Started to build a LWB Sammy for trophy races.
I found thisone near the French border.

http://users.telenet.be/taquan/LWB%20003%20(Large).jpg

http://users.telenet.be/taquan/LWB%20005%20(Large).jpg

Looked pretty decent although it is 25 jears old.
These axels will go under it. Nissan Patrol type 'R'

http://users.telenet.be/taquan/patrol%20assen%20(Large).JPG

In the front I'll keep the leaf springs, the rear will be a 4 link on airshocks.
The body will be bobtailed with a trayback.
The 4 link will be a challenge, so we start with that first.
Rear axle cleaned, reinforced and the link mounts on.

http://users.telenet.be/taquan/4link%20002%20(Large).jpg

Link bars

http://users.telenet.be/taquan/link%20bar(8)%20(Large).JPG

Heavy duty steel...:)

http://users.telenet.be/taquan/link%20bars%20(Large).JPG

4 link finished.

http://users.telenet.be/taquan/4link%20af%20(1)%20(Large).JPG

http://users.telenet.be/taquan/4link%20af%20(4)%20(Large).JPG

http://users.telenet.be/taquan/4link%20af%20(5)%20(Large).JPG

Part 2

http://users.telenet.be/taquan/4link%20af%20(7)%20(Large).JPG

http://users.telenet.be/taquan/4link%20af%20(8)%20(Large).JPG

http://users.telenet.be/taquan/4link%20af%20(Large).JPG

This is where we are right now. The Trailmaster shocks on the pictures are just for fitting. I don't have the airshocks yet.
The next step is to bobtail the body, after that we can fabricate the trayback and exo cage.
Feel free to comment. It's the first time i build a 4link and every help is welcome...
BTW, all the welding is done by my copilot Bart. :hot: Many thanks....

looks like you're off to a good start. Subscribed:beer:

Looking good:smokin:!
Afte my Tin Top project I'm also starting a LWB project.
So I'll be watching you're progress!

Rear axle rebuild and converted to disc brakes

http://users.telenet.be/taquan/bijna%20af%20(Large).JPG

Still looking for some callipers.

http://users.telenet.be/taquan/bijna%20af%20(1)%20(Large).JPG

Gearing is 4.111

http://users.telenet.be/taquan/bijna%20af%20(2)%20(Large).JPG

On it's wheels:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes4.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes.jpg

looking good

Got busy with some sheetmetal...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/body5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/body6.jpg

that suspension looks heavy duty

that suspension looks heavy duty

x2, I like it. It looks just like mine when I started out. You will never regret leaving lost of room behind the seats.

:smokin:

what's going on up front !?

what's going on up front !?

Nothing yet...:grinpimp:
First i finish the rear of the body and the trayback.

Up front will be Nissan leaf springs, SPOA.

Sheetmetalwork of the back is almost done:smokin:.
Pics tomorow when the sun is back...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/body001.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/body002.jpg

Started on the rollcage.
Chassis shortened and rear winchmount fabbed.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/trayback2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/trayback3.jpg

More pics:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/rolkooi1.jpg

The square tube will be the rocksliders.
Some advice please: should I weld them just in the body, or attach them to the chassis also? I personally prefer the 2nd, but the body can no longer move on the chassis. Will it break?
http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/rolkooi2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/rolkooi.jpg

I have seen them attached to the just the body (welded in ) and survive well.

I would stay away from welding them to the body and frame. If you ever want to pull the body off you will have to cut the supports off the frame. So I vote one or the other, weld to the frame or to the body, but not both.

You could also weld them to the body, and use a bolton type of support for the frame side. this way you could unbolt them and they could come off with the tub.

Personal preference; I like the way they look welded to the body rather than just the frame alone., I do not like the gap they have when they are not welded to the body.

You've done some great work, and have some nice fabrication skills. It looks really nicely done, I can't wait to see the finished product.

Some bodywork done. Inside is seamed and painted. Outside covered with Bondo. Still needs sanding...(I hate sanding:flipoff2:)
Rocksliders are next...

looks good. if i had to do my build over again i would make my back part longer. i just use another targa bar right beside the other. did you cut the rear door apart? i cut mine into.

