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Discussion Starter #1 (Edited)
Hello. My first thread wasn't the best so I'm starting over. Ill start off with a little about me. I am a 18 year old kid about to graduate and I purchased my first samurai about 3 months ago. I was looking to buy a four wheeler when I heard about the samurais and how versatile they are. After searching for a couple of days I found a decent one not to far from where I lived. I had no clue what I was doing or what I was getting myself into. Anyways I picked it up for around $2400, not sure if it was a good deal but it doesn't really matter to me, first time rookie mistake if I paid to much. My only worry after I bought it was the previous owner ground down the front hubs to be able to fit big wheels and lower it. Because he ground down the hubs there were no lockers to test out the 4x4, talk about sketchy. Brought it home on a late saturday night and couldn't wait to drive it around the next day.
On the trailer bringing her home.
View attachment 48466

First things were to add a couple accessories.
Inclinometer for those oh sh*t moments
View attachment 48474

The headlights were terrible! You couldn't see nothin in at night so some $30 led pods from amazon were a must.
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View attachment 48498

A jeep came into where I work a few weeks before and it had a set of pods set up just like this and I thought it looked cool so thats where they went.
As a 18 year old kid I have a wild imagination, always thinking of things I could do to my new toy. I knew I wanted to lift it and put some new shoes underneath it, but where do I start. After searching for a while, I found two lifts that stuck out to me. SPOA and a coil system or whatever its called. Sorry I still have a lot to learn. Also as a young teen I tend to spend my money as fast as I get it it seems so I knew from the start of this I would have to budget this project, and we all know how that goes. So SPOA it was! Me and a friend spent one saturday installing the low range SPOA kit, and I have to say it took a while, but to my surprise was pretty easy.
View attachment 48506

Thats me under it tightening up the drive shaft bolts after putting in the spacers. While looking for lift kits i found out about the steering issues that come when you lift the samurais. I will be fixing it but for now it works. Also the stock shocks were left on the car as well. Once again I will be addressing that but for now it will work.
 

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First off $2400 for a running Samurai that is not a rust bucket is a pretty fair deal, if not downright great. SPOA is nice but a coil spring setup can get very spendy and probably not necessary unless you plan to do some insane rock crawling. Mine has leafs and I'm shocked by its capability each time I go out and I do quite a bit more than fire trails. What you have there IMHO is already pretty decent, much more and you probably hit the point if diminishing returns unless you have a large budget.

Take it out and make friends with it, you will be surprised by what it can do. Anymore lifting or bigger tires might be a bragging right that lightens your wallet but if you really need more off road performance than what you have in the pics I believe lockers are a fantastic thing.

Regarding lighting, I tried to get by with as few lights as possible, the OEM headlights are shyt to be sure. I ordered some of the cheap Hella knock-offs for $20 each from Summet and put in some Osram Nightbreakers and they really light up the world and are DOT legal. Please do not but HIDs in them, its a dick move, trust me! I use the 6" offroad lights on my bumper and if the HL are not enough in the dark mid-nowhere these will light it all up. I DID use HID conversion kits in the aux lights. these two lighting systems have negated the need for pods and a bunch of stuff all over the body, I wanted to avoid the all expense paid trip to JC Whitney look with crap screwed on everywhere. Definately look for the headlight relay mod and do that along with upgraded headlights and you will be surprised how nice it is. Besides the more lights you use the more lights that can be bitten off by trees, I even pull my wiper blades before going wheeling but I live in the sticks here, lots of very angry trees. Oh yea, I do have a copy of the schematic for the headlight relay mod if you need it, PM me and I'll send it along.

Do remember that whatever money you put into this vehicle, you are highly unlikely to get it back when you sell. It seems to be the nature of offroad vehicles. Enjoy the ride, its pretty sweet.
 

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Discussion Starter #3
First off $2400 for a running Samurai that is not a rust bucket is a pretty fair deal, if not downright great. SPOA is nice but a coil spring setup can get very spendy and probably not necessary unless you plan to do some insane rock crawling. Mine has leafs and I'm shocked by its capability each time I go out and I do quite a bit more than fire trails. What you have there IMHO is already pretty decent, much more and you probably hit the point if diminishing returns unless you have a large budget.

Take it out and make friends with it, you will be surprised by what it can do. Anymore lifting or bigger tires might be a bragging right that lightens your wallet but if you really need more off road performance than what you have in the pics I believe lockers are a fantastic thing.

