SAMMI IN TEH RUFF STARTS NOWWWWWW

[Simko]

last night i picked up my first car EVER (sammi) shes rough, plagued with bondo, no front signals, more bondo, expanind foam and THE ROT :O


anyways she needs a LOT of work, new balljoints clutch etc. Ill be taking pictures etc and maybe memphis will make a restoration video for us all :brows:

[Memphis]

you are teh gay there is no boondo! Just xpandin foam!!
Post the pictars

[fullspectrum]

anyways she needs a LOT of work, new balljoints clutch etc. Balljoints???

Welcome to the club. I bought my first Sammy in the Summer. Lots of hidden rust and rot but all original. I look at the glass half full...at least I had no bondo to remove. :) Just keep at it and it'll be worth it in the end.

[Simko]

she needs the work yep, id really like to get locks on the doors, a working tailagate etc, and also be able to use one key to work all the locks and ignition!

ah i can dream :P

[Simko]

PICS!

so this is the big crowd killer bumper it has on it

http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4895.jpg

some cutting was done
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4894.jpg
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4893.jpg
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4892.jpg
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4891.jpg

so the rockers had a lot of bondo over the steel, we cut them out
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4888.jpg

there were a lot of mystery wires that got chopped accidently

and so this is what i found my rockers were REALLY made of:
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4890.jpg

yes... papier mache, expanding foam, a stick, bondo

[Memphis]

diamond in the ruff I sees!
High Five!

[Memphis]

ps. Fullspec, he ment the Birf's. Tis a little wobbly.

[fullspectrum]

ps. Fullspec, he ment the Birf's. Tis a little wobbly. Yeah I figured...I was in the same boat as you Simko. Lots 'O' rust...You'll get it done. Next time I'm buying a one way ticket to the California or the southern states and driving something home. I'd rather save a little longer than to have my head in the floors stichwelding and shaping floors in. All the while inhaling welding fumes. :shake: Well if EL NINO continues...the cars will last longer around here too...:D AHhhhhh..... Global Warming.....:)

[samzuki]

Next time I'm buying a one way ticket to the California or the southern states and driving something home.

If you're willing to go to that trouble, you might want to look into some of the fibreglass suppliers over seas. I can't remember the site, but I'm sure you could dig it up with some effort. They even had Suzuki pick up cabs. Really neat looking. Would make an awesome flatbed on an LWB :D

[Simko]

Heres some pics of the lady outside
this first one is an area that was rotted out, took the little plastic plate out, i hope this isnt TOO structurally important :P
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4898.jpg


Side Uno
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4897.jpg

La frente
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4896.jpg

Dos

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4900.jpg

After a quick run to the automotive princess came up with these:

Lots of lights for the rear bumper, (note turn signals and the brakes, but where are the reverse lights?)
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4903.jpg


BAM! here they are! Halogen reverse lights :P
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4902.jpg

and then a horn and a tach
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4901.jpg

[anthony]

how can you not love princess auto ??

i found a yj for sale last month with the frame rotted out where the shackles bolt on in the back .. the guy had filled it up with spray foam !!!! i don't have an engineering degree, but i'd bet dollars to donuts it's a tad less structurally sound than steel

[Memphis]

High Five! :thefinger

Your already over budget, go get your wheel cylinders you lazy fawk!

[SamiFlyer]

Run a bigger power wire for those reverse lights and put them on a relay. Otherwise you will just burn up the factory wires and short something out.;)


Sean :cool:

[Memphis]

Ron I don't work Saturday and Sunday now. It's time to get to work :thefinger
Dibs on rigging the horn up!!! :thefinger

[Simko]

So ive decided to make this my strip down, then build up thread

more pics


Tailgate, Bondoed, i sanded today but dont have pics

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4904.jpg

The little can i bought first, then the BIG DADDY size, and a waterbottle for scale

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4905.jpg

Gas tank i got from sarge (i hope my sending unit from USA will come soon )

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4906.jpg

with some caulking around the lip

Big 4L jug of rockerguard

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4907.jpg

[mudbug]

A friendly tip...if you have to use bondo make sure to grind off all the paint in the area to be covered and if your covering holes use the fiberglass crap.I hope you have fun fixing up your sami I know I had fun fixin up my tracker the best part is when it's finished;)

P.S how do you plan on doing the rockers ? I hope you have a mig !!!!

[Simko]

Got a mig! but im planning on making rocker rail/ rock sliders!

and for the sliders etc i have a big 220 arc

[mudbug]

Im glad to hear that you have a mig that will make the job so much better than what some guys do with screwes and rivets:yike I can't say too much bad about that ...when I was 16 I did the floars in my 71 javelin I'm still trying to forget the hack job I did on that poor thing:rofl:

[Simko]

dont worry, ill try to fit some rivets in somewhere!!!

[rocktracks]

keep up the good efforts:D

[Simko]

so... i stop using bondo? LOL

:P

[fullspectrum]

so... i stop using bondo? LOL

:P

I used sheemetal and either welded it in or riveted it in. Then I covered the seam with construction adhesive (called PLP from home Depot) goes on like silicone and dries hard, almost like very hard rubber. Then I put some paintable undercoating over it all. Believe me this stuff will never come off and it doesn't let moisture in behind it like bondo. Once it starts bubbling the bondo will come out. My method doesn't look as good but it will last longer. Good luck..I hate rust...:rant:

[Simko]

Im going to loko into this PLP. do you have msn messenger? i have some questions for ya as my sammy repairs KINDA have similar structure to yours (i gotta ask HOW) :P


for the PLP, how is it for applying during the cold winter time?

