ZUKIWORLD Online | Suzuki 4x4 Editorial and Forum
ZUKIWORLD Discussion Forum => Build Diaries, How-To, DIY => Topic started by: warrpath4x4 on July 26, 2021, 01:01:35 PM
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Because of course I needed something else to work on lol, but one of my co-workers is transferring to another state and had to many vehicles. I picked this up for cheap, and it runs and drives. He bought it back in the late 90's when he was in high school, since then he sold it, bought it back, and his kids have been using it moving irrigation water. Its been rolled at least 4 different times (which is why the windshield frame is in the back seat). I don't even know what I am gonna do with it yet but couldn't pass up the price, I may just fix a couple things and sell it, may run it this winter while we still build the Cherokee.
(https://i.imgur.com/5b1kQYG.jpg)
(https://i.imgur.com/tsoYepB.jpg)
(https://i.imgur.com/NXxvxMz.jpg)
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That looks like a solid starting point. Any guesses on what the front bumper weighs? It looks like it means business!
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That looks like a solid starting point. Any guesses on what the front bumper weighs? It looks like it means business!
no idea but it is stout, I will be removing it and building something smaller, I will try to get a weight of it once removed.
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Other than the windshield frame, it looks like the body is in relatively good shape, considering how hard it has lived! Good luck with the bumper. That thing looks like it came off of a tank or something. Better pull it soon, scrap is up right now!
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Pulled the broken windshield out last night, removed the track piece for the front of the soft top, I have a little rust repair to make before putting new glass in.
(https://i.imgur.com/hkONP7I.jpg)
(https://i.imgur.com/rqB40TK.jpg)
(https://i.imgur.com/rSwVpRj.jpg)
(https://i.imgur.com/ssZIST0.jpg)
This is the only rust spot in the lower portion of the frame.
(https://i.imgur.com/oJgYbfB.jpg)
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this weekend I worked on the windshield frame, cut out the rusted spots
(https://i.imgur.com/9IQXih0.jpg)
welded in new material but I don't have a pic of that yet, definitely not quitting my job to go do body work lol.
also pulled the front bumper (which only had 2 bolts)
(https://i.imgur.com/9zRGbEI.jpg)
and for those who were wondering how much it weighed....
(https://i.imgur.com/3XPFzsj.jpg)
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Well that is lighter than I would have guessed! It is good you are making progress!
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It's good to see another build on the forum. The earlier days of watching BrdHunter and his boys build their rigs, was better than any sort of tv time. I wish we had more of them going on. Mine has stalled, due to no free time.
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It's good to see another build on the forum. The earlier days of watching BrdHunter and his boys build their rigs, was better than any sort of tv time. I wish we had more of them going on. Mine has stalled, due to no free time.
Ya the Cherokee were building has kind of stalled, i got the front axle removed and stripped about 2 months ago. the wife asked me the other day "what do you need to finish the Cherokee?" time and motivation.
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Tuesday evening I bolted the frame on to the samurai for the first time, no glass in it yet as i figured it would be easier to install with the frame bolted down.
(https://i.imgur.com/fV8aDjp.jpg)
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That is starting to look like something!!!
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Just spent a bunch of money on this thing, lockers, soft tops (bikini, jammer, duster), 6.5 sumo transfer case gears, updated output shaft, alternator upgrade, extended brake lines, certified machine Toyota 3K carb (when they get some in stock).
I am meeting a guy tonight who has a set of seats I'm gonna look at, heated leather out of a Honda Odyssey
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Saturday we did a bunch of running around and went to Milton Freewater to the drive inn theater, but I picked up a piece of pipe to sleeve the front crossmember in the frame.
Sunday we slept in since we didn't get home till 3AM from the drive inn, got fair entries turned in, moved some firewood. Installing the sleeve was the only thing I got done on any vehicle. The pipe is 1.25 which has an OD of 1.66 and the tube in the frame is 1.75 ID, the frame tube was dented from previous abuse so it made the tube fit nice and snug after driving it in with a 15 pound sledge lol. Only issue was when I got the tube I verified they got me the right size, I did not verify they cut it to the correct length so it doesn't go all the way across like I wanted, its about an inch short on each side but it will work. I sleeved the tube so I can incorporate it into my winch mount since I don't really trust the stock bumper holes in the frame.
(https://i.imgur.com/3FeFhxx.jpg)
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So obviously the steering needs to be addressed, they welded the ends directly to the draglink which looks homebrew and moves around a lot.
