I finally ordered an install kit
for the 1.6 16v motor I have sitting down at my work. The plan is to put
that into my Zuk, and utilize my existing transmission and t-case. I have
decided not to go with the automatic transmission for several reasons. The
biggest reason is based on what I have seen on the trails. With the
automatic you cannot tell when the drive train is getting bound up, this is
usually followed by something breaking. Above are a couple shots of the
wiring harness and my dogs making sure it's ok to work on. My goal is to
strip out all the unneeded wires.
Since my install kit isn't here
yet I decided to start work on the front end. I want to make the front
tubing match the rear and tie it in so it is one big structure. The dash
will get some attention, the seats will get tied into the cage and I am going to
try and eliminate the rocker panels.
My old front end came off easy
enough (it's for sale).
The main hoop was the toughest
part since it has to tie into the existing cage at two points.
I was going for a different
look this time. This front end turned out kind of sinister looking.
While I am in there the winch is getting moved back two inches, this should keep
the fairlead off the rocks. Getting the front end stripped down and the
basic tubing in shape took about 13 hours.
I must have been good
this year, Santa brought me some new seats and harnesses! I weighed my old
Eclipse seats: 35lbs each, the new ones are 16lbs ea.
Another day was spent moving
the winch, getting the light brackets worked out, and getting the hood pins
installed. I played around with getting a second set of lights next to the
headlights but I need to find some smaller ones.
I dug into the rocker panels on
Monday. Here's the drivers side, you can see the footwell sits down
pretty low. For kicks I weighed my old nerf bars (4 x 4 x.25 angle iron),
they weighed in at 28lbs each. I left Monday night with nothing more done.
Tuesday the plan began to take
shape. First I needed to secure the firewall so I could cut the two outer
body mounts off. I ran a tube from the shock mount to the rear of the
rig. This tube will eventually be the nerf bar. I left the end
open so I could slide another tube inside of this one. From past
experience .120 wall tubing does not hold up well to repeated rock hits and
dragging. I also tied the upper and lower tubes together and made a panel
to hide the battery and wiring. The second picture shows the flex test,
it'll be close, I think it will just barely rub on the trail.
Here's a few more pictures I
took before I left Tuesday night. I haven't trimmed the passenger side
rocker panels yet.