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Project "Secret Squirrel"

82K views 469 replies 99 participants last post by  seafarinman  
#1 ·
Well this prodject was started like 8 months ago--but it has been thrown to the side a few times while I did a few other rigs. So alot of the buildup that I will be posting was done some time ago...

This is my good buddy jack's rig--he sold his last wheeler a few years back and has been itching to get back into it. So after some talking back and forth--we came up with a game plan and what parts he wanted it run. To put it bluntly--its going to be a toyota hidden under a small piece of zook :D

Here is how it started--- a $700 86' suzuki samerai and he drove it to my place--granted it died a mile from my place and had to be drag the rest of the way :D
 

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#6 ·
Well I pretty much gutted the inside---pulled every panel I could off and hosed the piss outa it--it was pretty yucky from sitting---I even found a pack of wild ump-lumpa's living under the drivers seat :D

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And so I figured--better do another ramp test to see just how much this thing performs--and would you look at that--that fawker gets it now :laughing:

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#10 ·
Well I pretty much gutted the inside---pulled every panel I could off and hosed the piss outa it--it was pretty yucky from sitting---I even found a pack of wild ump-lumpa's living under the drivers seat :D

Everyone knows it's OOMPA-LOOMPA, and, I think, they're listed on the Endangered Species List. You shouldn't harvest them without the right paperwork. W. Wonka is gonna kick your Sammi choppin' ass.

looks like a fun prodject/project....:laughing:
 
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#43 ·
It's "painfully slow", you goober! :flipoff2:

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Make sure you get the hardline on there correctly!! :flipoff2:

The way the motor was mounted was kind of an over sight on my end--I had NO idea they were clocked over to one side--the only dellema it caused was the master cylinder clearance--but made for a flat t-case...
That's really cool. I saw that in the first pics before you covered the tunnel, and was going to ask if it was intentional.

But once I actually got a sami to measure, thats when I realized its really not a big issue if you mount the motor level and just run a rotated T-case adapter (like I already have). Anyways - that light just clicked only recently after me and Crash started talking about it. When I do mine - I'm just going to mount my motor flat.
If you already have a clocked adapter, will it lift that front output higher than flat?
 
#14 ·
Well since I am running a Toy motor...I figured what the hell I like lots of levers and switches. OH and no these things were not this clean to start with.........:D and I had very little to do with it.

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#15 ·
Here is the front diff with all the crap cut off and sorta prepped.

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And I finally ripped the front axle and all other items out from under the rig.

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The front will be using YJ springs and I am moving the axle forward 3". So I will be extending the frame a hare at the front and incorpurating winch mount/tube placements into the whole thing and hopefully end up with a smooth transition from the very front to the sheet metal.
 
#16 ·
Since I am waiting on more parts to get the front some what figured out. I figured I would start to try and get the trans and t-cases in the rig. Plus this will help with getting closer to the proper weight of the rig for setting up the front suspension.

So to get these larger parts to fit some sheet metal lovin will be in order. One thing I have to figure out is where the rig will get lopped off at in the rear to stretch it/tube it out. So for now I will be removing sheet metal to get things fitted but at the same time trying to look 3 steps ahead.

Here is the bell housing. Its literraly almost against the tunnel/lip of the firewall :D

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And time to prep for a lil plasma fun :cheer: :cheer: :cheer:

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And here I just slit the tunnel with the intention of being able to fold the sheet metal back and weld it back up--stretching the tunnel..

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#17 ·
Ok so here is how the passenger side looked once I did a lil more trimming and some tach tach work. It worked out perfect and once welded up it should look perfect :;

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I ended up having to do a portion of the drivers side.

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#19 ·
And here we have all the cases bolted up. Once I got near the back of the tunel I found it was just TOO narrow to try and stretch it like I did the front. found it easier to just cut the origional stuff out and build a new one with that time comes.

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#20 ·
Ok here is how the clutch fork sits now. Sorry the angle isn't as good as I thought. But instead of totaly hitting the tunnel like it was it is tapping at the verry bottom edge now. So its going to be simple to clearance it and not get in the way of jacks ability to mash the go pedal :D

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And here you can see how the t-case will be sitting in the frame rails. Roughly 1/4" above the bottom of the frame rail unlike the 1.5" it was at--too high for my taists.

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#21 ·
Now is where I started making a nice mess along with alot of smoke with the plasma :cool: :cool: :cool:

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For now I just went and gutted the back of the tub but its all going away as soon as I can get the front suspension roughed in. But the front cut on the tub is where the tub will end so its not going any farther on the floor forward..

And here is the height I am shooting for. sorry about the poor angle.

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Another funny thing I found when I was removing the shocks--the housing is cracked at both perch's and the housing is twisting :*******: Good thing jack didn't drive it much because it had death writen alll over it,lol...
 
#22 ·
Well since I am waiting for a load of more parts that have kinda stopped me in my tracks. I deced to start the new tunnel to enclose the trans-t-cases...

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A few chunks of sheet metal and it should be done up. One interesting thing about the taco motor--notice how the whole works is tilted....
 
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#25 ·
For some reason there is alot of moisture in the body of this rig--its the oddest thing I have seen so bare metal spots are slowly getting surface rust on them. So I prepped the tunnel and shot some enamal primer on it to protect it.

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#26 ·
Since I am still lacking parts to get the front done I figured I would go ahead and get the rear crossmember done. I figured I would do a front range offroad type of crossmember so it will sit above the frame rails totaly. Here is the start of it.

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