Suzuki Buggy post rear-end detonation rebuild (lots of pics)

[ObeseFieldMouse]

So this is an update thread. Back in Sept. we were headed to Windrock, so I took the buggy down to work to fill the diffs (rear one leaked from damage to drain plug) and check everything over before hitting the road. This was Wednesday before we leave. This is what I found...



Figured since we were leaving the next day, not much I could do about it, so oh well...Lets make sure this turd is full. Filled it up, and if you noticed, theres a whole lot of fluid dumping out from places it shouldn't be...most all the fluid poured right back out in the floor...



I will later find out that this crap caused it all. Lesson learned about welding diffs. Notice the chunk missing.



Oh well...screw it. Hope it holds together. Went to Windrock, had a blast, but definately had a horrible bumping/grinding/howling you name it ungodly horrible noise in the back the 3 days we were there.




So when we got home, the rear diff locked up driving down the road infront on my house to the shed I store it in. Broke it loose with a few low range clutch dumps, and pulled the rear driveshaft. Went up to the house a few days later to cut the diff cover off and begin disassembly. These were my findings...




Evidently, lubrication IS needed...Bought a rear IFS housing (I had been running a pre-85 housing) and cut all the brackets off, got it all shined up and sexy like. Then pulled the Suzuki in the basement and pondered my next step for a few days. Should I go back with leaf springs because they worked impeccably, or go ahead a 4link it and risk losing what I'm used to driving. After a few days, I decided if i was going to spend money to build it, why not upgrade it. So, 45 minutes later....

 

[ObeseFieldMouse]

I then ordered a proper full spool, and a shit load of brackets, and built a diff.




Well, then I got to work trying to figure out how all these links were gonna fit under the thing. Mocked a few links up, and half bolted the driveshaft in. I wasn't really liking what i was seeing. The driveshaft had practically no clearance from the lower link mount. Beyond that, the lower link had maybe 2 inches of up travel before it would contact the upper link bracket, and the vertical separation between the upper and lower links was pathetic. Not a fan.





Things just got serious. Jerked the seats out of the truck and got out the fire wrench and blade of doom. Removed what I deemed to be in the way behind the seats.

 

[ObeseFieldMouse]

After some surgery, I tacked up a bracket or two and started locating my upper link mount and determining how to build a frame around it and "french" it in, if you will...





I was getting a lot done this particular day. I was off work, as it was Christmas Eve. Finished up the new frame rail stubby, and built a ladder style gusset along the lower link mounts to keep it rigid.




So now that was completed, I needed to finish up the axle. Had to locate the spring pads and clearance them to fit over the lower link mounts, and build an upper link tower. Unfortunately, my day was about to end real quick and in a hurry. I learned that when using a 10amp grinder, you definately shouldnt hold the object you're grinding down with your knee. As it turns out, a grind makes quick work of meat when it jumps. USE A VICE!! (or a friends knee)



A few layers of stitches, 2 weeks on crutches and a copious amount of cursing later, I finally got back to working on it, just at a much slower rate. Still sucks to bend.



Got to work building the upper axle truss. Worked out pretty well.

 

[ObeseFieldMouse]

After this, had my brother and friend come over this past weekend to help my still partially crippled tail get this turd ready for the flats open ride. Got the springs in, brake lines ran, driveshafts bolted in and I finished getting shocks etc installed and painted yesterday.




I still havn't gotten to test the flex beyond using a lift, but I'm sure I'll find out this weekend...



Now all I have to worry about is the gnomes in the engine trying to get out via hammer holes. I have an engine and turbocharger sitting in the basement that was supposed to be this winters project...

Hope ya'll enjoyed the write up. I got bored.

 

[jaybird1ton]

Looks good man. You coming this weekend to the flats?

PLAN YOUR NEXT RIDE @ THE FLATS 828-442-7932

 

[frankenyoter]

 

[ORV design and fab]

What springs you using in the rear? Seems to work well. Ill be at the flats as well. See ya then

 

[BRUISER]

nice job

 

[ObeseFieldMouse]

yea ill be there around 9am saturday. i have 6cyl cherokee coils at all 4 corners

 

[drkelly]

About time you did a build thread. The rig looks really good. I wish my Samurai was linked like that and on 37's.

 

[ObeseFieldMouse]

danny im pretty sure we could make that happen...i remember you already having some yota axles laying around somewhere...

 

[4wheelBUM]

Love the build! Im wanting to do the same to my rear suspension probably next winter. I have always liked your rig and it does great. If you don't mind me asking who did you get your links and brackets for the coils from? Im the guy you borrowed the allen socket from this weekend by the way at the Flatts! Name is Dustin and it was good to meet you.

 

[ObeseFieldMouse]

Most of the brackets I got from ballistic fabrication. The links are 2" .250 wall DOM tube, I bought threaded adapters and joints from trail gear. Wasnt really that bad to do. If you need some help, give me a shout. Name's Adam. I just posted some videos on the event thread. Blew the motor lol.

 

[cardudenc]

so the engine finally blew? I was n ft of u on the upper playground as u was playing on that 1 climb. I kept wondering when oil was going to go flying. lol

 

[ObeseFieldMouse]

Lol yea it did. It's been trying to blow up for two years. I finally convinced it. You know you have a problem when you have a spare engine in your basement floor...