Hey guys!  I had been wanting a Samurai for some time.  So I finnaly pulled the trigger on a 88.  Stock 1.3 with 180,000 miles.   Toyota axles... 5.29 gears.  The truck was extremely rough when I picked it up.  She was used... and abused but she is in better hands now!





The truck is relatively rust free.  Some rust under the flares... and a few small spots on the body. 

Since picking it up.. I did a simple tune up.  Changed all the fluids.  I also checked the compression.  It was dissapointing  at 130 130 130 150.  So it's in need of a rebuild... but for now it keeps on keeping on. 

Plans

- Get everything on the truck in PROPER working order.
- Pass PA inspection
- Source a passenger fender, hood and windshield.
- Delete rain gutter snorkel
- Do a rustoleum roll on paint job
- Fabricate front and rear bumper
- Prepare for an engine rebuild

Welcome, like the Rig, already has Toy axles which is a big plus and not much rust.

Since you mentioned this is your 1st Zuk here is some usefull info that might save you some time.

I wouldn't do anything to the motor as long as it runs. That compress shows low but should keep you rolling for quite awhile.

A good upgrade is the Toyota carb swap, big improvement even with your compessipn and not to hard to do.

There is a You Tube video someone made that may also help, think it is Samurai Toyota Carb Swap.

Here is a link to the carb swap info.
http://bbs.zuwharrie.com/content/topic,123850.msg1227190.html?PHPSESSID=c677ed1f3a8d115d502070c8d662d94b#new


Heard that monstaliner works great as a rollon paint job. Here is a link to a guy that did his.
http://bbs.zuwharrie.com/content/topic,132138.0.html?PHPSESSID=c677ed1f3a8d115d502070c8d662d94b


Incase you decide to go through your trans here is a helpful link.
http://www.zukikrawlers.com/showthread.php?t=45336


Stay away from the Parts Train fenders if you are looking to buy new. Went through that with mine, looks great once you finally get it on. Only had a couple of the mounting holes line up so welding new tabs on my new fender wasn't enjoyable. Took about a week to finally get it mounted.


You will enjoy welding on Zuk sheet metal if you haven't experinced that yet. Good thing you don't have many place to fix.


If you want here is a link showing how to make patterns for bumper building.
Go to post 349 and will continue for a couple of pages.
http://www.zukikrawlers.com/showthread.php?t=44942&page=14

Good Luck with your to do list.
Terry

Hey thanks for the great info. 

I plan on running the motor till it quits.  But in the mean time I would like to rebuild a donor motor.  At least get the block ready.

Yea I'm having a hard time finding a hood and fender!  I was planning on staying oem. 

So I have a few part orders out. 

I decided to go with the monstaliner!  But I will be doing just the tub to start in black.  Maybe get the technique down and learn about the product first hand before I attempt to paint the exterior.  Very excited to get going on this so thank you for the recommendation.

Mechanically the truck needs an exhaust.  The current system is dangling by 9 wire and consists of a flowmaster red hot.  It was also held on by one bolt at the manifold.  I ordered a Thorley header and will be taking it to a local shop for a mandrel bent 2'' with high flow cat and a undermined muffler. 

Also will be going through the brake system.  The master is leaking pretty bad.. and appears to have been leaking for some time.  Ordered the gasket for the Master -> Slave.  Hopefully that is my issue.   Also.. the truck was upgraded to rear samurai calipers.  I'm sure they are an upgrade but I would prefer the upgrade while retaining the ebrake.  So currently I'm stuck between the Subaru rears and the T case brake kits. 

I have found a auto salvage within 100 miles of me with two solid samurais.  I was quoted for 175.00 for a nice front passenger fender and 250.00 for the hood.  I'm sure you can find better deals out there... but I don't find those prices to high considering how hard it was to even find them.

Glad to see you are trying the Monstaliner, good idea to start on the tub 1st. I will be interested in your review. The guy really seemed to like his result on that link. It does seem to be a little tougher to apply consistantly depending on the temp.

Here is a good thread on rear disc brake upgrade using Maxima calipers. These calipers have an e-brake and can retrofit the Zuk e-brake parts to work with it.

http://www.zukikrawlers.com/showthread.php?s=56a2ef8465d83100c2b382fd16b8b6b7&t=50012

Might be better to get a new mastercylinder, they aren't that expensive. Just be sure you get the correct year. There is a difference IIRC in the length of the housing that goes inside the booster. It is noticeable when they are side by side.

Try and get that brake fluid leak fixed as soon as possible or you will have more holes to fix.

T

Here are the rear shocks.  The truck is flat.  As you can see in the pic the have little down travel.  So to me... these shocks are way to big.  They measure 22" from eye to eye how it sits.  The tube is 17.5".  What would be a good shock length recommendation?  I think the DT3336 would work... with 26.50/15.50.

https://m.youtube.com/watch?v=NNR_luA-T_s

https://m.youtube.com/watch?v=6Y0WhBfZRJ4

Some footage of this weekend.  Did some crawling... mudding.. a little if everything.  Impressions.. Truck will go through anything.  But man... is it stiff. Leaning towards removing a leaf. 

With the 1.3 on its out I found a gem on CL.  A 1.6 8v with 35,000 miles on it.  Very clean engine with great compression. 

Plan on pulling the 1.3 tommorow and prepping the engine for install. 

When my adapter plate gets here I'll install along with the propane conversion.

Decided to drop the lif down from 4" yj leafs to 2.5".  Plan on going OmE light loaf yj leafs to get this thing flexing.  35"'s are also in the works.

Are you sticking with the stock carb for the 1.6l or swapping over to injection?

I have a Weber on the 1.3 now.  But it's really dissapointing on the trails we drive.  I'm going propane injection.  Quickly turning into a trail only rig.

That can happen after a few runs. 

Swapped to the 1.6 and installed propane.  Took approximately 4 nights of about 3 hours.  Pretty easy swap.  Ordered the kit from low range.  Propane was easy as well.  Took the truck to my normal trails this past weekend.  Overall it was night and day.  The truck had enough power to crawl with the 37''s and steep inclines were no problem at all! 

I was in contact with low range about my suspension.  They recommended rear OME 2.5" leafs so I can flex.  But he also said the front OME leafs flex a ton.  Thoughts?

Man, need to log on more.  Just been busy at work.

The OME springs are going to be the most flexible, but I would look at just putting a 4-link in.  It's pretty easy to do if your good with a welder.

http://www.zukiworld.com/forum/build-diaries-how-to-diy/sj-410-rear-4-link-build/

Haha it's all good. 

Broke my camera on my phone.  It's been broken for some time now!  I've really been slacking on the pics and updates. 

I do a lot of welding / fabrication at work.  Currently rebuilding a Miller Bobcat so I can get to work.  Interesting write up on the 4 link. 

I'm gonna get some updates going here soon!