Project - 3VIL-Zook

[3VILC]

So after a couple of months of it sitting in the shed with not much happening I finally got motovated and made a some progress on this project so thought I'd start a bit of a write up.
Budget build SJ413 trailer truck.
It started life like this:

A 1987 SJ413, stashed in the back of a farm shed, a fair amount of rust, no seats, no engine, and a set of bald 30" ATs. But looked like it was once someones loved club truck from the build quality of the cage (not counting the bullbar, looks like that was a farm addon as its not even centered), it has a 3-link coil front, and there are brackets on the chassis that appear to be the start of a 4-link rear which I doubt a farmer would have bothered adding, rear mounted radiator, winch mount where radiator would be, and the start of a rear disc conversion.

At this point now its got a pair of race seats which I scored for $100, just factory looking ones from probably a GSR or similar, faded and one ripped but perfect for this use.
A carby G16A with SU carb conversion and stainless extractors, which has finally found its home in the engine bay, runs and drives al-be-it not very well yet, still seems to have a vacuum leak or timing issue to sort out.
Engine bay wiring loom completely stripped of everything not needed rather than a ton of wires chopped off and hanging everywhere as before. Just need to do the same to the dash loom and make available unused circuits for other things.
The 31s I kept from my hilux have now been swapped to the Zook rims.
The rear roof had more rust than I could be bothered with so off that came.
And at this point it basically now looks like this:


The list of things to get done before I can go out for a play:
Hook up a choke cable.
Get it running properly, I cant seem to get any adjustment on the mixture yet but it seems to burn quite hot so think it might be over lean.
Fix the vanishing water problem, I think this is from the broken temp sensor seems to weep a tiny amount out the end, and raditor cap leaks when hot hopefully radiator is OK cant see any other leaks, new cap and some stopleak should do the trick this is a budget build remember
Fix brakes so they actually stop, a trailer master should do the trick for now, cheap fiddle brake, and can add another for the rear later once I get round to sorting out the disc setup.
Patch up rust holes and maybe give it a lick of paint.
Go and get it dirty and add some more dents

So thats where its at now, will try remember to add updates once I get some more done.

[1FAT4D]

Looks like you are having some fun with it. Previous owner here, I knew you had good intentions for it, hope you have fun once it is going. Continue the hard work mate, I will be watching to see the outcome.

Cheers

[Sausager]

Any updates on this? Watching keenly

[3VILC]

Nothing much to look at as yet. Got a lot of little things done tho. Engine seems to run OK now after a budget head recon, can't tell much for sure until I get brakes done to be able to drive it.
Have stripped tho whole wiring loom back to the minimum needed to remove all the chopped off wires that were everywhere. Leaving a lot of spare fuses for the minimal extras to go back in.
Have complete front axle sitting here to raid the bits to finish the rear disc setup. Just need to go to pick apart and get a Subaru master cylinder and an assortment of hoses and probably new seal in all the calipers and should be good to go

[3VILC]

Well after a lot of crap times, a seperation, and having to sell my house n cough up half, the project has found its home in my new much bigger garage. Things are starting to progress, acquired a lot more of parts needed. Got a new radiator to replace the old SJ one mounted in the rear, off a Nissan march of all things. Got some v6 vitara discs and calipers to go on the front do the SJ calipers can find a new home on the rear, and the much needed subaru master cylinder is sitting in the back of my ute ready to go. Got a care package coming from lowrange offroad with extended hoses, manual line lock for temporary parking, and new shifter bushes. Another coming from burlen fuel systems to sort the carb out. Just a matter of getting on and fitting it all up.
Not much worthy of pics yet but here it is in its new home

[zukmeista]

Not sure if you are aware but the V6 calipers/rotors will need 16" rims to clear them.

[3VILC]

Ah bugger it don't remember reading that bit anywhere, of course I probably did and just forgot about it when I brought them
Anyone want to swap for a set of normal Vit or working SJ brakes? Assuming the non V6 ones fit

[zukmeista]

Yes 1.6 vitara gear will also fit and work with 15" rims.

[3VILC]

The main reason being that vit ones are less likely to be stuffed haha. I already have a pile of seized SJ calipers.

[3VILC]

Well after a few weeks and finally off the axle stands again for now, probably time for an update, with pics or it didnt happen
Actually got quite a bit done over the last few days, enough to go for another motovational blast around the section

Completed the Subaru master cylinder upgrade..

..and got the rear disc setup finished and plumbed, as well as the Vitara calipers on the front, tested, still needs more bleeding I think, parking lock wont hold on, but actually stops now

Also re-arranged how everything was mounted in the boot and got the new radiator mounted up, just got to wire up the fan so both speeds work. This setup allows the hoses to run straight down the center rather than under the passenger seat, and the bit of extra length gained allows more airflow behind the seat, it was very close before.

