Jordis 1988 Samurai (Re)Build

[d86]

Yeah, its taken me long enuf to get it done.

It's a labour of love. Sum refer to it as a sickness.

I HERE YOU THERE BROTHER.......

tony

[Tramp]

I do have a red shock boot for this damper too but havn't fitted it yet.

I recognise that, Ive got one for mine, but mines pro-comp



I would say you are better leaving the boot off this one, as they can fill up with mud and crap and it ends up bathing the shaft in grit which makes the seal go on the unit,

Luke

[Jordi]

Wow, ppl of SCUK, we have a bumper. Oh yes, custom design and fabricated by me!!! Take a look as the craftsmanship.

Yes, it's a piece of box section.

IMG_0063.JPG (68.9 KiB) Viewed 12672 times

Im rather proud of it, not quite sure where the lights are gonna go tho, may just mount them on the back of the cab.


It's not all good news tho. I have plumbed up the brakes and started bleeding them only to discover that the n/s front piston is peeing fluid out. So tomoz it will be stripped down to check the seal and if needs be order the rebuild kit from brakes int.

[Jordi]

Also thought I would share my rather funky welding mask. One of those auto darkening jobbies. With a solar panel to charge its battery as u weld. ebay job, £35 i think. Its pretty good and makes it a damn sight easier than my old mask as it was so dark u cud barely see even when u were arcing. I was trying to get the skull image but it was £10 more even tho is was same mask different image.

IMG_0064.JPG (38.69 KiB) Viewed 12676 times

[Jordi]

Well another day spent not exactly rebuilding but certainly working on it. Back bumper still looks swell. Stripped down both front calipers and cleaned out a pint of crud. Both seals seem fine and i once again bled the system this time with slightly better outcome. There still air in the system but it is pressurising and the seals seem to be holding. The piston boots have gone the journey tho.

As my other post says im going to run 31s without a lift and they seem to foul the bulkhead. So any advice on virtual lifts will be welcomed. Soon as i get the tyre issue resolved ill b bolting the front wings back on and whipping her down for an MOT.

[Jordi]

Ok, So based on advice from my other post I have now started attacking the bulkhead with the large grinder and also thought whilst it was plugged in i'd have a chop at the wing too. I've chopped more out since the foto was taken but I think it shows the idea. All i want to know is which Suzuki designer had the idea to make the bulkhead such an odd shape??? What was wrong with flat and smooth???

IMG_0069.JPG (188.81 KiB) Viewed 12610 times

IMG_0067.JPG (163.15 KiB) Viewed 12607 times

Seen as the bulkhead investigation was doing my knut I thought id sit my 'new' wing on and try her for size (complete with new 'bit' also wedged in place for effect. I hope its gonna look tidy, but we'll see.

IMG_0065.JPG (193.53 KiB) Viewed 12605 times

[Jordi]

IMG_0066.JPG (162.64 KiB) Viewed 12607 times

To avoid the sharp edge issue im gonna get sum rod probs 5mm and use it to edge the wings.

[Jordi]

More photos for you all to be amazed at my welding. In my defence, its a lot better than it was.

IMG_0081.JPG (114.81 KiB) Viewed 12580 times

IMG_0086.JPG (108.87 KiB) Viewed 12578 times

IMG_0080.JPG (105.54 KiB) Viewed 12578 times

Thats both bulkhead corners cut and plate tacked in. Hopefully, fingers crossed tomorrow i'll pull her outta the garage and give her a mini test outside the house just to make sure nothing fouls and get them welded up.

[Jordi]

I've also cut both wheel arches out now and tried them for size.

IMG_0072.JPG (97.87 KiB) Viewed 12576 times

IMG_0074.JPG (92.26 KiB) Viewed 12574 times

IMG_0075.JPG (122.87 KiB) Viewed 12571 times

I'm pretty pleased with the days work and whilst not perfect progress has been made. I also managed to rope an assistant into pumping the brake pedal whilst i finally got the brakes all bled properly and fitted new pads to go with the new shoes and pistons. I have new discs but wont be fitting them until MOT so as they dont get corroded.

[Jordi]

As mentioned above today was fairly productive. Using the below tools to cut and 'adjust' the plate to fit.

IMG_0083.JPG (114.76 KiB) Viewed 12575 times

There was however one slight 'catching fire' incident. No thankfully it wasnt the Sammy it was my leg. Luckily I had my gauntlets on and just damped it out.

IMG_0084.JPG (93.22 KiB) Viewed 12571 times

Roll on tomorrow!!!