What this page is all about

With all of the surfing around looking for docs, tuts, and/or articles on parts, specs, and/or conversions that I have done, I think its about time I put to paper all of the clutter I've been storing in my head for some time now. What I needed was a plan and hence this is what I came up with. It's basically a progression list of parts needed to complete my project and at the end is a list of spare parts. If you read through the list and it's descriptions and have any questions or suggestions on what I have planned or would like to sell, trade or buy any parts feel free to email me.

In the end my plan is to build the ultimate expedition vehicle that can go any where and carry four dudes, 200+ lb's of mountaineering gear, plenty of gas, and a cooler packed with base camp goodies with the option of pulling a trailer. It's got to be comfortable enough for 15+ hour highway trips and easy to strip for cleaning after being submerged in 5 ft if stagnant water. Parts also have to be abundant and cheap enough to replace at the drop of a hat. And by far one of the most important features is to maintain a decent gas mileage and emissions control.
History This list will be updated as changes are made.
§     Used 1988.5 Suzuki Samurai 100% stock, excellent condition $1,500.00
§     Calmini super 5" Lift system  $759.95
  It's an excellent kit and easy to install. Tech Note: buy an extra can or tube of silicon because the tube they supply isn't really enough and if you run out or don't cover enough of the bushing it will squeak.  
§     Calmini linkage steering  $269.95
  Much better but I still think I need to replace my steering shock.  
§     US Wheel 15x10" Modular rims with 2" backspacing from RockyRoad  $~327.00
  I couldn't afford beadlocks. They fit perfectly with no reduction in steering radius and even fit the stock spare mount.  
§     SuperSwamper 31x12.5" Thornbirds from Les Swhabs  $914.00
  Includes mounting and alignment. Tech Note: the large surface area of the tire and the light weight of the sam make it difficult to control during heavy rains and it can hydroplane at speeds as low as 30 mph.  
§     Trimmed fenders and bolted 3" Pacer flares at $2.50 a foot $~38.00
  Still not quite legal but it's a lot better than the 6 in. of protrusion from earlier. Tech Note: a scrollsaw is one of the best and easiest tools for cutting plastics such as fenders.  
Tech Spec  
  Displacement: 1298 cc Fuel: 10.6 gal  
  Power: 64 hp @ 5k Torque: 74 ft lbs @ 3.5k  
  Mileage: 24-29 mpg Emissions: 97/0.33  
  Weight: 2094 lbs Load:   
  Track: 59 in Wheelbase: 79.9 in  
  Articulation: 25 in Clearance: 10.75 in  
  Approach:  Departure:  
  Turn Radius: 16.7 ft Length: 135 in  
  Width: 73 in Height: 74 in  
  Current Sketch  
Now What Next I need more power to turn those knarly tires as depicted in the rendering on the background. My next agenda on a tight budget is to scrap the choked dinky stock exhaust system and replace it with a performance one. I'll probably go with the Calmini kit.
§     Petroworks carburetor vent tube  $9.95
  For a temporary fix if needed, my sam is an 88.5 and the tube appears to be only needed for 86-88's.  
§     Calmini performance exhaust system  $449.95
  The header must bolt to a 1.3L and 1.6L or I'll wait until I'm ready to drop in a new engine.  
Stock Parts that I'm either actively looking or keeping a eye open for. If you care to you can click on the part to see a photo. I have an ongoing debate as to how much of the samurai I want to keep stock. Much of the body I plan on keeping stock including the interior while much of the running gear, suspension, and engine I plan on changing.
Engine
§     None as of yet
Running
§     None as of yet
Suspension
§     None as of yet
Body
§     Driver side door $~100.00
   
§     Driver side mirror 88.5 $39.95
  From Petroworks. Actually the housing is fine, its just the glass that is gone.
§     Body plugs (x2) $2.00
  These are important when you live in Seattle.
§     Window-hood stopper  
  Or at least that is what it appears to be.
§     Soft-top rear tie-downs  
  I may scrap the velcro and go with a buckle system. Unfortunately velcro doesn't work well in a moist environment like Seattle and has a tendency to loosen.
§     Overhead roll bars with padding (x2)  
  There is a spot to mount an extra set of roll bars overhead, so why not. it's not as effective as an internal roll cage but it's much cheaper.
§     Interior driver side window crank $8.88
  From Petroworks. For some reason mine is brown unlike the rest of my vehicle.
§     Interior rear grab handles (x2)  
   
