Animal - The Project

[UBZ]

Been doing a lot of work on my Zuk, so though I should start a build up tread.

Well it all started early in the year when I was looking for a Suzuki as a daily driver so that I could take the Surf off the road for some much needed repairs and TLC.

The plan was to buy a tidy Stock Samurai and possibly look at some minor mods in the future.
Criteria were - Good runner / WOF / REG / Minor/no rust / In Budget.
After lurking on Tard Me for a month, being dismayed at the prevalent cost:rust ratio and the no WOF trend.I bit the bullet and started looking at Vitara's.
Arranged to go and have a look at a Vit in Tauranga and was told there about a 413 in Kawerau.

Ended up coming home much to my flat mates distress with this.


1985 Suzuki SJ413 JX SWB Convertible
G13a 1324cc big block, New Bosh 4's ,New leads and Coil
31x10.5 Kumhos
2" Spring lift (I Think) 1 " Shackle lift
New Shocks , Rebuilt knuckles , Super Winch manual hubs
Soft Top , Tonneua Cover, Roll Bar
Spare Motor / Gearbox / drive shafts / transfer etc etc etc etc
Current WOF and REG

Only visible rust was in the left rear corner

has a few battle scars (Adds Character)



Did a few minor mods .
Pulled out the Cargo Barrier (Can know put the Seat right back)
Adjusted the steering box free play (Was a very interesting drive home)
New Spring Bushes (Calmini - Soft like the rubber ones)
Oil Change / Time and tune up
Wired up electric fan properly (So i diddn't have to twist wires together)

Then drove the crap out of it for a couple of months.


Feel in love with the wee girl and the plans for future modifications started


Had WOF coming up so cut the rust out of rear and welded new metal in . Also tided up the body a little (Sprayed over rust patches )
Then decided that I should do something about the 2 inchs of mud in the interior , so I gave her a interior clean out and got a bit carried away.

Stripped the entire dash out, cleaned and rebuilt the air system, Got rid of all the previous owners dogey wiring.
painted firewall and made a new rubber firewall liner.

Then stripped all the old rubber floor insulation out with a hammer and chisel and found the start of some serious rust in the floor pans.
Welded new plate steel into the floor pans.

Rebuilt the dash ,stripped out the paneling in the rear and started cleaning the deck up so I could hippo line the entire tub.

Thats when every thing went to Custard.
Was driving over to a mates to do some more work on the Zuk and suddenly lost power and acquired a sound like I had a couple of big holes in the exhaust.

Nursed her home and checked and double checked all the electrics, Carb ,fuel pump etc etc etc for problems. Found none so off came the head. Found that the head gasket had let go between number 2 and 3 cylinders . Had spat a piece of gasket down number 3 and scored the bore pretty bad.
Out came that engine and in went the spare G13a (I had been told this was a runner just a little smokey)


The Zuk then sat for a month because I couldn't get the bastard to run at all. I tried every thing I could think of to no avail.
Then finally I though to check the cam position to crank and found that I was 180 deg out
Took about 15mins to fix and I had her running again.

However it didn't take long to realize that the spare motor had a nice metal on metal dinging sound coming from the bottom end. Closer inspection revealed that the big end was poked.

The Zuk then sat for another month as I tried to track down another motor.
Ended up finding one very close to home (Cheers Icekayak)
Pulled off the front clip to get the old engine out and found the start of more rust
Pulled the old engine


While waiting for my mate to come give me a hand to lift the new engine in ,I wondered what the Zuk would look like without its doors - so I pulled them off. Then I wondered what it would look like with the windscreen down - folded it down then took it off to.

Sat like that for a few days then I made the mistake of checking out the underbody for ease of cleaning/deadening. Looked like a nightmare with the body on the chassis. Only 6 bolts holding the body on.
Brian starts churning about all that rust forming on the underneath.

A few hours later .




The plan at this stage was to Strip /rust convert / paint the entire chassis.
Strip / rust convert / paint / deaden the bottom of the tub.
Re-paint body
Hippo line interior of tub
Virtual Lift
Custom Bar work
Exo cage
Gearing

Since then I have spent many hours with wire brush wheel on the drill .
Chassis half stripped and Rust converted


Will post up more pics as the revival progresses

[Dr_PC]

"I'll just do this little bit here" Famous last words and so another Zuk project starts. BUT it is starting to look a hell of a lot better and you will feel good about the wasted time when it is completed. Keep it up

[UBZ]

Chassis Half painted and new motor in place. About a third of the bottom of the tub converted and primed.


