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suzuki samurai trayback / 1.9tdi motor transplant

 
 
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:47 pm    Post subject: suzuki samurai trayback / 1.9tdi motor transplant Reply with quote

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: Smile


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

PostPosted: Tue Jun 08, 2010 10:48 pm    Post subject: Reply with quote










then came the engine change:



__________________________________
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

PostPosted: Tue Jun 08, 2010 10:50 pm    Post subject: Reply with quote







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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:52 pm    Post subject: Reply with quote



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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:52 pm    Post subject: Reply with quote

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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:54 pm    Post subject: Reply with quote

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 Smile , 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 Confused

__________________________________
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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:54 pm    Post subject: Reply with quote

anway, heres the finished pics:










__________________________________
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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 10:55 pm    Post subject: Reply with quote




Lastly, i welcome all constructive critisism, but this is my first off-roader build so please go easy Smile ,
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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View user's profile Send private message eBay Name
aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Tue Jun 08, 2010 11:04 pm    Post subject: Reply with quote

oh and there are hundreds more photos in my photobucket album:
http://s29.photobucket.com/albums/c282/aniesigh/the%20jeep/

__________________________________
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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robert
Winch Assistant


Joined: 22 Jan 2010
Odometer: 68
Location: uk



PostPosted: Wed Jun 09, 2010 7:02 am    Post subject: Reply with quote

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



PostPosted: Wed Jun 09, 2010 1:48 pm    Post subject: Reply with quote

+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



PostPosted: Wed Jun 09, 2010 2:29 pm    Post subject: Reply with quote

well done looks class Smile
__________________________________
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

PostPosted: Wed Jun 09, 2010 3:51 pm    Post subject: Reply with quote

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

PostPosted: Wed Jun 09, 2010 5:11 pm    Post subject: Reply with quote

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

PostPosted: Wed Jun 09, 2010 5:20 pm    Post subject: Reply with quote

cheers guys Smile
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 Very Happy

__________________________________
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

PostPosted: Thu Jun 10, 2010 6:58 am    Post subject: Reply with quote

That is a nice looking truck Smile

(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



PostPosted: Thu Jun 10, 2010 4:06 pm    Post subject: Reply with quote

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.



PostPosted: Thu Jun 10, 2010 8:23 pm    Post subject: Reply with quote

exellent...

looks great.

nice build up..

tony Very Happy

__________________________________
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



PostPosted: Tue Jun 15, 2010 8:51 am    Post subject: Reply with quote

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

PostPosted: Tue Jun 15, 2010 4:29 pm    Post subject: Reply with quote

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 Smile
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



PostPosted: Sun Jun 27, 2010 10:59 pm    Post subject: Reply with quote

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 Applause Dancing Very Happy
__________________________________
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

PostPosted: Mon Jun 28, 2010 2:42 pm    Post subject: Reply with quote

How does it go with that 1.9 turbo lump? Very nice truck btw Very Happy
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Diesel Destroyer
Mud Obsessed


Joined: 27 Jan 2006
Odometer: 6921
Location: Under the truck covered in EP90



PostPosted: Mon Jan 10, 2011 7:05 pm    Post subject: Reply with quote

SOLD Shocked

Someone got a bargain Adam.. hope they look after it and enjoy your hard work

__________________________________
Link to my current project build thread

http://muddybuggy.co.uk/viewtopic.php?f=17&t=45&start=80
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Mon Jan 10, 2011 7:44 pm    Post subject: Reply with quote

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 Wink
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 Laughing

__________________________________
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




PostPosted: Tue Jan 11, 2011 8:39 pm    Post subject: Reply with quote

if that was your first ever build theni cant wait too see the next! Very Happy
__________________________________
mmmmmmmmud
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aniesigh
Articulating


Joined: 15 Jul 2009
Odometer: 795
Location: north devon


1991 Suzuki Samurai

PostPosted: Wed Jan 12, 2011 9:53 am    Post subject: Reply with quote

thanks Very Happy me too Laughing
progress can be found in the custom builds section under 2.8td vitara,
cheers

__________________________________
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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JemAndes
Just got MTs


Joined: 25 Jul 2011
Odometer: 446
Location: 10th region (lakes region) Chile


1998 Daihatsu Fourtrak

PostPosted: Sat Aug 18, 2012 2:27 pm    Post subject: Reply with quote

Nice job on your first build. What a project to undertake. Looked sweet though!
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