The Heap. A Gen 2 Tracker/Vitara Build

[IdaSHO]

For sure. These are crazy fun, even on a tight budget.

My intentions are to make this mechanically 100%.
So as soon as fab work is finished up, body will come off the frame, engine and trans gone thru, front and rear diffs, brakes, etc... etc...

At this point I have near 3k of parts on order. I pick up wheels and tires this weekend so we can do a complete clearance/flex test.
Sourced a proper OSK timing set/kit for the 2.0 Also sourced some junkyard Aisin locking hubs for cheap.

 

[IdaSHO]

Well, its finally back in the shop.

Next up is to fab the rear bumper and spare tire mount.

 

[burt]

I need to plate the belly on mine. Being low picks up every stick and tries to jam it some where it seems like. Had one jam up against the belt a while back. I’m in the woods though so that might not be as much of a problem for everyone but it does it more than anything I can remember driving.

 

[IdaSHO]

Been scouring the 'net and local yards for a few items. One of them being OE Aisin front lockouts.

Took a chance and nabbed these off of Ebay for less than $50.
Always a chance they need hard parts, or are complete junk.
Not the case.... all they needed was a full tear down, cleanup, repaint, and gaskets/seals.
All in, well less than $100 for the set.

Just waiting on gaskets/seals now. But they cleanup nicely, and even came with the elusive cone-washers required to bolt the hub to the axle.

 

[IdaSHO]

Some sunday morning sketchup

Working out the material list for the rear bumper by putting things in cad

The rear bumper will include a hitch, as well as pivots for a rear mounted, fold down spare tire carrier.
The tire will be held between and held by the tailgate and carrier, to share the load, and an over-center latch will latch thru the wheel center bore from carrier to tailgate.
Clear as mud.... And will remain clear as mud until fabbed, as I cannot bend tube in sketchup

Anywho.... this is the gist of the bumper section

Carrier will be similar to this, but will only include the center hoop.
Instead of body mount connections, it will latch thru the center of the wheel to tailgate

 

[IdaSHO]

All, Ive updated the original post to include a running list of parts and cost.
It helps me tremendously to keep track of these goodies, to be as prepared for the job once Ive dug into it.
It also helps me keep track of what has been ordered, and will still need to be ordered.

As of right now, including purchase price, all materials so far, and the pile of parts I have on order Im sitting at $4504

 

[IdaSHO]

spare mockup

Bumper plans are pretty well complete. Certainly going to need a trip to the machine shop for steel though.
But this is about where it will be located. And it looks like I will be able to use the factory spare mount, but flipped so it bolts to the hoop of the carrier.

And this thing has been under a cover for months. MrCole swears there are critters in it

 

[IdaSHO]

Kicked the Tracker out of the shop for a moment in order to do service on the Wife's Rav4 (needed a balll joint)

Seemed a good time to get some quick Iphone shots.

I definitely like where this is going.....

 

[IdaSHO]

Rear bumper progress.
A couple of design changes, but looks to fit the bill.

Started with a couple of templates to generate all needed brackets...

Then started punching holes.
Anyone who isnt familiar with milwaukee's hole-dozer line... get some. Incredible bits that put up with near anything.

 

[IdaSHO]

All brackets dummy'd up with some pipe.

 

[IdaSHO]

Then starting with the end brackets (mounting brackets) I added some tabs, drilled and set 6 grade-8 riv-nuts, and started dry assembly.

Dry fit for good reason. Ill need to bend some pipe to match body lines. The bumper will also get a top/cap.

 

[ITTOG]

I have never bought their hole saws because they do not specifically say they are rated for metal. At least not the ones I see on amazon.

 

[borison]

Looks great, these little Samis have a lot of potential.

 

[IdaSHO]

Some afternoon shop shenanigans.

OEM bumper occupied this space, so in order to finish out the rear bumpers, custom 1/4's were needed.

 

[IdaSHO]

Just about there. Was able to finish up the custom rear 1/4 panels, as well as burn in much of the hitch.
Even with my marginal sheet-metal skills, they are likely the straightest panels on the thing

Next up is to add skirting for the section between the tailgate and the bumper, and finalize bumper design.