"SPOOKIZUK" - 1988 Suzuki Samurai Restoration

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Joined
Oct 5, 2025
Threads
1
Messages
32
Location
Alexandria, VA
Hello all, this is my first thread here on IH8MUD. I'll show what I've started with, what I've done, where I'm going, etc. I originally made an Instagram and Youtube page for the car, which I'll still update, but I think this thread will be much better to document my progress and discuss with you all. This has been a turbulent, exciting, and frustrating journey so far, but I hope I can glean some knowledge and encouragement from you all!

Last year, as I was wrapping up college, I got bit by the Samurai bug. Someone had parked a bone-stock, pristine condition tin top along the highway, and I became obsessed with owning a Samurai as I passed it to and from my hometown. Unfortunately, the price tag was too high, especially for a recent college grad still living at home. But the desire for a Zook remained and after getting settled into my first apartment, I took to FB Marketplace. Every Samurai was either too expensive, too far away, or was too buggy-fied for my liking. My vision was for a tastefully modified, but still street-legal and possibly daily-drivable, Samurai for light city driving and weekend adventures out to the Blue Ridge Mountains.

Enter SPOOKIZUK, a 1988.5 red soft-top. When I purchased her (my girlfriend named her 'Cheri', so I refer to the car as a 'she' often) she already had:
Jeep YJ SPOA lift
Toyota Pickup axles
1.6L 16 valve engine swap
Winch front bumper
Shrockworks rear bumper and gas tank armor
Calmini roof rack
no-name (likely harbor freight) LED light bar, light pods, etc...

Here she is on the U-Haul trailer, behind my Rav4:

IMG_8968.webp


The front tire straps that come with the trailer barely fit around the 32" tires, they are aired down to about 8 PSI to get the strap all the way around. I picked up the Suzuki in Siler City, North Carolina, and getting it home was... challenging. I'll tell that full story in the next post. Here's the Samurai with the rising sun at a rest stop outside Petersburg, VA:
IMG_8971.webp

I have since learned that buying a vehicle at 11 PM after a 6 hour drive is not advisable. I was so intent on getting the car and starting my return to the DC area that I made a half-@$$ed inspection of the car, and should have at least considered if I was prepared for the scale of the project this car would become (as you'll read in later posts). After a quick test-drive around the seller's farm, we loaded the car up, secured the tires, and I was on my merry way at a blistering 45 mph. I did not rent a flat-bed trailer from UHaul, as the combined weight of that trailer and the samurai would likely have exceeded my Rav4's towing capacity. In retrospect, the best plan would have been to borrow my best friend's truck, rent a trailer that gets all four tires off the ground, and inspect the vehicle in broad daylight, prepared to walk away. But, despite all the problems I would come to discover, I'm still happy that I purchased the car I did. I just had no idea what I was getting myself into.

Prior to buying this car, I had ~0 mechanical/automotive experience. I had changed my own oil and brakes once, and 10 years ago, I welded two plates of scrap together at a summer camp just well enough to earn the Welding Merit Badge. So this thread is going to put my inexperience on broad display, and you're going to see a young man learn a lot of lessons 'the hard way'. I welcome any advice, tips, criticism, etc and I invite you all to tell me where I can do better. A year into this project, I still feel like I am totally in over my head, but I think that in going off the deep-end, I've forced myself to adapt.

It's getting a bit late but I'll catch the thread up on what issues I've discovered, what I've done to address them, and what I plan to do next. Thanks for reading, I'm excited to learn from this community!
 
Honestly from the few pictures it looks pretty good. I remember you said you found some rust. Rust is one of those thins that if you look for it you usually find it on old vehicles. I wonder if the person you bought it from regeared the Tcase for those big tires. Your doors are in great shape compared to mine! I look forward to seeing what you do with it. right out of collage is probibly the best time to buy a vehicle. Hopefully you dont have a mortage yet or a child to pay for! those two things really throw a wrench in fixing old stuff!
 
