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Well the time has come to build a car with Bijouspud. We’ve been doing a few tyro events recently and wanted something we could push a bit harder than medium spuds jimny.
A hotel with work in Manchester yielded the accidental purchase of an sj413 from Blackburn.
It’s a failed project, but has a substantial spares mountain and has had some good welding done, and some left to sort…
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 The story begins! So super zook arrived home on a beaver tail Thursday morning, so Thursday night we started to have a play and see how the front end fitted up.  |
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Saturday went down a little like this…   |
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So the chassis seems solid, we’ve got a new set of leaf springs and shocks on the way.
We’ll repipe it all the way through. The chassis will be painted with raptor paint and the diffs / props with hammerite.
The fuel gauge didn’t work so I added a gallon in when we got it. Seems a wiring issue as it contained six gallons after removal…
Plan to be painted up and rebuilt for the end of the week weather permitting.
Then we are onto patches in the tub and a spot of paint!
Guess it might be a bit modern for these parts but it’s fun right :-)
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Very good car. Are you doing any mods, or are you restoring what you have got?
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Hi Diesel Max,
We are going for a ‘stock plus’ approach so circa 28 / 29 ish tyres. The springs will be a 40mm lift from stock, using an Old man emu kit. That should give us some road manners and decent articulation when we are doing the tyro trials.
Guess the biggest change will be a rock lobster modification in the transfer case. This drops the final drive by 12% in high range, which should even up with the tyre size increase from about 26” stock. But we get a an 80% drop in low range which should really help for trialling when we are making delicate moves. Should just idle along!
Longer term I’m eyeing up an Aisin roots 300 super charger for a little blow to get some more torques… but I need to get the charger finished and running on Redshed the mini first.
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Well todays project after work was to pull the front axle. Bit tricksy as it’s got a motor in it and nothing behind the gear box.. bit of improvised lifting had it out.
Tommorows job a through strip and clean. Bit of paint and build it up with all the lovely old man emu stuff that arrived today :-)
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Nov 21, 2023 21:19:36 GMT
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Well. I’ve been distracted from posting for a bit. But the super zooki is back together and running well. We’ve adopted a martinis racing theme and the truck goes by the moniker of Dirty Martini… our last weekend and took a win in our class :-)   |
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Nov 29, 2023 21:07:18 GMT
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So the next mission is to replace the pitman arm with a drop version. We are lifted about 2.5” not that it looks it with the 235/75s fitted. They come up at 29” over the circa 25.5” standard.
This means the drag link and steering link aren’t parallel. I’m not sure how much difference the 2.5 I’d lift makes… but in a sport where steering precision is king… it seems worth the change for £50 or so. If nothing else the bumpsteer will be reduced.
Now then… any tips for getting a pitman arm off the steering box for the first time in 31yrs… I’ve tried tapping it and a little puller.
I’ve got a proper pitman puller and I’m minded to hit it with the rattle gun and see if it pops
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Nov 29, 2023 22:00:46 GMT
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Blue spanner??  |
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owen
Part of things
Posts: 287
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Nov 30, 2023 12:58:03 GMT
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That is a really tidy sj, they were really badly rotten in early 2000's when I was playing in the mud with them. I always managed to get the pitman arm off with a big hammer give the arm a few hits around the area where the steering spline goes through, or heat it up a bit. If you have access to an air chisel you can get a hammer end for an air chisel and I have managed to shake things off with that before
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Well it’s been an eventful week in SJ lane. Drunk me bought Sober me an Arb air locker on pickup only from carmanthan. Thanks to FIL for saving the day and picking it up from Bristol. That’s the Xmas project sorted. Or so I thought. I’ve been going to that there london this week and using the SJ and a train car. Nothing to do with stick on plates and the extortionate rain station car park fees. Anyway as it’s a night run in what is essentially a tent and mud tyres any mechanical issues are not easily noticed. A mild burning smell on inclines that I assumed to be clutch. Come Friday am and the school run on the way, much knocking and clanking ensued. Seems we’ve blown out / burned all the oil in the last 500miles. It did smoke on occasions… but not that much I thought… So the original recently rebuild with little or no provenance G13b is farked. After an evening in the pub with the boys a deal was struck via Facebook marketplace and a substantial road trip (this time.to north wales ensued) we have a new g13b to go in.. but this one came out of a Suzuki swift GTi so we now have a 100bhp instead of 60 and a red line of 8600rpm…. Yes I think this could be a winner… more news as we find out why Suzuki never installed this motor..  |
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Dec 10, 2023 12:24:58 GMT
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So after pulling some bits around… it seems the Sami manifolds are for an egr equipped vehicle and have a different exhaust port shape. Very much rectangular as opposed to round.
I think the answer is the turbo fanimold and then using another turbo mounting flange to start the exhaust build.
Daft question but how do achieve a decent flowing translation from square to round? Just a gentle pip squishing? Or do I need an adapter of as of yet unknown name
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zeberdee
Club Retro Rides Member
Posts: 1,041 
Club RR Member Number: 2
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Super Zooki - the SJ Samuraizeberdee
@zeberdee
Club Retro Rides Member 2
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Dec 10, 2023 14:03:57 GMT
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At a guess i’d say you’ll need some round exhaust pipe & flatten it to shape .
Possibly need a bigger diameter due to squaring it off ??
Can’t say i’ve ever seen a round to square exhaust adapter , but could be wrong .
👍
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Last Edit: Dec 10, 2023 14:05:16 GMT by zeberdee
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pptom
Part of things
Posts: 475
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Dec 10, 2023 14:06:53 GMT
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I put one of those turbo manifolds in my G13b (in a midget, now sold)
Had to take it off after a while and have it milled flat as it wouldn't seal against the head due to manufacturing warpage, but couldn't complain for the price.
I brought a rectangular flange to mount to it and maybe 20cm of appropriate sized stainless tube, one end of which I 'massaged' in a vice, so it fitted the rectangular profile.
I may still have an original swift GTi manifold in the garage? But it would need work as they're a transverse engine as you know, and the manifold ends under the sump so would be pointing directly at your driver's side front wheel.
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Dec 11, 2023 15:31:02 GMT
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Thanks PPtom, after a bit of heartache and sketching out, I’ve decided the approach of longer runners and ports that need matching are a better choice for a 4wd rather than the short runners of the turbo manifold.
The hunt is on at the moment for a mk1 swift side exit thermostat cover… with that and the new side exit dizzy we should be close to fitting in… maybe a light dressed of the bulkhead or at worst a bulkhead box let in.
Then is a question of getting in some exhaust parts, I don’t think the p shooter is going to cut it.
Thinking about a 2”bore with a centre box and a cherry bomb out the back.
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pptom
Part of things
Posts: 475
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Dec 11, 2023 18:35:25 GMT
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The thermostat cover I used was labeled as a Suzuki Alto Mk7
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pptom
Part of things
Posts: 475
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Dec 11, 2023 19:19:59 GMT
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Also, I have a .DWG file of the manifold flange ready to send to a laser cutter, someone else sent it to me and I got a quote but went for the turbo manifold in the end.
Pm me your e.mail address if you're interested
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