ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: GO_OUTSIDE! on July 19, 2012, 08:43:35 AM
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Well, I finally bit the bullet and over payed ($1600) for a Samurai that has more wrong with it than right.
What she does have is 97K miles, an engine of questionable integrity, a good tranny and transfer case, good axles, good frame, and a mostly sound body. I call it potential.
The rest is broken, no exhaust, leaking brakes engine and radiator, no heat, no top, broken column switches, torn off bumper, rusted out floor pans, bent steering linkages, bald swampers... It was an interesting 3.5 hour drive home, especially once it got dark and i couldnt "hotwire" the headlights. I cant wait to get the wiring schematic and see WTF?! It didnt help that my meter was on the fritz and I had to borrow wire from the stereo.
Here's the picture from the ad:
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/1987samuraiadd.jpg)
I'll upload more pics as i go.
I am aiming for a reliable daily driver to possibly replace the KLR650 I currently dodge deer on every day. She will also pull double duty as a weekend trail warrior in the forests of Virginia, Pensylvania and West Virginia. All for under $6,000. She is currently sitting on 4" of SPOA with 30" tires and probably wont get much taller.
For now I have ordered some stuff from Rods Suzuki Salvage, Lowrange and of course Ebay.
This is the list of things I have started with:
Fast back bikini top
new cables, hoses, belt
Over the top steering kit
Lowrange tri Y header & complete magnaflow bolt on exhaust
Driveline spacers
master cylinder grommet
bushwacker 4.75" flares
fold down windshield kit
$25 aftermarket headlights
Ill build my own bumper and strengthen the stock roll bar somehow.
Likely ... slightly over budget... improvements may include:
Transfer case gears, 4.9:1 Lowrange offroad
Transfer case mount, Mega mount Rocky Road
Shocks probably Doetsch 3000 series
Clutch and Ujoints while its apart.
Carburetor
Maybe... if I want to bust the budget... in the future:
Seats
ARB locker
Winch
1.6L upgrade
Today I drive up and get a pair of complete front and rear used axles with wheels for $100. If nothing else I can use the tires.
Wish me luck!
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It looks solid in the picture, but sounds like a death trap to be driven right now. I'm amazed that you made it 3.5 hours with the description you gave us.
I'm looking for a Sami right now. So you will have to keep the thread going so I know all the things I will have to do with one that I find.
Thanks,
Rob
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after you get thru the essentials, consider moving seats up your priority list if you are going to DD.
there are many threads about what fits and is comfortable, short list being neon, prelude, tracker, and my fave, cavalier.
P/S would be be a great addition to DD as well.
good luck!
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Seats, although I want new racing seats very badly, have just been bumped by tune up parts. Yesterdays trip to Advance auto cost me nearly $200 in lubes, hoses etc...
I did come away from the local fire sprinkler shop with enough pipe for a bumper for $20, and picked up full front and rear axles for $110. The old tires on the axles are crap but one of the all terrains will work for a spare, and now I have spare everything wheel to wheel. Maybe I will upgrade to rear disc now... I knew I shouldnt have ordered that ebrake cable.
I ordered a set of Falken Rocky Mountains in 31x10.5 from tires direct today, I hope the positive reviews are correct. I really wanted to try the BF MT K2's but the budget keeps getting tighter and I dont want to give up the gears. Going with the Falkens saved over $350.
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I took some pics yesterday, today I wash it for a thorough inspection and replace the rusted floor pans.
My new sammy project
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_77897752x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_85537562x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_20330982x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_40404462x.jpg)
Im hoping I can fix that rocker without to much effort. Lots of rust in the rockers.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_35913422x.jpg)
My new spare axles.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_11197022x.jpg)
Hot air intake!
