help off the experts

[lukey4x4]

hey guys so bin thinking lately n got some plans for the sj next year, so after some info and help before I decide what to do , I do have a budget so got no spare money for trial and error so just wonded what you guys can recommend on what will work, so I picked up some Sammy axles last week as were only round the corner so stripped them down today ready to rebuild them when ever that will be so what I was thinking was putting some 35s on it I have 2 sets of rims to pick from 8j and 10j , I will be staying spoa and will be putting new leaf springs on it and new shocks and maybe shackles if need other ones, think I may need lift springs so any one know how much lift ?? , also upgraded axle parts whats people using or what shud I use, websites to buy these from?. axle trussing/bracing would have to take it someware to get done as don't weld so bit of a bummer there , I don't know if I would be biting off more than I can chew because not having the knowhow but I will see , thanks guys

[Jordi]

My thoughts. For 35s you want trussed and gusseted axles cases

Probably get away with 4.3 vit diffs and a lobster transfer box, but a lower ratio transfer box would help.

Full float rear axle conversion and HD front shafts and CVs

Definitely require a good anti wrap bar on the back axle.

On spoa probably get away with some arch trimming instead of lift springs, good quality springs are a must.

They will need to me on 15x10s i would think. Pretty much for 35s every thing wants strengthening.

Take a look at mikes build, the later pages.

http://forum.suzukiclubuk.co.uk/vi ... php?t=2864

There is also Scotties, Dans and mine all on 33s but modded slightly differently to do it.

[lukey4x4]

thanks Jordi do you know anyware that would weld them up for me mate , I was planning on just leaving my 410 transfer box in ,I didn't think about the diffs would the std ones be no good running 35s ? yea I wanted the full float rear pluss it has the disc conversion with it so would need some discs and calapers off a vit ? with the axles I just got the rear came with some pretty new/good 2" lift springs so my thoughts were to use these and buy 2 more for the front rather than cutting arches because I carnt weld so be a setback , where do you recommend buying from any websites ? I read through mikes a few days ago great build , thanks

[Jordi]

Me and Dan are on 4.3 diffs and a 4:1 t-box which is about right for 33s. 410 t box and standard samurai axles will be way too high geared for 35s. Minimum of a 4:1 t box and 4.3 R&P diffs

Cut the arches or get a good roll cage made if you are gonna lift it further. Judging by some of mikes posts its spends as much time on its side as it does waiting to be repaired from being on its side. The higher you go the wider you need to go, as in Toyota axles and off set wheels.

My full float was custom made with a built in disc conversion using standard SJ front hubs, discs and calipers. The side gears in the front diff also need changing to take a HD shaft.

RockWatt does all kinds of fab and machining work but expect a long wait, very long. Other than that any local fabricators should be able to weld them up. You can buy trusses and gussets from low range aswell as the side gears and front shafts and CVs.

Rockwatt can do a sweet custom full float or RS Entineering does a bolt on conversion.

[lukey4x4]

orrighty a get ya what diffs will I need then mate am not upto date what racio is what ? the full float off the RS site was what I was looking at but wasn't sure what discs it takes , does rockwatt have a website or is he just on fb, theres a engineering unit just round the corner from me but when I read through peoples builds I noticed it was quite easy to bend whilst welding so didn't want to take it to someone that doesn't know what they r doing ,al have a look on lowrange now , thanks mate

[ScottieJ]

Jordi's got most of it covered and all I'm going to say is that to build an SJ that is reliable and actually works with 33-35" tyres you are going to need to spend around £1500 minimum, probably more like £2000 if you have to pay for certain jobs to be somebody on upgrades to reduce the gearing and increase strength and that's just in the axles and transfer box. Do you have a 1.6 fitted? You'll need one.

Just a 410 transfer box won't be enough for off-road, you'll need a minimum of 4.16 low box aka a rocklobster plus lower geared diffs or it just won't have the power or control you need off-road.

[Jordi]

I think there may be a 4.9 vitara diff that fits but i'm not sure. I know there is 4.3 and 5.1 vitara diff that will fit. You need two front sets of ring & pinion. Not sure on their prices per diff.

All depends how much you want to spend? Think its still £350 for RockWatt to make a crawler box from a 410 and a 413 box if you supply them. That will make a 4.16:1 low ratio

Alternatively you can buy gear sets to lower the transfer box ratio further and run higher ratio diffs. Personaly i like to lower all the ratios a little. Gear sets vary in price the lower you go the higher the price.

Have a look at low ranges gear sets http://www.lowrangeoffroad.com/suzuki-o ... -case.html

Ignore their ratio guide, i think that it is based on running standard ratio 3.7:1 samurai diffs.

When having diffs built may as well get all the bearings done and a new crush collar and seal set fitted.

Fairly sure the RS has a built in disc conversion to take all standard SJ / Samurai hub assemblies. You need to supply front hubs, discs, calipers and brake flexi pipes.

Presume your already has a transmission hand brake? If not either a suzuki drum transmission brake or an x-eng disc brake will need fitting.

Edit:- All depends how far you want to go, Scottie can do a lot more of his own fab work than i can. I have paid to have some work done and think he is miles out in his cost estimation. My back axle was close to £2k but that does include a full set of bearings and diff lock, the cost of Scottie building my diffs, Rockwatts work on the casing and shafts.

[dan_2k_uk]

4.6s are the in between ratio I think you are thinking of Jordi.

[dan_2k_uk]

My bad. There are both.

So options are 4.3s (perfect for 33s), 4.6s, 4.9s, and 5.1s

[Jordi]

My bad. There are both.

So options are 4.3s (perfect for 33s), 4.6s, 4.9s, and 5.1s

Just had a feeling someone had mentioned 4.9s Dan, no idea there was a 4.6.