SJ413 Ute Build

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PuddleJumper
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SJ413 Ute Build

Post by PuddleJumper »

Having looked at all the Zuk builds on here i thought it was time i started mine.

After having a few (410/413) ZUks over the years (including a coil sprung 410) then a Escudo i've decided i wanted to get back into a SJ.
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I'd always been impressed with a friend of mines SJ413 LWB Ute which had been fitted with a Toyota 1NT Turbo Diesel engine, 32x9.5" Swampers a set of Calmini Transfercase gears and a Lockrite in the rear. That thing went pretty much anywhere he pointed it!

There not that many built LWB Zuks about compared to SWB's so a plan was hatched.

I wanted a street legel SJ413 LWB Ute.

I Picked up this 410 on Tademe - It has some bad points: Its a 410 so smaller CV's, Different chassis to a 413, Not registered. It did have one MAJOR good point.. It has a full fibreglass cab!! No more rust.. EVER
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I started collecting bits for it which included some live plates off another truck (which i still have) and also went halfs in a SWB 413 - I wanted to use the 413 running gear. After i picked the truck up it sat for awhile - (Buying a house got in the way of its progress)

Not very long after i'd moved to the new place i noticed another Zuk ute up for sale. This one had a current WOF and rego and was bone stock, so i raced up north and grabbed it - it will be a lot less dicking around at the end of the day and a lot less work.
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So heres what i'm after.

SJ413 LWB Ute
1600 16Valve EFI Escudo Engine
External cage, Bullbar, sidebars etc
Rear locker - Lockrite or perhaps Airlocker?..
Rear mounted winch
31" Silverstones - I already have these
Cut the front gaurds for clearance
Powersteering
Rear tipper tray??
Rear disc brakes
and a few other bits'n pieces

First things first the WOF was due in a month and the was some rust in the top of the passenger side A piller and also the front gaurds had rust around the bottom edge where they all go. Didnt look to bad until i started cutting it out.
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Once the rust was fixed it sprayed it with primer paint. Also added a logo from another brand of vehicle which i think looks good - Who can guess whats its off??!!
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Now for the very first MOD!

The motor and gearbox were noisey and the engine used more oil than fuel. No matter though i had a spare one of each in my spare parts deptment ;-)
They had been sitting in a wheel barrow for around 18 months but not long before that i rebuilt them both so i knew they were in good nick.

In they went during a long weekend - much nicer to drive on the road now for which i did for a few weeks... and so quite;-)

The fuel gauge had been playing (not reading all the time) and the utes dont come with a rev counter.. Gotta hav a rev counter ;-)

I have a spare speedo cluster in my spare parts department (my shed) so i removed the old and put in the new - 100% plug n play - I now a rev counter and a working fuel gauge - Though my milage did instantly increase by 5000Ks :(
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WOF time - It failed but only on one thing

It seems the rear wheel bearing had almost collasped. Had about 10mm of play at the wheel - odd because it wasnt noisey and no oil leaks.

But worse was to come... When the WOF man started the truck it was running on 3 cylinders and puffing out large clouds of steam out the exhaust also the smell of Antifreeze was apparent. ARSE! That 18 months of sitting in a wheelbarrow probably didnt do it much good it would seem:-(

Its still drivable and the engine still runs on 4 ok when cold but once up to operating temp it runs on 3 at idle. Oh well that means the engine swap will have to happen sooner rather than later.

With the rear wheel bearing needing replacment for the WOF i've decided to do the rear disc conversion now as the axles have to come out anyway.
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Dr_PC
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Re: SJ413 Ute Build

Post by Dr_PC »

Subscribe to this will be checking regulaly on updates. Expect to see it out competing when?
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Heath
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Re: SJ413 Ute Build

Post by Heath »

Dr_PC wrote:Subscribe to this will be checking regulaly on updates. Expect to see it out competing when?


Shouldnt be more then a couple of weeks before its completely finished eh Scott. :wink:

I must admit I like the idea of a LWB 413 with a 1600 donk. Maybe a project for me down south in my new garage... :?
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Rotazuk
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Re: SJ413 Ute Build

Post by Rotazuk »

Nice , will have to keep an eye one it .

So how many people have lwb suzuki's with a 1600 sitting in there shed's :)

And what are you doing with the fibreglass 410 with plates , hmmmm .

Cheers
Chris
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lincooln
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Re: SJ413 Ute Build

Post by lincooln »

Nice to see it up on here Scott. Looking forward to the finished product. If you ever need any help... :wink:

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UBZ
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Re: SJ413 Ute Build

Post by UBZ »

LWB Zuks rule. 8) 8)

I've got one in bits behind the shed :roll: :lol:
LR110 ..... LJ50 project :roll:
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lilpigzuk
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Re: SJ413 Ute Build

Post by lilpigzuk »

Rotazuk wrote:So how many people have lwb suzuki's with a 1600 sitting in there shed's :)

Cheers
Chris


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:oops:
Good work Scott. Should really get mine finished.......
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Subscribe to this will be checking regulaly on updates. Expect to see it out competing when?