.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_67544942x.jpg)
I'm hoping its just a hose leak
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_25387422x.jpg)
Bad windshield frame repair. Im going to put some aluminum diamond plate here when I find some.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_61347972x.jpg)
I think I should have bought a bigger piece of metal.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_35743582x.jpg)
Busted switch gave me hell getting her home in the dark. Suzuki must have switched the ground, because my plan to "hotwire" the headlights did not work. Ive got a new one on the way from Suzuki salvage.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_98293972x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_83813652x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_7602712x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_96757132x.jpg)
A little rust in the wheel wells. Not sure how Im going to fix this yet.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_4314752x.jpg)
I am pretty sure the PO cut off the exhaust to mask the knock in the engine. I asked him to put it back on for the trip home and when i got there he had jammed this on backwards with clothes hangers. I had to stop at auto zone to tape up the joint and help keep some of the fumes from coming through the holes in the floor pan. Didnt work, just added the smell of burning glue. Quieted things down a little though.
I have a Lowrange tri y header and magnaflow exhaust on the way.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_84544912x.jpg)
Not sure how Im going to fix this either.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_93370782x.jpg)
PO must have tagged a rock and further destroyed the frankenstein of a drag link. Replacing it with a Lowrange OTT setup.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_54475202x.jpg)
More evidence of the impact, and I think I need a new bumper.
Any body have any suggestions for shocks? I am wrestling with whether I want to hold off for a couple months and go long travel or just get a set of Doetsch 3095's which are 1-2" longer than stock and run it as is.
I ordered my gears last night and think I can still get them to add them to the order if I call today.
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multifunction switch always go bad; and yes, switched ground.
afa your front tube/shackle mount, you will find a 1 1/4 (if memory servers) black pipe fit right in both front and rear frame tubes and add sustantial strength
I used pro comp es100 from 4wheel parts, you will have to search for the chart that shows extended/collapsed and correct ends for your application.
you should flex the rig out to get extended/collapsed measurements, preferably after armor (bumpers, sliders, skid, etc.)
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Whats "afa your front tube shakckle mount mean"?
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Look ma, more rust!
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_46628772x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_33211482x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_79142102x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_50235722x.jpg)
Gonna take a little more TLC than I thought.
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I ordered some Chassis Saver for the rust.
Got my new tires and discovered that my left front wheel assembly is stiff. Im going to need to rebuild the steering knuckles and bearings. Son of a...
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Makes me think buying the best Sami I can find is the way to go. Maybe even one that is completely stock as long as there is no rust.
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Yes. That is absolutely right. I am at $4500 in parts right now plus $1600 for the sammy. I will spend the next 3 weeks working on it almost everyday, and will never see my money back if I sell it, but when Im done it will be tits. All I can hope for is I love it, it loves me back and it doesnt get stolen or set to fire.
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Found a cracked radiator inlet yesterday, lets see what I find today.
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Holy crap! Why is it so hard to get the heater hoses off? I had to cut them to get to the heater core and blower motor. Guess I will also have new heater hoses when Im done.
Exhaust manifold came off easy!
Driveshafts were tough but there out, as is the Transfer case.
Mirror relocation brackets are fabricated and awaiting mirrors.
I ordered some replacement LED lamps for the instrument panel while I had it apart.
And, I found more rust, this time on the frame near the left rear forward spring perch, gonna need to weld on some plating.
Im getting there though, and I am currently ahead of schedule.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_13297672x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_26239262x.jpg)
My poor mans garage.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_43063622x.jpg)
Turn signals fit great for now!
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Dedicated!
Everyone in my club tends to move the turn signals inside the grille. Not exactly legal, but they don't get broken. :)
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Found more rust! Bad stuff where the cross member that supports the T-case hits the frame. Im not looking forward to fixing that. I am now certain that the prick kid who sold me the truck left it all muddy on purpose to hide the rust. I am also certain he cut the muffler off to mask the rod knock. Pretty slimy for a young kid. I thought country folk were supposed to be moral.
Pulled the tranny yesterday to replace the clutch, at least that went smooth.
