ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Events and Activities Forum => ZUKIWORLD Challenge => Topic started by: ebewley on March 06, 2010, 08:21:35 AM
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To help promote the ZUKIWORLD ORDER Suzuki 4x4 Owners Association, we are please to announce the creation and sponsorship of the ZWO racing team. The two-man team consisting of veteran desert racer Dave Capell from Invincible Racing and experienced fabricator and designer Joe Cooper promises to represent ZUKIWORLD well. We hope to follow the build start to finish as they compete in the ZUKIWORLD Challenge racing series.
more to follow....
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Hi everyone. My name is Joe. Dave and I got a decent start going this week on the ZWO car. The car was in rough shape to say the least. We recieved this 95 tracker with 191 thousand on the odometerand they weren't easy miles. We started with a full tear-down of the interior. Pretty much everything was removed that can be removed.
Then we dismantled the front suspension in order to install an off the shelf lift kit. We're running with this set-up for now to prove that anyone can come out and be competitive with minimal cash and just basic safety gear. Here's how our weekend went.
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3732.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3733.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3736.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3753.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3746.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3749.jpg)
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I wonder if I'm the only person leaving the heater in place... Good looking start! What are you going to do for bumpers?
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I wonder if I'm the only person leaving the heater in place... Good looking start! What are you going to do for bumpers?
Probably! :)
-Eric
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I think we're going to use the heater. Without a winshield, I think it will come in handy! Bumpers will be pretty minimal since we're not planning on hitting anything at this point. Possibly made out of aluminum to save weight. -yes i'm serious ;D
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I see some floor material cut out of the back in the pile....part of your weight saving technique?...
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Thats just that foamy plasticy peely stuff that was peeling off. For weight savings i'm going to take the bulbs out of the tail-lights, and trim my toe-nails ;)
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I think we're going to use the heater. Without a winshield, I think it will come in handy! Bumpers will be pretty minimal since we're not planning on hitting anything at this point. Possibly made out of aluminum to save weight. -yes i'm serious ;D
You and your aluminum :laugh:. If you know Joe you know he is dead serious about using aluminum 8).
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Hey Joe and Dave,
I created a concept sketch for your racer!
-Eric
:laugh:
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We are dead serious about the aluminum. We dont want to give away all the secrets of Barbies dream Baja machine, but aluminum will be one of them.
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The beat up Samurai that used to run on the Ultimate Adventure all the time had muffler tubing bumpers to help save weight. Might be an easier option for you. :D
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Made a little progress tonight. We decided to ditch all the front drive-train and just run a 2wd racer. But we're keeping the t-case for better gearing, so we're left with the delema of what to do with the front out-put. Obviously we can't just leave it open because its a slip-yoke design and wouldn't hold oil. The best solution for us was to weld a cap over the cast aluminum output. I sliced an 8th inch off a solid aluminum bar, then pressed it into a slight dome shape to clear the output shaft.
As you may know, welding aluminum is tricky, cast aluminum is terrible, and doing it in cramped areas underneath a car is worse than terrible. Its only after this disclaimer that i'm willing to show you my ugly weld. But I did get it welded.
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3764.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3767.jpg)
After that was done I needed to tackle the computer placement. Its mounted exactly where you'd want your front drivers side down bar for the roll cage. I wasn't sure how others have gotten around it but this is what I did. I re-used the factory bracket to attach it to the underside of the firewall using a couple of 5/16ths bolts. This should allow it to be replaced in a relatively short amount of time. Now theres plenty of room for the down-bar.
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3768.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3769.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3770.jpg)
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Joe, I have a case I would like you to do that on. Don't need it for the 1st race, but maybe the 2nd? It is out of the car.
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Joe, I have a case I would like you to do that on. Don't need it for the 1st race, but maybe the 2nd? It is out of the car.
NO!
:)
-Eric
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I thought I'd post up some progress pictures since the cage is just starting to take shape. Lots more to add, but it *looks* like a cage now...
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3771.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3772.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3773.jpg)
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Looks good, I like the way you did your braces.
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The boss-man let me have the day off today so I had time to get back to the cage. I think I have the cockpit area the way I want it and ready to weld out. Seats are mounted and everything is braced up for some extreme speed! I think the cage is more than adaquate for the speeds we can achieve with the stock 4-banger. But later incarnations of this racer may include much more horsepower and I want the cage to be ready for whatever we can dish out.
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3780.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3774.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3775.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3776.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3777.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3778.jpg)
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Dude! That is frickin' sweet!
-Eric
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Looking Really Great! Not bad for your second Sidekick Cage...