Might be a little while off yet Dan so many things to do.. Doesn't have a very good turning circle i noticed though - Not very good for getting around red and yellow coloured pegs! :wink:
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

And what are you doing with the fibreglass 410 with plates , hmmmm .

Quite possibly will be up for grabs. Was toying with the idea of just keeping the cab as a spare for when my current one rots away (as they do)
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badnuz
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Re: SJ413 Ute Build

Post by badnuz »

hey scott welcome back to SJ land :)

must get out to the shed and make sure mine still starts lol!
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pruggerdore
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Re: SJ413 Ute Build

Post by pruggerdore »

Why are you not using the fibre glass body?. thats the best bit in my eyes. not a suzuki man but a completly fibre glass body gets my interest. are they after market.? are they lighter or are they heavily built (thicker)?
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Why are you not using the fibre glass body?. thats the best bit in my eyes. not a suzuki man but a completly fibre glass body gets my interest. are they after market.? are they lighter or are they heavily built (thicker)?


Theres a few differences between the 410 and the 413 cabs. One is the better dashboards in the 413 - However this can be retro fitted into the 410 also the transmission tunnel is smaller on the 410. Dunno if this would really cause any clearance issues as I've not checked. Just a whole bunch of extra work for which I'm not keen on doing at the moment...

This cab came from

http://www.4wdfiberglass.com/

Looks to be well made and strong - It is quite thick so weight wise there probably not much in it.
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Drurban
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Re: SJ413 Ute Build

Post by Drurban »

Hey Scott,

Starting to look good, looking forward in the finished result.

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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Righto first proper mod

I hate drum brakes. First puddle you go through they get wet and stay wet and once mud and crap gets in there that just acts as grinding paste. So I grabbed one of Bens disc brake conversion kits. I had the first rear disc brake conversion kit he made for the Escudo/Vitaras and had no issuses with it at all so i happily grabbed one for this truck - All his stuff is very nicley made.
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With the axles out I installed the new wheel bearings using two special service tools :wink:
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Found a bunch of genuine Suzuki seals I've had since god knows when! But I used the ones that came with the kit anyhow.
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With the axle fitted the calliper mounting bracket is fitted along with the brake hose bracket.
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Next up press the new wheel studs into the wheel mounting plate and bolt the on.
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Now you gotta make some new brake lines - I reused the R/R line as it only needed bending at the calliper end and a new flare where it meets the 'T' junction. Made a new one for the other side though.
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This is where i forgot to take a couple of pics :oops:
I had a Wilwood adjustable proportioning valve floating around so i put this on and made a couple of new hardlines to suit.
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Lastly I bleed the system with some nice new brake fluid. A quick drive up the road i came back and rebleed the system to get the last bits of air out. Once done i went for a half hour drive about the place and along some quite gravel roads so i could jam the brakes on to set the brake balance up ok - some fine tuning may be requiried but it seems very good now!

All in all a well worth while exercise as my truck now stops on a dime and no more crappy brake shoe adjustments! 8)


I got another conversion kit at the same time as this one. It looks like this..
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And also involves one of these..

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:mrgreen:
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Dr_PC
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Re: SJ413 Ute Build

Post by Dr_PC »

Maybe you should get Rex around to dampen down your enthusiasm a bit, You are screaming along.
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Maybe you should get Rex around to dampen down your enthusiasm a bit, You are screaming along.


:lol: :lol:
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lilpigzuk
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Re: SJ413 Ute Build

Post by lilpigzuk »

Dr_PC wrote:Maybe you should get Rex around to dampen down your enthusiasm a bit, You are screaming along.


Image Hows your buggy build coming along Dan :mrgreen:

Goddam, I have ALL those parts you've shown on my bench :cry:
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Rotazuk
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Re: SJ413 Ute Build

Post by Rotazuk »

When you get to taking out the vss from the speedo take all the tabs and screws from the vitara , not just the vss , and take your old inst cluster off tard me and take out a couple of light assys . Then you can use the factory tracks on the cluster wiring for the vss and engine check light .

Think I took pic's of rex's one , see if I can find them . If not get him to take a couple of pic's .

Chris
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

When you get to taking out the vss from the speedo take all the tabs and screws from the vitara , not just the vss , and take your old inst cluster off tard me and take out a couple of light assys . Then you can use the factory tracks on the cluster wiring for the vss and engine check light .