(https://i.imgur.com/sQtd7E5.jpg)
(https://i.imgur.com/doBoXyf.jpg)
I'm not sure which kit I want to go with though and was wondering if anyone had any insight between these or a better option?
(https://i.imgur.com/wA3eIdY.png)
(https://i.imgur.com/zM1WuzQ.png)
(https://i.imgur.com/iqEztAg.png)
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You just have to love some of the home-brew stuff you find on pasture rigs! A friend of mine bought a Sami that was a "never leave the property" hunting rig. They just torched and bent the steering arms to make it all work!
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yesterday I tried to order the Trail Tough steering, but their website didn't like my credit card and I couldn't get anyone to answer the phone. So today I ordered the Trail Gear align correct full kit but ordered it from Poly Performance with a military discount, no tax, and free shipping.
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Sounds like it worked out for the good! Hope things go together well and you get to have some safe fun!
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This weekend (and this week) I am working on the roof of our house so not much time for anything else. We did manage to pull the rear seat and seatbelt. Also pulled the plastic side trim in plans of making rocker protection/sliders, as part of that I was going to unbolt these.
(https://i.imgur.com/V0phY0h.jpg)
(https://i.imgur.com/lAulnM8.jpg)
Of course though they are welded to the frame, and not very well but enough to make it a hassle to remove. Also found the transmission crossmember has seen better days.
(https://i.imgur.com/8LJCpcN.jpg)
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Any progress is good progress, right? It sure stinks when things like the roof on your house gets in the way of working on our Suzukis!
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Got my lockers today and felt like an idiot lol.
I know I have to use the 26 spline spider gears from my rear axle and move them to the front when using the longfield chromoly axles and lockers, ive seen several videos of people using their rear spiders up front when installing lockers.... did not pickup on the little detail that most of them were running spools in the rear so they had the spider gears available lol. So I found some NOS spider gears for about $65-70 and ordered them, now I can run my lockers front AND rear.
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Good to hear the solution was easy to come across. Are you running mechanical lockers or air?
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Spartan lockers front and rear.
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got an email from Certified Machine that they got a shipment of Toyota 3K carbs in and should have all the back orders filled by tomorrow. I will be really interested in how much better the carb swap runs because the choke on this one is wired in place making it a cold blooded bastard.
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I got my TOY-250 from National Carburetors before knowing about Certified Machine. I really like the complete kit from Certified.
I was told that, when the OEM carb is operating correctly, it's the best carb for the 1.3L but none are probably working correctly after 30+ years. The TOY-250 was a great improvement over my old stock and I personally like the manual choke.
https://nationalcarburetors.com/NEW-Toyota-Corolla-1977-1978-10771166-CC-877--1078_p_431.html
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I got my TOY-250 from National Carburetors before knowing about Certified Machine. I really like the complete kit from Certified.
I was told that, when the OEM carb is operating correctly, it's the best carb for the 1.3L but none are probably working correctly after 30+ years. The TOY-250 was a great improvement over my old stock and I personally like the manual choke.
https://nationalcarburetors.com/NEW-Toyota-Corolla-1977-1978-10771166-CC-877--1078_p_431.html
I looked into the Toy 250 from National and even just getting a 3K off amazon, but like you said the one from Certified Machine is a kit, he test runs them, and he makes the needed modifications to fit the Samurai. I'm new to Samurais so I will take all the help I'm given and I have been doing my research lol. I looked at going propane, MY-Side, 1.6 but for the prices I liked the Certified Machine. I will definitely let everyone know how it works out.
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Certified Machine carb showed up yesterday, the mounting kit that comes with it has some quality machined pieces and quite the detailed instructions.
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Well the whole family came down with Covid so nothing happened for most of the last 2 weeks, were all doing better now and luckily none of us were too bad.
Back to building, first my son and i spent a day cleaning the "shop" and moving all the Cherokee parts out (stored in the Cherokee), moved the cherry picker, engine stands, and chain saws to another shed. There is just enough room to get the Sammi in and work around it.
(https://i.imgur.com/bqlZOVE.jpg)
(https://i.imgur.com/CdirdY5.jpg)
(https://i.imgur.com/4YiB3qx.jpg)
as you can see, there's not much room, this building used to be an old carriage house, there's a concrete floor and not much else of anything lol.
(https://i.imgur.com/ygKHiYQ.jpg)
(https://i.imgur.com/KZ315Jn.jpg)
removing the stock carb (with the choke wired) and installing a Toyota 3K from Certified Machine
(https://i.imgur.com/va9KQXx.jpg)
and since I have the extra space right now we are installing a Chevy alternator. I used the LROR kit, not too impressed with them, the kit includes the lower and upper brackets, belt, alternator, and pigtail. the belt doesn't fit, its too short and there's only about .25-.50" of adjustment before the alt fan hits the water pump pulley. so its not done yet.
