Build "Salt shaker" the Suzuki samurai build

[Roastchestnuts]

Some updates on the samurai: It runs great, I used it a bunch at the end of the summer. The 32/36 is a perfect carb for this little engine. I still need to install the windshield. Once I do that I want to get a bikini top for it.

I am probably going to install different T-case gears. I think this would help the little sammy on the beach. it boggs somtimes in 2nd with the tires. I have decided on keeping a similar tire size. like a 31x10.50. I will purchase the new tires and rims sometime this winter. I thought I didn't like the look but its fun in the way hotwheels cars are and its growing on me for sure. I am thinking chrome rims of some sort would look really good under it.

I need to find a new targa bar and doors. the doors had too many rust holes for me to want to redo them. the hardware is all still good though. I just need some shells for a good price. I got a new old land cruiser so my work on this samurai has slowed down.

The cheep mirrors will be replaced. They flop around too much for me and just are annoying. Eventully I want to either get my seats reupolstered or buy new ones too.

All in all this samurai might become my daily driver in the summers. its really awesome to zip around in it.

Look I found a jimny friend.

At the surf shops 40th anniversary party in July

 

[Roastchestnuts]

Updates:

I am still loving this thing! its so great for around here. I have been a little slack on getting back on this project. I still need to buy tires but I had to post pone buying them because I bought another land cruiser project. this time my dream fj55! Back to the samurai - I tried getting the original windshield in back in july I think and I immediately broke it. I had bought another peice of glass from suzukiparts usa I think. last week I left the frame, gasket and windshield with my inlaws and they are going to take it to eastern auto glass in New bern NC where they leave. I am hoping to have it back soonish. My wife is going to New Bern at the end of next week. Ill be sure to post a pictures.

The mirrors I bought from India via ebay are trash. firstly they sent me two passenger side ones so I had to modify them. they are also super floppy and you cant tighten them down. (what did I expect for 18$ because of this I bought north American samurai spec ones and I am going to mount them on the cowl.

Some other projects I need to get on - I gotta strip and paint the targa bar. (I have not decided yet if I am going to just replace this or not.) and I need to find doors. the ones that it came with are kinda trash. I am going to start looking soon.

Eventually I will find some seats or get the seats reupholstered.

 

[Roastchestnuts]

Used the samurai this past Friday for my Friday automotive club class to show the students how to change diff gear oil and how to set engine timing on a dizzy style motor. the students were super engaged and it was a good time! @SC-Cruiser snapped this shot. He told me this is how you get your projects done so fast! I told him they usually break more than they fix. They locked the tool box this time. We had not set the combination code up yet.

Unfortunately I am still waiting on my flipping windsheild. I used the Eastern Auto Glass in New Bern. I honestly cant say I recommend them. they have had my frame, new glass, and gasket for almost two weeks and when my wife was off the island she stopped by to pick it up and they had not even gotten to it yet... I know this is an easy job for them since its just the frame. Honestly I should have just attempted it again my self. They told my wife they would call back today. I feel like its a quick job if you are trained in just glass. But I am annoyed to say the least.

Other updates: I am going to buy new targa bars and support for it. I started looking at the targa bar and realized that it was way more rusty inside than I thought. Lots of places had to much rust for me to save.

still on the look out for doors close by. If anybody has any let me know! the hardware and glass in mine is good but the window channel is shot on one and the bottom is so rotted out IDK if its worth my time in saving it.

 

[Roastchestnuts]

Ordered a few parts for the samurai. small stuff like hood prop grommets and timing cover and rear handles for the rear seat. I am getting worried about parts availability because of the stupid terrifs.... I might go ahead and buy a targa bar for the sammy. I also want to buy a bikini top for when I get my windshield back. some other parts that I need to buy are the interior panels for the rear. I think it would clean up the rear quite nice.

I forgot to mention! I replaced the mirrors with the north American spec ones that go on the door. I mounted them on the cowl. It looks a little more jeepy than I want but the old once were usless at staying adjusted. Ill post a picture when Its not raining! they are installed on the photo above though.


Photo dump of the samurai over the summer below:

I love the new grill!

My current fleet

 

[spookizuk]

Wow! I'm not sure where to begin - this build has been really great to read through, and its inspiring me to make progress on my own. I just made my IH8MUD account to follow this thread and chime in. I remember seeing this exact Samurai on Marketplace often (I'm up in the DC area). I decided to pass on it because I didn't love the front bumper, and I went with another NC samurai. Mine has very similar rust issues that I've been pulling my hair out trying to address, especially since much of it was hidden with filler/fiberglass.... Did you have much rust around the body mounts, especially under the front seats? Mine are SO rusted.

