Project DiscoZuk

Starting a project or modification? Then post it's progress here and show us some pic's.
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lilpigzuk
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Project DiscoZuk

Post by lilpigzuk »

Have been collecting bits and pieces for a while now, so thought i should share the plans. Now this could end up being ORE longest project as time is at a premium in our household, but will do my best.
The reason for this project is my zuk had pretty much the most narrow track in the club, this was an advantage in some trials, but majority of the time wasnt and if anyone was going to roll it would be meImage

Also the hillclimbing abilities where fairly average with the short wheelbase and leaf sprung suspension.
The initial plan was to find a donour Discovery (93 onwards as they went to 24 slpine axles). Found a 94 that was a write off and came less engine and less RF hub - ripped off in accident :shock:
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Got it stripped down and sold off all the good bits which put me cashflow positive again 8) Stripped it down and started measuring mounts, wheelbase I would want etc - the plan was to move all the suspension mounts onto the zuk chassis Image

Having had a spare zuk chassis to sit next to it was decided I would be better off to shorten the disco chassis and throw the zuk body onto the disco chassis (Zuk chassis's have contually widening rails from the front to back while a Disco has parallel chassis rails). So far the marks have been made where I will cut the 11 inches out to bring wheelbase down to 88" (Disco's are 99 inch as Mike unfortunatly found out not 100" like the brochure says :lol: ) The Zuks are 79.9" standard and the original plan was to go 3 forward at the front and 5" at the rear. Another reason to choose 88" wheelbase is if this setup I will be using doenst work, I can go find a cheap 3.5L Rover V8 and throw a series body on it :wink:
Now Lilpig had more than enough power in its current guise, but due to the extra weight of the disco chassis I though it will need an extra bit of huff so have one of these on the wayImage

and thought it better have some new feet too :wink: Image

Well thats about it for now, was going to make the first cut last night in the chassis but my supercrap(cheap) compressor decided not too work, so will have another crack this weekend on some progress...
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Clint
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Post by Clint »

Looks real good. Should be an awesome wagon when it's done.
8)

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Mattman
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Post by Mattman »

Wicked. Definitely put a V8 into it!

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callum007
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Post by callum007 »

all looking good.. might have to come have a proper nosey at it.. give you a list of all the toyota parts that you should have used..
Dont follow me. i'll get stuck and need a tow..
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lilpigzuk
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Post by lilpigzuk »

callum007 wrote:all looking good.. might have to come have a proper nosey at it.. give you a list of all the toyota parts that you should have used..


yeah but nah........ will post when Im not pissed (had the family round tonight playing "buzz" playstation)

Really Rover bits with the weight Im carrying is up there with hilux running gear.....
Bring on the arguements I say :wink: :lol: 8) :wink: :lol: 8)
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SupraLux
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Post by SupraLux »

Hey, I'm all for putting Toyota bits under every truck in the world... even Al's :) But thats gonna be sweet... just stick to your plan... but do the V8... thats a whole lotta chassis to push about, and clearing those simexes needs ponies.

And the longest project in ORE history belongs to our almighty founder, Lord Mike! :lol: (with me a close second :oops: )

Still... neither of you have finished, so who knows? :P

Steve
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krawlr
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Post by krawlr »

looks like a ct blower
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Post by Rangielux »

Yeah yeah, Another vote for the V8 from me 8) 8) . find a EFI rover and bolt it straight up, half hour job with the trans already there, gearing will still be good too. Is the computer & wiring still in the body?

Chuck a tub on top (whatever you fancy) hook up the steering column and brakes and your away :)

And in the mean time you can still play in lilpig, and when the new ones done sell lilpig and give the money back to your Mrs :wink:

Which ever way, have fun :D
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lilpigzuk
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Post by lilpigzuk »

Rangielux wrote:Yeah yeah, Another vote for the V8 from me 8) 8) . find a EFI rover and bolt it straight up, half hour job with the trans already there, gearing will still be good too. Is the computer & wiring still in the body?

