Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mods

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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Jun 24, 2020 1:14 pm

Got all of the body mounts cut and re-installed for fit up, but waiting on a box of body mount bushings from Jerry to see if there's something I can use to replace the one or two that got trashed in the process. I actually broke my old craftsman vise trying to break free a rusted bolt/sleeve :shock: (on the plus side, as soon as I find a store with a comparable craftsman vise in stock, I can trade it out).

1.5" lower, still have cutting to do on the valence.
Screenshot_20200624-105501.png


Going to use some small angle to clean up the cut edge.
IMG_20200613_160656.jpg


Modified this class 3 hitch (made for 2nd gen Montero)
Screenshot_20200624-130938.png


Drilled two new holes to space the receiver closer to the frame and not hang down as far, then cut off the top 2 holes section:
Screenshot_20200624-105406.png


Anyway, while I wait on the body mount bushings I'll be fitting up the rad and e-fan mounts, then wiring up the fan and bigger alt, THEN if all goes well and the body lift stuff is done, I can start working on the the fuel system some more on the 3.4. I hope it's just overfueling, but there could be a bigger problem, as the oil always smells like gas. If it's just overfueling, I have options. Maybe it's just the tune. But if it's not that, I'll be d-o-n-e with this motor.

Also, because I am a glutton for punishment, I picked up a bone stock 94 samurai with the 1.3 EFI.
Screenshot_20200624-104441.png

It was a beach rig, so more rust that I wanted to deal with, but I figured it will be a trail rig so what does it matter that much... the frame is good, the suspension is pretty ragged, but that's all going to be replaced. It was lady owned and never beat on, just used and maintained pretty normally. 107k miles. Probably bit off more than I need to chew right now, but it's a really fun little rig. My goal is to keep it low, light, nimble, and able to hang with much bigger and $$$ rigs. Probably end up on 33's, roll cage, steering upgrade, fenders reworked for more room + a small lift and slight wheelbase stretch, locked, super low gears. Should be a real heartbreaker out on the trail.
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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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Jul 14, 2020 2:43 pm

Updates:

Jerry is THE MAN! His box o' body mount bushings showed up, and I was able to find one that worked perfect AND!!! there were 2 bolts in the box that I was able to use in the rear where I'd forgotten to buy enough resized replacements, and just by luck, they happened to fit just right. AWESOME. All mounts and bushings installed, and bolts loctite'd and torqued.

Next I needed to reattach the fuel filler hoses to the soft lines coming off the tank. The PHILIPS HEAD bolts that hold the fuel filler cover thing in the cargo area were the worst. Luckily, I just happened to have recently bought a "shake n break" attachment for an air hammer (the Samurai door hinges have notoriously difficult bigass philips head bolts). My air hammer was a little weak, but I coudn't use heat in that area and risk blowing stuff up. After spending an inordinate amount of time on these 3 bastiches, finally they were all out. They absolutely never loosened up. Every 1/4 turn was as much effort as breaking them free. They will be replaced with some hex bolts or allen heads at the least.

Screenshot_20200714-144038.png


Moving on to the steering - the steering shaft had an aluminum extension between the shaft and box, and the shaft itself may have had an extension welded in. Without the separate aluminum extension, the extended shaft is too short, and with the extension, it's too long - the shaft won't collapse enough to allow me to get it on. So I'm going to have to figure out what to disconnect where and either weld in an extension to remove the separate AL extension, or chop an inch out and reweld and reuse the separate ext.

I need to revise the fuel tank skid mounts to get that re-mounted, finish up the steering, and then I can focus on getting the rad, e-fan, and bigger alt mounted.

And I'd better hurry, because parts are starting to arrive for the Sami! I've got 6.5:1 gears and 31" tires waiting. I've got a cage, a locker, and electric power steering components on the way. I'm planning to run my old trooper rear springs under the rear of the Zuk and do a rear up front swap for the front suspension. Then a little virtual lift (fender chop and raise) and I'll be ready to do some open top SWB 4wheelin'.
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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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby chuffer » Wed Jul 15, 2020 2:21 am

I did a barrel roll in a Samurai on Guanella pass.

Don't do barrel rolls in your Sammy.

