The Popsicle stretch thread

[NC Zuk]

Instead of continuing with the other thread (it is 10 pages long) I figured I would start a new one. If you want to see how this whole thing began have a look here: http://bbs.zuwharrie.com/content/topic,30868.0.html

I realized a while back that in order to have a more capable Zuk I was going to need to gain some wheelbase. Currently my Sammi has an 81.5 inch wheelbase and sits on 35's. It is too short and a tad too tall. So to make it a better trail rig I am planning on extending the wheelbase to somewhere around 100-102 inches. I want this to be a clean chop so I posted a basic pic and asked for input. Here is what it looked like before I started and a photo chop of what I would like it to somewhat resemble when I am done. I plan of running larger tires in the future so the build will be done to accommodate them without having to rebuild later.

Before:



Proposed fender cutting:



Proposed outcome:





So I started by removing the front clip. This wasn't all that hard and required removing about 14 screws/bolts to pull it off. It was pretty easy and I was surprised at how little the whole front clip weighed when I pulled on it. I easily lifted it off myself.











Once I got that done I had so much going on that it took me a while to get back to work on it. So today I finally got busy. First up was lowering it so that I could work on it. It think I'll keep these tires for wheeling







From there I rolled it into the garage and got it onto jack stands. I am going to rework the front frame section (I'll explain that in a second) so I needed to remove the front axle and steering.






A long time ago, in a land far, far away I installed an 8v with EFI wiring from Aftermarket 4x4. It works great but left me with a lot of useless wiring from the carb and A/C that was in it years ago. It was a mess so since I am pulling the motor to work on the frame I figured it was time to get rid of the rats nest. I started by stripping all the tape off of the harness and removing the old unneeded wiring. I would have finished up but I ran out of electrical tape This is what was left after I stripped all the crap out. If you look at one of the pics way up above you can easily see the mess I had. I'll get a finished pic tomorrow.



Tomorrow I will pull the Engine and start on the front frame. So why am I pulling the engine and what am I doing to the frame? Too easy! If you look at the Samurai frame you will see that it slopes downward as it goes forward from the motor mounts. Since I am moving the axle forward 6-8 inches it would also cause my front end to be lifted even higher than it is right now. So I am gonna cut the frame off at the motor mounts and put in all new 2x4 Box tube. The box tube will also serve as a winch mounting point Here is a pic of how much the frame angles down. The frame will be straight out when I am done and run along the bottom line of the Level.






So tomorrow I hope to have the frame modified and done and then I will start on relocating the front axle and all the link mounts, steering box and panhard bar. I hope to finish up this work on Sunday and maybe even start bending some tube for the front clip.

[sukibogger]

Wow, lots of work ahead. good luck. I live in raleigh so if you need parts or what ever brought to you let me know.

[NC Zuk]

Wow, lots of work ahead. good luck. I live in raleigh so if you need parts or what ever brought to you let me know.

Thanks. I think I have what I need to get the front done except for the Grill ( whitfield! ) my lights will be here by Tuesday and I have all the tube and plate steel I need for now. I guess I need to order my Fuel Cell so it will be here when i get back from my next trip.

thanks for the offer!

[Biggerhammer]

Lookin' good. Do I get another speed wheeling trip out of it the next time we get together?

[NC Zuk]

Lookin' good. Do I get another speed wheeling trip out of it the next time we get together?

Sure! But I doubt it will be done by the Spring event. I have 2 trips before then and not a ton of time to work on it. I should get the front completely done by the end of next weekend................. I hope

[GeneralChaos]

Ahhhhh my eyes are burning, she's gone under the knife

But I'm sure it will be a work of Art when it's done.......hehe get it lol

Keep us updated Art

Steve

[sammi_davis]

I like the chop chop    Now get to chopping 

[ZUKIMON]

Hmm, I can't believe that no one has said anything yet.   Nice Frosty you have there!

[zooky]

cool to see you finally doing this, cant wait to see the finished product, thats something I always wanted to do but dont have the gonads.

Since I am moving the axle forward 6-8 inches it would also cause my front end to be lifted even higher than it is right now.

When you move the front axle forward, couldnt you just leave out the 'lift block' and maybe notch the frame a tad. That would leave the spring mount at the same height. One thing I had thought of doing (this may be kind of hard to explain) was to raise the spring mounts to the top of the frame instead of the bottom. What I would do is box out the section of frame (front and rear) where the spring mount currently is and mount the coil to the upper part of the box. This would lower the sami 4" (the thickness of the frame) and still allow me to run the tall springs. The benefit to this is that I would be lower (better center of gravity) and still have the flex of the longer coils. Currently, I run shorter coils because I didnt like the height, I love the new stance of my sami but it cost me some articulation.
Well, keep the details coming, I'm keeping an eye on this project...  
Oh yea, what did you decide to do about your drive train?
Are you going to switch to an FJ60 box? That could help you keep the frame length forward of the axle short to give you a excellent approach angle

[NC Zuk]

Randy, great minds think alike I want to change the front frame piece for a few reasons. One is to lower it and the other is to locate my winch where I think it should be. I have given hours of thought into notching the frame as you have mentioned to lower the ride height and keep the long springs. By putting a new front section of thicker wall box tube it will give me the ability to notch 2 inches our of the frame effectively lowering the rig 3 inches (minus that ugly lift block) If I had a plasma cutter I would tackle it in no time at all. But since I use only an angle grinder to do all of my metal cutting it would be a pretty large task. Not saying I won't do it but it won't be fun.

As for steering, I am gonna have some frame sticking out front to mount my winch to. the added length will give me the room to mount my steering box with no issues. I had thought about trying to mount the winch below the radiator but it was way too low for my taste.

[Blue Ridge Runner]

Dude, You need to borrow a plasma cutter. 

[zooky]

Randy, great minds think alike I want to change the front frame piece for a few reasons. One is to lower it and the other is to locate my winch where I think it should be. But since I use only an angle grinder to do all of my metal cutting it would be a pretty large task. Not saying I won't do it but it won't be fun.

I feel your pain, I am an angle grinder kind of guy myself
I also thought about lowering my winch but my method would be mounting it upside down from its current position to the bottom of the winch mount, that should lower the fairlead about 6" without lowering the bumper

[NC Zuk]

I feel your pain, I am an angle grinder kind of guy myself
I also thought about lowering my winch but my method would be mounting it upside down from its current position to the bottom of the winch mount, that should lower the fairlead about 6" without lowering the bumper

heeeeyyyyyyy.......... that just might work! I would have to put some tubing around it to protect it as I am prone to smash into stuff (trees included) I'll have to check that out!

[jerseyzuks]

If I had a plasma cutter I would tackle it in no time at all.

I'll let you borrow mine if you want it.  It's a little miller, shouldn't cost much to ship.

[Blue Ridge Runner]

I'll let you borrow mine if you want it.  It's a little miller, shouldn't cost much to ship.

Now that is a great idea. 

He will buy one afterwards. I want one real bad now.