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zukking01
09-10-2006, 01:04 PM
I am looking to do a 4.3 swap into my zuk. I have a rebuilt marine 4.3 with bad carb for a $100 :shocked!: or a 4.3 TBI vehicle with no trans for $300 :shocked!: I am leaning towards the TBI for $300

Anybody done this swap or know somwone who has? I need a trans but they tell me only a 200r4 will work but why not a 350? I know the 700r4 is too long but is the 300 too tall or what?

Making my own kit. Any advice on what to get, fans, anno can for brain box, how to run wires, where to cut harness? The TBI is somewhere in the 88 range so it should have less sensors/emissions. Any info would greatly help.

DesertZuki
09-10-2006, 02:15 PM
...I have a rebuilt marine 4.3 with bad carb for a $100 or a 4.3 TBI vehicle with no trans for $300...I had a boat mechanic tell me you can run car engines in boats but you can't run boat engines in cars (for long). I don't remember why other than something about tolerances being so much greater on one of the engines.

I am leaning towards the TBI for $300After having carbs almost all my life and having fuel injection now, I'd spend the extra money on the FI.

mkyhmltn
09-10-2006, 02:34 PM
Fords C4 will also work if your so inclined Flat-o products makes an adapter.
Check them out at www.flat-o.com.

Rock4xFab
09-10-2006, 03:55 PM
4.3, 700r4 and a toy case.. Fits fine. and runs 100mph no vibes, Problem with 350 is hwy REVs Who ever told you only 200r will work should go pound sand they dont have a clue, And if you contacted lightning conversions tell them to call me I will tell them They have no Clue. The 700r4 allows mating of a case not divorsed also it is with in an 1' in length to the 350 trans +you get an overdrive. I can run 65 at 1500 rpm

http://i10.photobucket.com/albums/a102/rockfab/kimera146.jpg

http://i10.photobucket.com/albums/a102/rockfab/kimera001.jpg

http://i10.photobucket.com/albums/a102/rockfab/overallside.jpg

http://i10.photobucket.com/albums/a102/rockfab/kimera8412.jpg

zukking01
09-10-2006, 06:11 PM
Who ever told you only 200r will work should go pound sand they dont have a clue

And the answer is..........................YES, lightening conversions.

I want the 4.3 TBI and I would like the 700r4 but why would I do a toy case over a zuk case? Do you sell adapters for this and if so give me a link. I didnt want a LC kit and RR kit is from LC so I was thinking I had to make my own.

Rock4xFab
09-11-2006, 07:26 AM
And the answer is..........................YES, lightening conversions.

I want the 4.3 TBI and I would like the 700r4 but why would I do a toy case over a zuk case? Do you sell adapters for this and if so give me a link. I didnt want a LC kit and RR kit is from LC so I was thinking I had to make my own.


With a 200 r4 you have to have t-case unmated do to it being a 2wd trans. Now with the 700r4 you can get a 4wd trans case setup. Advantage NO jack shaft and better drivleing setup. With a zuk case it has to be dropped 4-5 " and back 6" IT looks like crap and the front shaft still hits the oil pan. I will have to find those pics. We have redone a few of lightnings 4wd 4.3 converions.:shocked!: My kids have better skills. Now for a kit Yes we can source the parts you need to make it all work. Motor mounts, radiator, header, wiring etc. We have done ours with no body lifts to make a cleaner look, but it does help for the guy that may not have the fab/welding skills. Feel free to call us and we can go over everything with you.
-Scott
Rock 4X Fabrication,LCC
1-847-544-1823 and you can also go here to read a 68 page writeup I did on this build.

http://bbs.zuwharrie.com/content/topic,18810.msg184782.html#msg184782

Rock4xFab
09-12-2006, 12:44 AM
case brackets
http://i10.photobucket.com/albums/a102/rockfab/Tcasemountinstalled.jpg

http://i10.photobucket.com/albums/a102/rockfab/frontshot.jpg

http://i10.photobucket.com/albums/a102/rockfab/fuelterminated.jpg

http://i10.photobucket.com/albums/a102/rockfab/overallside.jpg

http://i10.photobucket.com/albums/a102/rockfab/sideshot.jpg

http://i10.photobucket.com/albums/a102/rockfab/speedsensor.jpg

http://i10.photobucket.com/albums/a102/rockfab/tank.jpg

http://i10.photobucket.com/albums/a102/rockfab/kimera002.jpg

http://i10.photobucket.com/albums/a102/rockfab/kimera001.jpg

Rock4xFab
09-12-2006, 12:47 AM
Radiator Griffin Aluminum $450. Motor side mounts Moroso, frame side we made, motor mount bushings we made. (Exhaust stock manifolds cut and modefied Lightning CRAP) from another thread S-10 4wd headers from headman can be used. T-case mount we made coupling it to a FROR center section for the toy case. They run a couple hundred bucks through FROR. Toy rear shaft used at both ends one lengthened, one shortened. Rear 18.5" long front is around 39" if I recall. Tub dog tunnel cut and modefied so as not to have to use a body lift we can supply the metal inserts and cut templates for $85.

alternative parts AA motor mounts $105
Ford mustang radiator early 65-67 erra $$??
DO not order Block hugger headers from sanderson THEY WILL NOT FIT.
When installing a true vortec injected motor.. harness and computers can be purchased through Howel or Painless , or Make it up yourself we have it is not hard if you have patience. STAY AWAY from fuel injection specialist out of Texas I was screwed twice with computer reprograms. FI motors need only a few basic signals left, 1 OIL PSI, EGR,WATER TEMP, KNock sensor, MAP, or MAS. 700r4 are the easiest trans due to no computer control. The 4L60E and 80E need VSS signals to calibrate and shift. I have one it works I would never do it again. Stay mated to a case if at all possable, divorced willl only make the drivelines shorter and angles to extreme.