[fullspectrum]

The PLP is in the silicone section at Home Depot. It's made by bulldog grip. It's in a black tube with gold and red writing I think?? Ask the guys in Orange for the PLP construction adhesive.

I put it on in the cold and painted and undercoated it before it was dry and the next day it was pretty much dry. It drys almost hard. I've used bondo and I don't like it. I stumbled across this stuff when I was doing my bathroom renovation. I was gluing a plywood subfloor down and I was amazed by this stuff. It glues stuff almost permanently. And works great as a seam sealer. I used it all over my Sammy. Goes on like silicone. It fills gaps and holes.

[Memphis]

Simko and I did a small overhaul on the zook last night. Couple days ago he cut and folded the drivers side front fender and stitched it together, I went over a couple spots and "cleaned them up" aka more unnecessary spot welds :thefinger. Then proceded to patch the gaps between the pinched seams. Needless to say, great idea Fullspectrum, Simko took some pics of my booty fab patches. I had to trim em with hand shears so I had to piece it together in sections unfortunately. Hey, we are both learning so what can ya do.

Now that he bought electric shears, I am positive the process will look much cleaner and look more like a complete (single patch) unit unless the PA shears turn out to be complete pieces of shit.

Ron post them pics up so everyone can make fun of my bird shit welds :D

Steel for the "rock sliders" and rear bumper have also been purchased from a reasonably priced supplier in London. We won't be welding those because it exceeds our sheet metal kaka welding abilities. Post up the pics you loser

[Simko]

New pics folks:

i started working on the fender on the front driver side, then memphis did some beauty frankenpatchwork: results before final grinding and sealing:

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4910.jpg

also a patch in the B pilllar
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4911.jpg


the hole in the rear right corner
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4913.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4916.jpg


and from the outside:
http://s2.photobucket.com/albums/y29/aaron_simkovich/?action=view&current=DSCN4917.jpg

[fullspectrum]

Looks like mine....:D Lots O fun Eh!??:roll: Keep it up the pain will be over soon...Good work.

[weldor guy]

Looking Good!!! Get,R Done... nice neibour hood man your neibors must love you!!! lol

[Simko]

so the patches sucked, they were removed and redone

pics!

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4936.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4937.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4931.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4930.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4929.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4928.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4927.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4949.jpg

[Canadian_zuk]

Looking good for your first time.:beer:

Take a little more time and clean off that paint before you weld. Your breathing all that black crap (burnt paint) you see streaking up your fender. You'll also find your welding skills will appear much better when welding clean metal.

Keep at it, I've seen much worse come back from the dead!

[Memphis]

not sure which pic your referring to CZ but the pic of me welding, we couldn't get the damn grinder in there, tried using a dremel and that didn't turn out so good. Thats the only part of the vehicle that has been "welded" and I use that word loosely lol over paint, everything else has been bare steel. I know the paint fumes aren't good for me :D

The Grinder is huge, heavy and a pita, the wire on his small hand grinder fawked off and the cheap son of a bitch won't buy a new grinder.

[Canadian_zuk]

Sorry, I must be seeing things. In post 26, it sure looks like there's alot of blue paint where all those spot welds are holding your patch on. I was refering to the black soot that's above the weld line. Most of the other pics also look as though the paint hasn't been cleaned from the weld zone.

I'm gettin old, have fun and work safe.:beer:

[Memphis]

I see what you mean now, the paint was cleared about 2" so the weld was made on bare steel. That pic was taken before I had any significant knowledge of how to weld, that patch has since been removed as seen in the last post by simko. So when I made that first hack attempt, I had the heat on way to high and the wire speed ridiculously fast so I have splatter (which contributed to the burned paint that you see from the pictures)

It looks a bit better now, but still ugly as sin. This is a learning process for both of us, I am enjoying every step of the way. I just wish I could learn to lay a nice bead. Thanks for the kind words :rofl:

[Memphis]

Well we removed the doors, ground down the hinges, they slide on and off nice and easy. Doors are going to be prepped for paint. Free Removable doors kick ass!

Ron did some hack tail gate fixes that didn't work, I pooped on some bondo on the hood and driver side front fender, not a whole bunch done today and no pics. That doesn't matter though because we aren't even close to being done what we've started so we'll get some new pictures probably by the end of the week.

[weldor guy]

nice job man thats how i did mine... at least you know that everything is steel now

[Simko]

nice job man thats how i did mine... at least you know that everything is steel now


sorta yep, i guess, we just took our time, cut the junk out, new steel and jeff welded up some purdiness.

[Memphis]

Only difference was a couple mouse nests instead of dog shit :thefinger

[anthony]

Only difference was a couple mouse nests instead of dog shit :thefinger

hahaha !!!!!

[Memphis]

We'll have a couple of new pics tonight likely, I think we are going to start mocking up the boat side rockers. This isn't for clearance or anything, just simplicity. The body is coming together very nice, I'd like get get it done but don't want to rush and have it fall apart.

