1987 samurai

warrpath4x4

Well-known member
Joined
Aug 16, 2021
I didn't get much time last night to work on it, had to get hay tarped before this storm that rolled in last night.

I did get the mounting holes drilled for the winch plate and got the grill cut to recess the winch in, I need to come up with something different for the front turn signals.

the winch is not bolted down, once I get the fairlead mounted I will probably slide the winch forward about half an inch giving it more room in front of the radiator, but I like how high and tucked in it sits.


13,000 pounds might be a little overkill for a Samurai lol but I already had it, it was this 13,000 pounder or another 13,000 pounder, an old Belleview winch, or a 2,000 ATV winch.
 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
Got the bumper mounted, winch on and wired, grill back in, i just need to decided what I am going to do for turn signals.

Tip for anyone who needs it, when trying to transfer hole locations to a template, I use soda boxes and a ballpeen hammer, tap where the hole is and it cuts it clean.



back to the bumper, I pulled the sammi out of the shed to get some better light and better pictures.









The turn signals were mounted behind the grill but after trimming the grill to fit the winch, there's not enough room. I could put them back behind the grill at angles but not sure I want to. I know there's lots of options for replacements, I just need to decide.

 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
I forgot to mention, the original bumper on this weighed 80 pounds by itself, this one weighs 35 pounds and the winch is 40 pounds. So overall its 5 pounds lighter and has a winch now.
 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
I pulled the Sammi out of the shed so I had more room on the passenger side, drilled out the spot welds on the trim bracket. Looks about like the driver side, no through rust but the surface rust has weakened the structural integrity of the rockers. I had originally planned to cut the homebrew nerf bars off and build new rocker guard/sliders that bolted on, now though I am thinking about cutting the rockers out and welding in some better steel... maybe a mini boatside to it.



I had not planned on keeping the original shocks, but I definitely need new ones lol


I have the week after Thanksgiving off and am hoping to spend most of it working on the sammi, plan is to rebuild the transfer case and axles. I already have chromoly shafts for the front and will be ordering chromoly rear shafts tomorrow.
 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
No work getting done, but I am ordering more stuff for it.

The other day I ordered a factory service manual for it, yesterday was lights and stuff for the new rear bumper and turn signal stuff, today I ordered the chromoly rear shafts with quick change bearings/retainers and seals.
 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
Sunday morning the kid and I got up early and drove 2.5 hours to go pick up some doors and a windshield frame for the sammi, unfortunately the guy sold the windshield frame before I got there.

Not bad for $60 for both doors, way better shape than my current ones


visited with the locals while we were there also
 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
Not working on the Sammi for 2 weeks getting ready for thanksgiving, here's the new dining room table my son and I built Saturday, wouldn't say its "professional" quality and I'm already thinking about building a new top for it when I have more time and A) fixing a few mistakes I learned along the way and B) using better lumber than home depot lol. but its ready for the holiday season.



 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
finished up the front turn signals tonight, just went simple.



3/4" LED lights





Even works with my jacked up fender lol



Changed out the turn signal flasher with a Grote 44892, no more fast flasher. I wish I could remember where I seen this so I could give them credit. I seen people talking about wiring in resistors, but this was just simply changing the flasher relay.

 

warrpath4x4

Well-known member
Joined
Aug 16, 2021
I had this week off, started by cleaning the shop up, then my son and I tore the transfer case out, I broke one of my 3 jaw pullers trying to get this flange off



We got it all apart, I came to the conclusion? question? thought? that I don't know how these you tubers always seem to have clean work spaces lol, they must be doing a lot of cleaning in between.



new KOYO bearings installed, 6.4 gear set installed, case is clearanced for the gears, but when I measured my clearance from the shafts to the case I needed some shims so I have to wait for those to come in.



waiting on the shims, we tore the front end down, new side gears, and spartan locker. it seems nothing can go easy on this, the shims supplied with the locker were way to thick, I ended up using some thick fender washers that I milled the diameter down to fit inside the locker. I don't know if its because of the brand new gears or what. everything fits snug now though. We got the third put back in but then I got a cold and it sucks, so I have not worked on it in 2 days.



question for anyone who has rebuilt a samurai transfer case, how many shims are too many between the case and shaft?