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Patrick's Samurai Build

Discussion in 'Trail Toys' started by SMKYTXN, Jan 7, 2019.

  1. Jan 7, 2019 at 9:30 PM
    #1
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
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    Houston
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    DCFB
    Here's the latest build going on over here at Trail Toys.

    Patrick has tasked me with building his Samurai. She wheeled pretty well as she sat, but 9.5” axles and links can’t hurt. I’ll be taking her to the roller stage and then handing her off to Patrick to finish up.

    Here’s the breakdown:

    Some year Suzuki Samurai
    Dual triangulated 4 link front and rear
    Custom subframe
    Flat belly
    New front tube clip
    New frame from the firewall forward and the tub back
    Fabricated 9.5” front
    FZJ80 full float rear
    Two piece front driveshaft

    Here’s how she looked when dropped off. She’s gonna look a fair bit different when I’m done with her.

    I stripped the rear axle in preparation for a full truss. Man that axle had a bunch of crap on it, and the factory welds look like crap.

    The front clip is going away, but the hood will be staying. It sure was nice to have the entire front clip unbolt in one piece.

    I tore all of the brake and fuel lines out as a fuel cell and all new lines will be added.

    The lift sure does help. This is the first rig that’s had both axles removed by the lift in one smooth motion.

    Photo Dec 01, 1 15 46 PM.jpg Photo Dec 01, 1 15 36 PM.jpg Photo Dec 01, 1 15 51 PM.jpg Photo Dec 01, 1 15 56 PM.jpg Photo Dec 18, 7 18 00 PM.jpg Photo Dec 19, 1 17 42 PM.jpg Photo Dec 19, 8 32 42 PM.jpg Photo Dec 19, 8 35 42 PM.jpg
     
  2. Jan 7, 2019 at 9:32 PM
    #2
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
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    #52810
    Messages:
    13,873
    Gender:
    Male
    First Name:
    Nathan
    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    Here's the new axle placement. I'm stretching the wheelbase to 102". The stretch is symmetric back to front.

    Photo Dec 20, 1 02 58 PM.jpg Photo Dec 20, 1 03 14 PM.jpg Photo Dec 20, 1 03 22 PM.jpg
     
  3. Jan 7, 2019 at 9:35 PM
    #3
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
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    #52810
    Messages:
    13,873
    Gender:
    Male
    First Name:
    Nathan
    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    I designed a custom subframe/flat belly for the Sami. With the lower links and carrier bearing being attached to the belly it'll be a job to get it out, but the belly will come out if needed.

    Photo Dec 27, 2 49 08 PM.jpg Photo Dec 29, 1 38 27 PM.jpg Photo Jan 05, 6 02 42 PM.jpg Photo Jan 05, 7 33 00 PM.jpg Photo Jan 05, 12 43 12 PM.jpg Photo Jan 05, 12 43 29 PM.jpg Photo Jan 06, 2 00 07 PM.jpg
     
  4. Jan 7, 2019 at 9:35 PM
    #4
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
    Mar 11, 2011
    Member:
    #52810
    Messages:
    13,873
    Gender:
    Male
    First Name:
    Nathan
    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    Now that the subframe is tacked in it's time to move her to the frame table and get to work on the axles and frame. I built a nice little table on top of the frame table to hold the belly. Funny enough the Sami balanced nicely on the table.

    I wanted her up high so I had worm to work. Hopefully that doesn't come back to bite me in the ass.

    Photo Jan 06, 4 28 34 PM.jpg Photo Jan 06, 5 07 29 PM.jpg Photo Jan 06, 5 07 39 PM.jpg
     
  5. Jan 11, 2019 at 8:45 PM
    #5
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
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    13,873
    Gender:
    Male
    First Name:
    Nathan
    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    Ok, so it's time to start putting the axles under this thing. It was clear from the start that the frame was going to have to move up if I was going to achieve negative lower links at bump. I couldn't adjust the frame until the axle was prepped, so it was time to build the truss. Of course no one makes a full width truss for the 80 series axle, so I had to design one myself. Here's the result.

    Photo Jan 08, 9 12 37 PM.jpg Photo Jan 09, 6 06 18 PM.jpg Photo Jan 11, 1 03 33 PM.jpg Photo Jan 11, 1 03 43 PM.jpg
    I'll be tweaking the drawing a bit and will then add these trusses to the lineup.

    Say goodbye to the rear floor and frame!

    Photo Jan 11, 5 18 16 PM.jpg Photo Jan 11, 5 52 25 PM.jpg Photo Jan 11, 7 27 44 PM.jpg

    I started on the new rear frame tonight and will get it knocked out tomorrow. The Sami frame flares out towards the back so the new frame comes back straight which gives more room for the axle at bump. The frame will have a cnotch as well.

    Photo Jan 11, 9 56 48 PM.jpg Photo Jan 11, 9 56 53 PM.jpg Photo Jan 11, 9 57 03 PM.jpg
     
  6. Jan 15, 2019 at 7:03 PM
    #6
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
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    Messages:
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    Gender:
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    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    The new front frame is tacked in as of tonight.

    Photo Jan 15, 2 19 43 PM.jpg Photo Jan 15, 3 59 11 PM.jpg Photo Jan 15, 3 59 01 PM.jpg Photo Jan 15, 3 59 06 PM.jpg
     
  7. Jan 18, 2019 at 9:24 AM
    #7
    SMKYTXN

    SMKYTXN [OP] If it can't be overdone it's not worth doing Vendor

    Joined:
    Mar 11, 2011
    Member:
    #52810
    Messages:
    13,873
    Gender:
    Male
    First Name:
    Nathan
    Houston
    Vehicle:
    11, 4dr, TRD Sport, 6sp
    DCFB
    The motor looks to be the next hurdle towards getting the front axle in place. I'm trying not to push her too far forward as I'm already looking at 40" lowers. The radiator and fan are gone for now, but will be relocated later.

    Photo Jan 16, 1 26 22 PM.jpg Photo Jan 16, 1 36 26 PM.jpg
    The uppers are going to be a tight fit. The plan is to run some DOM sliders and mount the uppers to them outside the frame rail.
    Photo Jan 16, 1 58 42 PM.jpg
    And she's gonna be stuffed. We're looking at at least 5" of up travel in the front with horizontal lowers at ride height.Photo Jan 16, 2 27 34 PM.jpg
     
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