Also, the screws on that filler cover are THE worst.
-Chris
Shiba Wichern Cellars - Pinot Noir from Oregon -
1988 Isuzu Trooper 2.6l 5-spd aka "Stinky"
2007 Toyota Tacoma aka "Taco-kun"
1986 Ford F250 aka "Mr. Green Jeans"
1979 IH Scout II aka "Boroboro-kun"
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Thu Jul 16, 2020 9:27 am

chuffer wrote:I did a barrel roll in a Samurai on Guanella pass.

Don't do barrel rolls in your Sammy.

Also, the screws on that filler cover are THE worst.


That's why I got the full 6 point roll cage! Although I'm really hoping to limit it to a flop or maybe a turtle situation rather than a balls out barrel roll :blackeye:
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby bradzuzu » Sun Aug 02, 2020 1:15 pm

I feel your pain buddy , nice to see you making progress atleast !! I’m sorry everything’s been a battle ..
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

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Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Aug 03, 2020 1:05 pm

Thanks Brad, you know how it is - reality is usually full of fun surprises throughout a project!

Got done:

Rad mounts, Fan mounts, AD244 alt mounted and wired (both of which I'm not totally done with but will have to see) The alt had a 2 wire plug, I only need one, and I've capped the other for now. Will be testing to see if that will do.

To do:

weld up holes in floor (captive nut fun)
weld angle to rockers to clean that up
fuel tank skid mounts need revising after BL reduction
bend up rear bumper (sch 40 and HF bender, minimalist)
wire in fan (have all flex a lite stuff, instructions seem very good even for a hack like me! So as long as the part work, I shouldn't have too many problems)
mount LS seats (armrests yo!)

Next projects:

ALDL detective work on the fueling
suspension lift reduction, which will entail new track bar mounts, going from a high steer tie rod to just running the drag link to the pass high steer arm, and the tie rod on the stock knuckle provisions. That's the only way to make room to lower the track bar mounts and make room for some more uptravel and lower the suspension simultaneously. Will also need to make new motor mounts so that there's more room for the upper links/brackets. It's either that or lose the coils and links all together and going to leaves, which I've threatened for some time now.

Then I have lockers, tcase gears, cage, and suspension to do on the zuk!!!
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Aug 18, 2020 1:36 pm

You ever get just about done with a project and realize: "dang, I totally should have done this whole thing differently"?

I finished up the rad and fan mounts, and made some baby steps on the wiring, but I'm not really digging the end result of how I have the rad and fan offset, all to dodge the steering box that is moved way fwd on the frame rail as part of the SAS. I'm thinking that I may step back and look at what it would take to mount a steering box with a forward pitman that mounts inside the frame rail. I think the Astro van box will be the ticket. Outside of the frame forward pitman won't work with the coil mounts in the way. My panhard is mounted right below where the box would probably end up, so I need to do more investigation. I could go with an outside the frame rear facing pitman box if it's far enough up the frame, facilitated by an extended steering shaft with an extra ujoint in it.

I also want to delete the oil cooler lines & the smog pump, and really just get rid of a bunch of junk in the engine bay. I have the correct tensioner to get rid of the smog pump, but I'll need to also pull the pass side exhaust mani to replace a broken bolt/stud while I'm there. I think between that a building new motor mounts, I'll end up with more room in the bay and less things to potentially go wrong.

So it looks like I'll be tinkering on this thing until next Fall haha :blackeye: :blackeye:
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby hessmess » Tue Aug 18, 2020 4:24 pm

Fall is right around the corner bubba!
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Aug 18, 2020 5:04 pm

hessmess wrote:Fall is right around the corner bubba!


Only 2.5 months til Uwharrie - I've got my work cut out for me!
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Aug 19, 2020 5:26 pm

Well, it looks like there would be a lot of work involved to switch steering boxes. Changing to an outside of the frame rear facing pitman wouldn't work because my body mount is in the way. And then the panhard/track bar mount is smack where an inside the frame fwd facing pitman box would sit. I may could run a new track bar bracket off the outside of the frame to make it work, but I would need to mock some stuff up. Lots of noggin scratchin' to do.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby btw1549 » Wed Aug 19, 2020 5:44 pm

Would moving the trac bar mount outside not cause rubbing issue when turning?
BtW - 1991 LS Trooper In Progress, Major Rust Repair, 3.4L & MUA5 Swap (The Tank)
https://forum.planetisuzoo.com/viewtopi ... 15&t=72642

2002 Isuzu Axiom In Progress, 3.5 Rebuild, AR5 swap, and Suspension Refresh/Lift
https://forum.planetisuzoo.com/viewtopi ... 15&t=74409