(https://i.imgur.com/Gxcbpxn.jpg)
But I did get the new carb installed.
(https://i.imgur.com/bhAHrI2.jpg)
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It sure seems that is not the alternator I would choose for that kit. There are 10SI alternators with a much smaller external fans that would be a much better choice. I would definitely not be happy with that matching of components.
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It sure seems that is not the alternator I would choose for that kit. There are 10SI alternators with a much smaller external fans that would be a much better choice. I would definitely not be happy with that matching of components.
ya the whole reason I bought a "kit" was so it would be easy to slap on
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Just asking - shouldn't the water pump pulley pass in front of the alternator fan? Do the vee belt pulleys actually line up?
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If I was to guess, the fan on the alternator is maybe supposed to slip behind the water pump pulley. Best case that would be a very tight fit, and if you ever lost a water pump bearing, seems you would lose an alternator fan also. With the number of variations of 10SI alternators out there, that is the worst style for the application.
I stand corrected...just did a search for 10SI alternators. Seems the other style of external fan is probably the same diameter, and maybe even "thicker". So maybe that is the best choice for the job. It sure does look problematic though!
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https://www.youtube.com/watch?v=v-IXLKJ6cB4 (https://www.youtube.com/watch?v=v-IXLKJ6cB4)
Might check out this video. Looks like there are some washers or a spacer for the lower mount.
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If I was to guess, the fan on the alternator is maybe supposed to slip behind the water pump pulley. Best case that would be a very tight fit, and if you ever lost a water pump bearing, seems you would lose an alternator fan also. With the number of variations of 10SI alternators out there, that is the worst style for the application.
I stand corrected...just did a search for 10SI alternators. Seems the other style of external fan is probably the same diameter, and maybe even "thicker". So maybe that is the best choice for the job. It sure does look problematic though!
I thought about sanding down the diameter of the alt fan a bit too
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Last night I got the alternator bracket fixed but there's still not much room between the alt fan and the water pump pulley.
(https://i.imgur.com/1fTAQ5T.jpg)
(https://i.imgur.com/Wvf31xJ.jpg)
The wiring directions I found kept talking about a red/white wire but my wires were different colors and there was actually 3 wires coming from the plug but 1 was cut, so I started stripping tape back and find this lol
(https://i.imgur.com/Wa80BBL.jpg)
I am not sure exactly where this thicker wire goes, it runs into a bundle that then runs inside the cab, when installing a bigger alternator I usually run bigger wires to the battery, I am not sure if I should/could get rid of this wire or if I should just piggyback a bigger wire from alt direct to the battery.
(https://i.imgur.com/H4wLJ3E.jpg)
and while tracing that wire I found these behind the battery, so I will fix them before they create bigger issues
(https://i.imgur.com/pmNtD2W.jpg)
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We wired up the alternator last night, then the sami wouldn't crank. Took a little bit of troubleshooting and found when I was moving the wiring around I pulled the starter wire off. She has way better throttle response with the new carb and idles smoother, definitely recommend the carb swap.
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Glad to see you got everything hooked up and going!
The current charge wire from the alternator, can it reach the battery? If it does, I think I would run a heavy cable between the battery and alternator and then connect that current wire to the battery. Otherwise, you could just piggy back as you already mentioned.
Good to see you are keeping hydrated and clear headed through all of this!
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Really didn't even touch the sammi this weekend, took my Son to the pumpkin patch Saturday and did some grocery shopping, Sunday we pulled the window A/C units from the bedrooms, I made bacon jam and jalapeno bacon jam, and smoked a roast.
Today I ordered a Prius electric steering column to adapt into the sammi.
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The kids are part of the motivation for the Zuki fun, right? My son is killing me...no matter how hot or miserable it is, if we are going to run to town, and I ask him what he wants to take, Zuk every time! Sometimes I don't give him the option cuz dad needs air conditioning sometimes! Is the Prius the go to electric power steering option?
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The kids are part of the motivation for the Zuki fun, right? My son is killing me...no matter how hot or miserable it is, if we are going to run to town, and I ask him what he wants to take, Zuk every time! Sometimes I don't give him the option cuz dad needs air conditioning sometimes! Is the Prius the go to electric power steering option?
from what I was seeing Prius or Corolla, but prius is the most prevalent and available. I ordered the column (electric motor), control module, and an extra shaft I will be using for $200 off ebay.
