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Zuk on 38's

Discussion in 'Other Builds' started by Tan Zuk, Mar 4, 2012.

  1. Oct 6, 2012 at 7:53 AM
    #101
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    The condenser Brackets are made. As usual they took much longer to do then 1st looking at it. Also used Ospho metal prep on them and a coat of POR50 to try and keep the rust down being they are in the front catching all the elements.

    Changed my mind a couple of times because the Brackets need a couple of bends. Never seem to have enough tools when you need them, so I had to do some bending the hard way. After getting everything bent up and the Condenser spaced from the Rad. I probably could have used a piece of 2x3x1/8 box tubing and cut it down to fit eliminating the need to do any bends. That would have saved a bunch of time.

    Here is the Condenser mounted to the Rad and Rad Support Brackets. This can be loaded as one unit from the engine compartment to be mounted.. This makes a much more user friendly to install. The mounting bolts holding the condenser in place are located in the engine compartment with welded in nuts there is no need for another wrench.

    Condenser Bracket

    [​IMG]


    Bracket Mounted

    [​IMG]


    [​IMG]


    Front Side Mounting Bolts

    [​IMG]


    Condenser Radiator Spacing

    [​IMG]


    Need to get the newly installed motor started now this has been knocked off the list. Then there will need to be some time spent on getting the PS and AC plumbed up with some hose and solid lines..
     
  2. Oct 6, 2012 at 7:53 AM
    #102
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Well it is definitely getting hot, gets over 100 degrees in the shop at noon time. I get over there around 7AM and out by 11 AM.

    Just getting all the odds and ends made, hooked up and working properly. This tends to take a long time because there is so much stuff to try and put in a little engine compartment.

    Got the motor running (Still need an exhaust before the final tuning is done)

    Needed to make a carb throttle cable to connect to the corrected ratio linkage that was made for the bike carbs.

    Carb throttle cable was made from the stock Zuk carb cable. It was shortened up quite a bit, got rid of the black plastic firewall cable holder. Replaced it with an aluminum screw in adapter. All fitted behind the Dizzy.

    Got the clutch cable and clutch working. Used the Center Force clutch this time and it seems to have a much different adjustment procedure from what I have been use to doing.

    Had a bit of an issue with the new tail shaft bushing that was replaced when rebuilding the trans. I have always checked to make sure the intermediate shaft fit the bushing before and after installation. The shaft was packed away up in the loft and since there had never been an issue in the past it was not double checked this time.

    Yes, if you are thinking it didn’t go in. I new that I was not going to pull the trans out just for that. The shaft needed to have about .002” polished off the OD and it now fits. This did take quite a while, used a micrometer to make sure the material was taken off equally.

    Got the TCG in from the UK the other day. Went with the 6.1’s with the 24% lower high gear reduction since this Rig will have mostly stop light to stop light driving. Cleaning up the spare Transfer Case now. Need to order some more parts from lowrange in a couple of week’s.
    (need to stay in monthly build budget)

    Made some more shiny stuff for the engine compartment.
     
  3. Oct 6, 2012 at 7:54 AM
    #103
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Purchased the UK 6.1 Transfer Case Gears

    Thought I would share some info on the 6.1 Transfer Case gears with the 24% high gear reduction since there doesn’t seem to be any reference info to be found.

    Wanted to purchase the 8.1 TCG with the 24% High Gear Reduction unfortunately they were not available for 2 years. Ended up with the 6.1 instead and had the same high gear reduction as the 8.1 TCG.


    The not so good:

    These particular gear sets are only offered in the UK and shipping is pricey. There is very little info provided from the manufacturer on the gears and there are no installation instructions provided to show the clearance procedure. You will need to purchase a complete rebuild kit from one of the venders because you only get the gear set, gaskets and some squashed seals. These gears will probably show up with surface rust on them because of environmental conditions in the UK.


    Clearance the housings::

    The 6.1 Countershaft Gear is a bit larger then the Trail Gear 6.5 Countershaft Gear. There is a need to clearance the case for the gear to fit.

    The Mill was the tool of choice used for these reasons:
    Maintaining a consistent radius to a determined depth.
    Large amount of material being removed.
    Thin walls after machining.

    ( There was about 3/16” removed from the side wall and about a ½” depth. This gave about a .050 clearance all the way around on the machined surfaces.)

    Here are the housings being machined for the Gear.

    Short Housing Pics.


    [​IMG]


    [​IMG]
     
  4. Oct 6, 2012 at 7:54 AM
    #104
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Large Housing Pics


    [​IMG]


    [​IMG]


    The break through hole will be taken care of with a set screw with thread sealer theaded in from the opposite side. Yes if your thinking that is very close. Took it to the limit to not weaken the housing or cause an outer break through.

    Going to be using a Zor Snatch to strengthen the unit and will help with the extra material that has been removed from the housings.
     
  5. Oct 6, 2012 at 7:55 AM
    #105
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Fitting the ZOR Snatch

    This is my second ZOR Snatch and did the wrestling match trying to get the bolts in on the 1st one. Hopefully you decided to get one when you are doing a gear replacement. This makes it much easier.

