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Old May 14th, 2010, 07:36 AM   #41
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Well its onto the brakea this weekend, imalso going to install an extended brake hose and order some terraflex revolvers, i really want more flex, i dont want any more lift and i really need some straight shackles in the rear.
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Old May 16th, 2010, 04:27 PM   #42
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the revolvers have been put on hold, i got a line on a 4.16:1 t case i think im going to buy, it will take a months worth of fun money but ill get it. than ill have to do the revolvers, a tank skid and finally a rocky road crawler II bumper. that will be the end of anything big for a while. i may try to figure out some kind of a front sway bar disco but ill have to dis connect it and see if it makes a difference in flex first.

p measured today and i have 10" of wheel travel in the rear and 6 in the front. im defiantly going to have to try the front with out the sway bar. revolvers should get the rear to about 12" i would think and straighten out my suspension. i have also heard stock bushings make a big difference so i may try replacing all the bushings all the way around and see what happens. and after a little research im going to pull my t-case mounts and beef them up and put together some stronger mounts. once i have the suspension how i want it ill have to replace the shocks and put on a drop pitman arm and ill be all done with things for a few years. ill just have fun and work on getting a mustang to park next to it.

Last edited by Jdc215; May 16th, 2010 at 10:57 PM.
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Old May 21st, 2010, 06:11 PM   #43
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i got an update on the transfer case. the guy said he would swap on some big flanges for me and the upgraded output shaft. and hes going to go throught the entire thing before selling it to me. i have been trying to figure out how to get a fender flare mounted back on the passanger side and repair some serious body issues. should be up at the mounds this month.
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Old May 21st, 2010, 06:24 PM   #44
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lookin good, i like these little buggers also... i know so many people that have trackers too, and those are pretty impressive for IFS, seen what they can do on some... property >>...
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Old May 25th, 2010, 09:38 PM   #45
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well i finally rapaired the passenger rear quarter. i wouldn't call it fixed, but i cut the old fender flair off, pushed out what i could of the bed skin, and mounted a new fender flair. now i need to fill a rusty gap between the inner fender well and the outer skin about a inch wide. i can see the tire from the inside. i need to do a little research and see what i can work out to fill the gap so i don't get mud inside the body. then ill put a new mirror in the passenger housing since i don't have to worry about the tire throwing rocks at it any more. im still saving to pick up my 4X T-case in three weeks. and i got the parts for my new transfer case mounts.
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Old May 30th, 2010, 01:41 AM   #46
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i took my dad to the mounds today. it was great. off-roading isnt really his thing but he had a lot of fun. i ran some of the rock courses and some pretty technical dirt trails and i just didnt have the torque, just reinforcing my decision to get a 4X t-case. i also blew up one of my rear wheel bearings, and i need to make some HD shackles for the rear. the factory ones are bent so i think ill just make some stock length ones and replace all the shackle bushings. making a two piece shackle with some 1/4" flat stock and a drill press should me more than adequate. i already have a set of stock axle shafts with good bearings, so when i get around to repairing the brake lines ill put on some sj410 backing plates and cut out my brake backing plates for quicker rear shaft swaps.

4X t-case
install T-case mounts
reinforce t-case mounting brackets and arm
make HD shackles
replace and reroute brake lines
weld on rear axle truss
replace drivers side axle shaft
replace passenger side mirror glass

long list of little things.
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Old May 30th, 2010, 01:41 AM   #47
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i took my dad to the mounds today. it was great. off-roading isnt really his thing but he had a lot of fun. i ran some of the rock courses and some pretty technical dirt trails and i just didnt have the torque, just reinforcing my decision to get a 4X t-case. i also blew up one of my rear wheel bearings, and i need to make some HD shackles for the rear. the factory ones are bent so i think ill just make some stock length ones and replace all the shackle bushings. making a two piece shackle with some 1/4" flat stock and a drill press should me more than adequate. i already have a set of stock axle shafts with good bearings, so when i get around to repairing the brake lines ill put on some sj410 backing plates and cut out my brake backing plates for quicker rear shaft swaps.

