Project Samurai, Part 4: Engine, Fabricaiton Work and More

Jul. 12, 2012 By Rick Sieman

Project Samurai, Part 4 Continued

We took the transmission and transfer cases to Karway to be inspected while we had them out. While we were there, we added a set of Trail Gear's 4.70 gears to the Toyota transfer case, which was an easy task. Basic tools and a grinder are all that's needed to get the job done. We took a rotary file to the case and then ground down one of the shift dogs to make room for the larger gear. We reassembled the transfer cases using Advanced Adapters’ dual case setup and then installed it in the vehicle.

With the cage in, we visited our local junkyard to look for a tilt wheel without airbags that would fit in such a small vehicle. After an exhaustive search, we found one from a 1995 Chevy Lumina. We had to cut the column in half and lengthen it to make it work. Don't be intimidated to do this. You do not have to pull the column completely apart. Take your time and use common sense.

We got all of our steering products from Howe Performance: power steering pumps, steering box, hydraulic rams, power steering coolers and the u-joints to connect the steering to the steering box. After mounting the steering box to the frame and determining the stroke of the pitman arm from lock to lock, we could now decide where the ram would mount for our hydraulic assist. This ram may assist and make your steering slightly easier, although that's not its primary use. It's used to protect the sector shaft and the steering box.  

Next, we needed to get the motor hoses and hydraulics plumbed. Throughout my many years of being in the automotive industry and in and out of hydraulic shops looking for fittings and hoses, it’s safe to say that most shops carry fittings for heavy equipment and industrial use. Period. 

It's difficult to find a place that carries fittings adaptable to automotive. On this extreme build, Parker Hoses had everything we needed, except for two fittings that were unavailable. Matt cut two fittings in half and was able to weld them together and made the fitting needed in 20 minutes. The end result looked and worked like an OEM piece. Keep in mind, this vehicle did not have any plumbing installed prior to going to the Parker Store. There is an incredible amount of hydraulic lines, fuel lines and brake lines.

This was no small task! Everything needed was in house. These guys are fantastic. They are highly knowledgeable and personable and have an extensive inventory. They support everything from drag racing and off-road to tuners. If the part is not available, they can probably make it, and normally they’d be willing to try. You've heard me mention the importance of tech support from companies you deal with. The Parker Store has it all.


Other Project Samurai Stories
Part 3 – Cage and Suspension Work

Part 2 – Fabrication Work Begins

Part 1 – Turbo-Diesel Jeep Killer? Here’s the hydraulic ram hooked to the Spidertax housing for the rear steering. There are individual brake lines for the turn brakes.

Oil cooler and power steering lines are wrapped in protective orange fire sleeves.

Brake lines were plumbed to the calipers.  

Flexible brake lines were run down the 4-link arms to a bulk head fitting, and then another flexible line went to the calipers.

This is the fitting going to the power steering pump that has a sharp 90-degree bend on it. No one makes this fitting, so it had to be fabricated by hand.

Here’s the engine plate and timing belt cover in the roughed-out condition before the serious machining.

All the belts and sprockets lined up perfectly after the machining.

The ‘Y’ was machined from a solid block of aluminum.

Randy's Ring and Pinion
10411 Airport Road
Everett, Wa.98204
Neal Hollingsworth ext. 5587
Kevin ext 5581

Trail Tough Products
1031 Narregan St.
Medford, Or. 97501
supplier Brent Bradshaw

Ron Davis Radiators
7334 N 108th Ave.
Glendale, Az. 85307

King Shocks
12842 Joy St.
Garden Grove, Ca. 92840
Mike or Brett

Currie Enterprises
1480 N Tustin Ave.
Anaheim, Ca. 92807

RCV Performance
611 Beacon St
Loves Park, Il. 61111
765-362-1909 765-307-7441
Owners Craig and John 815-877-7473

Rally Tops
Los Angeles, Ca
Jerry Mancini -

Howe Performance
12476 Julian Ave
Lakeside, Ca.92046

Shake and Shoot Bedliner
Dominion Sure Seal
6175 Danville Road
Mmississauga, Ontario,
Canada  L5T2H7

Acme Adapters
P O Box 2258
Clackamas, Or. 97015
Jeff Kerr

King One Winch
18424 Mount Langley St
Fountain Valley, Ca. 92708

Rocky Road Outfitters
1920 WendellLane
Heber, Utah 84032

Lithionics Battery
2449 McMullen Booth Rd
Clearwater, Fla. 33759
Steve Tartaglia

Kerma TDI
3000 Eaglebend Dr
Box 2142
Avon, Co.  81620

Rigid Industries
4641 E Ivy St
Mesa, Az. 85205
Paul and Damon

Advance Adapter
4320 Aerotech Center Way
Paso Robles, Ca.  93446

Reid Racing
1917 Oak Park Blvd
Pleasant Hill, Ca. 94523

7510 Hygiene road
Longmont, co. 80503

FK Rod Ends
865 W Queen St.
Southington, Ct. 06489

Yukon Gear and Axle
10411 Airport Road
Everett, Wa.98204

1845 Grand Ave
Phoenix, Az. 85007
Tawn Berman

Mittler Bros. MAchine and Tool
10 Cooperative Way
Wright City, Missouri 63390
Mike or Pam

FASS Fuel Systems
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