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Got my auxiliary battery tray roughed out last night
(https://i.imgur.com/gSB7Ja1.jpg)
(https://i.imgur.com/cdmdPlb.jpg)
its a little bit of a squeeze but the placement is almost perfect, it will be a really short run to power the prius electric steering.
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What size battery are you going with there? The Sidekick comes with a Group 51 originally, and I have had a Group 24 in it in the past. Right now it has a 51 back in it, because I had a broke down Honda with a good battery when I put it back together. I am thinking about sticking with the 51, because if I add a second battery that size of battery is easier to find place to stick it.
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I have a 34/78 AGM I am using for mockup, I plan to run it but I also need to get it tested. its an old battery and is sitting at 10V right now and 24 hours on my charger did nothing. not sure if its the battery or my charger. Its a bit of a squeeze but that size will work just fine.
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So is it an extra battery, or going to be the primary?
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So is it an extra battery, or going to be the primary?
extra battery to run the winch, lights, electric steering
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battery tray is just about done, I need to drill 2 more mounting holes into the fender, and drill the hole(s) for the hold down. I am planning on using one J-hook and a rivnut in the top flange of the fender for securing the hold down, then shoot it with some paint.
(https://i.imgur.com/fDQd4sT.jpg)
(https://i.imgur.com/QBcDxuZ.jpg)
(https://i.imgur.com/Zq55ers.jpg)
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That is looking sweet! Love the punched holes.
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Still need to pull it back out and paint it and cut the J-hook down but here is the otherwise finished battery tray.
(https://i.imgur.com/NcWIc2m.jpg)
countersunk the bolts
(https://i.imgur.com/BGLi6T4.jpg)
(https://i.imgur.com/VzzZtqc.jpg)
used a rivnut and a 6M bolt for this side
(https://i.imgur.com/HOHkl4c.jpg)
its nothing really special but I threw a beadroll in the hold down, really stiffens it up
(https://i.imgur.com/E9JpdVs.jpg)
Now to start building cables.
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That is looking sweet! Love the punched holes.
Thanks, I can do from 1/2" up to 3"
Here is a crossmember I did on a Cherokee
(https://i.imgur.com/Ps5W7YN.jpg)
(https://i.imgur.com/y3itjda.jpg)
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Is that die punching? Does punching the holes help add rigidity to something like your battery tray?
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No its not a punch (they do have them), I just use hole saws then use my shop press and a dimple die set to dimple the hole. Dimpling metal reduces the weight and adds a lot of strength to it, of course the weight depends on how thick the material is and how many/size of holes you make. I cant find it right now but years ago one of the off-road magazines had an article about dimple dies, they took a piece of sheetmetal and propped it up on a couple pieces of wood and stepped on it and it bent, then they took a sheet and dimpled it and performed the same test, this time the metal bowed but did not bend.
These are not the ones I have, just an example, you can also get them with a hole in the middle of the die where you can run a bolt through it to dimple sheetmetal that you cant fit in a press.
https://www.amazon.com/Dimple-Die-Set-Inches-0-50/dp/B00K0TPNGM (https://www.amazon.com/Dimple-Die-Set-Inches-0-50/dp/B00K0TPNGM)
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That is really cool. Got to have those racing holes to reduce weight! I remember an old feature article in a magazine, and I believe it was a Dodge Dakota, and the owner went to town on it with a variety of drill bits and hole saws, I can't remember how much weight he saved, but it was a decent amount. He drilled holes in the door handles, which looked pretty cool, but also used the hole saw to knock coupon out of the door jams and other "hidden" areas. Pretty crazy stuff.
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finished the dual battery install, painted the tray with bedliner, put a strip of rubber between the battery and the hold down, built new #2 battery cables, installed the VSR battery "isolator". it cranks over WAY faster now
(https://i.imgur.com/bdhAIOK.jpg)
(https://i.imgur.com/eYs7hFG.jpg)
then I was playing with my new spot weld cutter and removed the (not sure what you call it) piece that holds the plastic trim on the side. Not as bad as I was expecting, sometimes there are rust holes behind here.
(https://i.imgur.com/PIiBLuh.jpg)
you can see though that its dented towards the front. I plan to add some rocker protection and remove the current steps.
(https://i.imgur.com/PO5CBa5.jpg)
I kind of bounced around on projects after getting the batteries done, I removed the jack holder from under the hood (again playing with my spot weld cutter) and will be installing the winch controller in that space. I made a bracket to hold the controller and I started working on the winch mount, but no pics of those yet.