4X t-case
install T-case mounts
reinforce t-case mounting brackets and arm
make HD shackles
replace and reroute brake lines
weld on rear axle truss
replace drivers side axle shaft
replace passenger side mirror glass
get new wheels for mud tires

long list of little things...
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Old June 5th, 2010, 12:05 AM   #48
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well more things brake and more work. i had two bad wheel bearings in the rear just replaced those today with some new shafts with good bearings and i cut the backing plates on the shafts into make shift sj410 backing plates. then i took my old backing plates to a friend who milled out the center holes to 3". next im redoing the brake lineson the rear axle with a junction block and two drivers side wheel cylinders. i also have a bad input bearing on the transfer case. i already put together a poly mount kit and i just ordered a set of spidertrax HD arms to mount up the case. ill be picking up a new case this comeing friday that has been rebuilt with a set of 4.16 calmini forged gears, updated output front output shaft and big flanges to fit my samurai propperly. thats next weekends project. as lon as my rear diff is ok ill prolly be up to the mounds the following weekend. i wish i had a good camera, id post tons of pictures.

Last edited by Jdc215; June 5th, 2010 at 12:27 AM.
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Old June 8th, 2010, 03:09 PM   #49
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i got the brake lines in the rear redone, i have a single brake hose going to the proportioning valve so i re ran all the hard line on the axle with two drivers side wheel cylinders and a junction block. i left plenty of room to fit the trailtough axle truss in the rear too. i also did the sj410 backing plate mod but instead of buting the actual backing plates i just cut the existing ones to fit the exact same way. once i get the brake backing plate tacked to the axle tube flange ill be all set for some quick axle shaft swaps and quicker axle work in the future. the new wheel bearings on the new shafts should help things out to.

since the input bearing is bad on the transfer case an im buying one with 4.16 clamini gears in it, i figured i better upgrade the mounting system at the same time, so i ordered a set of spidertrax transfer case arms and a set of polly mounts. this should be bretty straight forward once i get the skid plate off. only thing im not certain how to do is remove and reinstall the speedo cable. once this is good id like to rebuild the rear diff. then ill save up for a rocky-road crawler II rear bumper and skid plate. i cant afford a tire carrier right now but all crawler bumpers are set up for one. and id like to upgrade my tank skid if im going to remove the old bent up hitch assembly.

should be picking up the transfer case saturday night all change the fluid and install it sunday, i may start the tear down on saturday evening but it depends on how it all goes. ill also be replacing the rear shackle bushings and makeing some new shackels real soon. i think all that will be less than $30 and its worth it to make some real cheap shackles out of 1/4" flat stock now since i wont have money for those terra flex revolvers any time soon. those are now behind the t-case, rear diff rebuild, tank skid and RR rear bumper. i also need to get my axle trusses and knuckle gussets welded on some time.

that red one isnt my zook just a picture of the rear bumper i want
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Last edited by Jdc215; June 12th, 2010 at 01:31 AM.
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Old June 9th, 2010, 12:59 AM   #50
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Nice Sammy , Looks like all you need now is a good cliff with lots of rocks & mud!
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Old June 17th, 2010, 09:05 PM   #51
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Quote:
Originally Posted by AG TROOPER View Post
Nice Sammy , Looks like all you need now is a good cliff with lots of rocks & mud!
not sure if thats a compliment or a diss but which ever

i founf that i have both a bad trans mount and a bad drivers side motor mount. i replaced the trans mount when i did the clutch, but i never realized the bad motor mount. i always wondered why it was so clunky. well, i ordered an "indestructable" trans mount from trail tough and i guess the motor mount from a 90 sidekick is the same exact thing just stronger. same fit and everything, so i ordered one from autozone, it was the cheapest place and the only one with a life time warranty. the original transfer case deal fell through so i found another one for less in california. ill have to swap on my drive flanges and front output shaft but no big deal. it should all be in soon. next up will be to get the rear diff rebuilt. i would do it myself but i just don t have the experience. i think i can get it done for about 250 out the door but whe'll see.
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Old June 20th, 2010, 06:39 AM   #52
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motor mount showed u today, after a little research i found that the mounts for a 1.6 8v is the exact same size and fit, but stronger, and its what most vendors call a "heavy duty" mount, so i ordered one from auto zone, everyone says their prolly junk but with a lifetime warranty well see how it holds up. transfer case should be in om Tuesday and the trans mount on Wednesday, then i start pulling everything apart.