The body work and the paint look fantastic. You've made progress so much faster than I have. Hats off to you!

 

[Roastchestnuts]

Wow! I'm not sure where to begin - this build has been really great to read through, and its inspiring me to make progress on my own. I just made my IH8MUD account to follow this thread and chime in. I remember seeing this exact Samurai on Marketplace often (I'm up in the DC area). I decided to pass on it because I didn't love the front bumper, and I went with another NC samurai. Mine has very similar rust issues that I've been pulling my hair out trying to address, especially since much of it was hidden with filler/fiberglass.... Did you have much rust around the body mounts, especially under the front seats? Mine are SO rusted.

The body work and the paint look fantastic. You've made progress so much faster than I have. Hats off to you!

Thanks man! yeah the front bumper was goofy because somebody did a shackle reversal and when they did that they welded up some 2x4 steel in the front. and removed the factory bumper. Not really sure why they did it the way they did. its very sturdy. a little more work to Undo though. I have been chewing on ideas to mount a factory bumper to the front.. I have one but it needs some fabrication for sure.

No rust on the body mounts thankfully but some under the rear seat where the tub is reinforced. I just welded in patches there and called it a day. I am hoping to get my windshield back soon too. That will be a huge plus with driving around. I also want to purchase some factory wheels at some point. I think they would look alot better. I might have to run a spacer with that though.

It certainly was way more rusty than I thought. (not anymore though ) The guy I bought it from I know and he lives in my little town and I remember this samurai back in 2013 when he first got it here. It actually made me want one! I had no idea id get that one haha. he was not hiding anything. there was more in hidden spots than he thought.

 

[spookizuk]

Thanks man! yeah the front bumper was goofy because somebody did a shackle reversal and when they did that they welded up some 2x4 steel in the front. and removed the factory bumper. Not really sure why they did it the way they did. its very sturdy. a little more work to Undo though. I have been chewing on ideas to mount a factory bumper to the front.. I have one but it needs some fabrication for sure.

No rust on the body mounts thankfully but some under the rear seat where the tub is reinforced. I just welded in patches there and called it a day. I am hoping to get my windshield back soon too. That will be a huge plus with driving around. I also want to purchase some factory wheels at some point. I think they would look alot better. I might have to run a spacer with that though.

It certainly was way more rusty than I thought. (not anymore though ) The guy I bought it from I know and he lives in my little town and I remember this samurai back in 2013 when he first got it here. It actually made me want one! I had no idea id get that one haha. he was not hiding anything. there was more in hidden spots than he thought.

For the front bumper, would you still be able to clear those tires? I'd think they might rub, but I also don't know the kind of flex you're seeing on the dunes and such. I just pulled my dash and windshield frame for the first time today. I don't know about the frame, but the cowling panel it mounts to might have to go.

 

[Roastchestnuts]

For the front bumper, would you still be able to clear those tires? I'd think they might rub, but I also don't know the kind of flex you're seeing on the dunes and such. I just pulled my dash and windshield frame for the first time today. I don't know about the frame, but the cowling panel it mounts to might have to go.

Yeah some trimming is required. But I think It would look so much better. Even If I shorten it or trim the sides. I have the power of the MIG welder at my fingertips. I just need to dive in and see what I come up with.

Best mod you can do on the cheep for the samurai is the fold down windsheild kit! I am so glad I did mine. its going to come in handy in the summer! Also I had to weld up the cowl where the windshield attaches to the frame. I made patches with flat 20 gage, a cheep harbor freight brake, hammer and an anvil. It worked out. used nutserts for mounting.

My original frame was toast! way worse than I thought too. it was the single most rusty thing on the samurai. I am surprised that it held the glass in actually.

 

[Roastchestnuts]

More bad news.... after 3 or 4 weeks (I cant remember witch) Eastern Autoglass still has not gotten my windshield done. I called them today to see whats up and they said the glass was just too tight for fitment. and they didnt want to break it. They said they had 1/8th of wiggle room(dont know why they told me this). They are going to try and cut different glass on their own and see if that will work. But honestly I would rather them just try and get the one that I supplied in. The glass is oem suzuki . and if they break it we would be in the exact same spot we are witch is getting another sheet of glass made.... . My guess is the windsheild frame tolerances on the Repop frame are a little too tight. Either way these guys should have gotten back to me sooner than this. it all Kinda smells like bull s*** to me.

 

[clrussell]

I’m not a glass guy..

However I’m fairly certain my uncle who is a glass guy has a belt sander just for glass.

I don’t see why you couldn’t trim a little off the glass and install.

