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Created by Matt Stocke
Aka "ZUKI4x4@AOL.COM"
The Project:
I bought my bone stock Samurai new in December of '94. I chose the Sammy because
I wanted something unique yet small and light. I wanted something new because
this was my first project that was long term, and didn't want to inherit someone
else's buildup mistakes or used vehicle problems. I am an engineer who works on
new interior parts that will go on GM vehicles and trucks. My current project is
some misc. interior parts on the new GM full size P/U due in 1999.
Suspension:
I started with 1000 miles on the odometer with a 3" Calmini spring lift and
a 3" body lift with 30 x 9.50 BFG MT's. After a year, I wanted a better
ride, more articulation, and I wanted an ARB frame mounted bumper with a Warn
5000lb winch. This would look a little funny with the body lift, but I
needed that much lift to clear the soon to come 31 x 11.50 Goodyear MT's. So I
started the Spring over project.
 After
tons of research and lots of telephone conversations with Tim at Wildwest
Offroad (see their web page), I got the necessary parts and part numbers for the
SPOA (longer brake lines, custom upper and lower front shock mounts, and custom
upper angled shock mount from Ken, aka ZUK). I removed the body lift, the old
springs, and took the axles off.
The first welder screwed up, and I had to have second shop re-do the perches
(they also did all of the shock mounts). Make sure the welder knows what they
are doing! I re-assembled everything with Wildwest longer shackles. I used the
stock rubber bushings for better ride and improved articulation. I replaced the
bumpstops with 2 1/2" progressive rate urethanes in the stock location. The
ride and movement are incredible! The shocks (for now) are Gabriel Red Ryder gas
because they are cheap and lightly valved. I also added a Wildwest non-weld on ladder
bar to control spring wrap, it retains the articulation
too.
Engine:
Taylor wires with a Calmini header is all so far - maybe Weber carbs later - I
hate this lack of power!
Body Mods:
I installed diamond tread rockers (I custom made them) to extend full length
which required bottom fender flare trimming. I also flattened and trimmed the
body seams for less tire contact. I trimmed the bottom rear "bed"
corners for less tire contact. Believe me this is all hard with only a craftsmen
moto tool and tin snips!
Bumpers:
In the front is an ARB bull bar and a 5000lb Warn winch which can come in real
handy (see photo of recovery). The new Warn 5000lb Warn has a slightly larger
drum housing than the 4500lb that the ARB bull bar was designed for (I didn't
find this out until I tried to assemble it), so I had to modify the cable
opening for clearance of the winch. In the rear, I custom made a rear bumper out
of 4"
square 3/16" wall tubing made to accept big rig standard tailights. The
entire bumper is TIG welded and completely
sealed, no holes or openings into the bumper. I also incorporated a receiver
hitch into the center for a Warn receiver shackle. It is mounted to the frame
with 8" x 6" x 1/2" steel plates welded to the bumper.
Interior, Rhino Lining, and other goodies:
I put a Tuffy storage box behind the front seats with a Hi-lift jack mounted to
it. I put a small tach in the dash, as well as a CB in the cubbyhole. I removed
the asphalt on the floor in prep for the Rhino Lining. After tons of prep and part
removal, I had the entire interior coated in Rhino Lining including the
storage box. The best part is the filling of all the useless little holes all
over the interior. The shop that performed the work did an OK job, but the
trimming and masking needed a little work before I re-assembled the inside. Ken
(aka ZUK) also made some removable
door hinges, and I made some door stops so I don't have to remove the straps
every time.
Future Plans:
I am buying a rebuilt GM alt with a custom bracket on it from a guy who did it
with his Sami. I am going to get a different pulley wheel to accomidate a new
type belt, and get a new belt of proper length. This should all hook up and get
me about 100-110 amp vs the 50amps I get now. To go with this I am getting an
Optima, maybe the newly released deep cycle Optima. No duals, don't need it . .
yet.
A painless wiring Cirkit Boss is on order to wire all the goodies including
the new Hella backup light mounted inside the spare tire. Front shock hoops for
longer shock with Rancho RS 9000's all around are soon. I also want to construct
a full cage mounted to the frame for protection. Eventually I will replace the
engine with a new one. I have not yet decided on what one yet, though (Quad 4,
Suzuki 1600, small V-6). A Snorkel is coming soon, and also a free flow exhaust
with a Supertrapp to complement the Calmini header I already have on the engine.
Current spec. List
- Stock engine
- Taylor Wires
- Calmini Header
- ARB Bull Bar
- Warn 5000lb Winch
- Hi-lift Jack
- Diamond Tread Rockers
- 31 x 11.50 Goodyear MT's
- 15 x 7.5 American Racing Gamblers
- Spring Over Conversion
- 1 1/2" longer shackles
- Custom upper and lower f/r shock mounts
- Tuffy storage box
- Tachometer
- CB with external speaker
- Custom built rear bumper
- Wet Okole seat covers
- Rhino Lining interior
- Removable door hinges w/ door stops
- 150 watt stainless KC's
- Warn receiver shackle
- Hella FF backup light
Email Matt Stocke at: Zuki4X4@AOL.COM for
further information.
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