Honestly from the few pictures it looks pretty good. I remember you said you found some rust. Rust is one of those thins that if you look for it you usually find it on old vehicles. I wonder if the person you bought it from regeared the Tcase for those big tires. Your doors are in great shape compared to mine! I look forward to seeing what you do with it. right out of collage is probibly the best time to buy a vehicle. Hopefully you dont have a mortage yet or a child to pay for! those two things really throw a wrench in fixing old stuff!
Yes, every 'grown up' I talked to suggested I take advantage of this while I'm young and obligation-free. But I also see that hasn't stopped you, congratulations on your growing family! I'm approaching this as a pretty comprehensive tear-down, so I hope the effort will pay off and this will be an adventure buggy for some time.

I'll make another post in this thread with photos of the rust I discovered last fall, as well as what lead to the car sitting over the winter without much progress.
 
When I got the car back to the DC area, I parked it on the little side-street in front of my apartment, where I planned to work on little things bit-by-bit, like the exhaust (Currently headers running to a chopped pipe- rough!). Unfortunately, the folks in the city parking enforcement didn't take too kindly to this. The vehicle was towed, without warning, as I had failed to register it in Virginia and put new plates on. When the vehicle was towed, I had removed the bucket seats, and unbolted much of the interior, like the roll-bar, to powerwash the car. It was idling rough, and unreliably starting. At the time it was towed, the car could drive, but it was rough- I knew it would need work, and now I had to drive it ~25 minutes back to my apartment, which I wasn't fully confident the car could do.

I brought just about every tool I had, or thought I might need, in a large duffel bag -full socket sets, electrical bag, wrenches, etc, and probably looked very suspicious on the metro ride out to the impound lot. Here it is shortly after escaping "jail":

IMG_9217.webp


I had about 8 miles of driving with the wind in my hair and hand out the window before the car stalled, and then totally gave up the ghost. No lights, no crank, there was definitely an electrical issue, but the car was totally kaput. Some kind construction workers helped me push it into a nearby lot and I called a tow.

Here's a sight I hope I never have to see again:
IMG_9220.webp


Having just faced the wrath of municipal towing, I decided to have the car towed to my parent's house about 35 minutes away. I just didn't have the space or freedom to really get some work done on it at my place. And this is where I began to see just how much work this car would take. This was just over a year ago.

Not much changed for a while on the car for a while. On a good day, after work, it takes an hour and twenty minutes from my job to my parent's, and when I was there, I had to disassemble, do whatever I was doing, and then reassemble the things, as the car was uncovered outside. Along with cold weather and some personal stuff requiring a lot of my time, I didn't make any notable progress on the car November-April. Weekends here and there were mostly spent tearing away the fiberglass patches over some bad rust, and then cutting that rust away. Here's some of the rust that was in the rear tub area, and around the seats/body mounts.

IMG_9403.webp


IMG_9404.webp


You can't tell in the above photo, but there's even MORE rust almost entirely surrounding the wheel well, and much of the quarter panel. Previous owner (or someone before him) didn't even bother with bondo, just sheets of fiberglass over active rust, then paint paint paint. They even 'bridged' a hole with some scrap metal and self-tapping screws, then fiberglass and more fiberglass.

What bothers me about this isnt the rust, it's that someone (likely the same person, maybe different owners, I don't know) spent a LOT of time and money taking this vehicle from stock to what it is. Complete engine swap. Rewired harness. Extensive modifications to the frame for aftermarket bumpers. Jeep YJ lift. Toyota axles. Regeared T-Case. And yet, after 8-10K in mods, parts, labor, etc... a lazy shortcut, which has ruined much of the body of the car. The fiberglass (which was also painted over, when the car was completely repainted) really must not have been THAT much faster than properly cutting and welding new steel. To quote Mike from Breaking Bad, "no more half measures, Walter". Someone took a half measure when they should have gone all the way.

Anyway, rant over. As you can tell I still get upset thinking about it. I've cut significant parts of the body off due to rust, and begin patching it up. Stay tuned for some of the worst weld's you've ever seen!
 
