Budget: $20,000.00

Working with a budget of $20,000, I want to build a buggy style rock crawler with all the trimmings. I plan to do this by using low cost used and/or found parts.

Tools / Cost List:

Item	Price
Pro-Tools Bender	625
MIG Welder	400
Total	$1,025

Parts / Cost List:

Item	Price
Parts Samurai	$1,000
VW 1.6L TD Toyota 4sp Transmission Corp 14 Rear Axles with Locker A ton of other small stuff
2nd Parts Buggy	$4,500
Fully Running with everything Coilover Shocks Air System + Tank F/R Four Links Hydro Steer Rock Lights Tons of other stuff
Tubed Chassis	$1,200
Tubing Stock	$250
Lower Link 2" DOM	?
Marlin Dual Crawler	$1,600
Dana 44 Front	$100
Dana 60 Rear	$Freebie
Drive Shafts	$Freebie
37x12.5 Tires	$900
17x10 Rims	$252
Brakes & MC	$370
Fuel Cell Parts	$138
Radiator	$170
Exhaust	$30
Steering	$210
8x4 Alm Sheets x3	$315
Dr. Smash	$6,000
Total	$17,035

Project Wicked Zuk

I've been driving my tin top Samurai since 2004 and I have it upgraded to where I like it. I find myself wanting to do more rock crawling, so I'm going to build a Samurai Buggy. The tin top will get more upgrades in the future, but this year I want to be driving a full on rock buggy.

Early in 2005 I bought another Samurai to start my new project. It has full width axles, VW 1.6L TD engine, hydro-steering, seats, custom dash, and a few things.

The Plan

37-40" tires on 17" rims.
Full Width Axles (Corp 10/14) with spool/lockers.
Full width axles, Dana 44/Dana 60 - welded.
Full hydro-steering.
Four link suspension F/B.
14"/16" SAW Coilover shocks.
Full Tube Chassis.
Full Skid Plate bottom.
VW 1.6TD Engine.
Toyota Transmission.
Marlin Crawler Transfer Case.

Deconstruction

Here it goes. Deconstruction. I now have it down to a rolling chassis. I haven't been able to find a new frame for it, so I'm thinking about buying a full tube chassis instead. Might get interesting around here.

Pipe bender and Marlin Dual Transfer case on their way. I'm hoping to see them today.

It's the beginning of the end. Wicked Fab's Two Seater Malvado Chassis, #1.

More progress: Engine mounts, placement, rear axle cleaned up, purchased D44 front

OK, so today I welded on the mounting brackets for the t-case cross member and bolted up my engine mounts. Next I need to measure everything and get the engine mounts finished up.

Milestone 1

Today was a good day! I finally have the engine mounted in the chassis. It's all bolted in and ready to go. Now I can finally move on to the next step.

My Garage is finally DONE!

Here is a photo of my bender stand.

I had a slight set back this weekend. After thinking about it, and after trying to get things aligned up right, I decided that the engine was in the wrong place.

First hint was that there was no leg room. I needed a cargo area, so I didn't want to put the seats back too far. I'm thinking about putting the gas tank right behind the seats. So I need some space back there.

Next was the drive shafts. The rear was too short and the front was too long. My original thought was to center the t-case so that both drive shafts were the same length. That way I just need one spare.

So this weekend I cut everything off and re-did it all.

I finally found out what's wrong with my shifter. Well, the problem is that my shifter won't fit into my Marlin crawler box. It just won't go all the way in. Everyone told me just to push it in and get the retainer ring on it. Well When I did that, I busted the end of the shifter off.

So I got a new shifter from Randy and I tried to put it in. Same thing. It would not go. I try it in the back, and it works perfect. Both of them work in the back no problem. So I take the top cap off and found out that the small bit that they welded on is welded on wrong. So I'm going to have to grind it open a bit so my shifter will work. UHG!

I've been working on it again. Finally started to make some money. I'm saving up so I can have someone build the suspension for me. I just want a rolling chassis now.

Milestone 2

I now have all the parts to finish my Wicked Zuk buggy. I purchased a parts buggy from Dead&Company on Reno4x4.com. It has everything I wanted for my Zuk buggy. It didn't have any axles on it, but it has the full four link plus hydro steer from POS. There is a few problems with it, but that doesn't matter. I'm going to be tearing it down starting now in September 2007.

I think that I'm on track to finish for summer of 2008! Oh, and I have a new job now, so I think I can afford to do it finally.

Dr. Smash

The buggy is now at Dr. Smash's shop. I'm paying Smash to get the buggy running. What I would like to get back is a buggy that Runs, Turns, and Stops. I would like to be able to go from Smash's to Prison Hill do some wheeling, all without breaking.

We decided to do a three link front so it would be easier to get the chassis low to the ground and clear the engine and all that stuff. It will be like a moon-buggy with the large pan-hard bar. It should do really well.