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Discussion Starter #1 (Edited)
Hello I just purchased a 1986 Samurai. Everything's stock besides a missing backseat, top, new carb, door panels and tow along kit. It has 104,xxx miles and it isn't in perfect running order. It has some rust, ill post pictures below. My first concern is the areas of the rust, and the best ways to treat them. After treatment I plan on covering the dash, removing the seats, and rhino lining the entire thing. Now mechanically, it runs ok. It was running good for a couple days but it seemed to be acting up a little today. It was sputtering slightly, although the engine could have been cold, the thermostat was dipped way cold. It could need a timing adjustment, bad plugs, maybe a dirty head? Just throwin things out there. But my main concern is the transmission. It's quit loud at higher speed and especially 4th and 5th gear. I'm almost positive it's the transmission, because riding in gear it's quiet, but it whines with the throttle. It's high pitched, sounds like a bad bearing? Just want to diagnose the problem ASAP so I'm not stranded one day. Other than that the 4wd light is constantly on. Any advice or comments are greatly appreciated. Thanks :)









 

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Discussion Starter #2
Quick bump and edit:
As far as the transmission noise goes, I know they aren't quiet in general. But it's an obvious whizzing whining and/or buzzing noise during acceleration. Similar to the noise a car makes going fast in reverse. I will add it ran better the day I bought it in relation to today. I also didn't mention that the cat converter is rusty. In the process of driving it on the highway for more than 100 miles home, I suspect the constant driving might have weakened the rust spots on the cat, causing holes and an exhaust leak. I stuck my hand by the cat during idle and I could clearly feel exhaust heat, so I'm wondering if the sputtering today would be caused by this? Thanks again:grin:
 

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In regards to the transmission to the usual checks and see the condition just as a start. For the seats I am doing a demonstration on my site since I am taking on seat out. It will be on DIYZuke shortly. For the rust as a temporary fix use some rust converter which is normally pretty cheap. After that if you don't feel like doing any metal work maybe use some fiberglass. Hope this helps
 

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Discussion Starter #4
In regards to the transmission to the usual checks and see the condition just as a start. For the seats I am doing a demonstration on my site since I am taking on seat out. It will be on DIYZuke shortly. For the rust as a temporary fix use some rust converter which is normally pretty cheap. After that if you don't feel like doing any metal work maybe use some fiberglass. Hope this helps
In regards to the transmission, I would like to figure out the cause of the noise before I take it apart and realize I would need extra parts and what-not. It is a whining noise in 3rd to 5th gears, it rides quiet in gear, only whines during acceleration, especially the beginning. I am also hear a rattling metal noise, maybe the flex plate? Or the bearing to the flex plate? Just wondering what noises to look for.

Now for the rust I plan on treating it here and there and once the rust is all covered and smooth I plan on rhino lining it inside and out.. As for the metal work is there a possible way to do it without welding? If not, what is the cheapest welding source? I wouldn't mind getting grinders and sanders for personal use as it is, but I would like to find methods that don't necessarily involve bondo. Your Fiberglass idea sounded promising. I just want the rust to be treated and sealed prior to painting so that I can stop as much rust as possible
 

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I have heard of having other ways such as soldering in small sports not sure how well that would work. You can sometimes get a cheap welder even if its used. No matter what way you'll need to treat it and grind out as far as the rust goes to ensure its all gone and then do your work. I have a few small spots on mine and I have not decided which way I will be going but it will be on my site once I know maybe i'll do it both ways. For the transmission that I am relatively new too so I would not be the best for that. I would not want to lead you to the wrong direction.
 

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Discussion Starter #6 (Edited)
I have heard of having other ways such as soldering in small sports not sure how well that would work. You can sometimes get a cheap welder even if its used. No matter what way you'll need to treat it and grind out as far as the rust goes to ensure its all gone and then do your work. I have a few small spots on mine and I have not decided which way I will be going but it will be on my site once I know maybe i'll do it both ways. For the transmission that I am relatively new too so I would not be the best for that. I would not want to lead you to the wrong direction.
Appreciate the advice ill have to look more into types of soldering my only concern would be the strength of the bonds at the weld. Never thought about getting a used welder either haha I guess my question for that would be what type of welding is best for smaller applications? I just would like a small setup so it's not like I need a huge tank to run the welder

Edit: Would stick welding be a good option?
 

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you need a wire welder check out Northorn or Harbor fright or Lowes you can get one that runs on 120v and uses flux core wire no gas needed although gas will give a cleaner weld.

Mike
 
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