Replaced the fuel filter and hoses.
Having a hell of a time finding replacement heater hoses.
I replaced the heater core while I was in the box replacing the blower motor. Although the motor turned out to be OK Im glad I did it cause it was full of crap.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_34484202x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_36511732x.jpg)
I cut some 7/8" holes in the heater box to give me access with a shop vac without having to take the whole dash apart for cleaning it out in the future. happily I have plugs that fit perfectly.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_58197572x.jpg)
I busted a bolt removing the old emergency brake cable, Ill never try to remove another bolt on this thing without applying some penetrant and letting it soak. One of the first things I did when I got it home was apply penetrant but I guess I missed some.
The mirror relocation brackets are on.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_78168652x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_92947372x.jpg)
I have started building a set of lower shock mounts. I am running out of time and money reall quick so Ill leave the uppers alone, but since Im replacing the shocks and longtravel cost the same as short travel I had to do something.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_95502x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_21990392x.jpg)
I called up "the answer man" at Gabriel and he very quickly and painlessly gave me the part numbers of some shocks that should work great. The fronts are 22.5"- 13.4" and the rears are 24"- 14" both for some very light vehicles. I was going to order the Doetsch shocks but these were $85 shipped for all four and delivered in 2-4 days.
Lets see which parts come today!
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Dedicated!
Everyone in my club tends to move the turn signals inside the grille. Not exactly legal, but they don't get broken. :)
I had every intention of doing exactly that, but was having trouble seeing my way through it. While I was mulling it over I stumbled upon this. It was super easy and took less than 30 min. I will be building a bumper in 2 weeks and will put the turn signals in it when Im done.
I would like to convert to a smaller LED turn signal if I can find some that will pass inspection.
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I found this video on you tube yesterday http://youtu.be/EeEP668Phuo (http://youtu.be/EeEP668Phuo) , I found it very helpfull for changing the clutch. Also, zook94 recommended cutting 1/2" off the frame tab that the tranny mount sits on and that made a world of difference getting the tranny back in place. I wish I had remembered to fill the tranny after I installed it though, so I wouldnt have taken a bath in gear oil. That really complicated things while I was trying to line it up and get it back into place. I recommend a jack on a hard flat surface. Working in the lawn is proving to have many disadvantages, but it sure is comfy.
Today is metal repair 101. Im going to replace parts of the floor pan and patch holes else where on the body.
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On the Samurai you can just take the shifter off and pour the gear oil in through the top. No mess required. :)
Note, this does not work on a 4wd Tracker. The shifter area and transmission do not have a passage to allow the oil through.
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I had heard that and I remembered it when I was filling it up, for some reason I forgot the bit about the oil pouring out the back if tilted rearwards.
Next time I will get it right... God I hope there isnt a next time. :o
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(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_80175702x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_36125272x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_90064922x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_48058712x.jpg)
The rust wins. There is so much rust between the body and frame that I would need to take the body off to repair it properly.
Im not going to do that, not yet anyway.
In the meanwhile I'll make some structural reairs and seal up the holes. Then Ill coat the whole thing in chassis saver and hope to slow the rust down until a later date.
From the look of it and the DMV history, this must have been someones beach truck.
This is the tranny tunnel repair. Its the best I could do as a hobbiest working with scrap metal.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_67865002x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_5458592x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_3615142x.jpg)
Going to finish the rust repairs today and rebuild the transfer case with 4.91 gears.
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The transfer case rebuild went smoothly enough. I broke 2 bolts, pushed out the Low gear when I didnt need to, put a bearing on backwards and am missing the shifter sheet, but otherwise very smooth. It would help if Low Range supplied instructions with their kits. I used the instructions for the Trail Creeper kit I found on the interweb and... well, thats why I pressed off the low range gear. It didnt hurt anything but its not any easy task without a press.
Rock Roads Mega Mount needed some tweaking and instructions for a boob like me. I got the mounts wrong and cut down the bolts before I realized that they went in from the bottom.
