SJ413 Ute Build

[PuddleJumper]

Selling the tyres on the vitara?

Dunno yet.. I may use them on the ute for every day use - They havn't had a lot of use.

[skidtoy]

looks good always liked the flatdeck zuks the best, wouldnt mind getting one when the nissan is finshed or i sell off some of my other cars haha

[PuddleJumper]

Not had alot of time to spend on my ute unfortunatly and probably wont be able to spend much time on it for the next couple of weekends..

I needed to reuse the vehicle speed sensor (VSS) from the Vitara speedo unit. Heres a pic of the Vitara speedo unit (left) and the 413 unit.


The VSS is the bit which is screwed to the back of the speedo.

Mr Suzuki being the clever man that he was designed it so it would screw straight into the back of the SJ413 speedo. All the screw holes and little slots where it slids in are already there


and here is my completed loom.. well apart from a few wires the need to be spliced into the 413 loom.

and here is the left overs of the loom that i dont need!

Picked up a new set of extractors too. Just got to add the oxygen sensor, cut, weld and modify it to fit.


So slowly but surely I'm making progress

[Rotazuk]

I could not find the pic's of the speedo but if you have not thrown out all the vitara speedo bits yet . Get the tab from the vitara speedo circled and install it in the 413 cluster . Then you will see they line up with disused tracks on the 413 circuit board/plastic bit . Just scrap away the clear coat . You need to put a jumper in in one point but again just scrap a bit of the clear away and solder a thin wire across it . Then you can add a pin to the conector and wire in the VSS that way . No messy wire to screww to the back of the cluster when fitting .



It may be the next tab over , can't quite remember but it will all make sence when you look at it .
Cheers
Chris

[PuddleJumper]

No messy wire to screww to the back of the cluster when fitting .

Thanks for the info Chris.

I ended up reusing a 2 wire plug in connector which lived on the back of the Vitara dash board. You can see it in the picture which shows the wiring loom if you squint hard enough!

This way if i need to remove the dash at any stage its just a matter of unpluging the plug

On a side note if anyone else has a 16Valve Vitara motor in there SJ zuk then can you post a pic of how you've mounted the aircleaner. Looks like i may have to reposition a few things for it to fit...

[lincooln]

Hey scott, Where and how much were the extractors you are fitting?

[PuddleJumper]

Hey scott, Where and how much were the extractors you are fitting?

PM sent

[lilpigzuk]

did you have the clay option vitara like mine Scott??



somewhere in this pic is the top a arm for the rear diff, and apparently a efi fuel tank



POS nearly got a match, was well over rusted bolt heads and 2 ton of clay....

[pandasport]

whats the story with the exhaust?? has it got holes in it or is it just camera tricks?

[PuddleJumper]

did you have the clay option vitara like mine Scott??



somewhere in this pic is the top a arm for the rear diff, and apparently a efi fuel tank



POS nearly got a match, was well over rusted bolt heads and 2 ton of clay....

Hey Rex you got one of the cleaner ones....

Ironically mine was number "2" and number 2 it was!




Did notice it made for great sound insulation

[PuddleJumper]

whats the story with the exhaust?? has it got holes in it or is it just camera tricks?

Apart from the holes in the normal places theres no other ones.. Camera trick I reackon.

[Heath]

Where the hell did you guys pick up those ... ah ... heavy weight zooks?

[lincooln]

Where the hell did you guys pick up those ... ah ... heavy weight zooks?

I am going to say the bottom of a a lake some where. where they had been left to fossilize.

[PuddleJumper]

Sorta mid week update. Been making the most of the daylight savings. Get home at 6ish then straight into the truck till the bugs come out to play (about 7.30ish )

I'm using the Vitara fuel tank as this already has the intank fuel pump so i dont need to muck about with external high pressure pumps etc etc. Also I'm going to use the space where the old fuel tank originally lived (length ways infront of the rear diff on the passenger side) to put a winch in there. I need to redo the exhaust from the new headers right back.. So the best thing to do is take the tray off - After a bit of CRC and removing 7 bolts and nuts...