(https://i.imgur.com/P6idn31.jpg)
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if anyone wants that stock jack holder, just let me know.
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Very nice battery/cable install! Does your Sami have the hard start relay installed on the starter solenoid circuit? Those spot weld cutters are handy, for sure. Did you pick up a Harbor Freight special, or do you have something a little bit nicer?
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Very nice battery/cable install! Does your Sami have the hard start relay installed on the starter solenoid circuit? Those spot weld cutters are handy, for sure. Did you pick up a Harbor Freight special, or do you have something a little bit nicer?
Its a little bit nicer but its still an amazon special. https://www.amazon.com/dp/B002XML5HK?psc=1&ref=ppx_yo2_dt_b_product_details (https://www.amazon.com/dp/B002XML5HK?psc=1&ref=ppx_yo2_dt_b_product_details)
I have not seen a relay for the starter, but I am not sure.
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I believe the hard start relay is setup to take load off the ignition switch. Instead of the ignition switch providing the juice to activate the starter solenoid, it activates a relay that supplies voltage to the solenoid. It takes load off of the ignition switch and can provide more juice to the solenoid.
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the other night I bent up some scrap sheet metal and made a mount for the winch control box inside the engine bay where the stock jack holder was, took a couple nights of shooting it with bedliner and letting it dry. I mounted it last night but obviously the box isn't mounted yet, just sitting there to check out any clearance issues.
(https://i.imgur.com/SrBDkuA.jpg)
(https://i.imgur.com/PvQTa4a.jpg)
(https://i.imgur.com/ekkq2lg.jpg)
(https://i.imgur.com/yNF9V6e.jpg)
Started prepping the frame for the winch mount, I am making bolt on but trying to make it better than the 4 original bolts lol.
sleeved the 4 bolt holes with 1/8" thick tubing
(https://i.imgur.com/qHs8eue.jpg)
capped the ends
(https://i.imgur.com/H84oIcm.jpg)
(https://i.imgur.com/J6quprt.jpg)
as mentioned before I sleeved the tube crossmember with a piece of 1.5" pipe, I am trying to work out a way to tie into the crossmember to add strength to the winch mount (I have a plan but need to see how it plays out)
(https://i.imgur.com/3FeFhxx.jpg)
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got the winch plate cut out, bent, and recessed for the crossmember.
its just squeezed between the rails right now, of course my goofball had to be in one of the pictures lol
(https://i.imgur.com/nIik5md.jpg)
(https://i.imgur.com/NFVRMMT.jpg)
(https://i.imgur.com/gf2sd2K.jpg)
(https://i.imgur.com/dZW1H9x.jpg)
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I didn't get much time last night to work on it, had to get hay tarped before this storm that rolled in last night.
I did get the mounting holes drilled for the winch plate and got the grill cut to recess the winch in, I need to come up with something different for the front turn signals.
the winch is not bolted down, once I get the fairlead mounted I will probably slide the winch forward about half an inch giving it more room in front of the radiator, but I like how high and tucked in it sits.
(https://i.imgur.com/dhip0cR.jpg)
13,000 pounds might be a little overkill for a Samurai lol but I already had it, it was this 13,000 pounder or another 13,000 pounder, an old Belleview winch, or a 2,000 ATV winch.
(https://i.imgur.com/lFwXrre.jpg)
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Looks sharp!
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"I wish I had gone with a smaller winch"
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That is all looking good! I figure if you are going with a "economy" winch, may as well go larger and improve the chances of it having a long working life.
Are you going to go back with the factory turn signals, or go with an aftermarket option?
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I don't know if that's a realistic position ...
Several years ago, just after I'd bought my GV I was chatting with the guy who owned the local Suzuki dealership, and the discussion got around to winches & winch bumpers, he warned me about the effects of adding weight out in front of the vehicle - he had a winch & bumper fitted on his truck, had the suspension tweaked to compensate for the weight, and then removed the winch & bumper and put it back to stock - he did not like the way the truck handled with the additional weight.
"Economy" does not necessarily translate into smaller, less powerful - on the other hand, larger does translate to heavier, and the more weight out on the nose of the vehicle, the more it affects handling. There has been a proliferation of "cheap, Chinese" winches of questionable quality, generally rated for a 12,000 lb pull (I suspect optimistically), personally I'd prefer to pay more for a smaller, lighter winch from a reputable manufacturer. A GV doesn't need more than a 8000 lb winch, on a Samurai you probably don't need more than a 6500.