mount installed, turns out i have been driving it with a bad mount since i bought it. everything feels alot better now. trans mount should help out too.

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Old June 23rd, 2010, 07:26 PM   #53
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the trans mount wasnt failed per say but it was defiantly stretched so i replaced it with the trailtough one today. looks like an excellent product, but only time will tell. next i removed the transfer case. at this point im fairly certain its only the transfer case thats bad, but if both are bad ill just have to replace both. oh well. well see how it goes. the transfer case should be in on either saturday or monday i hope. everything at this point is waiting on that. i also found that the nut holding the rear drive flange was loose and that is the source of the play. i took the nut off, cleaned everything off, put a shit tone of locktite on it, then tightened it down and locked the rum of the nut.
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Old June 28th, 2010, 05:05 PM   #54
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i got the new transfercase installed, alot later than i had hoped but its ni none the less and it will be up at the mounds saturday. i really like the case without a detent ball it shifts great. my only complaint is about the polly through bolt mounts. i dont like them they seem to cause excess drive trane vibration. after a little more research i found info on some polaris motor mounts for a quad (Part # 3022067) i have never heard anything but good but ill have to order some and see how they are. ill try to get the pictures posted.
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Last edited by Jdc215; July 5th, 2010 at 02:24 PM.
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Old July 11th, 2010, 10:36 AM   #55
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i just got a new job that constitues a 50% pay increase so i should be able to finish this 31" stage of the samurai. i wont go bigger for a few years.

steering stabilizer
rear shackles
shwockworks rear bumper
shrockworks gas tank plate
and
possibally some suspension mods
breeze drop links in the rear and 4" HD shackles in the front.
longer shocks
sway bar disconnect
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Old July 24th, 2010, 08:46 AM   #56
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the rear drive shaft i ordered showed up today but its about an inch and a half too long. its a great looking drive line but its just too long. i also ordered my axle rebuild kit and a Old Man Emu steering stabilizer. i should be able to get the front locker and chromolly shafts installed by next weekend, ill have the rebuild kit on or before Thursday so ill prolly try to tear it apart then. try to get the locker installed on friday or saturday and have it all back together by the end of the weekend. ill have to do a little work to get the steering stabilizer installed and i should have that drive shaft back some time late next week. should be all ready for the 7th. im planning on going up to the mounds that day since its been a while. seems like the weekends get booked so damn fast.
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Last edited by Jdc215; July 25th, 2010 at 09:32 AM.
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Old August 10th, 2010, 10:00 PM   #57
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i installed a front locker and i got the chromolly shafts in the front. only problem now is that i the front locker is clicking. ill have to figure that one out.
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Old August 10th, 2010, 11:25 PM   #58
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lookin good
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Old August 17th, 2010, 09:59 PM   #59
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samurai stage one is nearing completion i have a realtively short list remaining and i have already ordered the big ticket items, a tank skid plate ans shrockworks rear bumper. that only leaves a few things

passanger side mirror glass $20
homemade rear shackles $20
solve front locker problem ?
transfer case mounts $50
repair cracked header $20
reattach exhaust $50


stage two wont be for a couple of years but will include a 1.6 8v, spoa ML yjs or a coil conversion kit, chromolly rear shafts, 33" tires,TSLs or boggers something really agressive, soe sort of cage (not sure yet), hard top, HD front drive shaft, axle gears and possibly arb locers.

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Old August 18th, 2010, 07:38 PM   #60
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Were you east bound on 96 near the M5/275 interchange yesterday around 6:45am?
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