Rockit
09-14-2006, 12:57 AM
I just completed a 4.3 swap and I have to say it wasn't that hard but I did run into some problems that took some research to figure out. Rock4xfab is the Man, he helped me out with some of my questions and got me a radiator that fit perfect.

Some of the things that I did
Motor mounts I used from an s 10 blazed. the truck and van are different,
I used the sami t case with a slip yoke.1310 u-joint and a spicer 1309 flange yoke to mate the t case to the 350 th. Its a special built flange yoke that I got from 6 states and slyco has them also. They do need a little machining to make them fit.

The exhausted manifolds I used the steel ones. I think the left side one was hard to find because GM used one steel and one cast on alot of there motors. Then I had to modify them a little to miss the frame. and move the brake lines on the right side because they were right in the way.
I used a stock wiring harness from a 94 astro van, just cut off all the extra's that I didn't use. I added an extra fuse block to power up the computer. There'r only 4 or 5 wires that you need to use. if its a daily driver you need to use the vss (speed censor that runs off the speedo cable so it will close the loop on the computer) mine's just off road so I didn't use it.
My trans being the th 350 my top speed is only 45 to 50 miles per hour another problem if you want to drive it on the street. I only had to move the t case back a couple of inches with the set up I have which give a decent drive line lengh.
I did a two inch body lift but still had to modify the trans tunnel so the transmission would fit in it. My son has a 3" lift on his and his didn't need as much modifcation.
Well have fun and if you come through Price stop in and have a look

zukking01
09-14-2006, 08:34 AM
Thanks for all the info guys. I am looking at a 87 s10 4.3 non vortec tbi engine. I am also looking for a 700r4 and a 208 case. If I cant find a 208 I will go with a 241 but the 208 has a lower low range and the 700r4 has a overdrive so I will be able to wheel the crap out of it and DD the thing.

zukking01
09-19-2006, 11:45 PM
Just a little update.

I found a 89 4.3 tbi non vortec engine with a howell harness, ECU and a fuel pump for a bit of money. Was worht it to me not to have to deal with cutting wires. I now need the 700r4, whatever transfer case, shifting linkage, radiator, and motor mounts and I will be ready to gut this pig and get the new engine in her.

felixnstiches
09-21-2006, 01:45 AM
hey zook king....thank you for helping me out every now and then....it turns out i had a clogged jet in my carb....your project seams interesting and fun...to bad i can't be there to sit there and watch as well as help ya drink ya beer lol...anyways keep us updated please...oh yea what are you doing with your old set up?

zukking01
09-21-2006, 08:40 AM
Gload that I could help you fix your vehicle. You need to drop that carb and go to fuel injection. With that said....


I am selling my power trane in pieces. Some of it is in the for sale section like the tcase and the MY-FI but the engine, rebuilt trans and exhaust are too heavy to ship so I listed them locally.

zukking01
09-26-2006, 09:55 PM
I have now gutted the entire vehicle. Engine, trans, case, exhaust, P/S, and all drivelines. Now I have room to mock up my 4.3 and my 700r4 auto trans. Dont have a t case yet and still deciding on one. I will prabably find out on saturday what is available. What do you guys think of the np 208,241 and 300?

Hardline
09-26-2006, 10:43 PM
Hey Scott, Is there a reason for not going with a Dana 300? Gotta love them front digs! Also I currently have 6.5 gears in the T case. How much of a difference would there be seen in the crawl ratio. Thanks JJ

zukking01
09-26-2006, 11:25 PM
Is there a reason for not going with a Dana 300?

My bad, I wrote it wrong. I am looking for a np208, np241 or a dana(spicer) 300 case. They are almost rare in utah and ther run about 300-450 when they come around. I think I found a few internationals in a no name yard and they had their cases still mounted. I will find the price and find out what the cases are and maybe pick a few up. Can you give me all info known on the dana 300?

zukking01
09-30-2006, 10:59 AM
Alright... So the transmision I pulled from the yard last week is shot to crap. The torque converter iw melted to the imput shaft and when I pulled the drain plug the stench of burned trans fluid reaked. So I need to take it back and exchange it by pulling another one. This sucks.

Rockit
10-02-2006, 12:02 AM
I was woundering why you want to use the non vortec engine? I have done both the tbi and vortec engines in zuki's and I built my own wiring harness for both and I have to say the vortec was easier for me. When are you going to have this done so we can go to moab? Rock 4x4 fab said he may come out in Feb with a friend, that could be a trip to plan for.

zukking01
10-02-2006, 12:35 AM
The reason for the non vortec engine is because I have a howell harness for one that is complete labeled and with ecm. I have a lead on a trans but I am wating for a case. What case did you run behind your th350. I will be running a 700r4 and was thinking of a dana 300. I also have toyota axles with 4.88 gears, that is the reason for the 4th gear.

Rockit
10-02-2006, 10:04 AM
I just run the stock sami case with stock gears so far. In the axles I have 4.70 -1 top speed is only 45 miles an hour. That 700r is the way to go if you drive on the road.

zukking01
10-03-2006, 08:29 AM
I want to make this my DD but I will have to deal with making the engine swap legal or just register in Tooele or Idaho.

Rockit
10-03-2006, 09:41 PM
Are you going to move the rear axle back some. My sons sami is street legal with 4.3 conversion (almost tires to wide) and he moved has rear axle back a few inchs so his rear drive line would not be to short. The longer wheel base helps to.

zukking01
10-04-2006, 11:11 PM
My sons sami is street legal with 4.3 conversion.