Think I took pic's of rex's one , see if I can find them . If not get him to take a couple of pic's .



Thanks for the info Chris - I recall you telling me how you had done Rex's dash at the last fun rally. Yeah a picture would be cool. Not looking forward to doing the wiring to be honest... Not the most fun one can have.
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Dr_PC
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Re: SJ413 Ute Build

Post by Dr_PC »

lilpigzuk wrote:
Dr_PC wrote:Maybe you should get Rex around to dampen down your enthusiasm a bit, You are screaming along.


Image Hows your buggy build coming along Dan :mrgreen:

Goddam, I have ALL those parts you've shown on my bench :cry:

Yeah yeah ok, I have bought the paint.
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Didnt get much time to play with the truck this weekend so not alot done.

Started to strip some parts off the engine for easier removal - This thing has had a fairly hard life with the last 7 or so years having been spent all off road so every thing is caked in mud and clay!

Got some bits of the engine off and labeled a few the electrical bits which will make it a bit easier when trimming down the loom.
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Evidence of its hard life... Check out the front crossmember and also the the crossmember under the diff - Wondered why it didnt handle so well on the drive home :shock: :mrgreen:
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More progress next weekend with a bit of luck :D
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Small update.

Spent most of this weekend getting the motor and loom out of the donor truck. Every bolt seemed to be super tight! Borrowed a engine hoist which makes life SO MUCH easyier :D

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Stripped about 95% of all wiring out of the truck too... also labeled everything for easy identification for the next job of timming it all down.

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Also took the fuel tank out. Still undecided if i should use this or use my stock 413 tank with a external high pressure fuel pump..
As a bonus the tank was 3/4 full of gas too :D
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Bit of a update..

With the engine out i pulled the sump and oil pick up off. I had a spare buggered 413 motor so i grabbed the oil pickup off it to modify and also the deeper sump to use.
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Once the (Escudo/413) pick up was welded back together and sump put back on I thought i may as well change the cambelt whilst the engine was out as i dont know if its ever been changed in its life...
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I bought a bunch of parts including the cambelt, tensioner, waterpump, Cam/Crank/Rear crank seals and the rocker cover gasket set. Tidied up some of the bits with a bit of a repaint - Anyone know of any good cleaners that will take rust stains off alloy??
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Now for the part I've been putting off.. The wiring!
A quick chat to Ben whos done a few of the looms before reckons there not to bad - Just gotta take my time. I started on getting most of the insulation tape and plastics covers off - Over this coming week I'll try to do a bit more each night.. I had thoughts of plonking it in my lounge and doing it while watching telly.. :wink:
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Dr_PC
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Re: SJ413 Ute Build

Post by Dr_PC »

thoughts of plonking it in my lounge and doing it while watching telly..


Always the best idea, use to lap valves on holden heads in the lounge
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Heath
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Re: SJ413 Ute Build

Post by Heath »

Worst part by the look of it is the tape is gone. Found that to be the biggets pain in the arse. once its gone you can take it down to almost nothing. That's from the fuse block that is. The engine side needs almost everything... :mrgreen:

Have fun.
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Heath
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Re: SJ413 Ute Build

Post by Heath »

here's a good link to the eletrikery stuff.

http://www.suzukiinfo.com/vitara/wiring ... g16a-b.pdf

Best one i could find when I did mine. I blew it up to A3 and laminated it (cant find it now).

It shows all you need to get things going and if it isnt on here then you dont need it. Unless you want more stuff of course.

I got a cheap fuse box (4 fuse one and only needed 3) and put that and the ECU in a click clack container up under the dash where the heater was.
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PuddleJumper
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Re: SJ413 Ute Build

Post by PuddleJumper »

Some more progress...

Time to say goodbye to the old engine...
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Got it out in about 1 1/2 hours - Worst part was trying to hook up a anchor point to attach the pulley block too.
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The new engine went in VERY easy. Zuks are always so nice to work with :mrgreen:

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I'm gonna run the original radiator to see how it copes for the moment. I have the original Escudo radiator if i need it but I'm being lazy :roll:

Managed to get all the cooling plumbed up, Sorted out the accelerator cable and a few other minor bits 'n bobs. Still got the wiring to deal with - This is all currently spread out all over my lounge floor. Also I need to mount the Escudo fuel tank and get the exhaust sorted out.

Gonna have to modify the bonnet with a scoop to me thinks!
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lincooln
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Re: SJ413 Ute Build

Post by lincooln »

looking good scott
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Dr_PC
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Re: SJ413 Ute Build

Post by Dr_PC »

Coming along nicely
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Re: SJ413 Ute Build

Post by zukmeista »

Selling the tyres on the vitara?
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