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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:47 pm Post subject: suzuki samurai trayback / 1.9tdi motor transplant
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BEFORE I START, WARNING, THIS THREAD CONTAINS THE USE OF SCAFFOLDING FOR CAGE MATERIAL,AND SOME WELDS THAT ARENT ALL THE NEATEST IN THE WORLD IF THIS WILL FREAK YOU OUT PLEASE DON'T READ ANY FURTHER!,
Hi all, firstly i'll introduce myself, im adam, 20year old caravan and motorhome service technician from north devon, always been more into my bikes than 4 wheelers but have had a couple disco's and a shogun on the road, never much offroading action though,
anyway, onto the project, i was given the samurai by my old physics teacher, it started life as a standard 1.3 hard top rust bucket, having spent the last few years of its life living by the sea side, and being used to launch a boat!
so once i had the jeep i found this great website, and i began scouring through pages looking for ideas, i had no idea what i wanted to achieve really which was probably the wrong way to go about it, but i fancied a challenge so i got some ideas together, a trayback seemed a good idea as they look good, are a convenient way to move fuel tank and battery and make storage space,loose all the rust and integrate the cage, so that was that idea,
then came the engine choice, again i fancied a change, and saw topics of people fitting diesel engines which i liked the sound of, then i saw diesel destroyers VW conversion and i quickly remebered i had my old audi A4 sat about which i crashed and ruined the gearbox, so after a bit more research finding the block was the same, my sights were set!
so enough of the blabbing, heres some pics:
when i first got her (near enough)
and now:
heres how it all came together:
cut back off, add sheet steel, cut weld, fill, paint:
next was plenty more rust repairs, 80x80 box sills and plenty of patches:
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:50 pm Post subject:
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many thanks to diesel destroyer for his advice on clutch (offroad armoury VW conversion kit flywheel re-drilled to take 16v vitara clutch which was turned down to fit.
next came some bucket seats,:
then the bonnet wouldnt shut because of the engine, and i wanted to bodylift it anyway, so i accepted i was finally going to have to do what i had been trying to avoid, remove the body and the body mounts were completely rotten which i hadnt previously noticed!:
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:52 pm Post subject:
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with the front end back on and the body now 3" taller i could now start the less boring work, and added some rock sliders which would also later provide a base for cage, and mounts for fuel tank and battery, initially i used a caravan water tank as a fuel tank but then decided it was far too wide and would cause pickup issues on even a slight slope, this was later changed to a gas bottle converted to fuel tank ( was set on using something that i could steal from work!! )
then came the winch which i picked up on ebay for a cheeky £166 bargain, tds9.5 goldfish with the dyneema bowrope and steel rope spare too,
then another cheeky bargain, always wanted the 5 spoke vitara alloys from day one but planned to try get some used ones, then 4 brand new in box wheels with brand new nuts came up for sale in local paper for £100, haggled to £85 for the 4 and was more than happy with that!
next on the list was add-a-leaf, and polybush set, thanks to dave at llama 4x4:
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:52 pm Post subject:
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then was time for paint, no decision to be made on paint scheme, i had my road bike sprayed orange last year and also own an orange KTM bike so orange it was, i still needed to source a decent set of doors and bonnet at this point so was painted without for the time being:
then after a month or so break, work on the cage began when enthusiasm returned:
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:54 pm Post subject:
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then came a couple months of no progress, funds ran dry, enthusiasm was lacked, then i sold my quad and bought the tyres which i new would motivate me to get back started, sorry theres some big gaps in photos, my new phone camera turned out to be a waste of time so i gave up on it!
bonnet and doors were courced from friends and painted, shogun bonnet scoop added to N/S to provide airflow to intercooler and centre scoop is from an L200 and means the bonnet will shut!, wheels and tyres were fitted (31x10.5r15 kingpin extreme trekkers) more work was done on the cage which was then painted, also did some work on the interior, fitted CB, CD and gauges, (boost, temp and battery voltage)
then came power steering, it would have been logical to fit it earlier in the build but i new i wouldnt be able to motivate myself to do it untill i was getting close, used a vitara steering box connected to the audi's pump using the audi hose, unfortunately i learnt the hard way that when audi say mineral oil only, they mean it! a week later the P.S was no longer working so i had to replace the pump, and hope that the mineral fluid wouldnt ruin the vitara steering box which was designed to be used with ATF. once fitted this meant i could fit a smaller steering wheel which also made it easier to get in and out, (cut body slightly too short, seats don't go massively far back, DOH!!)