How did you do that with all the emissions hype in Utah? Does he have all emissions on vehicle and where did you go to pass?


I found a strong running 700r4 today for a measily $150 :shocked!: I picked the thing up and it looks great. Very little dirt and oil on it and still has fluid in it. Came with the down shift cable and the troque converter plus the bottom cover of trans, cooling lines and all the bolts. The guy even gives a money back guarantee on it.

zukking01
10-07-2006, 02:55 PM
I ended up with a NP205 all gear driven transfer case to go behind my 700r4. Got a great deal on the case but was told by many that it would bolt up to my 700r4 and I cant figure out how to do it. Anybody have some chevy experience?

mahana79
10-07-2006, 10:53 PM
im pretty sure the 205 never came behind a 700r4 stock so it is going to be a custom adapter

here is what i have found.
https://eshop.advanceadapters.com/commerce/catalog/product.jsp?product_id=1519&czuid=1160276641099

https://eshop.advanceadapters.com/commerce/catalog/product.jsp?product_id=1518&czuid=1160276641099

https://eshop.advanceadapters.com/commerce/catalog/product.jsp?product_id=2633&czuid=1160276641109

zukking01
10-07-2006, 11:03 PM
im pretty sure the 205 never came behind a 700r4 stock so it is going to be a custom adapter

You are correc. It came out of a th350 with a 27 spline count. Thanks for looking into it. I dont need to switch the shaft in the trans I just need a flange adapter because the splines are the same count. I have a guy locally that has the aluminum adapter for $40 but I think I want to make one out of steel and while I am at it clock the case to fit flat against the body to increase ground clearance.

zukking01
10-22-2006, 02:16 PM
I havent updated for a while so here it goes. I have the engine mounts made up and tacked in place. THe brake lines on the pass side are in the way and will need to be move a bit. The trans tunnel is cut a bit and will be fun fabricating a new one. The transfer case is broken from purchase so I returned it for full refund but an now looking for a new one. Nobody has one exept the crazy people who want 350-400 instead of the average 150-175 price. I still need a shifter for my 4 speed auto and then the rad. and p/s and other stuff aside from mocking it up. Will try to get pics in a bit. The wife came home from vacation and the camera is full so I need to make some space before pics can be taken.

Rockit
10-23-2006, 12:18 AM
How did you do that with all the emissions hype in Utah? Does he have all emissions on vehicle and where did you go to pass?


I found a strong running 700r4 today for a measily $150 :shocked!: I picked the thing up and it looks great. Very little dirt and oil on it and still has fluid in it. Came with the down shift cable and the troque converter plus the bottom cover of trans, cooling lines and all the bolts. The guy even gives a money back guarantee on it.


In Price we don't do emissions testing. Thats just you lucky guys up state.

okiesean
10-24-2006, 08:57 PM
Ever thought about going with a Turbo diesel motor out of a VW? I heard they are awesome and really dependable

okiesean
10-24-2006, 08:58 PM
Just a thought. I heard they have less problems with them than the 4.3L and the weight is supposedly a lot lighter.

okiesean
10-24-2006, 08:59 PM
PS Hey Rock4x where did you get that snorkel kit or did you make it?

Massazooketts
10-26-2006, 08:56 AM
a dana 300 bolts right up to the 700r4 minus one single bolt that can be drilled and installed if you would like. Total length is not bad, especially if you are going to stretch it a tiny bit. A 300 should be strong enough, and definitly not overkill like a 205.

zukking01
10-26-2006, 09:29 AM
a dana 300 bolts right up to the 700r4 minus one single bolt.

Yes and no, A dana 300 in stock for is something like a 23 spline. I would need to change the imput shaft to a 27 and it would cost about 450 from novak or AA. That is why I am going to go with the 205

Massazooketts
10-26-2006, 09:49 AM
Yes and no, A dana 300 in stock for is something like a 23 spline. I would need to change the imput shaft to a 27 and it would cost about 450 from novak or AA. That is why I am going to go with the 205

I forgot where I got mine a while back, but it was no where near that cost. I think it was like a 100 bucks or less. 150 tops. I will see if I can rmemeber where I got it.

zukking01
10-28-2006, 11:13 PM
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready007.jpg
This is the stock passenger side manifold that si in the way. YOu can modify it or buy hedders. I am on an EXTREME budget so I will make this one fit.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready008.jpg
Starting to cut and paste the manifold to my liking.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready009.jpg
Welded up. May not be the prettiest but it will do. :jumping:

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready010.jpg
Hope this thing works great.

What do you guys think of my custom exhaust, Good/bad?

zukking01
10-28-2006, 11:17 PM
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready001.jpg
Here is the new view of the engine and transmission compartment without the clip.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready002.jpg
Close up of the drivers motor mount. Overkill but I only had 3/8 flat bar.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready003.jpg
Took a lot out of the trans tunnel.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready004.jpg
Drivers side of trans tunnel from inside cab.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready005.jpg
Passenger side of tans tunnel from inside cab.

zukking01
10-28-2006, 11:22 PM
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready006.jpg
The new demon is from a 1989 s10 blazer 4.3 TBI

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready011.jpg
Pic of engine mounted.

http://s50.photobucket.com/albums/f333/zukking01/PictureInternetready012.jpg
Another mounted pic.

http://s50.photobucket.com/albums/f333/zukking01/PictureInternetready014.jpg
Showing just how tight this will be. 4.3/700r4/np205. Mounted nice and hight in the body. Will cover all holes with sheet metal and weld properly. No pop rivets here. :funny:

http://s50.photobucket.com/albums/f333/zukking01/PictureInternetready013.jpg
THis will be fun to get it all coverd and get the seats back in. Hopefully I can get the carpet to fit after it all.