I used two targabars also. (See picture below) Covered them with sheetmetal.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/opdewielekes4.jpg

I cut the whole backend of a metaltop (+/- 4 inches) and put them together....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/body002.jpg

I like the space behind the seats. It should be enough for a few waterproof boxes with food, drinks, spare clothes and sleepinggear and some spare parts.
The trophy's we plan to do are several day's....

that is about what i did. but i was not using a lwb. and i put the targa bars to gether and then filled the gap.

that is about what i did. but i was not using a lwb. and i put the targa bars to gether and then filled the gap.
Do you have pics??

Nice.
you going to put a window in that back section? looks like a hell of a blind spot.

yea here is the pictures of my build.

http://www.pirate4x4.com/forum/showthread.php?t=906101

No windows on the sides. Just room for sponsors:grinpimp::grinpimp:

@Wolverine: nice rig!!!

thanks man. yours is going great

First rockslider tacked in place. Tube will be welded to the body and bolted to the chassis...
What would be the best: keep the tube open for easy cleaning, or close it up???

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/rockslider1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/rockslider2.jpg

A hidden surprise......:flipoff2::flipoff2::flipoff2:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/roest002.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/roest005.jpg

Body 1st layer of primer..

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/lak.jpg

Looking good.

nice job lookn good

I would close up the tube. Mud is he worst for making rust. If you let any mud sit in there it will star rust pretty quickly. If you are worried about condensation you can drill tiny hole in the bottom and towards the rear of the tube, this will empty any water and condensation when you take off, or go uphill.

Thats a tidy job you've done with the cab :smokin:

I would close up the tube. Mud is he worst for making rust. If you let any mud sit in there it will star rust pretty quickly. If you are worried about condensation you can drill tiny hole in the bottom and towards the rear of the tube, this will empty any water and condensation when you take off, or go uphill.
OK, thanks, we'll do!
Somebody else told me to close it completely and put a little oil or dieselfuel in it so it won't rust on the inside, but i don't like the noise of a liquid moving under me. Makes me wanna p**...:beer:

I would close up the tube. Mud is he worst for making rust. If you let any mud sit in there it will star rust pretty quickly. If you are worried about condensation you can drill tiny hole in the bottom and towards the rear of the tube, this will empty any water and condensation when you take off, or go uphill.

I hate do disagree with you sky, cause you are always right. But drilling a small hole will cause water to force its way in when submerged in water, and with dirty water it will clog the hole and water wont drain.

I would close it up too, but not drilling a hole. wont be a problem and rust trough... unless you plan on the body holding for 60 years

wont be a problem and rust trough
Remember i live in Belgium! It rains 300 day's a year...:D.
Difficult to keep a vehicule rust-free....:mad3:
The oil or diesel solution isn't that bad maybe...:confused:

Remember i live in Belgium! It rains 300 day's a year...:D.

You're so lucky southern neighbour!
Over here it rains 400 days a year:D!

Frontaxle ready for SPOA:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/spoa2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/spoa3.jpg

Front leafspring mounts:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/scharnierpuntenvooras2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/scharnierpuntenvooras1.jpg

All components for the front suspension are ready:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/componentenvooras.jpg

My codriver/mechanic/welder started on the chassisextension....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/chassisextentie1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/chassisextentie2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/chassisextentie3.jpg

then he ran out of gas.......

This morning we get new gas, and here we go again...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal002.jpg

Brackets for the leafspring hangers...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal003.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal004.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal006.jpg

Immediately rust-protection...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal009.jpg

Chassis is completely painted...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal010.jpg

Axle housing cleaned and painted...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasfinal013.jpg

Let's hope everything fits tomorrow....

Nice build!! I love the look and the thoughts put in the in build so far!! :smokin:



God Bless,
David B.

Thank you!

It's on it's feet!!!!!:bounce2::bounce:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasaf001.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/voorasaf004.jpg

It's on it's feet!!!!!
Sweet! It's getting closer.

Nice build!! I love the look and the thoughts put in the in build so far!!