These are for sure common spots prone for rusting. I would think its where water gets trapped. My stuff was all in those areas too. The worst for me was the tub sides around the wheel wells. I ended up replacing my wheel wells and welding in extensive patches on my tub sides. would have been easier to just replace the tub I think. The tub sides rust out because the fender flair attachments. they are just spot-welded to the tub side. and you cant paint behind it so it just rusts. I am sure it starts rusting from factory. also water can get in between the wheel well and the inside of the tub side too if your top is leaking and that I feel causes rust over time too. Id be curious if Tin top samurais have the same issues.

Suzuki still sells the panel behind the wheel well on both sides. I got new ones. They are seam sealed and spot welded in. They rust out bad too.

I think people just slap bondo in these because they are not worth much unfortunately. I doubt ours are the only ones.
IMG_2433 2.webp


Same with the bondo on mine. found alot of it digging into it.
IMG_2432 2.webp


This is the part number for that panel on the drivers side.
IMG_2458 2.webp
 
Pulling more fiberglass, I discovered that the rust pretty much ran the entire outline of the wheel wells, and ruined enough of that to warrant just ripping them out. If I had the slightest clue what I was doing, I'd go the panel route and order replacements. Instead, a mixture of frustration, ignorance, and cutoff wheels led me here:

IMG_0712 (1).webp

My thought process is, weld up a new rear tub around the existing tailgate and soft top rails, so I can keep that same geometry above the 'water line' for running soft tops, hard tops, etc but design a whole new bed. I plan to draft up my own sliding storage drawer between the wheel wells, sort of like the Decked systems you see for pick ups, just so I can have a secure storage spot in a soft top. If I eventually use this car to commute around DC I'd like to have a spot like that to lock away a laptop etc.
This was back in June, it sat for a while under a tarp like this. Work got pretty crazy, so here and there I fixed small little rust spots and patched the rockers. (One of those needs to be redone). There was more work done that I might go back and cover, but I just want to catch the thread up so I can cover more of my recent work.

Flash forward to this past weekend, I welded up a rectangular frame out of 1" x 1" mild square steel to support the flat part of the rear, which will be made out of 18 Ga steel. I did this to replace some of the strength of the corrugations in the steel, since I'll just be putting in flat sheet instead. But that's all a ways down the road.
These are for sure common spots prone for rusting. I would think its where water gets trapped. My stuff was all in those areas too. The worst for me was the tub sides around the wheel wells. I ended up replacing my wheel wells and welding in extensive patches on my tub sides. would have been easier to just replace the tub I think. The tub sides rust out because the fender flair attachments. they are just spot-welded to the tub side. and you cant paint behind it so it just rusts. I am sure it starts rusting from factory. also water can get in between the wheel well and the inside of the tub side too if your top is leaking and that I feel causes rust over time too. Id be curious if Tin top samurais have the same issues.

Suzuki still sells the panel behind the wheel well on both sides. I got new ones. They are seam sealed and spot welded in. They rust out bad too.

I think people just slap bondo in these because they are not worth much unfortunately. I doubt ours are the only ones. View attachment 4011286

Same with the bondo on mine. found alot of it digging into it.
View attachment 4011287

This is the part number for that panel on the drivers side.
View attachment 4011289
I've seen similar rust patterns around the wheel wells in a few tin tops online. I think even with a tin top, having water ingress through road spray etc into that gap you mentioned just totally ruins that area all along the wheel well.

I'm currently a furloughed fed, so I'm stuck in this weird place between lots of time on my hands to work on the car, and not knowing when my next paycheck will be. Once the mini-frame I mentioned above is welded in (more detail to come) I'd feel confident pulling the tub off the chassis so I can address other rust spots, like the body mounts, from all angles and really make sure those are solid.
 
It took half the day, but I got the tank down. The parts store near me claimed to have a siphon pump in-stock, but of course, when I showed up it wasnt. That might be the third or fourth time that's happened there. Fortunately my tank had a 22mm drain plug, which is a socket size I don't have, so I got a new set of 1/2" drive sockets instead. Once the tank was drained into a jerry can I got to work on the four bolts holding the tank and skid plate up. The first three took 10 mins total- the front-right bolt took much longer. It was so close to the shock that I couldn't fit a ratchet, and only fit the end of a crescent wrench for about a 90 degree turn each time. The Shrockworks skid plate was so tight against the faces of the bolt it was a major PITA to get undone. I'm a bit frustrated that something that should take under an hour took most of my day, but I feel much better now about welding up my tub.