As you can see my extensive workshop is entirely weather dependent.

But made a alot of progress over the weekend.

Chassis fully stripped / primed and painted
Tub bottom about 70% complete
Fuel lines / tank re-installed and connected.
Brake lines installed.
Transfer case pulled and stripped in preparation for Rockhopper
Gears in for machining.

Found that the Jack Shalf unis are stuffed so will have to replace these.

Felt so good to re-assembly some of it instead of just taking stuff apart.

[UBZ]

Have had a productive week.
I have tried to do a little on the truck every day.


Bottom of Tub 90% Finished

Rear End all back together

Took these to the engineers earlier in the week. (410 Counter Gear / 413 Counter Gear)

Got this back

To Make this.

4.16 Rocklobster Transfer case gears 12% Reduction in High range and 75% Reduction in Low

Just pricing up all the bearings and other bits for a complete transfer case rebuild.

[Rotazuk]

I just got a bunch of bits from a place in ausie , suziestore or something . Lots of bits for suzuki's including some stuff the local dealers said did not exist

This is there site
http://suzistore.com.au/default.asp

Cheers
Chris

[UBZ]

The only people that I have found that do a complete re-build kit are Rocky Road and Low Range Offroad.
At $220 odd USD plus shipping im going to have look around locally first.

Suzi Store and Suzi Spares in Aus do re-build kits but both are missing bits.And are $250 odd AUS each.

I'm going to talk to my local parts guy tomorrow and maybe BNT as well.

The local Suzuki dealer out west is pulling his hair trying to find OEM parts for me.

[moonhopper]

The only people that I have found that do a complete re-build kit are Rocky Road and Low Range Offroad.
At $220 odd USD plus shipping im going to have look around locally first.

Suzi Store and Suzi Spares in Aus do re-build kits but both are missing bits.And are $250 odd AUS each.

I'm going to talk to my local parts guy tomorrow and maybe BNT as well.

The local Suzuki dealer out west is pulling his hair trying to find OEM parts for me.

let me know how you get on with a cost on the whole thing to build a rocklobsteer transfer

[Madaz]

The only people that I have found that do a complete re-build kit are Rocky Road and Low Range Offroad.
At $220 odd USD plus shipping im going to have look around locally first.

Suzi Store and Suzi Spares in Aus do re-build kits but both are missing bits.And are $250 odd AUS each.

I'm going to talk to my local parts guy tomorrow and maybe BNT as well.

The local Suzuki dealer out west is pulling his hair trying to find OEM parts for me.

Try Saeco for the bearings, they used to have all the bearings for suzuki gearboxes and transfer cases. (The biggest problem is finding someone in the shop who can be bothered looking up the parts.)
Also try Winger suzuki parts in Hamilton if you dont have any joy up in auckland, ask for Allan- hes worked there for years and actually knows what goes where on suzuki jeeps

[UBZ]

Got a little further during the week and over the weekend.

let me know how you get on with a cost on the whole thing to build a rocklobster transfer

I will do up a complete cost when i have all the parts in Hand.

I have sourced all the main roller bearings and seals for my transfer (Rocklobster) from my local NSK dealer (Prescion Bearings New Lynn)

Found that the main output shaft from my doner case had worn splines , so I stripped a second 413 case i got off MrO. Found this case was in mint condition, so no need to buy new needle bearings, counter shaft etc.
Will post more on this later.


Under Body 95% sealed with rubberized / rust shield paint. Just have to weld some plate for seat mount re-inforcement.


Cut the rear corner level and removed the flare mount in prep for virtual lift.


Cut out the only remaining rust from the front firewall. have still to decide how much to keep / chop for virtual lift in the front.

Spent 4 hours yesterday trying to track down 300mm of 16mm OD /2mm Wall ERW tube to replace rusted crush tubes, for my body mounts. I don't want to have to buy 5.5m of it! But no one seems to use it

Also found out that the cheap UNI joints BNT sell don't survive being installed Will have to bite the bullet and order some Japanese ones.

