Started a build for a lady i met on another forum.
The plans so far is CJ rears with RUF, 5" spoa (already installed), histeer, 2" body lift, custom tube bumpers with front stinger and rear tire carrier built by a local shop, 33" tires, 6.5:1 tcase setup, heavy duty tcase arms. all new seals in the motor, and tranny, 2" exaust, racing seats and harnesses (already installed), and no telling what i am forgetting that i have ordered or is on its way...

this weekend we got the zuk home, got all the parts ordered, and got the front clip off and fluids drained ready to pull the motor and get new seals installed.


here is the transfer case ready to be sent out for the new gears... AHHHH!!! 6.5s baby!! [naughty]


and some maintenance. the gas tank has a little rust and scale in it, so to keep it from giving zukseeker problems on the trails, we are gonna have it cleaned and coated and reinstall it.


not a LOT of progress, but its a start.

tomorrow night, i plan on pulling the rear end and getting it ready for the locked rearend that i have waiting to go under it. at this time, i will also install the front CJs i have for it, and get the rear springs moved up front.

Vendors we plan to use for this buildup include:
www.rock4xfabrication.com
www.Spidertrax.com
www.sky-manufacturing.com
www.hawksuzukiparts.com
www.whiterhinofab.com
www.roadlessgear.com
www.trail-gear.com
Bama-built tube doors,
and my buddy Redidbull for a little bling...

Thanks FGIALS for the help.

ok, got outside to work on the zuk tonight and realized i had failed to take into account building the leaf packs for the front...

i used the rear springs out of my zuk, since it was stock and had never been wheeled much if any...

i was also reminded the spring eye bolts had siezed up into the sleeve and when i removed them from the zuk i had to cut the bolts...  so out comes the PB Blast. i soaked em down real good and went into the shop and got 2 chisels, and a hammer. i used the small chisel to pry in between the eye and the spring, and used the other chisel to tap the sleeve out after letting it soak for a little while. man that PB Blast rocks!!




then i removed the overload off my springs, and used the bottome leaf (not the overload) of another rear pack and installed it on the bottom of my spring pack, giving me 4 long leafs... this should give the spring enough strength to resist warping, but if it is too stiff, i will remove it... the bump stops will also help the warping. i also brought up the front CJs from the barn, and somehow forgot to take any pics of the springs... all in all, constructing the spring packs cost me about 2.5 hours.

then it was on to disassembling the front... i got the front end up on jack stands, and then got front bolts out of the spring packs and the shackles removed. i removed the sway bar from the frame mounts and got the original brushguard mounts (no brush guard ) removed. i was moving right along. also got the front shocks removed. now time for the ubolt plates.

WHAT THA?!?!?!? the dang ubolt nuts are welded to the ubolts...    who does that anymore???  man!!!




ok, no biggie. break out the grinding wheel....

touched the grinding wheel to the ubolt and it caught and twisted and SNAP!! the cut off wheel breaks. lol  ok, time to quit for tonight.

tomorrow i go shopping for cut off wheels, paint for the springs, and bolts to hang the springs and new ubolts on all 4 corners.

Looks like you'e moving right along.  Keep us posted on your progress.  Looks like it should be a fun build.  Are you going to move the shackles to the back of the front springs?

Are you going to tube the front?

Looks like you'e moving right along.  Keep us posted on your progress.  Looks like it should be a fun build.  Are you going to move the shackles to the back of the front springs?

nope, dont like shackle reverse.

Are you going to tube the front?

no, i just removed the clip to make it easier to get to the motor...

i got the cutoff wheel after those ubolts again tonight. they are gone!



also got a little BTA!!!

all new seals and gaskets for motor, clutch kit, hose kit, new shocks, etc...
also got some hinges...



got my RUF plates to mount the CJ front springs out back and got a coat of paint on them and the springs...


sunday night or monday i will start pulling the motor now that the seals are in.

ok, got a little more done tonight.

got the front springs hung.



also got some BTA. Sky x-over steering and 2" body lift.
got the steering installed. man that was easy!!


finished front with shocks.



then we removed the mess of the rear suspension. (add a leaf with broken center pins) man we caught it trying to cut those ubolts...  not happy bout that!

but we got it and got one side done complete with CJ springs. when i take it to the fab shop for the bumpers, i am gonna have to get lower shock mounts made and welded on.



next we finish the rear and install the body lift on the tub.

tonight, we finished assembling the rear suspension and got the body lift on.



before 2" Sky Mfg body lift

after 2" Sky Mfg. body lift


also picked up the fuel tank from the shop that cleaned it up. best 70 bucks you can spend right there! (Thanks Richard!)


also like to thank FGIALS for all the help

also picked up the fuel tank from the shop that cleaned it up. best 70 bucks you can spend right there! (Thanks Richard!)

what kind of shop does that?

our local radiator shope does it...

ok, tonight we didnt get much done to this one. got mine about right as far as axle placement goes...

we dd manage to drop the tank and paint the skid, and that is where we stopped cause it was kinda cool and the undercoating wasnt drying...


new paint and undercoating.


old tank. what a rust bucket inside!


freshened up tank. much nicer! [thumbsup]


and a nice clean rear end. all the brackets that arent needed were ground off the crossmember.