Red_toy rebuild

Rotazuk · Post by **Rotazuk** » Sun Nov 07, 2004 9:25 pm

Hi
Well since it has been a bit quiet here , no new mods going on I will try and post pic's and a brief blurb on the rebuild on my suzuki 413 . This will not be a fast rebuild ( I would like it back together by xmas so guess easter sounds good ) and it is not road legal at this stage so no cert issues .

Some of you know I have had a smokey zuk for a year of so due to lack of maintenance , dam thing still runs great you just don't want to be behind me in a que and at Easter ( yep some months ago ) I broke something in the front diff . Not sure what yet will get to that . Well its been parked up while I sort out a few other things ( house , garage etc ) and some I have just pushed outside , waiting its turn .

Finally pulled it apart a week or so ago , first up was the engine as I knew I would have a few problems installing the new engine . Never do an engine change because the new engine was cheep !!!

Will add a pic now just to make sure I can then carry on in the next post .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Rotazuk · Post by **Rotazuk** » Sun Nov 07, 2004 9:38 pm

Ok , a little big but its there .

I got a nissan ca18de cheep with a gearbox etc so decided it was the go . Well the gearbox was too long even counting on the half shaft being removed .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg[

So after trying to find out what I could do and asking a million question on some nissan forums to no help i noticed a nivara gearbox on trade me and it looked the same around the middle . After asking a bunch of stupid questions I just brought the thing hoping and after dissembilling the two boxes found out they are the same , wahoo . Now have a ca18de bolted to a nivara gearbox .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

The overall length is shorter than the silva box and the zuk t/case and the rear output looks to be in the same place as the original zuk . Unfortunatly this means I will loose the 4.16 t/case I have in the current suzuki t/case and also the front output shaft it on the l/h side and the original suzuki is r/h , see never get a cheep engine .

While beating my head against a wall over the new engine I install the second hand seats I have from a gti suzuki als no pic yet .

Well thats it so far , any coments or ideas to help out as time goes on drop me a line .
Questions to sort out are
loose zuk diffs ( and lockers ) in favor of toy axles
Keep it in national rally rules or extent the wheel base ( don't rally but you never know what you may do down the road )
Coil it or just coil front ( inside class for rally rules )

Cheers
Chris

tomsoffroad · Post by **tomsoffroad** » Sun Nov 07, 2004 10:52 pm

Well done, should go well aye?

Rotazuk · Post by **Rotazuk** » Mon Nov 08, 2004 6:08 am

Finally got the rest of the photo's loaded to Red_toy folder , in photo section on pg 5 .
Cheers
Chris

Rotazuk · Post by **Rotazuk** » Sun Nov 14, 2004 5:41 pm

Hi
Well a bit of progress today . Cut out the old gearbox mount and tried the new lot in for size . Well it does not fit too well , a fair bit of floor cutting is going to be needed to get it back together I would say . Got the thing in the hole with a great deal of difficulty then went and lifted the body off anyway .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Will do a bit more trimming over the next few nights and try and locate the motor and box , then make some mounts etc .

Cheers
Chris

Rotazuk · Post by **Rotazuk** » Sun Nov 21, 2004 8:10 pm

Well another two days and don't have a lot to show for it . have the engine in the position I want it . Better be right , won't know until I try and put the body back on . Also built a new gearbox mount , yupie have got the jack out from under the thing at last .
Hope to get the engine mounts upder way this week then I can get the body and on it .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Rest of the pic's in the folder etc .

Cheers
Chris

Rotazuk · Post by **Rotazuk** » Thu Dec 09, 2004 7:36 pm

Been a bit slow , as expected but getting there . I have made up the l/h engine mount now so with that in place I will support the engine on the jack and make the right hand mount .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

I have used a bush of a radius arm to make a captured engine mount . Not sure if it will be too firm yet , guess I will find out the first time I fire it up .

CHeers
Chris

Rotazuk · Post by **Rotazuk** » Fri Dec 24, 2004 1:57 pm

Well its the day before xmas and I finally have the engine and gearbox bolted in place on its own . taken a while but been busy with nothing in particular .
Anyway now just have to lower the body back on and cut where it hits I guess .

