Dave's "S200KYS" Jimny 'laner Build...

Crickey Dave! Your poor Jim Jam!

The Blog was a great read as always!

The shafts are a disappointment. There's nothing like testing in Public!

Kirkynut

Glad you made it home Dave! poor old girl hope she gets.better soon


Thanks for sharing great read

A fruitful day yesterday, and a bit this morning...

On Monday I ordered a replacement rear ABS axle tube off eBay, reasonable value, £60 with £40 shipping... and it arrived the next day Tuesday... I would have ordered one from J999PRE, but, I didn't have time or a vehicle to go pick it up... not sure the wife would like me putting an axle casing in her Mokka... although Brett (Maverick) recently put one in the back of his own BMW convertible flying machine...

So, yesterday I took the old axle off...



Hmmm, a couple of tab brackets missing there? :blink:



And on the other side ALL the holes are ovalled

This allowed the axle to twist and took the shocks out...



And also with the nose of the diff rising up, the prop was forced to run at a strange angle which then...



.. took the prop out

So, to the repairs (yesterday)...



Old axle off, as pictured above too...



New bushes going in...



All in and waiting for the new axle casing...



Which has been prepped...

* Brake lines removed ready for the disk conversion flexies to go on
* Oil filler (heat and chisel!) and drain plugs removed and replaced
* Panhard retaining nut cut off and holes widened for the Zanfi panhard bracket to fit
* Shock mounts drilled out to take my long 12 grade 10mm bolts
* Sealing surface cleaned up ready for the diff
* Breather cap removed and tapped for BigJimny breather line



So axle all prepped ready for Sunday...

Yesterday I also ordered a pair of ProComps from JimnyBits... Russ has advised that the AVO shocks are rebuidable, so they may be able to fix them, so I'll ask for a price and go from there...

The ProComps arrived this morning, and I quickly whipped the bushes out and swapped them for some of my own...



The top left bush is the bottom one, you can see the bottom right bush is a bit thinner to fit up into the Jimny's chassis mounts, rather than having to attack the ProComp bushes with an angle grinder, etc..

And you'll notice the right hand bush is also a lower bush but has a special insert sleeve in it... the inner hole is 10mm for my long bolts rather than a normal 12mm mounting bolt... more on that when I rebuild it all...



There... bottom mount on the left and top mount on the right...

So, all the bits are here, ready for the rebuild on Sunday!

Great pictures, can I pinch them for the WIKI on trailing arm issues

I decided not to throw the old casing away...

I'll pop it at the back of the garage and over time I'll strengthen it all up with gussets and new brackets and refit it during a future rebuild...

mlines wrote: Great pictures, can I pinch them for the WIKI on trailing arm issues

Course you can boss

S200KYS wrote: I decided not to throw the old casing away...

I'll pop it at the back of the garage and over time I'll strengthen it all up with gussets and new brackets and refit it during a future rebuild...

Hi Dave,

is it worth checking the axle is still straight before it goes into spares store?

Paul.

Strengthened brackets made up on the old axle will be good.

I'm guessing it's not easy to check the axle for straightness but if it hasn't leaked at the seals I can't see a problem. I know it leaked at the seals this time but that was because of the shafts being trashed.

Kirkynut

It looks straight ? To the eye anyways... :silly:

I'll add a truss to it too then

Bloody repairs are keeping me away from finishing this one

11/60 wrote: Jesus dude, you really need to try harder, ripping off the back axle just demonstrates a lack of commitment to the cause! :evil: :evil: :evil: :evil:

back together in no time and stronger too, no doubt.

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Hmmm, yes, takes it's toll, it's had a couple of dozen adventures by now though... don't think Suzuki ever intended Jimnys to take this kind of punishment longterm...?!

Yup, soon be back together... Sunday hopefully!
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kirkynut wrote: Crickey Dave! Your poor Jim Jam!

The Blog was a great read as always!

The shafts are a disappointment. There's nothing like testing in Public!

Kirkynut

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Thanks, glad you enjoyed the blog!

Yes, but they now know how to make them better, that's the whole point of prototyping things! :evil:
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Daniel30 wrote: Glad you made it home Dave! poor old girl hope she gets.better soon


Thanks for sharing great read

Thanks Dan... Yes, front wheel drive Jimny! LOL :laugh:

LSD made for interesting driving though!

Soon be back together... and back to the Lake District for our annual weekend away 25th and 26th of June...

Cheers All...

Dave

Well done Dave

I should think the A-team would have had trouble doing all that in the time