1991 Suzuki Samurai build

[gp7186]

Right been on this forum for around 3 years but aint actually posted any of my progress so far. Had my zuk for 5 years now but dont use it as much as id like due to work and other commitments. Soon after i bought it i did an SPOA conversion and put 31x10.5x15 maxxis trepador tyres on it on offset bk wheels.So heres a few pics:

First off converted engine from the standard 1.3 petrol to 1.9td from a peugeot 306 using a ldv pilot gearbox. Now there was quite a bit of work involved but was worth it in the end .As an offroad only toy this in my opinion would be the best conversion available as you get so much power and good fuel economy and also the ldv pilot gearbox has like a crawler gear on 1st which makes it quite low ratio this is a pic almost finished.

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I then ran it like this for 2-3 years. Then because I was using it more on the road and the ldv gearbox ratios being so low it was maxing out at 55mph with samurai 3.7 diffs and standard transfer box and 31"tyres. With so little options on gearing to suit the xud engine I decided to rip it out and fit a 1.6 16v MPFI from a vitara running the samurai gearbox.
Engine bay cleaned wiring stripped back and sprayed .

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Donor vitara purchased

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Engine and loom removed

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Loom stripped and rewired to remove stuff not needed also input othe supplies for fuel pump, main power, e,t,c.

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Because the 16v g16b engine is quite tall the engine fouled the bonnet also the exhaust manifold was close to the nearside chassis so I decided to fabricate new mounts/spacers to lower the engine by 25mm and move over to the drives side by 10mm but still bolt to the original mounts

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I then fitted the engine and loom along with a 42mm aluminium honda civic radiator along with an electric fan from an escort rs turbo. Also had to mount the coil and main fusebox into the bay. Also the intake system was taken from the vitara just shortening the duct between the MAF sensor and airbox.

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[gp7186]

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Radiator and fan

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After fitting the standard vitara fuel pump into the samurai tank and modifying the vit fuel lines it fired up first time. I then used the vit exhaust and cut and welded it to use as a temporary exhaust which il replace this summer.

Then I needed to work on the body as the dreaded tin worm had well and truly set in under the plastic trims heres a few pics of the sills and arches e,t,c
Before pics

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The made a few repair panels for the wing bottoms and 90mm pipe welded to 60mmx60mm folded angle 4mm thick for the sills all arches and other panels were plated with 1.2mm mild steel. All joints seem welded.

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Then a little filler and then plently of paint

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Then some extended MDPE arches from a landrover defender

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[ScottieJ]

Well even though you've been browsing for 3 years to club UK

Thanks for sharing the build! Some really nice work going on there! I'm impressed

[gp7186]

Then after driving it I decided it needed better brakes on the back so decided on a rear disc conversion .After looking at various calipers I chose to go with renault megane rear calipers due to cheapness, small size and they have the handbrake built into the caliper. So I machined the drums to create a backing plate for the disc. I then machine an sj front disc down to 280mm in diameter and to 8mm thick which is the maximum thickness for the megane caliper. Then I machine a bracket which acted as both a caliper hanger and bearing retainer.

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After fitting I had to bleed the calipers off the sj because the bleed nipple was slightly lower than the top of the caliper was when mounted but now the brakes are brilliant and also dont lock up which I was worried about thinking I may have to fit a bias valve but at the moment they have passed the mot and the handbrake is brilliant .

Hopefully this year I will be fitting YJ springs and missing links and over the top steering conversion

Thanks for looking
Gaz

[gp7186]

Well even though you've been browsing for 3 years to club UK

Thanks for sharing the build! Some really nice work going on there! I'm impressed

Thanks yeah its been too long hopefully now il regularly update. Thanks for the comments

Gaz

[dan_2k_uk]

Nice work on the caliper hanngerss/retainers!

[Jordi]

Tidy build. Loving the rear disc conversion. I want rear discs but unless i fit the x-eng transmission brake i dont know what to do for a handbrake as i dont really want the Zuk drum handbrake.

Would you be interested in machining those hangers to sell?

Jordi

[Jordi]

I forgot to mention i despise how tidy your welding and body work is. Not jealous much. Looks really good!

Can't wait for some more updates.

Cheers
Jordi

[dazerede]

Looks good

[gp7186]

Tidy build. Loving the rear disc conversion. I want rear discs but unless i fit the x-eng transmission brake i dont know what to do for a handbrake as i dont really want the Zuk drum handbrake.

Would you be interested in machining those hangers to sell?

Jordi

Thanks for the reply and comments. You could use a transfer box mounted handbrake from the early 413/410. I would love to machine up things like the brackets to sell but being so busy at work I just couldnt fit it in and dont have access to lathe and mill at home perhaps when I extend my garage this summer if I have room I may try and fit a small lathe and mill in there

Tnanks gaz