My crap is finally coming together <-- insert joke

Beat the thing up bad last wheeling trip before winter so decided to do a small rebuild.

http://img205.imageshack.us/img205/7189/dsc00494copytq2.jpg

1) New YJ hybrid packs in the rear
http://img522.imageshack.us/img522/5623/dsc005509903629hi0.jpg
2) built new transmission crossmember
http://img518.imageshack.us/img518/6284/dsc008090485804qe0.jpg
3) Stretched the front 10" using Toyota rear springs
http://img518.imageshack.us/img518/2512/dsc005529914016mk9.jpg
http://img339.imageshack.us/img339/9984/dsc007854147661qg1.jpg
http://img265.imageshack.us/img265/8674/dsc008184217524dz7.jpg
4) Swapped in 1.6 8v EFI, wiring wasn't as bad as I thought it would be
http://img68.imageshack.us/img68/8777/dsc008551194698dr3.jpg
5) Skinned tailgate with tread plate and made it fold down
http://img355.imageshack.us/img355/6325/dsc008673318548hz9.jpg
6) Currently working on finishing the Astro Van steering box mount.
Had to move the radiator over to clear it.
http://img84.imageshack.us/img84/2177/dsc00478nq9.jpg
http://img504.imageshack.us/img504/7771/dsc00491al2.jpg

Sitting as of now, yeah I know BFG muds gay, got a good deal on them
http://img355.imageshack.us/img355/165/dsc008633275963bo3.jpg

Just need tube work, roll cage and finish some small crap then I'll be wheelin.

You might find that you will bend the main leaf on those springs at the clamp closest to the fixed mount end, about 4" from the end. Rudezuk had that set-up on his wifes rig for one or two trips, bent both front leaves in the same spot. He ended up going to a shackle reverse with the same toy springs. Just a heads up for what you might encounter.
Also, there's nothing wrong with the BFGs, I had 35s on mine and I really liked them.
Travis..

You might find that you will bend the main leaf on those springs at the clamp closest to the fixed mount end, about 4" from the end. Rudezuk had that set-up on his wifes rig for one or two trips, bent both front leaves in the same spot. He ended up going to a shackle reverse with the same toy springs. Just a heads up for what you might encounter.
Also, there's nothing wrong with the BFGs, I had 35s on mine and I really liked them.
Travis..

I figured they might be a bit weak considering how offset the center pin is.
The springs are 5 pack mix of YJ and Yota so hopefully that makes them stronger.

When did BFG Muds become ghey?:confused:

Those are probably the tire most of us started with

When did BFG Muds become ghey?:confused:

Those are probably the tire most of us started with

x2

Only reason I say that is everyone bitches that the sidewalls are too weak.
This is my first set, never ran anything except swampers. I like that fact that they are way lighter than swampers, hopefully they hold up ok.

Started working on remounting the ford shock towers

http://img116.imageshack.us/img116/8035/dsc009551301026fe0.jpg

Little draw latches I used for the tailgate. I bolted on a piece of angle then welded the latch to that. The rear quarters are tweeked so nothing lines up quite right.

http://img117.imageshack.us/img117/8344/dsc009591309929lg4.jpg

Hinges I picked up at the local welding supply.

http://img355.imageshack.us/img355/1861/dsc008663292795yv3.jpg

http://img116.imageshack.us/img116/6460/dsc009611315511ft3.jpg

Little bit more progress, I keep chipping away at the to do list.

Shock towers finished:

http://img224.imageshack.us/img224/7516/dsc009657033331bc6.jpg

Made the steering shaft. Cut the Samurai one off then ground the astro van shaft to slide inside it then welded it up.

http://img117.imageshack.us/img117/1028/dsc009646997132vy1.jpg

http://img389.imageshack.us/img389/8048/dsc009626983600di3.jpg

http://img377.imageshack.us/img377/4521/dsc009667040367tp0.jpg

http://img392.imageshack.us/img392/8066/dsc009686978276tl8.jpg

Finally got time to make the Saginaw pump bracket.
I made it from scrap parts off an old Econoline van, that's why the motor plate has so many holes in it.

http://img243.imageshack.us/img243/4812/dsc010020009204wt4.jpg
http://img144.imageshack.us/img144/8655/dsc010070020809se7.jpg
http://img217.imageshack.us/img217/6752/dsc010080025889hm1.jpg
http://img243.imageshack.us/img243/6079/dsc010060015535yh4.jpg

looks good :smokin:

I had some buddies over Friday night and somehow amongst all the beer drinking a tube front clip was started

http://img10.imageshack.us/img10/706/dsc010137532720di0.jpg

and the tailgate got painted

http://img19.imageshack.us/img19/3421/dsc010127527557mq1.jpg

I'm getting really close.

To do list:

Build grill and rest of front end.
Make bracket to use stock hood latch.
Install drag link after my buddy threads it.
Build battery box, get optima battery.
Get new radio antenna (TOP PRIORITY!)

