New Moab Samurai project

[drtsqrl]

Those of you that have wheeled with my friend Jim in his gray "BADCAT" Samurai know that it is very capable, but he decided he wanted to take it up a notch. So we are gathering parts and starting on his new rig. It's going to be a slow build, but hopefully will be ready by next fall.






Here are the plans:

• Samurai frame, tub, and hood
• Chevy 4.3 tbi with TH350 and an Atlas
• Dana 44 front and 12-Bolt rear salvaged from that abandoned Blazer we hauled off Kane Creek last summer. Re-built with chromo's, 5.13's, and Detroits.
• 106" wheelbase +/-
• 4-link rear, 3-link w/panhard front
• Ballistic Hybrid air/coilover shocks
• 39.5 Pitbulls

Here's a few pics. I'll update as we go.

Got the Samurai for free last summer.

Had some fun with the plasma and sawzall.

The tub is pretty much rust-free.

The 4.3 should fit great.

Axles ready to go.

 

[Herzog]

Finally we get to see you guys work that samurai magic. Subscribed.

 

[surgeryturtle]

Wow! Chief9 is going to be a huge Sami. He'll be as big as Redroxx! Did we ever decide the failed obstacle that caused this madness? My vote is for Widowmaker.....

 

[Thursty]

Awesome! Can't wait to see the progress.

 

[mbryson]

Wow. A documented Steven's build. AWESOME. Subscribed

 

[Bear T]

Awesome. Can't wait to see this one!!!

 

[Gravy]

killer mega excited steve

 

[iamsparticus]

way excited can't wait to see the final product

 

[drtsqrl]

Too cold and snowy to go wheelin' this weekend, so we got some done on the project. Our goals are to build a very capable rig, but it still has to be street legal (or at least legal enough to get by). Jim is retired, lives in Moab, and virtually all of his wheeling is done here (100+ trail days in 2009!), and he wants to be able to drive to and from the trails. He needs room in the back for a 40" spare tire, plus tools and room for equipment when he does trail work. So, we will be building a bed in the rear, full fender wells, and tube fenders. Here are some pics from the last few days.

We stripped the frame of all unnecessary brackets and crossmembers, and built some sliders from 2x4 box steel. The front and rear frame tubes were extended with the same material.

Set the tub back on to make sure everything lined up.

The front frame tubes were built 4 inches wider than stock to allow more room for the headers. We will cut the frame tubes to the correct length once we figure out exactly where the motor, radiator, etc is located.

We built the basic cage structure from the A-pillar back. Jim chose and exo-design for better interior and head room. We still have more triangulation and gussets to fab, but we ran out of tubing.

The cage is bolted to the sliders and rear bumper using poly bushings.


Jim ordered a TH350 and a 4-speed Atlas last week, but they probably won't be in till mid-January. In the meantime do some more work on the cage, and maybe start setting up the rear suspension.

 

[Herzog]

Loving it so far!

 

[Thursty]

Cool!

 

[zukijames]

you got more work done in a weekend then i have in the last 5 months

 

[drtsqrl]

Well, it's been snowing like crazy the last couple days in Moab, so that means no work and no wheelin. Might as well get some more done on the project.

The Yukon front shafts showed up yesterday.

Tires also came in. 39x14.5x17 Pitbull Maddogs. They measure about 38" mounted on 9.5" Allied beadlocks at 15 psi.

Took the cage and tub off, and flipped the frame upside down to build the control arm mounts.

We used a Ruff Stuff truss and a Ballistic mount for the axle end control arms.

Tire mounted and articulated to full stuff.

Control arms are 2" x .25 wall DOM lowers and 1.5" x .25 wall DOM uppers. Joints are Ballistic with weld-in adapters. The lowers are 34" and the uppers are 28.5" (center of axle to center of frame end joint). Antisquat is 80%. The small crossmember just forward of the axle will need to be moved to provide clearance for the upper control arms, and we'll need to cut a clearance hole in the bed for the axle control arm mounts at full stuff. This will give us a frame height of 21" and about 5" of uptravel on the shocks.

Ran some diagonals from the cage to the frame to give a bit of lateral stiffness.

 

[drtsqrl]

We have been waiting for parts for a while, but we did get the cage welded up and painted. We set the tub in place, and bolted the cage on (temporarily), the started a front tube clip and bolted the hood back on.

Then last week, we finally got some of the parts in we have been waiting for.


Put the primary spring on the rear shocks so we could check clearances, and fab'd up some mounts.




Boxed in the upper mounts.


Set the motor and trans in place with the tube clip bolted on.


Cut the tunnel out for the transmission. We'll build a new cover later.


Fab'd some motor mounts using 1/4 x 2 DOM and some poly bushings.


Set the front axle in place and started to fab some control arms.


Starting to look like something!



I'm hoping to get the front suspension built in the next week or so. The Atlas is supposed to be here in a couple of weeks, so the cage and tub will come back off then to make cross members and weld the front control arm brackets.

 

[Gravy]

Great work so far Jeff!

 

[Samuraiman]

Man you guys and your buggy threads are going to cost me money. Whats up with all that. I have a had a buggy in my mind for a long time. HMMM summers coming. Looking good Jeff.

 

[drtsqrl]

So we have been making progress, but I've just been too lazy to post for awhile. The suspension is pretty much complete, as well as a few other things. Right now we are still waiting on the Atlas. We took the cage and tub back off a week or so ago, and Jim is working on some details, such as body work and painting. Hopefully the t-case will arrive soon so we can get on with it. Here are a few pics:


Front shock mounts. The mounts are welded to the tube clip and bolted to the frame for easy removal.


We decided to go with a single radius arm design for the front. Would have rather done a 3-link, but there was just no room to do what we wanted with this thing sitting so low. We have built a couple of similar designs with good results, so I'm hoping this one will also work well.


Upper link attachment.


Steering box is Toyota IFS.


Frame end lower front link. The mount is sleeved all the way through the frame.


15 gallon fuel cell from Summit Racing will be mounted in an angle iron frame and strapped down.


The rear cargo area is just big enough to fit a full-sized spare. Since this pic was taken, we built sheet metal sides / inner fenders.


Front end shot with the tire mounted.

 

[iamsparticus]

Look in good i love the build, makes me want to build my 4runner

 

[Freeriders98]

Could I get some more pics of you front clip? I am looking to tube mine and looking for some ideas! Thanks

 

[drtsqrl]

Could I get some more pics of you front clip? I am looking to tube mine and looking for some ideas! Thanks

Right now everything is disassembled down to the frame so I can build the t-case cross member and clearance the floor. Hopefully we'll have the tub and cage back in in a few weeks, and I'll have some more pics then.