1997 Trooper, Just picked up with bad trans. Build thread coming soon...

A lot of parts rigs and future projects... 1988 2.6l 5 spd Trooper, 1988 2.6l Auto Trooper, 1989 2.8l 5spd Trooper, 1989 2.6l Auto Trooper with 4.77s, 1989 2.6l Auto RS Trooper, 1989 2.8l 5spd Trooper, 1990 2.8l Auto Trroper, 1991 2.8l Auto Trooper, 2002 3.5l Auto Axiom
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Thu Aug 20, 2020 12:51 pm

btw1549 wrote:Would moving the trac bar mount outside not cause rubbing issue when turning?


It's just ahead of the coil mount hoop thingy. So its pretty out of the way of tire scrub. But it would be tricky to mount the steering box on the inside of the frame and have the track bar mount on the other side, with the track bar running underneath.

Screenshot_20200820-123011~2.png


I find myself very close to just going to leaves. When I look at the pros and cons to make this suspension work better or just unhackify other interferences caused by the suspension, leafs become very attractive.

This suspension doesn't net me more travel than I'd have with a leaf setup (driveshaft bind prevents using available droop, axle side track bar mount/frame and upper link mount/motor mount interference prevents more compression). It may plant the tires a little better on the trail, but I don't know for sure. It's not great on the road, and lowering it a few inches without a lot of other work eats up most of my compression travel. So redoing track bar mounts, fabricating higher clearance motor mounts, building new track bar as well maybe also a new tie rod and drag link, or cutting all that out and welding in some spring perches and hangers....
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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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby btw1549 » Thu Aug 20, 2020 7:23 pm

What about moving it to the other side?
BtW - 1991 LS Trooper In Progress, Major Rust Repair, 3.4L & MUA5 Swap (The Tank)
https://forum.planetisuzoo.com/viewtopi ... 15&t=72642

2002 Isuzu Axiom In Progress, 3.5 Rebuild, AR5 swap, and Suspension Refresh/Lift
https://forum.planetisuzoo.com/viewtopi ... 15&t=74409

1997 Trooper, Just picked up with bad trans. Build thread coming soon...

A lot of parts rigs and future projects... 1988 2.6l 5 spd Trooper, 1988 2.6l Auto Trooper, 1989 2.8l 5spd Trooper, 1989 2.6l Auto Trooper with 4.77s, 1989 2.6l Auto RS Trooper, 1989 2.8l 5spd Trooper, 1990 2.8l Auto Trroper, 1991 2.8l Auto Trooper, 2002 3.5l Auto Axiom
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Fri Aug 21, 2020 9:30 am

If you mean moving it to the rear of the axle, I believe there will be oil pan interference. I will check tho - if there's a way to snake a bar back there with a few bends to clear everything, I would be fine with that. Would open up a lot of real estate.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby chuffer » Mon Aug 24, 2020 1:05 am

Full hydro it now?
-Chris
Shiba Wichern Cellars - Pinot Noir from Oregon -
1988 Isuzu Trooper 2.6l 5-spd aka "Stinky"
2007 Toyota Tacoma aka "Taco-kun"
1986 Ford F250 aka "Mr. Green Jeans"
1979 IH Scout II aka "Boroboro-kun"
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Aug 24, 2020 5:13 pm

chuffer wrote:Full hydro it now?


I'm not comfortable with absolutely no steering if the motor isn't running. I like the mechanical linkage.

I looked and there's no good way to run the track bar behind the axle. Upper links and oil pan in the way. If the upper mounts weren't where they are I could probably make it work.

I think a part of the overall issue is the "Y link" radius arm design, with the lower mounts flush with the bottom of the axle tube, and the uppers above the pumpkin. High clearance underneath, crowded up on top. If my radius arms were the traditional Ford truck/Bronco or FZJ80 Landcruiser design, where the radius arms mount much lower on the axle, I wouldn't have as many interferences, and there would also be more room to mount the track bar on either side of the axle.

I do think I'm going to be able to live with the relocated fan after all. It's not the cleanest solution, but I need to get a new radiator, as mine got more dinged up than I thought when it fell off the table when I was fitting up the fan :( Swapping to a different box is just going to be too much to bite off right now.