Can probably sort of make out the wedge needed to fit the vitara box to the samurai, copied from the stickies, chers guys!
Now i was down to finishing touches, mudguards were made from a sheet of 6mm plasticy stuff from local agricultural merchent, its called stock board and is ideal! more paint was splashed around, chequer plate on the tray, spot lights, big horn from truck operated from pull cord powered by old gas bottle filled with compressed air , bonnet strut, storage box in back,landrover lights fitted front and rear, vertical carbon exhaus pipe (from R1 motorbike) axles painted, breathers extended, brakes all re-connected and bled up, and we were ready for an MOT!!
all my nervous-ness and it failed on both headlight allignment and 1 nut on a leaf spring u-bolt that i'd cleverly forgotten about when i lost the nut!, again...DOH!, but was more than chuffed with the tiny list after almost a years work!
so she's now got a full 12month ticket with no advisories, am just waiting for the logbook back from the DVLA so i can tax and insure her and it'll be ready for the mud!
just need to come up with an idea for an air filter
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 08, 2010 10:55 pm Post subject:
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Lastly, i welcome all constructive critisism, but this is my first off-roader build so please go easy ,
many thanks to all those who have helped along the way at times when i have got stuck, particularly diesel destroyer with his advice on the engine transplant, plus other people who have subconciously helped aong the way, ive spent lots of time reading on here but not much posting!
its been about 10months of hard work and long evenings but its finally starting to pay off!
cheers all, hope you enjoy
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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robert Winch Assistant
Joined: 22 Jan 2010 Odometer: 68 Location: uk
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Posted: Wed Jun 09, 2010 7:02 am Post subject:
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thats very nice, some good work gone into that truck well done mate
looks the dogs danglys
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CiaranFox09 Just got MTs
Joined: 09 Dec 2008 Odometer: 364 Location: Charleville Co. Cork Ireland
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Posted: Wed Jun 09, 2010 1:48 pm Post subject:
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+1 looks great il bet its a rocket with that TDi and the orange and black is just sweet !
__________________________________ W.I.P Sj 413 Safety divices Roll cage,
,S.P.O.A,Cobra Seats, 235/85/16 Recip Maxi 3ds, Winch, rocksilders, trail tough t-case gears, 1.6 16v MPFI, |
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des johnston Gate Opener
Joined: 09 Mar 2010 Odometer: 41 Location: ireland
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Posted: Wed Jun 09, 2010 2:29 pm Post subject:
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well done looks class
__________________________________ www.leinster4x4.ie |
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Lil Beastie Off-Road Guru
Joined: 16 Jan 2010 Odometer: 1281 Location: Traveling between Reading and Slough
1995 Suzuki Samurai
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Posted: Wed Jun 09, 2010 3:51 pm Post subject:
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looks quality, youve got some skills there, and managed to do it with only 100 posts. nice.
__________________________________ 95 Suzuki Sammie - gone to portsmouth
Old Rosy - http://rat-look.com/forum/viewtopic.php?f=10&t=8805 |
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Kitesurf Difflock Royalty
Joined: 28 Feb 2005 Odometer: 14197 Location: Luton, Beds
1994 Toyota Surf
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Posted: Wed Jun 09, 2010 5:11 pm Post subject:
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Excellent write-up and nice build. Such a useful looking truck.
I wish you had posted real time progress so I could say, "Wait - don't cut it there." That is where I cut the back off my first SJ and came to regret it. At 5'6" I didn't have enough legroom and was never comfortable in it.
I am inspired to get on with mine again.