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"I wish I had gone with a smaller winch"
-Nobody
That is all looking good! I figure if you are going with a "economy" winch, may as well go larger and improve the chances of it having a long working life.
Are you going to go back with the factory turn signals, or go with an aftermarket option?
actually I had someone reply on a FB post "I only put an ATV winch on mine and haven't even used it, but you do you" LOL
I will go with aftermarket something or others, have not decided what or where yet.
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I don't know if that's a realistic position ...
Several years ago, just after I'd bought my GV I was chatting with the guy who owned the local Suzuki dealership, and the discussion got around to winches & winch bumpers, he warned me about the effects of adding weight out in front of the vehicle - he had a winch & bumper fitted on his truck, had the suspension tweaked to compensate for the weight, and then removed the winch & bumper and put it back to stock - he did not like the way the truck handled with the additional weight.
"Economy" does not necessarily translate into smaller, less powerful - on the other hand, larger does translate to heavier, and the more weight out on the nose of the vehicle, the more it affects handling. There has been a proliferation of "cheap, Chinese" winches of questionable quality, generally rated for a 12,000 lb pull (I suspect optimistically), personally I'd prefer to pay more for a smaller, lighter winch from a reputable manufacturer. A GV doesn't need more than a 8000 lb winch, on a Samurai you probably don't need more than a 6500.
The placement of most of the prebuilt winch bumpers is the main reason I am building my own, most hang the weight in front and up high compared to the frame/axle placement. Mine is tucked in as close as i can get it and i had no issues cutting the grill to do it. Weight is another reason my winches have synthetic rope, no it wont hold up to dragging it across a rock like steel cable, but the benefits out weigh the negatives for me.
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The placement of most of the prebuilt winch bumpers is the main reason I am building my own, most hang the weight in front and up high compared to the frame/axle placement. Mine is tucked in as close as i can get it and i had no issues cutting the grill to do it. Weight is another reason my winches have synthetic rope, no it wont hold up to dragging it across a rock like steel cable, but the benefits out weigh the negatives for me.
I hear you, and you'll get no argument from me - just make sure that your winch isn't using a cone brake inside the drum (which many of the 'economy' winches do), before you swap the wire for synthetic.
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I have seriously considered just using a 6k ATV/UTV winch for my 'Kick. At the 150% weight rule, a 5k would probably do, a 6K for sure. I agree with tucking the winch as tight and close to the body. I like my Suzuki because it is small, nimble, and fits into all kinds of places. I don't need a bumper hanging a foot off the front messing with that!
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I have seriously considered just using a 6k ATV/UTV winch for my 'Kick. At the 150% weight rule, a 5k would probably do, a 6K for sure. I agree with tucking the winch as tight and close to the body. I like my Suzuki because it is small, nimble, and fits into all kinds of places. I don't need a bumper hanging a foot off the front messing with that!
I'm currently running winch-less and I considered a ATV/UTV winch because it's smaller and lighter and I really don't think I would need it much. It would probably work just fine unless I was axle deep in mud.
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its not finished but its closer, I still need to drill the mounting holes for the winch, build the fairlead mount, cap off the ends of the tube, and paint.
(https://i.imgur.com/DF11kr3.jpg)
(https://i.imgur.com/hQaOlCC.jpg)
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Got the bumper mounted, winch on and wired, grill back in, i just need to decided what I am going to do for turn signals.
Tip for anyone who needs it, when trying to transfer hole locations to a template, I use soda boxes and a ballpeen hammer, tap where the hole is and it cuts it clean.
(https://i.imgur.com/dStTGxO.jpg)
back to the bumper, I pulled the sammi out of the shed to get some better light and better pictures.
(https://i.imgur.com/2XYDhYb.jpg)
(https://i.imgur.com/4ApBvgb.jpg)
(https://i.imgur.com/CjA77R1.jpg)
(https://i.imgur.com/lagx9C1.jpg)
The turn signals were mounted behind the grill but after trimming the grill to fit the winch, there's not enough room. I could put them back behind the grill at angles but not sure I want to. I know there's lots of options for replacements, I just need to decide.
(https://i.imgur.com/ccbez4x.jpg)
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I forgot to mention, the original bumper on this weighed 80 pounds by itself, this one weighs 35 pounds and the winch is 40 pounds. So overall its 5 pounds lighter and has a winch now.
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Tip for anyone who needs it, when trying to transfer hole locations to a template, I use soda boxes and a ballpeen hammer, tap where the hole is and it cuts it clean.