Question for you guys since I don't know anything about exhausts. One of the PO's put in a 2" exhaust system. as smart as they were they used the stock manifold and attempted to bolt up the down pipe (if thats the correct word) with an oversized flange and poop the shit out of it so it didn't leak. Obviously this is not correct or safe. for those of you that have put in a 2" exhaust system what did you do if you kept the stock manifold?

The hack job piping has to come out and be redone. So what I am thinking is, pull it all out, get the correct flange for the down pipe, then find a short extension that is stock diameter to 2" or 2.25" not exactly sure which size was used... then reconnect the exhaust and build new hangers for it, I don't think the chicken wire will pass safety...

Any advise for passing an E test as well? The sammy doesn't smoke or anything and it doesn't smell like it's rich but would it be a wise idea to purchase a carb rebuild? It is idling waaaaaay too high right now (while it was still running) but I think the exhaust leak and intake boot leak are contributors to this problem...

[Canadian_zuk]

....get the correct flange for the down pipe, then find a short extension that is stock diameter to 2" or 2.25" not exactly sure which size was used... then reconnect the exhaust and build new hangers for it, I don't think the chicken wire will pass safety.....

yup, that's what I'd do. Sami's don't crave the backpressure that most imports need. You can go as big as you want after the collecter, but anything more than 2" is a waste of $$ and will provide no added benifit. Unless your running NOS.



Any advise for passing an E test as well? The sammy doesn't smoke or anything and it doesn't smell like it's rich but would it be a wise idea to purchase a carb rebuild? It is idling waaaaaay too high right now (while it was still running) but I think the exhaust leak and intake boot leak are contributors to this problem...

Carb eh? Fix the leaks and hope for the best. You'll need to get that idle down. If you can find a rebuild kit, go for it. 20 years, it probably needs it. :)

-CZ

[Memphis]

Simko bought a fuel tank off of Sarge, he needs to get it cleaned and sealed so it can be installed then we'll be ready to tinker with the idle. I'd like to get it done now just so we can have a change from all the body work we have been doing but it's not my call. I'll have to look into a rebuild kit for the carb.

Hopefully the other three fender wells go as smooth as the front drivers side did, the rear driver is going to be redone as well. Trial and error for the most part in the beginning but it has paid off, nobody thinks that we are going to obtain a safety certificate for it, that is only pushing us harder to get it done right.

One more thing that popped into my head. Who has ever had to fix the stock zook horn? We took the dash apart, started tracing wires same thing under the hood, for some reason the horn will not work. I took 2 wires and hooked it directly to the battery and the horn itself works but there is a short some where in the 2 wires running back to the column. Any advice, or a possible way to bypass it but still use the stock switch? His is an 89' if that makes a difference apparently there is a horn fuse and a horn relay which we think we have found... online people said there was no horn relay... Suzuki wants $50 for the horn relay and thats a pretty expensive fix especially when we don't know what the problem really is...not sure if the relay is pooched or not.

Had my one buddy who is currently apprenticing at a dealership here in London take a look at it, probed around with the volt meter and stuff but I was not exactly sure what he was doing, didn't bother asking him to explain what was going on because I suck at wiring. He started piecing the problem together but we had to call it a night.

[Canadian_zuk]

One more thing that popped into my head. Who has ever had to fix the stock zook horn? We took the dash apart, started tracing wires same thing under the hood, for some reason the horn will not work. I took 2 wires and hooked it directly to the battery and the horn itself works but there is a short some where in the 2 wires running back to the column. Any advice, or a possible way to bypass it but still use the stock switch? His is an 89' if that makes a difference apparently there is a horn fuse and a horn relay which we think we have found... online people said there was no horn relay... Suzuki wants $50 for the horn relay and thats a pretty expensive fix especially when we don't know what the problem really is...not sure if the relay is pooched or not.

The problem is in the switch itself. There is a little brass pin that is spring loaded and makes contact with a copper ring under the steering wheel cover. That little pin is now worn out (too short to reach the ring when you push the horn). Get a new one from suzuki, or do what I did, remove it and solder a finishing nail to the power wire in it's place. :)

[anthony]

chicken wire will pass safety...

2 inch exhaust ?!?!?!?! you guys should just scrap it, but first send me the rear drive shaft :rofl:

get a new flange and pipe at crappy tire and swage it by heating it and rolling a decent sized bar inside it .. the real pain is exhaust studs, lots of heat wrench and gentle persuasion required

[fullspectrum]

Carb eh? Fix the leaks and hope for the best. You'll need to get that idle down. If you can find a rebuild kit, go for it. 20 years, it probably needs it. :)

-CZ

Mine was running like a bag of crap. Was thinking of buying a rebuild kit but it's around $60. There's a company in Australia that sells a kit for the Aisin carb on the Canadian Sammy's. I took my carb apart carefully so I could reuse the gaskets. I took carb cleaner and cleaned all the passages, fuel bowl etc. I took some wire off a wire brish to clean out any small holes and passages. Put it all back together and put a fuel filter on to keep any crap from the tank getting back in it. I adjusted the mixture screw, idle screw and choke. Before I couldn't adjust it to idle properly. Now it starts good, choke works and comes off and it idles steady. What a difference it is to drive now.

I'd start by cleaning the fuel bowl and passages. Then spend the money for a kit.