I agree I check in whenever you post. :smokin: Build

Some more pics...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/oppootjes002.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/oppootjes003.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/oppootjes004.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/oppootjes011.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/oppootjes012.jpg

what leafs are you using in the front?

what leafs are you using in the front?

Nissan Patrol 1986, 3300 Diesel, type R260. Same as the axles.
It's a little high right now, but with the big engine + winch in front, it will be all right....... i hope.....:shaking:

i fucking hate you you have a rolling garage thats no fair i have to drive my project into mine u just roll yours over the project im so jelous

i fucking hate you you have a rolling garage thats no fair i have to drive my project into mine u just roll yours over the project im so jelous

x2 i want a movable carport!! although hate is a strong word i believe its fitting in this instance..lol

The rolling carport is there for a reason....
I didn't get a building permit for a carport.
A friend of mine, who is a architect, told me when a structure is 'movable', you don't need a building permit....
So i build myself a carport on wheels. I can move it for about 100 inch.
It's not much, but enough to bend the law a little bit....:grinpimp::grinpimp:

The rolling carport is there for a reason....
I didn't get a building permit for a carport.
A friend of mine, who is a architect, told me when a structure is 'movable', you don't need a building permit....
So i build myself a carport on wheels. I can move it for about 100 inch.
It's not much, but enough to bend the law a little bit....:grinpimp::grinpimp:

im all about fucking over the govt, they rape me daily always makes me smile when they get a little of the shaft back.

jups Big enegine? whats its gone be? of wat ga je er nu inpooien, op pirate mag je het verklappen éé

I'm looking for a 3l v6 Mitsubishi Pajero/Montero, but SSSSSSSST, it's still a secret....:shaking:

Rain off the dust....

As you can see there is a lot of rust on the fenders. When I cut it off, the inner fender comes lose. How do I repair this? Cut a arc of new metal and weld it in place???

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/inderegen001.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/inderegen002.jpg

Santa was early this year!!!!
The donorcar for the engine is at home:D:D:D:D

here you go, I am lucky we do not get that kind of rust here. These should help a few options for you.

http://bbs.zuwharrie.com/content/topic,63129.0/all.html

http://bbs.zuwharrie.com/content/topic,113348.0.html

OK, thanks.

Engine donor....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/V64.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/V61.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/V62.jpg

It's alive....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/th_DSCN4641.jpg (http://s800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/?action=view&current=DSCN4641.mp4)

Question .... you went to all the effort of remanufacturing the front of the chassis but you didnt do a shackle reversal...???? being you are building a trophy truck wouldnt it be better for a reversed shackle on the front....

Question .... you went to all the effort of remanufacturing the front of the chassis but you didnt do a shackle reversal...???? being you are building a trophy truck wouldnt it be better for a reversed shackle on the front....


they are an absolute waste of time. building a front end right, and not using a reversal will lead to far fewer problems.

I have had that remark before.
Why should a shackle reverse be better? I think the shackles under the chassis are a anchor point on hilltops...

I have had that remark before.
Why should a shackle reverse be better? I think the shackles under the chassis are a anchor point on hilltops...

better for the bushing btdt

Engine cleared...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/demontage35.jpg

I like the presents under the Xmas tree this year.....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/xmas.jpg

Cool!
Thanks Santa:D!
Send him over to me!!

We'll take a break...... Our fingers are turning blue when working....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/sneeuw1.jpg http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/sneeuw2.jpg http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/sneeuw3.jpg http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/sneeuw4.jpg http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/sneeuw5.jpg

Best wishes for 2011!!!

http://i800.photobucket.com/albums/yy288/peterHasendonckx/kerstkaart.jpg

The best to you in 2011 also!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

I see I'm not the only one working outside. No roof for me---But in Feb. 2011, I will be renting a one car oversized garage with Heat!!!

Earl

THX, working outside sucks in winter, but i love it during the summer!
I can't get a building permit for a real garage....:mad3:

Did some shopping...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/giraf3.jpg

Approved by my 8year old monkey....:D

Garage Monkeys rock, firts my boy at 12, then my girl at 11, now my niece at 9.

