2002 RS

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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:40 pm

20200509_182330.jpg
I've started working on making up some plans for building a new front bumper with less protrusion and more approach angle. I'm gonna shoot for tucking my winch in and raising it up higher. First step was relocating the winch solenoid to the engine bay.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:42 pm

Opened up the solenoid box and wired up my switch to it.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:45 pm

Routed my cab switch wires in and connected them up to the solenoid. Tried to take my time and make it look good. Used some wire loom to route the wires to protect them and keep them from being so visible.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:47 pm

With the solenoid relocated it freed up about 2in of space for me to raise the winch higher.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:52 pm

With the solenoid relocated I had to shift my battery around. On the factory battery tray the two rear tabs can be bent down and that allowed me to shift the battery. I had to make 2 new holes to use the factory tie down. I plan on going dual battery one day but I'll prob wait till I SAS and do the ABS delete to have more room for placement.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:56 pm

Since I was on a electric hook up kick I decided to run wires and set up all my switches for future lights. I only have front and rear at the moment but I plan on getting a led bar and some side lights hooked up. I ran some 6/8ga wire into the cab to make a fuse bank for connecting everything to. Helped a bunch to unclutter the engine bay with wires going everywhere.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 6:59 pm

With the engine bay area done it was time to work on the fuse bank in the cab. I hooked up all my switches and ran wires through looms as much as possible to keep it organized.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 7:06 pm

I moved a few of the factory switches around for better access and to prevent accidental activation. After testing all my connections I felt fine to reassemble my dash area. The factory hole for the 4x4/cruise/fog is just perfect to put a 4gang rocker panel over. I moved the center console power/winter switch to up on the dash and placed the anti-theft blinking red light to the console area. I don't use the hard top much so I had open slots from removing the rear window defrost and wiper switch.
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Re: 2002 RS

Postby MyRS » Sat May 16, 2020 7:13 pm

I'm just waiting on getting the rest of my lights in and I'll get all those plugged in and running. I haven't driven at night yet to see how bright the switches are. I may look into getting a dimmer to work with them or I'll lightly coat them with something to soften up the light. The switch panel looks pretty good. I just need to get better looking screws.
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Re: 2002 RS

Postby MyRS » Sun May 17, 2020 10:03 pm

Went out last night on a trail near my house. I found a couple spots to see how the rear axle would flex with the extended brackets for the sway bar. It flexed pretty good. I could move the coil a little but I think I'm going to go with limiting straps to be safe. And then the other side compressed really good and I was able to find where I been making contact in the rear. On occasion I'd hear the tread rubbing.
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Re: 2002 RS

Postby MyRS » Sun May 17, 2020 10:06 pm

And I was pretty sure that extending the brackets and not reinforcing them would lend to failure pretty quickly. And it did, the drivers link bent up and made a nice metal clanking sound the rest of the ride. I'll make a better set and gusset them to help with the stresses.
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Re: 2002 RS

Postby paulevans76 » Mon May 18, 2020 3:17 pm

I would use limit straps for sure. Ideally you don't want the shocks or anything else to be the end limit of your droop, as it could cause additional wear n tear. I'd also capture one end of the coils and leave the other free. Set the straps so they don't allow it to droop beyond the point that the coil wouldn't reseat.
Scratch n Dent special 1991 Trooper S
3.4 V6 - Holley TBI, CompCams 252H, 1.6:1 roller rockers, +1mm DOHC pistons, MSD ignition, custom tune, "Ed Mc Special" 2.5" exhaust
MUA5 w/ 3.07's & fixed yoke
SAS - Waggy F D44 - 5.38's, RCV's, OX locker; Rodeo R 44 - Detroit, truss
Front Y-link radius arms, coils; Rear SOA, OME leaves, anti-wrap bar
35x12.50/17 General Grabber X3's on 17x9 Interco Birddogs
Trail armor and Warn XD9000
The White Whale - a temporary daily driver 1991 Trooper - 2.8 V6, MUA5 - stocker resto (sold)
1994 Samurai - 1.3 FI - OME suspension, 31's, 6.5:1 tcase, 5k milemarker SxS winch, more to come!