Here's a link to a page that helped me....http://moose.ca/~slowzuki/slowzuki/powertrain/Fuel/Aisin_Carb/aisin.htm

And here's a link to the Australian Company that sell the Aisin carb kit for Canadian Sammys. Search for model 90-18. It's around $30 Canadian. http://www.nardek.com.au/

[Memphis]

Thanks for the info in advance, however more delays have pushed the completion further back. Attempted to repair the rockers tonight in a boat side style fashion, however, through constructive shit talking I was told it was not strong enough and now it is all hacked up and beat to hell. :roll:

So simko and I started some chicken scratch sketches and this is what we've come up with.

This was my original repair:
http://img.photobucket.com/albums/v94/jpaddock/Zookpower/BoatSide.jpg

I was shown through physical force from our friend Fire Crotch that it was a weak and stupid idea, so now it is beat to hell

Now Simko and I did some Etch A Sketchin' and tossed ideas back and forth. Then we combined both of ours into one. Structure AND Safety are very important so this is what we have wrote down on a cocktail napkin:

http://img.photobucket.com/albums/v94/jpaddock/Zookpower/BoatSideHD.jpg

Ok, now time to explain the new setup, first the Reinforcement Plates. They will be welded to the interior and exterior of the inner rocker to beef the area up. Because I can't weld, and the structure would probably be compromised welding thick angle iron to thin steel, the side with the reinforcement will be bolted on, that way, if there is any need to remove it, the rocker can piss off. Now because of the door, Simko's old man has industrial rivets, I haven't seen em myself but ya gotta have an air rivet gun to install em, so we figure pop a couple rivets in the door sill that way it will still close as normal.

Then a piece of flat stock will be welded to the angle iron to beef it up.

Does this sound like a good plan or a waste of $$$$ thought about square tube, but the tub on this sammy has seen better days, and welding the square tube to the tub would just be dumb on my part because it wouldn't be done properly

What would you guys do different? We want this thing to be safe

[SamiFlyer]

That's not a bad idea. I was going to do something similar because the rockers on my 4dr are gone.

http://www.gno.edu.on.ca/Simon/Toughguy/toughguy/truck/Kickit/IMG_8366%20(Medium).JPG

http://www.gno.edu.on.ca/Simon/Toughguy/toughguy/truck/Kickit/IMG_8367%20(Medium).JPG

However, I decided that I wanted to have some metal sticking past the bottom of the door to protect it from scraping along rocks, trees, etc, so I bought some 2x4 box steel 0.125 (1/8th) inch wall and I will weld it in place of that hanging piece of sheetmetal you see in the pics. It will be strong enough to jack from without bending and will be low-profile enough to not be a ground clearance issue.


Sean :cool:

[fullspectrum]

Thanks for the info in advance, however more delays have pushed the completion further back. Attempted to repair the rockers tonight in a boat side style fashion, however, through constructive shit talking I was told it was not strong enough and now it is all hacked up and beat to hell. :roll:

So simko and I started some chicken scratch sketches and this is what we've come up with.

This was my original repair:
http://img.photobucket.com/albums/v94/jpaddock/Zookpower/BoatSide.jpg

I was shown through physical force from our friend Fire Crotch that it was a weak and stupid idea, so now it is beat to hell

Now Simko and I did some Etch A Sketchin' and tossed ideas back and forth. Then we combined both of ours into one. Structure AND Safety are very important so this is what we have wrote down on a cocktail napkin:

http://img.photobucket.com/albums/v94/jpaddock/Zookpower/BoatSideHD.jpg

Ok, now time to explain the new setup, first the Reinforcement Plates. They will be welded to the interior and exterior of the inner rocker to beef the area up. Because I can't weld, and the structure would probably be compromised welding thick angle iron to thin steel, the side with the reinforcement will be bolted on, that way, if there is any need to remove it, the rocker can piss off. Now because of the door, Simko's old man has industrial rivets, I haven't seen em myself but ya gotta have an air rivet gun to install em, so we figure pop a couple rivets in the door sill that way it will still close as normal.

Then a piece of flat stock will be welded to the angle iron to beef it up.

Does this sound like a good plan or a waste of $$$$ thought about square tube, but the tub on this sammy has seen better days, and welding the square tube to the tub would just be dumb on my part because it wouldn't be done properly

What would you guys do different? We want this thing to be safe


Does your Rocker look like this? I made some C channel out of some hunks of flat metal I got from a metal scrapyard. I cut the bad rocker off and slipped
the c-channel up and in. Welded it to the outside(ugly) and welded and rivited it to the inside. Then I wrapped the outside with some sheetmetal and more rivits. Not the best fix but It's strong. I can lift the truck from the rocker.

[samzuki]

When I did the body on mine, I wanted a strong rocker solution. In the end, I had some stock looking replacement panels made. I did this because I couldn't figure out how to attach thick and heavy steel to thin (and I mean really thin) tin. I see guys with the 2x4 rockers all the time. How do you do it?

[Memphis]

fullspectrum, Simko's rockers look very similar to that, some of the inner rocker was rotted as well (it has now been patched but this is why we are concerned about the strength of the rocker, I thought about C Channel, perhaps plans will change. More doodles to come...

[fullspectrum]

fullspectrum, Simko's rockers look very similar to that, some of the inner rocker was rotted as well (it has now been patched but this is why we are concerned about the strength of the rocker, I thought about C Channel, perhaps plans will change. More doodles to come...