Love the front gussets on the down bars near the windshield.... very nice !
Did you extend the cage forward through the firewall to the frame or strut towers? Or... is that a secret? Are you doing the down bars in the rear like we did mine?
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Yep, all that is coming. Just haven't got there yet. I will post up the pics when I do.
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Rear cage and rear suspension are taking shape. Thats a dummy shock poking up thru the sheet metal...
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3781.jpg)
(http://i5.photobucket.com/albums/y160/sonnydigiosio/Desert%20racer/DSCF3782.jpg)
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Thats sweet. Joe!
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Very interesting!
-Eric
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More updates...
-Eric
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Sorry for posting in an old thread, but where might I find some more info on the rigs built for the Zukiworld Challenge?? I am very interested in "affordable" racing. I would love to see some buildup threads to see if I might be able to build one ???
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Sorry for posting in an old thread, but where might I find some more info on the rigs built for the Zukiworld Challenge?? I am very interested in "affordable" racing. I would love to see some buildup threads to see if I might be able to build one ???
What do you want to know? I can help here on the forum with any questions you have or you can PM me with your phone number and we can knock it out quickly.
-Eric
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Sorry for posting in an old thread, but where might I find some more info on the rigs built for the Zukiworld Challenge?? I am very interested in "affordable" racing. I would love to see some buildup threads to see if I might be able to build one ???
What do you want to know? I can help here on the forum with any questions you have or you can PM me with your phone number and we can knock it out quickly.
-Eric
Thanks Eric, I read the rules posted here, I'd just like to see what others have built. Especially those who have already run a season. Did this car here ever get finished and run any races?? I like pictures ;D Are there threads of past races?? Are people hush hush about their rigs because of the competitive aspect of the events?
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Sorry for posting in an old thread, but where might I find some more info on the rigs built for the Zukiworld Challenge?? I am very interested in "affordable" racing. I would love to see some buildup threads to see if I might be able to build one ???
What do you want to know? I can help here on the forum with any questions you have or you can PM me with your phone number and we can knock it out quickly.
-Eric
Thanks Eric, I read the rules posted here, I'd just like to see what others have built. Especially those who have already run a season. Did this car here ever get finished and run any races?? I like pictures ;D Are there threads of past races?? Are people hush hush about their rigs because of the competitive aspect of the events?
Definitely not hush-hush on my end. You are more than welcome to come look at the ZWO car and the Liberty Overland car and gleen anything you would like off of them.
There are articles on the main page and in the archive about the racing.
-Eric
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So the race is next week, time to start working on the race car.
The race winning thoroughbred has been put out to pasture since last year. It fired right up. First things first. The steering reservoir outlet had broken off during the last year and had to be replaced.
Prior to work.
(https://lh4.googleusercontent.com/zU4p2t9QzWRw72kmlh2YPhvWVrYWJz93CeF-9VpKRqjLWVjJX3dYdUBKAp9Txt_vPVPyl-Yjn87G6uH882XNyHzRVg96AKMO0RTWNAT89lNU_Zqk8yM)
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(https://lh3.googleusercontent.com/IQ1GiN5rcabvHnS_3DJEgv8G2NhYZiuNuD6lNqfritE_sIun35SWE130IIX8_BeFnLF2y7HLSIB9clAAUqCVv6hx53T5TQPeuZIrtTPW9U_KXJEAhrY)
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The factory struts didnt stand a chance. The valving is totally gone and the bilstein was doing all the work.
Out with the old!
(https://lh4.googleusercontent.com/5_CZv8h1Lm0VrxjQ9Rcsw3Rn3bVwmz8fr2zkpDoOoBPBRA1cg1S8gK9FTONK92o14idiJDpG6aUvmwHLgdQuU7J-qdMYq8mTnWjIXy8FjvrG4Zxwbqg)
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Fuel Cell.
The floor is not flat behind the rear seat. I cut out the unflat area only to use the strength of the factory crossmember built into the floor.
(https://lh4.googleusercontent.com/B8yow36GOA9Q_OruRlXM6bPz6t07R-f20yGZS8vrhuvKiFaD3nYKbHSSAxyG2f2Dl2jNfZMRY0g871tpPSe_MxAkuITssMxiDMJiDiBsoXfIjCUfsAQ)
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And built a little frame for under the new fuel cell.