Madzooki
10-29-2006, 05:34 PM
DId the NP205 fit between the framerails without having to make it offcenter.

Paul

zukking01
10-29-2006, 06:40 PM
DId the NP205 fit between the framerails without having to make it offcenter.Paul

THe 205 fit right in the end of the trans tunnel with no special clocking ring or offset adapter. The only thing needed was an adapter that stretched the end of the 700r4 so that it would fit on the tail shaft. The adapter didnt work as great as I had been told. I had to shave 1/4" off the transmisson output shaft and regrind the tapered edge.

Yes it fit inbetween the fraimrail barely. I am actually going to drill throught the pass frame and sleeve it and mount the t-case to that.

Marshall
10-29-2006, 08:01 PM
Nice work man! I like the job you did on the exhaust manifold, it looks good.

Madzooki
10-30-2006, 10:56 PM
Thats good to know.

Paul

AZLugz
10-31-2006, 08:30 AM
I wish I could weld and fab like some of you guys do, i guess that is just not what God intended for me, guess my stuff will always be "bolt ons"!!!!!!

Thats some awesome work, it is really cool to see the ideas that people come up with and the way they put them together!!!

zukking01
11-01-2006, 02:35 PM
Bought a chevy p/s pump to go to the engine and it didnt fit right so I spaced it out 3/8" to make it fit right. Also got a yota IFS p/s box. Found out it conflicts with my custom suspension. After alot of thinking I will remove the suspension and install the box. Hopefully it will work well.

AZLugz
11-01-2006, 03:12 PM
Time for a NEWB question. What do you do for a shifter for the automatic, are you swapping the column or mounting one on the floor??

Rock4xFab
11-01-2006, 06:08 PM
PS Hey Rock4x where did you get that snorkel kit or did you make it?

Made it...

Rock4xFab
11-01-2006, 06:09 PM
Time for a NEWB question. What do you do for a shifter for the automatic, are you swapping the column or mounting one on the floor??
You can use any aftermarket 4spd auto shifter or something like a camaro or Firbird floor shifter. We use the Hurst units expensive but nice

zukking01
11-01-2006, 09:03 PM
You can use any aftermarket 4spd auto shifter or something like a camaro or Firbird floor shifter. We use the Hurst units expensive but nice

There is you answer. I looked into the firebird, camero, and a Euro but I have decided on a b&m shifter from ebay. I will try to get a ratchet shifter.

AZLugz
11-02-2006, 08:56 AM
Cool, Thx!!

Skut
11-06-2006, 01:43 AM
got a pic of a V8 sami smokin the tires?

zukking01
11-12-2006, 09:35 PM
I have made the bracket to mount the transfer case to the frame. Have one of the two mounts welded to the frame. Will get the other one up soos with pics.
THe mount is made of 3/8 flat bar and a section of 1/4 plate. THe bushings are spring bushings from wrangler front springs. I put them in square tube and pinched the sides to hold it in. Hope this works well. It is hard to weld stuff under the vehicle when I dont have much room to work with and I keep burning myself with all the sparks. It will be worth it when it is done.

THis is the bracket from the front.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready.jpg


Here is the bracket from the top.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready038.jpg

Marshall
11-12-2006, 09:53 PM
Looks like that will be pretty stout.
The only thing that would make that easier is to take the body off the frame.

Rock4xFab
11-12-2006, 11:44 PM
Looks good Scott

zukking01
11-13-2006, 08:53 AM
Looks good Scott


Glad you like it. Thanks for the advice Rock4xFab. I will be removing the suspension section and put the toyota steering box on the outside of the frame and then I will order a radiator from you.

zorproducts
11-13-2006, 11:43 AM
Scott, I am sending out that brass connector today.
My

zukking01
11-13-2006, 04:31 PM
Scott, I am sending out that brass connector today.
My

Thank you Myron. I appreciate it.

zukking01
11-15-2006, 10:45 PM
I was going to fab the sides for the trans tunnel and I was looking at it and realized how much room was wasted in the stock tunnel. I pulled out duct tape to mark some lines and whipped out the grinder and went to town. I then made a cardboard template to be the first new section. This is what I came up with.

The template transfered to steel and cut out with the bends begining.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready039-1.jpg

Cut out trans tunnel.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready040.jpg

With the new cover on.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready041.jpg

THe cover will go to where the duct tape lines are and will be blended in. THis crap is thin and hard to weld on.

Marshall
11-15-2006, 11:13 PM
That will look nice! Your doing some nice work, keep it up.:happy

zukking01
11-16-2006, 09:28 PM
I have welded in the first section and cut out the second section, bent it up, and tacked it in. The progress is starting to show and I am realizing how fast this will go if I spend a few hours a day on it. The metal work is tediouse, but will be worth it as I love the way the new center is looking. I might even slant the 90 degree section and put some guages in it and make a cool cup holder.

Here is the drivers side tacked in. Looks dirty and smokey but will clean up nicely like the welds on the top of the first piece.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready042.jpg

bigflex
11-17-2006, 03:59 AM
lookin good!:happy that will give you alot more space!bigok



you could even put a screen in there with all that room! talk about up town.:funny:

zukking01
11-19-2006, 01:52 PM
I hope you all love tediouse sheet metal pics as much as I do.
My welder started acting up really bad. I think I need to rebuild the gun and cable. It would only weld if the cable was slightly bent forward and even then it would just kep on spotting and never give me a good long arc. It was pissing me off. Hopefully I can fix it and get this thing done.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready044.jpg
This is the gaping hole under the drivers seat I cut out to get my transfer case all tucked in.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready043.jpg
This is the box I made to cover the gaping hole.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready045.jpg
THis is the box welded in place and fits great under the seat. Need to clean up those welds.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready046.jpg
Here is the drivers side tunnel all welded and partly cleaned up.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready047.jpg
The passenger side is starting to take shape.

