Project Zuburban (Honor Build)

[norzuki]

Hey Guys,

I though I would start this build-up over here too.

I am building this rig for a friend of mine that lost his life in Afganistan. He was a true friend to me and I decided to honor him with this build.

The build consist of a stretched tin top. I stretched it 22", but from looking at the length I might be cutting it down about 6". I will decide that after I get the suspension up under it and all.

here is what I have:

- 1.6 16 valve
- tracker radiator
- 35 x 13.50 x 15 Krawlers + 15 x 8 rims
- 1981 toyota axles
- Marlin Crawler high steer arms
- beefy tie rid and drag link
- YJ Missing links front & rear
- dodge neon seats

I still need:
- hydro assist kit
- mass air flow sensor for a 1993 1.6 16 valve
- adapter plate to bolt the zuk 5-speed to the 16 valve
- a pair of 5 pack YJ's

here are some pics:

http://www.zuwharrie.com/gallery/albums/userpics/10108/cut_side.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/body_space_add%7E0.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/drivers_side_body_fill01%7E0.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/passenger_side_body_fill%7E0.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/roof03.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/roof.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/frame_ext22%7E0.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/fish_plate%7E0.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/krawler_tires.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/axles_primered.jpg

[TEXXCRAWLER]

:jerry:

[lostsamurai]

ive got a 93 and a 94 mass air flow sensor ill sell ya the 93 and ship on your dime where ya located and whats a fair price? i also have a set of 3" lifted yjs but they are under my rig ill trade ya for stock rear tj coils

[norzuki]

Went to the blasting booth again today and done the missing links...


they sooo puuurdy :happypill:

http://www.zuwharrie.com/gallery/albums/userpics/10108/missing_links_blasted.jpg

[norzuki]

Today my plans are to get the axle housings set up under the rig and start installing the YJ missing link suspension. I have got to run up to a friends house and pick up a 5-speed tranny first....so we will see how far I get.

I think I have all of the high dollar parts except the 6.5:1 t-case gears...now I all I need to do is get the small items.

Front axle bearings
Rear axle bearings + seals
t-case bearing kit + seals
tranny bearings + syncros
exhaust

I know there is more, btu for now thats all I can think of here at work.

I am trying to gather all parts needed for hydro assist now.....I have the IFS box / high steer arms / tie rod & drag link....... I need to get a ram / hose and fittings.

[bigBs84]

Sorry to hear about your friend :thud: But that is a stand up thing you are doing I hope everything works out for you, good luck with the build.:rockon:

[norzuki]

Sorry to hear about your friend :thud: But that is a stand up thing you are doing I hope everything works out for you, good luck with the build.:rockon:



Thanks man !! He was a "all around" great person. Theres times when ,, while I am working on the rig I think about him and the funny cut-up stuff we used to do and him helping with my first rig. I miss that !!

Its all coming together though...I am finally getting to where I can focus on building the rig. I hope to have it done b-4 September (hunting season starts)

[jonny]

I realy like what youre doing.ive got a couple of friends in iraq.Joseph Porter.James Chin.may god be with you.hope to see you soon.:(

[norzuki]

got some goodies from the big brown truck the other day :happypill:

got the Trail Gear 6.5:1 t-case gears and I know I am gonna love them. Also recieved a few odds and ends for the 16 valve that I didn't have. I have ordered some new poly bushings to cover eveything front to back as far as the YJ springs and all. I will have to wait till next Friday b-4 I can order:

- t-case rebuild kit
- tranny rebuild kit
- bearings for front & rear axles
- rock 4x high clearance tranny crossmember
- mighty kong t-case bucket
- harness modified <--(if I can find another 16 valve harness)
- clutch
- finish the body work

a lot to do in a short time for sure :D

[norzuki]

Hopefully one of the T/G guys will chime in here....


http://www.trail-gear.com/images/2008-1590b-600.jpg

I am thinking about installing these in the front and rear. I will also be running the Missing Link Set-up from Trail Tough.

My question is:

will the rig be stable on the pavement as a daily driver? I just don't want no side to side (body roll) kind of. I am sure that the pan hard bar will keep everything in line though. Just wondering.

[Chris Dunbar]

If you run the Creeper Joint Shackles in the front your steering will not work correctly. You will have a lot of steering lag.