(https://lh5.googleusercontent.com/oKrE5Cpz0x_FeABGDASItANtyAlyBQl2JQqZ5_m4IIqR0wy2pN3NEjunGpZfteSALRAUajYAcwvoXQDsCjkAs4MUvFr9YQGGDQZjLDZQXfewtmzxr8w)
(https://lh4.googleusercontent.com/3XxRedQ1CrZsaN6WrWEIqAsl4u8dBi6zvH-NI9hyE5YgMob-cz4ScY34GJx22_kbKP7Szw9wu27c9qnygaWD_dEmQGVtiy7Hf-UDohzz7g7v2kss2lk)
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Dont buy the angular spout for this fuel cell (Summit) shown in the photo above.. There is no way to reach inside to hold the bolt heads, so its basically impossible to install.
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What a mess, but making progress in several areas at once.
(https://lh6.googleusercontent.com/iPM-p1df9eS37u3DJbr7sMySGbxzRHBKtwRPohDu9wuVYFtc9jnBEZokbcXbhyoxtWGY-9qDvkS4zQjnRwyoncGo4FQBYsD9BC74f2tCinExbb1Ng1M)
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Looking good David - I had a similar problem with my jegs branded rci ripoff fuel cell. What a piece of junk! all the bolts were over tightened, where's the foam?, the lower plate for the bulkhead is plastic so the 'studs' don't really work right, etc...
I guess you get what you pay for.
-Eric
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What are your plans for lights?
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Tentatively, four PIAA PRO 80XT's.
Not much new today.
I picked up these camber adjusters because my struts are spaced down a ways. They seem pretty cool but are much smaller in diameter than the original bolt. Time will tell. I am going to carry the original bolt just in case.
(https://lh6.googleusercontent.com/4b9f6f9sZ5nDz4nVeOMLFZ1RWY858Dn6ybzGutZ7COoFYwQXQ-fyO-4SvBOr_GMKJyGFSRh_RoP1K_0KVQSqpbBmFxmnemkmBdl5y0Ka4WGTR4XCEn8)
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The new front shock package arrived today. I test fit them. I will need to remake the upper mount for the auxillary shock. To be expected.
(https://lh5.googleusercontent.com/AKYmo1FSVKXaQTtWtZiZN97O9CcgkQkXZVurPkstZKVD438pC4TIMyNVYOwnerDiTcQ60n_VH8frHHnoRLDv-fpt15_vJYmSy4RJ3NSp9wC0pK6BKVE)
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It's good to see someone else has been saving a lot of work for last minutes.
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Its what I do best.
Someday, I will be ready in advance. Maybe.
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Progress is slow. I took the weekend off since there is lots of time left.
Lower shock mounts.
(https://lh5.googleusercontent.com/ZDKp1Yb6xn5G_yNgz6b-_6Cy8f0lzk7iHnVYjuilopnjyTPOHKirRTYss5n2UnO32PjyHoKk_oGp5QlaWZ4ZaI17J_pZR0gvj5MqxrkUx_YwtMKno2E)
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I revalved the new shocks that are going on the rear.
(https://lh6.googleusercontent.com/Z4OPbPBvaoSI3umPBquJaIttlvnm8kVt3H0Uw6OrxLvILjqfM2lV-_Kw6hjfqMP98ybARM_T6BKdX3muoZwvmdd3kDGuS7MWGWYCLQo7bWm6p1v_jnk)
All done.
(https://lh4.googleusercontent.com/N04CoQePSMook7fygZnKt0FHVWh4Hrt0rQbX0nG1m5wKm37L4QFDhlu7zZKqIi8w70rjjPROuL12K12pHecsa0vC0xfJnEZo1qXIjpi4qHhHFt3mUBg)
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Progress is slow. I took the weekend off since there is lots of time left.
Nice... I decided to really dig in over the weekend and wash my racer.
-Eric
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I forgot to mention - The rear shocks have their fishnets on cuz they are SEXY!
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Its 4:20 dude. And I just finished working on the racer for tonight. I made some good progress but forgot to take pics in my stupor. I will try to get some tomorrow but it will be a busy day.
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Now that the race is over and I have a little time...the rest of the pics from the slam session build-up.
Front lower shock mounts.
(https://lh5.googleusercontent.com/ZDKp1Yb6xn5G_yNgz6b-_6Cy8f0lzk7iHnVYjuilopnjyTPOHKirRTYss5n2UnO32PjyHoKk_oGp5QlaWZ4ZaI17J_pZR0gvj5MqxrkUx_YwtMKno2E)
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I was replacing my rear 14" bilsteins with new ones and discovered that my old ones had a 2" longer body. The new ones wouldnt reach the mounts on the roll cage. So I whipped these extension brackets up.