My little Harbor Freight compact jack did a great job keeping the tank up, but I definitely need a full-size floor jack going forward. I think the compact one will ride in my daily for tire/brake changes once I get something more appropriate.

I'm starting to get some "might-as-well-itis" with the build, like the LROR sport cage and Petroworks 15 gal tank, but those might have to wait until after the shutdown. 15 gal onboard fuel storage would be nice, but the new tank is over $600, while I can still get the same capacity from just carrying a 5 gal Jerry Can. I'm definitely going to get the sport cage though- I figure if I do roll over, $500 for some extra protection is worth what the medical bills would be without it.
 
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It took half the day, but I got the tank down. The parts store near me claimed to have a siphon pump in-stock, but of course, when I showed up it wasnt. That might be the third or fourth time that's happened there. Fortunately my tank had a 22mm drain plug, which is a socket size I don't have, so I got a new set of 1/2" drive sockets instead. Once the tank was drained into a jerry can I got to work on the four bolts holding the tank and skid plate up. The first three took 10 mins total- the front-right bolt took much longer. It was so close to the shock that I couldn't fit a ratchet, and only fit the end of a crescent wrench for about a 90 degree turn each time. The Shrockworks skid plate was so tight against the faces of the bolt it was a major PITA to get undone. I'm a bit frustrated that something that should take under an hour took most of my day, but I feel much better now about welding up my tub.

My little Harbor Freight compact jack did a great job keeping the tank up, but I definitely need a full-size floor jack going forward. I think the compact one will ride in my daily for tire/brake changes once I get something more appropriate.

I'm starting to get some "might-as-well-itis" with the build, like the LROR sport cage and Petroworks 15 gal tank, but those might have to wait until after the shutdown. 15 gal onboard fuel storage would be nice, but the new tank is over $600, while I can still get the same capacity from just carrying a 5 gal Jerry Can. I'm definitely going to get the sport cage though- I figure if I do roll over, $500 for some extra protection is worth what the medical bills would be without it.
Dude if it makes you feel better my tank took forever to get off. It also spent time at the beach so sand was falling into my eyes the whole time too. My skid plate is pretty much shot and thats what holds the tank. its still holding the tank up but I also think I am going to get one of the Petroworks tanks just so I can upgrade and replace that plate. I remember one has an electric fuel pump option and one mechanical. I think I will stick with the mechanical when I do mine just because I like the simplicity. In all my car projects I have learned is there is always more "Might as well do this while I am in there" you are making a lot of progress. Dont get too overwhelmed!
 
Dude if it makes you feel better my tank took forever to get off. It also spent time at the beach so sand was falling into my eyes the whole time too. My skid plate is pretty much shot and thats what holds the tank. its still holding the tank up but I also think I am going to get one of the Petroworks tanks just so I can upgrade and replace that plate. I remember one has an electric fuel pump option and one mechanical. I think I will stick with the mechanical when I do mine just because I like the simplicity. In all my car projects I have learned is there is always more "Might as well do this while I am in there" you are making a lot of progress. Dont get too overwhelmed!
Yep I got quite the dusting, still haven't gotten all the caked mud out of every little crevice yet. I'm pretty sure I need the electric pump one since I have EFI, but now that the tank's out I'm not going to worry about the fuel system. Lots more issues to tackle first!
 
Yep I got quite the dusting, still haven't gotten all the caked mud out of every little crevice yet. I'm pretty sure I need the electric pump one since I have EFI, but now that the tank's out I'm not going to worry about the fuel system. Lots more issues to tackle first!
yeah you would need the electric pump I think on yours. I still have the little 1.3L motor. which is really not bad I like how small it is.
 