Chuck a tub on top (whatever you fancy) hook up the steering column and brakes and your away :)

And in the mean time you can still play in lilpig, and when the new ones done sell lilpig and give the money back to your Mrs :wink:

Which ever way, have fun :D


With the original plan of putting the running gear under the zuk chassis, I sold trans to help fund it...... dumbarse idea that one :oops:

I will run the little 1300cc and see how it goes first before I go down the V8 route. On that note, the Supercharger arrived this morning 8) Its like a mid winter christmas :lol:

Just need to get in the shed now instead on drinking, fawk Im hungover today :oops: :(
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Post by SupraLux »

lilpigzuk wrote:Just need to get in the shed now instead on drinking, fawk Im hungover today :oops: :(


Nothing like the sweet singing of a 9" grinder to break out of a nasty hangover :lol:
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Post by callum007 »

i dont think i could think of anything worse..
Dont follow me. i'll get stuck and need a tow..
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lilpigzuk
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Post by lilpigzuk »

Put the rum down for an evening and hey presto, 88" wheelbase chassis and no rear overhang.... phew, thats enough work for this week :lol: :lol:

Image

Image
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mike
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Post by mike »

looking real good. looks like I better get mine done before my project does become the longest running in nz :oops:

I used a couple of old railway lengths to line/level mine back up for welding. My garage floor was about as smooth as worsley spur track :shock:


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lilpigzuk
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Post by lilpigzuk »

I wouldnt rush, I get next to no time to get in the garage due to baby girl in the household :lol:
My garage floor is fairly new and running a straight edge along it seemed like it will be level enough for what I want (trailer queen - not road legal) so a few mm here and there doesnt worry me.
Just need to get the old man over as his welding is 8) compared to mine.
Once thats done, strip axles and put all bits into new housings (Im sure these ones are bent - rear definetly). Once it is a rolling chassis, things should move along more swiftly :?
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callum007
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Post by callum007 »

you dont need some nissan parts for it do you??

its taking up room in the shed. need to shift it for the boat
Dont follow me. i'll get stuck and need a tow..
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lilpigzuk
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Post by lilpigzuk »

Funny, how projects get lost here.... Well Im waking this one up, have another bubs due later this year, so if it doesnt happen before Sep, it wont happen....
Recieved one 88" chassis today, have collected some parts in the mean time.
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Post by lilpigzuk »

After the laurie sanson trial yesterday, it just confirmed even more Im over leaf springs and short short wheelbase.
Got out to the shed tonight and bolted up some early rangie running gear I had spare so that is now a rolling chassis and I can start scribbling on chassis where motor, gearbox, and transfer will sit. Trying too end up with the front of the engine behind the front diff. Just have too work out how short a rear driveshaft I can run that wont bind on articulation as it should have a fair bit - well hoping too....

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Using Disco/rangie front V8 springs all round. Is the lightest spring rate Land Rover did from factory, and I have access too quite a few.... Have sandblasted a full set of radius/trailing/A arms so will fit them with all new bushes once I finished rebuilding the 24 spline diffs. Classis Rangie and early discovery had twin line front callipers which would of made it a slight pain in the arse too plumb the brakes, have managed too score late model dicovery ones which were single line - straight swap with a spare set of dual line fronts I had.
Pick up recoed gearbox tomorrow, have a few transfer cases lying round, and just need too get too rotazuks too bit up the spare GTi engine i have sitting there and will then see how it all sits 8)
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Post by niblik »

lucky you know some chump in the rover business.. :D

chassis looks good guy..

workshop looks like crap though.. you need to move the operation back outdoors into the southside chop shop.. :wink: :lol:
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Post by rokhound »

Go Rex.

You got balls Nib given him shit about garage :P . Rex has only been back onto this project 2 days, and he has almost caught up with you on the 40 :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol: :lol:
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mike
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Post by mike »

hmmmm niceee, that chassis looks familiar :D

Might as well throw the Series 3 body on there and make it really coooooool 8)

I actually downgraded my diff from the 24 spline axles as i had a spare one i could weld up :wink: I thought i would bust something but, most likely as its so light there isnt as much load as a normal rangie/disco. So the chances of you blowing anything are going to be really slim with the 24's :twisted:

waiting with interest on this one 8)

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Post by lilpigzuk »

So heres the big block that going too be powering it :lol: One Suzuki Swift Gti engine (G13B - a whopping 1300cc :oops: ) It is out of a 87 Swift, they made 3 versions of this engine Mk I, II, III. This is the mark I.

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It has the same block as a Suzuki 413 (G13A) so for an easy power upgrade they bolt up to the 413 gearbox and engine mounts etc. However, being that it is out of a front wheel drive car, there are a couple of things that need to be changed.
The rest of this may be a little boring unless you want to know whats invloved...
First you need to bin the front wheel drive sump and pick up

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Then fit a 413 Oil Pick up.

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The pick up does bolt on, but the bracket needs too be bent slightly and one edge grinded to miss the Balancing weights of the crank (GTi engines have balanced cranks hence they are a very free revving engine - 7800 redline 8) )

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Then bolt on a 413 Sump

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There are some other bits and pieces that need too be seen too but will cover them later in the build.
So Rotazuks is a happy man as its another one of my parts that leaves his shed. dragged the engine home and lower in too chassis to check out how low it can be mounted.