(https://lh5.googleusercontent.com/13ZJxhbLCEoqYO_0B2HL-GCJIfRK9AXjd5wk9BkuPAQ_gigWFX_6Y32E-kXq-UqYkp-e0s23VU9chpg1f24nSgkiRR9NtNYRNJ12hSvppDFzQDZ7zn8)
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I thought we would be racing into the night and wanted good lighting. I didnt get time to put a couple more on the bumper in case I rolled.
(https://lh5.googleusercontent.com/LdBSjjBtx0xzmT6rcf6k4PViW67EIXwq_Op-zjx68a5oDi1Fhqr_x5vvhItjRC5f6VTVgv50HUPMf6mi4XkPltCQBDeiEzjY68Q6pgwtOUgbTAQ6bqw)
(https://lh6.googleusercontent.com/DSoTTD3Ff59Xw9K8jxKB0GfejyCuqDKXFBvZPrKCW_YD9FcDJMfL0VeqTav7LMQvVKIbAW9EISCL-n-4v1jqhM_uCMsFPXHKTCYlB8AhuTOTSUQV2lM)
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The front shocks are all squared away and installed.
(https://lh3.googleusercontent.com/LSjdTuNOCATFL1q5X3HbzEZfj9alGOXCQmoeBQBPOZzFzM2REvX1BqrAGJpqReuYpwZFODPnX1cqGXJzxgEoDQIlV09fhx5ZWLLbMi_na6bI_HF3y_Y)
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The rears too. I had cables limiting the rear end before. I upgraded to actual straps but left the cables on for good measure.
(https://lh3.googleusercontent.com/PBwufDO9xl0Kx42kXquD1cB2g3fkTOAVJK00fTyzWCpi3fBLxWDkE_q8uD8UCGOwYgcAvitI7c-TanzrM0OF4tjqBOnyprYz5C1mqu862ZoW46DtX1A)
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Three of my wheels were bent from the last race. I had new aluminum ones lined up but they needed the centers machined out. At the last minute my machinist ran into some troubles and couldnt do it.
They looked like this.
(https://lh6.googleusercontent.com/cbSihPVrd-63I7XUL-MeLrNRLYzOn4WA0j9umGtZOKTJvKAh-6qJnmbcsXCTLyDcamFdSviw8gcObMgtlCRCt1XDnAc6c1B2qNL0LDTVBhg1BSAm1K8)
So I used a BFH on them and they looked like this.
(https://lh6.googleusercontent.com/dw1_JewwBDRsTEHFM-T7OykBXpChmA6EaW3v1O1kgNz9IWntCl2Zw4x3RgFRkNv_rhffP06WgxoHMM73WiU8_Sq_p3AfLEiZYZZT5v6RfOELrhaGVBc)
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Then we built a bunch of other stuff, tire rack, fuel cell hold down, oil storage rack, jack mount, installed a pumper, GPS, and 2 meter Radio. I dont have pictures of this part because it was the middle of the night and I was high on Monster.
Here is the finished product the minute it rolled out the door.
(https://lh4.googleusercontent.com/MvTegsRpW4lfNEakfaTuLsMkk_ZKw1wL_N6sN1OETDH8Xx-NFpfoDGheILNKm7kPMcBeoF4izGZ_LblmyRVgfYQWkM5c3dCG-820ux8U5vgmish961s)
(https://lh4.googleusercontent.com/VYVD0X5wIp0C8_Ar0Wtr_bg70-vwBHu6s-CdUwdqTplO5VIOEM9sJfsVw7bcCGXvHR5Hr-8ywqMhjOXuMqOanRZW6Sq8vhSWpXEOmt_iTCh5IpXxi2Y)
(https://lh4.googleusercontent.com/XEOJ-5M7OG3xNtzYHIMufWWBUjzKmiEh7yt1NnI-SfslZx5K8kKQzod6AscPbPlunITRq0RBSDs3K07HQ08X-xArZb7o_sJrY01_yS-_QJtczgycf0E)
(https://lh3.googleusercontent.com/XgivbTgSAjzeWyo41fbRwElpmxxyqqPVcaJY-9WgcHH5x7ZCGlq3oTihkJn18KGTgcRnLTtePcOHKC_Ap_U4v15IVfqei5MI9d9CldH0lI5z2dxaul4)
(https://lh4.googleusercontent.com/wuxaLqooauSXf-cZ2dP3p4cHzHTkPwSoUSnFmlH6s7Jy1mMX96TSEoADyKbia5tGWkRI2zrq0WsyYKTMtwW4YPU6mXZQpoQXz8T3Z04sTu1PbEQB52k)
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Although we won the USA 500 race, the truck was in rough shape at the end. About 125 miles before the finish we overshot a hill with a huge drop on the other side and nose dived into the ground pretty hard. The alignment was out of wack after that. We also had broken an engine mount early in the race and the engine was held in by a ratchet strap. When I went to replace the broken engine mount I discovered why the alignment was so wrong. Both strut towers and the frame had bent in. So much that a new engine mount could not be installed. The frame was just too narrow. The rear axle also has a slight bow that I am going to ignore for now. It doesnt seem to be affecting its function and I dont have the time or inclination to fix it.
