Just a simple Sami buggy

[untchabl]

Decided to start a build thread for my little project. Been collecting parts and working on it for a few months now and starting to see some progress.

First of all, I want to say a huge thanks to Jason (@DirkaDirka875) for letting me take over his shop so he can help me with all the chassis fabrication.

Goals for the build
- simple 2-seater trail rig
- 106-108" wheelbase
- Tracker 2.0 engine & 4-speed transmission with Tracker/Toyota doubler
- 4-linked front and rear on Toyota axles with air shocks

Let's start at the beginning, this whole project started because the wife totaled our little knock-around 99 Tracker. I had been wanting another trail rig since our Wildcat just wasn't the same as a real buggy. So the Tracker made a perfect drivetrain donor.

Here is the Tracker after the wreck.

With the drivetrain sorted out, I found a rough Samurai body on Craigslist and stripped it down and pieces started falling off.

Built a frame out of 2"x4" .120 (the angle iron is just to keep it square)

Next up, chassis fab...

 

[untchabl]

After I got the chassis to this point, I took it over to @DirkaDirka875 shop to start bending tube. I'll just post a bunch of pics from the start until where we are now.

Chassis is 1.5" .120 DOM, sliders are 1.5" .250 DOM, lower links will be 2" .250 DOM, uppers 1.5" .120 DOM.

 

[XJsavage]

Turning a tub upside down to attach a subframe to is one neat trick I never would've thought of.
On those mounts where they attach to the sheet metal, is that a two sided plate that's thru bolted and welded or just welded?

 

[untchabl]

Turning a tub upside down to attach a subframe to is one neat trick I never would've thought of.
On those mounts where they attach to the sheet metal, is that a two sided plate that's thru bolted and welded or just welded?

The plates are only on the bottom and just welded to the sheet metal. The tub isn't going to be structural. Only thing that will be mounted to it is the pedals, brake booster and the auto shifter. Everything else will be mounted on the chassis, including the seats.

 

[untchabl]

More updates.

@DirkaDirka875 got the front shock hoops tied into the tube under the hood and he got the lower link mounts & lower links tacked up. We also got the driver side seat mount built and started on the rear of the chassis.

 

[untchabl]

Today we got the rear upper links done and are almost done with the rear of the chassis.

 

[BRUISER]

Very nice

 

[untchabl]

Got a set of 37" red label Krawlers this week. Trying to sell a few things so I can order some aluminum beadlocks.

And it's now a roller. With the loaner set of 37" Iroks, belly height is 15" at full bump.

 

[untchabl]

Beadlocks came in this week along with double ended steering ram.

 

[untchabl]

Got more of the rear of the chassis done several weeks ago.

Modified the stock motor mounts

 

[untchabl]

Yesterday we did the windshield spreaders and roof bars.

Fender braces

And the passenger seat mount

 

[Creekin]

Very nice
Looks like the fuel cell sits in the front between the driver and passenger?

 

[untchabl]

Very nice
Looks like the fuel cell sits in the front between the driver and passenger?

The fuel cell is just sitting there, that's not where it's going to be located.

 

[cgm147]

I dig it! I'd love to build me a Sami buggy at some point. Just curious about the seat mounting with the single tube under the front of the seat. I like it just not sure about it. Is that the final product on them?

Sent from my SM-G960U using Tapatalk

 

[untchabl]

I dig it! I'd love to build me a Sami buggy at some point. Just curious about the seat mounting with the single tube under the front of the seat. I like it just not sure about it. Is that the final product on them?

Sent from my SM-G960U using Tapatalk

Other than capping off the open ends of the tube and finish welding, the seat mounts are done. The single tube goes straight down to the top of the frame rails. I don't see them being an issue but I'm no expert so I welcome input from others.

 

[Loganwayne]

Maybe tie the front of the seats together with a tube across the trans tunnel. They probably will be fine but that would keep them from moving more than what you have now


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[Cribb]

Looks awesome. I remember you telling me about this when I bought those 2 tires from you. I'd like to think I've supported this build! Just kidding. Awesome work. I wish I had that talent and equipment. Looking forward to seeing it on the trails.

 

[jeepin' jen]

Man that looks good! Can I drop mine off!?

 

[untchabl]

Man that looks good! Can I drop mine off!?

Not sure if you'll want to do that. It won't cost you an arm or leg but how about a finger?

@DirkaDirka875 had a little accident several weeks ago while we were working on the buggy. He's all healed up now and back at it again.

My buggy has been named "Just the Tip" by several wheeling buddies after this.

 

[WARRIORWELDING]

ouch! glad that healed up good. Scars are like Tattoos with better stories..

 

[jeepin' jen]

Ouch that sucks - but glad to hear he's all healed up! Not sure I can afford that but maybe he can offer some pointers (sorry I couldn't resist )

 

[Infamous1]

Damn Jason now your finger matches your jim dangler!!

 

[untchabl]

@DirkaDirka875 pulled it out of the shop so he could turn it around. Next work day we plan to pull the mock-up drivetrain and install the real engine and trans so we can start on the t-case mount.

 

[untchabl]

Pulled out the mock-up drivetrain and installed the real one today.

Figured out the stock transmission tunnel wasn't going to work with the way we want to mount the transmission shifter, so we cut it out. We'll clean it up and make a new tunnel once we finish the rest of the cutting necessary to mount the t-case and keep a flat belly.

Got the driver side door bar started. Next time we'll do the passenger side and start on the dash.

Found out the fuel cell I've got isn't going to work out the way we want to so I ordered another one this evening. Hopefully it will be here by the end of the week so we can build the mounts next Monday. Every work day we move one step closer to getting it out of Jason's shop and ready to come home.

 

[untchabl]

Had another good work day yesterday. New fuel cell came in last week so we added more tube to the rear and built a mount. Just need to add a couple small pieces of tube for the Swag Action Packer mount and the NextVenture Canyon cooler mount then the rear is done.

We also got the door bars finished and started on the dash. Dash is going to be simple flat aluminum panels. A tablet with the Torque app is going to be used for gauges. Going to order an orbital mounted steering column this week.