hizuke project

[new2zukes]

well dint do much on the zuke this weekend just had a good cleanout of the shed and cut some driveshafts up with the old hacksaw. i have a few little problems to sort out that i might need a little bit of expert help thats anyone that reads this:) well i tryed to get the brake lines off so i can fit some longer ones that i dont currantly have but the bloody thing wouldnt budge even tryed the gd old pipe wrench thing. anyway stopped with that or id end up throwing it on the floor and braking something. layed all the driveshafts on the floor trying to work out what im going to do for the front. all i need to know is how far the slip joint should go in when the truck is sitting on level ground then i can work out how long to make it.

i will be glueing the hilux one with the star next to it onto the the sammy one with the star next to it with a piece of tube sleaved to make it a lil longer.
and i have decided the steering box out of the hilux will be a bit too much work to make it fit so im going to the local wreckers to pick me out a power steer box to suit need one that hasnt got a drop pitman because when she flexes the springs will hit the steering box.
if you think any of this will not work please say as i really dont no much about this stuff.

cheers

martin

[toysuzi]

what i have done
i have not got a good pic of it done
but used 3mm plate welded on to the chassis and fitted crush tubes and bolted it on

got the power steer box and found the pump and mount
but still need to find were i put the pullyes.

I had to take the frount clip off again and cleaned
up the front of the chassis to mount the box
also using a Daihatsu pit man arm as is a lot flatter

[new2zukes]

cheers for that info, what daihatsu did it come off? feroza? how did you manage to get the pitman arm off as they will proberly be stuck on there pretty good. thanks

martin

[toysuzi]

rocky
and a puller and gas

[new2zukes]

well got a little done last couple days nothing seems to be going right though. welded a little bar to get my wheels lined up only temperary of coarse so i could get the box mounted and get it all working.

then drilled the holes for the box as far over as i could it isnt going to be far enough though as it hits on where the springs are mounted and the pitman arm hits on the tierod. so i cut and welded the arm for temperary messures so i can try find an arm short enough.

then got a piece of 3mm pl8 and drilled the wholes for when i can get hold of some crush tube.

and the draglink in the pic below shows that when it flexes upwards the rod will hit on the chassi as the end has to be ontop of the hi-steer arms because of the tappered whole. would be better if it was underneith.presume i will just have to set the bumpstop accordingly so the rod doesnt hit the chassi.




cheers
martin

[new2zukes]

well got in the shed for 5 mins tonight after getting some steel. welded the hilux side of the front driveshaft.



a little question before i stuff things up, when i get the length for the d/shaft do i make it so the truck is on flat ground and put the slip joint so it is exactly in the middle? should the slip joint have even movement front and back?



and some steel for the tierod.



cheers

martin

[new2zukes]

well almost to the stage i can actually drive my truck got the front brake hoses in nice and long might have to use some cable ties to stop wheels rubbing on them. will be getting rear lines tomorrow and hopefully my p/s box.

got my rim centres cut out and rewelded in a little back now my wheelbase is 1760 wide just went out and messured my trailer and thats also 1760 so she's going to be a tight fit.
thats about it for now.

martin

[new2zukes]

well a little done today, had to do a bit of asking around to find out how to do my driveshaft length but got it in the end by flexing it and messuring the movement in the slip joint amazingly it only moved 10mm's either way.. so i put the slip joint exactly in the middle. so now its all welded up i have 4wd thats about all .


martin

[GotFlex]

how bout usesing a 80 series pitman arm its flatter, i have one that i was goin to use. ill try get a picture

[new2zukes]

hi thanks for the info but im guna go with a vitara box now. i cant get the hilux box back far enough so the pitman arm doesnt hit the tie rod and i presume the 80 series is about the same length pitman arm.

cheers
martin

[new2zukes]

well got my power steer box out of a vitara, its a little off center as the pic bolow shows but i was going to fix this by making a wedge shape piece of steel to bring it back in line then crush tube it on an angle.

then its the pitman arm, its angled so il just pull it off which should be a little struggle then put the original sammy pitman arm on thats straighter.

all i need now is a power steer pump i already have the fluid lines.thats about all .

martin

[new2zukes]

well finally some progress, i have got the vitara box mounted on a bit of an angled wedge have welded up a steering rod from box to steering arms have welded the steering shaft up and all i need now is to get a power steering box off a vitara then i will have power steering:)


got the truck running today and moved it 1 foot forwards but have no oil in diffs so couldnt go too far.

thats about all.


martin

[new2zukes]

well got a bit more done today, i put crush tubes in the steering box just need to get a longer bolt for one of them as i had to mount the box on an angle. started welding the plate below then one if the wire feed gears sheered a few teeth so made it very hard to weld anything so have ordered a new one.

flexed it up to try get the shock mounts right but need some longer shocks as it will bottomout before it hits full flex, they are hilux fronts in pic which are a little longer than the zuke ones i got. but might have to make do for now and just put bump stops a little lower.


well thats about all for today and i gota cut firewood for parents tomurrow so prob not much goin to happen till next weekend.
also mounted the steering dampner but didnt take any pics of that.


martin

[new2zukes]

well tryed to put photo on as usual but now it says that it is too big whats the problem here? it was fine before the revamp of the site. has the pic sizes changed or is it just me? its a little hard for someone who is computer challenged to resize when i have put it on photobucket can someone please help.thanks..

martin

[UBZ]

Re-size the pic to 640x 480 with Microsoft Office Picture Manager (Picture tab / re-size) or Inframe view or similar program before you upload to photobucket.
Then everyone can view the full pic with out scrolling etc..

