Zuk on 38's

[dirtyoldman]

Met a guy once who somehow put Warn locking hubs on the rear axle of his modded Samuri..he said less wear and tear on the innards when towed behind his RV....made sense

 

[Tan Zuk]

Met a guy once who somehow put Warn locking hubs on the rear axle of his modded Samuri..he said less wear and tear on the innards when towed behind his RV....made sense

Haven't ever heard of that one. Nice tip tho

 

[Tan Zuk]

I also do fiberglass work ( Not By Choice)

After installing the front Shrock Work bumper it looked like it was missing something. I decided to make a lower valance to conceal the 8” frame extension. I’m also getting a bit older and needed an additional step. I decided to make some running boards for the 2nd step. The back tire is being used as the 1st.

The bumpers, fiberglass pieces and the body moldings were Rhino Lined to match the paint for durability.


Front Lower Valance

Side View Running Board

Rear Side View Running Boards

 

[Tan Zuk]

Front Frame Extension is 8” and is level to the ground instead of following the frame. I also smooth out all my welds. This tends to add a lot more time to a build just my preference.

 

[Tan Zuk]

The Rig is rather high as you can see. This presented some unique problems trying to get the steering geometry setup without a steep angle. I will go through the mods and the parts that needed to be made to correct the problems in the next couple of posts.


I also have an unusual steering set up with the FJ80 box, Lifted YJ springs and the addition of the Panhard bar just to make it more complicated. There is not a great deal of room to work with when you have to add a shock tower in the mix on the DS.



Steering Front View. I still need to do some welding and fitting yet.
The steering geometry is set at 5 degrees.

Panhard Bar was bent at one end to 5 degrees to shorten the PS mounting bracket. I have a 3/4 Heim in the DS and will be using a suspension bushing on the PS. This will help the bar from flopping with the bend in it.

Extended High Steer Arm was made from 8620 the same material the 6 shooter arm is made out of. These pieces will be tig welded together. The block started off at 30 pounds. After several hours of whittling I got it down to a more manageable 9 pounds.

 

[Tan Zuk]

To help eliminate one problem:

I started off by dropping the FJ80 box 1” to help decrees the drag link angle. The Frame was notched 1” and the holes filled in the frame before adding the frame plates. This was done to the inside, outside, top, bottom and the notch.

1" Frame Drop Mod

1/4 Outside Drop Plate

Outside plate mounted with DOM bushings and rosset welding holes.

Inside plate mounted

 

[Tan Zuk]

Now that I have the FJ80 box mod done. The next issue was mounts for shocks, panhard and bump stops. This took me quite a while to come up with something to incorporate all of this into 2 mounts.

Note:

These mounts were made to sandwich over the TG Shock and Ball support Brackets on both sides.



Driver Side (Side View) Shock Mount and Bumpstop Pad

Passenger Side (Rear View) Shock Mount ,Panhard Bracket and Bumpstop Pad that still needs to be added to the top.

Passenger Side (Side View) Shock Mount ,Panhard Bracket and Bumpstop Pad

Passenger Side (Front View) Shock Mount ,Panhard Bracket and Bumpstop Pad

Drivers Side Frame Panhard Bracket and Lower Bumpstop Mount

NOTE:

Thought I would add that I switched over to the 6 shooters after the pics were taken.

 

[Tan Zuk]

This is the side that got to be very congested.


Components:
Fj80 Box
Panhard Bar Bracket
Ford Shock Tower

Mods:
1" Frame Notch
Frame Plating
Bump Out for the Steering U-Joint and Box Plating

Drivers Side Bumpstop Mounting and Pad Locations. There will be additional bracing added to the Panhard Bar Mount for the stress of the Bumpstop Action.

FJ80 Box 1/2 Extension Block. I added this to lengthen the Drag Link. This will also cut down on the angle and decrease the rotational effects of the Panhard Bar.

Note:

The Drag Link length is 37 1/2 inches. Anything over 36 inches is ideal for a Panhard Bar applications.

 

[Tan Zuk]

Ok, there is a lot of info there to look at. I will post more later this way you can ask questions if needed.

Thanks for stopping in and following along

 

[66nova]

That is one cool build. definitely not going to see another one. Nice work.


Sent from Ft. Worth TX