So where does all of this leave things? If I want to reduce ride height and improve suspension travel, I'm still left with building and relocating the track bar mounts and building a new track bar, and redoing the motor mounts, if I leave everything else alone. Otherwise, I can redesign the radius arms and mounts themselves, plus the track bar. Or, slap a set of leaf springs under it and cut all the extra stuff out of the way and go on with my life until I'm limited by that setup, and THEN go with something more complicated.

OH, in other news, I'm not diggin the bigger alternator, it actually rests against my battery. So, I'm just going to go back to the stocker, but a 100amp version instead of the 85amp. I'll upsize my charging wire and grounds as well. If that's not enough for the fan, I'll upgrade again.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Sep 16, 2020 8:43 am

Nothing going on lately, mostly working on the samurai. New radiator should be here today, and I'll remove the fan, old rad, tensioner pulley, smog pump, exhaust manifold on pass side. Then I'll be trying to fix the broken exhaust manifold stud, and put everything back together minus the smog pump, routing everything 3.1 style. Then I'll install rad and fan, wire that joker, install alternator, belt, and get her making vroomy noises again.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Sep 23, 2020 12:37 pm

New rad showed up. Need to modify for mounting the fan, get it back in and get it wired.

Got the rad, fan, alt, alt braces/mounts, smog pump, tensioner, and exhaust manifold off.

Need to get the broken stud out of the head, that will be fun. I have exhaust manifold gaskets and a new stud on the way.

If I can get Humpty Dumpty back together again, and running, I'll just have some body stuff to weld back up, and reinstall carpet and seats. Oh and I have to finish up the gas tank skid mounts.

Buddies want to do a uwharrie trip in a month so it's gonna be a mad dash.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Fri Sep 25, 2020 11:10 am

FINALLY got the broken stud out of the head. Only took a dozen or so tries.
PXL_20200924_191849821~2.jpg


Location, angle, visibility were tough. Only had a few threads sticking out. Would have been very difficult to get a drill lined up to extract any other way.

Now I'm waiting for a break in the rain to start putting stuff back together!
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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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Wed Oct 07, 2020 2:06 pm

Got the stud I needed, installed exhaust mani, alt, brace, rodeo tensioner, deleted the AC bracket and the idler there, as the belt wouldn't fit without it. Installed PS cooler on rad, fan on rad, whole shebang in the rig. I need to turn over the motor and try expel the rest of the old coolant and PS fluid and get everything topped back off and burped/bled. Still need to wire the fan, too.

Also need to figure out the steering column solution, likely going to have to pull the column, because I can't see anywhere between the firewall and ujoint at the box where I can disconnect it. Fun.

Got the cargo area hole welded up, but my old welder must have popped an internal breaker or something because it won't turn on now. Time to put together the new dual voltage rig and gas cylinder and try that out on the remaining body work. Got a patch to do on the drivers side beside the bench seat area, angle iron to clean up the rocker cuts.

I got one side of the fuel tank skid done, just need to do the other and that will be wrapped up.

15 days, oh boy. :blackeye:
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Oct 13, 2020 11:43 am

Welded in patches in the floor (YUGE PITA, from blowing holes through it to the undercoating catching on fire and smoking the whole time, yeesh), including the rear seat latch hook that was cut off by the previous owner. Got the steering shaft extension done, got the fuel tank mounts all done as well.

Topped off the rad and PS. Got it fired up, fan works, took it for the first spin in God knows how long. Will probably change the oil and grease the u-joints.

Need to adjust the trans shifter, as it hits the radio now in 1st gear, and I have to hold it in order to keep it from popping out. Would like to weld in the rocker panel angle iron to pretty it up, but that's more of a nice to have. If I have time to whip up a simple new rear bumper, I will, but I may go back to the big ol' swing out if it comes down to it.

If I could keep the thing from pulling slightly to the right all the time, it would be cool, but ah, details.

9 days until URE.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Mon Oct 19, 2020 5:23 pm

Adjusted the bend to the shifter - actually broke the old weld when attempting to bend it, so I had to throw some hot boogers back on it. Then I welded the angle iron to the rockers to cover up the ugly cuts (still need to do some seam sealer to make it look less terrible), and put the swing out tire carrier bumper back on. Will post some updated pics when I finish the seam sealer!

Had to replace a few old rad hose clamps, replace cig lighter fuse, and "adjust" some radio wiring that was causing issues.

May go ahead and mount the LS front seats, or may wait depending on free time.