One of the basic "shop skills" - cutting gaskets from gasket sheeting with nothing more than a smear of grease and a ball peen hammer - I suspect this is a lost art
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I pulled the Sammi out of the shed so I had more room on the passenger side, drilled out the spot welds on the trim bracket. Looks about like the driver side, no through rust but the surface rust has weakened the structural integrity of the rockers. I had originally planned to cut the homebrew nerf bars off and build new rocker guard/sliders that bolted on, now though I am thinking about cutting the rockers out and welding in some better steel... maybe a mini boatside to it.
(https://i.imgur.com/tVMzaom.jpg)
I had not planned on keeping the original shocks, but I definitely need new ones lol
(https://i.imgur.com/Xw6eFEP.jpg)
I have the week after Thanksgiving off and am hoping to spend most of it working on the sammi, plan is to rebuild the transfer case and axles. I already have chromoly shafts for the front and will be ordering chromoly rear shafts tomorrow.
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Is that shock mount cracked, or is it just an optical illusion? I have cut the rocker out on 1 side of my 'Kick and replaced with 2x4 rec tubing. I did it a few years ago. I just have never gotten to doing the passenger side. I guess it moved up the priority because I crushed it on a rock in the pasture the other day. I am not sure how easy it is to do on a Sami, but it was not bad on the 'Kick. I also attached a "step" to the tubing when I built it, so a double function mod!
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Is that shock mount cracked, or is it just an optical illusion? I have cut the rocker out on 1 side of my 'Kick and replaced with 2x4 rec tubing. I did it a few years ago. I just have never gotten to doing the passenger side. I guess it moved up the priority because I crushed it on a rock in the pasture the other day. I am not sure how easy it is to do on a Sami, but it was not bad on the 'Kick. I also attached a "step" to the tubing when I built it, so a double function mod!
I did not notice the "crack" when I took the photo but noticed it when I was uploading the photo. I will have to take a look tonight when I get home.
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Looking again, I vote casting line. Appears to be another on the other side of the shock bolt, that one is just right to have a shadow really accent it
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In my SJ I ran angle iron sliders just bolted through the body. But my rockers were in bad shape to begin with.
For the turn signals have you looked into some of the single row led kits?
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Looking again, I vote casting line. Appears to be another on the other side of the shock bolt, that one is just right to have a shadow really accent it
Not cracked, you were correct that it’s a casting mark.
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I ordered some stuff tonight to make a new rear bumper, front turn signals, and tomorrow I will go pickup a new tool to make my turn signal idea work (if the stores inventory is correct on their website)
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No work getting done, but I am ordering more stuff for it.
The other day I ordered a factory service manual for it, yesterday was lights and stuff for the new rear bumper and turn signal stuff, today I ordered the chromoly rear shafts with quick change bearings/retainers and seals.
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I understand no work completely. I am plenty busy, just not working on the Suzuki. Rifle season opens in an week, having a big group of friends out for skeet shooting, and lots of other things going on...hopefully the Suzuki fits in there somewhere!
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Sunday morning the kid and I got up early and drove 2.5 hours to go pick up some doors and a windshield frame for the sammi, unfortunately the guy sold the windshield frame before I got there.
Not bad for $60 for both doors, way better shape than my current ones
(https://i.imgur.com/ja3z4Ks.jpg)
visited with the locals while we were there also
(https://i.imgur.com/emeQymZ.jpg)
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You have to take the wins when you get them!
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Sunday morning the kid and I got up early and drove 2.5 hours to go pick up some doors and a windshield frame for the sammi, unfortunately the guy sold the windshield frame before I got there.
I bought a windshield and frame at a cleanup once, leaned it up against the rear tire. Forgot it was the and proceeded to back over it and break the windshield. :D
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I bought a windshield and frame at a cleanup once, leaned it up against the rear tire. Forgot it was the and proceeded to back over it and break the windshield. :D
that sucks
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Not working on the Sammi for 2 weeks getting ready for thanksgiving, here's the new dining room table my son and I built Saturday, wouldn't say its "professional" quality and I'm already thinking about building a new top for it when I have more time and A) fixing a few mistakes I learned along the way and B) using better lumber than home depot lol. but its ready for the holiday season.
(https://i.imgur.com/pEEFNBX.jpg)
(https://i.imgur.com/9tNDTZW.jpg)
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A little more sanding of the top and some clear sealant, and it'll be perfect, if you like the "rustic appearance", which I'll admit not everyone does - alas, I no longer have the space or the tools for that type of work
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finished up the front turn signals tonight, just went simple.