Well I didn't have much of an inner rocker left. Maybe 2 inches. I cut notches in the c-channel so it would but up against the floor and I rivited and welded it in on both sides. Seems to be very strong now.

[Loco]

When I did the body on mine, I wanted a strong rocker solution. In the end, I had some stock looking replacement panels made. I did this because I couldn't figure out how to attach thick and heavy steel to thin (and I mean really thin) tin. I see guys with the 2x4 rockers all the time. How do you do it?

You'd be best off tying them (2x4, 3x3, etc.) into the frame. I have some pics of something similar at home, I'll see if I can post them later tonight when I get home from work.

[SamiFlyer]

When I did the body on mine, I wanted a strong rocker solution. In the end, I had some stock looking replacement panels made. I did this because I couldn't figure out how to attach thick and heavy steel to thin (and I mean really thin) tin. I see guys with the 2x4 rockers all the time. How do you do it?

My 2x4 box tubing is 1/8" wall and quite a bit thicker than the sheetmetal I want to bond it too. If you look at my pictures yo will see that there are alot of holes from me drilling and grinding all the rivets that were holding the previous patch. I bought some 16ga sheetmetal (actually about 1/16" thick) and I will weld a strip of it to the underside of that drilled out lip on my rocker. The 16ga steel will stick out past the lip about 1/2" or so and that is where I will attach the box tubing to. That way I don't have to worry about welding sheetmetal to thick steel and having it blow holes everywhere. I will do the same on the inside but instead of a strip of 16ga, I will make a 1x1 piece of angle that runs the length of the rocker. This should suffice to hold the box tubing and spread the load should I actually hit rocks and trees or need to jack the truck up with it.


Sean :cool:

[Loco]

When I did the body on mine, I wanted a strong rocker solution. In the end, I had some stock looking replacement panels made. I did this because I couldn't figure out how to attach thick and heavy steel to thin (and I mean really thin) tin. I see guys with the 2x4 rockers all the time. How do you do it?You'd be best off tying them (2x4, 3x3, etc.) into the frame. I have some pics of something similar at home, I'll see if I can post them later tonight when I get home from work.

Ok, here are those pics. They show it done with 4x4 angle iron (meant to go over the original rockers) but you can mount tube instead if you're cutting the rockers out.

[Memphis]

Loco, THAT IS A GREAT FUKN' IDEER!!!
Holy crap didn't even think about doing that kind of tie in, that looks stout as hell!!

[Loco]

I wish I could take credit for it but I got from a sami-mod CD I bought on ebay (overall pretty lame but had a couple of gems like that). It's in a pdf file with instructions on how to do it. PM me your email and I'll send it to ya.

[SamiFlyer]

Send it to samiflyer at hotmail and I'll host it.


Sean :cool:

[SamiFlyer]

Voici mes amis.

Rockerpanel Protection PDF (http://www.gno.edu.on.ca/Simon/Toughguy/toughguy/truck/ZP/Suzuki4x4-Tech-Rockerpanelprotection.pdf)


Sean :cool:

[fullspectrum]

That does look beefy and stronger/easier than what I did. I wasn't sure if I was putting a bodylift in at the time though. You could still do that with the bodylift I would think...

[Simko]

hey guys what are these things being held in the pic:

my sammi i s a 1989

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4951.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4952.jpg

[Loco]

Looks like your O2 sensor if I'm not mistaken.

[Memphis]

Major overhaul today, for the most part, the front end of the truck is welded up, 95% complete, thank God I was getting sick of working on it. Inner rockers have been patched and quickly spray bombed to keep the surface rust away. Hopefully next weekend we will fab up the rock sliders and get a start on the ass end of the truck. The front end was real ****in boring :thefinger

[TheSarg]

No i dont think its the O2, it looks like its plugged in ok, and i dont remember the 02 being grounded, if the roads arent bad ill go look tomorrow at the tin top at the shop n see whut that thingy is

[Fardcohe]

That would'nt be the tranny relay for the back light ? it'seems to be grounded at the same place than the maker's lights. Or that would be your brake fluid sensor..

read ya !

[Memphis]

Hey guys sorry I should have said something about those pics in my post above. It is not the 02 Sensor, that is a seperate wire as Sarg already saw. The wires that I am holding in my hand are a going to be a pita to find out. In the first pic, a wire is grounded to the fender and the other wire is cut and dangling. The second pic, the connector is running back into a loom of wires and I don't know where it goes after it reaches the firewall. It either goes through into the drivers side or run down the wall to the passenger side.

Not sure if any of this helps but... all I know is that these connectors in the pics have nothing to connect too LOL. Also, I can't remember the colour code on the 2 wires, but the loom of wires that the plug in the second pic runs into, there are 2 wires that are snipped as well. I'll cut some of the loom and we'll get more pics, hopefully tonight?

