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Old August 18th, 2010, 10:01 PM   #61
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every day, i hope i didnt cut you off or something.
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Old August 30th, 2010, 09:40 PM   #62
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the trail tough gas tan skid plate showed up today, its great, i like that it will match the frame hugger and it seems to be built tough as nails. my dad says it just looks like worse fuel economy. maybe hes right, but oh well. i call it good protection. shrockworks says i should have the bumper before the end of September. shackles and the front locker needs to get figured out.
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Old September 1st, 2010, 05:34 PM   #63
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after all my looking around i had settled on the shrockworks tank skid but i ended up with the trailtough instead. they are both essentially the same design and for the same price the trailtough model is already finished and it probable will never make a difference but there is less material cut out for the logo which should make it a little stronger. honestly the mounts will fail long before that is a factor but whatever. it matches my frame hugger plate. still waiting on the shrockworks bumper. that will narrow the list to:

fix locker problem
repair header
install exhaust
build new rear shackles

possibly a doorless mod and i definatly need a battery tie down.

all this stuff shouldn't be too expensive.
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Old September 5th, 2010, 03:12 PM   #64
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i have begun to dig a little deeper into locker problem, after further examination i think either i have a bad front output shaft or the front axle housing is bent. i'm going to try to check the front output tomorrow since i don't have work. the transfer case i swapped in has the early style front output and the one i took out has the later style so i'm going to swap that first. if it doesn't fix the problem at least ill have the better shaft installed.
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Old September 20th, 2010, 09:05 PM   #65
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front output shaft has been ordered, the rear locker took a huge crap so its getting replaced with a trail tough mini spool the shrock works rear bumper is showing up later this week too and i replaced the exhaust but i don't know if the belly skid plate will still fit properly, but i installed a trail tough gas tank skid plate.

to come
adjust valves
install new parts
make new rear shackles
install axle trusses
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Old September 20th, 2010, 09:13 PM   #66
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This build thread needs more pictures.
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Old September 24th, 2010, 10:04 PM   #67
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ill get some pictures of the new parts. it may not be untill next weekend that i get this thing all together. ill also get a picture with the rear bumper on. i just need to work a few bugs out of my hand throttle before i post up what i did.

