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Old 05-18-2009, 11:41 PM   #51 (permalink)
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finished.
what kind of paint you used? is this rubberized paint used on the underchassis?

what axle did you use?
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Old 05-19-2009, 11:01 AM   #52 (permalink)
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We are using black metal enamel paint. Can be bought at most paint stores. Pretty hard stuff but will still scuff if u hit objects. Thought about a liner product but too much maintenance and eventually sun fade issues

Axles are Toyota 8" out of a 79-85 Toyota Hilux (Tacoma). Shafts are Longfields.
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Old 05-25-2009, 02:14 PM   #53 (permalink)
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So the axle gusset kit from Marlin came in. I'm going to use it, even though after further review, it looks like the Trail Gear gussets would be better since they use a double gusset up top....
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Old 05-26-2009, 11:28 AM   #54 (permalink)
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Lookin good! I can't wait to see how this project turns out!
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Old 05-27-2009, 05:02 AM   #55 (permalink)
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I'm running the box for rocks from D&D machine. I have the 231/300 set up, and love it. You will only have 3.84:1 with the 203/205. I have 7.12:1 with the 231/300, and several choices of gears. Here's a link to a good deal on a 231 crawl box for sale.http://www.nc4x4.com/forums/showthread.php?t=65386. $500.00 is a good deal.
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Old 05-29-2009, 07:43 AM   #56 (permalink)
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wait wait.. sorry for sounding stupid, but you used your old sidekick chassis under the amigo body? \

and also, did you use 1/4" steel on those bumpers? lookin' good but it's too huge

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Old 05-29-2009, 11:56 PM   #57 (permalink)
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no the chassis is from the Amigo....all i reused so to speak from the sidekick were the parts derived from other vehicles. the 4.3L, turbo 350, np205, toyota axles etc....

anyway, let me get this thing on the ground and get some photos.

the gussets were all ground down (marlin brand) and tacked on tonight. a plate had to be cut to fit on the passenger side so the ubolts can fit around the angle created by lack of space to the center chunk.

got the diff back as well, and it is rebuilt with the 5.29 gears and ready to drop in.....making progress....slowly but surely.
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Old 05-30-2009, 03:36 PM   #58 (permalink)
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[QUOTE You will only have 3.84:1 with the 203/205. [/QUOTE]

It's actually 3.94:1 with the 203/205 as the 203 has a 2.01:1 low range and the 205 has a 1.96:1 low range. I'm not trying to be a dick either, Just trying to keep as much accurate information available.
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Old 05-30-2009, 11:54 PM   #59 (permalink)
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ok, thanks for clarifying.. hehe

nice amigo! but why did you put on the zuk emblem?
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Old 06-02-2009, 07:26 AM   #60 (permalink)
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Very few people know either the Isuzu Emblem or the Suzuki emblem anyway, so putting the suzuki one on there only fawks with about 50 people in the entire world
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Old 06-02-2009, 09:52 AM   #61 (permalink)
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for those of you still interested and not turned off by the suzuki emblem...

got the marlin knuckle gussets ground down (lots of work - thanks Scooter) - and tacked them....clearance was good
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Old 06-02-2009, 09:56 AM   #62 (permalink)
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here's the part that may make some of you cringe....in order to compensate for the offset of the center chunk, a plate had to be cut and welded to the spring perch to attach the ubolt...no big deal; however, there isn't much room so we welded a nut as a mounting location for one of the bolts. we've beat on it with a hammer and torqued it down -- doesn't seem to be moving at all. we are thinking of taking metal tubing and using that to absorb some of the compression that may be experienced so the bolt won't break off...any one have an opinion (here we go)
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Old 06-02-2009, 09:58 AM   #63 (permalink)
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here's work on the other side...had to get a better bracket to mount the hydraulic ram to. prior, the ram was extending and hitting the center chunk....moved it over, and should fix the problems...
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Old 06-02-2009, 09:59 AM   #64 (permalink)
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here we are in the paint shop with the front axle

was going to put it together but had to stop and buy a knuckle rebuild kit from inch worm - will be here friday ....great customer service btw...
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Old 06-02-2009, 05:11 PM   #65 (permalink)
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Anyone know where I can get stronger steering stops since I'm running hydo steering? The ones in the Marlin kit aren't strong enough.
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Old 06-04-2009, 11:06 AM   #66 (permalink)
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ARe you putting full hydro, or hyrdo asst?
Either way, the ram shoud be set up to stop at the right spots, at the same time as the the steering box/ pitman arm trhow. If your relying on a stop to fight against the ram and steering, you gonna probably gonna stress and break stuff.
The only reason Ive had "steering stops" is for rollovers and situations where the tire gets smacked hard.
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Old 06-04-2009, 10:06 PM   #67 (permalink)
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Full hydro
Will be back at it tomorrow night.
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Old 06-13-2009, 07:11 PM   #68 (permalink)
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front suspension pics

almost done with front suspension

set the knuckle shims at 12lbs on both sides. oh, here's a few friends out heading out to a bon-fire....
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Old 06-13-2009, 07:15 PM   #69 (permalink)
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took a break...gotta love the houston area...

anyway, back to the build - mounted the tires....I REALLY HOPE THE RANCHO SPRINGS SAG A LOT? I'm going to reinstall the over-load leaves on the Ford springs to level it out a bit....
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Old 06-13-2009, 07:17 PM   #70 (permalink)
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dont' have the steering re-attached yet...but the knuckles were rotated properly (thanks Scooter).

Here's a pic of the FRONT drivers side rear hanger with the full weight of the vehicle and no floor jack help...
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Old 06-17-2009, 04:27 PM   #71 (permalink)
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So when does the "police" theme come in to play? Lightbar? Intercom?Shotgun mount on passenger side?
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Old 06-17-2009, 05:59 PM   #72 (permalink)
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I'm gunna take a stab at it and say he got the amigo at a police auction....
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Old 06-18-2009, 11:49 AM   #73 (permalink)
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I'm gunna take a stab at it and say he got the amigo at a police auction....
no quite OJ - actually, I have lights that mount on a dodge ram diesel that I disassembeled, and wired in red/white/blue led lights. The body will be painted black and white like a State Trooper car (one's here in Texas). Probably put a decal on the side that says 'Recovery' or something along those lines.

It's hard getting enough time to work on it consistently, but it's coming along.
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Old 06-18-2009, 02:54 PM   #74 (permalink)
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ah, going for the DPS look.....
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Old 06-18-2009, 05:32 PM   #75 (permalink)
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Buddy,that is pretty cool build,like the ingenuity.
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