(https://i.imgur.com/Y3oKiK6.jpg)
3/4" LED lights
(https://i.imgur.com/8TeA9yK.jpg)
(https://i.imgur.com/m7U1LNj.jpg)
Even works with my jacked up fender lol
(https://i.imgur.com/BZA52Ko.jpg)
Changed out the turn signal flasher with a Grote 44892, no more fast flasher. I wish I could remember where I seen this so I could give them credit. I seen people talking about wiring in resistors, but this was just simply changing the flasher relay.
(https://i.imgur.com/QxSXiFD.jpg)
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holy huge pictures, i need to figure out this new phone lol.
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Yes, very large pictures! Looks good though. Sometimes simple is the best plan.
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(I think I got the picture size fixed)
I had this week off, started by cleaning the shop up, then my son and I tore the transfer case out, I broke one of my 3 jaw pullers trying to get this flange off
(https://i.imgur.com/kKB6wqn.jpg)
We got it all apart, I came to the conclusion? question? thought? that I don't know how these you tubers always seem to have clean work spaces lol, they must be doing a lot of cleaning in between.
(https://i.imgur.com/NTUVoLS.jpg)
new KOYO bearings installed, 6.4 gear set installed, case is clearanced for the gears, but when I measured my clearance from the shafts to the case I needed some shims so I have to wait for those to come in.
(https://i.imgur.com/hGATbfs.jpg)
waiting on the shims, we tore the front end down, new side gears, and spartan locker. it seems nothing can go easy on this, the shims supplied with the locker were way to thick, I ended up using some thick fender washers that I milled the diameter down to fit inside the locker. I don't know if its because of the brand new gears or what. everything fits snug now though. We got the third put back in but then I got a cold and it sucks, so I have not worked on it in 2 days.
(https://i.imgur.com/keND0KW.jpg)
question for anyone who has rebuilt a samurai transfer case, how many shims are too many between the case and shaft?
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not your typical store bought nerf bar
(https://i.imgur.com/9fgVH4N.jpg)
this thing is 1/8" thick and welded to the frame, but it hangs down too low for me.
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What ratio are you running in the diffs? Those nerf bars are all there!
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the diffs are stock 3:73 for right now, I might re-gear it later but just want to get it driving again before the snow falls.
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Not sure if you have checked out Low Range Off Road, but I am on their email list. Got an email today about new items in their Clearance section. One of them is the Samurai windshield frame, if you are still looking for one.
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Not sure if you have checked out Low Range Off Road, but I am on their email list. Got an email today about new items in their Clearance section. One of them is the Samurai windshield frame, if you are still looking for one.
thanks for the heads up, I will go check it out
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with the holidays and cold temps, nothing has gotten done really. I did bring the knuckles and spindles into work and run them through our chemical parts washer and steam washer.
right now were dealing with highs in the teens and low 20's and the shop feels colder inside than outside, makes it very hard to want to do anything so im picking one of these up.
https://www.amazon.com/dp/B09HX24JKC?psc=1&ref=ppx_yo2_dt_b_product_details (https://www.amazon.com/dp/B09HX24JKC?psc=1&ref=ppx_yo2_dt_b_product_details)
says it heats 1,000 sqft of space, should make it nice and toasty in my 200+/- sqft space lol.
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I have a similar heater, and it is great! I need to buy a new regulator for mine, as it began leaking, so I can't use it right now. I need to get motivated about getting an indoor place cleaned up to work in!
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wow its been 1.5 almost 2 years since i have done anything with this, between multiple projects (this, XJ, stepside, tractor), ranch, life, being a board member of our local rodeo arena, there just hasnt been much time or drive to work on any of the projects. its also just seems like on the vehicle projects im always playing "but first", i need to work on the stepside but it still runs and is a "back up" rig BUT FIRST i need to get the 94 XJ up and going, BUT FIRST i need to get the 93 XJ out of the way, BUT FIRST i need to get the tractor fixed. such is life right? right??
We were supposed to be going with some friends on the WABDR (Washington Backroad Discovery Route) this weekend but a family medical issue is preventing that so i have the rest of this week off. Barring a huge honey-do list i am going to try and finish up the tractor and start back in on the Samurai. I ordered a new clutch for it, transfer case is still out, makes pulling the trans pretty easy and a no brainer at this point. Also picked up a straight windshield frame for it for $80 off FB market place.
goal is to tear the front third member back out and switch the spider gears to some OEM rear spiders instead of the aftermarket ones i have not been happy with. put the front axle back together getting it on 4 tires again. pull the trans and do the clutch. get the transfer case and cradle put back in place.