__________________________________ Motorist who drove his 4x4 up Snowdon sentenced to appear on Top Gear. |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Wed Jun 09, 2010 5:20 pm Post subject:
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cheers guys
haha yes i very soon realised the error of my ways, its not too bad, i chose to cut it there as thats where the rear windows ended, otherwise it would have had a funny shaped bit, in hindsight i would sacrifice that for more legroom but you live and learn,
i opted to finish the project and then do a build thread as im renouned for not finishing projects!
glad it has inspired you, these long evenings are perfect for progress
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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Twiss Mud Obsessed
Joined: 18 Feb 2008 Odometer: 6438 Location: Birkirkara, Malta
1993 Suzuki Samurai
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Posted: Thu Jun 10, 2010 6:58 am Post subject:
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That is a nice looking truck
(I like the disclaimer as well lol)
__________________________________ Twiss
'95 Samurai 416 16v
'92 Maruti Gypsy MG410
www.suzukiclubuk.co.uk |
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Diesel Destroyer Mud Obsessed
Joined: 27 Jan 2006 Odometer: 6921 Location: Under the truck covered in EP90
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Posted: Thu Jun 10, 2010 4:06 pm Post subject:
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How does it drive??
More importantly.. how does it crawl down hills?? Cant beat diesel for engine braking..
Looks like a nice job.. fair play mate
__________________________________ Link to my current project build thread
http://muddybuggy.co.uk/viewtopic.php?f=17&t=45&start=80 |
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d86 Articulating
Joined: 27 Aug 2008 Odometer: 635 Location: bath,somerset,u.k.
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Posted: Thu Jun 10, 2010 8:23 pm Post subject:
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exellent...
looks great.
nice build up..
tony
__________________________________ if at first you dont succed,give up and get somone else to do it.!! |
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matstar89 Winch Assistant
Joined: 25 Aug 2009 Odometer: 85 Location: north devon
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Posted: Tue Jun 15, 2010 8:51 am Post subject:
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looking good adam! should have put a piccy on of the wiring loom! that would have scared people!
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Tue Jun 15, 2010 4:29 pm Post subject:
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well i havent actually used it off road yet as im waiting for logbook to come back from dvla so untill then i don't know what its really like but seems to go well round the estate where i work,
cheers for all the positive comments guys
shouldn't you be moving house matt??
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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sponge bob Just got MTs
Joined: 19 Jul 2004 Odometer: 141 Location: newlyn cornwall
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Posted: Sun Jun 27, 2010 10:59 pm Post subject:
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i am landy man myself , but hell what a truck it looks like a great bit of kit , a bloody great job of a first buld well done you
__________________________________ if you don't break it you are not trying hard enough !!!!! |
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Stal1878 Mud Obsessed
Joined: 02 Mar 2010 Odometer: 3320 Location: Somerset
1990 Daihatsu Fourtrak
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Posted: Mon Jun 28, 2010 2:42 pm Post subject:
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How does it go with that 1.9 turbo lump? Very nice truck btw
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Diesel Destroyer Mud Obsessed
Joined: 27 Jan 2006 Odometer: 6921 Location: Under the truck covered in EP90
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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Posted: Mon Jan 10, 2011 7:44 pm Post subject:
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yep, my baby's been gone for quite a while now, strangely i wasn't too bothered about selling as i new it just meant the start of another project, to be fair i enjoy building them at least as much as driving them, already thinking of the next project once the Vit's done! that british dirt series looks good
the most annoying thing about selling it, as i sold it locally was when i see it about i know people looking at it will be thinking the chap that bought it did all the work on it!
sold for £1100 with no wheels/tyres/winch or CB which was about what it owed me in parts (not including SJ as was given that and already had the audi) , i'll forget about the hundreds of hours of work
__________________________________ 1990 Suzuki Samurai 1.9TDI (sold)
http://forum.difflock.com/viewtopic.php?t=53747
new truck build thread:
http://forum.difflock.com/viewtopic.php?p=595221#595221 |
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Willzuki Just got MTs
Joined: 09 Nov 2010 Odometer: 118
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Posted: Tue Jan 11, 2011 8:39 pm Post subject:
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if that was your first ever build theni cant wait too see the next!
__________________________________ mmmmmmmmud |
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aniesigh Articulating
Joined: 15 Jul 2009 Odometer: 795 Location: north devon
1991 Suzuki Samurai
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JemAndes Just got MTs
Joined: 25 Jul 2011 Odometer: 446 Location: 10th region (lakes region) Chile
1998 Daihatsu Fourtrak
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Posted: Sat Aug 18, 2012 2:27 pm Post subject:
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Nice job on your first build. What a project to undertake. Looked sweet though!
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