The Creeper Joint Shackles will be OK for the rear on the street as long as you are not running a spool.

[norzuki]

If you run the Creeper Joint Shackles in the front your steering will not work correctly. You will have a lot of steering lag.

The Creeper Joint Shackles will be OK for the rear on the street as long as you are not running a spool.

Thanks Chris,

It was a good thought for great flex, but I think I will just stay with the missing links.

I know this is becoming a slow build and all, but I am getting the parts in slowly now. Hopefully I will have the suspension in by this weekend. By next weekend I will have the axles rebuilt and installed. After that I will be installing the 16 valve motor / tranny & t-case. Then I will finish welding the body up. Me working all of this overtime at work is a bugger, but I guess it a blessing. I will just keep working as much as I can each day.

[norzuki]

Got a something from Roadless gear the other day :happypill:

http://www.zuwharrie.com/gallery/albums/userpics/10108/grill.jpg

Front and rear axle bearing will be here Thursday. I hope to have the axle and tires under the rig this weekend.

With the crazy overtime I am working...................I don't know, but we will see.

[norzuki]

The axles will have to wait till later.

I got the t-case torn down / cleaned up and ready for installation of the new 6.5:1 t-case gears. :hammer:


Just a note: Work is kicking my tail :shout:

I get about 1-2 hrs in the shop until another person can be hired for the open position here at work.

Anywho ....... I will try and have pics of the messy shop and installation just so everyone can see I am doing something :clap:

More later.right now I am at work till 6:30 today

Dave

[norzuki]

Wooo Hoooo !!

Got the new 6.5:1 t-case gears and all new bearings put in. Everything back together and just to be safe....I rotated the flanges quite a bit to see if the bigger gear cleared the inside of the t-case. All is good in the neighborhood.
:thumbs:


http://www.zuwharrie.com/gallery/albums/userpics/10108/tcase_rebuilt.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/tcase_rebuilt01.jpg

[norzuki]

Got a little more accomplished today after I took a nap from work which was well needed from Hurrican Hanna over the weekend.

Anyhow............I managed to complete the drivers side knuckle today before I had to come to work. I hope to have the front and rear axles done by Friday. I ordered some more stuff laast week and I hope it will be here tomorrow for the rear disk breaks :) All I need to buy are the monte carlo calipers and break lines......oh and also order the 10 psi check valve for the rear and a line lock of some sort.

After the axles are done I will begin to get the under the rig this weekend if all goes as planned.

Dave

[norzuki]

UPDATE:

I got the passenger side knuckle done and managed to score a 1987 Toyota IFS rear which is 2" wider than the 1981 front. It also has a Lock Right in it. I will be getting some 1 1/4" spacers soon for the front...so it will match the rear.

I am going to run this axle, but unsure if I want to run the lock right in the rear of up front.

Here was my 1st thought.......run the lock right up front and spool the rear.

I got the 1987 rear axle almost cleaned up and it will be ready for some perches, shock tabs and paint tomorrow. I will have pics of this......to atleast show some progress. Things should start to move forward a little quicker from here on out. I am getting a few more things next week and I will be ready for the motor / tranny / t-case install next weekend hopefully.

QUESTION ABOUT YJ PACKS

here is my YJ inventory:

(5) YJ 4-packs stock
(1) YJ 5-pack stock

I want to make one more 5-pack so I can run 5-packs in the rear........any suggestions?

Dave

[norzuki]

Got alot done today .... then I had to sight my bow in for my trip tomorrow.

stripped and painted the rear '87 axle and started installing the rear disk set-up from Sky Manufacturing.

http://www.zuwharrie.com/gallery/albums/userpics/10108/axles.jpg

[lostsamurai]

grind the stud and seperate your leaf packs you can mix and match anything you want i added 2 leafs in the front and removed one in the rear

[norzuki]

grind the stud and seperate your leaf packs you can mix and match anything you want i added 2 leafs in the front and removed one in the rear

Thanks for the advice bud.

I got the rear axle done last night and I am cleaning and painting the plates and u-bolts for the rear flip kit and the front toyota axle swap kit.

I will be finishing up the leafs this week. I want to put the motor / tranny & t-case in by mid week.