I used some Kevlar fabric i had laying around and Chassis Saver to patch the holes in the floorboards and elsewhere in the interior of the body.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_33687892x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_58888742x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_56541472x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_6538092x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_54758182x-1.jpg)
This is what it looks like from below if you only coat one side, I coated the bottom after the picture and the end result is an impressively strong patch for a single layer of Kevlar and some fancy paint. I used the silver Chasis Saver because of its ability to fill in holes and gaps. I will put 2 coats of bed liner on next and it should last long enough for a proper repair.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_85655582x-1.jpg)
I started replacing the U-joints and WOW what a pain in the ass! I wish I had a press, the vice isnt strong enough so I am using a 3lb hammer to push the cup out as far as I can and then grab it with the vice and working on it till it comes apart. It is slow going and I almost gave up when the first U-joint looked good. Then I found the resolve to replace the other joint and discovered two caps were dry and one spline and its bearings had been eroded to dust.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_82850872x-1.jpg)
I finished building my lower shock mounts.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_44677182x.jpg)
And then decided to add a little extra material on top to hold the mounts on to the axle tube for hard hits, and a little piece on the bottom to deflect any hits to the bottom of the shock from rocks or what have you. I figured since they will be hanging a bit below the axle I dont want to snag them on a rock and rip a hole in my axle. Their not pretty, but considering I've had about 15min of welding instruction over the course of my life and Im working with hand tools and little patience, I'm happy. At least they are not rusting yet.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_62619552x.jpg)
If I all goes well with the steering knuckle rebuild, I should be driving her to work on Monday! ;D
I can see the light! Even if its just the sun through a rust hole. :-\
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The bedlining is done, the engine comparment is back together (except for some vaccum line mystery), and the dash is back together complete with new LED gauge lighting and speedo cable!
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Getting close!
If you jump over to Ack's Faq you can find a vacuum diagram.
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Getting close is right, I'm having trouble putting the tools down and coming in for dinner.
Yesterday I placed some sheet metal over the holes in the wheel wells to protect the patching.
Today I finish replacing the ujoints (if they arrive) and start on building a front bumper.
All I have left is rebuilding the knuckles, replacing the exhaust, welding on the shock mounts, replacing the brake lines and installing the fender flares (if they ever get here). Oh and some little stuff like putting the seats back in and refilling the diffs...
Wow, actually that still seems like a lot to have done by Sunday evening.
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Here are some pics of the sheet metal repair in the wheel wells.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_12179612x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_758412x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_69954382x.jpg)
I thought I was going to get the bumper built yesterday but only got as far as repairing the front crossmember.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_69848052x.jpg)
Im not sure if I am going to work on the bumper or the shock mounts tonight.
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Thinking that Samurai was either beach driven OR northern salt got too it!!Picked up mine ready to drive,new tires ($1400),4x4 works great.Think there is a small (3"x6") hole pass floorboard...terrible terrible!!
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Thinking that Samurai was either beach driven OR northern salt got too it!!Picked up mine ready to drive,new tires ($1400),4x4 works great.Think there is a small (3"x6") hole pass floorboard...terrible terrible!!
Thanks for rubbing it in.
I welded the shock mounts on and installed the shocks. That went pretty smoothly.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_34678382x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_5699892x.jpg)
I also built the bumper... This took 3x as long as it should have, including running out of wire and having to take a trip to Lowes. Of course they didnt have a big spool so I had to get a small spool and re configure the welder. Im happy with the final product though.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_18850492x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_56869622x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_67549252x.jpg)
The bolt on exhaust system required quite a bit of reworking to get it to fit. In fact the rear tailpipe had a few bends removed and still needs some work. Its a Lowrange Tri Y header and Magnaflow full system. Its a little louder than I would like but not ridiculous.
The steering knuckles didnt get rebuilt, it turns out the caliper was frozen, so I replaced it with one off the spare front end.
