Not so DD Sami project

[amgraham]

Ran across a too-good-to-pass-up deal on an 87 Samurai today. I'd been looking for a DD beater to give the 4Runner a rest and this may just do it. It's got 105K original miles, runs great. Needs a windshield, some exhaust, a little rust repair in the floors, The t-case seems to be stuck (can't get it to shift.. stuck in 2wd) and it has a bad shimmy in the front around 50. I think it'll work well for awhile for me to beat around town in. I'll do some small stuff but keep it low on little tires and maybe ramp it up later with some Yota axles and such to make a wheeler for my brother. In the meantime I'll post up the little repairs and stuff I get done. Any suggestions? Must see info sites? Lay it on me. Pics for now:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02401.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02402.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02403.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02404.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02405.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02406.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02407.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02408.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02409.jpg

[akxj]

zuwharrie.com
zukikrawlers.com

seem to be pretty essential i think....pirate section is alright and seems to be pretty friendly...not like usual pirate mentality...good look rig....laters...

[ChevyMudTruck]

http://www.puresuzuki.com/
http://projectsamurai.com

both got some decent parts . . . forget the other sites I use to look at . . had 4 of them damn things

[amgraham]

Thanks guys.

Everyone likes some stock flex :razz:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02421.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02422.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02423.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02424.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02425.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02426.jpg

[jhama78]

I wish I fit in a sammy... like akxj said check out the suzuki section especially the FAQ on pirate4x4.com/forums :thumb:

[VBblazerEric]

that thing is cleannnnn

[gtrsnax]

Good score. I see yours and cant help but think "man, that would probably be a lot of fun"

[amgraham]

I wish I fit in a sammy... like akxj said check out the suzuki section especially the FAQ on pirate4x4.com/forums :thumb:

Huh, I have the same problem. I look really funny in there. My fam said I looked like one of the shriners in the little cars at the parades :mrgreen: . Whatever, I don't care.

Deflared it today trying to discover all the rust work I will need to do:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02428.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02429.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02430.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02431.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02432.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02433.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02434.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02435.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02411.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02412.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02413.jpg

[gtrsnax]

Wow, what exactly was holding the flares in place anyway?

[amgraham]

Wow, what exactly was holding the flares in place anyway?

Not much :???:

[Wheelin22RE]

that's like unwrapping underwear at christmas.

[gadzo]

check a detent ball inside the t case i had a smi that wouldn't come pout of 4 low to shit i had to get out with a allen wrench re move the ball shit and re install it was always a pain but it was only a $50 beach beater

[amgraham]

Took the Zuk out to a buddies house in Cville today and did a bunch of stuff to it. Including the brass t-case shifter sheet (completely took care of the shifter prob), tach cluster swap, door hinge cut so they are now removable, H4 headlight swap, valve adjustment, cut swaybar off, and a few other odds and ends. Pics:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02462.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02463.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02464.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02465.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02466.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02467.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02468.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02469.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02470.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02471.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02472.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02473.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02475.jpg

[green73]

What does it get for MPG vs. the Toyota?

BEWARE those things are just as addictive to modify as any other 4X4 out there. Next thing you know you are looking for Yota mini truck axles, a TDI Jetta engine, and many other things.

[amgraham]

What does it get for MPG vs. the Toyota?

BEWARE those things are just as addictive to modify as any other 4X4 out there. Next thing you know you are looking for Yota mini truck axles, a TDI Jetta engine, and many other things.

Haha.. I'm already snooping around for YJ springs :mrgreen: . I dunno what kind of MPG it gets.. the speedo is off but I don't know how much and the gas gauge is broke. I would guess about 25 on the Zuk and I normally get 16-20 around town depending on how pissed off I am that week :D .

[amgraham]

Snagged a piece of DOM to reinforce the front crossmember and a few other things. Picking up a set of used 30" BFG muds tomorrow, got another set of wheels coming Saturday along with some TJ flares. Coming together :cool:

[amgraham]

Picked up up the tires today.. Craigslist is great. 4 75%ish 30x9.50 15s on Taco steelies. Set them next to the Zuk for an idea of looks and also took a few pics next to the 4Runner for size comparison. Notice the snow.. Wild, huh? It's been like 2 years since it's snowed any here. Anyway, pics:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02476.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02477.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02478.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02479.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02480.jpg

[amgraham]

Ok, here's the blow by blow from today...

