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Old January 16th, 2010, 07:33 PM   #1
Jdc215
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Default The Beast (My Little ZUK Build)

1991 Suzuki Samurai its going to fill the same role as my Bronco II but the bronco has some timing issues ill try to work on this spring and the samurai gets better fuel economy and its a manual. i like them both and both are meant to be Daily Drivers and weekend wheelers. BTW i didn't come up with the name thats what my boss calls it.


Latest Picture




stock axles
3.73 gears
Manual trans
1.6L 8V FI motor
4" BDS lift springs
1.25" wheel spacers
Petroworks performance clutch
front lock-rite
rear air locker
30x9.5 firestone destination mt on 15x7 Sidekick steelies


Parts List
$1500 Samurai
$250 clutch and Bearings
$15 rear main seal
$15 Pan Ghasket
$19 Gatorback timing belt
$25 Brake pads
$60 2 Brake Rotors
$43 Brake Caliper
$37 water pump
$23 trans mount
$20 CB radio
$300 XRC8
$25 spark plugs
$40 MSD wires
$15 Dirtributor cap
$5 Distributor rotor
$200 Calimini header
$80 Hi-Lift Jack
$20 Tracker Wheels
$50 1.25" Wheel Spacers
$20 YJ Springs
$10 part of a trail tough front ML YJ kit
$22 Fuel Filter
$26 antenna
$300 winch bumper
$15 starter relay
$70 alternator
$40 alternator install kit
$25 5/8 clevis x2
$150 battery and terminals
$10 Belt
$15 brake shoes
$9 spring kit
$145 Rear Locker
$150 skid plate
$23 rear axle truss
$30 front axle truss
$40 4 u joints
$8 shackles
$8 diff caps
$35 new rear axle shafts with bearings
$8 new hardware
$160 Spidertrax HD transfer case arms
$15 wheel cylinder
$10 brake line and fittings
$200 chromolly front axle shafts
$700 4.16 transfer case rebuilt
$70 trans mount
$40 motor mount
$170 spidertrax transfer case arms
$15 transfer case mounts
$280 rear drive shaft
$230 front lock-rite
$150 front axle rebuild kit
$300 rear bumper
$200 gas tank skid plate
$25 exhaust parts
$100 front output shaft
$100 mini spool
$20 header weld
$35 hand throttle
$10 starter
$4 pcv valve
$18 spark plugs
$20 antenna
$30 rear view mirrow
$15 window channel
$10 new hub bolts
$10 HD rear shackles
$800 1.6 motor swap
$40 polaris mounts
$15 pinion flange
$160 new exhaust
$250 new soft tops
$10 exterior door handle
$5 interior pull handle
$25 factory replacement speakers
$40 hardware to re attach soft top
$240 new Bestop
$150 aluminum interior pannels
$15 rag joint
$200 transfer case rebuild
$75 new rear axle
$100 overhead tray
$50 clutch cable
$680 air locker and compressor
$35 ZOR crab diff guard
$200 used mud tires 30x9.5-15
$20 1 new tracker wheel
$100 teraflex revolvers
$80 rear shocks
$50 Spidertrax rear shock mount
$20 extended rear brake line

Total Cost so Far: $10738

i just ordered a Smitty built XRC8 should be in later this week. ill be ordering a ZOR front winch bumper should have that in the next week or two. i still need to fab us some of the mounting hardware ill weld on some d-rings from tractor supply, paint it and mount up the new KC slim lights. im also planning to rig up an internal controller for the winch. im planning on putting some new shackles on to compensate for any lost ride in the front. i also have a cobra 19 ill be mounting with a wilson 3' fiberglass flex. after that ill get a belly skid, tank skid, rear bumper and Rock Sliders. finally im collecting the parts to do a YJ Missing link spring Swap. initially ill go spring under,stage 2 i will go spring over, Cromo shafts, lockers, power steering, Narrow swampers, lower gears, cage and a more powerful motor. this is all going to take place over quite a period of time but for now and probably the next few years it will stay on the 31" tires because it is my Daily Driver.

Last edited by Jdc215; February 8th, 2012 at 10:00 PM.
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Old January 16th, 2010, 07:47 PM   #2
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just did the brakes today i meant to do the oil change and water pump too but my roommate left and i ended up needing a new caliper so in the end it took all day. ill do the oil and water pump tomorrow so i can go to work Monday.
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Old January 21st, 2010, 03:54 PM   #3
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water pump is in and i no longer have any leaks, just got the winch today and a pay check which means im ordering the ZOR winch bumper too. should be pretty nice.
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Old January 21st, 2010, 06:42 PM   #4
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Looks good, I like those little samurai's.
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Old February 2nd, 2010, 06:35 PM   #5
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i just did the clicky starter fix. it seems to have worked but. i wont really know until tomorrow morning when everything is good and cold. my cb antenna just came in, its a Wilson 3' Flex. my 105 AMP alternator should be in on thursday. winch bumper should be in on friday. i still need to buy a new battery, battery hold down, lights, battery clamps, alternator mounting bracket, new v-blet and an O2 sensor that ive been missing for several months now. last but not least some shackles to lift and level a little.