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Re: 2002 RS

Postby MyRS » Mon May 18, 2020 11:50 pm

Thanks for the info paulevans, I'll look into the coil retainer too. I been reading up on limit straps a bit and I've taken a few measurements. I'll be ordering some straps and make up some brackets in the next week or so. When I bought this RS and started to mod it I was in Florida, not much articulation going on. But out here it's a whole new animal.
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Re: 2002 RS

Postby MyRS » Sat Jul 18, 2020 4:56 pm

My limit straps and brackets came in the other day. I miss calculated the first go around and the 14 inch straps were too long, I ended up using a set of 12 inch straps. I'll save the 14s for later when I SAS and whatnot. Got everything lined up and welded on. Wasn't too hard to hook everything up, just welding in funny angles and without a lift is a pain.
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Re: 2002 RS

Postby MyRS » Sat Jul 18, 2020 4:59 pm

I did however break off 3 of the 4 bolts that hold on my bump stops, and 2 of the 4 bolts holding the sway bar on twisted right off. So for now I don't have the rear sway bar in. I needed to make a 2 inch extension for the bump stops so I'll fab those up one day and get them hooked back up.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:13 am

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So the limit straps are working well. I have been on a few rides, and haven't had any issues with the axles drooping far enough to allow the coil to wiggle.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:26 am

20210409_095308 (2).jpg
I started some half doors years ago when I was living in FL. Finally got around to finishing them up, well almost finished. I drove around for a few days like this before committing the time to try and finish them.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:28 am

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Trimmed up some abs plastic to fill the gap. I made it smooth with the outside and contoured to the door panel on the inside.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:30 am

20210415_095040.jpg
I reused the factory latch mechanism. I routed the manual door lock rod and knob to be the release. It's working well, and was really simple to do.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:34 am

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20210419_160219 (2).jpg
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I am almost done with the passenger side. Just a few more tweaks to it and I'll get them painted.
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Re: 2002 RS

Postby MyRS » Thu Apr 22, 2021 12:37 am

I cleaned up the wiring harness so my speaker, mirror, and curtesy light all work. I am definitely gonna upgrade to some bigger door speakers though. If I'm driving over 40ish mph I can barely hear the radio. I also plan on installing a removeable cross bar on the passenger side. Just a little extra insurance my kid don't fall out while on the trail.
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Re: 2002 RS

Postby paulevans76 » Thu Apr 22, 2021 1:49 pm

Very cool. Every time I go on a trial ride I remember that I want to do half doors! I bet it makes it a lot easier to see what is going on when you're crawlin.
Scratch n Dent special 1991 Trooper S
3.4 V6 - Holley TBI, CompCams 252H, 1.6:1 roller rockers, +1mm DOHC pistons, MSD ignition, custom tune, "Ed Mc Special" 2.5" exhaust
MUA5 w/ 3.07's & fixed yoke
SAS - Waggy F D44 - 5.38's, RCV's, OX locker; Rodeo R 44 - Detroit, truss
Front Y-link radius arms, coils; Rear SOA, OME leaves, anti-wrap bar
35x12.50/17 General Grabber X3's on 17x9 Interco Birddogs
Trail armor and Warn XD9000
The White Whale - a temporary daily driver 1991 Trooper - 2.8 V6, MUA5 - stocker resto (sold)
1994 Samurai - 1.3 FI - OME suspension, 31's, 6.5:1 tcase, 5k milemarker SxS winch, more to come!
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Re: 2002 RS

Postby MyRS » Tue Apr 27, 2021 11:12 pm

I think a tube door would be less hassle to build. But yes it does allow for greater visibility of your tires and side of vehicle.
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Re: 2002 RS

Postby MyRS » Wed May 12, 2021 12:29 am

I got my half doors back from the paint shop. The did a pretty good job. Looks a 100 times better matching vs the silver. Now that they are painted the frame pieces stand out bad, they definitely need to be painted. I'm gonna try and redo them in a mild steel so I can weld up the opening where I cut and bent them.
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Re: 2002 RS

Postby Enemigo » Wed May 12, 2021 12:33 am

That looks pretty fun.
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