Started off with a little tuneup. The blue wires add at least 10 hamster power:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02487.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02488.jpg

I took the BFGs off the Taco rims the other day and mounted one on the one stock steelie I had so I bolted it up to see how it cleared. That's a 30x9.50 BFG MT on a 15x5.5 rim. I REALLY like how the tire sits on the rim and it actually fits the truck quite well. It rubs slightly on the pinch weld when flexed out and is pretty close to the leaf spring at full lock in the back but I don't think it'll actually touch. Still, I was surprised they fit as well as they did:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02489.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02490.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02494.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02495.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02496.jpg

Also got the TJ flares and they'll pretty much let me cut whatever I want off the fenders. So, we just started cutting, hammering, and folding the inner fenderwells up. While Jason was helping fold the sheetmetal up I went to work cutting down the front crossmember and welding up that piece of DOM I had in there (before you guys give me crap I got it as a piece of scrap for cheap so I don't mind using it here. I went looking for sch 40). This was a pain because the rotten metal kept burning through and then I turned the heat down and it wasn't penetrating the DOM. So, I finally found a happy medium but it didn't end up pretty. I ground down a lot of it but it was dark by that time so I'll probably have to grind and weld on it some more in the daylight to get it satisfactory. Anyway:

Fenders:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02499.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02500.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02501.jpg

Rust in crossmember:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02502.jpg

DOM in:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02503.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02504.jpg

Booger welds:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02505.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02506.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02507.jpg

Grinding shots:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02508.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02509.jpg

My goal is to paint the other stock wheels I got from Jeff today and get the tires mounted this week sometime. The wheels will be black. I also will figure out what kind of filler I'm going to use for sealing up the rust holes. That should be an adventure...

[amgraham]

Ok, last night when I got back from my exam I was still hopped up on caffeine and ended up priming and painting the stock rims. Today while I was waiting for a car I'm working on to cool off I ran and had the tires mounted up and stuck them on the Zuk. I hammered the pinch welds in the front and haven't done anything to the rear and it doesn't rub a bit, and I think the combo looks great. Pics from me screwing around the yard:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02510.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02512.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02513.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02514.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02515.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02516.jpg

And a comparison shot with a stock IFS Yota on 31s:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02521.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02523.jpg

I also picked up a toolbox last night. A buddy of mine bought a YJ and it had this box in it. He decided that he wanted a back seat instead so took the box out. I'm trading him some welding work for it and it fits perfect. It's a little bigger than I had planned but actually functions quite well. Pics:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02517.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02518.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02519.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02520.jpg

Picked up a can of Fiber Hair today.. I've never used it before so wish me luck on that. Hopefully have the holes patched up and TJ flares on by next week but no promises.

[AlxJ64]

That thing is commin along nicely.. I'd like to see it at the farm.. It'd be a good place for you to put it through all the paces,.. :thumb:

[amgraham]

That thing is commin along nicely.. I'd like to see it at the farm.. It'd be a good place for you to put it through all the paces,.. :thumb:

Heheh.. Thanks man. I'm picking up some lockrited axles, springs, shackles, and missing links before the first of the year.. Shh, don't tell anyone :wink:

[amgraham]

Tonight when I was cleaning up I was thinking about what to do with my turn signals. I had thought about trying to fit them behind the grille so I popped it out to see what I could do. I figured out I could drill 2 small holes in the upright supports and use one of the stock screws to attach the signals there. Then, I just put the grille back in. They look really clean, work like a charm, and I don't see any reason why they won't pass inspection. They are really bright considering they're behind the grille. Best 15 minute, free mod I've done :) . Pics:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02524.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02525.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02526.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02528.jpg

[amgraham]

I did a little more on the Zuk last night. I drove it around Sunday afternoon and the "tailpipe" fell off. Yes, that is 2 glasspacks welded together and that dent is where it was riding on top of the axle tube :roll: :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02536.jpg

I went nuts with the Sawzall again and cut a bunch more off the wheelwells trying to prepare to seal them up. Man, rust is a pain in the butt:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02537.jpg

