hizuke project

[new2zukes]

thanks heeps for that info means i dont have to redo things:) i thought it was fine too but i just needed to make sure. im only putting a 2l hilux motor in it so not that much power. cheers

martin

[new2zukes]

well got all the shock mounts finished today, and the bump stops on the front done just need to do the back now. made up most of the brake lines to the rear took a while to work out what i wanted just need to get a t piece for the rear and the short side of the rear line. had to make a new crossmember for the rear made it out of 50mm tube 4mm thickness, hope it all works ok got about 100mm travel both ways on front and rear shocks.





martin

[new2zukes]

well didnt know what else i could do on the truck today without the body and motor so decided to paint the rear diff as it shouldnt need anymore welding done on it then went and picked up my bucket seats nice n light and compfy.

[new2zukes]

well finally it almost looks like a truck, went and picked up a mates red rust zuke body so i could go chop chop on it.

then after i sliped a few times with the angle grinder it looked like this.


and did a bit of rust repairs so that the body doesnt come off when i roll the thing and ran out of gas so just tacked everything in place and il have to finish off welding the rest next weekend.
to me it looks a little high, so more likely to go rolly down the hill, its 1770 wide and 640 to the bottom of the sills its runing 31inch tires but will be running 35s when i have some money. anyway cant wait till its done hopefull not long now all i need is the motor in and mounts all made up then just some finishing touches then gota get a cage made.
thats about all.


martin

[Bulletproof]

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.

That idea is what I have done to the hilux , except I used a coil spring and it works well.

Page 3 of" bulletproof hilux spec"shows it

Cheers Richard

[new2zukes]

well some progress stripped the motor out and put the new power plant in. first time ever pulling a motor out but it went ok. made up some mounts for the now motor and got it in the right place ( i hope) sorta looks a little off centre but truck doesnt lean to one side so it should be fine all i need to do now is find an old wreck of a hilux and steal the gearbox cross member off it so i can reweld it to the zuke chassi. thats the plan anyway.




also picked up my beadlock rings on friday just need to get a m8 to spin the rims on the lathe and weld them on.

then tonight i thought id do a bit of welding. so finished off welding the passenger floor in.

hope to get a little more done during the week but when i get home from work its dark and i just never want to do anything,

martin

[new2zukes]

well got me cage just need to glue the 2 bits together.



and also i tryed to get my 3y motor going but decided to stop trying when the carb got set on fire. i think i had all the right wires set up but if someone could confurm this that would be great.

the green plug by the dizzy has a possitive and negative hooked up and thats all, starter is working fine. have i missed something so i can get the motor to start?
hope someone can help thanks

martin

[new2zukes]

well got a few things in, got drivers seat mounts almost sorted got cage all welded in place but ran out of rods, made feet for the cage (was a real mission) got everything else just in place to see what it will look like when its done, just need to get the radiator and lpg set up then it should be a runner, well after i find an alternator and fit the power steer pump. then just gota do some tidying up and strip everything down. well a couple of pics.





martin

[meatc]

Looking good. I will drop the passenger side brackets you want off this week sometime (or maybe the whole seat). I am going to get the Vitara off Sean so dont dump those seats you got from him. Joys of kids I am going to need a 4 seater sooner or later.

[new2zukes]

yep no probs they are sitting in the hay shed, and i dont know why i took them as i dont need them as im getting that bracket off you. well its a game of shuffle the junk. anyways il drop a box round to you at some point and come have a look at the new improved buggy. well speak soon.

martin

[new2zukes]

well not posted for a while so thought id put up a little update. welded a roof on so i dont get covered in mud. put the passenger seat in put the lpg kit in which i dont know how to wire up so if anyone can help me with this that would be great, im running full time lpg.
made my trans tunel (not flash but it doesnt need to be.) mounted the radiator in the rear just need ot make some tubes to run the water mounted the accelerator pedal and cable which was a bit of a mission as i lost the original cable so had to mod a differant one to fit but it has an up idler thing in the cab so i can up the revs when winching. think thats about all i done, there is a few more bits and pieces that ive dont but cant think what they are hehehe. few pics to show progress.







martin

[tomsoffroad]

Did you sort your coil wiring?
There should be 1 wire coming out of the dizzy which will go to the negitive on the coil and to the rev counter if you have one, usually green on the rev counter. Then feed the positive on the coil some power and you'll be away.
If the carb burst into flames check you timing
Have fun

[new2zukes]

ok thanks for that info

[new2zukes]

well bit more done, got the alternator and powersteering sorted.

got a fuel injection manifold for my lpg.

cut down my doors.

got the radiator hoses from back to front used 1 1/4 inch tubing.

also have a little problem with my motor, its leaking water in a place i dont think it should be leaking from. i dont know much about motors but think it could be a head gasket and a whole in the side of the block but dont know. there are 2 caps that could maybe replaced? well any help with this would be kewl. thanks.