§     Center console doors $12.00
  AKA center bezel.
§     Dash screw and bracket   
  I need to find an anodized screw that matches the rest for the panel under the steering column. My dad's sam has a set that doesn't match and it looks pretty ghetto.
§     Rear tow hooks (x2)  
   
§     Steering house cover  
  The sun has pretty much taken it's toll on the cheap plastic and it's deteriorating.
§     Rear right mud flap  
  Yes they are pretty small for such a large tire but that adds to the toy look.
§     Trailer hitch receiver mount  
  My current one is bent. I could bend it back but for right now I'm just too lazy.
§     Book shelf cover  
  Or what ever that shelf under to glove box is called. I looks as if some sort of cover went over the compartment to keep stuff from sliding out when you accelerate. If one doesn't exist I'll have to make one.
§     Rear right side signal cover $~5.00
   
§     Brush guards  
  Only for the headlights if I get the ABR bumper.
§     Rear view mirror stopper  
  Those Thornbirds really rattle my mirror. it looks as is a mirror stopper/brace came with stock sam's but I can't confirm it.
§     Both right and left front fender joints  
  Due to extreme shackle swing back.
§     Battery tie down    
  Eventually I'm going to have a real problem if I don't get one of these. a stock one is my first bet but I'll go with a sturdy aftermarket one if I need to.
§     Rear seat fold down release handles  
  For some reason the original owner decided to cut them off.
§     Both right and left hand mirrors 86  
  To bolt onto windshield when doors are off or soft doors are on. unlike the 88.5-95 the 86-88 mirrors fit perfectly up front.
§     Windshield fold-down kit $99.00
  From Rocky Road. Not really a priority as of yet.
Electric
§     Air conditioning  
  You don't appreciate it until you need it.
§     Power steering  
  If not stock then some other easy to install kit.
§     Power brakes  
  If not stock then some other easy to install kit.
§     Radio antenna  
  The tip of mine is broken off.
§     Overhead indoor light  
Extras
§     None as of yet
Aftermarket Parts that I'm either planning for or considering.
Engine
§     Calmini exhaust system $449.95
  Includes catalytic converter, muffler, and exhaust header.
§     Weber 40mm sidedraft carburetor kit $799.95
  Still debating. Pro's - lots of power, Con's - poor mileage and emissions.
§     Calmini mid-range camshaft $149.95
   
§     Sidekick 1.6L 8-valve engine with harness $~1195.00
  I'm saving the 1.9L diesel for a later project.
§     Calmini 1.6L conversion kit $249.95
  With fuel pump.
§     Rebuild alternator to a higher amperage  
  When I start running an amp, 4 lights, a winch, and a cooler I'm gonna have a problem with out proper amperage.
§     Petroworks heavy-duty 3-row radiator $165.00
   
§     Petroworks power steering cooler $24.95
   
§     Oil radiator  
   
§     Transmission fluid radiator  
  Just keepin' it cool.
Running
§     Centerforce dual friction clutch $229.95
  From Calmini.
§     Clutch though-out bearing $39.95
  From Calmini.
§     Calmini birfield cups $99.95
   
§     Heavy duty front and rear axles $519.80
  Or full floater axle. if I go with a full floater rear axle then I shouldn't need a ring and pinion. Front 139.95x2 and rear 119.95x2
§     Calmini limited slip differential unit $399.95
  Or ABR Air Locker $649.00.
§     Calmini ring and pinion 4.57:1 ratio reduction $189.95
  So I can use 5th gear again
§     Calmini pinion bearing set $139.95
   
§     KAD driveshaft. $299.00
  From Rocky Road.
§     Heavy-duty t-case mounting arm $114.00
  From Rocky Road or Spidertrax.
§     Superwinch Locking Hubs $111.95
   
§     PBE Line Locker $259.00
  From Rocky Road. This is a necessity if I go with a Weber carb. If I stall in a climb with out fuel injection I can lock the breaks and start the rig with out worries of rolling backwards.
§     Replacement steering shock  
  Still Looking
Suspension
§     SKY Traction Bar $275.00
  Torsion bar.
§     Calmini rear u-bolt skid plates $59.95
  Rear skids aren't actually listed by Calmini.
Body
§     ARB front bull bar bumper $450.00
  From Rocky Road.
§     Custom rear bumper/swing-away system with tire, twin jerry can, axe, shovel, highlife jack mounts, and cooler rack  
  Still looking for a manufacturer.
§     Calmini safari rack $389.95
   