Cheers
Chris

Rotazuk · Post by **Rotazuk** » Mon Mar 28, 2005 6:35 pm

Gezz
last post 24th dec , luckily there has been some progress since then .
Cut a large hole in the floor on xmas day to get the body back on and have only just welded it back together last week .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

As you can see the engine just clears the firewall by about an inch , good guess . This means there should still be room for the radiator up front , nowhere else for it now . Have cut the rear guards out some more and starting to widen them a bit . Have tacked the cage in place , just needs to be lifted off to finish and let me get the body off again to do the susp mounts etc , then it can get all painted and put back together .
Big things left to do , short list
front and rear susp , inc steering .
mount radiator .
Wire up engine .

Hope to have it sorted by the end of April if I get two weeks off over that time .

Few more pic's in the folder etc

Cheers
Chris

Rotazuk · Post by **Rotazuk** » Tue Apr 19, 2005 9:15 pm

Well I have got the two weeks off and had to good days work done .
Hope to have the rear axle in place tomorrow . Nicked into work to press the a arm ball joint in place and think I got the clearance a bit wrong . Pressed in ok but took 5 ton . Its a new press and was marked in bar and kn , great for people that deal with tons etc . Anyway its in and I figure it will never come out . Still seems to pivot ok .

Will put up some more pic's once tha taxle is located and there is a bit of visual progress .

Cheers

Rotazuk · Post by **Rotazuk** » Mon Apr 25, 2005 9:24 pm

Hello
Well after six days flat out I have got the rear axle all sorted .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

If it all works out ok it shout only be lifted about an inch , will have to wait and see when its all back in one piece . Currently the cage is on , welded up and painted so just need to remove it and put the body back on then cage back etc . Before that I have to move the front diff head , tomorrow with a bit of luck , and then locate that .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Once its back in one significant piece I just have an endless list of minor things . Wire up the computer , install a radiator , get some drive shafts made and get an exhaust done .

The count done is on

Cheers
Chris

SupraLux · Post by **SupraLux** » Mon Apr 25, 2005 10:21 pm

Nice work, but what have you done front axle wise? You mentioned (and they are, from memory) that the t/c output to the front is on the wrong side for a hilux axle?

I was going to suggest cutting the weld around the knuckles and rotating them through 180 degrees and then flipping the axle over... hey presto a l/h input front driveshaft.

well, its a bitch of a job as i understand - I haven't done it. Can be done tho, although turning the knuckles requires quite a bit of force. At least filling the axle with oil becomes nice and easy since the filler is on top... draining it might be an issue tho

Anyway... keep us posted, looks awesome.

Steve

lilpigzuk · Post by **lilpigzuk** » Tue Apr 26, 2005 7:54 am

I believe it will be a cut and move the diffhead to the left then reweld the tubes on. Rather Chris than me

Rex

Rotazuk · Post by **Rotazuk** » Tue Apr 26, 2005 1:23 pm

Well its lunch time and I have the front axle back in one piece , couple more welds to do and it will be sorted ( I hope ) .

As Steve siad I have a Nissan t/case that has a l/h front output . So after much though I decided to jig the front diff , cut it into three bits , side the diff head across and weld it back together again and swap axle shafts side to side when I re assemble it .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

The rest of the pics are in the folder etc . I have moved the head across 410 mm , diff between the two shafts and hopefully there is a bit of room for error as I would only be within +- a mm . Will have to wait and see I guess .

Well back to it

Chris

Rotazuk · Post by **Rotazuk** » Sun Jun 26, 2005 5:38 pm

Well , progress . Last week i started the engine , it fired up after a false start that was sorted . For some reasion I wired the ecu ignition sence to the ignition relay , alas that is driven by the ecu , no win situation . After a quick rewire and a day later it hopped into life , rather load as there is no exhaust , also no radiator so did not run it long ( 5 to 10 sec's ) . Just wanted to be sure it could run , so now moving on with the rest of it .