My roll cage goes through the engine compartment and ties into the strut tower and auxillary shock mount. you can see in the pics that both sides are bent in.
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/310500_2199714275579_1328965449_32283011_1850173038_n.jpg)
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/314635_2199713715565_1328965449_32283010_181487346_n.jpg)
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After 2 seconds of deliberation I came up with an ingenioous plan to straighten the bend using a high lift jack.
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/303862_2199715115600_1328965449_32283013_156245532_n.jpg)
I was able to get it pretty straight but it wants to bounce back. An engine compartment cross bar was in the original plan but I just was never able to get it done. Now it is a priority, so that will be next.
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NICE!
-Eric
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Seems like it wouldn't be hard at all to duct tape a dial micrometer to your "frame alignment apparatus" so after the 15th whack with the BFH you'll know its right where it need to be.
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Time to add another brace across the center. :D
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All done. Simple and affective, although I will probably have to cut it out when it comes time to change engines.
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-snc7/300724_2202232458532_1328965449_32284554_1267408622_n.jpg)
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Looks like you biased the tubes a little passed centerline. :)
-Eric
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Not totally intentionally. I jacked out the frame until the bolt holes lined up for the engine mount, then Luke welded in the bar while I was at work. Its hard to tell what all was distorted. It will work fine though.
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The Geo symbol is crooked. You need to get on that.
:D
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Well things were going pretty well. My trailer was organized and packed. Trailer hooked to the truck. Race car was clean and running good. I had enough free time to play with a few things.
The steering hasnt been strong since the reservoir broke in a previous race and ran dry for a long time. I decided to change out the pump. To do that I had to remove the oil filter. "Why not change the oil" I thought. So I did. With the old pump off I found that the steering pump bracket only had one of three bolts in it. I scavenged some bolts off of a parts engine and installed them then put the whole thing back together. I fire the engine up and test the steering. Much better. Check for leaks and find that my engine has suddenly started leaking profuse amounts of oil. Somehow the work I did disturbed the oil pump gasket at a pressure galley thats very near the edge where the steering pump bracket mounts up. I thought maybe the pump had cracked but I have it all apart and there doesnt appear to be anything amiss other than a deteriorated gasket.
Two days until I leave for the race and here is how it looks.
(https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/300131_2217322715779_1328965449_32296976_823191794_n.jpg)
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You know,your getting to these things a little early. Maybe you could put it all back together in the trailer Friday night before the race... then you would have the benifit of the stress of a real deadline :) After you put some of those parts back on I'm sure it'll run better. :)
BTW... I haven't brought it up in a while. Should do a Seafoam tuneup before the race. Why? Because I use Seafoam to fix everything :)
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The Zukiworld Order race car will live to race another day. I found that a bolt was missing that held the oil pump onto the block. This had allowed a small leak and subsequent deterioration of the gasket. The oil pump is back in and the car is running good. I couldnt go for a test drive since I dont have any lights. Hopefully that will go good tomorrow.
I guess its a good thing I found out now, rather than at a race. This car has been full of missing bolts. The more I look at it the more I find. I think there must have been a previous owner that had no business being under the hood of his car.
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The joys of other peoples work. :)
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This car has been full of missing bolts. The more I look at it the more I find. I think there must have been a previous owner that had no business being under the hood of his car.
Each part that leaves is weakness leaving the system. Lighter, faster, less parts left to fail... this makes a statistically better vehicle, right? It's all by design.
:)
-Eric
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how's going now?
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Cool to see someone from close to my neck of the woods I'm just over the river in independence Or.
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Just got back. The engine ran like greased lightning all weekend. 1st place in five of six moto's. The first race was a DNF. My fuel hose flipped up on top of the foam in the fuel cell when I landed off a jump and I lost fuel pressure. With some help from a track official it was missdiagnosed as a lack of spark so I towed it off the track.
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The suspension looked a lot nicer then mine as well, again. :)
We'll be right with you next year!
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Good! I am ready for some good competition. Watching your in-car video made me wish for more door to door action.
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I'll get the other two moto's on-line later today. :)
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I got good video as well. I will try to get the time to trim it and then upload it in the next few days.