I will be covering the whole thing with a roll in bed liner. Dont know if I will go with the Herculiner or the Duplicolor bed liner.

bigflex
11-19-2006, 11:51 PM
yes sir I love sheet metal work! most of mine has been shaving and body drops and such but all of it is fun! its coming together nicely keep up the good work!:happy

zukking01
12-07-2006, 10:56 PM
WOW it has been a crazy few weeks with all the holiday stuff. I was welding the new trans. tunnel and caught the downshift cable on the tran. on fire.smokin So I removed the drivetrane to finish up the trans tunnel. While I was at it I reinforced the motor and transfer case mounts with some 1/8 flat bar. I even painted the 4.3/700r4/np205 red and the little things black. I will paint the whole engine compartment gloss black to show off the bright engine.

Here is the new fishplated motor mounts. Stronger is better.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready049.jpg
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready048.jpg
Here is the drivers side transfer case bracket.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready052.jpg

THis is the passenger case bracket. It is on the bottom of the frame but the trans. mount helps protect it and there was no way I could squeeze it between the case and the frame. Approx 1/2 inch of wiggle room.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready051.jpg

This is the new color.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready053.jpg
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready050.jpg

ittybitty
12-07-2006, 11:03 PM
stay away from the duplicolor bed liner...the herculiner is much a much better product from what Ive seen...I just put the herculiner in mine and love it...I have the Durabak in my jeep and it has held up really well also...you can check out some pics of mine with the herculiner under the build up garage and the post is titled "Ittybitty Build Up" Lookin awesome though!

zukking01
12-24-2006, 06:08 PM
Thought I would post some pics of the little progress that has been done. I have mounted the toyota power sttering box, made the steering link and added the hedman hedders. THe hedman hedders are almost bolt on. I had to slightly perswade them to fit.(beat them with a hammer) They are close to the frame on the drivers side but on the pass side they fit nicely. I had to remove the brake lines and fuel lines on the pass side because they conflicted with the hedder. I will route new lines later.

Pic of the pass. side headder.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready055.jpg

Pic of the drivers side hedder and the new steering link. Used a sammy from the wheel and joined it to the yota before the rag joint. Quick and easy.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready054.jpg

I fish plated the outside of the frame where the new box is. I used one of the original box mounts and drilled two new ones. It is really easy but cutting the sheet metal on the front clip made me nervous.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready056.jpg


I have the link that goes on the toy box and I will be machining it to go in my RR ott setup. I will pull out the end that went to the sammy box and I will install the new piece in it.

SpaCityZuki
12-25-2006, 08:14 AM
Lookin good!! Cant wait to see the final product......rockonn

Rockit
12-25-2006, 11:51 PM
Your making good progress. It will be running before you know it. Do you have a new Pitman arm, or you going to modify the one you have? I just picked one up for my son's sami. I still havn't checked on the distributor I'm planning on going tomorrow.

zukking01
12-26-2006, 12:26 AM
Your making good progress. It will be running before you know it. Do you have a new Pitman arm, or you going to modify the one you have? I just picked one up for my son's sami. I still havn't checked on the distributor I'm planning on going tomorrow.

I pulled one at tear-a-part and got raped! They charger me $41 and change for me to pull it. I got screwed hard but I now have the distributor. I have the original yoyota steering arm. I will shorten it and use a tap and dye on it to make it a inster into my RR OTT kit. This way it will be bolt on and adjustable while still using all original parts.

Nor Cal Wheelin
01-03-2007, 03:49 PM
That thing is looking really good... RIGHT ON FOR THINKING OUT SIDE THE BOX!!!!!! I have heard from a thousand different people that a 700r4 wont fit in a sammy and I have heard from 2 thousand people that a 205 wont fit...:rofl: Yet there it is.....:funny:
On a serious knote though.....
I would be worried about the 1:96.1 low range in the 205... But they make a 3.1 kit from lo-max... And I am willing to bet dollars to doughnuts that you (( WONT )) be able to break that case.... I like it and cant wait to see pics of it up and running....:happy

bigflex
01-04-2007, 12:35 AM
That thing is looking really good... RIGHT ON FOR THINKING OUT SIDE THE BOX!!!!!! I have heard from a thousand different people that a 700r4 wont fit in a sammy and I have heard from 2 thousand people that a 205 wont fit...:rofl: Yet there it is.....:funny:
On a serious knote though.....
I would be worried about the 1:96.1 low range in the 205... But they make a 3.1 kit from lo-max... And I am willing to bet dollars to doughnuts that you (( WONT )) be able to break that case.... I like it and cant wait to see pics of it up and running....:happy


I think the main reason it fits so well is because he is runnin a factory Long Wheelbase sami! but anything is possible when you have the skills and want to! looking great so far!:happy I am anctious to see her running!popcornn

zukking01
01-04-2007, 01:30 AM
Thanks for the needed encoragement. I have the p/s lines all hooked up and the front clip back on. I installed the transmission ratchet shifter and cut the 205 shifter again. It is a little stubby but looks great. I ordered the radiator from rock4xfab for a great deal.

I think all I have left to do it is hook up the fuel ines and pump, Wire the thing, plumb brake lines from scratch, make drivelines, rino line it, install radiator and trans cooler, Fab an exhaust from hedder back, hook up plugs and wires, and reinstall the hood. No big deal and I am sure I am mission a thing or two. Funny thing is I have all these tools and cant find the spark plug gapper that costs a dollar. How crappy is that.

