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Old 01-07-2019, 08:58 AM   #101 (permalink)
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Time for a cage. Picked this thing up from a guy who never installed it for $100. Normally LROR sells it for $400. Started installing it this last weekend. I need to fab up a new rollbar to fit into my new pickup configuration.





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Old 01-07-2019, 09:18 AM   #102 (permalink)
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I really like what you've done with this thing!
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Old 01-07-2019, 09:35 AM   #103 (permalink)
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I really like what you've done with this thing!
Thanks! It's came a long way since I bought it when I was 16 and had absolutely no idea what I was doing to it!

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Old 02-04-2019, 08:01 AM   #104 (permalink)
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Decided to go back to SPUA after all, and drop my tire size down. I don't do enough wheeling to keep it SPOA. With the 1:1 high range, 3.73 diffs, and 33's, the gearing is way too high. By dropping the tire size down, I think I'll be able to daily it a little better, and plus, I can still do some of the easier trails here and there still.
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Old 02-04-2019, 04:33 PM   #105 (permalink)
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Put 4.57ís in the diffs and drive it.

From what Iíve seen dropping to SPUA isnít compatible with the VW motor.

Normally the message is thereís no problem running SPUA with whatever tire size youíre willing to street drive/run on Suzuki axles, the engine is going to fight you trying to drop the car down.
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Old 02-04-2019, 04:34 PM   #106 (permalink)
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Thereís certainly no connection between capability and SPOA. Many would say itís an inverse relationship.
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Old 02-05-2019, 06:58 AM   #107 (permalink)
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Quote:
Originally Posted by Gwagensteve View Post
Put 4.57ís in the diffs and drive it.

From what Iíve seen dropping to SPUA isnít compatible with the VW motor.

Normally the message is thereís no problem running SPUA with whatever tire size youíre willing to street drive/run on Suzuki axles, the engine is going to fight you trying to drop the car down.
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Thereís certainly no connection between capability and SPOA. Many would say itís an inverse relationship.
I ran my rig SPUA with 3" lift springs for 3 years, and never had a problem with the oil pan to axle issue. I've played around with the gearing calculator a ton, and realistically, to get my high range much more reasonable, I would want 5.13's. My other option is to just swap back to a samurai transfercase, and I've been seriously considering it quite a bit.
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Old 02-05-2019, 11:50 AM   #108 (permalink)
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Maybe I will keep it SPOA on 33's and just throw 5.13's in it. I just found some gears for cheap.
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Old 02-05-2019, 04:03 PM   #109 (permalink)
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You could drop it to SPUA then, put the 5.12’s in it, leave the 33’s on, and have the best of both worlds.

Last edited by Gwagensteve; 02-05-2019 at 04:03 PM.
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Old 02-06-2019, 07:19 AM   #110 (permalink)
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Suppose that's not a terrible idea. Picked up one set of gears last night, now gotta get the other set, and pick up the stuff to swap the gears over to my steel thirds.

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Old 02-20-2019, 08:00 AM   #111 (permalink)
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Pulled the rear third out last night, and started disassembly this morning at work. Got the ring gear swapped over, had to use the samurai bolts, because for some reason, the tracker ones were too long, and I couldn't get some of them to thread all the way down, they were bottoming out. I measured up the old crush sleeve, and set up some shims with my solid pinion spacer to within two thousands of an inch difference. I will have to install everything and test it to see if I need to make any adjustments.







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Old 02-20-2019, 03:16 PM   #112 (permalink)
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Finished up my setup for now, and set backlash and checked my pattern. Picture is crappy, but the pattern seems to be pretty good, especially since this is the first time I've ever tried setting up a differential.



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Old 03-11-2019, 03:00 PM   #113 (permalink)
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Regeared the front axle, just gotta put the third back in now and reassemble. Drivers side was leaking gear oil, even though I just rebuilt the axle less than 300 miles ago. I put in aftermarket shafts, and when I did the inner seal, the stupid thing didn't fit very snug at all, of course, it popped completely out without any pressure, so I "glued" it in place with some ultra gray RTV.







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Old 03-18-2019, 07:39 AM   #114 (permalink)
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I decided I wanted to do away with my heim setup. Although it worked great, it technically wasn't "legal" to drive on the street. Plus, by the time I had the misalignment spacers, joint, washers, and bolt stacked together, it was way tall. I needed to get a drop pitman arm for my for my sidekick power steering box anyways, so I decided to convert to fj80 tie rod ends. The great thing about this is, when I carry spare TRE's, they can be used for my drag link, or tie rod. I previously ran a 9/16 bolt in my setup, and the fj80 stud is just slightly larger, so all I had to do was ream out my mercedes arm on the top, and then my new pitman arm. I still need to buy a right hand thread end because lowrange was out of stock.








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Old 04-15-2019, 12:31 PM   #115 (permalink)
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Finished up my mercedes stage 1 high steer. Mounted my radiator, filled the power steering and cooling system with fluids. Power steering works excellent so far. Seems to have some sort of odd vibe while driving though, so I need to dig into it and figure out exactly what's going on. Hoping it's just something simple. Also this rig was in last months issue of 4wd and offroad, so I was pretty proud of that.







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Old 04-15-2019, 01:12 PM   #116 (permalink)
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contrats on the write up
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Old 04-26-2019, 10:26 PM   #117 (permalink)
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Any pics of the finished cage? And are you planning a full cab enclosure with a rear window?
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Old 04-29-2019, 12:00 PM   #118 (permalink)
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Any pics of the finished cage? And are you planning a full cab enclosure with a rear window?
I still haven't finished the cage yet. I need to have a new roll bar bent up to fit. I don't plan on a full enclosure. The whole reason I built it the way I did was to avoid having a full enclosure. I have contemplated a fiberglass unit with a window, but it would be just for cold weather use, and removable if so.
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Old 05-14-2019, 09:35 AM   #119 (permalink)
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Been having a bit of an issue with hard starting, and hazing at idle, so I decided to try throwing a new set of injector nozzles in. I found you can buy chinese nozzles on ebay for cheap, and the reviews for the most part are pretty decent. Plus since this engine is all mechanical, I think they'll work. New nozzles were about $40 for the set.

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Old 05-15-2019, 01:02 PM   #120 (permalink)
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New nozzles are in, I have to clean out the injector holes yet, and install new copper crush washers. Hoping that this will help my hard cold starting issues, as well as stop the haze at idle, and strong exhaust smell.

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Old 05-28-2019, 08:22 AM   #121 (permalink)
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Started installing my cage this past weekend. I have everything welded up except the main bar. I'm planning on sandwiching my flatbed frame with some 1/4" plate, and bolting it down, so it'll all still be removable. Then I plan on running more DOM down to the frame, and then cross bracing the main bar to prevent it from racking if I do flop.













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Old 06-03-2019, 12:09 PM   #122 (permalink)
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Hacked up the core support the other day so that I could use my electric fan, it's not perfect, but I'm just trying to have this thing done before Moab in a little over 3 weeks. Threw some hood pins on from Figmo at roadlessgear as well since I removed the factory latch, and I threw some paint on the cage. Still need to finish the roll bar.







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Old 07-10-2019, 09:07 AM   #123 (permalink)
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I used expanded steel as the bed floor in a flatbed that I had built for my old Toyota. It was strong, easy to wash, and provided infinite tie down options.
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Old 07-10-2019, 09:42 AM   #124 (permalink)
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I used expanded steel as the bed floor in a flatbed that I had built for my old Toyota. It was strong, easy to wash, and provided infinite tie down options.
I have been strongly considering this route, and I scored this pallet of heavy duty expanded metal from Lowrange the other day, so I think I'm going to use it for it. I could use some weight in back too to help even out the weight.

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Old 07-10-2019, 09:46 AM   #125 (permalink)
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Another lovely update, something is majorly wrong with my engine. I lost compression on at least one cylinder. I need to pull it apart, I'm hoping it's just a head gasket and maybe a warped head. It got overheated last year when wheeling and my lower radiator hose got ripped off the radiator, so I'm hoping I can get away with possibly a used head and new gasket, won't know for sure til I get everything apart and checked though. Other considerations are just replacing the whole engine with a 2.0 gasoline VW engine.

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