[coxsy]

frost plugs if engine sits for awhile they rust from inside

[new2zukes]

well thats proberly it as the motor has been sitting on its side for about 3 years . thanks for the info, do you know how to get them out as they dont seem to have any way to get them out.
thanks.

martin

[coxsy]

they are a hammer fit use a punch ans hammer maybe vise grips

[vvilly]

they are a hammer fit use a punch ans hammer maybe vise grips

many moons ago i brought a mk4 cortina on its maiden voyage it went clunk and pissed steam all over the show on closer inspection some idiot repaired the frost plug with a slf tapping screw and no more gaps its probally the most rangiest thing i have ever seen

[coxsy]

my post is for removing it, not to repair it replace with a new one

[new2zukes]

lol ye no more gaps is for rough builders ye im going to get some more some time this week.

[new2zukes]

well it has been almost 2 months since i posted an update and lilpigzuk reminded me i should proberly update so here goes.
well got the bonnet catches on and some side bars to brace the winch mount.


where the side bars mount to.(roll cage)


finished mounting the alternator and tensioner.


got the lpg system almost finished, had to mod the air intake as it was facing the wrong way for me, so did a bit of cut and welding. then re-mounted the regulator and solonoid for the lpg unit.hooked up all the water hoses that conect to the reg.




got a new radiator out of an mr2 and re set all the tube from back to front.all hoses will be covered up with roll cage padding to stop me burning myself. also a piece of panel steel will be put in front of the radiator in case it springs a leak at some point and burn the crap out of me.




remounted clutch as it was in the wrong place, first mounted it too high didnt have enough travel then too low and it was too stiff, so finaly found the mid way point. should work a bit nicer when i get my new shiney clutch in there that i got for
$90 off trademe. and strengthened master cylinder with a bit of 3mm plate.



and made a new pedle mount as i used a diesel hilux pedal as it had an idle hand controlled.


and finaly did a bit of rust repair and primed it. and cut the other half door down.


i have now decided to throw away the leafs and go coil sprung so bought a complete surf rear diff with lsd diff head for $100 off trademe already has coils setup just need to make mounts for it. and perchassed some front trailing arms and panhard rod off a range rover front end thanks to 'lilpigzuk' for this will be picking them up from 'armz' on sunday thanks 'armz' for bringing them up from aucks for me


well thats about all for now.

martin

[Heath]

I've got a set of std prado SWB springs/shocks/struts you can have for $100. I know the struts are no good for you but you may find a use for them (coil overs maybe?).

[new2zukes]

hey thanks for offer but springs and shocks are all sorted, will not have heeps of travel on the rear end so dont need that longer shock as for springs ive got rear vitara springs all round.

[new2zukes]

well got the rear suspension all tacked in and flexed up to see if its going to work. it doesnt seem to droop very far. i dont quite know why but i have a few pics of the suspension. the top arms are 550 long and the bottom arms are 916 long. the pictures are of full articulation with chassis level. i only have about 100mm droop from where id like the ride hight to be.at a guess i would say the top arms are a little too short but i dont have too much choice as i dont have slot of room. well here are the pics anyway.

[new2zukes]

well an update, got the flex sorted in the rear, this is just the rear flex.


now got the front arms sorted just need to sort the panhard rod out.




i have used a whole saw and cut out some side walls from an old tire to pack the arms out to make the axles parrallel. the left arm is only attached on one side to make flexing easyer, well all the trucks ive seen have done this so i thought id see how it goes. everything is just tacked in untilll i can see if its all going to work.

i also recieved my almost brand new lpg kit for the 3y-e manifold just need main lpg line then that can all hopefully make the motor run. i also replaced all the frost plugs as one had sprung a leak and it was just as easy to pull all 4 out. got my exaust tube (2.5 inch) now need to find some extractors and muffler.the end off the exaust will come out just behind the passengers door.

well thats all for this week, might not get alot more done till next weekend as i gota help me old man to build his house.

[Dr_PC]

Good progress Martin, Keep it up we are still watching.

[flyingbrick]

Awesome work dude

Rather than packing the bushes out with tire rubber why dont you just grind off the tacks and put the mount further forwards where its supposed to be?

Also it looks like the radius arm is going to swing up and hit the body mount?

[new2zukes]

hey thats correct it will hit the body mount but i have yet to slip in there with the grinder as i want to do most of my grinding outside as there is alot of dry wood floating around my workshop due to the old man being a joiner (well i am too but dont use the workshop for wood) as for grinding the tacks back off that was just too much work and putting 1 extra rubber behind one side was a million times quicker. oh and ive burned all the mounts in now. took a while as the welder kept overheating. well will hopefully have more done soon, might struggle mounting panhard rod due to limmited room but it WILL fit. and need to find some longer shocks than the ones i got, oh and another set of vitara rear springs.

[new2zukes]

got the front suspension done still have to finish burning it in as i have just tacked it to see if it will work. seems to work ok.




just need to make shock towers, that will be tomorrows job.

[new2zukes]

well got the shock towers sorted there is a little rubbing with the springs on the shocks but i will just make the top of the springs captive to stop this. also sorted out where im going to put the rear shocks will have to put up with the ones i have at the mo they have about 220mm travel and when i can find some longer ones at the right price i will get them.