Then, I pulled the bling bumper and cut all the bracketry off the crossmember. Can someone explain to me why the license plate has twice the brackets than the whole bumper has? :roll: I still need to weld in a tube to reinforce it and I have a piece of 2"x4"x1/4" for the rear bumper. I'll weld up some brackets this week to put it on there. It'll probably double the weight at the rear of the truck :lol: . I'm going to go by Northern and Harbor freight in a little bit and see if I can find some lights that will work so I don't have to reuse the stock taillights. Pics:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02538.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02539.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02540.jpg

[amgraham]

I was pretty productive on the project tonight. Painted the tire carrier and bolted it on. Then I threw one of the tires on there to check for clearance. Fits well, tight against the tailgate so it won't rattle:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02541.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02542.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02543.jpg

Welded up some brackets on that piece of 2x4x1/4" for the rear bumper. I was planning to use the ends off the stock hitch but after cutting them off and playing around with them I ended up using a couple pieces of 1/4" angle.. I made them a little wide to leave room for bracing when I add recovery points and such. Oh, and the hands in the second pic are my buddy's.. He said his hands were cold and the bumper was still warm from welding :) :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02544.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02545.jpg

Welded in some blind nuts:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02546.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02547.jpg

Then I mounted up the bumper. It fits pretty well. I'm probably gonna cap it, clean it up and paint it, then add recovery points, receiver, and bracing later since I have more pressing matters to still deal with:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02548.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02549.jpg

Then I got really brave and started cutting out for the taillights. Of course I broke my only jigsaw blade and it was too late to get another one. That's not going to stop me though.. I grabbed my trusty Sawzall (what else? ;) ) and gave it a shot. I got a rough hole cut out then went at it with the grinder. It took awhile but I finally got it to where the grommet fit in pretty good. I have to run the wiring and paint before I pop the lights in for good though. I started on the other side but it is a little tougher since it has "bracing" (2 pieces of tinfoil instead of one). I think they're gonna work out pretty well though:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02551.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02550.jpg

That's it for now...

[akxj]

gettin better and better lookin everyday....man, that thing had the cancer bad in those wheel wells...

[amgraham]

Clifton came over yesterday to help on the Zuk. Unfortunately, I had to swap the clutch in Jason's truck and we took a break to hit the meet and greet. Still, a lot got done.. I'll let the pictures talk this time (sorry some are fuzzy):

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02552.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02553.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02554.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02555.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02556.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02557.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02558.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02559.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02560.jpg

[akxj]

keep cutting and boatside that bitch!!!

[IH8RDS]

keep cutting and boatside that bitch!!!

Ha HA You beat me to it :mrgreen:

[amgraham]

keep cutting and boatside that bitch!!!

Haha.. How'd I know you were gonna say that :mrgreen: . I have those 2 pieces of angle but I might need to scrounge up a few pieces of plate to sink up in those rockers.. But, the thing is, the angle fits in those rockers perfect... Hmm... Like most things on this project it'll probably come down to my mood at the time and how long I hold the trigger on the Sawzall :twisted:

Thanks guys!

[amgraham]

Today after I did some mods to my dad's flatbed I got the Zuk ready for another round of work tomorrow. I set it up on jackstands, air chiseled out the 2 blind nuts that I stripped out last time I mounted the rear bumper and welded new ones in, then that got me thinking about the bumper so I capped the ends and cleaned it up some. I rounded off the top corners but I think I'm gonna leave the welds natural the rest of the way around. I also wallowed out the mounting holes a little so it'll be easier to bolt up. Pics from today:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02614.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02615.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02616.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02617.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02618.jpg

Picked up a bunch of steel plate the other day (3/16, 1/4, 3/8). Tomorrow we're going to try to get the wheelwells further along and I'll probably start working on boatside rockers and belly skids. I'll have more pics tomorrow.

[amgraham]

Got up this morning at 8 to start working.. It was supposed to have quit raining around midnight last night. When I woke up I thought I heard rain on the roof. Looked out the window and it was a full on downpour.. So, back to bed :D . Clifton called and woke me back up about 9:30 and asked if we were still on and it seemed to have quit raining so I told him to come on over. This is the view that greeted me when I went out in the yard (notice the puddles):

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02619.jpg

Of course, it started raining again shortly after Clifton got here so we decided it was time for the redneck garage:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02620.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02621.jpg

Clifton was trying to get the wheelwells finished up in the rear, at least ready for fiberglass.

