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Old 09-28-2015, 05:29 AM   #1 (permalink)
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Default Barbados Build

Hey, I'm from Barbados W.I, and this would be my second suzuki samurai build.... The first was quite basic and on a college budget. I sold that and bought me a Swift GTi,to build for track days. Had that for about 3-4 years and began to miss the samurai and offroading fun so I decided to ditch the Swift build and get me back a Samurai and do a ground up build to the best of my ability & budget.

Here goes:

Will be using a leaf spring chassis & running gear for ease of lifting and aftermarket support and the newer coil spring body and other components as I prefer the look of it

Leaf spring chassis & drivetrain donor


Body, power steering & gearbox donor


Had me a full set of Wilwoood calipers (4-Pot Fronts & 2-Pot Rears) for the swift build but since I am no longer building the swift these will go towards the samurai build


Lifted the body off the donor chassis to gut, clean and repaint.

Body off



Clean, Prep & Paint Ingredients



Coating



Donor body off chassis



Lockright auto locker
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Old 09-28-2015, 09:49 AM   #2 (permalink)
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Some used Pro Comp 15x10 Steel Rims w/ 2.5" of backspacing


After sandblasting & powdercoat



Some used Interco Super Swamper LTBs until I get here up and running (31x11.5R15)


New Body Mount Bushings & Poly Energy Suspension Bushing Kit


Previous Intake & Exhaust Setup....Will be changing both intake & exhaust manifolds for something a bit more.....adequate


Last edited by fordem; 09-28-2015 at 11:57 AM. Reason: Delete duplicate images
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Old 09-29-2015, 05:32 AM   #3 (permalink)
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Used Calmini 5" Lift Kit


Refurbish Time....Sent the shackle kit to be sandblasted & powdercoated


Pulling the springs apart to refurbish myself


Coated them in same truck bed coating I did the chassis in



Some anti friction coating to prevent/reduce wear & rust


New differential stud kit & spring center bolts



Rebuilt spring packs with new bushings ready to go in

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Old 09-30-2015, 07:27 AM   #4 (permalink)
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Shackle kit back from powdercoating



New Suspension Hardware


Spring Packs ready to go on


All together she goes




Rolling chassis again, off to next garage for the body to go on



On it goes
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Old 10-01-2015, 05:51 AM   #5 (permalink)
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Previous engine setup mockup


Tires mounted & fitted





Fender coverage


ARP Flywheel Bolts & SCE Pro Copper Exhaust Gaskets


Calmini HD Transfer Case Cradle


New 3" Drop Pitman Arm w/ Steering Damper Bracket


Mopar Intercooler Water Sprayer Kit..... Since when offroad there isn't much airflow over the intercooler as when on the highway, this is one of the bits I'll be adding to help keep IATs at a manageable level
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Old 10-01-2015, 08:28 PM   #6 (permalink)
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New Intake System...Opted to go with ITBs as I'm looking for insane response over outright HP...So I ditched the Cultus Intake Manifold and go for something a bit more efficient....Should flow more too :mrgreen:

FWD SR20DET Intake Plenum....Will only be using the top half to seal off the ITBs


Suzuki GSXR600 ITBs...Will be pulling them apart to clean and remove the secondary throttle plates and shaft



Secondary & Primary butterflies out


After a good few hours of cleaning, all mocked back until I get the rest of the intake finished


All the room I have to make the intake work...Only a mere 9" between head flange and brake master cylinder... Intake Flange & runners will be coming from SPR


Couplers cut to length


New Throttle Butterfly Screws....Had to file them down to length since couldn't get hold of any soo short.


Dropped off the plenum gasket to have the template for the base plate cut out of 12mm aluminium. Will continue the intake when I get that bit finished.
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Old 10-02-2015, 07:55 AM   #7 (permalink)
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What are your plans for ignition - there's not exactly a whole lot of room for the distributor in a north-south orientation.
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Old 10-03-2015, 01:50 AM   #8 (permalink)
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Quote:
Originally Posted by fordem View Post
What are your plans for ignition - there's not exactly a whole lot of room for the distributor in a north-south orientation.
Crank triggered Coil On Plugs
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Old 10-03-2015, 01:51 AM   #9 (permalink)
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Meanwhile I removed all the sound deadening material from the interior floor to prepare the body for its multi point custom roll cage to be installed soon.. About 60lbs of that stuff came out






Back into storage until I get more bits to continue..


Plenum Base Plate


Idea of how it will look minus the intake plenum


SGP MLS head gasket
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Old 10-03-2015, 01:52 AM   #10 (permalink)
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Ditched the 1.3L idea and decided to go 1.6L with Twin Cam Swift head...Sold the Jimny block and acquired myself two abandoned G16 bottom ends I got from a friend to refurbish and bring back to life....One with alloy mains the other with steel mains. The steel mains bottom half didn't have a crank so I'll be using the block with steel main caps for extra strength with the alloy main crankshaft.

Alloy main, crankshaft donor


Steel main block



Head & Block that will be used..


Considered getting the block blasted and powdercoated... Havent decided as yet but gave it a good degrease and pressure wash to start mocking up the bits needed






Suzuki EPS column to replace the factory coil spring hydraulic system & 6lb aluminum flywheel:jumping:


Since the column is from a Suzuki who usual keeps they stuff common, the standard suzuki splines are used so the mock up steering wheel also fitsbigok
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