While I wait for the roll cage I'm working on replacing the rear wheel wells and floor. I welded up this little frame to give the steel some added support, since the original had corrugations. This is 1 x 1 x .083" steel square tubing, which I also gave a few coats of primer. I'm proud of how solid it is, I have started dreaming up what the rear storage system is going to look like and I think this will certainly give the rear a lot of strength.
IMG_1439.webp

Due to how the section under the tailgate is stamped, I had a weird under-lip. To seal up the bottom I cut this into Tabs and folded them up against the frame I made. Once this is all welded up I think it should be pretty solid. After all the welding and priming, I think this frame will stiffen up the rear to pull the body off the frame.


Sorry for poor photo quality, not sure why my iPhone totally bugged out here.

IMG_1438.webp
 
I have a bit of a different update, I hope this is appropriate for my Suzuki build thread. The roll cage arrived, and I welded the frame I made to the tailgate section. The folded-up original body panel is all sealed up now, and the frame nests in there nicely I think.

More notably, my uncle drove down from New Hampshire today pick up my mom's 1931 Ford Model A Fordor. It hasn't started in over a year, so I drained the tank and gave it 5 gals of new gas. We charged the battery all of this morning, and decided we'd try to start her before he arrived so it could get on the trailer. She fired right up. 94 years old, original starter motor. In my 24 years I never remember this car starting on the first try. I think she had grown a little restless.
1762576571767.webp

Here's a little bit of history about the car, if you care to read. It's more of a note to myself and my future family about why I'm undertaking this project:

My grandfather bought this 1931 Ford in the very early 1960's, and spent much of my mom's childhood restoring and repairing it. He was president of his local Model A Owner's Club, and this weekend I found some of his old newsletters, trip reports, and personal restoration notes. It is really cool to read over his own notes and know that he felt just as in-over-his-head with that project as I do with mine. Around the late 1970's he began experiencing some health problems, and the car sat in the family barn at the mercy of mice and New England winters. In 1982, due to his illness, he paid to have the project professionally finished. He died, unexpectedly, just weeks before they finished. He never got to see the car in its current state and enjoy it with my mom. The car continued to sit until 2003, when my grandmother passed, so with the help of our local Model A Club chapter she had it trailered down to Virginia. They helped her get it running, and working on this car was her way of connecting with the man who left her life too soon. We went to local car shows, local meet-ups, and brought the car to school for history lessons and such. I spent a lot of my own childhood on the rear bench seat, just like my mom had. Here I am as a teenager, the day I learned to drive a standard transmission.

1762575370930.webp


While I was away at college we didn't drive the car much, and over time my mom decided that the car had served its purpose. It had helped her feel connected to him and it taught my siblings and I about the grandfather we never got to meet. So she was searching for potential buyers, when her brother reached out and offered to take it back to New Hampshire where my grandfather first worked on it. I'm very glad that the car will stay in the family.
IMG_1538.webp

So today was we prepared the car for its return trip, and I got this last picture of her with SpookiZuk in the background. We also went for one last ride (including hitting the drive through - the Wendy's employees got a kick out of that).

1762576509025.webp

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I'm learning so much during my own project, and it feels meaningful to connect with my grandfather in my own way, knowing he faced a lot of the same challenges I am. It sort of feels like I'm carrying the torch.

Sorry for the winded post on family history yada-yada. This is a tech thread! So tomorrow I'll move Spookizuk into the newly vacated garage bay and share more details on that.
 
I have a bit of a different update, I hope this is appropriate for my Suzuki build thread. The roll cage arrived, and I welded the frame I made to the tailgate section. The folded-up original body panel is all sealed up now, and the frame nests in there nicely I think.