Nor Cal Wheelin
01-05-2007, 01:11 PM
:rofl: Ok so I am a Tard... Never thought to look at the pic under the name....

I think this would work in a stretched sammy also though...?? I have been wrong before though....whip

Still like what ya got going there... Cant wait to see her running..:happy

zukking01
01-05-2007, 07:40 PM
I think this would work in a stretched sammy also though...?? I have been wrong before though....whip

This would work in a stretched zuk. People runt he 4.3 and a 200r4 transmission with a zuk case. My 700r4 is just a 4wd version of the 200r4. The way I look at it sitting under my vehicle says there is no problem running this exact setup under a normal zuk. The married case provides for a shorter powertrane so the driveline in the rear would be bigger.

zukking01
01-27-2007, 11:45 AM
I will get pics up soon but I have some progress from last post. I have the front clip back on and the two shifters completely installed. The brake lines have been redone and the fuel line is in place just needs to be secured and hose clamped. The wires are half done and the radiator has been started. I cut the front frame support out to get the radiator in so I will be replacing that also. Big projects means big bucks so I have taken on a second job and that is taking all my free time away from the zuk.... and family.

flea
01-27-2007, 02:28 PM
well man im following right behind you and your at a good pace.
great thread btw.
im doing the 4.3 tbi to th350 to yotas
pulling the 1.3 stuff this weekend.

zukking01
01-31-2007, 08:13 PM
Here are some small but long needed update pics.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready061.jpg

This is the new fuel pump bracket. I made it out of 3/8 x 3 flat bar. I drilled two holes and welded washers as reinforcement. It mounts in the park brake cable holder threads. The black bracket is the old spark coil removed from the firewall and cut down to size.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready062.jpg

Crappy pic of the new fuel line but you can tell it is secured to the frame and this is where the 5 foot sections were joined. I joined them with fuel line and hose clamps. The mounting brackets are made of 1/8 steel bent to shape using 2 handheld pliers.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready064.jpg

This is a pic of the new b&m shifter for the auto and the one in front is a cut down 205 shifter. You can also see how the trans tunnel turned out. I am really happy with it.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready067.jpg

Here is the front clip back on and the wiring half done. I need to find out the firing order and run the plug wires. Still need to mount the radiator and bumper and weld in the new front support because I cut the old one out for the radiator to fit. You can also see I painted the inside of the hood black while it was off.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready063.jpg

Here is what a 205 looks like in a zuk. It is a tight fit and it looks like the driveshaft will hit but it has plenty of room plus if needed I could notch the bear bracket for added clearance.

zukking01
01-31-2007, 08:18 PM
So I had to deal with the steering issue. I bought RR OTT kit for a tracker box but have swapped it out and now I am stuck. I went to a salvage yard and found the arm taht goes to the pitman and I bought it for a whopping $10.

I then cut the arm really short and cut off the steering stabalizer eyelet. I had my father-in-law machine a thread on the arm and I got a compression nut on it.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready066.jpg

This is what it will look like when it is installed. I just replaced the old fitting on the end with this new machined one. Looks like it will work great. I might even be able to get a stabalizer in the hole.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready065.jpg

Nor Cal Wheelin
01-31-2007, 08:29 PM
Still looking great..... Hope ya get her done soon. Wanting to see some pics of her out and about....popcornn :happy

otto
02-02-2007, 04:21 AM
Hey king.. just curious and a newb.. I am on my last legs with my 1.6 8v in my Track/Kick and was wondering what do you thing the best fit would be ?? I do have a thread open asking this question but haven't gotten any replies..just beaten to death I think.. anyway, seeing that you have done some major fab work on yours (excellent if I may add) do you think there would be as much work to do the same to my rig.. I only have a stick welder but can do some mig.. also have access to most hand tools but no garage..I would like to stay with EFI but I don't think I would have the patience to do the whole harness thing so I'll probably go with a carb...what would be the least amount of modifications that I would HAVEto do to accomplish this.. it is also my daily driver and really can't have it laid up for a month either..or should I just go with a 16V.. I wasn't planning on doing a novel so I thought I should give you as much detail as I could.. Thanks in advance.. :happy

zukking01
02-02-2007, 09:14 AM
Hey king.. just curious and a newb.. I am on my last legs with my 1.6 8v in my Track/Kick and was wondering what do you thing the best fit would be ?? I do have a thread open asking this question but haven't gotten any replies..just beaten to death I think.. anyway, seeing that you have done some major fab work on yours (excellent if I may add) do you think there would be as much work to do the same to my rig.. I only have a stick welder but can do some mig.. also have access to most hand tools but no garage..I would like to stay with EFI but I don't think I would have the patience to do the whole harness thing so I'll probably go with a carb...what would be the least amount of modifications that I would HAVEto do to accomplish this.. it is also my daily driver and really can't have it laid up for a month either..or should I just go with a 16V.. I wasn't planning on doing a novel so I thought I should give you as much detail as I could.. Thanks in advance.. :happy


I think there is a kit for it because I have seen two trackers with v8 written on them and they haul @$$ around town. Check the internet gor a kit but I think you can make anything fit as long as you are patient and can weld. You should be able to get it to fit a bit easier than I did. What will be your setup. 3 or 4 speed auto or going with a manual. Divorced or mated transfer case?

zukking01
02-02-2007, 09:30 AM
NOT telling you to buy it but get ideas from it. Lightning conversions has a 4.3 kit for the tracker that is 2k and uses the 4.3/700r4/D300 combo. This is a great kit and is easily obtainable plus you can regear the 300 with lower gear sets. Or you could use the atlas II case but that is pricey. I tore my front clip off and mounted the motor close to the fire wall and then started cutting things that were in the way and beefing it up wherever I could.