One last thing I'm doing is replacing the cherry bomb vortex muffler. The vortex has an extremely annoying drone at like 1800 rpm, 2200 rpm, 2800 rpm, etc, haha, just has these spots where am usually cruising where it's just awful. This is what happens when you watch the chase scenes in "Bullit" while you are muffler shopping :blackeye: Going with a regular ol' turbo style muffler to quiet it down.
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: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby lorenzo816 » Mon Oct 19, 2020 10:05 pm

I really need to jump on here more. From the few texts you sent me and then reading all this, man you had some serious scope creep.
That's a bunch of work. I totally agree tho on the want to drive cool old trucks on the trail and can get on the highway too. #notaJeep Why I also own a Scout too. ;)
Eventually I see you getting a decent enough suv that can haul a light enough trailer to tow your junk farther than uwharrie so I can take you to some of the places I wheel.
It aint so much about breaking as it is comfort driving back home. Hell, I drove to Harlan, KY in my isuzu, wheeled all weekend and drove home. Thats a bear of a trip!.
Hope to see you soon again brother. Good work.
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby hessmess » Tue Oct 20, 2020 8:55 am

I did the loud muffler route myself. It lasted maybe a month, running a turbo now. Still a bit loud but I am a bit hard of hearing anyway.
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
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89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
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Re: Coil/Radius arm SAS 1st gen Trooper - fine tuning/new mo

Postby paulevans76 » Tue Oct 27, 2020 2:48 pm

Got the muffler done and buttoned everything up for the 2 hr drive to Uwharrie on Thurs. Wow, the turbo muffler is much nicer!!! Now I can hear the typical manifold donut gasket leak up front :lol:

Drive was mostly uneventful but I will say I am ready to take this thing somewhere to figure out the pulling to the right issue. Developed a new vibe at >55mph which I think is just the rear driveshaft CV asking for grease. Also my power steering at idle just stinks and I need to figure something out with that eventually too.

Made it to Uwharrie, everything seemed to be running as well as it was going to. Buddy and I woke up early to join a Nissan group for a trail clean up on Friday morning. At some point, my electric fan stopped working and I nearly overheated a few times. We determined it to be the ignition on source. I picked a bad wire to use for that. So we spliced in a new connection to the battery and figured we could just disco that when done for the day.

In the midst of all that, while I was pulling off the main trail, I noticed my braking was getting super soft. I asked someone to watch my driver front brake line and eased into the brake and it was obviously leaking :crybaby: The line was leaking at the lower fitting. I think it must have gotten bent or stretched but it had definitely failed. So we spent about an hour and a half digging for things to repair that. The guys happened to find a fitting for the hardline and a plug for that fitting and thank God it held pressure. Big thanks to trooper buddy Dylan W and his buddies in the Nissan crew. They were awesome. I made it back to camp and parked the trooper and tried to figure out how to salvage the weekend.

We spent the rest of the afternoon trying to find something at the parts stores in the surrounding areas that would work, or someone to make a new hose, or someone to repair mine. No dice. Frustrating. Being 10mmx1.0 at one end and 7/16x24 at the other made it difficult. I decided to use my buddy's truck and trailer to drive the trooper back home the following morning.

After dropping it at the house, I turned around and drove back to Uwharrie, and we just relaxed and did some bunny slope trails with my buddy w/ all 4 of us (all 6'+ and 200lb+) crammed in his 1st gen 4runner :lol: He's got a SAS'd 86 with dual cases and 35's and lockers. It could have walked every trail out there with no drama, but we wanted to be smart since we were just out there solo. I drove it a little and I loved the deeper gearing.

Anywho, I just ordered (3) new -3AN brake lines with a 90* at one end, (3) 10mm to -3AN adapter fittings, and a pair of -3AN x 7/16 banjo fittings for the waggy calipers. Now, if a line fails, I have a spare. I want to eventually reconfig the front brake line system and just run a single line down to a T and hardline across the axle with some short hose at the ends to connect to the calipers. Keeps everything tucked out of the way. But for now the traditional set up will do. Once I have the brakes fixed, I'm going to see what I can do about the pulling issue.

I think after Fall Zu-wharrie in a couple weeks, I'm going to focus solely on finishing the samurai and then focus on addressing all of the trooper's remaining issues and gremlins - gearing, street manners, the steering, the motor possibly overfueling, the lack of parking brake... etc. It's turning into a pain to drive on the street and a pain to wheel and that's kinda the opposite of what I'm after!
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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