I see you're using the Saginaw pump as I want to do for mine when I get the 16v in. What did you do for the front pulley? The guy I'm getting ym bracket from said the stock double row pulley isn't big enough for the pump. Thanks!

I see you're using the Saginaw pump as I want to do for mine when I get the 16v in. What did you do for the front pulley? The guy I'm getting ym bracket from said the stock double row pulley isn't big enough for the pump. Thanks!

Are you talking about the diameter of the pulley? Or that the Suzuki pulley is only 4 rib opposed to the 6 rib saginaw pulley?

As far as the belt goes no problem just put on a 4 rib belt and let it ride on the middle of the pump pulley.

If you mean the pulley is too small on the engine to run the pump with enough speed I don't know yet. I just got my drag link done and probably won't be able to test it until tomorrow.

Are you talking about the diameter of the pulley? Or that the Suzuki pulley is only 4 rib opposed to the 6 rib saginaw pulley?

As far as the belt goes no problem just put on a 4 rib belt and let it ride on the middle of the pump pulley.

If you mean the pulley is too small on the engine to run the pump with enough speed I don't know yet. I just got my drag link done and probably won't be able to test it until tomorrow.

Yeah, sorry. I was meaning it being too smal in diameter. they said that I would need the outer pulley the same size as the inner. I wonder if it's possable to use the pulley off of the Tracj/Kick pump on the Saginaw?

You may be right. My pump is out of a 95 s-10 and the diameter is 6.5". If it doesn't work I'll let you know if I find a smaller one that does.

I see you're using the Saginaw pump as I want to do for mine when I get the 16v in. What did you do for the front pulley? The guy I'm getting ym bracket from said the stock double row pulley isn't big enough for the pump. Thanks!

you are right on the pulley sizes. I belive that the canned ham pump and the T/C pump share the same shaft size (i could be wrong) so you may be able to use a spidertrax or PSC pulley

.748 ID on the pulley bore. So I guess whatever pulley with that ID should work. They are press on. when I got the pump the pulley was not on it so I stuck the pump in the freezer and heated the pulley then it dropped right on.

Here is a serpentine one but its says it's plastic dunno how that would work.

http://frugalmechanic.com/auto-part/215016-dorman-oe-solutions-power-steering-pulley-300-123#fits

Fits these Vehicles

* 1991-1993 Buick Regal
* 1991-1993 Chevrolet Beretta
* 1991-1994 Chevrolet Cavalier
* 1991-1993 Chevrolet Corsica
* 1991-1997 Chevrolet Lumina
* 1995-1997 Chevrolet Monte Carlo
* 1991-1996 Oldsmobile Cutlass Supreme
* 1991-1991 Pontiac 6000
* 1991-1996 Pontiac Grand Prix
* 1991-1994 Pontiac Sunbird

Or if you want V belt

http://frugalmechanic.com/auto-part/215008-dorman-oe-solutions-power-steering-pulley-300-122

good trick there! looking good i think the shackle revers is the next thing you should put on your to do list! my budd has bent 5 pairs of springs in 8 months. and has gone coils with links now. bet you bend them quickly.

good trick there! looking good i think the shackle revers is the next thing you should put on your to do list! my budd has bent 5 pairs of springs in 8 months. and has gone coils with links now. bet you bend them quickly.

Damn, second guy to say that. I believe it but I'll give them a shot and learn the hard way like I do with everything else.

Looks good Marshall. If you bend the leafs, at least the front end will be stripped and ready for links. I don't think you'll bend them with those BFGs unless you ram into something with the shackles. Once you get a bigger tire, I would start worrying about the rear springs bending. All 4 leafs on my rig are bent :laughing:

Are you running an anti-wrap bar in the rear right now?

Looks good Marshall. If you bend the leafs, at least the front end will be stripped and ready for links. I don't think you'll bend them with those BFGs unless you ram into something with the shackles. Once you get a bigger tire, I would start worrying about the rear springs bending. All 4 leafs on my rig are bent :laughing:

Are you running an anti-wrap bar in the rear right now?

Not right now I'm sure I will need one of those too. My old Samurai springs bent up pretty bad in the back on 33s but the YJs actually held up well with the 33s.

good trick there! looking good i think the shackle revers is the next thing you should put on your to do list! my budd has bent 5 pairs of springs in 8 months. and has gone coils with links now. bet you bend them quickly.

and you know we are gonna agree to disagree lol:flipoff2:

Worked on the front a little tonight.

http://img15.imageshack.us/img15/2412/dsc010172674953ul1.jpg
http://img26.imageshack.us/img26/4255/dsc010182681609ee9.jpg

I like the way you set up your front clip

and you know we are gonna agree to disagree lol:flipoff2:

dude is very hard on his rig. his shackles are up front and he hits them on things alot ao his FSJ springs have been thrashed bad may times!:laughing:

I dig your rig

Thanks for the good words. I'm a newb builder, this is my first real offroad rig.