Regarding lighting, I tried to get by with as few lights as possible, the OEM headlights are shyt to be sure. I ordered some of the cheap Hella knock-offs for $20 each from Summet and put in some Osram Nightbreakers and they really light up the world and are DOT legal. Please do not but HIDs in them, its a dick move, trust me! I use the 6" offroad lights on my bumper and if the HL are not enough in the dark mid-nowhere these will light it all up. I DID use HID conversion kits in the aux lights. these two lighting systems have negated the need for pods and a bunch of stuff all over the body, I wanted to avoid the all expense paid trip to JC Whitney look with crap screwed on everywhere. Definately look for the headlight relay mod and do that along with upgraded headlights and you will be surprised how nice it is. Besides the more lights you use the more lights that can be bitten off by trees, I even pull my wiper blades before going wheeling but I live in the sticks here, lots of very angry trees. Oh yea, I do have a copy of the schematic for the headlight relay mod if you need it, PM me and I'll send it along.

Do remember that whatever money you put into this vehicle, you are highly unlikely to get it back when you sell. It seems to be the nature of offroad vehicles. Enjoy the ride, its pretty sweet.
Thanks for the advice! I think ill take you up on that relay mod for sure. How do you like your bumper? I was looking at getting the same one, winch and everything. I emailed zukoffroad where I found the bumper and asked if they could send me one with no cut outs for the lights so I could cut my own for different lights and LED flush mounts. I know more pods put they're just so addictingB)
 

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I hear ya on the pod thing. I love the bumper. You can get them cut for the common LED light fixture, its cheap and easy, I have LED lights/blinkers on all corners, you will need to replace the flasher with IIRC an EP34. There really isnt much room behind the bumper. If you have access to a plasma cutter or something it should be to bad.

I really like the bumper and the winch. The customer service I got while buying the bumper was well above and beyond. You wont go wrong with this setup.
I'll PM my email so you can get the schematic.

Tony
 

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Discussion Starter #5
So I took the Sami out for a little fun at a friends house and let's just say it didn't end well.
View attachment 48602
Something in the carb or throttle cables kept getting stuck and caused it to rev out without stopping until you turned it off. You turn it on, it would idle for a few seconds then rev out again. We finally figured out how to limp it back, if you threw it in gear in the few seconds it idled normally and took off it would idle fine and you could drive but as soon as you touched the gas it would rev out and you would have to start over again. It sat at my work for a couple of weeks because I got busy and the starter went out, or so I thought. Winched it on a trailer and brought it home. After messing with it for a while I had some help from my dad by skipping the starter cylinoid using a metal chizzle and it kicked right off. So then I came to the conclusion that the cylinoid was bad, but just for fun I tried starting it with the key and it fired off right away like nothing had happened, and no revving either! Beats me what was wrong but I have a new weber carb sitting in the garage waiting to be put in cause the old one(original) is just warn out. I also got my homemade door panels on. Just a piece of wood paneling and some Bedliner, I think they turned out alright.
View attachment 48610
 

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Do a search for "clicky starter fix", its a common ailment with an easy fix.

The revving thing I'm not sure without putting my hands on it but it sure sounds like fuel management issues. I have never played with a Sami carb before but I hear they can be finicky. Does the throttle cable operate the linkage properly, does it snap back without sticking or binding when you let it go? Give it a once over for vacuum leaks, the hoses are nearing their 30th birthday.

Luckily it's all a pretty basic and solid vehicle and the common issues are very well covered here, also there are many here that have vast knowledge.

Is this going to be your first project vehicle?

Tony
 

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Same Carb problem

Brodyb,
I am having a similar problem with my carb. When I took it on a drive the last three times the carb throttle seems to hang open when you are going through the gears. When I accelerate, as I am shifting, the engine RPM continues to redline. This seems to happen only when I am being aggressive on the throttle. It's scary when the motor is going to WOT and you don't even have your foot on the gas!!:eek: I have checked the linkage and the throttle cable and can find nothing wrong. No stiff spots, no hang ups. When I'm at my shop I have run the engine and can not duplicate the problem. It only seems to do it when I have it on the road.
So, if you find out what the problem is, let me know. If I can find out what is causing my problem, I will let you know. Good luck with your build.
 

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Carb sticking

I had an issue with a Weber 32/36 carb I put on a Gen I Montero I used to have, and had the same issue with the Weber that's on my Sammy, in that the throttle wouldn't "snap" back. My solution to both Weber applications was to install a return spring that would help the linkage snap back like it's supposed to. I'll take a pic of the spring that I put on the Weber on the Sammy and post it later.

If it dies, that could be a fuel issue. But if it keeps running or even revs higher, that could be solved with an external return spring. It's a cheap and easy fix, certainly can't hurt...
 