And of course mini-me, chief project supervisor is checking all my bolts are tight.. or trying to undo them

The list of things to do know (I'm sure it gets longer?!):
Try adjust engine mounts to get extractors to clear top suspension link.
Fit new tuning bits into carb (arrived in a care package from UK).
Make up an intake pipe (3" suction hose internal snorkel, primative but will work)
Cut and move wheel centers in for more offset
Make spotlight mounts
Make up a switch panel where heater controls would be, and finish wiring everything, including fan
Then finish the less inportant cosmetic stuff, making chequerplate panels to cover the bigger 'speed holes', patch up the rest of the rust, maybe a lick of paint some day

[3VILC]

So thought I should chuck up another update from the weekend. Didnt get a huge amount done, still trying to figure out the overfueling and high idle problems.
Moved the left side engine mount up and added more spacers this makes a lot better clearance with the extractors and the top link. Hacked the flange off the extractors and started welding a pipe in, decided i really dislike welding upside down, blew a hole then created a huge mess trying to weld it back up haha so decided to leave that for another day after Id calmed down haha.

Air intake.jpeg (20.53 KiB) Viewed 5182 times

filter.jpeg (12.99 KiB) Viewed 5182 times

Did get the intake finally made up, filter in the glove box, simple but works and cant get splashed, probably wouldnt be too keen fording water that high with a petrol engine and a truck that light anyway so should be fine

switches.jpeg (16.78 KiB) Viewed 5182 times

Also made up a switch panel to go where the heater controls should be, now just have to wire it all in. Figured I should wire the fan up so I can test run for longer than a 5mins. Got a nissan 2 speed fan so a bit of trick wiring there to get both speeds as well as off for warming up all from 1 switch

[3VILC]

Well must be time for a bit of an update, things been in the shed now for nearly a year! At last getting somewhere near usable tho
After fighting what felt like lean out at high revs for a while, I readjusted the mixture back to where it should be at idle, and cleaned all the plugs up and thrashed around the section for a bit. Pulled the plugs and they black again. Tuning it richer makes the problem less noticeable so its definitely not rich, of course, thats why chucking the high voltage coil off my Hilux in made a slight improvement too, the ignitions breaking down at high revs! So brand new coil, leads, plugs, cap n rotor, and it runs sweet a nut now
Cant take many interesting photos of that, but swapped the zero offset steelies for some -15 alloys, tyres still hit the arms at full lock, so accidentally brought some 50mm spacers and took a flex shot up the retaining wall

Started welding up a battery bracket and touched the tip onto the work by accident, replaced tip, wire is still jamming, dismantled torch and its slightly deformed the wire liner too..doh so can't weld anything at the most, which is most of what I've got left to do haha.
That and sort out why the stupid hydraulic park lock isn't working

[3VILC]

Well not too much to update really.
Fixed the welder with a bit of sleeve from the choke cable offcuts, primative but works just may have to dismantle the torch to re-feed wire not much of a biggie the amount I use it, nobody had a replacement liner that would've fit, teach me for buying chinese but for the amount I use it and the price its all good really. So finished off the dual battery clamp. Just got to finish removing the bottom of the bullbar (since it obscures the recovery eyes welded into the winch frame), requires making a new mount for the right side before I cut the left side to prevent it pulling too much out of shape (as you may recall I have already cut the mounts once to pull it into center as it was welded cock-eyed). Some clever clogs has welded a nut inside the eye hole on one side and lack a 19mm+ drill bit to drill it out to take a shackle pin so that may be just used to hold the end of the cable when not in use, can't come up with a reasonable plan to attach normal recovery hooks at the front. Also need to make up brackets to mount the lights, and hi-lift etc.
Replaced the mechanical fuel pump that I think was knackered anyway, with a returnless electric setup designed for this type of carb, seems to be working well.
Got an old truck curtain to make into a canvas top for the back, since I cut the roof just infront of the seat headrests i dont like the idea of water dripping down my neck cost: free, and probably enough left to make 2 maybe 3 more should it get ripped although its pretty thick canvas so should take some abuse. Also got some truck mudflaps to attempt to make some splash guards for the front wheels since the inner guards are removed to clear the tyres.
Discovered a knackered kingpin bearing, so just brought a whole front hub repair kit, just need some shed time to get that all fitted before taking it out.
Got bored one night so shot a quick coat of paint at it, looks extremely average close-up, but by the time its covered in scatches and clay stains its not going to matter anyway. And of course couldnt resist adding some stickers

Hoping to have it ready for prehaps the 2nd weekend of Woodhill being open 13/14 June I think

[tommie]

Hey, would be keen to convoy you up that weekend of you go, take my zook up for a run. Was thinking this weekend but may be busy up there, im just over in Matamata.

[3VILC]

Finally I can say its had a good testing.
Took it up to Woodhill on Sunday. Went sweet as a nut all day everything ran mint didn't even have to adjust anything. Very impressed at how the little beast goes.

[OffroaderGuy]

You did a pretty awesome job in this build. any updates on what it looks like now? Guess you did more modifications or enhancements in it.

[3VILC]

Haven't changed a huge amount really just tidied it up and got it all running.
Next major plan is trying to get the back to flex as well as the front. Longer shocks will be the first try, but does have brackets on the chassis to 4-link the rear so could be another more complicated option, the 3-link front certainly works very well.

This is how it looked as it came off the trailer Sunday morning, before it got dirty: