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Old 02-07-2018, 06:56 AM   #1 (permalink)
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'86 samurai tdi swapped -> truck conversion

This thread will follow the LWB build of my 86 samurai that already TDI swapped, into a truck build. I'll try to post lots of pix. Any questions, just ask.
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Old 02-07-2018, 06:58 AM   #2 (permalink)
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Heres the sami, before chopping, and after.










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Old 02-07-2018, 07:01 AM   #3 (permalink)
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Removed the cab, and started stripping the frame of all the nasty crap that I can hardly grind through. Pretty sure the PO used some extra undercoating on it, I had to heat with a torch and use a scraper to get most of it off.



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Old 02-07-2018, 07:06 AM   #4 (permalink)
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I originally didn't want to chop this thing up, it was my first car when I was 16. But after wheeling with Tylor and Anthony from LROR at Moab, I decided I need a longer wheelbase.


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Old 02-07-2018, 07:13 AM   #5 (permalink)
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My current setup consists of:
Brand new YJ's SPUA, with Dr. Z's kit, on 31's. But I think I'll be going to Toyota front leafs on all four corners SPOA soon.

Engine: 1.9 AHU TDI from a 1998 jetta. 12mm mechanical injection pump conversion, PP520 injector nozzles, k24 turbo.

Tranny: Acme Adapter plate, Geo tracker 5 speed, with transfercase. I decided this route to get the 1:1 high range, while still being able to do gears in the case for lowrange.

Transfer case: Tracker case, trail creeper 4.24 gears, Trail Tough rear slip yoke eliminator. Trail gear twin sticks.

Axles: Front- LROR chromo 26 spline shafts, trussed, spartan locker.
Rear: LROR silverback axles, spartan locker, LROR disc brake conversion kit.



















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Old 02-07-2018, 07:19 AM   #6 (permalink)
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Doing some test fitting of my seats. They're from a suzuki swift GTI. They fit awesome, and are super comfortable. They also have just enough room for me to enclose the back bottom of the cab. I plan on leaving the top open, and making a custom soft top.

Samurai by steven l, on Flickr

Samurai by steven l, on Flickr

Samurai by steven l, on Flickr
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Old 02-07-2018, 07:22 AM   #7 (permalink)
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This is roughly the look I'll be going for. This is O1lburners rig, he was cool enough to send me a lot of pictures of his build several years back.


Samurai by steven l, on Flickr
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Old 02-07-2018, 07:35 AM   #8 (permalink)
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looks good man
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Old 02-07-2018, 08:28 AM   #9 (permalink)
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I like it!
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Old 02-07-2018, 10:14 AM   #10 (permalink)
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Love it

The suzuki section seems to be picking up steam lately
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Old 02-07-2018, 10:47 AM   #11 (permalink)
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Here's a vid from almost two years ago. In this video I was sitting on 3" rear lift springs on all four corners, with missing links in front. At this time, I still had the samurai transfercase, with a sidekick 2wd 5 speed and a shortened intermediate shaft. Open diffs and all.




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Old 02-07-2018, 10:52 AM   #12 (permalink)
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And a video I made quite a while back, when it was first up and running.


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Old 02-12-2018, 05:43 AM   #13 (permalink)
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EDIT: Picture fix

Chopped and stretched the frame today. 18 longer now. Still need to plate the frame, its currently just tacked into place.

Untitled by steven l, on Flickr

Untitled by steven l, on Flickr

Untitled by steven l, on Flickr

Untitled by steven l, on Flickr
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Old 02-12-2018, 05:37 PM   #14 (permalink)
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You have my attention.
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Old 02-12-2018, 06:43 PM   #15 (permalink)
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Hey glad to see your documenting your build on here too! I will be following for sure.
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Old 02-13-2018, 11:34 AM   #16 (permalink)
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What are the years that the 1.9 AHU come in the Jetta and do you know if the engines are in any other VW's? Do you know the stock Hp and Tq?
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Old 02-13-2018, 11:57 AM   #17 (permalink)
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What are the years that the 1.9 AHU come in the Jetta and do you know if the engines are in any other VW's? Do you know the stock Hp and Tq?
The 1Z came in 96-97 passats, and is basically the same as an AHU. The AHU came in 97-99 mk3 jettas. In 1999.5 the mk4 jetta and ALH was introduced. You probably won't find the engine in anything else, other than some industrial pumps, generators, reefers, etc. Stock HP and TQ are like 90 hp, and 155 foot lbs. My motor has some upgrades though, I would estimate I'm around 125 hp and 200 ft pounds.
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Old 02-13-2018, 12:08 PM   #18 (permalink)
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The 1Z came in 96-97 passats, and is basically the same as an AHU. The AHU came in 97-99 mk3 jettas. In 1999.5 the mk4 jetta and ALH was introduced. You probably won't find the engine in anything else, other than some industrial pumps, generators, reefers, etc. Stock HP and TQ are like 90 hp, and 155 foot lbs. My motor has some upgrades though, I would estimate I'm around 125 hp and 200 ft pounds.
I'm looking for something that's all mechanical, wanting to do another diesel project. Did 2 Cummins 6bt transplants so thought about something a little smaller next time. Thanks for your help.
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Old 02-13-2018, 02:22 PM   #19 (permalink)
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I'm looking for something that's all mechanical, wanting to do another diesel project. Did 2 Cummins 6bt transplants so thought about something a little smaller next time. Thanks for your help.
Mine is all mechanical. I had to swap out injection pumps. Here's a couple videos that show a little detail of it.




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Old 02-13-2018, 02:41 PM   #20 (permalink)
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So it's not a stock engine that's mechanical you have to put a different Injection pump on to make it a all mechanical engine?
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Old 02-13-2018, 02:44 PM   #21 (permalink)
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So it's not a stock engine that's mechanical you have to put a different Injection pump on to make it a all mechanical engine?
Yep. The stock TDI is electronically controlled.
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Old 02-13-2018, 02:51 PM   #22 (permalink)
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Yep. The stock TDI is electronically controlled.
That's what I thought, so what kind of a IP are you using to make it all work mechanical?
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Old 02-13-2018, 03:14 PM   #23 (permalink)
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That's what I thought, so what kind of a IP are you using to make it all work mechanical?
I'm using a pump from a european motor, but a 4bt VE pump is another common swap, it takes a little more work to do that though, but it works.
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Old 02-13-2018, 03:19 PM   #24 (permalink)
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I'm using a pump from a european motor, but a 4bt VE pump is another common swap, it takes a little more work to do that though, but it works.
I guess I better quit messing up your thread asking questions about your engine when it not about that. I'll just see if Google can help me, thanks
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Old 02-13-2018, 03:21 PM   #25 (permalink)
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I guess I better quit messing up your thread asking questions about your engine when it not about that. I'll just see if Google can help me, thanks
I don't mind answering any questions, I've built two TDI samurai's. If you wanna PM me any questions you're welcome to.
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