Dan's Suzuki Samurai build

[dan_2k_uk]

Got the power steering pump on without modding the rad mount and using a standard belt as I wanted.

Will write this as a sort of write up in-case it wants using in the DIY section.

I don't know if this would clear a standard 1.3 rad bracket as mine is the 1.6 and I've modified the bracket. If it does foul it will certainly only need a little snip of the bracket rather than cutting the chassis mount which is better IMO.


Rather than using the official mount points (Red) I used one of them and one of the ones above (Green)




I shaved a bit off the bottom "key shaped" hole with a grinder (could easily be done with a file and some time) then filed it so both the top and "key shaped" holes were perfectly in the same plane. (I used a flat sheet on the other 3 bolt holes which are level to get this bang on level as it totally effects the angle the pump will mount at!)

Shaved off bit for reference +1.6mm for thickness of cutting disc



Finished Flat




Then modified the bracket holes a touch to suit the new spacing by drilling another hole and filing between the 2.






Then extended the groove that the adjuster nut runs in along to the extra hole that is already there using a hacksaw and round file to allow more movement.






Cut the redundant tab off the back as it will obscure one of the timing belt cover nuts if needed in the future.




Then fitted to the truck




Finally fit the pump and if all is done correctly it should line up perfectly. (This belt is actually slightly shorter than standard (813mm) at 800mm but you could probably get away with anything up to 840mm.



It seems rock solid just mounted with 2 bolts (with big heads) but if it gives problems in the future there is a handy bolt hole in the side of it (you can see the square nut in the last photo) where a bit of angle iron can be bolted and then fixed to the spare bolt hole on the block to the right of the top bolt.


I know Tom wanted to see this hence the extra effort on the write up.

Dan

[turbo-tom]

cheers dani shall hav a read

[ianedwards]

Nice one, will come in handy this.

Ian

[dan_2k_uk]

Power steering is all fitted apart from the steering colum linkage.

Read somewhere that it can be shortened by removing the plastic plugs but even with my biggest hammer I cant make it telescope in.

Any ideas

Dan

[ianedwards]

Did you go for the vitara or jimny box ?

Got to be honest I haven't really looked at mine yet. If you could pull it apart you could cut a bit off and grind the shaft down a bit more to fit in the other half a bit further and then hammer it in, it might be in as far as it will go. but That's a guess without having a look at one.

Ian

[dan_2k_uk]

Went for the jimny box as I have already got the rad mounted nice and didnt want to move it.

It wont budge either in or out. Sprayed a load of wd40 inside it so maybe things will go better tomorrow with some daylight on it.

Dan

[justaddmud]

nice idea with the mount, thats one of the reasons i went another route with the EPAS as i couldnt get anything to fit

If you havent already, and you still have the box out, try and popthe drop arm off, i didn't and on my box, it doesnt sit right, i run out of lock on the steering box one way, and have way too much on the other

[ScottieJ]

Power steering is all fitted apart from the steering colum linkage.

Read somewhere that it can be shortened by removing the plastic plugs but even with my biggest hammer I cant make it telescope in.

Any ideas

Dan

Just hit it! HARD! I didn't even remove the plastic plugs, you can always heat it up to melt the plastic and then hit it.

Handy little write up, we'll have to put it in the DIY section

[dan_2k_uk]

I measured the turns lock to lock on the steering box and centered it and its bang on.

Will have to hit the bar harder then. Need to find something to hold it as im a bit afraid of damaging the little uj.

Feel free to do whatever you want with the write up. Just trying to save others the time and hassle.

Dan

[ScottieJ]

Take the UJ off dan