The frame is finished sans paint, which will get applied tomorrow. We like to inhale our paint fumes first thing in the morning.
3/26/2011 – We’re making fast work of our Trail Tough Zuk build. We wrapped up the frame fabrication today, as well as both front and rear Toyota axle housings. We’re having so much fun with this build, we’ll likely work on it every day until it’s wrapped up.
After taking some simple measurements, both ends of the frame are cut off and replaced with assemblies that are included in the Trail Tough “Trail Slayer” buggy kit. Two cross-members incorporating link mounts are also installed that can either be bolted on, or welded. We welded them for added strength.
Next up is to paint the frame and get the links set up with the axle housings and coil springs, then we’ll stick the 16 valve motor and automatic transmission in, along with a wicked cool transfer case from Trail Tough that we’ll tell you about later.
Rick is cutting the rear of the frame off, wishing he didn't have to take the kids to soccer practice.
3/27/2011
More progress; After the flat black paint job dried we installed all of the links and both housings, as well as bolting the springs to their respective mounts. These are 16″ springs, and having them bolted to their perches ensures they will stay put.
Here’s a view looking forward from the rear:
All of the links are pre-set based on measurements included in the well written instructions. All we had to do was bolt it all together
Here’s another view, from front looking back.
The springs are distorted due to not having any weight on the chassis. Once we get the engine/transmission/t-case and body back on, the axle will move back to it’s centered position. This off-center position of the front housing is caused by the panhard bar pulling it sideways as if the axle were drooped several inches down. The rear doesn’t do this because the triangulated upper control arms keep the axle centered.
May 7, 2011 – It’s alive!
Trail Tough takes the guesswork out of the wiring harness for it’s customers. We sent them the factory engine harness, and they modified it to work with our Tracker engine. The end result was an engine swap that fired up and ran correctly on the first try. Thanks Brent and crew for making it so easy!
We also sent our transfer case to Trail Tough for updates, and it came back loaded with 6.4:1 Rockmonster gears, rear driveline disconnect, a 2 Low kit, all new bearings and seals and a Mighty Kong transfer case and skid plate.
The Buggy Bed Kit is a great addition that allows for the fuel tank to be raised up and mounted to the top of the frame rails, and looks damn cool. Constructed of aluminum, it’s light weight and super strong.
The 42″ Irok’s on Raceline Monster beadlocks fit the build better than we thought they would. We were concerned that they would be way too big for a Samurai, but Brent Bradshaw designed this entire kit for tires sized up to 42″. He assured us that they would work well, and he was dead on track.
And from Yukon Gear and Axle, the Toyota 3rd’s are built with 5.29 gear sets and Zip Locker air lockers. These things are so easy to build it’s ridiculous.
With the weather at Lattitude 47 finally warming up and the sweet sound of the engine running, Rick looks like he has ants in his pants and is itching to get this rig on the trail. The short list of things to do include brakes, drivelines, the front clip, a full roll cage, and the complete PSC Motorsports hydro assist steering system.
We’ll be back soon with the rest of the build.
7/25/11
It’s hard to believe that we’ve been working on this build for four months. Four months is a long time, but it sure went by fast. I guess if we had nothing else to do, it would have been finished in just a few weeks. We like the end result, and hope you do too.
Thank you to all of the manufacturers for helping with this project:
Trail Tough, PSC Motorsports, Yukon Gear and Axle, Warn, Raceline Wheels, Those Guys Rod & Custom and the CRAWL Fab Team.
Special thanks to Brent Bradshaw and his team at Trail Tough. Your products are amazing, and your passion for quality was evident every time we opened a box. We are proud to have had the opportunity to work with you.
Watch for a feature on this rig in an upcoming issue!
This is the most kick ass project ive seen thus far
But I might b a little bias
looks like too much fun! cant wait for a ride in the flats!
Impessive build
any updates on this?
We’ve been working the boring stuff, brake lines, fuel lines etc. We also put the 42″ Irok’s on the Raceline Monster beadlocks. After we get back from EJS we’ll build the Toyota 3rd members with Yukon Zip lockers and have us a roller. Stay tuned!
This build is badass… My FJ40 with 40′s was BUILT under 2k, it will run you for your money! It has a custom badass driver and I fab everything… ;^D Love ya Rick!
very nice wish I could get my zuk someday to be as capable as this will be. Look forward to the updates.
Nice build, very simuler to what we are building. We’re using air shocks though. Think I may have to pinch some insperation from your build though.
Awesome! That is one the cleanest over the top Sammis I have ever seen.
Awesome build. I am from Australia and building one up.. I like the suspension and link set up. Don’t suppose you want to share the measurements for the link set up and what suspension you are running? Please… Great work guys…
Looks great but it should looks just like mine. Could have chose a different color.
Cool build, makes me want to get a suzuki. I have one question though,could you tell me where you got the headlights? I’ve been looking for a set for my buggy and really like the ones on this project but can’t find them.
The headlights were provided by Trail Tough, John. They’re snow plow headlights adapted to wire directly into our harness. Give Brent a call at 877-789-8547 and he’ll get you fixed up.
Now they need to do one for the Sidekick and the newer Vitara and the XL-7 ! It also needs to be a kit that will allow the vehicle to pass smog laws…
Hi
I’m doing similar project here in Greece with Mercedes 240 GD axles and SIMEX 35” tires. How many libres are the 16” springs you use ?