Before:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02622.jpg

After:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02623.jpg

Ryan came over and I had him hold the TJ flares while I Sawzalled off the back sides of them to get them flat. Then he took care fo cleaning them up with the grinder:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02624.jpg

While goofing and getting up the nerve to do the big cuts that were coming I installed my horns of the 560 SEL :P :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02625.jpg

Cut the driver's fender and floorboard (a little rough but I'll clean them up and plate them later):

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02626.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02627.jpg

Ryan decided it would be a good idea to sign his name on the fender with the angle grinder:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02628.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02629.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02630.jpg

Chop:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02631.jpg

We briefly discussed how cool Lexan floorboards would be :D :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02632.jpg

Did the first shot of Fibre Hair.. Yeah, it looks like crap but it's sealed up and will look ok after some sanding, paint, and behind some kind of panels :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02636.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02633.jpg

Here's some of the filler panels Clifton welded in on the other side.. This will get covered with Fibre Hair too:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02634.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02635.jpg

Cut the rest of the rockers out and started putting together a plan for something down there:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02637.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02638.jpg

I did some other stuff like pulling the gas tank (contemplating a fuel cell to get it out from under the truck) and thinking through maybe building a new crossmember and how to build the belly skid. A lot of work left though. Thanks tons to Clifton for helping so much, Ryan for lending a hand despite the food poisoning ;) , and to Buck, Jason, and Jason for coming by and hanging out.

[8th Man]

Great fun!

Looks like you guys made the most of yet another terrible weekend (weather wise).

[amgraham]

Great fun!

Looks like you guys made the most of yet another terrible weekend (weather wise).

Yeah, I hear that.. I'm sitting inside wishing I was outside but I don't have the resolve right now to do 2 soggy days in a row...

[amgraham]

Ok, catching up on some updates..

Finished painting the bumper and mounted it up... Can't wait for my plasma to get here so I can cut the recovery points in and build the brackets for the front bumper:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02712.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02713.jpg

Fiberglassed the other fenderwell:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02717.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02718.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02719.jpg

More coming...

[amgraham]

The other night Clifton came by while I was finishing up some work on another car and he worked on the passenger front.

Cleaned up the front fender cut:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02720.jpg

Patched in the floorboard:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02721.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02724.jpg

Cut out the battery tray and started brainstorming for a new one:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02722.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02723.jpg

Yesterday I was sick but still wanted to work outside so I did some easy stuff (or so I thought...). Pulled the rear driveshaft and found a surprise.. Someone had put a new u-joint in and didn't drive one of the caps all the way in so it wobbles back and forth.. I'm surprised that it didn't vibrate:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02725.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02726.jpg

Pulled the rear drums and found a busted axle seal and wore out brake shoes. That's ok since I'm putting different axles assys in soon.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02727.jpg

I was trying to pull the axles and the third to Lincoln lock it but I couldn't get the bleeders or brake lines loose... I've got them soaking in PB so hopefully I can get them out soon.

Then I went to look at a parts Sammy. I told the guy I'd buy it if I could find a truck and trailer and that I'd call him back as soon as I knew. He said cool. I arrange for a truck, trailer, and some help to load it and call the dude.. He says that his brother said he wanted it before and he was just going to give it to him.. Like Ron White would say, this sent me into an all new dimension of pissed off.. I wasted about 3 hours and bugged 2 different friends all for nothing.. It's not the loosing of the truck, it's just the complete disregard some people have for other's time..

So, I came home and did little stuff that I knew I couldn't screw up. I started planning out where to mount my CB and antenna, ran my taillight harnesses, installed my stock clock (that was fun whittling a hole in the dash then smacking it with a hammer :) ), and then trying some different tag locations.. I think the spare tire will work best if I can figure out a good way to mount it. Oh, and Jason was being helpful as usual ;) :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02729.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02730.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02731.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02732.jpg

That's it for now.. But, it's nice today so I'll probably get some more done.

[amgraham]

Ok, more updates. I fought through the cold and went out in the nice weather and worked on the sammy yesterday afternoon/eve. Clifton came over too and glassed some on the outside of the wheelwells and did some more metal work on the front.