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Old October 18th, 2010, 10:38 PM   #68
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just put a new starter on it, new spark plugs and pcv valve nothing flashy but it all needed to be done. i also need to change the oil, weld on the axle trusses and make some shackles. i really want to put some terraflex revolvers in the rear but that also means a new rear brake line and new rear shocks. if things keep going like they are i wont get them but if my financial load lightens up i might just do it. if i get everything new it should be around 350 all said and done.
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Old December 23rd, 2010, 10:59 PM   #69
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its been too long so i posted up some of the latest pictures. i have put a shrock works rear bumper, trail tough tank skid, and a whole pile of other small stuff into it. the first thing on the to do list is to fix what i broke on thanksgiving. i sheared the hub bolts on the passenger side. its been rough trying to find new cone washers. second i need to install my radio antenna, tinting rear view mirror and widow channel. all minor but need doing. than i can figure out why the front locker isnt working right and finally i can toss around the idea of a 1.6L 8V motor swap. it should be real easy but it will cost at least $500 and i dont want to swap in a new motor just to find out it has as many problems as the one i took out. the motor wont start rolling for at least a month. but im burning oil bad and it would be nice to have a little more power. i also made a new set of shackles for the rear. i am really liking the shrock works rear bumper, its tough as nails and people can actually see the lights. that reminds me, i miss having a set of driving lights on the front but 6" lights wont really fit right on the front with the bumper how it is. im on the look out for a quality set of 4" or 5" lights to put up there too. finally i just picked up a 3" drop pitman arm for cheap so i need to decide if im going to install it or leave it in the garage until i feel like doing it. at the end of the day the basic configuration of the truck wont change much for a long time. but when it does it should only cost a few thousand to have it flexing like mad on 33s
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Last edited by Jdc215; December 24th, 2010 at 09:50 PM.
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Old January 3rd, 2011, 11:10 PM   #70
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i got a little lesson in AGM batteries today. apparently they dont charge very well once they have been fully discharged. for example when you brake a hub and use your winch alot to get out of cherokee trail at the mounds. apparently once it has been discharged it then wont take a charge from the alternator very well, such as when you attempt to carpool to work with your dad in your dual Purpose rig. long story short mom had to rescue us on the side of 96 in the mini van and neither of us make it to work. all should be well and heres hoping that after a deep charge it will make it to livonia tomorrow morning.
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Old February 20th, 2011, 04:20 PM   #71
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not much has changed on the samurai lately. i did end up swapping in a 1.6 and reused the 1.3 injection. i also have a new set of stock speakers to go in it, it currently dosnt have any. i have few little wiring things to get done and i have a front locker in the mail, if im lucky i should be able to have it all ready to go this coming Saturday for the chilly run up at the mounds.
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Old February 28th, 2011, 10:35 PM   #72
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well i just got done telling my wheeling buddy dave that i didnt plan on doing anything major to my samurai in the next few years but some how i just came across a set of 32x9.5 tsl tires for a pretty sweet price and i really dont know how i could turn it down. so... well see what happens but they would be a sweet upgrade. maybe i can use the good years on the road and tsls offroad. well see.
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Old March 2nd, 2011, 11:22 AM   #73
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Sounds like a sweet rig. I owned one a few years back and used it as a DD and Trail rig. They make a damn fine rig, no matter what people may say. Did you ever check to see if your front housing is bent? Mine was tweaked just a little and a lock rite wouldn't work due to that.
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Old March 5th, 2011, 06:22 PM   #74
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i checked last time i rebuilt it, i checked visually and i used a piece of black pipe. i know black pipe isnt perfect but as best i could tell it seems to be straight. i just purchased a third member with a 1510 lockrite in it. it arrived the day before a planned trip so i threw it in on friday evening and it worked sweet saturday morning. now i need to return the brand new locker i purchased and ill warente the locker that failed. thats about 500 in refund and i only paid 210 for the one that is working right now. im really happy with it right now, i need to optimize my timing, and buy a new top. the rear diff had begone to devolpe some bearing issues but i already have another third with good bearings so ill have to tear that appart here soon should be 100% soon. id say its 90% right now.
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Old March 7th, 2011, 09:25 PM   #75
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tomorrow i'm going to pick up the parts to fix any thing that may be wrong with the rear diff and i ordered some kind of Polaris motor mounts to mount to mount my transfer case. some how they are supposed to be the best option offering both rubber isolation and strength. i'm attempting to address the unacceptable clunk in the rear drive train. id post more pictures to this thread but i seem to have run out of available space and i don't know how to make more space
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Old October 17th, 2011, 10:11 PM   #76
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new U-bolts, rebalanced drive shaft, rebuilt transfer case, a rebuilt differential, a readjusted throttle position sensor and some all terrains have this thing running as smooth as silk.


well maybe not that smooth, but as smooth as a samurai can run.
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Old October 30th, 2011, 10:25 PM   #77
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i got everything ready to go in, which is a rebuilt transfer case, new rear diff, new rear bearings and brake shoes. then i need to get the rear drive shaft looked at to make sure its still balanced (its had some rough times) the rear axle still has to be cleaned out, the trans needs to be flushed and i need to buy some lube for the transfer case. i know all this sounds boring but i keep this thread more for myself than anything else.
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Old December 28th, 2011, 03:05 AM   #78
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im so lucky i got to tear it apart again. i bought a chinese air locker, cleaned and repainted the new housing, welded on an axle truss and ZOR crab diff cover. im also installing a set of teraflex revovlers in the rear, spidertrax shocks rear upper shock mount and i have an air compressor to mount under the hood, a bunch of wireing and a few lines to run. brake lines, breather hose, air line for the locker. then i have to get the timing right, adjust the throttle position sensor correctly and get it to idle around 850 when its warm. i had it all adjusted but then i tried to swap to a larger throttle body and everything got jacked.
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