[2MEKE]

Spent 4 hours yesterday trying to track down 300mm of 16mm OD /2mm Wall ERW tube to replace rusted crush tubes, for my body mounts. I don't want to have to buy 5.5m of it! But no one seems to use it

Try Omega Metals in Hugo Johnson Drive...he's scrap dealer but buy heaps of damaged stock from Steel & Tube (just bought 65 ton)...might be lucky

[suzolla]

Hi,
Does it have to be exactly 16 OD x 12 ID. If not could use 3/8" (10mm) NB Schedule 40 pipe which has an OD of about 17.2mm and ID of about 12.5mm.
How long do the pieces need to be, I may be able to find some at work and post to you.
Other option is to drill some bar in lathe.
Let me know if the pipe would be okay and I have a look.
Is it going to be welded in or just a loose spacer tube, if loose could use some galv pipe.

Tim

[UBZ]

Try Omega Metals in Hugo Johnson Drive...he's scrap dealer but buy heaps of damaged stock from Steel & Tube (just bought 65 ton)...might be lucky

Cheers , going to see them Saturday morning. To look at 65T of scrape.
Prob come home with a bit more steel than expected

Hi,
Does it have to be exactly 16 OD x 12 ID. If not could use 3/8" (10mm) NB Schedule 40 pipe which has an OD of about 17.2mm and ID of about 12.5mm.
How long do the pieces need to be, I may be able to find some at work and post to you.
Other option is to drill some bar in lathe.
Let me know if the pipe would be okay and I have a look.
Is it going to be welded in or just a loose spacer tube, if loose could use some galv pipe.

Tim

Pieces are only 30-40mm long?? (Cant find rule)It defiantly needs to be 16mm OD . 12mm ID as the sleeve sits inside the rubber body mount, and the bolt is welded into the body. (See left of pic Below) Don't want any slop.Galv would be better as no rust.Checking on a stainless option thru a mate.

[icekayak]

May be interested in a set if you end up with too much tube
From memory the ones off the black convertible weren't flash... But don't want to spend much.

[UBZ]

May be interested in a set if you end up with too much tube
From memory the ones off the black convertible weren't flash... But don't want to spend much.

I bit the bullet and went and bought 5.5m from Steel and Tube. only $25 Got plenty if you want some. Is also the same size as the crush tubes in the spring bushes

Bit of an quick up date from the weekend.



I got the tub back on
Fire wall painted and loom back in. And started eyeing the cuts for virtual lift.

its amazing how encouraging it is to see the tub and font guards on again

[turoa]

Looking good. its always cool to put all the big stuff back on

are you going to chassis mount the cage?

[UBZ]

are you going to chassis mount the cage?

Roll bar is only on their for looks at the mo.
Will be going in the bin eventually. (Worst looking crush bends i have seen in a long time).

Plan is to build a full chassis mounted exo cage / front /rear bars for it. To protect my nice panel and paint work

[mudzilla]

Good work Chris..U've been busy..Bring it down when your finished..

[UBZ]

Current progress after the weekend.


As it is at the mo


Inside of tub all ready for hippo liner


Cut started for rear virtual lift.


Cut started for front virtual lift


Another view showing the clearance gained


Comparison of uncut side.

Have done a little more to the drivers side front guard, have removed battery tray and air box brackets as we want to lift the whole inner guard up for true virtual lift in the front.

Will post some more pics when I have them.

C.

[UBZ]

half update. Damm rain stopped us in half weld
The joys of an outdoor work shop.


cut the inner guards from the outer last weekend. Ground off all the unnecessary brackets and crap and cleaned and painted them up.


Outer lip of inner guard. 30mm of outer guard that was left over from the virtual lift has been ground off at the spot welds.
This should retain all the integrity of the inner guard.


Out guard fully cut ,painted up and ready to be married up to inner.


Close up of front cut showing the line we took.


Firewall Massage to match guard cut line.

Today we welded up the firewall and played around with the inner guard placement until we were rained inside.

[UBZ]

Bit of a update.Have been slack and not posting up my progress. Camera is playing up so will post pics when i can retrive them.

Have been slowly ploding away at it when time permits.
Hippo lined the interrior. (what a distaster) . Hippo liner lifted in serveral places lifting the ech primimer off the bare metal. Must have been dirty or something just diddnt like something else. Have lernt my leson though and will be getting it done by the pros next time. Have used under body paint to try abnd cover it up a little. Will have to re-do it all in the future some time.

Rebuilt and installed the dash etc.
Finished the engine pumbing.
Spent a day breaking my head trying to get it to start.
Helps when you wire up the coil properly.

It Runs.
Sounds good to , needs a tune and a little tweaking here and there , but a shite load better than the last one.

Started running cable for rear mounted batterys. Designed the dual battery / winch and electrical system.

