Outer Limits 4x4 Board

My zuk is a 86 Hard top (NT) which I bought for $800 unregistered a few months back.

It came with 30x9.5s on repack springs and with GTI engine, steering wheel and seats. It needed a new windscreen, radiator and a service.

It took a while but after cleaning it up a bit I finally got it registered.
Now the fun begins.

The zuk is going to stay on the cheap but also be a kick ass offroad weapon.

First thing I have done is cut the guards. I want to try and keep a low COG and get the majority of my lift from the tyres.
I have cut 2.5 inches off the outer guard and lifted the inner and then teched them together I will eventually weld the panels and clean it up.

Here is a pic of the cut front guards.

Pic of the rear

I have now put in some Cj 7 springs they are approx 4 inches longer than the zuk rears and 6 inches than the fronts.

I have attached the springs by using an adapter plates on the rear hangers which move the spring location rearward approx 3inches.

img]http://usera.imagecave.com/crazy11/112_1204-copy.jpg[/img]

The first prob was at the front where I was going to run a missing link shackle at the front to give me the extra length for the spring but I mis calculated something some where and the spring was way too long.

what did you use for the guards what ever it was not to bad a job no sharp lines all round

I used a grinder and a hammer. On the narrow tracks there is a curved indentation that goes around the guard.

I cut about 15mm below that and then rolled the edge along the curved line.

I think this helped because it turned out a lot better than I expected.

Once it is finished I got some tj wrangler flares to go on it.

To fit the longer spring at the front I had to do a chassis extension.

I cut of the spring hangers got some 90mm box section (4mm thick) and got a mate to weld it to the front.

we then braced it with some plate and stuff and welded the hangers back to the box section.

As you can see from the next pic this helped a bit but the spring is still too long and the shackles are sticking out on too much of an angle. I am going to have to cut the rear mount off and weld it further back down the chassis.

what about longer shackles that wouldnt help would it

The springs have moved the front diff forward and the rear diff back wards which you can sort of see from the pic.

When I moved the rear hanger back I put it too far and the rear shackle now hangs inwards and limits the rear travel so I will have to cut that off again and moved it in a bit.

The suspension still needs a bit more work. Here is a pic of the front flexing. We couldn't get the jack any higher and don't have a ramp yet. The front wheel was still firmly on the ground in the pic. You can see the leaves haven't even started opening yet nor is the shackle all the way down. Not bad for springs that cost $10.00 each and $50.00 worth of adapter plates.

Longer shackles would help a bit but not enough I don't think.

I can move the rear spring hanger back and i have got relocator plates to keep the diff moved forward to keep the increased wheel base.

Here is a front pic, again not a full stretch. Once I have got it right I will measure all the shock lengths I need and get the appropriate ones with extended towers.

Drew also put in a 1lt trasnsfer case to help bring the gearing down. Eventually I will also put in my 4.11 diffs all welded up!!!!

Look out guys we have a "man of action"
great work.
Peter.

lookin good dude,, there is a pretty good ramp down the road from my place at ascot if ya wanna flex it up, what size tyre u gonna run?

thats not bad so they are just standard jeep springs or from some thing else and did it give you any lift compared to the old ones and did you have to make any parts like hangers etc

The springs are just standard cj7 front springs. I am running a 5 leaf pack and I reckon it has given me about a 2 inch lift.

I will probably throw in one more leaf because it is a little soft still which might bump it up a bit more.

I just cut the hangers on the front and rear and moved them out and welded them back on. (obviously the front needed the extension but the rear went back 2 inches standard). I just used 5mm plate to extend the inner hangers about 3inch bak but now I will probably just cut and move them aswell as I need more length.

I am thinking of trying to find some rears to go in the back as I have made the distance too long anyway.

I will probably run 32s but it depends on what I find and how the gearing goes for if I go bigger.

you can always come toRockingham if you want and put it up my ramp

Definately when the suspension is finished I will head down that way and flex it up before we all go for a drive.

Wolverine wrote:As you can see from the next pic this helped a bit but the spring is still too long and the shackles are sticking out on too much of an angle. I am going to have to cut the rear mount off and weld it further back down the chassis.

i'm no leaf spring expert, but that shackle angle looks pretty much perfect to me. just run bigger tires to get over the approach angle thing

Nah too prone to inversion...

Looking good.

What tyres do you plan on running?

Gotta admire a good backyard job! Looks like the bomb for the money you spent, well done

great thread mate.

Ric

You'll be challanging redzook fir a flex comp soon Looking very nice

nice work wolverine

i did the guard chop the same way you did hehe

Sweet as Wolverine. Good to see not only are you back on the net but you’re also getting things done.

If you want anything send me a pm as I have heaps for sale including gearing

Cheers guys. I will hopefully have the suspension finished by the end of this week.

In the mean time I am just gathering things like extended brake lines and shock towers. Drew and I are going to check out some f250 towers and see how they go.

For the rear mounts we are going to make our own with some 6mm plate to run the shocks in a pyramid shape, although there has been some murmouring of cutting the floor.

Still have to weld diffs and design some kind of front bar.

For tyres I have my eye on a set of 32's swampers for now but I will see how I go.

Also DEWSE give it up what are the new plans!!!!!!!!!!!

wolferine wrote:Cheers guys. I will hopefully have the suspension finished by the end of this week.

In the mean time I am just gathering things like extended brake lines and shock towers. Drew and I are going to check out some f250 towers and see how they go.

For the rear mounts we are going to make our own with some 6mm plate to run the shocks in a pyramid shape, although there has been some murmouring of cutting the floor.

Still have to weld diffs and design some kind of front bar.

For tyres I have my eye on a set of 32's swampers for now but I will see how I go.

Also DEWSE give it up what are the new plans!!!!!!!!!!!

Plans are boring two wheel drive at the moment.

Okay I have some front towers for sale they are weld on but can be changed to suit, also I have some bolt on rear mounts that will only work with a body lift. Basically you just bolt them to the top of the cross member. I have four N76 ome shocks with 13inch travel as well.

ps: got extended brake lines as well