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Thread: 87 Suzuki Samurai

  1. #201
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    Default Re: 87 Suzuki Samurai



    What a beautiful baby, looks happy in that photo. Looks like your little Samurai is coming along nicely, love your trip report. (to bad about the accident but glade your Ok)

  2. #202
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    Default Re: 87 Suzuki Samurai



    that accident sucks, sorry that happenned. Looks like a lot of good stuff is happenning too!
    ___________
    _O IIIIIIII O_


    "I'm the worst person I know. My merit was to control my faults." -Helio Gracie

  3. #203
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    Default Re: 87 Suzuki Samurai



    Thanks Guys!

  4. #204
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    Default Re: 87 Suzuki Samurai



    I had been hearing a rattle for a while and I thought I narrowed it down to my fan clutch going bad. I wasn't experiencing any overheating or anything but I decided to swap out my fan in favor of an electric one. I had been following some of the local Zuk guys on a Facebook group and they had posted a nice electric fan setup utilizing the fan from a Kia Spectra. With the rattle really worrying me and $100 gift card to Amazon I ordered the fan and a fan controller from Amazon. I was hoping to get the fan installed in time for a camping trip because I was worried about the rattle..... Turns out that rattle was the loosening frame side bolt from the exhaust manifold to the catalytic converter. I put off installing the electric fan for a week. I decided to go through with the swap because I had purchased the parts and formulated the plan.


    The fan fits the stock Samurai radiator almost perfectly.



    The fan has these squarish tabs on the passenger side that fit into some squarish holes in the some brackets I'd need to make. I chose to make them from Aluminum because it would be easier to drill some holes and square them up with a jigsaw and file. I got some brackets from work in the scrap bin to use.















    The drivers side mounts were easier. I used a 3/4" wide 1/8" thick piece of flat stock aluminum for the bracket. I was able to use two holes from the original fan shroud mounting bolts.





    I used some 1/2" deep drill bushings as spacers for some bolts to mount the fan to the radiator on the drivers side.





    The fan is a tight fit and I ended up finally removing the hood prop to move the radiator as far forward as I could. I never used the hood prop anyway.








    In addition to getting this new fan off Amazon I just had to use a plug from a kia because I couldn't stand the thought of using spade connectors to power it. I ran to the junkyard in search of a kia to still the fan plug/harness from and ended up leaving with a spare kia fan and the harness for it!


    I used a hayden fan controller to control the fan. It uses a temperature probe that I conveniently installed into a spare port on the thermostat housing.





    I got it all wired and through it all in front of the battery because I'm a lazy guy.







    Fast forward a week later and I get emissions here in Colorado, and Pass!!





    They didn't even question the engine swap!


    I'm going to the zoo with my kids and notice that my temperature gauge is too hot. My fan didn't kick on. I immediately suspect the fan controller after parking and entering the zoo. After I hotwire the fan and get home I discover that the wire that powers the fan controller itself got smashed between my battery and fender. Kicking myself, I repair the wire and commit to improving the wiring in the area on the coming weekend.



  5. #205
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    Default Re: 87 Suzuki Samurai



    I used some HDPE (cutting board material from the tailgate table project) to make some mounts for the Sidekick Fuse Block, fan controller and the ARB Compressor Relay.










    We've been getting some decent rain here in Colorado lately and the Samurai leaks horribly. I suspect water is getting in under the windshield frame and the door seals leak as well. Either way your feet and knees get wet while driving in a heavy rain. I ordered a new lower windshield seal from Roadless Gear, which was a good 1/4" thicker than the original and I was very hopeful that it would fix the leak.










    The new door seals were more spongy and thicker than the old ones as well.







    Pretty confident that I won't be getting water in through the door seals anymore but the windshield frame is still leaking...

  6. #206
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    Default Re: 87 Suzuki Samurai



    I got a welder for Fathers day from Abby and decided to start putting it to use. I finally got handles welded to the retaining nut on the tire carrier.



    Now, it's just the cheap Harbor Freight welder but it's a start and I can start joining steel to steel. With that in mind I decided to tackle the rust hole in the back of the Samurai. I cut around the hole with a grinder and a dremel.





    In the process of welding in the patch piece I discovered more rust closer to the side of the tub and hidden underneath the sealant they put over the joints.





    This really had me beating my head against a wall. I was starting to consider just going for the virtual lift and welding in trailer fenders so I could finally clear some bigger tires. The area was too tight to get at with my grinder and the dremel just wasn't the right tool for the job. I purchased a cheap body saw from harbor freight. The tool worked well and I was able to remove even more of the floor the tub behind the wheel well.





    Now I'm honestly not sure how much of this is me being a poor welder or the fact that I have a poor 90 amp welder with no gas and I'm using flux core wire.
    I smoothed the welds with a flap disk and slathered everything with some epoxy that Abby just happened to have out as she was building my daughter a bed.





    Sprayed it with black spray paint and called it done.







    With that project done it was time for our 4th of July adventure. I needed to take my kids to meet their Grandpa (my dad) in New Mexico. When I would go visit my dad in New Mexico we would go camping and fishing at Morphy Lake. We loaded the kids in the back of the Samurai and packed up the trailer and set off.







    After having lunch with my Dad in town we set off to find a camp site at the lake much to our disappointment.





    Oh well. We found a campsite nearby down a forest road. We had run into mud our whole way up to the lake and even more up to the campsite.











    I had rigged some fishing rods to the roof rack with some zip ties so I suppose some fishing rod holders are in the works soon.



  7. #207
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    Default Re: 87 Suzuki Samurai



    After doing some camping and fishing and meeting back up with my dad and grandma we headed back home to Colorado. About 20 minutes outside of Las Vegas, New Mexico we ran into trouble with the trailer. One of the tires blew. I guess it didn't like being pulled at 75mph.








    We had good luck though. The Tractor Supply store just happened to be open on the 4th and my dad was able to bring us two new trailer tires.


    The entire trip went well and of course we couldn't help but having one mishap with that blown tire. But the only nagging thing that I disliked about the trip was the soft top flap noise and the HEAT. Unfortunately I couldn't take the doors off with the kids in the back so We had to leave them on which allows the samurai to get pretty warm. I think I need to really work on putting the air conditioning parts together for the Samurai. I really need to get serious about that. And I really want to find a hard top....

  8. #208
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    Default Re: 87 Suzuki Samurai



    Thanks for sharing, I wish I could do more camping than I do, Maybe next summer.

  9. #209
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    Default Re: 87 Suzuki Samurai



    I hear you. We're really making a big push to get out and camp this summer. We spent last summer buying and gathering gear, this summer we're dead set on using it.

  10. #210
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    Default Re: 87 Suzuki Samurai



    So far we have just done day trips. We got the chance to Kayak Rampart Reservoir (wakeless day use lake) a couple Sundays ago was a good day (we got there very early as it gets real crowded). We scooped out the campgrounds as I would like to make a weekend out of our next trip or at least a overnighter like Sunday-Monday as that is our two days off.

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