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This is roughly where it will sit, front crank pulley is basically inline with the middle of the front diff, so hopefully it should end up nicely balanced.

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Have bolted up machined flywheel, new clutch kit and gearbox. Took photos but they are all blurry due to having the shakes from hangover :roll: :oops:
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Post by Ryan »

looking real good pig....im jelous!!! :twisted:
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Post by niblik »

lilpigzuk wrote: due to having the shakes from hangover :roll: :oops:


just not enough rum in the system fella.. :wink:

go the big block zuk..!!

good work.. what sorta body ya gonna have on this thing? and how heavy is the chassis in comparison to the one that the engine came from?

go piggy mk2 8)
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Post by Rotazuk »

For interest sake it would be good to weigh Lil Pig now and then once no 2 is done and see what the difference is :D
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Post by niblik »

Rotazuk wrote:For interest sake it would be good to weigh Lil Pig now and then once no 2 is done and see what the difference is :D


thats sorta what i was thinkin.. :thumright:

i'll be doin the same type of comparison with 'ole rusty' and the new 40..

lucky for me i have a weigh bridge at my work available for just such a scenario.. :wink: :cheers:
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Post by lilpigzuk »

niblik wrote:
lilpigzuk wrote: due to having the shakes from hangover :roll: :oops:


just not enough rum in the system fella.. :wink:

go the big block zuk..!!

good work.. what sorta body ya gonna have on this thing? and how heavy is the chassis in comparison to the one that the engine came from?

go piggy mk2 8)


I dont think I will be carrying much more weight than it has in current guise. Will try and get them both weighed.
Body wise is still a little up in the air. A wee possibility I will be using some of rotazuks parts - pending whether he dismantles or not :wink: I think the current body is too farked too consider re-using - rust and dents etc
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Post by mike »

lucky for me i have a weigh bridge at my work available for just such a scenario..


Thats very interesting to know :wink: Perhaps you could be the owner of LR for a day and get its weight :lol:


I actually thought the old RR chassis was quite heavy with all its running gear and stuff on and I've got an aluminum body on it and alloy v8 and still want more power :D

Having access to lots of rover parts how come you dont throw 3.9EFI V8 in it? oh imagine all the torque and the sound 8)

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Post by turoa »

He has one mike, im trying to get him to sell it to me, but he wont :(

BTW, looking good rex, even though it is sacriledge to combine suzukis and rovers.

wanna sell me that v8 yet
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Post by Cloggy_NZ »

You would be wanting to run a transfer case with an ultra low gearing in it too I would think.
Those GTI motors want to rev freely, that would also mean maximum torque may not be produced until that little engine is spinning at around 4500rpm or thereabouts. Not the best combination with the tall 3.54 rover diffs.
Much better suited to a V8 I reckon.
Go on, you know you want too :D
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Post by lilpigzuk »

Cloggy_NZ wrote:You would be wanting to run a transfer case with an ultra low gearing in it too I would think.
Those GTI motors want to rev freely, that would also mean maximum torque may not be produced until that little engine is spinning at around 4500rpm or thereabouts. Not the best combination with the tall 3.54 rover diffs.
Much better suited to a V8 I reckon.
Go on, you know you want too :D


they certainly rev freely. Have been running one for the past 4 - 5 years. Suits my driving style brilliantly :lol: Had big discussions about engine for this with rotazuk. Want to stick with the small engine as I think it will work and its something completely different.
There was the option of running it in "fwd style" ie, use car gearbox running into front car diff (which would be locked to act as transfer case), Means you only have low ratio which quite a few trials vehicles run now. this was going too leave me with similar final drive ratio too what I have now. Again I didnt want too be left with low ratio only. Being that I am going from 3.9 diff ratio (zuk) to 3.54 (landy) I was going too lose a litle crawl ratio, then going from 31" to 32" tyres (which measure more 33") I would lose a little more again. However I have got a series 3 rockhopper transfercase in the collection somewhere - a little noisy but its there) That has a reduction of 5.14 compared too the series 1 rockhopper I run at the moment which is 4.16. So if I find this set up is too high geared I will look at running the series 3 transfer.
And then if I find this is just all a little underpowered I have a complete 3.9 with loom, ecu etc sitting under a bench in the garage :lol:
I was soo very nearly tempted too go with the Rover V8 not long ago. One of our suppliers at work sent me a set of gas shocks free of charge so I could evaluate them and let them know what I thought. I have a feeling they will be too "hard" for this project, but the dude I deal with (Adrian) at britpart sent me this link of him trying them in a mates D90... Just cant beat the sound.... 8)

http://www.youtube.com/watch?v=pehL7dhu36w
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