Zuki Build

[UBZ]

that blanking plate above looks like where the EGR valve would bolt up. and id say the little plug is for an EGR sensor.
take the plate off and see if their is a gallery going down to the little plug with the leak.
If so , just drill out the little plug , tap and fit a bolt to block the hole , problem solved.

[Swamped]

That blank plate is where the mechanical fuel pump usually goes I thought.

[UBZ]

yeah you might be right, id forgot you had removed the mech fuel pump.

[Swamped]

Nah the swift just didn't have one to begin with.

[Swamped]

Ok so I've had a few people harassing me as to what progress I've made so thought I'd do a couple hours on it last night. Body is having rust taken out of it that I don't want to do due to location ie the hole in the middle of the roof lol. So am only doing chassis stuff at the moment.



This is the current state of the chassis. Fuel and brake lines all done, tank in, started diff breathers and prop shaft rebuilding, front calipers rebuilt with new pads and rotors.



Still need:
410 TC
rear prop shaft
Gearbox mount
main seal on motor
maybe a new clutch.

Would like both rear upper pillars from a tin-top actually if anyone has one from a ute chop or roll-over close to hamilton that would be excellent. Running out of people to ask haha.

Is there any advantage gained by moving the upper rear shock attachment points closer together?? I've seen it done on a couple trucks and wondered if anything was gained from it.

[niblik]

only to gain a bit in length when at full droop i believe.. other than that, vertical is gooderested..

[Swamped]

Thought I'd stick up some more pics.










This is all the rust removed so far.

Have also sourced
2x 410 transfers
extra drive shafts
spare gearbox
410 grill
Thanks to lilpigzuk for helping sort parts

[UBZ]

Looking good, wasn't to bad rust wise for it's age

[Swamped]

Yeah doing the guard chop is saving me taking a bunch of rust out anyway so about the same amount of work. There was nothing in the sills which was good.
I was thinking of doing a one inch body lift but the clearance it has just with the body work alone may mean I don't need it. Obviously it will sit lower with a tank full of gas and all the drive components in it but with a couple mates to simulate the extra weight standing on the front of the chassis its looking good.
The wheel offset has been more than expected to which is good. This is the first time the chassis has seen the body in a while.

Will start doing the rear main seal tomorrow and hopefully have it all back together with a new clutch.

[Swamped]

More pics:
Rear Guard


Started cutting the front guards but am trying something different. Hopefully it works all good.



With the outer only cut to fit.






Passengers side pretty much complete


As it stands now.

[UBZ]

Virtual lift is more work than you expect ah.
Rear is looking sweet.
Couple of ? About the front .
Will you be able to remove the front guards ?
What are you doing about the accellorator pedal, if you tub out the drivers side the same?

[Swamped]

Front guards are removable. Same bolts as before.
The original idea was to leave the gas pedal where it is but space it back a bit to allow for the normal amount of travel but will have to make sure thats still possible. Kinda ballsed up the passenger side so ended up taking a bit more out of it. Just have to make it work I guess.
Virtual lift has been ok but the front looked like it was going to suck so I'm just going to run conveyor belt flares which cover the big gap in the pics.
Now that one of my other projects is completed I can do more on this again. Was planning to have it done in 6months when i started

[Swamped]

Havn't posted much for a while so heres some pics of recent progress. Front virtual lift completed, 410 grill fitted and bonnet fixed and fitted.
Finally looks like a truck again but its gonna come to bits again for paint woot.

Currently doing seat mounts and making sure the seats I want to use will actually fit.

[Dr_PC]

Always good to see a wagon coming together

[flyingbrick]

looks great doug!

[Swamped]

cheers man. Still a crap load of work to do though. Doors are fitted now and all good so its almost time for teardown and panel prep. Its final re-assembly can't come soon enough.

[suzookyman]

gotta love that 410 grill, did the same thing to my old 413, best visual mod i did!.Nice truck mate, im heading down a similar path soon too so watch this space!
Al

[flyingbrick]

did it have the ugly plastic grille before?

[Swamped]

Yeah it did have a plastic one. I still have the original grill. I just need some 410 light surrounds now otherwise will make somthin up. I more wanted the metal one as its heeeaps tougher but its ended up looking good too.

[Swamped]

Made a little bit of progress.
FTO seats mounted all good.
Drivers door still needs a bit of persuasion to fit correctly dammit.

[Swamped]

Got the pedal assembly done. Heres some pics for ya UBZ

[suzukisport]

Once your finished you wont want to get it dirty, looks a great job you are doing.

[Swamped]

I only want to do shit once haha. Plan is to exo it once everything else is done.

[DieselBoy]

Plan is to exo it once everything else is done.

Nooooooooooooo

[suzukisport]

Plan is to exo it once everything else is done.

How would you get your cross brase in without going through the body for its strength?

[Swamped]

Thing only weighs 800kg or thereabouts. A decent exo will work with it. Was gonna cross brace over the back door and make it removable and maybe the same over the windscreen
My neighbours exo'd jimny goes fine and has been on its roof a few times. Takes it easy as. May still go internal yet but decent sliders with a cage on it would be fine.

What I don't like is that debris and shit gets caught between the cage and body and has torn bloody great holes in the body of my friends truck before. Also means more weight up high too hence the internal still being on the cards possibly....long way to go before anything happens in that department though

Have to complete the driveline ie rocklobster tc, rebuild driveshaft unis, power steering (I like my creature comforts) and all the bodywork/panelprep left to do before paint

[Swamped]

Had the body blasted a wee while ago now and just found some pics.
Had to wrap the body in that industrial gladwrap cos of course it decided to rain the day we did it. And then it turned out not to rain on the way between towns grrr. Kept all the road crap off it though which was good.

Its now been primed and just needs a bit more bodywork to fix some problems the blasting uncovered and then be looking to paint.

[DMcCready]

Body looks way too straight for a 4wd! keep up the good work

Gotta love the zooks!

[flyingbrick]

thats cool man.

Who did the blasting? What kinda $$? What did they blast it with?

looks great. No warped pannels?

[UBZ]

Smicko as!

Decided on a color yet?