Pic of the clock installed.. Don't know if it actually works yet (No battery in the truck):

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02739.jpg

Finally ended up pulling the other end of the brake line loose as I still can't get that bleeder loose. It's all good anyway.. That wetness that I thought was an axle seal is actually a hole in the brake line that I probably wouldn't have noticed otherwise. So, I'll have to get a new wheel cyl and brake line:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02740.jpg

These look like go cart axles compared to the yota axles I'm used to:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02741.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02742.jpg

Some glass.. Doesn't look much different:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02743.jpg

Pulled the third and decided to weld 'er up for now until I get my other lockers and such. I still have to play with the backlash a little or something because it has a bit of a hard spot in it after reassembly.. The part I welded up seems to be fine though:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02744.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02745.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02746.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02747.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02748.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02749.jpg

Metal work that Clifton did while I was working on the axle:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02750.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02751.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02752.jpg

Pretty productive I think for just a couple hours...

[gtrsnax]

If that u-joint wobbles inside it's cap, the needle bearings are probably powder and useless. I've been there before. Based on your pictures, it doesnt seem like a seating issue to me.

[amgraham]

If that u-joint wobbles inside it's cap, the needle bearings are probably powder and useless. I've been there before. Based on your pictures, it doesnt seem like a seating issue to me.

No, it is.. I should have taken a pic of the normal one.. The clip is supposed to be like a 1/16" down or so... There is no play otherwise except up and down at the cap. When I get back home today I'll pull it apart and see if I can get it to seat.

I know exactly what you mean though.. My last F-150 had red dust and no needle bearings come out when I pulled the u-joint caps :mrgreen:

[gtrsnax]

Oh, duh, I see the way it is now. Yeah, that booger (the C clip) can shoot out at any moment!

[amgraham]

Ok, so I've been slack on the updates lately but I've at least been taking pics. I'll try to bring everything up to date.

Clifton working some more on the fender earlier this week:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02755.jpg

Rear brakes needed some attention:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02756.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02757.jpg

Here's the reason I finally discovered for all the wetness on the passenger rear leaf:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02769.jpg

Had to order a new wheel cylinder, shoes, and brake line.

Here's a pic of the progress Clifton made on the fender:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02758.jpg

While waiting on parts and stuff I started on the front bumper:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02761.jpg

After a year of faithful service my Harbor Freight band saw gave up the ghost mid cut.. ruined 3 blades in about 20 minutes :( . The guide wheels wore out and the blade kept cocking sideways bending the teeth.. Good thing I have the extended warranty.. Took it back and they gave me a brand new one. Here's the old:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02760.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02759.jpg

Here's the CB I will be using in this rig.. Old school Cobra 21:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02762.jpg

More progress on the fender:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02763.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02764.jpg

Worked on getting the taillights finished.. The holes are a little tall but they seem to fit in there pretty solid. After I finished grinding on the holes I laid some paint and installed grommets for the harnesses:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02765.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02766.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02767.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02768.jpg

A bunch of pics of the taillights installed.. I was trying to get good shots of them and a couple with them on.. They look really good:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02772.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02773.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02775.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02780.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02784.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02785.jpg

It took me awhile to figure out how to run the harness from one side to the other. Ran it through the stock bolt holes as it will probably be easier to make something to cover them. Also, used the stock clips underneath:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02782.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02781.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02783.jpg

Painted some stuff on the back:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02786.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02787.jpg

Brake parts finally came in:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02771.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02770.jpg

At this point I realized that the braking brake arms on both sides were frozen. It took PB blaster overnight and a torch to free them up. After I got them together they work like a charm:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02776.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02778.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02777.jpg

The parking brake cable pin was frozen on one side and while drilling it out I snapped the spring. After searching around everywhere I couldn't find one. Ended up finding a set of throttle return springs at Advance and cut one down to make a new one. After that I used a couple bolts with double nuts to replace the pins and adjusted the cable and it works well now:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02788.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02790.jpg

I didn't get any pics today because it started pouring rain. But, it's back on all fours for now because I had to work on something else and get the sammy out of the way. Clifton pretty much finished up the passenger front other than some grinding and bondo. He also bondo'd some of the rear. I'll get pics of that stuff later.

[akxj]

are those saw warrantied....mine did the same thing now i just collect dust in my shop???

[amgraham]

are those saw warrantied....mine did the same thing now i just collect dust in my shop???