I usually give them the air blower tool to sweep out the garage. after that they don;t run and hide when the compressor kicks on :D

Does she "help" you with your build?

It's a 'he' (the long hair can be deceiving) and, yes, he helps me sometimes. He brings tools and drinks, but when we start welding or grinding he's gone...
That's OK by me. Safety first...

It's a 'he' (the long hair can be deceiving) and, yes, he helps me sometimes. He brings tools and drinks, but when we start welding or grinding he's gone...
That's OK by me. Safety first...

here comes the awkwardness....

here comes the awkwardness....

Hahaha

Damn I feel like an ass. Well, to his credit I didn't look close and was thinking about my niece helping me in the garage. Now that I take a look at the picture it is obvious.

Same thing with me, grinders out = kids gone. I have extra welding helmets though, and I have taught both my boys to weld (they can run a straighter bead than I)

Instead of buying stuff for your Zuk, send your son to the hairdresser:D!
Oh, who am I kidding.
I just bought some Arb Lockers.
My kids haven't had a decent meal in weeks:shaking:!

My kids haven't had a decent meal in weeks!

HAHA!! Sometimes i go with my son to my mother in law. With his puppy eyes he gets a warm meal in no time...:D:D:D

My older boy always comes home from my moms house with his mouth full, and food in one hand lol.

Funny how good mom's are universal across countries :D

Airshocks....16" Radflo

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/airshocks1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/airshocks2.jpg

Sweet, is that about the spot you;'re going to mount 'em? They look sharp

im concerned about that front shackle angle. how much squat do you expect from the engine transplant?

im concerned about that front shackle angle. how much squat do you expect from the engine transplant?
When I sit on the front bumper, it drops about 3" and i weigh 110 KGs. The new engine adds about 100 KGs. I think (hope) it will be all right...

Sweet, is that about the spot you;'re going to mount 'em? They look sharp
Don't know yet. Must do some flextests to be sure...

Outside temperature was above zero (Celcius), so we got a little busy.
When you are used to work on Zuk's, this is really heavy stuff...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu4.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu6.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitbouwmitsu7.jpg

I don't know if you're nuts or heroic:smokin:...
It was freakin' cold today:D!

We survived....:(:(:(

That transmission is huge!!!

That's one of the reasons i use a LWB...:)

I don't know if you're nuts or heroic:smokin:...
It was freakin' cold today:D!

I once put in a motor outside @ -5F. Told myself not again. I'm impressed:D

Earl

I got rid of the old Pajero body.
Did some flextests to determine the mounting points of the airshocks.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/flextest1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/flextest19.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/flextest26.jpg

Removed the little 1.3L

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/1300eruit1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/1300eruit2.jpg

Enginebay cleaned:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/tekoop7.jpg

I have to sell some stuff.... The wife is getting nervous....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/tekoop13.jpg

i have to sell some stuff.... The wife is getting nervous....
:smokin: :D

Progress of today:

Transmission ready::D

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/boite.jpg

Cleaned and painted :

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/boite1.jpg


Got rid of some floorpanels...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/boite6.jpg


Hanging like this, there is just enough room left for the engine!

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/boite8.jpg


Now we can fab some support brackets...

Flip front:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/flipfront1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/flipfront2.jpg

Engine fitted:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorpassen.jpg

Lot of room left:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorpassen5.jpg

Engine in it's place. Only with straps so we can easy measure and test fit the brackets:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorpassen7.jpg

cool build. how you gonna do the front drive shaft looks like the transfer case outpute is driver side and the axle is pass?

Front axle will be turned over...

Engine support brackets finished:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorsteunen2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorsteunen3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorsteunen7.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorsteunen4.jpg

Engine in it's final location. A little higher as expected, so the hood doesn't close anymore, but this was better for the drive shaft alignment.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorsteunen6.jpg

A little progress on the exhaust headers. Form is roughly OK. Base plate needs to be cleaned up and made 10 MM thinner. Tubing tacked in place just for fitting. Nothing final.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitlaatspruitstuk10.jpg

Plenty of room left..

