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

Happy Bday

Many Happy Returns!

Thanks for the birthday messages... now fifty :lol:

On our latest trip I managed to rip the offside rear shock off it's mounting point on the chassis crossmember -



But completed the trip with it ty-wrapped to the panhard rod...

Today was the day to fix it...



So in the week I tidied all the 'ZookBOB' production equipment out of the way, so that today...



I could squeeze the Jimny into the nice warm garage / man cave to...



...be able to work around, especially have enough room around the back.



The offending mount, the bolt has ripped through it



Referencing the bolts for the centre seat mountings and the roll cage plates...



I could work out where I needed to cut my access hole...



There!



And open up a flap above the mounting.



I then cut the front off the mount where the bolt had ripped itself out



And then cut the sides back...

I then set about making a new mount -





From some suitably sized box section...



I then welded a nut on the back and a reinforcing washer on the front, before...



Welding the new mount in place, and then, after painting the top of it...



I removed all the sound-deadening tar with a blow torch and scraper and then wire brushed and sanded ready for...



And then welded the flap back, sanded down the welds and hammerited the patch to protect it...



And then did the same underneath and then reconnected the shock...

Almost done, just need to repack everything back into the rear of the Jimny

funnily enough i had to cut a similar hole in my floor to get my standard shocks off

Good work Dave!

that looked like a nightmare to to me, fix but you made it look easy!

I wonder if you have that shock hitting your panhard or panhard mount like i do, which may have contributed to it breaking?

Cor, that's a neat job! Well done! I wouldn't have had a clue what to do...

Nice neat work there Dave. Though I thought you were going to leave the patch as an access cover?

Thanks all

it turned out to be such a nice clean cut with a slitting disk (I feared the floor was double skinned) that I had a nice 1mm gap to neatly MIG the patch back in place... it would gave taken longer to fit rivnuts and make a larger panel to fit over the hole...

Hopefully i won't need to do it again?! :lol:

I know a lot of people on here don't like shock spacers... but I needed to make some custom ones for S200KYS today..

After fitting the new springs I noticed the shocks were too short! They are +4" ProComp ES1000's on the back, but the springs are that long that they were fully extended at rest, so going over speed bumps the back was "hopping" a bit...

I thought about buying longer shocks, but it's December and funds are limited due to the impending festivities, and besides, examing the shocks they had spring marks all up the back of them, so no use fitting new shocks for the same thing to happen, so I decided to knock up some shock spacers to get the Jimny ready for this Sunday's outing, a day-trip (!) to the Lake District!



So I made them offset so that the shock was relocated away from the spring...

Very much how Martin had them made when he first started selling these kind of relocators



Here you can clearly see the offset backwards, and the narrower mounting tube underneath the "U" shape of the relocator



And here you can see the shock relocated midway between the panhard and the spring...

You can also see the spring marks on the shock now it's been twisted 90 degrees...

And... you can see how much twist was on the bottom shock bushes, see the angle the bracket is sat at?!...

The brackets are un-plated / painted at the moment as I need them for the weekend... I'll get them back off next week and send them for plating, and order some new shocks after Christmas and get them re-fitted together...

Very nice.

Nice looking forwards to seeing them on Sunday!

Dont forget them axle gussets you had for me