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Suzuki SJ Body Welding Stuff


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Both front arches are now done with trim mounts, and I only have the left rear to do.

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I have started taking the front end apart and wire brushed in an angle grinder and painted everything. I just want it done now, and I hate yellow.

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Progress! I’ve been in this every evening for a couple of hours. Only one outer arch to go.

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I removed all the bits from the engine bay, clean everything up with the bench grinder wire brush and put everything back together again. This was sprayed, screw rollering, it’s awful and takes a stupid amount of time to get anything acceptable. Never again

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I’ll do the same with the running gear lastly, I have axle rebuild kits coming from India so should arrive when I start.

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Still have a huge amount of things to do though. Engine and gearbox don’t use the existing mounts, so will have to make them. I’m going to start the inner arches and rear corners in the weekend.

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Last outer arch done! I shaped the whole thing with a hammer, some pliers, and a wooden pallet. Was going to start and finish the inner arches this weekend.

Unfortunately ...

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Bottle tipped over and broke the new regulator off again. Will have to attach the new one ‘remotely’ when I get another one, this is just taking the piss. It sticks out too much.

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On 7/5/2020 at 12:08 AM, Spiny Norman said:

Fun wee things these, my mate bought a new one on an F reg which I christened 'Bouncer', not after the dog in Neighbours but because you travelled about a mile vertically for every five you went forwards in it.  Just trying to drive it in a straight line was a challenge and that was a split new one.
Fuck knows what a 35 year old one is like.

A mate of mine also had a new one on an F plate. It was exactly as you said - all over the place even on straight and even roads. I had a go once and it demanded total concentration and constant corrections just to maintain a straight line on tarmac.

I love them though. I had a Jimny soft top on hire in Greece early 2000s and it was great fun.

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Well another regulator bought (these are only £15 on eBay and are good), but this time I’m not taking any chances.

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Also slipped with the drill and ...

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I spent my regulator-less time shaping some metal so I could weld it on. I bought this stuff which is a godsend, and also a vice.

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Everything fits and I just have to cut a bit out and weld a few curves in and the body is done.

I started on the inner arch, but stopped as I was getting a headache from garage stuff.

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  • DavidB changed the title to Suzuki SJ Body Welding Stuff

Probably won’t update this again but welded the rear arches and floor up now.

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tapped the end of the welder and the whole tip broke off. I would have had this done if if were not for these occurring maladies. 😪 Welder is fantastic, but everything is going wrong in a way.

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Im trying to source bits needed to complete the build for the Suzuki 16v engine but it seems difficult so I’ll stick it on eBay and going to put a C20XE in it. I know them in and out and gearboxes are always available and easily adaptable.

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19 minutes ago, DavidB said:

Probably won’t update this again but welded the rear arches and floor up now.

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tapped the end of the welder and the whole tip broke off. I would have had this done if if were not for these occurring maladies. 😪 Welder is fantastic, but everything is going wrong in a way.

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Im trying to source bits needed to complete the build for the Suzuki 16v engine but it seems difficult so I’ll stick it on eBay and going to put a C20XE in it. I know them in and out and gearboxes are always available and easily adaptable.

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Bloody nora! An XE in an SJ? You're mental! 😆

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  • 3 weeks later...

I finished the welding off with a tiny 2” square plate on the drivers floor. I discovered a large plate that I didn’t like was just slapped on over bare corrosion. What!

i cut half of the floor out and removed the plates which were made of 3mm metal and just hammered into place. And probably welded with an arc welder. It was also double skinned underneath to hide bodge. This took ages to cut out and I’m not sure what is going on in the photo.

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I also fixed the seat mounting point, as the fixer welded several 5mm metal construction washers over it.

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On 10/8/2020 at 9:17 PM, DavidB said:

 😪 

Im trying to source bits needed to complete the build for the Suzuki 16v engine but it seems difficult so I’ll stick it on eBay and going to put a C20XE in it. I know them in and out and gearboxes are always available and easily adaptable.

What are you struggling with ?

The engine should only need a clean fuel supply (facet fuel pump to regulator and filter, then to carbs)

Ignition is piece of piss, as Dizzy should be very similar plugs.

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