Outer Limits 4x4 Board

Current Setup
- 1.6L 8v Vit Motor, Weber 32/36 DGAV, Extractors, 2" pipe.
- 2" Lovells Leaves
- Home-made Drop Shackles, 1/2" Lift.
- Cofap Long Travel Shocks (wish they were longer)
- 215/75r15 H/T Tyres. (Cooper fronts, Goodyear Rears)
- Welded Rear

The Mods
- Remove existing leaves and mounts
- Chassis Extension and Hilux mounts
- Hilux front springs, SPOA.
- Shockies [unkown]
- Hi-Steer
- 31x10.5r15 Cooper STT Armor-tek Tyres on SPeedy 15x7 Rims
- 5.14:1 Calmini Reduction Gears
- Driveshafts [unknown]
- Custom front bar
- Calibrated speedo (i class this as a mod - only zuk i know that will be correct!)
- ENGINEERED. (Inspections, Swerve Tests, Paperwork)

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Attached is a pic of the zuk in its current form - work will begin this weekend, and end hopefully by the end of the month (sooner if possible!). Engineering sometime in October hopefully. All paperwork and initial approval from DPI has been received.

I'll try to keep pics flowing and info rolling in as this progresses with new info i discover along the way (spring rates, shocks to use, how we solved the driveshafts, any issues). Any questions or comments / handy hints appreciated!

sounds good

but how are you going to get a spoa in wa engineered??

ive spoken to my engineer - SPOA or SPUA doesnt make a single bit of difference so long as the lift doesnt exceed 4" (it will but we are taking the measurements off my already 2.5" lifted zuk, so we will get away with it).

And in the end - if it passes the swerve test and all work is done in a safe manner - its fine.

But - like everything - contact Reno Marchesi at DPI (www.dpi.wa.gov.au) and ask him if what youre doing will be ok - if he says yes, then do the paperwork, get initial approval, see an engineer, then start work.

looks like you have a bit off work in front of you,sounds like fun.

keep us posted...

Will you need to do SPOA with Hilux springs to clear 31's?

Cool.

Was SPUA plans before?

What highsteer are you using.

cheers

I will need SPOA on lux leaves, as the only time lux leaves are as soft as zuk ones is when theyre almost flat... so all the lift is in the SPOA. The leaves are purely for articulation - hilux rather than YJ cos hilux are cheaper and easier to come by. Hilux mounts are also about 1/2" shorter than zuk ones, so im losing a bit of lift just using these mounts - although it will likely be gained back when the mounts are moved down the chassis to accomodate the longer leaves.

Steering is through opposite lock (they use an eastern states contractor to make them). if opp lock cant get me the kit by mid next week (theyve taken 7 weeks so far! grrr!) then ill get snake racing's kit.

alien wrote: Steering is through opposite lock (they use an eastern states contractor to make them). if opp lock cant get me the kit by mid next week (theyve taken 7 weeks so far! grrr!) then ill get snake racing's kit.

How much are they stinging ya for the kit? Trying to decide on $$ for the next buildup.

cheers

Opp. Lock Hi-Steer ~$750-800

Snake Racing Hi-Steer - $850

After waiting 7 weeks for opposite lock and still no result though, Snake racing are looking to be worth the extra $100!

Cool cheers - I got a mate that work at OL so may be able to get something when i need it.

U checked out sky manufacturing?

cheers

Nic - he work at Balcatta or another store??? if you can, and he doesnt mind - can you find out from him a delivery time on high-steer?

And no i completely forgot about sky engineering - will check them out.

have you got the lux leafs yet?

Yes, 4 packs of standard height leaves, brand new, $90 a pack incl. GST.

From Hilux Cruiser Spares on Felspar Rd in Welshpool.

The packs are sets of 4 leaves, have military wrap etc, but are made in malaysia, brand is ADM... if they last me 2 years i'll be stoked.

At this stage ill be running the top 2 leaves, dropping the 3rd and keeping the bottom leaf. the 3rd one gives it all its height and stiffness.

why dont u go an overkill high steer?

if your interested i might be able to get a set, not new they are from an 87 hilux witch has a 5ltr in it so the springs aren't all new and stiff.problaly get themreal cheap

overkill's hi-steer was $1500.

i cant justify paying double for the same result... overkill was the first place i called - i want to support the guys on the forums but yeah...

suzy - i already have mine =) Engineer also wouldnt really like to see an old set in there. better to show a reciept for new springs - even if the packs have been mucked around with.

Hey alien just a quick question, what made you choose the cooper STT?

The new armor-tek belts theyre using, tread wraps onto sidewall, nice deep tread, aggressive pattern but still good on road (soft compound), 15.3mm tread depth.

That and ive had coopers before and found them to be bulletproof.

I do really like the Simex's but theyre too expensive and on road look like theyd be scary. This zuk is my daily driver and sees much more bitumen than offroad - so i want it to be safe =)

Getting them at $269ea. expensive for a 31" tyre, but from experience, worth it.

alien wrote:ive spoken to my engineer - SPOA or SPUA doesnt make a single bit of difference so long as the lift doesnt exceed 4" (it will but we are taking the measurements off my already 2.5" lifted zuk, so we will get away with it).

you serious we can only have a 4" over all lift from standard in WA- thats body and suspention combined?
is coil spring conversion legal in WA?... this piece of info really screwed my plans

Sorry, you've misunderstood.... DPI will only give approval to a vehicle netting a total 6" of lift or below, including suspension, body, tyres EVERYTHING AND ANYTHING that raises the vehicle's overall eyebrow (headlights) height above stock.

Youll have to talk to DPI about whether coils are legal - im sure they will be so long as theyre engineered. (??)

What i meant by 4" was that a 31" tyre is 1.5" taller all round than a stock 26" zuk tyre. so 6" total.

Patchy wrote:

alien wrote:ive spoken to my engineer - SPOA or SPUA doesnt make a single bit of difference so long as the lift doesnt exceed 4" (it will but we are taking the measurements off my already 2.5" lifted zuk, so we will get away with it).

you serious we can only have a 4" over all lift from standard in WA- thats body and suspention combined?
is coil spring conversion legal in WA?... this piece of info really screwed my plans

Legally 6" overall lift is ollowed i think inc the tyres. Coil lift if done legally ha to be done through same chanells. inc swerve test etc.

I am thinking coils as well in the new zook but not doing swerve test and that as far as i am planning.

thanks

what i wanna no is why go spoa if most of ur drivin is on bitumen? and a daily,

i explained it above - the lux leaves wont give me the lift i want, so im using the SPOA for the lift and the leaves for my flexyness...

Just because i drive it to work and around the city all week and only go out on weekends doesnt mean im not allowed to have a capable zuk =)

so is this still hapeneing.....

any updates....

no major updates - just stripping it down on weeknights after work...

hopefully a fair bit will get done this weekend.

i pick up the tyres tomorrow morning.

Bit of an update:

Everything (perches and mounts) has been ground off, chassis is in preparation for extension.

Had a bit of a set back - my pin kit doesnt 100% match up with my mounts, but we can elongate the holes and fix this (see my topic on Mounts and Pin Kits).

Also, the perches i got from Opposite Lock were incorrect - they gave me suzuki perches - which are 10mm too narrow to use on hilux springs!!!! so i have them under strict instructions to fix it by friday, as welding should begin this weekend.

Getting this thing to pass the swerve test is going to be great fun - im even going to take the good old sway bar out of the shed!!!

Photos will come - using a film camera as both digi cameras i have access to are in use =( so gotta finish the roll and scan them (crap!)

EDIT: forgot to mention - the tyres look fantastic! the tread is deeper than i first thought - hopefully ill get a chance to measure their actual height shortly.

EDIT EDIT: big thumbs up to Sam / Shaun at Overkill!!! $610 for Crossover steering is awesome!!! Ordering tomorrow.

UPDATE (may include minor vendor bashing):

After the supplier of my perches (Opposite Lock Balcatta) totally screwing up the measurements after 4 weeks of waiting, i cancelled my order with them (I strongly urge everyone NOT to deal with these guys - i waited 8 weeks to hear from them that my steering was 8 weeks away!) I have since ordered my gear through overkill, who have been excellent to me, although theres been 2 weeks delays due to courier issues.

Unfortunately for me, all this delay may have cost me the chance to have my zuk engineered... the swerve test is due to happen next week and theres no way in hell we're gonna have it done by then... which means getting everything done and checked, but no swerve test till mid to late next year. Leaving me with an unroadworthy zuk. (if i get yellow stickered im screwed).

We are still going ahead though, hoping the swerve test gets delayed, as its being arranged by Russell at opp. lock - and with his track record im thinking we have a few more weeks up our sleeves... I HOPE!!![/b]

It seems after that vendor bashing, the fate of your zook is in thier hands, would be frustrating but thats life S**T Happens.

small talk wrote:It seems after that vendor bashing, the fate of your zook is in thier hands, would be frustrating but thats life S**T Happens.

How is that fender bashing ???
He has not said anything untrue or derogatory ....

Sounds like a great build to me .. dont worry to much about passing the swerve test .. it will do it easy ... if you dont have enough lift .. clearance the guards ... (31's will clear easy though ..if you wanted to get a set of 33's down the track fro weekend warrior stuff ... use the angle gringer to make more room)

You planning on trimming you lux diffs at all ?? to gain some clearance under the center's ???

love_mud wrote:

small talk wrote:It seems after that vendor bashing, the fate of your zook is in thier hands, would be frustrating but thats life S**T Happens.

How is that fender bashing ???
He has not said anything untrue or derogatory ....

Sounds like a great build to me .. dont worry to much about passing the swerve test .. it will do it easy ... if you dont have enough lift .. clearance the guards ... (31's will clear easy though ..if you wanted to get a set of 33's down the track fro weekend warrior stuff ... use the angle gringer to make more room)

You planning on trimming you lux diffs at all ?? to gain some clearance under the center's ???

I believe he is using zook diffs but spoa with lux leaves.