The OTT steering kit from Low Range had some clearance issues with the caliper and required somne grinding of the control arms to fit.
I finally was able to put a seat in it and take it for a spin for the first time in what seems like weeks. I couldnt turn left and it seems I had the steering adjusted one extra turn of the wheel. I fixed it this morning and took it to work, a little late but who cares.
End result, this thing is weak.
So, do I mess with the carb, rebuild the engine or swap in a 1.6 8V?
What should I expect a fresh 1.3L with full exhaust, 4.91 gears and 31" all terrains to be like? Right now I cant get it out of 4th exept down hill. On the freeway it is all I can do to keep her at an indicated 55mph. The smell of the exhaust tells me soemthing isnt right with the mixture. Its a brand new catalytic converter, it shouldnt make my eyes burn going down the road.
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I am enjoying reading your thread. Pls post more details and pics bro. 8)
I went through the same modification headaches before.
http://www.zukiworld.com/forum/technical-discussion-beginner-repair/newbie-with-samurai/msg230195/#msg230195 (http://www.zukiworld.com/forum/technical-discussion-beginner-repair/newbie-with-samurai/msg230195/#msg230195)
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Well I got pulled over already for no inspection. So I had to put on the original fender flares until the bushwackers get here and get an inspection.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_88381552x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_26802302x.jpg)
I also rechecked the timing and found that it was a little retarded, actually it was alot retarded (2degrees BTDC). I also plugged the crankcase breather hose and it is running better, but it still has a knock and some bearing noise associated with the clutch. I am going to pull the engine either for a rebuild or to swap in a 1.6 8V. Im trying to get an idea of what to expect from the 1.3L if it was freshened up with the header, 4.91 gears and 31" all terrains.
Any ideas?
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Passed inspection!!!!!!!!!!!!!!!! ;D
I took it to work this morning and it is running much better, not perfect, but much better. 55mph no problem, 65mph on the freeway with not to much effort. I readjusted the timing, landed a vacuum line and plugged the crankcase breather line. The line was coming off the valve cover, hitting a T, then off to the manifold and 12" of 3/8 hose open on the other end. She still smells like she needs some more tuning, hopefully I can make some positive adjustments on the way home today.
I havent had the time to thoroughly go through the carb and all its associated servos and vacuum lines, but I did adjust the cold fast idle effectively.
Im not sure how much time I want to spend on this setup, I am pretty sure I will be upgrading to a 1.6 8V soon. I am thinking of running a Corolla carb on the 1.6 with the stock 1.3 manifold.
Im going to need some springs to hold the brake lines away from the wheels and tie rods.
Im still sucking in exhaust, hopefully I can reroute it out the corner and get it to stop coming back into the cab. Amazing that with the top and doors off this would be a problem.
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I have a great time reading about your project. I'm still looking for a project right now; I hope it is a little less involeved than yours has been. :)
Rob
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Do a good job looking for rust, it likes to hide under carpets, and behind trim. :(
Also, dont rush into it. I watched ebay and craigslist for a couple weeks before I settled for this one. Since then I have seen half a dozen better buys.
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Rust and engine issues are high on my list. I can do work on T-case, lift, gears, interior and getting it painted. I just don't want something that is going to take a ton of time and effort just to make right again.
Thanks for the tips!
Rob
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If you can do the gears you can rebuild/replace the engine if the price is right. I get stumped when it comes to setting up the gears in a differential.
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I have rebuilt exactly 1 engine. It was out of my first car a 1970 240z. I can figure out the gears and have a busy of mine look it over before I close the case and difs up.
Rob
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For the front brake lines I just used some from a Geo Tracker. Worked great:
(https://lh5.googleusercontent.com/-h_ZINFH65Rg/Rvsf59IW09I/AAAAAAAAALA/OQqK60BcPpg/s512/CIMG1495.JPG)
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I like, i also like the diff vent. What is going on with the stering linkages? How is one above and one below the spring pack?
