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, Dana 44/Dana 60 – welded.
• Full hydro-steering.
• Four link suspension F/B.
• 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.

Tube 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.

Wednesday the 30th of April 2008

It’s been a long time coming. Forever really. But things are finally starting
to move on the buggy. Dr. Smash is taking care of me.

It’s Running!

Well, it’s running and it’s doing good. Still have a few more things to work out. There is a lot of rattling. A lot. So I need to get the rubber in there to quiet that down. The Diff gears are way to high and I need to upgrade them to like 5.38′s. The rear seal on the engine is leaking pretty good. Going to try some stop leak on that. The steering valve is still giving me problems with turning left. Looks like I need a new one. Then a few other misc things. Always going to be something.

Updates for August 30th 2008

Got the buggy to the Rubicon! But the engine puked on me before I made
it to Cadillac Hill. Thank you Tim for pulling me back to staging.

Thank you to LD on Reno4x4 for the replacement Engine. I now have
another 1.6 VW that I’m moving all my turbo stuff to. So far the engine
looks great.

Anyway, it’s all good now.

Updates for September 21st 2008

Almost made it to the Rubicon again with my buggy for the Marlin Crawler
Roundup. The new engine started puking oil in the water just like last
time.

So now I’m looking for a new engine… Again. I need a 85 or up VW diesel.
I’d like to find the 1.9TD, but a 1.6TD 85 and up would be fine.

Everything else is great. Hope to be wheeling by next year.

Updates for October 19th 2008

Had Smash do the sides, so pretty much the body work is done…except the
fenders.

Updates for October 30st 2008

Ends up that my engines were fine. It was the oil cooler that was bad.
It was letting oil into the water. After getting the new oil cooler on
and replacing all the hoses I’m back running again.

I tried to go to the Fordyce trail, but my injector pump blew out. Fuel
was just pouring out. So after getting back I took it apart and tried
to put a new o-ring in it. After getting it put back into the buggy
I could not get the engine to start. I think I messed up the IP somehow.

Updates for January 1st 2010

I still haven’t had a full wheeling trip yet. I’m still having engine
issue. Still leaking fluids all over the place. I tried to find a
shop that would fix it up for me, but nobody wants to do it. So looks
like I’m going to have to do it myself. I purchased the seals, gaskets,
and stuff to repair the leaks. Now I have to put them in. Not looking
forward to that. The buggy still hasn’t ran since Fordyce. Well, maybe
I’ll have it running before summer. I can’t believe it’s been four years
already. Gotta get this done.

Updates for March 29th 2010

Got the engine all ready, painted, new stuff. Dropped it in the buggy.
I’m now having issues getting it timed. Still has the oil leak out the
back. Wondering if I should just dump this engine and go with something
else.

I’m thinking that something got messed up in the pump and I just can’t
get it timed right. It’s smoking a lot, noisy, and no power. I had to
replace a o-ring in the pump because it was leaking. So I had the back
all apart on it. Probably needs to be tuned.

I seen online that I can get a new pump for $400. But I have found
Sidekick engines on eBay for $600-$800. I could probably swap a Sidekick
engine in for like $1000 all said and done. A new VW engine is $2000.

Updates for June 2010

It’s been a long time coming.  I have been wheeling the WZ for a while now.  It works great!  It was rocky at first, but I have all the PITA issues fixed up.  Engine is running pretty good and the vibrations are all cleared up.

I have a few more things to do on the WZ to make it perfect.  Mainly just making things stronger.  The font axle needs to be replaced with a D60.  The engine needs to be replaced with the 1.9TD so I can go faster than 30MPH.  I still need to fix the transfer case.  Small things.

But I’m really happy with it.

Updates for August 2011

Over the past year I’ve been breaking my front axles pretty much every time I go out.  The last time I was told that I could get new cromo axles for around $600.  So I finally decided that I could put another $1000 into the rig and upgrade axles and u-joints.  $2300 later I have upgraded axles, u-joints, outers, drive fanges, and brakes.  That was way, way over budget.

I have also put the WZ up for sale.  I want to get about $14,000 for it.  I hate to do it, but I just can’t afford this sport.  I’m also getting way, way out of shape so I’m looking to get back into Mountain Biking.  I am going to buy a Santa Cruz Blur TR Carbon.  Can’t wait.