Suzuki Forums banner

1 - 20 of 30 Posts

·
Registered
Joined
·
74 Posts
Discussion Starter #1
I'm going to take the doors and windshield off of the '88 Samurai that's hidden in the woods for my wife's Christmas present. We have acreage and she will be able to explore our trails with it, unlike now where my tractor has but one seat and she has to hike.

One of BillJohn's pages explains that the windshield screws have been loctited in and need an impact screwdriver to remove. I've got the driver and when DW is off shopping, I will attack. I have a grinder if that fails. Anything else I should know?

What about the doors? I broke a bit with a ratchet a couple of days ago trying to remove one door hinge screw. I assume the impact driver again?

Is it gonna be ugly under where the hinge attached? Is there a better way? I don't plan on reinstalling the doors ever but would prefer to keep everything undamaged if possible. I could grind off and punch out the hinge pin if the finished job would be better looking.

Any tips are appreciated and I'll have more questions. I'd been planning on buying something like a Kawasaki Mule for her but have you seen how much they want for that or anything like it? WAY OUT of my budget! And there are NO used ones anywhere. Thus she's getting a Samurai and I'm sure she'll love it.

Beats walking.

Phil
 

·
Registered
Joined
·
94 Posts
I pull my doors off all the time with just un-bolting them. Yes they are tight to begin but should come off reasonably well with a proper driver. Worst case scenario use approx 1/4" drill bit and drill until the head of the bolt falls off and then use set of needlenose vice grips to remove the stud portion. I then used a set of bolts that are from a GM product (I can't remember which vehicle) that I bought at the local hardware store in a package. Another option is just drill out the hinge pin itself.

It may be a little ugly under the hinge if the doors have never been off, the factory paint came off with my hinges but it was easy to touch up.

As far as windshield I have allen bolts holding mine together that leads me to believe that it has been removed before and I can't really comment further.

Good luck! Lucky girl getting a gift like this for X-mas!
 

·
Registered
Joined
·
74 Posts
Discussion Starter #3
Thanks, PP. That's how it LOOKED but after seeing BillJohn's mention of loctite on the windshield screws I was beginning to wonder if the whole vehicle was put together with the stuff. I'm sure the doors have never been off before but I was unsure whether the body was painted before they were originally installed or after.

Guess I'll try and have some touch-up paint on hand.

Phil
 

·
Premium Member
Joined
·
1,862 Posts
You can also cut the hinges with a dremel tool and make it so that you can remove the doors or replace them in about 20 seconds... each. Maybe less. The first time I did a hinge cut on a zook (the one in the picture), it took me about 30 minutes. I also did it without removing the hinges from the vehicle... so no fighting the screws. The doors will only come off as it approaches a 90 degree angle from the vehicle.

Door Hinge
 

·
Registered
Joined
·
201 Posts
for the windshield bolts, just have a little torch and warm it up, will liquefy the lock tite stuff and then you will be able to unscrew them.


on the doors, just cut the top part of the hinge, then you will be able to slide the doors off at anytime, and no problem with paint issues...i will look for a link on how to, be right back.....look at this





that is a little bling, but look at the design, same concept - cutting the top part of the hinge.

best of luck
 

·
Registered
Joined
·
201 Posts
[edit] post deleted [edit]

you Bill are better than i, have beat me aat the punch....twice :lol:

but yeah you will love riding with the doors off option. heck i leave the top on and have all windows out and doors off :cool:
 

·
Registered
Joined
·
74 Posts
Discussion Starter #9
Thanks Mule and Bill! I hope to be working on this Saturday, but I'm in the woods with no power so I'll attempt to remove the screws and then modify the hinges and reinstall later. That'll solve the touch-up paint problem at least.

And Bill.... thanks for the link to ZNO and the detailed instructions at your site. I've looked at your pages for over a month and never saw the door hinge instructions. Those billet hinges are nice but I think I'll be doing the mod as you describe.

I don't have a propane torch but do have oxy-acetelene, however I'm hoping the impact driver will be sufficient. Under the hinges looks exactly as I was expecting (this one is white too) so I'll mod and reinstall the hinge halves.

Phil
 

·
Registered
Joined
·
74 Posts
Discussion Starter #10
I was able to loosen all the screws using the impact driver. Only one stripped (lower windshield bracket, removing the windshield with the two upper screws and will drill the lower out later).

Now that they're loose, I'll try to take everything off Saturday (only day without rain). Thanks for your help.

Phil
 

·
Premium Member
Joined
·
1,862 Posts
I was able to loosen all the screws using the impact driver. Only one stripped (lower windshield bracket, removing the windshield with the two upper screws and will drill the lower out later).

Now that they're loose, I'll try to take everything off Saturday (only day without rain). Thanks for your help.

