View Full Version : Zuk 2.0, 4spd auto, 1.8 zuk to D300

April 16th, 2009, 09:13 AM
I've been working on this for awhile and am trying to get motivated to install. Sucks to tear apart a perfectly working buggy :(. Still trying to figure out the twinstick on the dana 300 since I want the shifters directly behind the doubler. I found some nice push/pull cables locally that I will probably use :D.

BTW from bell housing to center of the t-case yoke is within an inch of the stock trans and t-case length!


Going into this buggy that currently has a 1.6 16 valve.

And the doubler for my brothers zuk


April 16th, 2009, 09:23 AM
Got more work done :D

Got the cross over pipes for the radiator done :D. Tig welded them at school, no pix of that yet.


Shifter mocked up :D


Cross Member mocked up. Going to make a full skid plate, but also thought about making a tube go around the dana 300 tied into the cross member and another set of bushings at the frame with it's own skid :shrug: lol.


And floor board mods :D. The dana 300 only sticks below the frame about 1/2" :o


April 16th, 2009, 09:42 AM
Very cool !! You have my attention:D

April 16th, 2009, 09:43 AM
I ended using a High Angle Drive Line toy flange for the front so the front shaft bolts right up :D. The rear I got a 1310 cv flange which I will have to rotate the rear pinion up to match the higher centered rear output on the t-case. At the same time I'm going to replace the dry rotted suzuki bushings on the lower links with some wrangler poly bushings.

For the t-case shifters I ended up getting a good deal on a cable shifter setup, and all i have to do is go buy some cables when the shifters show up :D. At first I spent alot of time bending dana 300 shifters for the twin stick and when I started to cram the t-case in I realized there's no way in hell unless I wanted a single seater with some booty fab.

April 16th, 2009, 05:04 PM
Hey Chris, i just put McMaster Carr cable in my buggy with twin sticked 205. They are much stronger and smoother than a lot of the other cables i found. I'm not sure of the part #, but if you search np205 twinstick on pirate there is a post that lists it. They are reasonably priced and work much better than the ones i've had in the past.

April 20th, 2009, 09:45 PM
Cool I'll check into the cables you are describing :D

Heres some updates.

Motor mounts done,, wiring laid out, power steering cooler relocated, and cooling system done :D.


May 7th, 2009, 12:56 PM
You are going to really like the 2.0! I am really diggin ours!


May 8th, 2009, 09:26 AM
Yeah I got it running about a week ago and damn that thing is fun with the auto :D. I will post some updates shortly on here :D

One problem I had with the doubler is the shaft walked back and spit out the needle bearing in the front of the kick case :eek:. So to get it up the side of our driveway we had to hold it in low. Yesterday I took it apart and was amazed that there wasn't more damage. I made a shim out of a grade 8 5/8's nut to fit in the input of the dana 300 case and siliconed it in there to keep it from bouncing around. Now the kick shaft has no where to go ;).

No cables for the cable shifters yet, seems everyone is back ordered on the 2" throw cables :( I have the floor board cut out but I will not be patching it back together until I get some cables.

I used a vitara a/c fan front mounted on the 'kick radiator and she's running nice and cool! I need to put a tranny cooler on but were about broke on this project so hopefully I can find one for free or at least near cheap lol.

Anyways we will be wheeling it tomorrow at independence.

May 11th, 2009, 06:53 PM
Howd it do? I had to make our shafts just the right length to prevent that problem.
Either that of I have thought of machineing a snap ring on the shaft to prevent that as well.

I buy all of our cables from Inland truck parts. They are really beefy with a push rating of like 70lbs. When you are bound up in the rocks and a back cost you a point I really lay into the shifters and they have held up great so far!


May 12th, 2009, 08:55 AM
It held up awesome. The only real issue I have is from raising the pinion up to match the centered output, and having an offset diff causes the driveshaft to hit the link when flexed out on the passenger side. Other than that I had a fuse blow several times from a wire I forgot to clip that was hitting the frame.

I still have to tidy up the wiring, and do a few other things.

Driving it with an auto is going to take alot of getting used to. I am used to being able to bump up ledges by popping the clutch at high rpms, and with the auto I need to relearn my self. We do like the fact that we don't kill the zuk a hundred times on the trail lol.