    Here are a couple of steps that may make it much more enjoyable to install the ZOR Snatch on the case. This is a trial fitting and will need to be removed to install the gears.


    [​IMG]


    [​IMG]


    [​IMG]
     
  6. Oct 6, 2012 at 7:55 AM
    #106
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Dual Pass Aluminum 15” Finned power steering cooler mounted to the under side of the stock round cross member.


    [​IMG]


    [​IMG]
     
  7. Oct 6, 2012 at 7:56 AM
    #107
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Here are a few things that were made or hooked up to tidy up the engine compartment. Have a long way to go yet.


    [​IMG]


    [​IMG]


    [​IMG]


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    [​IMG]


    [​IMG]


    [​IMG]
     
  8. Oct 6, 2012 at 7:56 AM
    #108
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Update with pics:

    Since there was some confusion and I don’t speak good redneck yet. I will just go back to the old way of posting.

    Parts Removed again for some adjustments to the Upper Front Spring Mounts

    [​IMG]


    This mount was store bought and was never happy with it because of the thinner material used. New this was going to be cut off later so it was used just to get things started.

    [​IMG]


    This pic is to show the layout of the original mount the new mount location and the frame extension that was welded on parallel to the ground

    The shackle angle had settled in at 36* and about ¾ “ lower then when it was set up with the guesstimated weight that was added when 1st setting it up.

    With the addition of a few more items and some added plating this is what lead to the adjustment being done now. I would like to be back at about 25* shackle angle. This will also bring the original height back as well.

    [​IMG]


    Here are a few pics of the Nw Font Upper Spring Mounts in different stages of being made.

    [​IMG]

    [​IMG]

    [​IMG]

    Going to try and get the old mounts cut off tomorrow. Went from way too hot to raining all day. Will need to make some location bumpers to get the mounts back to the proper width and a 43” length eye to eye bar for the length.
     
  9. Oct 6, 2012 at 7:57 AM
    #109
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Back on all 4 again.

    Got the old front spring mounts cut off. The new front spring mounts were repositioned ½ “ further up on the frame extension to a mounting dimension of 42 ¾”. This is still shy of the 43” dimension that the YJ uses for their mounting position.

    This did not affect my caster angle or any of the other suspension that was setup previously. This has been all double checked now and all is good. The shackle angle is now set to allow for some additional passenger side suspension parts and some spring sag.

    The reason again for moving the spring mounts forward was to bring the shackle angle and the height back to where it was originally setup. The first spring mount dimension was just a base line to get the suspension started.



    [​IMG]


    [​IMG]


    [​IMG]


    Here is a removable bump stop aligner that was made before removing the old spring mount. This was used to transfer the same mounting position but moving it ½” forward. This tool was also removable since the old mount still needed to be cut off.


    [​IMG]


    [​IMG]



    Time to finish up the modifications of the transfer case mounts.
     
  10. Oct 6, 2012 at 7:58 AM
    #110
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Here are a couple of pics of the High Back PRP Suspension seats. They are a close match to the new panels that had been remade.


    [​IMG]


    [​IMG]
     
  11. Oct 6, 2012 at 7:58 AM
    #111
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    Thats it for awhile
     
  12. Oct 6, 2012 at 8:01 AM
    #112
    JLee

    JLee The Man! Vendor

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    I lost track thousands of dollars ago.
    Every time I see this build it's even better Awesome work :thumbsup:
     
  13. Oct 6, 2012 at 8:34 AM
    #113
    MJM777

    MJM777 Well-Known Member

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    This is the first time iv'e seen this build....all i can say is WOW!!! Truly amazing. I applaud your talent and skills...can't wait to see more.
     
  14. Oct 6, 2012 at 8:41 AM
    #114
    n0rth

    n0rth Well-Known Member

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    Amazing work, excellent attention to detail and great explanations and insight to the process behind the madness.
     
  15. Oct 6, 2012 at 8:53 AM
    #115
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    JLee
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    nOrth

    Thanks for taking your time to look in on my build. Just trying to make it interesting and easier to understand with the extra captions in the pics.

    Greatly Appreciate the compliments as well.
     
  16. Oct 6, 2012 at 9:00 AM
    #116
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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    I have a running tab on the build and have just about got to the amount that I wanted to spend when I 1st thought about building it. Very important to try and get a good approximation of your budget before starting.

    The intake alone was 260 hours cut out of a solid block of aluminum. Really don't keep a running tab on my build time. It is just a hobby to keep me busy. If I wasn't working on this one probably have to start another build.
     
  17. Dec 29, 2013 at 7:07 AM
    #117
    Tan Zuk

    Tan Zuk [OP] You will Love it or Hate it!!!

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  18. Dec 29, 2013 at 9:01 AM
    #118
    sytfu510

    sytfu510 INSTAGRAM: sytfu510

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    Just awesome work man!
     
  19. Jan 26, 2014 at 8:39 PM
    #119
    UssMoGn

    UssMoGn Well-Known Member

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  20. Jan 26, 2014 at 8:52 PM
    #120
    ChamYota

    ChamYota AKA Crash Bandicoot

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    This shit is sick as fuck
     
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