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitlaatspruitstuk6.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/uitlaatspruitstuk4.jpg

Transmissiontunnel.
http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur11.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur16.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur15.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur14.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur13.jpg

Exo-cage:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/raamkader2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/raamkader3.jpg

I looked back and didn't see any pictures of how you made/tied in the roof.

I am working out a hard top design, do you have any pictures of hwo you made the structure?

I have a few ideas,but I want to get some more from people who have done it.

The front part of the roof was made earlier for another Zuk and was meant as a removable bikini top.( this explains the rust...)
First was a structure made with 10 MM square tubing. A 1.5 MM stainless steel plate was bend over it (by manpower, PFFFF) and welded in place.
The roof is attached by big rivets and a lot of sealant.
The rear part are just the side panels bend over the 2 targa bars and the top covered with sheetmetal. All sealed and riveted. I use Sikatack for sealing/glueing. Very strong stuff!!! Stronger as welding and a lot faster.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/dak1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/dak2.jpg

Mitsubishi meters in the polyester dash. A tight fit....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/IB.jpg

is it just me or is anyone else seeing a bandwidth exceeded icon instead of photos?

it starts with post#6

it starts with post#6

Doing in on my side also.

Damn, i'll have to remove some old stuff i think....

Apparently my pictures are to popular!!!! They are downloaded so often my bandwidth is exceeded....:flipoff2:
Next month my counter will be reseted, please a little patience....:mad3::mad3::mad3:

cool ill check back later tonight

Pictures are still visible at facebook
http://www.facebook.com/media/set/?set=a.1732159656421.2088981.1011407715

Pic's are back!!!

Here are some new. Top cross of the cage almost done.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/raamkader5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/kruisdak2.jpg

More tube-bending....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/neus3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/neus4.jpg

I think that those gussets should be in the midle of the tube....

Other than that, I like it! :D

What kind of bender do you have?

This is the bender i use:

http://www.northerntool.com/images/product/images/144206_lg.jpg

Colorsample: Suzukiyellow....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koolzaadgeel.jpg

Some air for the engine...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorkap9.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorkap8.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorkap7.jpg

Nice build Peter. Still working on cold or is it beter now?

Last 2 weeks we have almost 30°C :shocked::shocked::shocked:
Perfect!!!

Same here Peter. Finally my balls warm up.

took me a little google to figure out how hot that was. we're at 36 and rising in texas!

Hood finished....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorkapaf1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/motorkapaf3.jpg

wow, it looks very good

Nice hood and color.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN5319.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN5320.jpg

Nice hood and color.

X2

Really like how you added in the extra lights.

Earl

Been busy with some rattle cans......

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/kleur1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/kleur2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/kleur3.jpg

the cage looks great for having used that pipe bender! what type of tube did you use?

Thanks!

Diameter 48 mm, 3 mm wall.

What kind of tube or hose should i use to connect the radiator in the back?
Steel tubing rusts inside and rust kills the water pump.
Diameter should be between 30 and 35 mm. (1" 1/4?)

Any suggestions?

Whoops.....there goes my bandwidth again.........:flipoff2:

this guy plumbed his rear mounted radiator through his tube chassis under the area where a door should be then doubled up a section of tubing to reinforce and prevent a puncture. He had the return under the opposite side.its steel of course but if you run plenty of antifreeze and flush it you shouldnt have to worry about rust.
609415

You should use stailess and hoses...
No rust! :D

A friend of mine used 2 or 2 1/2" outdoor galvanized electrical conduit. The Electrical conduit is galvanized on the inside and the outside so with worked very well. It was also very easy to bend and work with.

Like this, but a thinner wall. Since your pictures are gone for the remainder of the month, I figured I;d give the picture addicts something to look at.
http://www.hutsvilleads.com/North-Hutsville/2009/New-galvanized-conduit-90-degree-elbow-3-1-2-brand-.jpg

Thanks!
Something to look for tomorrow at the DIY store.

Hey no problem, I hope it helps.

You may want to look at top rail for chain link fence as well. It too is galvanized inside and out, and thin wall so it is easy to bend.

Whichever is the least expensive should be the go.