BTW I tested the power steering and even at 800 rpm it seams very strong.
I think it will work just fine with the large pulley.

Mounted the stock headlights to the front clip:

http://img17.imageshack.us/img17/8519/dsc010289501819te2.jpg

http://img17.imageshack.us/img17/238/dsc010209480920hv9.jpg

http://img6.imageshack.us/img6/417/dsc010249485761oi4.jpg

Made the stock hood latch functional but welding it to a piece of angle iron then welding that to the front tube:

http://img27.imageshack.us/img27/3893/dsc010269491376sq9.jpg

http://img27.imageshack.us/img27/4377/dsc010279496741cp3.jpg

http://img15.imageshack.us/img15/4258/dsc010309506367zc8.jpg

very clean headlight mounting. I love it.

This thing is DONE! (except for a bunch of little shit, but I could wheel it tomorrow)

I took it for a test drive and it has gobs more power than the worn out 1.3 even with 35s on it now. The steering is 1 finger and it tracks straight. I didn't go far as it is not insured right now.

http://img5.imageshack.us/img5/8185/dsc010332612064.jpg
http://img5.imageshack.us/img5/3005/dsc010342617299.jpg
http://img8.imageshack.us/img8/1577/dsc010322606708.jpg
http://img5.imageshack.us/img5/3130/dsc010372595758.jpg

looking sharp

Finally got to wheel this thing. It did pretty well but I need a trac bar and some lower axle gears.

YouTube - Marshalls Sami at Tuttle (http://www.youtube.com/watch?v=VzDORN3loks)

Couple more vids

I don't always just throttle it up but right now my rig doesn't crawl those ledges real well. Combination of the tires not grabbing and not geared low enough.
YouTube - MCledge (http://www.youtube.com/watch?v=EDcga3a0obw)


Erin's Sami, this thing is bad ass.

YouTube - erinledge (http://www.youtube.com/watch?v=_I6NLl2iuDs)

I know this is a old ass thread. I followed your signature. I am wondering how it's working now, and if you made any changes, Did your springs hold up?

Erin's Sami, this thing is bad ass.

YouTube - erinledge (http://www.youtube.com/watch?v=_I6NLl2iuDs)

lol that IS a sweet rig but WTF is that dude trying to do to the tire :laughing:

I know this is a old ass thread. I followed your signature. I am wondering how it's working now, and if you made any changes, Did your springs hold up?

I haven't made any changes to the suspension except the spring clamps on the rear half of the front springs. The springs did start to bend after the first wheeling trip, the clamps have fixed the problem but also limit flex. Over all it works pretty damn good and the 93" wheelbase on 35s I think is perfect. If I did it over again I would probably set it up shackle reverse.

lol that IS a sweet rig but WTF is that dude trying to do to the tire :laughing:

I have no idea really :laughing:

Thanks for the feedback, I am still figuring out which way I am going to go when I extend my wheelbase. Cool videos..gives me some motivation to get my wiring finished.

that is a nice simple rig. i can't believe it's a 93" wheelbase, it looks longer for some reason.

Thanks guys. I just wanted to add the BFGs have not held up well. I've gashed 2 of them. The tread is good but the sidewalls just don't last in the rocks.

http://i665.photobucket.com/albums/vv12/MarshallC/0530001537.jpg

Couple things....

1. Your rig looks great
2. I like the grizzly in the background
3. thats an awesome rear bumper, did you make it? or where did you get it?
4. i like the front "S" skull and cross-pistons, where you get it?
5. do you have any pics of your swing away spare?
6. i really need to learn to weld, save me a shit ton

in New England, the first thing people will tell you about those BFGs is the sidealls are junk

Couple things....

1. Your rig looks great
2. I like the grizzly in the background
3. thats an awesome rear bumper, did you make it? or where did you get it?
4. i like the front "S" skull and cross-pistons, where you get it?
5. do you have any pics of your swing away spare?
6. i really need to learn to weld, save me a shit ton

Thanks. I actually gave up the chewing for 8 months, but now I'm back and grizzly is still the best.

The rear bumper I actually bought a long time ago from a guy in Minnesota that was making them out of his garage. It was long before I even owned a welder. It would easy to make though 1/8" 2x6 box steel, make brackets to bolt on and cut holes for lights.

The tire carrier I made just recently, it's kind of fugly but gets the job done.
http://i665.photobucket.com/albums/vv12/MarshallC/1205091834.jpg
http://i665.photobucket.com/albums/vv12/MarshallC/1123091845b.jpg
http://i665.photobucket.com/albums/vv12/MarshallC/1206091544.jpg


The Zuki logo I bought on ebay.
Yes you should get a welder, life will be good. Then a torch and life will be really good. :D

in New England, the first thing people will tell you about those BFGs is the sidealls are junk

I'm wondering if it's just BFGs or all radial mud terrains. Next tires I buy will probably be TSLs or Iroks.