Suzuki sj 410 from Cornwall PROJECT Never Ending Project

[Edweird]

That's pretty similar to what I had to pay.

Hard to believe that it hasn't sailed through an MOT already with bodywork that good.

[dazerede]

ye got to clean the brake pipes and adjust the handbrake , new coolant sensor ,new indercator/light stalk arm , adjust front lights and clean up the original front bumper and paint and then it should be done ready for the MOT

[Edweird]

Well, so long as you've got the bits, that's less than a days work.

The way I did the handbrake was to lay underneath it on level ground with the handbrake off. You can move the truck easily by turning the rear prop-shaft, which also moves the drum which has a hole in it for adjusting the mechanism inside. What I did was screw one side out until it began to make it harder to move the truck by turning the prop, then backed it off again a little bit, then to the other side, then check them both again.

As for headlights. I took advantage of a misty night to get mine set up. The mist was thin enough to see fine, but showed where the headlights were pointing if you were stood outside the truck. The best way to set them up in my opinion is so that if you've got your 2 second gap on a 60mph road your dip beam shines just on the road behind the car in front. Works out at about 53 metres.
Sad bugger that I am, I measured it and put my truck 50 metres behind my Stepdad's Discovery, then adjusted my headlights on dip so that they just lit up the tyres, but the reflectors on the bumper corners stayed dark. I think they're supposed to have a slight angle on them, but mine just point straight forwards and it lights the road up nicely.

If you haven't already, go to Halfords or somewhere and get yourself a pair of T45/H4 bulbs. The SJ standard bulbs are old T45s, which share the fitting with a H4, and I found Halfords did a H4 in a T45 fitting and my god was it an enormous improvement. I'm pretty sure they were £4.99 each, but it's well worth it.

[Jay18]

here are the headlight bulbs very cheap but as edweird said the H4 halogen bulbs are a million times better think i will be in halfords and get them H4 t45 fitment bulbs


Click Here for Ebay Listing

[dazerede]

chears edweird i might get the handbrake done probably tomorrow and i cant really check the headlights yet due to the indercator and light stalk is broken and my cousin is going to do the lights for me when it goes in for the mot
ye i got some headlights bulbs they where pretty simular to these
Click Here for Ebay Listing
and they fitted allright qiute tight but it was better than the big household headlights

[dazerede]

well its my BIRTHDAY and my truck isnt ready for the road yet
starting to make my door panels from scratch show pics later

[Jay18]

HAPPY BIRTHDAY mate i know how you feel, when my 17th came around my sj was nowhere near finnished, is there much to do to it?

[dan_2k_uk]

Happy birthday fella. Sure it will be done soon enough if you keep up the hard work.

The handbrake adjustment Ed mentioned is slightly easier and a touch safer if you just jack up the rear axle.

Wouldn't want the truck rolling off without you in it. Trust me!

Dan

[dazerede]

well the door cards are all done and the next job is handbrake you lot make it look easy to adjust the handbrake i shall soon find out

[Edweird]

Just make sure you're on a flat whilst you're laying underneath with the handbrake off, otherwise you might find yourself with a truck that's trying to roll downhill out of your garage with you underneath it, so you have to use your feet and your bare hands on the UJ on the T-box to heft the thing back onto level ground.