With the tray off i then removed the spare wheel holder (those two long flat plates with the curved bit on it)
Also gave it a quick water blast then sat the tank on some axle stands - working out the best place for the tank


I like it in this position. Its up nice 'n high so should be safe from getting dented though i may need to perhaps push the tank right across as far as it will allow to give my some room for the exhaust... Any one have any other suggestions?.

Once the tank is in i want the cut the chassis off just behind the rear of the spring hangers - obviously I'll put a new crossmember at the same time.

Another update over the weekend with some luck!

[Heath]

Could exit the exhaust in front of the tyres off to one side and keep well clear of tank?

[PuddleJumper]

Righto change of plan!

Initially i wanted the fuel tank behind the rear axle but after lots of staring and pondering i decided to put in front of the rear axle and when i get a winch that can go in the rearmost part. A quick measure with the tape and it all looked ok.

So with my newly formed plan i removed the bits that were in the way.. Exhaust hanger brackets a couple of fuel tank mounting points and also the fuel tank support running length ways.

With this out of the way i sat the fuel tank in to make sure it was gonna work out regarding clearances betwwen the chassis rails and also diff clearance and clearance from the bottom of the deck with will be going back on in a modified form

Cut down some 30x30x3 box to use as a cross member.... Only enough for one

Once that was in (not welded yet) i thought i may as well run the fuel lines and finish off the wiring for the sender unit and fuel pump. Lucky i did as i found this...

Bare power wire for the fuel pump - I cut, soldered and heatshrunk all the wires i need to then i started on the fuel lines. I cut a bracket off the Vitara donor truck as it was a perfect fit fot the EFI fuel filter to attach to.

Also ran a vitara hard line back upto the engine bay for the charchol canister.

Got a few other bit done too. Like mounting the aircleaner box and a few other small bits.

Plan is to start this thing up on Labour weekend...

[Dr_PC]

Plan is to start this thing up on Labour weekend...

Geez my rally truck wont be ready by then, damm you work fast

[PuddleJumper]

ITS ALIVE! ITS ALIVE!

Spent half of yesterday and some of today sorting the exhaust out. I reused most of the stuff that came on the ute and just cut and tacked them all together. This will changed at a later date but my plan was to get it running this weekend. With that done i again tacked the fuel tank crossmembers into place - Hooked all the fuel line back up (I'd taken the tank out to take the paint off the chassis where the crossmemers went) Reattached the fuel lines, installed a new EFI filter at the same time, put some nice new engine oil in...

Then with fingers crossed i turned the ignition to 'on' - The EFI fuel pump buzzed for about 3 seconds - Then turning the the key to 'Start' it wound over for about 5 revolutions and it fired in to life

I could here the alternator belt squeeling for a few moments - but i was more interested the the oil pressure light. Must have been about 3 or 4 seconds before that went out.

I'd added the Vitara check engine display light into the SJ dash and I'm pleased to say it hasn't brought up any faults (yet)

I'm definetly going to need a bonnet scoop on this thing as i'm not going to be doing any body lift on it.

Apart from going backwards and forward in the drive i've not taken it for a spin yet. WIll be interseting to see how it performs

[meatc]

Check out my bonnet auction
http://www.trademe.co.nz/Browse/Listing.aspx?id=326691749

Will get you some measurements of the hump if you want. Its about 60mm high and the black stripes in the photo are on the flat area.

[PuddleJumper]

Check out my bonnet auction
http://www.trademe.co.nz/Browse/Listing.aspx?id=326691749

Will get you some measurements of the hump if you want. Its about 60mm high and the black stripes in the photo are on the flat area.

If you can measure the hump that would be great! 60mm should be enough height wise. Just width ways I'm worried about.

Thanks!
Scott

[meatc]

Check out my bonnet auction
http://www.trademe.co.nz/Browse/Listing.aspx?id=326691749

Will get you some measurements of the hump if you want. Its about 60mm high and the black stripes in the photo are on the flat area.

