I was looking around on the zuk board a few months ago and saw a thread about someone putting a toy d-train in their zuk. The tranny tunnel had to be modified to fit the larger tranny tcase. The guy did a really nice job. It looked like he used stealth technology, know which one I'm talking about?

I'm planning on doing a 3" drive train lift in my 85 Runner with no body lift, and was wondering what material he used. I was thinking maybe building the new tunnel out of some heavy card board and fiber glass the whole thing. I've only worked with fiber glass once, to do a small repair on a boat. Any suggestions on materials? What type of fiberglass is best? How thick does it need to be?

thanx...

http://www.pirate4x4.com/forum/showthread.php?s=&threadid=12320&highlight=tunnel


That is the post you are refering to. He used foam core. Great job it looks like.

That's the one, thanks....

No problem. Glad to help.

It was me...I used foam core, which you can get from artist supply stores. I used 3/16ths thick stock and joined the panels with gaffers tape (get it at the art store too). When laminated foam core is REALLLLLLLY strong. You can avoid tape if you score one side (dont cut all the way through the fc) and use the outer paper to make the joint.

I also used gaffers tape to transition from the tunnel to the floor so it would be air tight, then made about a 1 inch tape border that would be a mounting flange. Then I glassed to the outer edge of the tape. This way the glass will stick to the tape, but not the floor. The tape will work as a release agent when you lift off the tunnel. Do at least two coats in the car before you try lifting it out. Use a sharp putty knike under the edge to work it loose.

I used epoxy resin and s glass which are more expensive than polyester resin and regular glass, but way more durable. I glassed it insssside and out, three layers each If you havent done much with glass, TAP plastics has good pamphlets. The secret is lots of prep (prefitting the fabric etc) getting a flexible fabric that conforms well, and using as LITTLE resin as possible. I would practic on something on your bench before you went after that hard to make tunnel.

OR I could get a mold made of my tunnel for toy and kick tranny people if there was enough interest??? Then you could just screw it on, trace the outer edge, take it off, cut out your tunnel 1/inch insde the line and screw it back on!

DAMN that was long!!!! :eek: :eek:

Swawfish When putting in the Toy tranny how did you get the clutch to work is it still cable (stock zuk) or what Thanks

I can answer that question for you, I'm the person who supplied the adapter to mate the 1.6 to the Toy tranny. You use the stock cable setup along with a stock throw-out bearing (that is slightly modified) inside a stock 1.6 bellhousing. Also the clutch disc needs to be modified a little and the pilot bearing needs to be replaced with one that is the matching diameter of the Toy input shaft. The modified clutch disk, throw-out bearing, and pilot bearing can be provided along with the adapter if you desire. Kerry @ SOS

BTW-You can see the finished tunnel at www.sonic.net/jkwaters/scwafish.htm and the whole toy tc install should be on the ORC suzi page on Feb 1.

Thanks scwafish, that's some great info. Looks like I'll be making a stop at Hobby Lobby. Now to just figure out what to do with my gas tank...

I'm not sure if it's my system or the link to your pics, but it froze my system twice:( so I couldn't see the finished pics.

Originally posted by kerry1.6-toyota
I can answer that question for you, I'm the person who supplied the adapter to mate the 1.6 to the Toy tranny. You use the stock cable setup along with a stock throw-out bearing (that is slightly modified) inside a stock 1.6 bellhousing. Also the clutch disc needs to be modified a little and the pilot bearing needs to be replaced with one that is the matching diameter of the Toy input shaft. The modified clutch disk, throw-out bearing, and pilot bearing can be provided along with the adapter if you desire. Kerry @ SOS
What if he was askig about using an ALL toyota drivetrain in the Sammy? Not just throwing in the tranny and cases? I think that's the way i will go when I throw my drivetrain into a Zuki. Maybe replace the stock pedal and cable with a circle-track hydro setup?

If all Toy drivetrain, install becomes simpiler except for the weight factor of the Toy engine, but it's not that big a deal. In fact I am in the process of installing a Toy drive train, w/ dual cases in a Sammy as we speak.....hopefully if the client gets his finances and parts hunting going a little quicker it will be rolling by March. Kerry

Since its still a toy tranny either way your gonna have to cut the tunnel.

;)