Hope this helps

C.

[new2zukes]

thanks UBZ got the pics sorted will have to resize them from now on. cheers

martin

[new2zukes]

well got a fari bit done today, i did alot of grinding, grinded the other side of the shock and bump stop mounts. then made a bar up for the front to make things a little firmer when i drive into a tree or another truck



but while i was grinding i slipped and cut a bit out of my powersteering lines, so i though hole + welder = fixed. all i want to know is is this ok?


finished welding the steering box mounting point.

here is a pic of the steering dampener i did last weekend.



also i forgot to turn the gas on before i welded one of the brackets the left weld is without gas and the right is with. i dont see the difference, can someone shed some light on this please. what if i dont weld with gas?


then i got a bit carried away with the grinding (like you do) and cut the rear guard off as it was rusty anyways but went a bit far and cut inside the guard so its a bit drafty in the back but its going to get chopped or have a vertual lift at some stage anyways.

thats all for today hopefully more tomorrow.

martin

[vvega]

in regards to the p/s line
better to get a joiner .. if it s on the pressure side you may have blocked the tube and if there was ANY oil in the tube you will have pinholes ..
if its on the return side and you have to much penetration you may develop pressure in the line resulting in blow seals and or a ineffective p/s unit .. its the pressure differential that makes it all work ..
also .. if you got any scaling inside or grindings from the weld and that travels into the box your box could well seize up or eat itself

worse case scenarios .. but all avoidable with a proper hydraulic joiner

hop that helps ... wayne

[suzookyman]

hey that pump you want has still got p lines attached so
all good just bolt it up-sweet
Al

[new2zukes]

thanks for that info shud have asked before i pulled the trigger i supose, you dont know where to get hydro lines joined do you?

cheers

martin

[vvega]

fluid fittings in auckland .. but any hose doctor can help

[new2zukes]

hey that pump you want has still got p lines attached so
all good just bolt it up-sweet
Al

ah kewl that will be the better option il just use the one i welded as parts incase a hose springs a leak at some point.

cheers
martin

[new2zukes]

well plans have changed once again, speaking to a few m8s i am selling my white zuke body to a m8 and im going to have his zuke body that he roled a few weeks back. im going to chop me m8s roled one so there is only a and b pillars no roof or windscreen then build a cage around that. and as for the motor another m8 has a 3y motor box and t/case sitting around so i should be able to pick that up for cheapish, aparantly it just needs a little attension but he said he will help me out with that so all should be go now. pic of zuke without body lots easyer to see what im doing.


martin

[new2zukes]

well got the shock mounts made today but havent welded them on to chassi as it might make putting the new motor in a little more interesting.



got the power steering pump off 'suzookyman' so thanks al for that.

finished making the rear traction bar took a while as i didnt have a mig enough drill bit so went to my work and used the bosses drill press. hope it all works:)


martin

[MNC]

martin

Hi Mate,

Where did you get that traction bar from and mind me asking how much it was?

Cheers,

[vvega]

needs a front link on it of it wont work properly
mnc in about to start making one for mine .. want me to make you one as well ?

[kaney]

martin

Hi Mate,

Where did you get that traction bar from and mind me asking how much it was?

Cheers,

it looks alot like a top linkage for '3-point linkage' on a tractor?? correct?

[Heath]

just as an aside hasd anyone mounted a third leaf spring set up instead of a track bar? Up high enough it should move in the same arc as the others and allow the others to be lighter (vehicle weight carried by three springs), therefore more flex and the geometry should hold the diff in the same plane of movement.

Just a thought.

[new2zukes]

needs a front link on it of it wont work properly
mnc in about to start making one for mine .. want me to make you one as well ?

hey what you mean by a front link?

martin

Hi Mate,

Where did you get that traction bar from and mind me asking how much it was?

Cheers,

its a tractor linkage about you can get one from any agricultureal store. i think. strong as .

martin

[DieselBoy]

Nah, that should be sweet martin.

The rotational axis during axle wrap is the center of the axle shaft's.

Therefore the top of the diff head has to either move forwards or backwards to allow wrap to occurr.

By positioning the bar on the diff head where you have, you have stopped its ability to move forwards, or backwards, therefore stopping the axle from being able to wrap.

It'l be sweet.

Some run a triangulated anti wrap brace, with the another bargoing to the base of the diff head. Its not neccessary to stop wrap, but what it does do is share the load between the top and bottom mounting points, rather than all the force going through just one. Important if you have high Hp.