It is looking a little more promising for completion b-4 the Zu Event at the end of October :thumbs:


If I can get home b-4 dark today I will have some pics this evening.


Dave

[norzuki]

A little bit more done:

1987 IFS Rear axle on the ground:

- Sky Man. Caliper Brackets
- 1987 Monte Carlo Caliper
- 1995 or '97 Chevy Rotors front
- new bearings
- Marlin Crawler upgraded oils seals
- lock rite

http://www.zuwharrie.com/gallery/albums/userpics/10108/rear_axle_on.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/passengerside_rear_axle01.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/passengerside_rear_axle.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/sky_caliper_bracket_installed01.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/sky_caliper_bracket_installed.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/driverside_rear_axle.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/rear_axle_under_rig.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/rear_axle_side_shot.jpg

[norzuki]

Got the front axle under the rig today and started hooling up the steering. I have pics but was short of time. I am here at work now, but will post up pics tomorrow evening.

[YeloSub7]

looking good man! I always thought the samurai was a neat truck! Nice streatch job too, can't wait to see this finished!

[norzuki]

Thanks Man !!

I just got home and here are the pics:

http://www.zuwharrie.com/gallery/albums/userpics/10108/front_lift.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/pass_side_lift.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/side_lift.jpg

[norzuki]

Motor / tranny are in along with the Rock4x tranny crossmember. I also got the front clip on too.

http://www.zuwharrie.com/gallery/albums/userpics/10108/pass_side_with_front_clip.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/front_with_front_clip.jpg

[norzuki]

16 VALVE TIMING ??


#1 cylinder TDC

Does this look right as far as setting the timing up?

CAM SHAFT TIMING MARK

http://www.zuwharrie.com/gallery/albums/userpics/10108/camshaft_mark.jpg


CRANK SHAFT TIMING MARK

http://www.zuwharrie.com/gallery/albums/userpics/10108/crankshaft_timing_mark.jpg

IS THE ROTOR POINTING AT THE #1 PLUG ??

http://www.zuwharrie.com/gallery/albums/userpics/10108/disty_number1.jpg

[norzuki]

Anyone ??

[Toyzuki]

Its hard to tell without looking at the cap. Even if its close you can make it run. just pull the locking bolt out and turn it to where it will run. then pull it out and jump one tooth at a time till you can get the bolt back in. Then use the timing light to get it right.

[norzuki]

almost there fellas !!

I still have quite a bit to do though and being stuck here at work isn't helping. The rig takes a trip to Ben's (aka:zukitough) house this weekend to finich welding the body and top. I hope to have it back by either Sunday or Monday at the latest. next week I start working night shift so I will have up tll 5pm to work on the rig each day. I am off Wednesday so a great deal will be done then.

With time not being on my side I will have to post pics later on...maybe after the event, but I can tell you . THIS RIG IS GOING TO BE AWSOME !!

Dave

[norzuki]

We got the drivers side done up and reay for paint last night.

keep in mind we are working at night and not it a shop. The new panels I had made up are not lining up so Ben (aka:Zukitough) is only welding the top & sides of the panels. I will finish the bottom when I get it home on Monday.

I can't post pics from work, but I can atleast give updates LOL !!

Ya'll keep your fingers crossed and pray for me....... I got a lot to do b-4 Thursday.

Dave

[norzuki]

well ...2 short nights and one 4 hr day later. Zuburban has the outer body welded up.......primed and ready for paint.

I just had enough time to get in to work tonight. I will go into toen tomorrow the get the bedliner and ORANGE PAINT. I picked up the front stock calipers today and will be putting them on tomorrow also...along with the FJ60 P/S box.

Wednesday I AM OFF !! All day to work on the rig.

- fab up some kind of brackets for the 1.6 16 valve radiator and get it in.
- install plumbing for radiator and all other water hoses.
- Plumb up the front brakes // new break lines
- install proportioning valve
- install line lock
- install dash
- install dodge neon seats
- install stock gas tank
- install fuel lines and high pressure fuel pump
- finish soildering 3 more wires on the modified harness
- Fab up front bumper


I hope to pick up the drive stretched drive shafts wither tomorrow or Wednesday.

If I get all of this done tomorrow all I will have left to really do is finish welding up the inside where it was cut.

Lord give me strength !! I know Art is with me and I am determined to get this done b-4 Friday.