§     Bestop Sunsport soft top $254.95
  I wish Bestop made a hummer style slant top.
§     Calmini rocker skids $119.95
   
§     Quick release soft doors $~299.95
  I wish Bestop made a set.
§     Warn 8k lb winch $775.00
  From Petroworks. You never know when you may have to pull yourself and two other guys out at the same time.
§     Snorkel  
  Nuff said.
§     Internal roll cage $295.00
  Calmini, Petroworks $495.00, Trail Tough $295.00, and RockyRoad all have one, haven't decided yet.
§     Calmini front heavy duty tow bar $169.95
  I never want to pay towing ever again.
§     Seat covers for off roading  
  Something cheap, washable, and easy to put on and take off like a cotton t-shirt.
§     Bolt-on 2" trailer receiver from RockyRoad $48.00
   
§     2" trailer hitch ball  
   
§     Car cover  
  My rig is usually garaged but it would still be nice to have one.
§     Safari rack tarp or webbing  
  Preferably something to keep the rain off the gear.
§     Tubing  
  To make a makeshift heater route to the back seat in an effort to shut my buddies up during long winter trips - something removable.
§     Skid armor  
  Haven't decided yet. Most armor available is to heavy and needs to be ventilated.
§     Rhino-liner treatment  
  The whole underside and frame
§     Bomb-ass paint job  
  Just think Vamp MK II.
Electric
§     Xenon or IPF Headlamps  
   
§     Hella M500 light (x4) $69.95
   
§     Heavy duty 30 AMP relay from RockyRoad $6.45
   
§     Secondary AC plug routed to the back of the rig  
  For the ARB refrigerated cooler.
§     Second battery with dash switch  
  Have the Hellas, amp, and winch running off of the second.
§     Calmini secondary battery mount $59.95
   
§     CB radio  
  For those places my cell phone just wont reach.
§     6 or 8 ft whip antenna (x2)  
  Trying to make it look like an RC car as much as possible.
§     Diamond MM. Mp3 deck  
  Only deck with a hard drive.
§     Custom rear speakers with box built into tailgate  
  Need to conserve room.
§     PA system  
  For those times when honking is not enough.
§     Hella air horn $34.95
  Make that beep a BWHAP.
§     NOS kit  
  All I need really is the right carb attachment, I've had the setup for years. I'll only use it when I'm ready to start replacing parts.
Extras
§     ARB air compressor $189.95
  Or Spidertrax air compressor $269.10.
§     ARB air up kit $119.00
   
§     On-board welder $850.00
  From Rocky Road.
§     Calmini on-board welder bracket kit $129.95
   
§     D-cell Maglight mounting clips & Maglight  
   
§     ARB refrigerator 64 quart $~1099.00
   
§     Blitz 5 gal. steel gas cans (x2) $21.95
  From 4 Wheel Parts Wholesalers.
§     Blitz 6 gal. plastic gas can  $9.95
  From 4 Wheel Parts Wholesalers.
§     Blitz 6.5 gal. plastic water can  $9.95
  From 4 Wheel Parts Wholesalers.
§     Fire extinguisher mounts and unit  
   
§     Hi-lift Jack  
   
§     Jack-mate  
   
§     Axe   
   
§     Shovel  
   
§     Samurai LWB rear end  
  As a side note I'm looking for a the rear half of an LWB samurai from the doors back. I may not need the running gear either if that's an issue and it does not matter is it's a convertible or hard top.
Spare Parts Parts that I have lying around. This list will expand as time proceeds.
§     Stock brake lines (x3)
§     Stock locking hub (one working one not)
§     Stock front and rear spring and shock assemblies
§     Stock front u-bolts and corresponding bolt-plates
§     Stock front sway-bar
§     Stock Tie rod
§     Stock 88.5 wheels with snow tires (x4)
§     Stock 87 wheels with tires (x5)
   
Contact [email protected]
Disclaimer If links fail or images don't load it's due to the instability of the host provider and not this site, but thats what you get with a free host so I can't bitch; Eventually I hope to find a decent host. Also if you get a half billion adds popping up and want to remidy that try downloading this cool app called Popup Ad Filter.
Community .