www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Conversions

TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

Reply
 
Thread Tools
Old February 23rd, 2016, 07:21   #16
Pry_P
Veteran Member
 
Join Date: Oct 2004
Location: Quebec, Canada
Default

Long time no update on this. I've been working on it slowly since the end of summer.

I got the cab laying on the chassis and did some quick test drive around the yard. Very happy the way it ran



Meanwhile I scored this Samurai for 150$. I couldn't let it go.
It is still in good running condition, But I will part it out. Notice the custom Plywood top! It is also nicely covered with roofing shingles. Seller said it's 25 year rated !!!



Decided I would put the samurai Transfer-Case and Axles on the LJ. Will be tougher than the tiny LJ Transfer case and parts will be easier to find in the future. I also gain front Discs instead of drums. That said, I have to ditch out the custom drive shafts, T-case support & steering rods I made last summer and fabricate new ones again. This will be later this spring.

Lately I have been working on fixing rust and holes in the cab.
Look what kind of rust I am faced with... Pictures even make is look better than reality..!! Have to fabricate every body panel from scratch. Replacement Panels are VERY expensive and hard to get. Rust also goes beyond these available replacement panels.

Passenger Side Floor:


Driver side Floor cut, exposing rust in inner rocker panel:


Passenger Side front cab corner/floor:


Passenger Side Floor & outer rocker panel removed, ready for new sheetmetal:


Both new floors cut, bent and welded, made from 14ga checker plate.


Viewed from inside:


This is the front fenders and grille. I will be able to re-use the grille with some time and effort. The outer fenders I got this Idea from a guy in Edmonton. I bought a 60$ 16ga fender for a tandem trailer, cut it in half to have both sides.
With some trimming it will be 95% close to the shape of the original fenders.
Will need to repair existing / fabricate new inner fenders.


Still a lot of work to do. The worst is bodywork. Swapping Samurai Axle and T-case should go along very easy.
__________________
-2005 Mercedes E320 CDI
-1993 1st gen Dodge W250, Cummins, 5 speed.
-1981 Suzuki LJ81 TDI in progress

Last edited by Pry_P; February 23rd, 2016 at 10:51.
Pry_P is offline   Reply With Quote
Old February 23rd, 2016, 18:51   #17
1.9ZOOK
Veteran Member
 
1.9ZOOK's Avatar
 
Join Date: Dec 2015
Location: Dunsmuir,Ca.
TDI(s): ALH Samurai
Fuel Economy: pending
Default

Nice job on the floors...
with the new front axle,you won't have to worry about the oil pan any more.
1.9ZOOK is offline   Reply With Quote
Old February 23rd, 2016, 19:16   #18
samuraitd
Veteran Member
 
samuraitd's Avatar
 
Join Date: Jan 2013
Location: Provo, UT
Default

If you don't mind me asking, how tall are you? It looks to me like anybody over 5'8"ish would be too tall to drive it. But it sure is awesome!
__________________
1986 Samurai AHU MTDI swapped, stretched, built
samuraitd is offline   Reply With Quote
Old February 24th, 2016, 07:46   #19
Pry_P
Veteran Member
 
Join Date: Oct 2004
Location: Quebec, Canada
Default

Quote:
Originally Posted by 1.9ZOOK View Post
Nice job on the floors...
with the new front axle,you won't have to worry about the oil pan any more.
Yes of course that was another advantage. I even might be able to lower the engine by 1" or 2" and forget the body lift for the hood to clear the intake.

Quote:
Originally Posted by samuraitd View Post
If you don't mind me asking, how tall are you? It looks to me like anybody over 5'8"ish would be too tall to drive it. But it sure is awesome!
I'm around 6' and yes I am a bit too tall to be comfortable in it. In the summer it's ok, but when I was plowing with it during the winter, it was a challenge to get in and out with boots and winter suit.
__________________
-2005 Mercedes E320 CDI
-1993 1st gen Dodge W250, Cummins, 5 speed.
-1981 Suzuki LJ81 TDI in progress
Pry_P is offline   Reply With Quote
Old September 1st, 2016, 10:16   #20
samuraitd
Veteran Member
 
samuraitd's Avatar
 
Join Date: Jan 2013
Location: Provo, UT
Default

Any updates?
__________________
1986 Samurai AHU MTDI swapped, stretched, built
samuraitd is offline   Reply With Quote
Old September 5th, 2016, 11:55   #21
Pry_P
Veteran Member
 
Join Date: Oct 2004
Location: Quebec, Canada
Default

Quote:
Originally Posted by samuraitd View Post
Any updates?
Nothing new this summer.
Ordered new front grill, windshield and window gaskets, ect.
Building a new 30x42 shop right now. Will continue to work on the truck this winter, when new shop will be all set and warm !
__________________
-2005 Mercedes E320 CDI
-1993 1st gen Dodge W250, Cummins, 5 speed.
-1981 Suzuki LJ81 TDI in progress
Pry_P is offline   Reply With Quote
Old February 22nd, 2018, 05:12   #22
Pry_P
Veteran Member
 
Join Date: Oct 2004
Location: Quebec, Canada
Default

I re-started to work on this project 3 weeks ago. The new shop is built and all set. Here are some updates.

I have no picture of that, but last year I installed the samurai transfer case with a custom support, and samurai axles.


I tried to set up a little sandblast tent, but still too dusty inside the shop. I moved sandblasting to an outdoor anclosed trailer. Installed a 10k 2 post lift in the new shop. A joy to work with.




I finalized the cab mounts. For bushings, I used Dodge 1st gen cummins transmission tail bushings.



I installed the new fender, made from trailer fenders..
With a lot of trimming, the fit is perfect.



__________________
-2005 Mercedes E320 CDI
-1993 1st gen Dodge W250, Cummins, 5 speed.
-1981 Suzuki LJ81 TDI in progress
Pry_P is offline   Reply With Quote
Old March 1st, 2018, 18:51   #23
A-man930
Member
 
Join Date: Jul 2014
Location: St. Louis
Default

Subscribed. Cool truck!
A-man930 is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
1981 Rabbit Truck TDI (afn) annieneff TDI Conversions 68 October 30th, 2015 10:37
feeler: MK1 81 AHU TDI CJansen TDI Cars for Sale/Wanted 3 September 9th, 2013 14:15
1981 Rabbit Pickup Truck--> Quattro TDI ALH Freestyle72 TDI Conversions 13 May 30th, 2013 00:20
1981 rabbit truck with a BRM tdi cam.tdi TDI Conversions 6 June 25th, 2011 20:29
tdi into 81 rabbit diesel (truck)? 8418 VW MKIV-A4 TDIs (VE and PD) 2 November 25th, 2001 01:55


All times are GMT -7. The time now is 20:40.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.15050 seconds with 10 queries
[Output: 90.65 Kb. compressed to 78.40 Kb. by saving 12.25 Kb. (13.51%)]