I think they will exchange them within 30 days but after that you need the extended warranty. I pay $20 a year to keep the warranty going so I can take it back whenever.

[amgraham]

Ok, the Samurai moved for the first time yesterday since the last time I posted up. I've had a lot going on with school and such plus I kinda hit that mid-build slump that you normally get. Anyway, I have an update now...

The weekend of the second I went to Tennessee to visit my grandfather and while I was there picked up this load of goodies:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02981.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02982.jpg

Yeah, my bro and I couldn't help but hum the Sanford and Son theme song on the way back. :D In there is a set of sammy axles with Lockrights installed, Rocky Road high steer, sammy/CJ hybrid springs, front and rear missing link shackles, shocks, YJ springs, spare axle shafts, 3rds, and several other random pieces. I'm gonna figure out what to do with all the stuff soon...

Until I decide on exactly what I want to do with the suspension I decided to continue on working on some of the random stuff that needs to be buttoned up. First off I pulled the rear bumper and braced up the sides:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02983.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02984.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02989.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02991.jpg

Then I broke out my new toy:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03008.jpg

And cut in my receiver hitch:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02985.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02986.jpg

Turned out pretty good IMO (I'm still gonna add shackle hangers when I get some more). Also, after I reinstalled the bumper I went ahead and painted then reassembled the tailgate. I did a bad masking job but it looks decent enough for this project:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02987.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02988.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02990.jpg

Earlier Ryan and I put the gas tank back in with another stock skid. I'm itching to get it drivable again so I can ride it around a few days and work some of the kinks out then pull it back down for the suspension/axles. So, for now the stock tank with the busted sending unit goes back in. In this vein of roadworthiness I also decided to make my tag mount idea a reality. So, I sketched out a design on a piece of 3/16" plate:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02992.jpg

Cut it out then had to make a receiver tube out of angle because I couldn't find 2 pieces that fit into each other:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02993.jpg

Welded a piece of 1" to the back of the plate:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02994.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02995.jpg

And welded the receiver tube to the tire carrier:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02997.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02998.jpg

Painted everything:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03005.jpg

Mount back on:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03006.jpg

And the final deal:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03010.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03011.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03012.jpg

I really like how this turned out. I have to drill it to put a pin in and run the tag light wires with a plug to make it easily removable to get the spare off. I think it'll work just fine.

Let's see.. Other random stuff.. Painted the quarter Clifton finished up a few weeks ago:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02996.jpg

I had a piece of my bandsaw that I don't use and I thought it would work perfect as a battery tray.. I was right.. Cut it down and it lays in there just right, ready for welding:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03007.jpg

Thank you to Ryan for helping me out today!

Now, thank you to Jason for this next part...

I put a stereo system in my shop when we first built it years ago. Slowly it got to sounding bad and I really didn't use it much since it was inconveniently located in a hard to reach place above my toolbox. So, I have been listening to a cheap little boombox with whatever metal object that was handy shoved into the antenna. Yesterday we made the decision to revamp the system.

He had a set of Marantz speakers laying around that sound great and fit well mounted in the same place where I had my old ones (on the ceiling):

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03000.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03001.jpg

I had this amp/tuner laying around that my grandparents bought new in 1968 or something from JC Penney. It still works fairly well, sounds great, and looks like you're flying the space shuttle to boot :D :

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02999.jpg

Here's the part that's most beneficial to me.. I had a set of Bose outdoor speakers that have been on the shelf for at least 8 years. I got them off the back of a house where a lady was moving and she said she didn't want them. So, who knows how old they really are. Anyway, we mounted them up outside and they sound great and point the music well right at my work area but are loud enough to where if we had a party going on or something in the yard they would probably be sufficient. I'm just all kinds of stoked about having a decent sound system:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03002.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03003.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03004.jpg

Currently I have the tuner and a aux input cable for my mp3 player. Jason says he has a CD player I can hook up to it as well so I think I'll be set.

Whew! Long update. I may get some more done tomorrow.. We'll see.

[amgraham]

Well, I still haven't driven it.. But, I'm getting closer. The plan now is to get the body work done, drive it a couple weeks while I do some stuff on the 4Runner, then swap out the springs, axles, and such. I've been sitting on some updates because there really hasn't been too much happening but here's the progress to get you up to date.