My friend used reversible ans, so in the winter the radiator blew to the cab, it kept it nice and warm even though it was not fully enclosed..

That type of bender won't play well with thin wall....tends to kink.
You can fill the tube with sand and cap the ends, but what a pain in the A.

My friend used reversible fans, so in the winter the radiator blew to the cab, it kept it nice and warm even though it was not fully enclosed..

That's a nice trick to keep warm, but my cab is fully closed and the heaterbox still operational....

Radiator:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN5451.jpg

With fan's:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN5450.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN5452.jpg

First sponsor!!!!!:bounce2::bounce:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stikkers.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stikkers3.jpg

The decal and paint look really good. Radiator palcement looks aces too.

Bended some galvanized tube:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling6.jpg

Connected with silicone hoses.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling9.jpg

Radiator cleaned,

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling8.jpg

Tubing connected to the engine,

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling17.jpg

Radiator and fans installed,

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling19.jpg

Radiator connected. The temp sensor needs a reduction ring and the expansiontank is not at it's final place yet, but the coolingsystem is getting there....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/koeling22.jpg

Looks like you have good connectors at the high point so it should be easy to bleed. Looks like it is going to work well, also looks nice and clean :D

Congratulations on the first sponsor :D :D

Thanks!

This thing is comin right a long. Good work!

I can't wait to see the trail pictures as a finished rig!


Pyro

Fuel tank finally gets it's place. It will be covered for security. Donor was a Mitsubishi pick-up truck. It holds 90 Liters.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/benzinetank3.jpg

Rear mudflaps done. Just have to make holes for the airshocks.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps6.jpg

Front mudflaps cut, but not installed yet.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps4.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy Sam/mudflaps5.jpg

Cutting the rubber was a PITA!
It is 7/8" thick and has 5 layers of nylon fabric.
I first tried a grinder with a cutting disc for metal, a circular saw and a sharp knife with no success. the rubber burned.
A jig saw did the job. Slow speed, a new sharp blade and a lot of patience....

Very nice build man! :smokin::smokin:

I like the mud flaps on the back, let's see how they come out in the front...

Original roll bar cut to pieces and transformed into something useful.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger4.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger6.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger9.jpg

Only tacked in to place. The real welding will be done by a specialist...

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/stinger10.jpg

Cool little sami. I like it.

It's just :smokin::smokin::smokin:

Are you going to put a winch on it?

Main winch will be installed behind the passenger seat with the cable routed next to the chassis to the front. (Probably hydraulic, depends on the budget...)
Rear winch will be electrical (T-Max 9000) just behind the radiator, and a little top winch will be installed in the future above the radiator.
European trophy's can be very technical and are 3 winches really necessary...

http://youtu.be/iFzLPTElqM4

http://youtu.be/u-wiDfFQGic

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/benzinetank5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/benzinetank7.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/benzinetank10.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/benzinetank12.jpg

Some plumbing....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/benzineleidingen.jpg

Starts to look like a racing car....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/interieur.jpg

I'm going to review the filler hose. It's to exposed.

nice use of the stock roll bar. It gives me an idea for a tire carrier.

A lovely project. Amazing work.. Just went through all the pages.. Did you get to do work on the headers?
Ehsan

A lovely project. Amazing work.. Just went through all the pages.. Did you get to do work on the headers?

Thank you. Headers are not finished yet. First i continue on the interior, second is the electric system. After that are the headers. Then we make the engine growl...:D

Wooden panels replaced by metal. It's not finished yet, but you can see where I'm going....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/metalenbak.jpg

nice sami really like the hood

Fuel tank casing finished.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/ijzerenbak.jpg

Front mud flaps finished.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/mudflaps10.jpg

Looking good, any plans for covering the fuel filler yet?

From the picture of the front end, it's look sharp! I like the way you cut the hood for the lights too, I have never seen than done before. Some cool stuff about the mounting, you get no glare from the hood, they are nice and protected, and the wiring is protected too.

