KAP Suzuki Jimny - rebuilt for the road

Hi all,

I have been lurking in the background for a while, but my Jimny is coming on well, so I am out the cupboard (or garage) to write about it
I have a a very early KAP Jimny that I bought about 2 years ago from a guy near Falkirk. I wasn't road legal when I bought it, but I only used it a trialler with my local club. It just came out for a day, thrashed around then left for 2 months under a tarp. Those days weren't good days for it!

Anyhow, things have changed, I have moved to Northumbria (Alnwick), and sold my 110 double cab, so the Jimny needs to come back to life as my everyday car, green laner and trails vehicle. Not too much to ask then!

First, I went underneath, found all the obvious faults, put them right then I put it in for an MOT, which it failed… on emissions, rear brakes, lights (F&R), & on top of this the gearbox and clutch was completely shot. If it hadn’t had a completely rust free body I would have scrapped it. But not many year 2000 Jimny (W) are completely rust free. So I decided to carry on, new rear brake pistons, fitting kit and pads fitted and adjusted. Replacement headlight and wiring and all the earths checked over, full service, FWH from Jimnybits, replacements seats and its hopefully getting an MOT this afternoon. So I’m keeping everything crossed. The garage are also changing the clutch, gearbox and transfer box because, as you know, access isn’t great.

So that’s the past, now the future….

Fit seat spacers (30mm) to raise the height of drivers and passenger seat. I made these out of pipe and just ordered longer 8.8 M10 metric fine bolts to replace the standard bolts that wont fit.


Rip out carpets and put in Drew Off Road sound deadening that is also wipe (hose) clean.

Maybe remove the cage and do a body lift, then refit the cage (a lot of work)

Rebush the back end.
Remove rear seats.

Fit tablet for navigation



I’ll post some better pictures of the zook tomorrow.

Phil

Looks a lot like this one in the galley

www.bigjimny.com/index.php/gallery/category/21-madmick

Yep, thats my car, what year were those taken?

...and good news on MOT front, it passed

Phil

I have noticed the drivers side front spring 'bows' forward then back again to meet the axle, and doesn't sit centrally at the top of the spring mount, is there a rubber guide or similar that I'm missing?

Well, not many replies yet, but hopefully that doesn't mean people aren't interested.

Today, I had my first shot on the road after getting MOT, insurance and tax sorted out. Its slow and over geared, and the steering has very little 'feel' to it. I may investigate a steering damper kit? There doesn't seem to be any death wobble, but time will tell. It already has caster corrected arms on it.

I have refitted a lot of the interior, and tried the seats spacers to raise the seats up 30mm, I think these are going to be good when fitted, but the longer bolts didn't arrive today. I also removed the 4 spotlights and still need to weld up the holes. I had a look at a LED light bar to replace them.

Heres some pic's taken today







Phil

Today, I fitted the seat spacers, it raises the seat by 30mm, and gives me a far more comfortable seating position. I bought 8x M10 metric fine 8.8, 50mm long bolts from ebay.



Spacer fitted (bolt not tightened)



I am also struggling with the lamdba sensor, it appears to have been disconnected for some time, but the car side the loom seems very short (about 2-3inches). Is this normal? I bought a cheapo lambda sensor from ebay without a plug, now it looks like it is going to be very difficult to connect up.

Just a few jobs today and (sorry) no pictures.

I replaced the lambda sensor with a cheapo generic one from ebay with no plug (£17), it was easy to wire up and the test drive, although brief, didn’t have any engine warning lights coming up, so a result there & it hopefully stay that way. It’s a 22mm spanner if you’re planning to do the job (I had to pop out and buy one)

I ordered a Jimny bits steering damper kit, I have HD steering bars (tube) that slides over the standard steering bars to strengthen them up, so I have removed this temporarily until I get the kit fitted, then I'll see if I can resuse the tube again. Its 5 PM and no courier yet, so it seems unlikely I’ll get the damper kit today

The raised seat worked really well, I’m 6ft but I just like the more upright driving position.

Also, there are plenty of people reading the thread, but some words of encouragement would be good!

Phil

Well, i like it, even if nobody else does!

Looks a capable machine. i think the body lift you suggested may be a lot harder with it having the roll cage and bumpers?

I might copy you with the seat spacer idea as well, i could do with sitting a bit higher.

keep up the good work!

Riccy

looking good i like the spots compared to a light bar, looks very capable well done for putting in the work to keep her going

Looking good mate.

Thanks for the feedback guys, its nice to know this is read and enjoyed.

Today’s job was fit the steering damper, I had complained above about the over light steering, I did have my reservations about how much good the damper could do, especially as the kit is £86, but I’m glad I fitted it. If Martin offered me my money back to return the kit, I wouldn’t take it. The steering now has some feel to it, and when it hits a pot hole the car doesn’t feel like it’s going to jump in to the oncoming traffic! It’s no sports car, but it does feel a lot safer now, even at the heady speeds of 55mph.

I decide to Waxoyl that part of the chassis leg before fitting it - as it could become a bit of a rust trap.

Out of interest – What is the cruising speed that most people get, I’m running 205 simex style tyres, and it feels happy and could be driven all day at around 55mph (I was hoping for better!), it will go faster (but not much!)

The kit :



Fitted:



Phil

The first pic seems to have become corrupt, so I'll try again, the kit: