KJA cut n shut

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stevepsj413
Engaged 4wd low
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KJA cut n shut

Post by stevepsj413 » Fri Aug 21, 2015 7:40 pm

Thought i'd share some photos on here of my latest project. Its a 1986 suzuki sj413 kja pickup, i got it of the guy who i got my hardtop samurai off, it had been sat in a field for the last 10+ years, most of the parts had long since been removed and used elsewhere and the rot had well and truly set in to the remains of the cab, but it did come with a spare cab, also rotten and a spare bed, which was only slightly rotten, the deal was done and it was mine! That was at the begining of March since then i've been flat out on it when im not at work. Its getting there slowly so heres the photos to show you.
Attachments
This was how it looked when i first saw it.
This was how it looked when i first saw it.
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The roof had a sunroof put in it which had rot all round it, it was totally shot round both A pillars, and the front bulkhead and floors were past repair, the only saveable part of the cab was the rear bulkhead and B pillars
The roof had a sunroof put in it which had rot all round it, it was totally shot round both A pillars, and the front bulkhead and floors were past repair, the only saveable part of the cab was the rear bulkhead and B pillars
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This is the other cab that came with it, it had sat in that spot for years and the rear bulkhead and B pillars were absolutely rotten, can you see what im thinking yet?
This is the other cab that came with it, it had sat in that spot for years and the rear bulkhead and B pillars were absolutely rotten, can you see what im thinking yet?
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8th March, towed it to my lock up on an a-frame
8th March, towed it to my lock up on an a-frame
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Got the prop shafts with it, and the transfer box with the prop brake was still on it.
Got the prop shafts with it, and the transfer box with the prop brake was still on it.
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Also got a bonnet with it.
Also got a bonnet with it.
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This is the bed i got with it, the metal arches are rotten and the bottom of the bulkhead and front bed mounts are also rotted out, the main part of the bed is solid tho.
This is the bed i got with it, the metal arches are rotten and the bottom of the bulkhead and front bed mounts are also rotted out, the main part of the bed is solid tho.
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The bed thats on it at the moment.
The bed thats on it at the moment.
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Original dealer sticker, i think it sums it up perfectly
Original dealer sticker, i think it sums it up perfectly
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Didnt get the other cab until 4th april, couldnt get a trailer till then, but i had done the work needed to the chassis
Didnt get the other cab until 4th april, couldnt get a trailer till then, but i had done the work needed to the chassis
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The chassis needed a new rail welding in to fix the petrol tank to a couple of the bed mounts needed replacing and someone had cut the engine mounts off, i soon had these done. I'd taken the axles and running gear home and was refurbishing those in my garage at home.
The chassis needed a new rail welding in to fix the petrol tank to a couple of the bed mounts needed replacing and someone had cut the engine mounts off, i soon had these done. I'd taken the axles and running gear home and was refurbishing those in my garage at home.
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Next was onto cutting the B pillars off the black cab, i just used a spot weld drill round the roof and bottom of the sill panels and then cut across the floor with a grinder.
Next was onto cutting the B pillars off the black cab, i just used a spot weld drill round the roof and bottom of the sill panels and then cut across the floor with a grinder.
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Then i did the same with the blue cab, drilled the same spot welds round the roof and sills and then cut the floor.
Then i did the same with the blue cab, drilled the same spot welds round the roof and sills and then cut the floor.
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The two halves lined up well, even the spot welds i'd drilled all lined up
The two halves lined up well, even the spot welds i'd drilled all lined up
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Welded together and the doors lined up sweet as a nut.
Welded together and the doors lined up sweet as a nut.
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Left the floor to overlap by an inch and welded the top and bottom of it.
Left the floor to overlap by an inch and welded the top and bottom of it.
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Had a new rear tunnel because the old one was rotten, drilled the spots out and welded the new one in.
Had a new rear tunnel because the old one was rotten, drilled the spots out and welded the new one in.
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Next was the sills, grinder time again.
Next was the sills, grinder time again.
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Replaced with 90mm x 90mm 3mm wall box section.
Replaced with 90mm x 90mm 3mm wall box section.
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After a bit of seam sealering it was time for undercoat.
After a bit of seam sealering it was time for undercoat.
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Then topcoat, i went for the original suzuki quattro blue 26f paint, only got a little 25l compressor and im no painter, but for a first time spraying a car im happy enough with it.
Then topcoat, i went for the original suzuki quattro blue 26f paint, only got a little 25l compressor and im no painter, but for a first time spraying a car im happy enough with it.
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donkeychomp
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Re: KJA cut n shut

Post by donkeychomp » Fri Aug 21, 2015 8:04 pm

Bloody hell! I'm well impressed, top work matey.
If it ticks over...leave it
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stevepsj413
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Re: KJA cut n shut

Post by stevepsj413 » Fri Aug 21, 2015 8:09 pm

Time to start re-assembly.
Attachments
Cab back on the chassis
Cab back on the chassis
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Steering wheel and dash wiring loom in.
Steering wheel and dash wiring loom in.
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Had no keys with it so i took the barrel to bits and filed the pins so it starts with the same key as my other samurai, also did the same to the door locks.
Had no keys with it so i took the barrel to bits and filed the pins so it starts with the same key as my other samurai, also did the same to the door locks.
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Had a passenger side wing and front panel off a samurai so i painted and fitted these next.
Had a passenger side wing and front panel off a samurai so i painted and fitted these next.
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Re-fitted back screen, left the sticker on.
Re-fitted back screen, left the sticker on.
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Then painted the bonnet and fitted an engine, put a 1.6 8v vitara carb lump in her.
Then painted the bonnet and fitted an engine, put a 1.6 8v vitara carb lump in her.
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Then repaired the bed, plated the bulkhead and put new bed mounts on it, i also cut the rotted archs off.
Then repaired the bed, plated the bulkhead and put new bed mounts on it, i also cut the rotted archs off.
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Then painted and undersealed it.
Then painted and undersealed it.
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Fitted back on the chassis
Fitted back on the chassis
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Needed some replacement archs...
Needed some replacement archs...
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...my mate got me some off his ride on lawnmower, painted them and fitted them.
...my mate got me some off his ride on lawnmower, painted them and fitted them.
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Front screen in
Front screen in
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The sides and back were past it so i got some 1" box section and a tall filing cabinet from work
The sides and back were past it so i got some 1" box section and a tall filing cabinet from work
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Fitted the sides, just waiting for the latches to arrive before i fit the back.
Fitted the sides, just waiting for the latches to arrive before i fit the back.
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Martin86
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Re: KJA cut n shut

Post by Martin86 » Sat Aug 22, 2015 10:12 am

Wow 8-)
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RickUK
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Re: KJA cut n shut

Post by RickUK » Sat Aug 22, 2015 10:16 am

Must admit from the 1st photo to the last photo that is a rather stunning transformation,infact remarkable :doublethumbs:
Deceased.
SJ413 tinwormed to the great car grave yard in the sky.
Vitara LWB V6 engine deceased and also in the great grave yard in the sky.
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Tramp
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Re: KJA cut n shut

Post by Tramp » Sat Aug 22, 2015 12:47 pm

Great work, looking fantastic, it's a shame you can't save the embossed 'suzuki' from the tailgate, but it's looking really well. You did well saving this Kia, better ones than that have been scrapped!
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Rhinoman
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Re: KJA cut n shut

Post by Rhinoman » Sat Aug 22, 2015 2:02 pm

Good work, you were lucky to get the extra cab.
2006 Jimny JLX+ 1.3 VVT
2000 Vitara 4u2 - Calmini 3+3, 33" MTs, 5:83 R&Ps, winch bumper, remapped ECU.
1986 Suzuki SJ413K - G16 conversion
1984 Suzuki SJ410 - Blitz
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dan_2k_uk
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Re: KJA cut n shut

Post by dan_2k_uk » Sat Aug 22, 2015 8:22 pm

Nice work. Another one saved.
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ROBBIE
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Re: KJA cut n shut

Post by ROBBIE » Sun Aug 23, 2015 9:38 pm

Nice work mate, something to be proud of :salute:
Sid James gone but never forgotten
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gamble63
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Re: KJA cut n shut

Post by gamble63 » Mon Aug 24, 2015 2:23 pm

amazing, that is very impressive!
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