[B]Can someone tell me if this is the correct way for setting TDC on the 16 valve??

#1- "E" on cam shaft pulley pointing at 12 o'clock
#2- indention on the crank shaft pulley 12 o'clock
#3- rotor button pointing at #1 spark plug wire[B]


Dave

[norzuki]

well .... even further reading ..... I read where the rotor needs to point to #4 on the disty for it to be true TDC.

now I am confused and want to turn this thing ove for the 1st time on Wednesday.

Dave

[norzuki]

A bit more done Sunday:

- FJ60 box mounted + steering shaft fabbed up and installed
- front calipers are in
- made a bracket to mount the "T" fitting on top of front axle
a- this will allow me to run just 1 soft line down to axle like the rear
- started cutting a small section of the lower body panel that my buddy Ben
welded in. I need to move about a 2" wide section down about 1" so the
body line will line up.
- installed the PCS TC pump bracket and also the TC style pump
- installed SpiderTrax upper shock mount
- welded in lower shock mounts on rear axle


I am close :thumbs:

I might get it to where I can try starting the motor Friday.

Dave

[norzuki]

after a long morning at the eye Doctor today (drilled out a piece of steel from my eye)

I managed to start putting the bed liner on. I got (driver side) - (hood) and (front grill area) done today b-4 I had to come in to work. I will post up some pics in the morning.

I done some searching about line lock (line routing) but wasn't able to find any info about it.

I was thinking about putting the (Manual Line Lock) on the tranny tunnel on the drivers side for easy access......the (IN LINE) is coming through the fire wall (along the tranny tunnel).... but I am unsure of how I want to route the line going bock to the rear breaks.



Should I:

a- drill another hole in the tranny tunnel and run the (OUT) line through that
hole and then up and over the tranny......and connect back to the
break manifold at the passenger side frame rail

b- drill another hole in the tranny tunnel and just run a new line back to the
rear breaks and by pass the manifold all together


keep in mind that I have re-done the break lines:

1- front single (long) soft line, then hard line on the axle, then soft lines at
the wheels

2- rear single (long) soft line, the hard lines to the wheels

any thoughts or suggestions




Dave

[norzuki]

A few pics from yesterday:

http://www.zuwharrie.com/gallery/albums/userpics/10108/primed_for_paint.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/front_bedliner.jpg

http://www.zuwharrie.com/gallery/albums/userpics/10108/front_bedliner_corner.jpg

[norzuki]

1st Coat

there will be 2 more coats....it will be brighter.

http://www.zuwharrie.com/gallery/albums/userpics/10108/first_cost_orange.jpg

[samuraiguytn]

Thats a cool looking Zuke. Props to you. I wouldn't mind one like that...

[norzuki]

Thats a cool looking Zuke. Props to you. I wouldn't mind one like that...

Thanks Bud !! I am tickled "ORANGE" !!

As stated earlier.......There will be 2 more coats of orange on it before it is all said and done. Right now the black bed liner is still showing through.

It is going to be tough to have it done b-4 Thanksgiving, but that is my goal now.

alot of the things left to do is just installing and that shouldn't take to long. I think the most time consuming things left to do is tear out "ALL" of the old stock break lines and run new.....along with installing the line lock.

I will be at it tonight. A buddy of mine gave me a 400-WHPS area light to use and man let me tell ya.........if you want to light up the world get one of these ....... I will have some pics from tonight and you will see how bright this light is.

I am going to start taking out the break lines tonight.

Dave

[riLo]

I'm in the process of building some yota axles for my sami. i was hoping to use the same Sky rear disc brackets you have. What kind of e-brake setup are you running? i havent decided on that part yet. i'd really like to get my hands on the spidertrax t-case mounted e-brake, but best i can tell they arent making them anymore.

[norzuki]

I'm in the process of building some yota axles for my sami. i was hoping to use the same Sky rear disc brackets you have. What kind of e-brake setup are you running? i havent decided on that part yet. i'd really like to get my hands on the spidertrax t-case mounted e-brake, but best i can tell they arent making them anymore.


I am using a Jamar Push Button manual line lock (Sean @ Low Range Offroad)and also a proportioning valve for the rear disk breaks.

Hope that helps buddy

Dave