[GearHead]

No i dont think its the O2, it looks like its plugged in ok, and i dont remember the 02 being grounded, if the roads arent bad ill go look tomorrow at the tin top at the shop n see whut that thingy is


Did the truck have AC at one time, i think i remember a plug to the ac compressor that was on that side of the motor. Look on the heater controls and see if there is a old ac button.

later
steve

[frwinks]

I made a set of those sliders and they've been great. I used 1/4" DP bent @90*and some angle. The steel came out to under fitty bucks plus the hardware:D One of those cheap'n'easy yet very effective mods. If you need any dims, lMK dood, I hook u up ;)
http://img.photobucket.com/albums/v190/frwinks/SAMMI/IMG_2761.jpg

http://img.photobucket.com/albums/v190/frwinks/SAMMI/IMG_2756.jpg

http://img.photobucket.com/albums/v190/frwinks/SAMMI/IMG_2773.jpg

they've been taking a good bashin'ntrashin' and keep askin' fer more:D :D
http://smg.photobucket.com/albums/v190/frwinks/Suzican%202006/?action=view&current=MVI_5674.flv

[TheSarg]

Gearhead may be bang on, cause i looked today and mine didnt have it, oh wait i looked at the 86 shit, it dont have an O2 sensor either, ill call 10tapper tonite n get him to check his 88.5

[twistedzuki]

hey guys what are these things being held in the pic:

my sammi i s a 1989

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4951.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4952.jpg

I may b wrong but that plug you are holding belongs to the windshield washer squiter motor on the fluid bottle....? what u think.....

[TheSarg]

I thought that too, but isnt that plug back and have a 90 degree end on it?

[Simko]

thwe washer bottle is hooked up!
unless it was the jack daniels dispenser washer bottle :(

thats now removed

[samzuki]

thwe washer bottle is hooked up!
unless it was the jack daniels dispenser washer bottle :(

thats now removed

Was it functional? Did it spray into the vehicle :D

[Simko]

Yes it did LOL however the P.O. had it filled with washer fluid.

[twistedzuki]

could it have been a second hook up for a rear window wiper like on kicks...they have two pumps!!

[Simko]

Suzi Gurus:

I think i need to replace all my hard gas lines, is there a special how to/ special line i need? How many flarings do i need done on the lines im going to Napa/ part store tmw to get some, how many feet of it do i need? (im assuming it comes in a roll)

[TheSarg]

grab a 25 foot roll and a buncha ends, take an old end in on a line to match the tube and the end, then goto PA to get a flaring kit, this is one of those things u need in yer box o tools anyways, then practice away

PA also sells lil benders which come in handy as well depending on what line u get

[MuddMachine]

Hey when you're doing patchwork, you'd be best off to weld the patches solid. Tacking it will cauze it to rot away faster cuz crap and moisture gets in there and all that effort ends up going down the drain.

[Simko]

shit, if Anthony;s gnna update his thread i gotta too then :P


Seats!!!!!
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4975.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4972.jpg
FLARE!
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4974.jpg

SILLY MODS! Redhead feriend did it for kicks, but i think it looks good :O

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4973.jpg

[Memphis]

wheres the horn you stupid fawk?:roll:

[Simko]

profanity not required... really shows intelligence


long story short, horn is 3 red trumpets

[Memphis]

profanity not required... really shows intelligence


long story short, horn is 3 red trumpets

says the man that didn't even purchase his own shat box :thefinger

[Simko]

exactly. the MAN

[anthony]

those seats look awesome in there, what are they out of ??

and what is that gooey shit all over the fender ?? you guys really like fenders out there in london huh ?? a little too much i'd say

suzican ??

[Simko]

seats are out of an old blazer

suzican = no go i think, probly wont be ready by then. but we can hope

Gooey = seam sealer, never knew about metal sealer and we wanted to keep the edges from rustin a bit.

[anthony]

it looks more like semen than seam sealer .. fess up :thefinger

[Simko]

damn ya got me there.. ZAP! i wishi had that kinda output!

What the hell!
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4978.jpg

ROCKER REPLACEMENTS
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4977.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4976.jpg



Random fishy
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4082.jpg

[anthony]

nice cat

[samzuki]

Isn't that a bass? Kinda looks like mine...

[SamiFlyer]

I see your little guppies and raise you a snapping turtle.

http://www.gno.edu.on.ca/Simon/Toughguy/toughguy/truck/ZP/IMG_6368%20(Medium).JPG

http://www.gno.edu.on.ca/Simon/Toughguy/toughguy/truck/ZP/IMG_6362%20(Medium).JPG



Sean :cool:

[samzuki]

So do they really bite Sean?

[samzuki]

How about a 29" Northern Pike?

[Simko]

jebus sean! Turtle soup or just makin soem leather?


Not bad jason ill see what i can UP the ante with

[vern350]

what do i win? BTW simko the truck is coming along nicely. I also like those seats, the leather is going to be nicer than cloth for staying clean.

[Simko]

dAM DOWN RIGGERS!!!!!!!! what lake is that on.........salmon?

[SamiFlyer]

So do they really bite Sean?

Oh hell yeah! The dog came too close and started sniffing at it while I was holding it. At first it was pulling its head in to hide but after a couple seconds it snapped and took a small chunk off the end of the dog's nose! I never knew they were that fast! And to think that I jumped from a moving boat to get this thing! I was alone in the boat too! I just wanted to bring it back to show my three boys and we let it go after. The shell was just over 12" wide and 15" long. I can't even imagine how old it must have been. :)


Sean :cool:

[Memphis]

when I look at that first turtle picture, all I can think of is Milo and Otus and Otus floating across the damn beach LOL. He looks so helpless hahaha

The plans for the day, our euro buddy is coming over and welding the rocker/sliders in solid. I'll probably try and get the passenger seat mounted up. And Simko, well he'll be the shop bitch and make hot chocolate :thefinger

[vern350]

lake huron, just out from manitoulin island.