zukking01
02-03-2007, 07:39 PM
I bought these custom u joints to swap out into my K.A.D. shaft. I swapped out one that is a chevy 1/2 to 3/4 and the other was a chevy 1/2 to toyota. So now my rear driveline is done. Cost was about $50 and it is beefy.

zukking01
02-15-2007, 09:49 PM
Here we go again. This time I have some good update pics. I bought the radiator from Rock4xfab and it is awesome but huge. I opted for the larger radiator and now I had to get it in by any means possible. Hee is a pic of the final brackets made to hold the radiator and trans coooler. The funky tee is where the trans cooler mounts and the big channel on the bottom is where the radiator mounts.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready068.jpg

This is where the radiator is mounted. Huge but fits.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready070.jpg


Trans cooler mounted in front of radiator.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready071.jpg

Bumper mounted and as you can see the radiator hangs below it.
http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready072.jpg

This is why I made the bracket so heavy duty and I cut a section out to have the radiator bottles fit in and here is a pic of the plate to help protect it.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready069.jpg

A pic of the huge mount on the inside of the hood to hold the radiator in place. I like the red.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready073.jpg

Here is what it looks like with the grill and bumper on. Front is almost complete.

http://i50.photobucket.com/albums/f333/zukking01/PictureInternetready074.jpg

Marshall
02-15-2007, 10:02 PM
Nice work man, that will keep er cool.

zukking01
02-19-2007, 12:32 AM
So I have been working on my zuk intensley for the last week and I started on the wiring on friday and stopped at 2:30 am and started again at 7:30 am.

I have the engine wired and ready. I filled the fuel ine with pressure and when I turn it on it dosent make pumping noise. Is there a sensor that tells when it is full?

Also the starter was making noise like it was stuck but might have been a dead battery. I swapped it out for a spare and it was turning slightly but no spark. I found out that my spare distributor is shot so I swapped my main one back in. It is missing one out or 6 electric nodes in it so I will replace later but for now I have spark. After dealing with that I cant get the starter to engage. It pops the shaft out, turns the engine a bit and then the shaft pulls back in and still spins. Is it because the battery cant power it so it releases so I dont kill the starter? I charger the battery and found cell 2 and 3 were almost dry and after the charge cell 2 is almost dry again so maybe a new battery also. I will get a new distributor and check the starter. Anybody have and info that might help. Any comments of suggestions will help.

Gearhead61
02-19-2007, 11:38 AM
Starting with a good strong battery will be really important. Low voltage will make your truck do all kinds of weird things.

How bad was the engine wiring?

zukking01
02-19-2007, 05:57 PM
How bad was the engine wiring?

Pretty easy. I have a howell painless harness so everything is labeled and I took the old wires and tested to see what they were like acc. run, start so I didnt have to run new ones and that makes it great. I took out a few wires from the harness so it is a bit cleaner. I think it took me about 5 hours taking my time and being my first time I think that is a good time.

zukking01
02-19-2007, 11:24 PM
I bought a good used distributor and a duralast 800cca battery today. Put them in and the thing dosent want to fire. The starter did that funny disengage and till spin thing again so I will be swapping it out for another. When I turn the key the engine turns over but it is sometimes slow and sometimes fast. Hopefully it has to do with the starter. Anyone have any hints on getting it to start or suggestions on what to check?

POWERSTROKEN
02-20-2007, 04:41 AM
Awesome work man. Sweet build. I can tell you about lightnings crap as I bought one right from them. The POS didnt even get me home. I am doing the 4.3 CPI swap into my Tin Top. I have the Howel harness, and radiator from my LC. I am very interested in seeing pics of your tunnel kit Scott as I need to get something for mine. I have been out of the loop for 7 months and let everything drop. I am back brothers and the Tin Top project will get back under way.

zukking01
02-20-2007, 09:44 AM
I have som epics of the tunnel carved out and being plated. I redid the whole center section where the shifter was. They are on posts 37, 56, 58, 60 Hope this helps. It is made of 14 or 16 guage sheet steel.

zukking01
03-21-2007, 07:57 PM
MOJOR UPDATE!!!!

I just got the thing to start. It runs but it wont run for long. It dies and so I think the idle is out because of the timing. I will give more updates as I get them but I am exited to hear it run.

WVhillbilly
03-21-2007, 08:10 PM
Check that temp sensor. Should be on the passenger side of the block. It gave me fits won't run, then runs no idle. Then runs OK one day and not the next. Think it's like a $15 part, can make you mad as hell tho. I didn't give me a trouble code either.

BONEZUKI
03-27-2007, 05:46 PM
What kind of exhaust are you running?

zukking01
03-27-2007, 06:59 PM
I am running hedman hedders from a 89-92 2wd s10 blazer with 4.3.
Off the header I have 2" that meets in a y pipe to a 2.5" all the way out.
I am running a cat. and a turbo muffler.

BONEZUKI
03-28-2007, 05:29 PM
how does it sound? im not gonna be running a cat and i want it to sound pretty deep. especially when i get on it! thinking about a flowmaster muffler.

Gearhead61
04-08-2007, 01:27 PM
Any updates on this sucker?

zukking01
04-08-2007, 05:19 PM
Any updates on this sucker?

SADFULLY YES.
The 4.3 that I have has a rod nock in it so I have another one coming next week. I will be trading my spare complete toy axles with OTT steering for the 4.3 with 86k and $200 cash.

The interior has been bed lined covering all paint inside. I need to reinstall the seats, hook up rear driveline, make front driveline, finish exhaust from cat back and get a electric fan up front. I will also be swapping the detroit into the rear and the tru-trac to the front and bleed the brakes. This might get done tomorrow but dont hold you breath.

