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Old August 15th, 2013, 10:40 PM   #21
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I was planning to get the rear gears all setup tonight, but when I checked the engagement it looks like my pinion is not engaged enough, so tomorrow I need to hunt down a crush sleeve. Last time I regeared a Sami I got lucky and could re-use the old ones, but it looks like someone really cranked down on the pinion nut hard at some time in the past.
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Old August 23rd, 2013, 02:30 PM   #22
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Finally some sexy showed up at the door :D

Stainless Steel Tig Welded Tri-Y header to replace the severely cracked manifold.

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Old August 23rd, 2013, 02:48 PM   #23
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Crush sleeves are apparently unavailable locally and back ordered nationally. So my plan is to blow apart some of my spare axles and hopefully I'll have some with usable sleeves in them. The pinion shaft diameter is actually just slightly thicker than a Dana 44 pinion shaft :what: so I may take some spare 44 shims and bore them out to use in conjunction with the sleeve. Either that or a big ol hardware store washer ;)
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Old August 23rd, 2013, 04:20 PM   #24
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The engine swap and some other un-related projects this week left the shop in a mess, so I spent the day cleaning house. Now back to wrenching!
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Old August 23rd, 2013, 06:12 PM   #25
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Fired up the new plasma and cut off the backing plates from a set of spare rear shafts, leaving only a square ring that acts as a flange to hold in the bearing. This will be much easier to pack spare rear shafts on the trail.

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Old September 4th, 2013, 03:30 PM   #26
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Centers of the original rear drums cut out with the plasma to fit inside the front discs. The writeup I'm following said to machine them, but there is no need. The lug studs will be holding the new "ring" to the discs.

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Old September 10th, 2013, 03:29 PM   #27
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Front carrier loaded up with a pre-1990 four pin carrier and lockright with 5.12 gears.
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Old September 10th, 2013, 03:30 PM   #28
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Old September 16th, 2013, 09:48 PM   #29
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Hopefully I can start spicing up this thread now that I have figured out how to use Photobucket (I think)

As for progress, both axles are re-assembled and I am in the middle of a disc brake swap for the rear which uses all front stock stuff.

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Old September 16th, 2013, 10:03 PM   #30
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Looking good! I love Sami's and will get one at some point. Why not the yota in the background?
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Old September 16th, 2013, 10:10 PM   #31
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Looking good! I love Sami's and will get one at some point. Why not the yota in the background?
Thats the shop truck for now, although its been to the Mounds twice.
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Old September 17th, 2013, 10:12 PM   #32
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This morning started with the removal of the driver fender flare to start figuring out what I was going to do about tire clearance now that the 31s are mounted up.



Lots of rust under the old inner flare bracket.



Using the old inner bracket as a template I cut out most of the rust with the plasma.



Making a few final cuts with a sawzall up near the headlight area I was able to remove the stock inner fender in one big piece, leaving only now the greatly enlarged wheel opening.



And replacing the inner fender, pushing it up 2 inches higher than it was before. Welding thin Japanese sheetmetal is a pain with .035 wire! I really need to set up an .023 machine!



The only modification necessary to the body tub that was necessary to raise the inner fenders was to slice and hammer over this small lip under the brake booster.



Top view of re-installed inner fender. I even took the time to cut and reweld the three small brackets that work as braces/stiffeners. The tiny factory jack still fits under the hood too.


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Old September 17th, 2013, 10:18 PM   #33
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After picking up the kids from school I spent some time finishing up the rear disc swap. I know this looks rough, but it is totally functional. This was also a "dry run" Idea and I may clean it up later. I followed the instructions as were posted in the earlier link. My only small modification/add to them was to tack weld the spacer washers (top of caliper bracket) because I could already see them falling out into the mud on the trail during a repair since they are sandwiched between the caliper and bracket. Now, rear shaft replacement is a 15-20 minute job tops, vs. an hour plus for original drum setups.


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Old September 19th, 2013, 09:38 PM   #34
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The raising of the passenger side inner fender went faster now that I had an idea where to cut and what to do. After everything was welded up on both sides I went ahead and sprayed the "fixed" areas with spray bedliner in a can, since that's apparently what one of the previous owners of this rig already did. I was impressed how well it blended in.

I did take the time to measure the "virtual lift" and both inner fenders were raised exactly two inches. I probably could have pushed it another inch, but there would have been several other clearance issues I'd have to deal with. At two inches I have just enough room to make everything work.



Here is a shot of the drivers side, you can see the stainless header is now installed. I had to add about 6 inches to the O2 sensor wire.


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Old September 19th, 2013, 10:01 PM   #35
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Way too much work going on in this thread and not enough casual banter like most of the other build threads on this site...

Looking good... Maybe I'll see it in person when you are up here...
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Old September 19th, 2013, 10:20 PM   #36
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Those inner fenders look pretty darn good
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Old September 19th, 2013, 10:24 PM   #37
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Those inner fenders look pretty darn good
Thank you. I'm happy how they turned out.
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Old September 19th, 2013, 10:26 PM   #38
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Way too much work going on in this thread and not enough casual banter like most of the other build threads on this site...

Looking good... Maybe I'll see it in person when you are up here...
I hope so too! My fingers are really crossed right now. I am having a huge issue with my left eye that will probably require some immediate medical care, so I'm hoping it won't interfere. I should know monday. I only need one to drive!
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Old September 20th, 2013, 06:36 AM   #39
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I wouldn't worry. You've always driven like your eyes are closed anyway..................
Tell the better half to drive, right after she finishes making you a sammich.
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Old September 20th, 2013, 07:50 AM   #40
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I wouldn't worry. You've always driven like your eyes are closed anyway..................
Tell the better half to drive, right after she finishes making you a sammich.
You know I never thought of it like that! I really do! Lol

A Canadian crash course teaching her to drive a manual...hmm that might work!
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