Front axle is still only half done . Due to a lack of materials ( steel ) I glassed the rear flares today , a good sand back and they should not be too bad . Once the rubber ones go on they will just about cover the tyres .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Will make a start on drive shafts next week , rear is ok but the front will be a major . think I will need a double cv joint type .

Cheers
Chris

Rotazuk · Post by **Rotazuk** » Sun Jul 03, 2005 7:54 pm

I got a bit of work done today , have the upper spring mounts for the front axle done and have the axle in for a try .

Bad bits .

I stuffed up when measuring the spring compression somewhere along the line and the front sits 20mm higher than it should , grrr , will look funny .
Had a quick measure and it is 110mm ( 4 1/4 inch ) taller than stock on the rear and 130 ( 5 inches ) at the front .

Also the front steering is going to be a real pain as the ptiman arm sits right over the tie rod . Needed to have the axle further forward , I was planning to and now can't remember why not . too late to change it now .
I will just have to make a steering arm off the king pin etc like the high steer but it will have to be a low steer version due to the lack of height .

As you can see its starting to take shape now .
major things left to do are the drive shafts , clutch , exhaust . then just heaps of endless tiding up .

Chris

Rotazuk · Post by **Rotazuk** » Thu Sep 01, 2005 10:42 pm

Hi'
Just a quick update as I am in a good mood . I have finally installed the axles into my cut up front diff . I moved the diff head from the right to teh left . Initially I did not think I was going to get the axles in , the long one did not want to go , but its there now and the length is right . The short shaft went straight in , no hassles .
Lets just hope I have it lined up ok , spins free enough but you never know until its track proven .

Chris

PS also just worked out the glitch I have had in my megasquirt ecu , cool , so on with teh build of that also :lol:

SupraLux · Post by **SupraLux** » Fri Sep 02, 2005 8:51 am

Are you running those front Simexes backwards? Or is it just the light.

Hows things with the MegaSquirt - I was going to make one of those up for the Supra motors but just never got around to it...

The truck is looking awesome... keep the pics and info coming. How long till test day?

Steve

De-Ranged · Post by **De-Ranged** » Fri Sep 02, 2005 9:35 am

Would be real keen on any tips etc on that ecu as I'm looking at that for the lexus... when I get around to it :lol:

Truck is looking good!!

Cheers Reece

Rotazuk · Post by **Rotazuk** » Sat Sep 03, 2005 9:46 pm

Well spotted on the tyre backwards . Its the spare and its the only one with full tread so was using it to see how much of the guards to cut out .
Since then the gearbox has been out and back in again , while it was out I put the low ratio gear set in the transfer case

. Have the front and rear drive shafts done , steering rod done ( by someone else ) and put a 3m clutch cable in . Surprisingly it does not feel too bad , will have to see what its like in six months though , not that hopeful .
Plan to take it for an exhaust this week and have it running for a quick play the weekend after next . Hope it all holed together .

Not sure what I will do with the megasquirt yet , its sort of a back up for the nissan egeine as they have individual coils , I donlt think they are going to like the ofroad bumps too much so will look at putting a dissy on it and running the megasquirt or adapt it to a dstributor less version , either way turbo it at the same time .

Will get some more pic's when its almost together .

Chris

Rotazuk · Post by **Rotazuk** » Sat Sep 17, 2005 4:07 pm

Well its all back together again . Its not finished ( never will be ) , need to tidy a few things up and finish the wheel carrier and tool box etc . But it is ready for its maden test run . Has ripped up and down the steet very briefly so I know it all goes round and round . The front diff seems ok , can't say the same for the rear . Also I mast have warped the sump when I cut it in half as its leaking again ( been off twice now ) , will just have to dry sump it one day , that will fix it :lol:

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Also have the seats and belts all in so looking good . Was hoping to roll it out side to get a decent pic but tipical auckland weather , its raining again .

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

Will post once it has been offroad .

