ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: shorthorn on October 19, 2012, 07:48:03 PM
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Decided to finally start a build diary and show you guys what I'm up to. I have gained a lot of knowledge and ideas from this site and I want to thank you all for your intuition and willingness to share! 8) I've had my 95 Tracker for a few years now and over time have been trying to make it into a better trail machine, which is hard considering how awesome these things already are. I come from a full-size American made background, but a while back I had the opportunity to pick this ole thing up for 150 smackers. Couldn't pass up on some fun even if it didn't last long, I thought. That thought has since metamorphosed into a passion for these lil Jap rockers. I started out at this thing with dreams of huge Rockwells and super heavy build quality. I have since come to realize the error of my ways, thanks to you guys and your ingenuity. Now I'm focusing on lighter and as much Zuk as i can retain.
I am going to try to upload some pics in the general order things have progressed. Your feedback is much anticipated and appreciated!!
modification list:
235 retread tires
custom front bumper
custom square tube rear bumper
rebuilt/overbeefed rear framerails and crossmember/third link mount
removed rear floor
gas tank raised to flush with bottom of framerails
replaced rocker panels with 3" square 1/4" wall tube for sliders, tied to the frame
custom full skidplate
reworked exhaust that enters the framerail behind the front seats and exits in the back
4door springs in front with strut mount reversal
mustang II springs in back. They are bigger around than factory, but they look like they'll work.
solid welded diff gears in the back
fozzy locker in the front
The first one is how it was when it came.
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27058;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27058;image)
Second with a new set of retread tires(235 methinks)
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27060;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27060;image)
Third and fourth, after the first mile on his test voyage the rear control arm bracket removed itself from the frame. Me, being the redneck farmer I am, immediately got out the sawzall, welder, and some scrap metal
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27062;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27062;image)
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27064;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27064;image)
Five is new rear framerails I made.
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27066;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27066;image)
Six kind of shows the skidplate I made. It goes the whole way to the rear frame bump where my exhaust enters the frame. I'll try and get some better ones of it soon.
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27068;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27068;image)
Seven is a pic of how I pulled the a-arm mounts back down. They got pushed up in on the trail.
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27070;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27070;image)
Eight is the new front bumper I made.
http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27072;image (http://www.zukiworld.com/forum/index.php?action=dlattach;topic=36630.0;attach=27072;image)
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I tried to add the images to the body of my first post, but I'm to html illiterate to do so. Sorry. :-[
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Here is my latest set of changes. The biggest one being beefing up the front differential housing and welding the gears in it too. The ones in the back are already welded up.
First pic is of the 'fozzy locker' in the front.
Second is some of the reinforcement I've added to the housing.
Third is the some of the third member reinforcement done.
Fourth is possibly finished housing. I'm undecided if it needs more beef. Suggestions?
Fifth is a comparo of the stock 95 cv to the one from a 99 I'm prepping for the Hagen widening mod.
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That does look much stronger, but the depth of that bracing is costing you an inch or 2 of ground clearance, maybe more with your skid plate factored in.
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Got the bracing done on the diff today. Hope it will make this thing last!
That does look much stronger, but the depth of that bracing is costing you an inch or 2 of ground clearance, maybe more with your skid plate factored in.
I actually trimmed it up a little. It is a bit higher than the crossmember and the a-arms. Won't know for sure how much until I get it in and mount the skidplate back up. Hopefully I get that done tomorrow. I'll get some pics up of it mounted when I do.
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I thought I had updated this a while back but maybe it never went through.
I have done a LOT to this since the last post.
Changes to date:
Custom heavy duty identical CV shafts made from 93 Chrysler Concorde CV's.
Front widened 4" with customized adjustable a-arms.
Adjustable width strut towers
31"Ag tires
Trail-Gear 4.24:1 transfer case gears(what a HUGE difference they made)
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Progress is looking pretty good. great work on this. good job on the custom bumper, by the way
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This is another build I spent hours reading. Part of the enjoyment of getting another Sidekick, was going through all the build logs.
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Thanks for the encouragement guys!
Here's the latest:
Cuz and I took the tracker, which has earned the new moniker TrackTOR or TrackTAR since it get's used as much for farming as crawling, to a local rock crawl competition. We were doing well for the first four minutes out of three ten minute rounds. Then an old problem reared it's head. We got it stuck down in a bowl type situation and broke the front driver's CV trying to pull up on a rock with steering at full right lock. This will reveal the weakest link every time in my past experience.
So I guess it's back to the drawing board. I'm thinking circa '99 F150 CV's and possibly wheel assemblies so I can use off the shelf replacements. The alternative is one ton Chevy setups with the hubs cut down and redrilled to fit 5x5.5 pattern wheels. Any thoughts on this plan and which would be the better option would be MUCH appreciated.
Also, previous to the comp I had to replace the rear axle shafts as I broke the left one and twisted the right. I'm thinking the best replacement will be a Ford 9". I had another hair-brained idea of fitting the stock Zuk rear axle with full-float outers from a D60 or 14 bolt. Any thoughts?
Thanks guys!
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Could you post more information and pics on your front widening mods?
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I think there were some on here, but I'm not sure what happened to the pics.
Here ya go. A pic of the modified a-arms 1.0. I can only upload one pic at a time cuz they're too big.
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Pic of the strut slider.
There's a wedge shaped block that goes between the top of the strut plate and the tower, but I don't have a pic of it. They're a hassle to move because the bolts are all really close together, but it works.
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There was a data loss on the forum. I remember the 1.0 heim joints, from one of your previous posts.
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I thought maybe something to that effect happened. Didn't remember what pics I had up before.
2.0
Don't have 2.5 pics yet. Had to cut a notch in the top on the inside. The inner boot was rubbing, so I took about 3/4" out the width of the boot and then I trimmed the bumpstops 1/2" to allow for more up travel. Not sure how well this worked because I haven't assessed the damage fully yet.
The overall result is that the CV's are straight when the wheel is centered. I think it sits about the same as it would with stock arms.
Looked back through this post a little. I did not do the Hagen widening mod. I accomplished all of the widening via the a-arms. I modified the tractor rod ends to use original Kick ball joints, so I could get a LOT wider if need be. I like the current width. It's somewhere around 80" outside the tires I think. Just fits between the rails on my car trailer.
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Here's a little update. We removed the a-arms and rebushed them with urethane. Cut the old bent tabs off the frame and made new heavier ones. Ground a little ridge out of the one cv at the bottom inside the cup that may have been colliding. And ran the steering stops in a bit. The cv axles were colliding with the cups at full lock/droop. Haven't had one broken axle problem since and we've had one competition and a few hard trips on it.
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How well did those retreads hold up. I'm thinking about buying some for my rig. I'm not going to drive in on the highway just gravel roads and light trails