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Nice job.... Alot of it looks oh so familiar from not so long ago. It is coming along very nice!!!
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After a tremendous amount of cutting and welding I have been able to modify the exhaust to exit the vehicle in the corner where it was intended. It has made a big difference in the amount of fumes I huff on my way to work.
Lesson learned, spend a little more time at the start of the project or you will spend alot more time at the end of it. A few degrees off at one end makes a big difference at the other end of an exhaust sytem.
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I am stumped by the wiring harness modification for the 1.6L 8V swap. I cant afford to pay someone else to do it (I am down to my last couple of bucks), could someone tell me how? The engine I am putting in comes from a 1993 or 1994.
Also, it looks like I screwed up somewhere and have to pull the airbox back out to find out why I dont get any airflow.
The truck is running well, pulling 65 on the flats but with a rod knock and 10MPG.
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I like, i also like the diff vent. What is going on with the stering linkages? How is one above and one below the spring pack?
It is half of an Over The Top steering setup. It reduces bump steer compared to a standard Z-Bar setup but is cheaper then a full high-steer. You do tend to bend front tie rods though, but if it didn't hit that it would smack into the axle instead. Of course, I have bent front springs hitting stumps at speed...
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Hey its all good,mine is far from perfect...its not running now!!OK it needs a elec fuel pump,then I gotta paint it too...really like your built bumper,great!
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Picked up the engine, harness and adapter saturday from Sean at aftermarket 4x4. Ordered timing belt, water pump, thermostat, gaskets, rear main seals, crank seal and cam seal today.
The trail tough adapter kit comes with a spacer to reuse the samurai engine mount on the driver side. No need to buy new mounts.
Sean, reminded me that I can use the Toyota carb until I get the harness ready for the FI, so thats what I'll do.
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I had the blower motor wired backwards, turns out squirrel cage fans only blow air in one direction. That sucker blows alot of air when wired correctly.
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Glad it was an easy fix.
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Me too!
I've decided to skip the carb conversion unless something stops me from putting on the FI. I dont feel like going through all the effort of getting the wrong Toyota carb to work, not that I couldnt 'cause I could! :P
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Why am I having such a hard time with this stupid engine swap?!!!!!! Everyone said it would be so easy. Maybe Im just worn out and am no longer seeing this as a fun challenge, It could be my mood but this is starting to feel like the never ending project from hell that will nickel and dime me right up until it gets totalled and the insurance company pays me 1/10th of what I have put into it. I have spent nearly all my free time for the past 5 weeks working on this and have driven it twice. I am now looking at yet another long weekend wrenching when I want to be exploring trails! I really feel like adding a redfaced emoticon here.
Luckily I bought my engine from Sean at aftermarket4X4 and he has been good about answering my questions when I cant get help from the internet.
Before anyone gets their feelings hurt, I do appreciate all the help I have gotten here.
Now that Im done ranting, and yes I do feel better, Ill get back to working on figuring out how to replace all the exterior seals and gaskets, belts and hoses and water pump on the 8V. Hopefully I will have it in and running by Tuesday.
I wanted to have the engine in already but my home made engine hoist wont lift the engine high enough so I had to rent one.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_59517192x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_68932102x.jpg)
Right now the engine is supported by one engine mount bolt a block of wood and the hoist. When I get the real hoist tonight Ill try to swap one for the other before the engine falls through the engine compartment and hits me in the foot.
Removing the gear box with the engine like that was not fun. I seem to be making some bad decisions as my time and money is running out. Im down to $300 cash and $500 credit before Im flat broke. And, I need to sell my Tacoma for at least $9,000
before I go to California in 2 weeks so I can pay off the credit cards and pay for the trip. I still have to spend some time getting the Taco ready for sale. This is getting tight. I should have gone straight for the engine swap instead of D$*kng around with the 1.3L. Oh well life is all a learning experience.