Also I’m not a glass guy, more of an alcoholic redneck

 

[Roastchestnuts]

I’m not a glass guy..

However I’m fairly certain my uncle who is a glass guy has a belt sander just for glass.

I don’t see why you couldn’t trim a little off the glass and install.

Also I’m not a glass guy, more of an alcoholic redneck

yeah... I am not a glass guy either. however I did successfully get the fj40 glass back in in less time than they have had my samurai windshield. And I will say I was very angry after I wrote the above. However I do think the lack of communication and the fact that its actually been 4 weeks is unacceptable. I was called one time last week on Friday saying they were trying to get it done but were not going to get it in. Then I called yesterday after work and they said what I wrote above. at this point I just gotta see it through I feel like. I dont want to pick it up without it being done because its such a hassle with where I live.

really just want to get that windsheild back on so I can move forward with my project.

 

[Roastchestnuts]

So another update: still no word from the glass shop this week. they told me last Tuesday last week that they would get it done by the end of the week. I am going to call them this afternoon and if they still have not gotten the glass done I am going to get my inlaws to pick it up and I am going to take it some other place. Its been almost 5 weeks maybe more? I cant remember when they dropped it off it was so long ago. It was in early September.

I think I might try and do it myself and just risk breaking it. and if it breaks I might try a lexan windshield from low range off road IDK. If I was closer I would stop by every day till they got it done. I just think its horse s*** that they have not gotten it done. Hell if they cant do it just tell me you cant! I feel I have been patient enough. I will post more when I get more information from the auto glass shop.

 

[Roastchestnuts]

Called eastern auto glass 5 minutes ago and left a message. they called me back and told me they were grinding the class down to make it fit. witch was not communicated to me the last time I talked to them. They told me they were cutting a new sheet. But to grind the glass down they had to take it to another shop. They said they would contact me when it was done. I told them Id check in at the end of the week if I had not heard from them. Basically I am going to give it another week.

I hate to say this but I guess I just gotta see it through with them. They have not given me a quote yet. I hope they let me know before its installed. I am annoyed to say the least but I gotta put my energy into My Isuzu truck not the samurai right now instead of being frustrated at these people.

This is almost as bad as hassling the vintage teq parts guy to send me my orders!

 

[spookizuk]

Sorry to hear its such a hassle with them. Are you worried about the Lexan scratching or hazing?

 

[Roastchestnuts]

Sorry to hear its such a hassle with them. Are you worried about the Lexan scratching or hazing?

yeah its been frustrating. they are hopefully going to put in glass. but if they cant do that I am doing the lexan stuff and install my self. It will scratch over time. but the stuff low range off road is using seems to be pretty good. but I really need to move forward with this project. I want to put the soft top back on soon before it gets too cold!

 

[aztoyman]

Here is a video of a guy with a Toyota pickup that sands his windshield so he can install it with a rubber gasket instead of the US versions that are glued in. (We can't get the proper size glass here) He has to sand about 1/2 inch off. Go to about 11 minutes in for the sanding.

 

[Roastchestnuts]

Here is a video of a guy with a Toyota pickup that sands his windshield so he can install it with a rubber gasket instead of the US versions that are glued in. (We can't get the proper size glass here) He has to sand about 1/2 inch off. Go to about 11 minutes in for the sanding.

This just shows me that this glass shop should not take 5 weeks to even start doing this.... Hell I can do what this guys doing.

 

[Roastchestnuts]

I bought this little guy to make me feel better about my windshield hahaha. I m sure these little dash doors just get lost over time just like mine is missing. It will my nice to have it. I also finally found a good enough fuel hose cover for the interior. Mine was so rusted out I never re installed it. This one is crusty but savable for sure. Mine was rusted out an inch up from the lower mounting point.

 

[Roastchestnuts]

Drove it to work this morning.... flooded areas are finally started to go down thank goodness. 65 degrees feels much colder without a windshield....even when only going 25mph (the speed limit in town) I am ready to have that thing back as you all know.

 

[Roastchestnuts]

No real updates on the Samurai. I used it to pull my isuzu pup out of the swampy area its been. Its swampy because the flooding we have had on the island. Classic aftermath - its now not swampy but muddy. I did smash the crap out of my finger draining the gear oil out of the transmission of the isuzu pup. I read in the hayes manual I have that the Transmission takes 5w30 engine oil. IT for sure had gear oil in it. can anyone confirm that it takes 5w30 engine oil??

Ohh and classic Ebay... the fuel interior cover got refunded and it said the reasons was it was damaged or lost..... WTF! Well if anybody sees one for sale for a good price let me know!