Thanks, my wife always says i have a wild imagination...:lmao:

Japanese spaghetti :shocked::rasta:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/japansespagetti2.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/japansespagetti1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/japansespagetti3.jpg

Japanese spaghetti :shocked::rasta:

Uhg, you are going to need some of that "special imagination" to visualize where you are going to route and mount all those wires relays and boxes lol. I do not envy you. :D

Is easy... Just follow the wires who are connected to the ECU, all others will be cut.:grinpimp:

Everything connected, but nothing cut yet. Added some fuel, and here she goes!!!

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/th_DSCN6049.jpg (http://s800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/?action=view&current=DSCN6049.mp4)

Now i know she runs fine, i can start cutting the wiring harness...

Nice it's alive! Sounds good too. :D

I'm happy for you Peter!

It's always a great joy when the engine actually runs! :D:D:flipoff2:

Today we started with this:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/bedrading2.jpg

Cleaned:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/geineeraf.jpg

Started cutting and this is what remains: (only engine control, warning lights and meters)

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/gestript.jpg

Leftovers....

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/overschot.jpg

New wiring is already in the car.
Engine starts and runs smooth. All warning lights and meters work...
Next is final routing and taping of the wiring.
I also have to make a second wiring for the lights and some 'offroad' equipment...:D

Dash is getting there. Most of the wiring is inside. Nothing connected yet.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/middenconsole1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/middenconsole2.jpg

Progress of today:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/inlegplaat4.jpg

lookin good,cant wait to see it on the road/track :D

Dashplates finished:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/inlegplaten1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/inlegplaten2.jpg

Batterytray finished.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/batterytray3.jpg

Today we went from this:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/IB1.jpg

to this:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/IB1-1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/IB5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/IB9.jpg

Looking good!

Gesendet von meinem GT-S5690 mit Tapatalk

Very nice work.

I love the attention to the details!

Codrivers workspace.....
Trough the tubes flows hot air from the heater and in the horizontal tube are little holes towards the windshield, so i have a windshield defogger, heated handhelds for the codriver and a support bracket for the Terratrip, GPS and ECU in 1 piece!!!!:cool::cool:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/dash8.jpg

Codrivers workspace.....
Trough the tubes flows hot air from the heater and in the horizontal tube are little holes towards the windshield, so i have a windshield defogger, heated handhelds for the codriver and a support bracket for the Terratrip, GPS and ECU in 1 piece!!!!:cool::cool:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/dash8.jpg

Wow. really Nice!!!!

Next time in BE we have to enjoy a belgian beer to see that Zook!!!

Heel mooi gemaakt, echt klasse!!!

Rear winch mounted. Support of the roller fairlead has yet to be fabricated. (will be something special...:grinpimp:)

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/achterwinch5.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/achterwinch6.jpg

is the cable going to be pulling as it is laying in the picture?

Certainly NOT!
Cable is on the winch as i got it (= wrong!)
Roller fairlead comes on top on a 45° angle so the winch can be used as rear- and top winch.
Winch itself needs some attention. There is a short in the motor circuitry and the gearbox is clogged.... nothing serious... :shaking:

cool - have seen people mount winches like that (especially 8274s) which puts the full force of the winch against the tensile strength of the 4 small mounting bolts.

You can mount it as you like, it always comes down on those 4 bolts...:(

true, but I'll bet in shear they are stronger than in tension

Agree...

Thanks!

Diameter 48 mm, 3 mm wall.

That is an Innocenti Tube normally used for scaffolding.

Steel: S 235 (Fe 360)
D = mm 48
s = mm 3,2
Af = cm2 4,5
p = kg/m 3,53
x Jx = cm4 11,35
x Wx = cm3 4,73

Seats & main switch. Interior is finished!!:D

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/zetels1.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/zetels3.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/hoofdschakelaar1.jpg

Rear winch.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/DSCN6319.jpg

Snorkel:

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/snorkel.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/snorkel4.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/snorkel2.jpg

We have light, we have sound, but no movement yet....
overzicht draaiend.MOV - YouTube (http://www.youtube.com/watch?v=3rsTHt87egY)

Air intake box.

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/scoop10.jpg

http://i800.photobucket.com/albums/yy288/peterHasendonckx/4x4/Trophy%20Sam/scoop12.jpg