[Simko]

MORE PICS:

BUMPER!
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4985.jpg

a rocker replacement

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4987.jpg

[SamiFlyer]

Looks good Simko. :beer:


Sean :cool:

P.S.- I haven't forgotten about the wiring pics and diagram. Just haven't had any time to do it yet. I'm workin' on it. :)

[rocktracks]

turning out pretty good:D

[Memphis]

It is getting there slowly, the body is pretty much done for the most part. Have to seal the gap between the tube rocker and the inner rocker, the rear cab corners by the tail gate and 1 tiny hole up front by the head light.

Still on the list to do:
Wiring front signals, all the wiring in the rear.
Figure out why the wipers don't work, they worked before the dash was apart! (How do we check that switch?)
Brakes all around (Have)
Speedo Cable (Coming)
Ebrake Cables (Coming)
Mount Gas Tank (find or build a skid plate as well)
Redo some of the hard lines to the tank

CLUTCH!

The list is slowly getting shorter.

[Lego Racer]

Wow lots of work on that zuk!! Keep it up. I like reading this stuff. Find out what others are doing.

[Memphis]

Bump for updates:

1. The WIPERS and WASHERS work! Bad grounds, disconnected pump motor.
2. The seats are mounted, however I am going to redo the passenger side mounts, because well, they aren't up to my standards
3. All the lights work EXCEPT for the front marker lights, however they do function as turn signals. What can we do to fix this problem?
4. Got bored, simko went out and bought CB stuff so I rigged that up for him too

breaker breaker 1-9, over and out

[anthony]

do the front side markers work ???

[Memphis]

they were missing when we bought the sammi, not sure whats supposed to work and whats not...should there be 4 marker lights for the front end? I am under the impression that the ones installed on the grill by us are not supposed to be lit, only flash...

So as of right now, when you turn on the headlight switch there are NO marker lights up front, but the signals work fine other then blinking really fast, like a bulb is out, but there isn't any blown bulbs.

[Simko]

right now theyre wired so they flash like signals, but when headlists are on they do not work as marker lights :(

[Simko]

woah, as if we posted @ the same time... im goign to bed

[anthony]

yea they're markers and flashers .. if i remember rightly from when i switched mine to LEDs the wire you need is red with a yellow tracer .. the flasher light wire was green with yellow and the other light is ground

alternatively wire a relay into one of the back ones to turn on the front .. kinda retarded but itll pass safety

you guys are gay for sure by the way, posting at the same time :rofl:

[Lego Racer]

There should be 3 wires. 2 positives and 1 ground. The 1 positive will work when you turn your lights on. The second positive turns on when you signal light turns on. I ran both negitive wires back to the wiring harness.

The color of wires on mine are: White/Yellow= Marker positive, Green= Signal positive and the Black is the negitive. Hopefully that works for you.

[Memphis]

We will have a look, little bit of a problem however... the drivers side wiring is intact. The passenger, something is cooked, the "green" wire you are referring to is spliced into another wire (can't remember colour) because the green is the only wire getting power...

I probably just confused the hell out of someone...

With the green spliced, the signals still work but again, no maker lights and they flash very fast.

[Memphis]

Front markers still ain't working but all the wiring is correct on the drivers side, not sure why one side atleast wouldn't light up...

Would it be illegal to run a separate set of marker lights? I am assuming that is what you did Lego Racer, hopefully you see this reply. Could ya let us know why you ran an additional set of lights?

Tonight the tank got mounted, she fired up like a fawkin champ after sitting for 3-4months, can't remember now so long ago since Simko picked up this ugly diamond. We went for a cruise, other then insane clutch slippage she drove pretty damn good. Had a little gas leak, (opps) forgot to tighten the return line clamp :thefinger

[samzuki]

Front markers still ain't working but all the wiring is correct on the drivers side, not sure why one side atleast wouldn't light up...

Could you have burnt or broken bulbs?

[Memphis]

We have 1 sets of original markers up front on the fenders (2 wire red/tracer and black) then we have a set from PA, single wire and ground to mounting point

something is messed up on the passenger side because the markers aren't getting power sent to them, only the signal (green wire) is getting sent power - previous owner spliced the signal wire into marker wires to give power. That is why the passenger side doesn't work... but it doesn't make any sense for the drivers side which is all intact according to haynes.

[Lego Racer]

Sorry for the delay, been really busy on my zuk here latly.


Front markers still ain't working but all the wiring is correct on the drivers side, not sure why one side atleast wouldn't light up...

Would it be illegal to run a separate set of marker lights? I am assuming that is what you did Lego Racer, hopefully you see this reply. Could ya let us know why you ran an additional set of lights?

No it isn't illegal to run a separate set of marker lights. As long as they are full time when the lights are turned on. You can actually wire them the same way as you would a tac light. Mind you, you might have to open the dash up to find the wiring for your headlight switch...Or better yet you MIGHT be able to wire them right up to the headlight wires. As in splicing them in. I would get a test light and follow the wire back might have a break in the wire somewhere.