I'll get some pictures up soon :D>

April 18th, 2011, 04:13 PM

April 18th, 2011, 04:14 PM

April 18th, 2011, 04:14 PM

April 18th, 2011, 04:15 PM
I was all bummed out after taking the shocks to a motorcycle shop to have them charged, get back to the shop, bust ass welding everything up, put the shocks on, and they compress all the way Told them 200 psi of nitro, so hopefully their regulator was fawked up. Other than that the steering box needs mounted, and figure out wtf to do with the front clip.

Heading to General Air tomorrow to get me a nitro regulator so I don't have to take them off every time I need them charged lol. Still have to mount the steering box, and test :D

April 20th, 2011, 09:26 AM
My buddys Samurai that I've been helping him with :)

Back on Topic

put the tires on finally, and I didn't want to take the tires off to drill and sleeve the frame for the steering box, so up goes the side lol. The damn air shocks keep bleading down, I hope it's just the shrader valves because the stems are bent. Good thing I was able to trade my extra Co2 bottle for some nitrogen. Also found a nitrogen regulator at the pawn shop for $35 :D.


April 20th, 2011, 09:31 AM
Heres the frame side mounts, put them on the side of the frame so theres no rock anchors :D


These were fun to match up lol, excuse the mess.


This is when I was wondering what was wrong with me :tisk:


April 25th, 2011, 10:19 AM

The air shocks keep bleeding down, I noticed that the valve cores are bent from the previous owner so I'm hoping thats where it's happening. On another note it sidehills like shit. Think I'm going to add another screw in the valve, and change the rebound. I may even lower the pan hard mount at the frame to get a better roll center.

On the rear I'm thinking I will try first by out boarding the 1/4 elliptic springs to the edge of the axle to decrease the leverage. At the same time I'm going to mount them in front of the axle so I can lower it a couple of inches, and it will also allow me to add more springs to the pack.

Other than that it felt more stable in uneven transitions where articulation kept it level. With the leaf springs the rear would do all the work and it would be leaned over more. Now with the air shocks the only problem is side hilling.

April 28th, 2011, 09:40 AM
Dad testing it out on our property, since moving the quarter elliptic springs 5"s further out at the axle the suspension is more balanced. I started out with quite a bit of nitrogen at first, probably around 200 psi. After running it around for awhile I burped the shocks out until there was about 4"s of shaft showing, and it helped out even more. I think it's about on par with the old leafs now as far as side hilling.

April 29th, 2011, 08:41 AM
Well we went and played on our friends property for awhile, and we broke a Nitro stub shaft. The shafts are running spicer joints, and we have only had them out at Penrose once :(.

These photos were after the fact lol.


The snappage, threw a stock shaft in for now. We beat on stock shafts for years and finally a u joint let go, pretty lame an aftermarket shaft broke that easy. Super clean break too, doesn't seem right:rant:


April 29th, 2011, 10:47 AM
The vendor I got these Nitro shafts from said they are made in India guess thats what you get when you try to get a good deal. They will upgrade the stub shaft to an American made stub for $75 that I guess hasn't been broke yet, but you know how that saying goes. Also the inners they said they won't warranty if they are broke, so much for lifetime warranty .

June 9th, 2011, 10:24 AM
Check out our facebook page for some videos and pictures, hope to have some videos uploaded of Catzuk and Msuits soon :D.

Waiting for my brother to upload Carnage videos too.


June 21st, 2011, 01:57 PM
Water falls at Penrose Sunday


rock hopper
June 21st, 2011, 10:05 PM
When in doubt throttle out

June 23rd, 2011, 02:04 PM
Nice finally got a reply.i used to try and crawl everything but with this Aerio motor and automatic it feels so natural to drive it like that plus trails are getting so nasty there really isnt much choice.

June 23rd, 2011, 02:33 PM
Looks like a fun little rig. Good videos.

June 23rd, 2011, 05:16 PM
that thing looks like it works pretty good:thumbsup:

June 24th, 2011, 08:07 AM
hell ya that thing looks good on the rocks so your side issue has been fixed???

June 24th, 2011, 11:02 AM
Thanks guys, I'm really happy how the front has worked out :). The side swaying was fixed by moving the rear 1/4 elliptic springs outboard at the axle instead of inline with the frame. I really don't think I need a swaybar at all unless maybe I do some kind of air/coil overs on the back.

August 31st, 2011, 11:46 AM
Vote for our ride if you don't mind please :D


October 9th, 2011, 11:17 AM
you zipped right up the falls!!!Nice :thumbsup: