Mikes Samurai build / use / fixing broken bits after abuse

Got an vehicle build underway? post up pictures and tell us all how its going!

Builds threads only please.
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mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Mikes Samurai build / use / fixing broken bits after abuse

Post by mike harris » Thu Mar 10, 2011 1:17 pm

Hello people,

This is my start to now samurai build. I have got ome pics of the body project on other forums, but this does the job what's on here.

Happy reading :)

Mike

when i got it
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then after modding.

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to now!
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i have made some progress ill get some pics, rear floors in and wheel well, windscreen has been started, bulkhead has been welded up but plenty more to do.

thankyou

mike
Last edited by mike harris on Thu Nov 06, 2014 10:43 pm, edited 22 times in total.

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mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:18 pm

bit more progress.

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mike

User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:20 pm

sorry its been a while since i have done an update, i ahve been busy at work these last couple of mounths, for those who havent seen my suzuki heres the link to the pictures of it after it had been shot blasted and some of the repair work.

http://forum.difflock.com/viewtopic.php ... highlight=" onclick="window.open(this.href);return false;


i am currently doing the sills and the inner sills and the floors, i have cut out the rot and as you can see there isnt much left!

i will post some pictures up of it now as i have repaired all the inner sill and the drivers floor.

ill also get some pictures of the windscreen whitch is now also done. after teh other sill is done along with the other floor i will do the centre of the roof and the passenger wheel arch, whitch i now have thanks to steve, big thanks to him.

i have also sripped my chasis and painted it, whitch was intresting, spray gun in a small garage, fumes where quite bad, but exept from the runs it looks good, ill bolt my axles back on after i have made up some axle breathers for them, i have also fiitted a rocklobster as well, so the gearing on my suzuki will be a bit odd !!

thanks

mike


you can now see what i am up against here, the prevous owner tried to put a set of sills on it and just laid it over the top, i have new outer sills to go on and ill be cutting the rest of the crap bit out!!

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the body mounts i made using two skins of 1.5 mm steel, the orignal was three skins but made of much thiner metal, i drilled holes in the patch i made and plug welded it as well as seem welding it all the way around.


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this is a reapair i had to do in the channel surport for the front floor, the prevous repair had been mig welded, but not using any gas!!!


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as you can see there was a lot of rot, i have now repaired the whole inner pannel, and i am making up the outer part this week using my friends folder, i plan in slitting the pannel i make and welding the slits up, as well as spot welding it on.


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the body mounts i made using two skins of 1.5 mm steel, the orignal was three skins but made of much thiner metal, i drilled holes in the patch i made and plug welded it as well as seem welding it all the way around.


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this is a reapair i had to do in the channel surport for the front floor, the prevous repair had been mig welded, but not using any gas!!!


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as you can see there was a lot of rot, i have now repaired the whole inner pannel, and i am making up the outer part this week using my friends folder, i plan in slitting the pannel i make and welding the slits up, as well as spot welding it on.


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mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:21 pm

this is my newly painted chasis looking good.

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i am sorry that they were thken the wronf way round!!

some more pics of the finished body mount with the extra layer welded on.


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here are some of the inner sill now it has been repaired.

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mike

User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:22 pm

more...


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here is the windscreen all done and primed.


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sorry for the order problem!!

but here is the sill i made for it, and zapping it on there!!

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the bulkhead is also now welded up it is not having a heater or bonnet pulls so all the holes got welded up then seam sealed.

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this is the state of the other sill and what this one looked liek before i started.

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nice welding!! not.

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and finally some pics of the roof before i weld it up.

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thanks


mike

User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:23 pm

i have finished my axles, well missed a bit on the old paint front but hay ho, just thought id post up some pics of my axles all looking good, and my custom leaf springs :

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sorry for the differant angles of the same thing!!!

mike

User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:24 pm

i have just got the pics sorted out of the priming of the underside, and the seam sealing of the underside, since this pics where taken i have also stone chipped the underside, and also started to do the filler work, i have also seam sealed all the inside seams, and sprayed the bulkhead, next i am going to prep it for paint, just waiting for the front end to come back from the blasters, i want to try and spray everything in one go.

thanks

mike

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User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:25 pm

some pics of it after stone chip and some of the filler work, more seam sealing.

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User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:26 pm

i painted the bulk head,
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started to do some of the filler work in the sills,


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seam sealing the front floors.

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bit of seam sealing on the rear step.

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mike

User avatar
mike harris
SCUK is my life
SCUK is my life
Posts: 1827
Joined: Sat Jan 08, 2011 8:30 pm
Location: hascombe Surrey

Re: Suzuki Samurai Van Project Rust Free !!!

Post by mike harris » Thu Mar 10, 2011 1:28 pm

seam selaing the rear floor:

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