I did end up trying two different sets of lights. My first set were basic marker lights and never worked for some reason. Then I tried with the LED's and they worked. Don't ask me why they worked over the other lights. I will open the wires up today and take a pic for you. I will re-post later tonight.

[Lego Racer]

Ok I was board here is the wiring. Well how I did it anyways. I was wrong with my colors though. The Red/blue wire goes to my marker and the green wire goes to my signal. Both grounds off the lights were sent to the same negitive.
http://i138.photobucket.com/albums/q252/legoracer01/Signalwireing008.jpg


As for the bumper here is my buddies that were building with out a bumper. See where the the shackle is on the front and the bolts that are coming through.
http://i138.photobucket.com/albums/q252/legoracer01/Signalwireing003.jpg
That is where I bolted the bumper to. I used the winch this weekend and it was a hard enough pull that I killed the winch (it was an 8000lbs Champion). No deflection off the bumper. Even hit a tree with it and didn't do nothing to it at all. Built Zuk tough!

[weldor guy]

ROLMFAO man just think about how many atm's you could take out with a bumper like that. free bump for nice fab work. (where are the lights?)







MORE PICS:

BUMPER!
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4985.jpg

a rocker replacement

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4987.jpg

[Memphis]

In the tail gate, it looks pretty bad ass :D
Don't have a picture of it yet. The Bumper needs to have some custom trim work done to make it look classy and it needs caps.

I honestly want to see what the rocker is capable of killing, it's stronger then the bumper!

[Simko]

long due update!!!

Lots of bodywork still being done, new fuel lines are in etc
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0272.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0273.jpg

both leather seats are now SECURELY mounted http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0275.jpg


my reverse/plate/tail/signals
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0276.jpg

BONDOOOOOOO
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0277.jpg


Tachometer installed
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0279.jpg


lil bit of primer green
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0280.jpg




CB installed
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0281.jpg

[anthony]

if i bought shares in bondo i could retire off your driver side QP :) .. looking good homeboy

[Memphis]

he bought the Gooder bondo, this stuff doesn't crack easily at all tried and trued with the hammer test on the passenger rear corner.

[anthony]

hahaha "gooder" :rofl:

[Memphis]

you know aaron, that piss green paint looks really good in the pictures. Perhaps it's time to rethink the other paint idea :D

[samzuki]

long due update!!!

Lots of bodywork still being done, new fuel lines are in etc
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0272.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0273.jpg

both leather seats are now SECURELY mounted http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0275.jpg


my reverse/plate/tail/signals
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0276.jpg

BONDOOOOOOO
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0277.jpg


Tachometer installed
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0279.jpg


lil bit of primer green
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0280.jpg




CB installed
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0281.jpg


Dude.....what's up with those 'shoes' :rofl:

[Memphis]

for a second I thought you meant the tires and the funny wear pattern, but you can't really tell that from the pics. Then I clued in and yer makin fun of moi :thefinger

Long story short, went fishing 3 hours earlier, walked in the river, didn't want to wear wet shoes so I stole aaron's Crocks. Yes I know I look like a dumbass, thats why I don't own a pair ;)

[Canadian_zuk]

... thats why I don't own a pair ;)

The evidence says otherwise.:D

[Memphis]

They were comfy, but sucked to weld in, DAMN SPLATTER :rofl:

[Memphis]

BUMP!!

THIS POS IS ALIVE AND WELL

We need to take some more pics... I've fixed so much crap on this thing:

Wiring is DONE! FUK YA
Bumpers are DONE
Simko's Bondo-ing is DONE for the most part
Happy times... it's also gone through 6 paint jobs... as it sits it's White :rofl:


Hopefully we'll get some pics tonight

[Simko]

Holy late reply'!

pics: memphis put some big shackles on, so she sits a bit higher.

also front bumper is up

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0435.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0434.jpg

new waterpump is in, no more coolant leaks!

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0433.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0432.jpg

[ILikeMud]

Holy freakin shackles.

Jeff says this thing is running and on the road now? Is it true?

[Memphis]

it is, AND it's a different colour :thefinger
Simko needs to update the pics!

[Simko]

http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4997.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN4999.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN5000.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN5001.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/DSCN5002.jpg

[ILikeMud]

How many colors has that thing been?

Let me drive it! I need to see if my fat ass can fit in a Sammi.

[Simko]

8 colours maybe?

registered originally as black, then blue by PO, then primer?

Flat black, lime green, white, poopy brown, green now

you live in sauga fat boy,... thats far from london

[ILikeMud]

Hmmm, almost as many colors as my old Yota.
Jeff has been trying to meet up for ages. Maybe next time I head to Michigan....not that I know when that will be.

[Simko]

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0569.jpg

http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0568.jpg


still need to do shock mounts and decent shackles, all comin in from breeze

[TheSarg]

omg are you actually shaving now? my how u've grown young man, bout as fast as yer zook too!!! hehe

[Memphis]

omg are you actually shaving now? my how u've grown young man, bout as fast as yer zook too!!! hehe

Fast. Puh
Ron Pylon wouldn't be even half way to this point if I didn't kick him in the ass every step of the way!

Only thing that needs to really be addressed is the steering, but it's under way too. She has clearance for 33's but I don't think they are in the plans :(

[Simko]

OH NOES!
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0800.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0801.jpg
http://i2.photobucket.com/albums/y29/aaron_simkovich/IMGP0804.jpg