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Old 10-09-2019, 07:01 PM   #26 (permalink)
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Rear u bolts are drivers front are just stock Toyota u bolts upside down with skid plate welded between the u bolts.
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Old 10-09-2019, 07:03 PM   #27 (permalink)
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Zuki 2.0 build mod stock


I really hate stock rear samurai spring mounts. They are to far out and to low. Here is what I came up with. My green samurai is kind of the same.
Kicks the rocks around the spring. Even with frame so they skid across. And skinner so I can run 5Ē backspacing wheels if I want. Ended up with 3.5Ē.
Housing front and rear is 81 Toyota
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Last edited by toyotanuts; 10-09-2019 at 07:07 PM.
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Old 10-10-2019, 03:52 AM   #28 (permalink)
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Drilled hole for nut and washer in inside of the frame. This should make for smooth slide across rocks. Want this build to be low so no hang ups.
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Old 10-10-2019, 03:53 AM   #29 (permalink)
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Mod stock

Nice Samurai, looks very well thought out. I followed XRocks all year, looks like a really good time. Thinking of trying to come to a couple events next year, may even try to compete, just need to look at the rule book a little more in depth.
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Old 10-10-2019, 03:56 AM   #30 (permalink)
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Wheelbase and body rules

One thing that I saw when I originally looked at the rules was the 3" wheelbase stretch and body requirements, are they not being so strict about these two or does your samurai truly only 82-83" wheelbase? The wheelbase would disqualify me, I'm about 3" in the front and 2" in the rear.
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Old 10-10-2019, 03:57 AM   #31 (permalink)
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Zuki 2.0 build mod stock


Centered the gas tank. Made rear bumper and rear shackles. Also can see 3/4Ē plastic I used for skid plate for fuel tank. Used angle to tie plastic to. Had to dent the tank some to get this angle on the skid.
Also mounted rear suck down winch to frame above the axle. I donít have picture of this that I can find. But itís on the wide cross member the shocks bolt to. Being such I short wheelbase I use this a lot on downhills. I can get pictures if someone wants them.
You can also see rear square u bolts and disc brakes. I used V6 91 Toyota calipers and rotors on front and rear axle! Have cutting brake for each tire!!
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Last edited by toyotanuts; 10-10-2019 at 04:29 AM.
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Old 10-10-2019, 04:03 AM   #32 (permalink)
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Quote:
Originally Posted by covecrawler View Post
One thing that I saw when I originally looked at the rules was the 3" wheelbase stretch and body requirements, are they not being so strict about these two or does your samurai truly only 82-83" wheelbase? The wheelbase would disqualify me, I'm about 3" in the front and 2" in the rear.


Iím 83Ē but they never checked mine. Iím pretty sure they stick to the 3Ē rule. You May ask Hans.
Would it be hard to move 2Ē??
I do know no comp cut. Whatís wrong on your body?
Itís a lot of fun. I really like itís one day comps so they donít take your whole weekend and you can wheel some if you want.
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Old 10-10-2019, 04:07 AM   #33 (permalink)
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My body is currently fine, only trimmed lightly. Working on a cage at the moment, we'll see what happens this spring, I may come compete, I ran the VA State Rockcrawl one year and had a blast.
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Old 10-10-2019, 04:23 AM   #34 (permalink)
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Quote:
Originally Posted by covecrawler View Post
My body is currently fine, only trimmed lightly. Working on a cage at the moment, we'll see what happens this spring, I may come compete, I ran the VA State Rockcrawl one year and had a blast.


Ok
You can cut body up to the hood. Rear you can cut out to top of fender well. My rear fender well was rusted out bad ( like 4Ē gap between outer body and fender well). So I cut body no higher than the stock rear inner fender height. Had to make new rear inner fenders.
I would love to cut rear out more and allow more up travel but it does good the way it is.
Front tires hit the hood pipe at the hood and at the light I have.
Message me if you have anymore questions or post on here!!
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Old 10-10-2019, 06:19 AM   #35 (permalink)
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Zuki 2.0 build mod stock


Front spring mounts on rear side are almost stock. Using 2 1/2 yj rubicon express springs.
So I had to move mounts in a little and make them wider. I bent the rear of hanger so rock would slide around if I need to reverse off a rock.

I really hate all the yj conversation mounts that hang down a mile getting stuck on everything!
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Last edited by toyotanuts; 10-10-2019 at 06:20 AM.
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Old 10-10-2019, 06:23 AM   #36 (permalink)
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Zuki 2.0 build mod stock


Made cross member to support trans and also support Dana 300 on front output side. This will help keep weight of 300 from hanging off back of trans and the torque of driveshaft from turning t case.
The bottom of the crossmember is flush with frame so it will help support a skid plate in the future.
Really love front dig so worth it.
I ran samurai cases years ago. Never had any luck with them for wheeling. Maybe the street.
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Last edited by toyotanuts; 10-10-2019 at 06:24 AM.
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Old 10-10-2019, 06:27 AM   #37 (permalink)
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Bent some metal to L shape and made brackets on both sides. Used 1 1/2Ē Chevy bushing on transfer case and motor mounts.
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Old 10-10-2019, 06:31 AM   #38 (permalink)
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Shackles at ride height. I moved mount up and on the front of the frame. This way when going against a rock they will invert against frame and act as a ramp and slide down the leaf spring. The shackle bottoms out against frame. Used 1/4Ē wall on the tubing cause it is going to get hit hard and pulled on hard!!
Keep shackles on the front for
winch suck down to work better.
Steering room
Short stock Toyota drive shaft splines works
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Old 10-10-2019, 06:35 AM   #39 (permalink)
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Having suck down winch (front and rear) to help set up steering, bump stops, shackle tie in points, really helps a whole lot. This photo shows full bump with winch sucked down.