More notably, my uncle drove down from New Hampshire today pick up my mom's 1931 Ford Model A Fordor. It hasn't started in over a year, so I drained the tank and gave it 5 gals of new gas. We charged the battery all of this morning, and decided we'd try to start her before he arrived so it could get on the trailer. She fired right up. 94 years old, original starter motor. In my 24 years I never remember this car starting on the first try. I think she had grown a little restless.
View attachment 4026297
Here's a little bit of history about the car, if you care to read. It's more of a note to myself and my future family about why I'm undertaking this project:

My grandfather bought this 1931 Ford in the very early 1960's, and spent much of my mom's childhood restoring and repairing it. He was president of his local Model A Owner's Club, and this weekend I found some of his old newsletters, trip reports, and personal restoration notes. It is really cool to read over his own notes and know that he felt just as in-over-his-head with that project as I do with mine. Around the late 1970's he began experiencing some health problems, and the car sat in the family barn at the mercy of mice and New England winters. In 1982, due to his illness, he paid to have the project professionally finished. He died, unexpectedly, just weeks before they finished. He never got to see the car in its current state and enjoy it with my mom. The car continued to sit until 2003, when my grandmother passed, so with the help of our local Model A Club chapter she had it trailered down to Virginia. They helped her get it running, and working on this car was her way of connecting with the man who left her life too soon. We went to local car shows, local meet-ups, and brought the car to school for history lessons and such. I spent a lot of my own childhood on the rear bench seat, just like my mom had. Here I am as a teenager, the day I learned to drive a standard transmission.

View attachment 4026288

While I was away at college we didn't drive the car much, and over time my mom decided that the car had served its purpose. It had helped her feel connected to him and it taught my siblings and I about the grandfather we never got to meet. So she was searching for potential buyers, when her brother reached out and offered to take it back to New Hampshire where my grandfather first worked on it. I'm very glad that the car will stay in the family.
View attachment 4026294
So today was we prepared the car for its return trip, and I got this last picture of her with SpookiZuk in the background. We also went for one last ride (including hitting the drive through - the Wendy's employees got a kick out of that).

View attachment 4026296
View attachment 4026295
I'm learning so much during my own project, and it feels meaningful to connect with my grandfather in my own way, knowing he faced a lot of the same challenges I am. It sort of feels like I'm carrying the torch.

Sorry for the winded post on family history yada-yada. This is a tech thread! So tomorrow I'll move Spookizuk into the newly vacated garage bay and share more details on that.
Dude if you are ever up in Mount Desert Island Maine you should go to the seal cove auto museum! they have vehicles from 1930 and back. some of them are the only examples in the world! Thats so cool you guys are keeping that model A in the family! one day you might want to drive your kids around in it. I have always wanted one of these too. one day when I build a garage I might get one. Might need to do a willys jeep in the future too though too. Thanks for sharing the story of that model A!
 
Dude if you are ever up in Mount Desert Island Maine you should go to the seal cove auto museum! they have vehicles from 1930 and back. some of them are the only examples in the world! Thats so cool you guys are keeping that model A in the family! one day you might want to drive your kids around in it. I have always wanted one of these too. one day when I build a garage I might get one. Might need to do a willys jeep in the future too though too. Thanks for sharing the story of that model A!
I'll have to check it out! My girlfriend and I were thinking of planning a trip up there sometime next year. I highly recommend you get one eventually if you can find one. Some of my earliest memories were going to car shows in that Model A with my mom, and hanging out with the club. Unfortunately, so many of them have since passed. I'm afraid interest is waning in that generation of cars and the youths (my generation) are more interested in performance and the 1970s+ sporty stuff.
 
With the Model A gone, I moved the Suzuki into the vacant space so my mom can have her garage bay back. Here's my setup:

IMG_1590.webp

I'm removing/disconnection some things to try and pull the front clip when I'm back here next weekend. With the shutdown ended I have a lot less time to work on the car, unfortunately. But it's nice being employed again too. While pulling the headlights, I dropped one, and ruined one of the few things on this car that didn't need replacing. Oops! Fortunately they're not too expensive. I've seen a lot of people swap to these LED's, but I think I like the classic look of a round halogen.
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I also bought and assembled a cherry picker from Harbor Freight for when I eventually pull the tub off the frame. Not a ton of progress to report, but I'm glad I've got all my stuff set up. I wasn't able to work on the car all winter last year so I'm really glad its inside and I have some space to work with.
 
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