Phil
Another way i have found that works (especially when you have already stripped the slot for the screwdriver) is to use a grinder to take off the head of the screw. The heat from the grinding will melt the locking compound (locktite) and when you have removed the hinge you will have a bit sticking out to grip with a pair of vice grips. just watch out, what is left will be hot.
 

·
Registered
Joined
·
74 Posts
Discussion Starter #12
Thanks, Bill. I'll try the 1/4" drill bit first since it'd do less damage to the bracket but if there's any problem I'll break out the grinder.

I'm sure glad you had instructions to use the impact driver... I'd have gotten nowhere without it.

Phil
 

·
Registered
Joined
·
181 Posts
Just a thought, here in B.C., it's illegal and a $50 fine for driving with no doors.
(yea and what about motorcycles) anyway I picked up some netting, (you know like Nascar drivers have on their windows), I picked up a set from the local army surplus store for cheap. Check out my avitar, I think they look pretty good and their legal and still give you the feeling of no doors.
 

·
Premium Member
Joined
·
1,862 Posts
Just a thought, here in B.C., it's illegal and a $50 fine for driving with no doors.
(yea and what about motorcycles) anyway I picked up some netting, (you know like Nascar drivers have on their windows), I picked up a set from the local army surplus store for cheap. Check out my avitar, I think they look pretty good and their legal and still give you the feeling of no doors.
Good point. Here in Texas it isn't illegal but the spouse sure appreciates the doors when we start to get tippy in the rocks. I would suggest looking around for a set of tube doors. There are a few folks (smaller shops) that can make them for the zook. If you guys have an interest in them I can see if the folks I know of still make them.
 

·
Registered
Joined
·
94 Posts
Grats, that is a great idea. I also live in BC and we have had this exact discussion with a DOT guy at some of our ICLICK/NCOAS club meetings. It is a little cold today for no doors (-30 celcius right now) It will give me some time to fab something up. You should start a thread and give us a better idea how the are created.
 

·
Registered
Joined
·
181 Posts
Well if your familiar with the Canadian Army's Italis (I think that's how you spell it) Canada's answer to the Hummer, LOL,:haha: The netting is standard
on those vehicles and my local army surplus carried them, they fix perfectly without any modifications, just need minor hardware to attach to your door openings. Also to get in and out, they use seat belt connections on the A piller side of the door opening.
 

·
Registered
Joined
·
94 Posts
My buddy lives in coquitlam so if you could pass on the info for what Surplus store you use I could get him to grab a set for me.
 

·
Registered
Joined
·
74 Posts
Discussion Starter #18
Just a thought, here in B.C., it's illegal and a $50 fine for driving with no doors.
Prob'ly illegal here in CA too but I've never checked. This zook is gonna be non-opped with DMV and won't see pavement again. I've posted a question (so far unanswered) about the rollover tendency of a Samurai at 3mph since that is about as fast as this one will ever go. For years my wife hasn't been able to 'tour' our parcel without hiking... our Chebby pickup is too big for the trails and my little tractor (like this one WWW.MOSSROAD.COM) only seats one. I bought a little trailer years ago to let her ride and it rolled over on a sidehill (luckily no injuries, my mother-in-law was also on that ride.... ewwww that could've been BAD).


The Samurai is perfect. SMALL. simple. fun.

Future mods (and questions here) will be lowering the transfer case gear ratio, among other things, and reducing any rollover tendencies. I'll forbid her from getting near ANY orange cones since that seems to be the common factor in all the rollovers.


Phil
 

·
Registered
Joined
·
94 Posts
I'm sure we are all familiar the "Consumer Reports" testing of the Samurai, what a joke. As a rough comparison I have 8-9" of lift and use my rig everyday in offroad conditions and I have never felt that it was going over. I have had it safely on 3 wheels but it wasn't an uncomfortable feeling...even with 2 kids in car seats strapped in. I also (as of last night) accidently drifted around an icy corner at 40 mph and caught a curb (damn lockers on ice!) with no rollover feeling. And lastly they have a rollbar for a reason. I taught my kids to grab the bottom of the seat or there shoulder belt if they felt un-easy. This stops the tendency to put your arm out and break your fall.
 

·
Registered
Joined
·
74 Posts
Discussion Starter #20
I have never felt that it was going over. I have had it safely on 3 wheels but it wasn't an uncomfortable feeling...even with 2 kids in car seats strapped in.
Thanks PP. I wish you were closer as we have at least two things in common (I have over 50 beer signs in 'my' little half-bathroom).

The other present she's getting is a booster seat so she'll be able to take her favorite grandkid on the trails with her.

Good advice on grabbing the bottom of the seat. I'll pass it on. And of course I'm leaving the roll bar on.

Phil
 
1 - 20 of 30 Posts
Top