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Old February 2nd, 2010, 08:32 PM   #6
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heres a preview of what the bumper looks like. its basically a ZOR prefab center section with rock crawler ends raised about 3/4 of an inch with some custom tabs for 3/4" d-rings.
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Old February 3rd, 2010, 12:06 AM   #7
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interested in 5.13 axle gears? they helped big time on and offroad
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Old February 3rd, 2010, 12:14 PM   #8
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Little Beast. HAHAHAHAHAHAHA

More like, Little Turd.
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Old February 3rd, 2010, 12:20 PM   #9
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i like the suks more and more, nice work.



Quote:
Originally Posted by lotusexige View Post
Little Beast. HAHAHAHAHAHAHA

More like, Little Turd.
i hope your friends otherwise your an ass.
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Old February 3rd, 2010, 01:47 PM   #10
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Quote:
Originally Posted by Jdc215 View Post
that is a sexy bumper!
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You ain't got no problem, Jules. I'm on the motherfucker.
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Old February 3rd, 2010, 04:33 PM   #11
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Quote:
Originally Posted by lotusexige View Post
Little Beast. HAHAHAHAHAHAHA

More like, Little Turd.
i never would have connected the samurai with the word Beast, but TK dubbed it and it seems to have stuck at work.

just mounted the CB radio today fit nicely on the right side of the trans tunnel and i already had a rubber grommet to run the power wires through. i think it fits nicely, now lets just hope my passengers agree. i never have to ride over there and i normally drive alone, i just hope the radio doesn't make my GF hate it more than she already does.

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Old February 4th, 2010, 03:18 AM   #12
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Quote:
Originally Posted by Jdc215 View Post
i never would have connected the samurai with the word Beast, but TK dubbed it and it seems to have stuck at work.
i used to work with a guy named "tiny"

- he looked like brock lesnar.



good luck on the build
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Old February 4th, 2010, 08:55 PM   #13
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just got my alternator in today and ordered the mounting kit. ill pick up the battery, battery hold down and terminal clamps tomorrow. im going with an AMG dry vell over a Optima since i heard that optima's quality control sucks balls right now, and this battery is cheaper.
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Old February 5th, 2010, 04:21 PM   #14
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today i picked up the AGM battery, battery hold down, i ordered a gatorback V-belt and the ZOR bumper arrived. ill try to get the battery in tonight, and start working on the bumper over the weekend. i initially bought the side terminal post adapters but that wont clear so ill have to get the regular flat type. i hope my GF can get me up to the auto parts so i can get the battery in.
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Last edited by Jdc215; February 5th, 2010 at 09:41 PM.
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Old February 5th, 2010, 10:27 PM   #15
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i got the battery in the engine compartment, i had a little trouble with the connection with the fused link but after putting a new termination on i had no problems at all.everything looks good and there is plenty of room for the winch cables to attach on the top. next i need to get the alternator in and the current front end apparatus removed and make sure the frame is in suitable condition for attaching the winch bumper.
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Old February 8th, 2010, 05:57 PM   #16
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i finished painting the bumper tonight and started removing that old POS on he frame but its going to be tough, whoever welded the former piece of crap on the front burned th crap out of the holes i need to mount the winch bumper. any ideas on ho to repair it a samurai frame??
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Old February 9th, 2010, 03:11 PM   #17
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after looking closely at the frame and current fixture, there has been a little frame damage and its going to be more work than i anticipated but nothing unachievable, its just going to take longer. myron at ZOR was great about helping me work out a solution and he sent me some pieces of fitted steel to solve my problem for only the price of shipping.
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Old February 9th, 2010, 06:19 PM   #18
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i love the bumper john
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Old February 12th, 2010, 05:54 PM   #19
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last night i put in the GM alternator. i really hope the 105 amps will keep up with the winch. right now im just trying to find someone who can help me repair my frame so i can mount the bumper. i have that all painted and im just itching to get it all together.
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Old February 14th, 2010, 10:17 AM   #20
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i mounted up the ZOR bumper yesterday. took about 6 hours of working and BSing around to get the old crap off and the new bumper on but it was fun with friends. new turn signals are in, now all i have to do is install the winch.
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