Keep all 5 leafs in the front!
Removed lower on in the rear. Was to stiff. Axle wrap doing ok so far.
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Old 10-10-2019, 06:38 AM   #40 (permalink)
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Zuki 2.0 build mod stock


Ended up with steering box with stock arm on it. Got tie rod under steering kit off of eBay. 1/4Ē wall tube on tie rod and .120 wall on drag link.
Rcv axle shaft. Limited bump stops to 45 degrees (if Iím measuring right. Hard to do but I donít feel any binding)
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Last edited by toyotanuts; 10-10-2019 at 06:38 AM.
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Old 10-10-2019, 06:40 AM   #41 (permalink)
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Used ifs hubs. I like these cause I can take c clip off of end of outer shaft and remove whole hub assembly like it was a unit bearing!! Makes repairs quick.
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Old 10-10-2019, 06:43 AM   #42 (permalink)
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I donít like high steer cause it always causes issues with knuckles, studs etc. hydro assist donít help. I ties steering arm in with steering bump-stop to help from breaking.
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Old 10-10-2019, 06:44 AM   #43 (permalink)
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Zuki 2.0 build mod stock


Also braced up stock arm on outside edge and added 5 stud to steering.
You can also see the spindle bolts you can get to to removed hub assembly as one unit.
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Last edited by toyotanuts; 10-10-2019 at 06:46 AM.
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Old 10-10-2019, 06:48 AM   #44 (permalink)
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Zuki 2.0 build mod stock


Got to mounted. Little lower than I wanted but to clear oil pan and suck winch rope it almost had to be. The tie rod protects it a lot.
You can also see how I did rear and front drivers u bolt plate skids. I did break one already but I think we welded on it to much and got it hot. I really like the ramps on front and back and how skinny to mount is to get around rocks. Also leaf spring mounts are flush with housing in the middle! So I gain height and donít hang down low!! I did have to grind down center pin a little.
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Last edited by toyotanuts; 10-10-2019 at 06:51 AM.
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Old 10-10-2019, 06:57 AM   #45 (permalink)
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Here is steering completed. I would like to say the steering is unreal! It works great! 1 1/2Ē x 8Ē psc ram works great with the fj 80 box. The 80 box has a bigger piston so I think that why itís so much better than my ifs on my other rig. My girls can turn it with one hand with front locker on.
Tie rod does hit pitman arm just a little on full flex.
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Old 10-10-2019, 09:06 AM   #46 (permalink)
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Finally catching up here from talking to you on FB. Man what a great setup. It's impressive that you are able to make all of that work SUA with only a 2.5" lift spring. I'm going to borrow a lot of ideas

What did your rear shackle mount end up looking like?

Is that also the stock fuel tank? I know you said you dented it for clearance and centered it, did you also move it towards the rear?

Have you had any trouble out of notching the front housing like that? I'm assuming that is just for frame rail clearance. Edit: nevermind, I see that it's to inboard the spring perch.
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Last edited by DirtRoads; 10-10-2019 at 09:24 AM.
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Old 10-10-2019, 09:11 AM   #47 (permalink)
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Zuki 2.0 build mod stock

Quote:
Originally Posted by DirtRoads View Post
Finally catching up here from talking to you on FB. Man what a great setup. It's impressive that you are able to make all of that work SUA with only a 2.5" lift spring. I'm going to borrow a lot of ideas

What did your rear shackle mount end up looking like?

Is that also the stock fuel tank? I know you said you dented it for clearance and centered it, did you also move it towards the rear?

Have you had any trouble out of notching the front housing like that? I'm assuming that is just for frame rail clearance.


Stock fuel tank yes. But I moved it to center of vechicle so the springs would clear etc.

Axle- didnít have problems on short side which is the side I botched. But I do think the long side between leaf and knuckle is bent. I replace axle seal twice on long side and it leaks bad.
I may get after market. Maybe trail gear cause it looks like I could keep springs close.

Rear shackle is through the frame.
You can see it I picture above with rear bumper.
I donít have a side shot but itís almost strait up and down.
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Last edited by toyotanuts; 10-10-2019 at 09:18 AM.
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Old 10-10-2019, 11:59 AM   #48 (permalink)
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I am not that up on the 4spds. what years do the 03-72l come from in the Montero? do you need anything other than the trans? The zuk bell bolted on without any issues? Used a zuk TC? is it still electronic controlled?

thanks
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Old 10-10-2019, 02:43 PM   #49 (permalink)
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I used 2.0 tracker bell and parts not zuki!
I try and find the years
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Old 10-10-2019, 02:48 PM   #50 (permalink)
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Quote:
Originally Posted by paradisePWoffrd View Post
I am not that up on the 4spds. what years do the 03-72l come from in the Montero? do you need anything other than the trans? The zuk bell bolted on without any issues? Used a zuk TC? is it still electronic controlled?

thanks





http://www.txchange.com/id.htm

90-5/94

I think I always searched for a 92/93 to be safe.
The bell housing that comes on the montero has a big v drop in housing between the top two bolts.
Hard to miss. I have old one if you need a picture.
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