I should have it running again in 2-3 weeks and I hope to figure out how to register it somehow but the 4.3 is not a legal swap so I will have to figure it out.

BONEZUKI
04-08-2007, 05:23 PM
do you have to pass emissions??? sorry bout the rod. that sucks.

Gearhead61
04-08-2007, 07:54 PM
Man what a bummer! Good luck gettin' everything else settled in.

zukking01
04-08-2007, 10:16 PM
do you have to pass emissions??? sorry bout the rod. that sucks.

I have to pass so I will have to come up with something. I have a few tricks up my sleeve and I think I can get it working.

BONEZUKI
04-09-2007, 04:12 PM
NOT ME!!! Just gonna run a flowmaster, and 2" pipe out the rear. maybe dual, if it will fit.

zuk buggy
04-10-2007, 08:33 PM
great info here. now i really need to decide what drive train i want to go with

BONEZUKI
04-11-2007, 07:48 PM
just ordered my starter, gasket kit, edelbrock carb, alternater, and thermostat. hey zukking, where do i get my radiator???

Gearhead61
04-11-2007, 08:50 PM
Talk to Scott at Rock4x he is a vendor here. I think his s/n is RockRat

BONEZUKI
04-11-2007, 08:53 PM
Me gearhead, for the Radiator???

zukking01
04-11-2007, 10:09 PM
Me gearhead, for the Radiator???

Yeah you get it from scott aka rock4xfab. He is the man to talk to for your 4.3 swapping needs. He got me started and sold me a sweet aluminum radiator. I think it is a 3 core but it is definitly a sweet radiator. I opted for the bigger one and it is to the top of the inside of the hood and it sticks just below the frame rail but I made a great skid/holder for it and I would rather have a bigger radiator to keep it cool on the rocks.

Gearhead61
04-11-2007, 10:29 PM
Do you have any sort of size comparison for the two radiators? How about the price you paid for yours?

BONEZUKI
04-12-2007, 05:04 PM
just sent a message to rock4xfab, thanks zukking. do i have to run an electric fan or will a Clutch fan fit?????????

zukking01
04-12-2007, 06:50 PM
Do you have any sort of size comparison for the two radiators? How about the price you paid for yours?

What comparison? betweent he stock one and the big one, or the 4.3 normal and the 4.3 big one I bought? I think the rad. I bought is really big but I know I want my 4.3 to be cooled so it is great. rock4xfab can give you prices with dimensions. I think I paid around $200 with shipping but that might have been before shipping. Worth every penny and then some from the looks of the quality.

just sent a message to rock4xfab, thanks zukking. do i have to run an electric fan or will a Clutch fan fit?????????

I put my engine too far forward so I will be running a electric fan wither a half fan under the crank pully or one in front of the grill with a custom bumper to protect and hide it so it dosent look ghetto.

I dont think anybody can really run the stock fan because it is really big width size.

BONEZUKI
04-13-2007, 03:53 PM
could you have mounted the engine back any further???

zukking01
04-15-2007, 11:09 PM
could you have mounted the engine back any further???

Yes I could have but I thought I had it back enough at the time but I could have gotten about 4" closer and that would have allowed an electric fan easily but the rear driveshaft would be really short on a normal wheelbase samurai.

BONEZUKI
04-16-2007, 05:02 PM
still not sure what kinda fan im gonna use, just gonna wait and see until i get it all mocked up. just was wondering, cause im ordering all the parts now, so they will be waiting at the house for me when i get home and i can get right to work on it.

zukking01
04-17-2007, 12:40 AM
Dont worry about a fan. You will have plenty of time to go to a yard while you are wiring it and finishing touches. Get it mocked up and find out how much space you have before rushing it. Trust me you will have time. Just get the key compnents like trans, engine, tcase, radiator and clutch/shifter for trans.

BONEZUKI
04-18-2007, 05:46 PM
hey zuk, if i went fenderless in the front. do you think i would still be able to have inner fenderwells with the 4.3swap?

zukking01
04-18-2007, 09:31 PM
hey zuk, if i went fenderless in the front. do you think i would still be able to have inner fenderwells with the 4.3swap?

I am running everything minus the cutout for the toy IFS box and steering shaft. It was not hard to get the wheel wells and fenders to work so it you want to run just the wheel wells wothout fenders I see no proble with that and I actually saw a guy at MOAB running this setup only he made some ghetto custom hedders.

BONEZUKI
04-19-2007, 03:20 PM
i would probably custom make some wheelwells that formed to the tube kit. so that it doesnt look takky. thanks for all the help. bonezuki

zukking01
08-12-2007, 09:51 AM
BUMP for Zuki78

letsgomuddin85
06-16-2008, 09:06 PM
☼ did you need to extend your frame at all im planing a carbed 4.3 th350 or 700r4 trans and 205 transfer n my 87 soft top with yj springs and toyota axles dueal exhaust electric fan an maybe elec water pump ☼

zukking01
06-17-2008, 12:25 AM
☼ did you need to extend your frame at all im planing a carbed 4.3 th350 or 700r4 trans and 205 transfer n my 87 soft top with yj springs and toyota axles dueal exhaust electric fan an maybe elec water pump ☼

I didnt lengthen the frame. The lwb has a longer frame after the doors so that dosent have any effect on the swap. The 4.3, 700r4 and np205 fig great but the 205 is tight to the body so I had to do metal work with that as well as the trans tunnel. HOLESHOT did a great 4.3 swap that is posted on here also.

The only thing I would have done different would be put the engine closer to the firewall. I dont have room for a radiator and fan in the engine bay so I had to mount the fan on the outside and now I need to put the radiator on the outside and the fan on the inside to make it work more efficiently.