'87 Suzuki Samurai Build

[Diesel_Zuk]

So I've had an account on here for a while, but never posted. Figured I would start a thread documenting the build on my current Samurai. It's an '87, got it for $400, but without an engine, transmission, tcase, windshield frame, doors, or useable seats.

This is not be my first Samurai build, I previously had an '86 that I chopped, stretched, TDI swapped, and just went way overboard with. Sold that to pay off some debt, and have since gone stir crazy, needing something to work on. Here's a pic of my old Samurai.

 

[Diesel_Zuk]

Here's how I got the Sami. Was full of junk, and nasty seats. Got all that ripped off, and got it hosed out and down well. The tub is in really good shape overall. I paid $400, but had no title. Had to fill out several forms, and take some pictures, go into the DMV, but a couple weeks later, I had the title in my hand.

 

[Diesel_Zuk]

First order of business was to drop the transfer case and open it up. Unfortunately, the guy let it sit since 2004 when he bought it. When I got it, there was no top on the vehicle, and no boot over the shifter. So the case was completely full of water. Nothing was worth saving, or even trying to save. After some hunting, I found another used case. Made a deal with the guy, and gave him $80 for the case and a down pipe with the cat.

 

[Diesel_Zuk]

Got a set of doors from a guy I know for $50. Need new seals, a couple handles probably, but overall the frames are in good shape, and have the glass still.

Got the front axle pulled out, and took it into work, started stripping it apart in my down time. Threw it in the back of my Jetta Wagon, with plenty of room to spare!

Got it all cleaned up with a wire wheel, took forever, but it was worth it to clean it up.

On my last build, I used YJ leaf springs on all four corners. On this build, I am doing coils up front with radius arms, and YJ's spring under in the rear.

 

[Diesel_Zuk]

Bought a Kaiser locker for the front. Just a 22 spline, so I will be using factory axles for now, with birfield rings from Roadless Gear. If I have issues, I will swap to 22 spline longfields later. Lots of guys in South America are running these Kaiser lockers, and from what I hear, prefer them over ARB. I contacted them about a 26 spline for the rear, cost is $840 shipped to the states though, so I am planning on a Chinese elocker for the rear at this time, they're around $425 or so shipped over.

Started painting up axle parts that won't need welded on.

 

[Diesel_Zuk]

Got some other parts, YJ brackets for the rear frame mount. And part of an EOS transfercase cradle. I am able to get the rest I needed, so it was worth it to pick up.

Bought a Titanium 125 flux core welder from Harbor Freight. The reviews I've seen on it are great, and my brother has one, and seems to like it pretty well, for the most part.

 

[Diesel_Zuk]

.....and this is where the "budget" part of this build comes into play. The other lowrange parts above though, I got for almost free also.

Scored a one piece hardtop. Paid the lady $80 for it. (Also the Jetta Wagon comes in handy again!)

A set of Eagle Alloy 15x8, 3.5" back space, no visible corrosion on the face that I've noticed, for $50

Suzuki Swift GTI seats, for free more or less. These are the exact seats that came from my last Samurai, the guy I sold it to gave me them back. I gave him some other parts to make it even though.

Two Samurai rear seats, and one set of belts. One is a hideous yellow, not pictured.

The rear hitch base off my last Samurai.

And found another donor Samurai, for $300 for the engine, trans, tcase, and windshield frame, but haven't went and actually purchased and hauled it home yet.

And I paid $250 shipped for the Kaiser locker mentioned earlier as well.

 

[Diesel_Zuk]

Here's where I am at currently. Got my radius arm bracket's drawn up, and now drawn up on some steel plate. I don't have any fancy cutting tools besides hand tools, a grinder with cutoff wheels, and a drill press at work, so I will be cutting these all out by hand.

For the radius arms, I plan on using Johnny joints. They are pricey little things though. So after doing some research, I found I can get them from outside of the country. I can buy 6, with shipping for $186. I'm 99% sure the company I found selling them, supplies the ones for Barnes4x4 and other retailers.

 

[DETN8R]

Nice! I also have an 87 Samurai. Looking forward to following your progress!

 

[UHAULER]

Wrong thread