Anybody, have time to send me a copy of the "how to set the timing on the 1.6L 8V engine" section from thier FSM? I let the cam shaft rotate before I could mark it for reference while pulling off, rather, trying to pull off the cam pulley last night. Them skeeters are distracting.
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The engine is in!
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_28802922x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_36669272x.jpg)
This is what needed to be ground off the starter
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_95907532x.jpg)
Im hoping this doesnt mean I need new valve seals.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_40286492x.jpg)
All the seals are replaced, all the gaskets are replaced, new water pump and new timing belt. Ready for another 100K!
Today is an especially slow day at work, Im hoping to hang up the tracker harness and start chopping.
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Getting closer!
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My wife and I went to see Built to Spill last night and as a result I didnt make it to work today so I got to put in some quality time with the Samurai. Built to Spill were awesome by the way.
It wasnt as fast or as pretty as I would have liked but...The Fuel pump is in.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_89238702x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_78375742x.jpg)
I have about 8 hours in the wiring harness right now. It is partially installed, hopefully tomorrow I will turn the key and things will be better in my world.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_93198072x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_56209452x-1.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_41046272x-1.jpg)
I didnt have the luxury of labeling the harness when it came out of the donor so I had to research every wire in the harness using 3 different wiring diagrams because I wasnt sure which vehicle the harness or engine came from. I hope I didnt screw up.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_91370732x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_99017202x-1.jpg)
I waited till 1pm to start working on the harness I should have begun earlier, I didnt get finished till 6:30, long after I clock out. It was a slow day at work. They can make me show up on Labor day but dont expect me to do much.
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An alternative to your fuel pump setup down the road is to get a tank from an EFI Samurai and use the fuel pump setup from a Geo Tracker 8 valve.
That rubber should keep the fuel pump isolated and nice and quiet. When I put an electric pump in the SJ I just replaced the fuel filter and ran a secondary filter up front.
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I had to turn off the radio in my shop to hear the fuel pump, thats how quiet it is! Trouble is, that fuel filter prevents the pump from priming, I had to dismount it and turn it upside down to get the gas to the pump.
Once that was done though... BOOM it fired up!!!!!
!!!!!!!!!!!!!!!!!!!!!!!!!ITS ALIVE!!!!!!!!!!!!!!!!!!!
Ill be going for a test ride tonight!!!!
I would like to investigate the Tracker fuel tank swap to get an intank pump and a few more gallons. I have read a few too many posts about these inline pumps failing. Whats the fuel capacity of the FI Samurai tank, is it also 10 gallons?
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She runs great and has more power WOO HOO!!! ... right until I move upward in the gears and put the engine under load, then she flat spots like trying to push a mule. Hopefully, it will be a simple fix :laugh:
I didnt want to rip my rusted up old body to shreds trying to get the body mounts off to raise the front clip. So, I raised and clearanced the hood instead.
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_99883642x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_96192942x.jpg)
(http://i1058.photobucket.com/albums/t407/ekull3/Samurai%20build/preview_image_0_568542x.jpg)
I kind of like it.
Today, I will get an air cleaner attached and someday turn it into a snorkel/cold air intake.
AND!!!!! My fender flares finally (5 weeks on back order) arrived!!!! So, those are definitely going on today.
Holy Sh1t, I just realized I never set the precise timing on the engine, hopefully that is the trouble with the power delivery!
...Why isnt there an emoticon of a guy running out of the house with a whirlwind of keyboard and mouse left behind? Oh well, pretend you just saw one.
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I put on the air cleaner and advanced the timing. I am having trouble setting the timing, the strobe shows the timing jumping around and claims it is already advanced 8 degrees. I pushed it up another 10 degrees and am not getting any pre-detonation, is that OK?
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Did you set the jumper wire so the timing won't advance automatically?
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Oops.
I will in a few minutes, thanks for the reminder ;D