spots overnight and they also tend to wander at highway speeds.  If your daily commute is 5 miles or so at 45mph, this might not be a factor.
-These tires are again, heavy.  This is yet another reason not to use them for a daily driver as fuel economy will suffer.
-Poor ride due to the stiff sidewalls.  I have read of Samurai owners running these tires with minimal air pressure for 5 miles or so to "break them in" and to make the sidewalls not as stiff for the lightweight Samurai.  However, I did not do that myself.  Since I am running them on 5-1/2" rims, that will allow me to run them at 5PSI on the trail, and not lose a bead.  I will report more after this weekend.

Finally, another tire that I am considering for a different trail-built Samurai is the Gateway Buckshot Mudder. 
http://ok4wd.com/gateway-buckshot-mudder

Diablito stood up to the Gruber ORV Proving Grounds Challenge and passed with flying colors.   

Whoa! I said whoa Diablito! 

 A good read. Thanks Jonny.......

Read your feedback on the swampers just now. Thanks! nice review. The diablito looks awesome

Whoa! I said whoa Diablito! 

Amazing country you have to wheel in. 
Samurai's are great great off road, even with open diff's.  With lockable diff's they much better (but you know that).  Good job.