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Discussion Starter #9
Thanks for all the help guys! As for the starter ill check into that clicky starter fix sense that sounds like the problem. Everything with the starter and carb are working fine now. No problem really starting it except for once or twice it will just click but then I try again and it kicks right over, and the carb or throttle or whatever was making it rev must have fixed itself because I have not had it happen once sense I got it running again. Like I said I have a new weber carb just like social said that should be installed soon. Ive been so busy getting ready for college that Im trying to balance it with the time I put into the sami, and trying to stay out of trouble with the parents if I spend TOO much time on the sami and not enough on school.:wacko:
 

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How long has the carb been on it?
It was already on the truck when I got it, and I've had it about 6 weeks.

I remember when I installed the Weber on the Montero, there were all these hoses attached to the stock carb that ended up not being used. From what I remember, there was a hose that went from the carb to the distributor, a hose that went from the engine to the air cleaner, and of course the fuel line, that was pretty much it.
 

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Discussion Starter #13
Well its been a busy few days but ive been working on a little project for my sami.
View attachment 48826
View attachment 48834

So I built the actual rack in my welding class at school. Its all 3/4 inch sq tubing, nothing too fancy, just to throw random stuff up there for more room inside(and for a place to mount the light bar);) Tomorrow I will wire up the light bar and get it all nice and neat. Also got the zor subspeed winch bumper on the way so that should be fun:D I will show that when it comes in but I will be doing some modifications to it for some cool stuff but that's a secret! Guess we'll just have to wait and see. Lots to come in the next week or two so hopefully ill remember to take plenty of pictures to show everything.
 

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Nice looking rack! You should also put a couple of those smaller LED lights on the back. That light bar on the rack should throw down some serious daylight!
 

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Discussion Starter #15
Well its been a while and I have been doing a few things for the build. First off was I got my new front bumper in a few days ago and so far it looks pretty impressive.
View attachment 49170
As you can see its in a few pieces. I decided to do the DIY bumper kit for 2 reasons. One was that is was a LOT cheaper and two because I have access to a welder and need something to do at school. The kit saved me about $150 and all I have to do is weld on the two end pieces and the d-rings. Instead of mounting to thin metal brackets like the stock bumper, this one mounts right to the frame and is at least 1/4 inch thicker than the stock bumper making it strong and sturdy, and keeps me stress free when being pulled out of the mud! A winch is coming later but I have to save up the funds for a nice one.
Next was a little idea I had while at work when I found a single n-fab step laying in the back with my name written all over it:cool: Ive been wanting a set of steps/rock sliders for a while but everything I find is just expensive. So I decided to make my own.
View attachment 49178
I started by measuring the length I wanted them, then cut each ends so I could use the steps where they already were. Sorry for the lack of pictures by the way I am terrible at taking them. I then capped the ends I cut off and smoothed it over. Then I used a coat hanger to mock up a custom bracket for them and that's about where I am now.
Hopefully this weekend I can get the steps and bumper welded and mounted up so I cant send them both off to be powder coated.
 

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Very nice looking, simalar to what I have and I'm very pleased with it and the way it mounts. I have the missing links and stops to so I had to do a little modding to get it all back together. It was a short afternoons work to get it all together but well worth the effort and time. I go out solo enough that I can not go without a winch.
 

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congrats on u'r purchase

It looks good . recommend u invest in parts that are hard 2 find and a little pricey . It will add 2 your longevity ,and enjoyment down the rd.
 

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Discussion Starter #18
View attachment 49297
Got the bumper fully welded up, holes for the led pods cut and d-rings welded. Still have a little bit of grinding to do on 2 welds and drill the holes for my blinkers and its ready for powder coating.
Also got new door and window seals in yesterday. No more raddling windows! The old ones were almost completely gone and just fell apart when I got them out.
 

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Discussion Starter #19
I got the new weber carb on yesterday and I cannot believe the difference! It is night and day better. Throttle response is like no other, it runs smoother and doesn't bog down like before. I also got ride of most of the emissions crap that was on it so it looks much cleaners and less cluttered under the hood. There is still a few minor adjustments and tweeks that need to be fixed but for the most part there wasn't much that had to be done. I had some help from a friend that pointed out that it was starving for fuel just a tad but that might be due to a fuel hose size change and not the right fitting to change them but I will be fixing that soon. We also talked about some plans for a snorkel so that I'm sure will be comin soon. The bumper is finished at the powder coating place but I have not had to time to go get it.
 

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I trust there will be photos of the finished bumper....
 
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