If you can measure the hump that would be great! 60mm should be enough height wise. Just width ways I'm worried about.

Thanks!
Scott

Hump is
45mm high
550 wide at rear
520ish at front
has full 45mm height from rear edge to about 580mm forward then slopes to nothing on the front edge of standard bonnet line.

If sold via here will do it for start price on Trdeme. Should be able to get it to Whangarei in next couple of weeks, and depending on which boat we buy may be able to get further south (like mid waikato).

[Bolo]

keen to see whats next for this , keep up the great work

[PuddleJumper]

Couple of things done this week.

Relocated the windscreen washer bottle back to the fire wall with a simple strip of alloy checker plate i had lying around. Just need to extened the wiring to reach now

Also welded up exhaust leak in my new extractors - there was a hole right on the weld of where the rear pipe meets the main mouting plate on no.4 cylinder. Must have been covered by the black paint and didnt see it.

The air intake hose between the airfilter box and inlet plenum has a small plastic box which looks akward and sat fairly high.

So i cut a spare piece of exhaust up.. Found some flat plate and filled it into shape.

Took it to work the next day where i had one of my work mates TIG weld it up
Got it home and painted it...

Then stuck it in the hole!


Also put a new thermostat in as the old one had seized open so the motor never really got warm.

Took my first proper drive in it too! No bonnet attached but thats ok
Driving impressions so far... Gee it goes well
Has heaps of pull and will actually sit you back in the seat when accelerating hard. Easily pulls in 5th gear going up hills - Not something the old 1300 did really. It is a little under tyred though at the moment but i have a set of 31x10.5 which will be going on soon enough once the front gaurds are cut.....

[badnuz]

one word: very nice

like the fact you hace the vitara dash warning lights

[PuddleJumper]

one word: very nice

Hey Euan its been a while... Hows your Zuk goin? Still got her??

[PuddleJumper]

Did a few bits' n pieces this week end. Needed to sort the bonnet out. I was given a '09 Hilux Turbo Diesel scoop but it just didnt want to play (30mm to short ) so next best thing - A hole saw and thin cutting disc. Short while later... Hey presto!


I'll put a scoop of some type on... I'm thinking mid 80's Mitsi Cordia or Tredia
Next job. Take one piece of steel. Cut to fit.

Weld into place - This is my new rear cross member.

Everything from here back is getting cut off
At sum stage I'm gonna need to make these fit...


Went to put some petrol in today and when i undid the cap there was a huge amont of pressure in the take - It actually blew some petrol out the filler!! Best to have a quick looksee. I suspected a blocked fuel cap so i took it to bits. Its a two piece unit so it easily unclips.

Just as i suspected! Blocked hole. Though this doesnt suprise me as it was a tad dirty under the vehicle too

Bit of a wipe... Nice clean hole now

Next mission on the list is the rear tray.
I was going to do just a tube frame but the original tray has grown on me. So it'll be shortened by around 640mm and also narrowed by 220mm.

Will be driving the ute to work tommorow for its first long drive

[lincooln]

looking good scott

[PuddleJumper]

Got 90% of my tray sorted out over the weekend. Still have a fair bit to do on it. Shorten the deck sides, finish up some welding, mount the fuel filler, find and attach some LED tailights, make a new plywood deck then sand it all and paint it. A few pics.








Hope to finish this off by the end of this weekend

[lincooln]

faaaark you are moving with that project. Looking good man. cant wait to see it going

[PuddleJumper]

Bit of a update. Bought a sheet of 14mm Plywood to use as my new deck. Chopped it up and fitted it - Well sort of.. Gravity is holding it in at the moment as it all needs to come back off again as i still need to sort my fuel filler and also the taillight wiring needs to be shortened and new lights need to be installed.



Also made a start on the front of the truck by removing the bumper. Took off the swaybar too for some added wheel travel - Then cut the bumper outriggers off.

Before


After


Obviously still a bit of work to go!