Cheers

Chris

wjw · Post by **wjw** » Sat Sep 17, 2005 4:38 pm

Looks good

wopass · Post by **wopass** » Sun Sep 18, 2005 11:52 am

looks rad mate, where you gonna give it a shakedown? sing out if you need a

recovery truck.... :wink:

and what are those seats out of man, they look comfy as

Rotazuk · Post by **Rotazuk** » Sun Sep 18, 2005 5:23 pm

Yeh its first run will definantly be acompanied by the rangie wuth its muddies on . I give it 3/10 it makes a day ok :oops:

Seats are out of a suzuki swift gti . They are a big improvement over the originals , even a small plonker like me fits in snug .

Cheers

chris

DieselBoy · Post by **DieselBoy** » Mon Sep 19, 2005 9:39 am

wow, just remembering the photo's posted many months back.............

SupraLux · Post by **SupraLux** » Mon Sep 19, 2005 9:44 am

Its looking really awesome... correct me if I'm wrong - but didn't you get the axles in that truck from me about 4 1/2 years ago to build this rig???

And I thought *I* was the slowest project truck builder on here :lol:

Glad to see it finally come to fruition, I'm looking forward to the progress reports on how it runs...

Steve

Rotazuk · Post by **Rotazuk** » Mon Sep 19, 2005 7:15 pm

hey its not that slow .
yep it has taken almost a year , looked back to the first post , not far off it .
I got the axles of Steve near on 5 years ago destend for an old 410 I had at the time . Alas worked overseas for a few years and the 410 did not like sitting out in the weather half cut up . Neither did the axles , they are stuffed . the front will be ok but the rear has rust on the gears etc so I am expecting it to explode some time soon . It also has a stuffed pinion bearing , did it up twice now and it just keeps coming loose . So on the look out for another 4.56 diff head . I have a set of axles in the garage but they are 4.3 I think and I suspect the rear has been welded . Will pull it soon and have a look ( in reality only after I blow this one :lol:

)

The first trip will tell .

Cheers

Chris

SupraLux · Post by **SupraLux** » Mon Sep 19, 2005 11:23 pm

Pretty sure the 4.5 open diff I have here is in good nick. Its in a front axle assy at the moment, but will be extracted soon. I'll really only be able to 'feel' test it, but its from a front so has probably had a reasonably light life (assuming its an original front diff - I can't verify that). Pay for freight and use it if you want it - if its any good you can have it for $150 - if not throw it away or add it to the parts bin.

I remember those axles well... I copped a huge amount of grief from the freight company because the guy turned up to get them but couldn't lift them on to the truck

Had to come back later with someone else... God knows what he expected two complete 4WD axles to weigh... imagine if they'd been nissan ones!

Funny thing was I bought the truck they came out of from up Auckland way and had it shipped all the way down to here just to take the axles out and send them all the way back...

Steve

Rotazuk · Post by **Rotazuk** » Sun Sep 25, 2005 9:18 pm

Well got out in the suzuki ( if thats what you can call it ) today . To my surprise I drove it on the trailer at the end of the day . It does a have a small water leak that must have let go just before it got put on the trailer as it went un-noticed .
Went ok for a first day out . Big difference in the way it drives , being so much wider and no lockers . Every creak and bang you wonder what it is .
Anyway here is a couple of pic's

All set to go

A little to much right foot ( its all the extra power :lol:

)

And the mess to clean up

I can't call it a sucess after only one day out but the front axle seems to be ok . It leaks oil etc but I figured it would ( no point in rebuilding it if it did not work ) so I will give it another go and if all is well splash out and get some swivel kits for it .

Will post when I break something ( yet do have a good look over it after the clean , why ruin a good day out

)

Cheers

Chris

SupraLux · Post by **SupraLux** » Mon Sep 26, 2005 12:06 pm

Thats looking awesome... great to see it out... I see what you mean about the slightly bum-down level. Surely some longer shackles or a couple of plates welded to the spring perches would fix that pretty quickly?

Steve

Red_toy rebuild

Red_toy rebuild

Red toy - Just about there

;-p

The end