The Heap. A Gen 2 Tracker/Vitara Build

[IdaSHO]

Then its time to get the motor and trans sorted and mated.

Fresh rear main seal, freshly surfaced flywheel, proper Japanese pilot bearing and Exedy clutch kit including throw-out bearing.
And after the typical nonsense getting things lined back up, engine and trans were mated and in the chassis.

 

[operator john]

SWEET

 

[IdaSHO]

Flipped end for end in my small shop, and working on the rear of the chassis.

Axle out, suspension blown apart, fuel tank out, lower geared (5.12) rear third member installed, chassis painted, and looking good.

Axle is now waiting on parts from Japan, both wheel seals, seal protectors, etc.
Rear wheel bearings are in good shape, so they will be reused.

 

[IdaSHO]

Fuel tank back in, fresh fuel filter...
Axle on the bench waiting for axle seals and such, but it still allowed me to sort out the fresh rear brakes.

Axle prep... when repacking the (seemingly) useable rear wheel bearings, I noticed the inner race spinning on the axle shaft.
So the retainer was cut, and the bearing, that SHOULD be press fit, slipped right off the axle shaft.
We shall see how a new bearing fits. But I expect the need for bearing loctite compound.

 

[IdaSHO]

Fresh axle seals, wheel bearings, done...
Fresh drums, fresh parking brake cables, fresh KYB shocks.... rear axle back in.

 

[IdaSHO]

Drive shafts rebuilt, front bearings torqued, front hubs installed.

Things are getting very close now.

 

[IdaSHO]

Getting back around to the tracker....

Body is back in the shop, being torn down.
Started with removing the windshield and dash/heaterbox.

 

[IdaSHO]

Entire body stripped of hardware and harness.
Next up is final fab work....

 

[IdaSHO]

Some final fabrication done.

The slightly "boat-sided" rocker/sliders fabbed up and in place.
These will be bolted on, so just drill/tap needed.

Windshield frame cleaning.... happy to see no corrosion to worry about.

And final work to the custom rear quarters/corners.

Nearly ready enough for paint prep.....

 

[IdaSHO]

nearing completion of all metal fabrication, I realize that these silly clips are obsolete, and essentially none available in the country.
These clips accept trim screws that hold the soft top trims in place. They are required, unless you ditch the trims and pony up for a hard top. I prefer the soft top.
So I check options, including modifying the body to accept a simple off the shelf clip.... but realize the best thing to do is (finally) pick up a 3d printer and just make the darn things myself.

So I picked up a 3d printer and made it happen...
These are printed using ASA, so they are perfect for auto use. Chemical, heat, and UV resistent.

 

[IdaSHO]

And while we are at it... lets fix the broken primary blend door on the heater box
yeah... 3d printer has already paid for itself. Certainly a purchase I should have done YEARS ago

 

[IdaSHO]

And about the dolly.

Doing the math, after finishing up fabrication work on the body I realized I didnt have ANY way to get the body into the temporary shed that I use for sand blasting.
So with some scraps I had, and a couple of large casters, I built a dolly.

Then body was tossed into the blasting booth, all new bits blasted. Then back into the shop for final sanding and paint prep.
The main body gets epoxy primed in the morning.

 

[IdaSHO]

Productive morning.

Officially the primer can me seam-sealed and/or top coated after 1-hour and up to 7 days without sanding.
Ill give it 24hrs until its seam sealed, and plan on shooting the top coat (monstaliner) next friday.

 

[utherjorge]

Gorgeous. Excellent work.

 

[SVTRIT]

At first I thought this was going to be a beater build. You are doing this rig right!!! I wish I had your talents.

Nice work!