I started a big job on a customers Suzuki this week.
The car.
I've got to do an engine conversion to replace the tiny 1 litre with a slightly bigger 1.3. The first job was to fit a bonnet from a 1.3 which has a bulge to allow for the higher engine.
I pulled the old engine and gearbox out.
With that done I got it on the hoist for a full front end rebuild of the axle, with all new bearings and seals.
While on the hoist I've got to change all the suspension and remove and clean the fuel tank out.
On Friday I finally got a day to work on the Jimny project.
First job was to alter the A frame on the rear suspension setup.
Removed the A frame.
Pressed the bushes out.
I could then put it on the Brobo saw to cut mounts off.
22.5 degree cut in order to turn the mount 45 degrees.
I could then turn the ends around.
To ensure a really strong weld I ground the ends of the tube to ensure I would get full root penetration.
Got my TIG setup.
Welded it in 2 passes, a root pass first.
Followed by a capping run.
Got some new bushes.
Cut the old mounts off the chassis.
Bolted the A frame in position.
I cut some 6mm thick steel.
Clamped the 6mm flat together and stack drilled it on the pillar drill.
Welded a piece of flat on the end of each piece of angle.
I bolted the other pieces of flat in position using the old bushes and welded the flat to the angle.
Bushes removed and ready to be welded to the chassis.
I could then test the articulation.
There isnt any weight above the rear springs so I think thats why their not compressing. With the cage, fuel tank, batteries, winch, seats etc. it should work better, if not we can source some softer springs.
The next major job is the roll cage but in order to design it I need to know the position and height of the drivers seat and steering wheel.
I fitted the steering column, steering wheel and dash board loosely in position.
I cut and welded some angle together.
Tacked them to the chassis.
And bolted the dash in position.
I could then work out the height of the seat.
Clamped a small pallet to the chassis.
That raised the seat up high enough.
And thats as far as I got.
I've started designing the cage and I want it be the exact shape and size of a Jimny body. So the front hoop will follow the angles and rake of the windscreen.
And finally LJ............
The replacement instrument cluster I fitted and tried to connect, fried the oil pressure sender gauge on my engine as the instrument cluster was from a 24volt car and not 12v. Or atleast thats what the auto electrician thinks.
Removed the old one.
Ordered a new one.
I'm not convinced its exactly the right one, but I'm fairly certain it will work.
I've not been happy with how high LJ is for a while now, its sitting far too high which compromises the handling and means I run the risk of getting stopped by the police.
I've used springs which are readily available here (79 series fronts) but they are too high.
If I owned an 80 it would be easy with loads of companies making suspension, but LJ being a reasonably rare model and with 70's with this suspension setup only being sold for about 5 years and never in Australia, options are limited!
A few companies make springs and shocks for earlier LJ70's which have a different suspension setup but AFAIK only one Australian company make suspension for the later square headlight models like LJ.
Dobinsons!
http://www.dobinsonsprings.com/4x4-vehicles/toyota/landcruiser/70-series/bundera/toy-65-a/
My boss spoke to Mr Dobinson himself and got me a great one off price!
So hes ordered me the +60mm lift kit.
Hoping to get it all fitted before my Easter High Country trip.
)