Virtual lift is progressing.
Firewall cut and massaged on both sides to match the new guard line. And welded up.
Still need to cap the ends of the rocker panels but have a plan for this know.
Inner foront guards have been re-attached to the outters but 30mm higher and all welded up.
Have to block a few samll holes and all done.
JUst need to start on the rear know

New Air box location sorted and everything fits. Just have to fab up some brackets.

Just about finshed assembying the Rocklobster , only have to sort out the hand break know. and then i will have a drive trian agian.

The list of jobs grows longer, as the urge to drive her grows stronger.

[Big-AL]

and...

* Get clutch cable back of Big AL

[UBZ]

and...
* Get NEWclutch cable from Big AL

There you go mate I fixed it for you

Hit a bit of a snag last night wit the re-assemble of the rocklobster.
It seems that someone has been little to persuasive with the end of the thread on the parking break output shaft. (Probably me ).
Destroyed 3 nuts trying to make it work. Need to go and find a large M14/M16 die tomorrow and re-thread the shaft.
Always the way. the last nut or bolt won't go on

Anyone know where I can get transfer case flange nut from here in Auckland? Or I might just have to rob one for the spare parts pile.

Rocklobster seems to be working fine. shifts gears sweet and is alot quieter than the stock 413 transfer i pulled out.
Definitely worth following the re-assembly instructions in the workshop manual as I found out. The transfer has to re-assembled in a particular order for it all to go in right. I had to go backwards a few times because I thought I knew what I was doing.

[UBZ]

Current progress . I have a new work space . Neighbors boy racer son know has to park his POS civic in the rain so that the carport can be used for (quote her words)"a more serious project"

Front virtual lift progressing well. Main inner guards welded up. Still need to patch up a few holes and mount flares.

Another view of the clearance gained.

Weld line we took up inside of guard

Rocklobster all finished and installed.

Jack Shaft re-built with new uni's. Gear box oiled up and drive shafts installed.

Run Battery Cables run into the rear. Crimped them off and temp connected. Want to add proper isolation and rewire some engine wiring.

Used electrical cable glands to go through the firewall.

New rear brakes, new front brakes. Re-installed Master cylinder ,new fluid and all bleed up sweet.
Also hooked up the the Transfer handbrake setup.

Samurai diffs getting ready to go underneath.

Took her for a drive yesterday. Just up a street a little.
First time in a long time.
Motor is a little smokey and tired but still has power.
4.16 Transfer Case gears are awesome. Was having fun just idling around the place in 1st low.

Just need to finish the body work , paint , and sort all the little jobs. Like WOF and electrics
Them start thinking about bar work.

[Helga410]

All we need to do is chop the back guard up and re weld to match the evil looking front clearance
Don't worry, while you are away, I'll look after (part her out for my truck) her!

[UBZ]

Small update.

Have been working on the rear virtual lift as time permits.


Cut 30mm from the outside panel and removed it by grinding out the spot welds. Done this to both sides know.

Used persuasive panel beating and a couple of small cuts to marry the inner guard to the new outer line.
Started to weld it up but ran out of gas.

Trying a 33 for size. Should be plenty of room to run the 32's I want to use.

[Dr_PC]

It's getting close to being able to use in anger keep it up, Sounds like a good neighbour as well

[UBZ]

It's getting close to being able to use in anger keep it up, Sounds like a good neighbour as well

That's what Ive been telling myself for the last 3 months be finished soon keep finding stuff to do.

[meatc]

That's what Ive been telling myself for the last 3 months :roll: be finished soon keep finding stuff to do.

Is that all Mines been off the road/track for nearly 2 years. All things going to plan will b back in the mud this weekend (if it rains some more) and it still requires paint winch and the other nice to have stuff.

Youre smokin and should have it well finished by the time the rain and mud returns for winter.

[lilpigzuk]

Rocklobster all finished and installed.

Look at putting some strengthening ribs in your t/c arms. With a rocklobster they will get a heap of extra torque applied too them and end up twisting.





Not mine but only pics I could find on outerlimits. Strengthening the arms will put more pressure on the rubber mounts so keep an eye on them, I see Jafa does beefed up rubber (solid) mounts for zuks

Didnt do it to lilpig, but 410s have a shorter right hand arm so it didnt twist the arm, but looking at the actual chassis mounts when I pulled out t/c they are well bent and rubber mounts were shot.

[hitbiga]

Nice work chris, ive got the steering for samurai diffs off finally so hopefully next week i can get them 2u.