I finished the tag mount, ran the wiring and drilled for the pin. Yeah, I know it's a little crooked but that's mainly because of slack in the receiver. Once I shim it up so it doesn't rattle and all it'll be straight.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03013.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03014.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03015.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03016.jpg

Someone gave me a free Grant steering wheel that's a lot nicer than the one I had before. So, I got an adapter and put that on, wired up the horn, etc.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03017.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03018.jpg

Rigged up a redneck intake. It consists of the stock carb hat, a Dodge Dakota cold air hose cut down, a 3" cone filter, and duct tape. It's free and will work for now since I broke the stocker and I'm thinking of building a snork sometime.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03019.jpg

Cleaned up the scrap heap... Got $140 for this load of junk. They call me Lamont.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03020.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03021.jpg

I needed to break the bead on the spare I bought for the 4Runner.. I was unsuccessful but it was interesting watching Jason and George jump up and down on it :D .

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03022.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03023.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03024.jpg

Clifton was finishing up the last of the body welding. Every time he was almost done he would be tapping something into place with the hammer and a new hole would appear. He got to this point, had the major stuff welded, and called it good before something else fell apart.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03025.jpg

Finish welded driver's fender, ready for glass.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03026.jpg

Passenger fender after a couple coats of glass:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03027.jpg

Had a couple holes in the cargo area I fiberglassed so I can paint the floor and install the box.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03028.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03029.jpg

Here's the finished floorboard before fiberglass. I fiberglassed that and the fender then so it's now ready for a little sanding and paint or some kind of coating.

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03030.jpg

Also, I pulled the glovebox (cracking the hood release cable housing in the process) in preparation for relocating the hood release location (always hated it being in the glovebox) and installing the radio either in the glovebox or directly into the dash (Between the middle vent and the Samurai logo). Not quite sure which I'm gonna do yet. As for getting it rolling, I bled the brakes (with help from Ryan) and now just have to finish the glass, bondo, and paint then install the seats and flares. Also have to figure out sliders in there too since my rockers are completely open. May do that on an afternoon this week after I finish my first wave of schoolwork. After Friday I'm on spring break so I should be able to get a fair amount done then. Anyway...

[amgraham]

Time for an update. The other day I put a lot of stuff back together. The breakdown:

Hurdle one: Realized the new shifter I got was for a late model. Solution? Find a bolt that fits in the groove (5/16"), tap the housing for it, and there we go.

Hurdle two: Redneck intake fell apart. Not enough surface area for duct tape to be effective. Solution? Cut down an old plastic cup I found in the garage and made an adapter. Then added more duct tape. Works like a champ.

Hurdle three: The bodywork. Clifton gave it another shot of Bondo to get it closer to paint time. However, I got impatient and spray bombed the floorboards, threw the seats back in, and took it for a ride. A couple hours later...

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03055.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03056.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03057.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03058.jpg

Didn't mean to drench it in mud, it just kind of happened ;) . I hosed it off in preparation for today. I believe the body work is done.. Laying paint tomorrow hopefully. Then flares. Pics from the last of the Bondo today:

http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03075.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03076.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03077.jpg
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC03078.jpg

Not done yet, but at least it's drivable. Been great weather for cruising it around this week too.

[gtrsnax]

Thats awesome. Thanks for the update. Thats exactly the same idea I had for my license plate too. The welding was a bit early in the "just stick it on for now, finish it pretty later"

[VBblazerEric]

hell yeah man looking good, i kinda wanna get my girl friend one of these......so i can drive it

[Kack]

holy shit a license plate light!!!!!!. nice work. Can't wait to watch that sammy ping pong around on the next trip

[amgraham]

Haha.. Thanks guys. Yeah, I know the updates are pretty stupid right now but on some of the other boards people have been appreciative of the detail of all this crap. I'm so glad to have the body work done. Laid paint today and may get the flares on tomorrow. Still need to do the rockers/sliders, skids, springs, shackles, and axles but I'm gonna space them out a little bit so I don't get burnt out like I did this time. For now I'm switching over to the 4Runner to get it ready for a trip to Rausch in May and probably June too. Need to do the Chevy springs on that, BJ spacers, IFS truss, new front crossmember, beat my skids into submission, maybe sliders, front bearing repack, and maybe some new steering components. Sigh.. I need more money...