ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: Sævar Örn on April 25, 2011, 05:12:22 AM
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Hi, I got tired of my vitara breaking endless front diffs, and i also wanted bigger tires so... let the pictures speak.
Im about half way done with the front end... i hope to finish this project before the summer ends. And the car will need to be road legal and have neat enough driving characteristics to use as a daily driver like before.
(http://www.facebook.com/photo.php?fbid=10150199520467907&set=a.10150194118842907.377915.642127906&type=1)
Suzuki - body = ready for the burning torch and cutting wheel
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/200005_10150199520582907_642127906_9007888_511469_n.jpg)
Use the free time to clean this whole mess up
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185598_10150199521072907_642127906_9007901_3247042_n.jpg)
Look at those ridiculous angles.... PFFF :lol:
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196354_10150200766967907_642127906_9021099_793697_n.jpg)
Motor off frame....
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198923_10150200767022907_642127906_9021100_7319150_n.jpg)
Rolling chassis, will start with the front axle swap. Rear should be easy enough...
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/189256_10150200767142907_642127906_9021104_4336246_n.jpg)
Bye bye IFS, LOL
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/199268_10150200767187907_642127906_9021106_5979514_n.jpg)
neat to remove as a complete unit...
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196220_10150200767252907_642127906_9021108_761480_n.jpg)
Somthing missing??
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/184804_10150207655962907_642127906_9088434_2251679_n.jpg)
1996 Toyota SR5 IFS rear axle with electric locker unit
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/190088_10150207656207907_642127906_9088443_2491887_n.jpg)
1991 Toyota solid front axle from double cab diesel(same as 79-86 except slightly wider) Although not as wide as the SR5 rear axle I got, but I use 5mm thick spacers in the front to correct that.
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/185869_10150201048657907_642127906_9025095_2949711_n.jpg)
Bye bye IFS subframe, LOL
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196088_10150209327217907_642127906_9106617_3900571_n.jpg)
First test fit, taking measurements and thinking a lot... lol
:eek:
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198538_10150251690342907_642127906_9275074_1343754_n.jpg)
custom building brackets the cheap way... not pretty but it works, some trimming will be done later + paint
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207525_10150251690412907_642127906_9275079_4170544_n.jpg)
Brackets match width of frame rails, magically they are the same exact width as the leaf spring hangers on the solid front axle originally from the toyota... so measuring was easy..
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/197301_10150251690452907_642127906_9275081_7887820_n.jpg)
Ive never welded much before, but i think this should hold the axle to the car... in this place i am worried of clearance between bracket + bolt and 3rd member, but we can worry about this later...
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206779_10150251690482907_642127906_9275082_3427050_n.jpg)
Ready to build brackets to the frame...
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/205285_10150251690572907_642127906_9275087_4255890_n.jpg)
Making sure everything is exactly centered...
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/205644_10150251913822907_642127906_9278139_4618967_n.jpg)
brackets + jimny trailing arms
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/199895_10150251913867907_642127906_9278141_7736619_n.jpg)
after some welding practice... perfect i think :)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/199722_10150254579662907_642127906_9307734_2495373_n.jpg)
dont worry this is not the only welds holding bracket to frame, i will also use this bracket to make body mounts on top of... this will make a complete weld up along the frame rail making it indestructible
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/197256_10150254580352907_642127906_9307749_4100701_n.jpg)
Ta-da!!
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/207178_10150259654442907_642127906_9327091_724203_n.jpg)
Some free flex test of trailing arms, looks promising...
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/216152_10150277782867907_642127906_9484031_2952173_n.jpg)
panhard bar bracket on outside of frame rail because of little space...
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/223438_10150279057827907_642127906_9498965_4573301_n.jpg)
some things puzzled to their places to get an idea of space... springs are from vitara, i plan to use springs from suzuki jimny...
Panhard bar is too long and doesnt fit, need to bend it over the diff cover and make a good bracket on the axle front side in exact same height as the pull-rod for steering. The angle will be exactly the same as pull-rod so i dont get a pull in the steering wheel when car articulates... ... suspension science.. i will not tire you in a language im not good at.. :)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/223518_10150279057927907_642127906_9498967_4554511_n.jpg)
idea of placement for coil springs... May cause some axle wrap but its impossible to put directly on top of axle i think... i will think this more...
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/216197_10150279058067907_642127906_9498969_5517942_n.jpg)
Plenty of clearance from pitman arm...
any questions?
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Thank you for sharing!
-Eric
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Looks good!! Where are you from?
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Hi, Im from Iceland. Im 19 years old and graduated car mechanic
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/227519_10150302211982907_642127906_9725332_5104852_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229464_10150302212072907_642127906_9725333_1987214_n.jpg)
Springbowls from Old Man Emu, originally ment for 4runnner/pickup springs but i flipped them and luckily the suzuki springs fit right inside!
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/229580_10150303728992907_642127906_9745051_6573554_n.jpg)
Fitted the motor and found that I needed to bend the panhard rod a little more... this was done easily in a tube bender and looks good now, have no picture sorry but clearance on dropped suspension is about 3"
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/226329_10150303729097907_642127906_9745052_5663397_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/230407_10150306784827907_642127906_9771732_280855_n.jpg)
In the rear I will put the A arm in the trash bin and make 4 link suspension
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/248926_10150308514147907_642127906_9786600_6621301_n.jpg)
Rear axle moves back about 2"w
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/228220_10150308514212907_642127906_9786603_232935_n.jpg)
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/247595_10150309618432907_642127906_9796899_3226795_n.jpg)
Links from an icelandic Hilux 4 link suspension kit of which can be bought
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/249731_10150309618467907_642127906_9796901_2357793_n.jpg)
Getting there...