1991 Snow Tracker Build

[FleshEater]

Thanks for the feedback guys!

This morning it occurred to me that I’m trying to build two capable rigs. One is running and wheeling at the moment, and the other is not.

I was all ready to start hacking this up, but since it requires almost the same amount of attention as the Samurai, I’m just going to get the Samurai done first. At least this way if I get another invite from Byro I can wheel SOMETHING.

So, this pig is going on the back burner and I’m going to re-focus on the Sami. We’ve been having such a dry summer I’m able to do most of my work outside.

 

[YotaAtieToo]

I've really liked the spartan for the money, had 4 of them now I think. If you don't like it, at least it's only $300 or whatever.

 

[FleshEater]

I've really liked the spartan for the money, had 4 of them now I think. If you don't like it, at least it's only $300 or whatever.

I’m sure I’ll like it. Was just being a cheap fucker.

 

[YotaAtieToo]

I’m sure I’ll like it. Was just being a cheap fucker.

Being cheap is getting a lunchbox

I mean, if you're really pinching pennies, go ahead and weld it, I've done it on a hand full of axles.

Fwiw, arb rear, welded front will turn sharper than Spartans front and rear

Just plan on at least hydro assist.

 

[FleshEater]

I’m so glad I didn’t get mad enough to chop this up just yet.

A couple weekends ago I drank some beer, which I hadn’t done in a year or more, and conjured up an idea with my buddies to try and destroy this Tracker.

From the drunken evening…

So, seeing that it was handling all the abuse, I spent this week cutting a full blown trail.

This trail is one of many to come and while it’s tough, the future trails will be impossible for this as it is. This is kind of inspiration to get the Sami DONE.

Anyways, I weedeated a little today and said screw it and ran it in this. I had to photo op myself. Pulled cable 3 times and it’s a legit trail for this. There’s also tons of new lines to try on the rock piles.

Poseur shots.

 

[FleshEater]

More.

 

[YotaAtieToo]

You change your mind almost as much as me

Still planning on the D30?

 

[FleshEater]

You change your mind almost as much as me

Still planning on the D30?

Almost.

Nope. It’s getting Toyota axles and 35’s. There’s no reason to keep this street legal anymore.

The red Tracker might get the Dana 30.

 

[FleshEater]

My oldest kid was running trails today on his ATV and spooked a bear about 12’ from him. It scared him, so we took the Tracker out.

He was going to try and get his 125 Yamaha through this trail, even though I told him you basically have to walk it through while lifting it over obstacles.

We got one picture in a spot that we got hung up on. Whole lot of throttle got it out. Storms started rolling in so we headed back to the house after one trail.

Pictures never look as difficult as a trail looks in person. I’m just surprised this hasn’t broken yet.

 

[FleshEater]

We went to Ben Franklin Range today in Templeton PA. It wasn’t a bad trip. Lots of mud, and some rocks. I beat the piss out of this thing again and it just took it like a cheap whore. I’ve noticed we’re always involved in wheeling and not picture taking. Only got three pics today.

A YouTuber caught us in a rock section, so I might get footage from that. Who knows.

Finally cleaned it up, too.

 

[FleshEater]

The saga with this continues.

I had this out last Saturday night on my property, with too much beer in me, and a determination to destroy something on the front end. Well that didn’t happen. No idea how, because I had this in the rocks pinned to the floor many times trying to catch traction with a front tire. It went over obstacles it never should have with the “who cares” attitude.

This got me thinking, instead of having it down for however long an SAS would take in the front and new links and rear set up, why not just build it as is? Perhaps see just how much abuse this can take.

Since YotaAtieToo has mentioned a few times about building an aluminum cage around the front diff, Wuz-A-zuk offered up the aluminum welding service to see if we can make it live on 35’s. I’m going to keep looking for a steel diff from a Vitara, but in the meantime…

Then I remembered a thread I found long ago on a junk yard lift for these. If I’m not mistaken Cherokee and Explorer coils can work and net me more lift. Then I’m considering the rear upper link and front lower arms from Altered Ego or just get the whole kit for their 4.5” setup. Lock the front. Get the Toyota CV adapter, do the Hagen mod, and stick 35’s under it and beat it.

Yotatietoo said via text, “A mild rig is better than no rig.” If I can keep pushing the limit with this while I build the Sami, then it’ll keep me searching harder and harder trails.

Honestly, I underestimated how much work it takes to build a custom crawler. First time and I was gungho.

 

[JR4X]

I don’t know how you’re going to gear it where it can make use of 35’s. Mines on the struggle bus with 30’s and 5.13’s and 4.24’s. I think I killed the engine bashing snow with the little bastid. I beat on it for years with no issues but two snow runs and I’ve got no compression in one cylinder.

Wish I could find some of the ol 5.89’s laying on somebody’s shelf.

 

[Byro]

Yota axles gusset diff/and/or Vitara dig and keep it on the 32s, beat on it extensively?

 

[FleshEater]

I don’t know how you’re going to gear it where it can make use of 35’s. Mines on the struggle bus with 30’s and 5.13’s and 4.24’s. I think I killed the engine bashing snow with the little bastid. I beat on it for years with no issues but two snow runs and I’ve got no compression in one cylinder.

Wish I could find some of the ol 5.89’s laying on somebody’s shelf.

You have to remember, this is a trail rig only and will never see snow again.

I ran the numbers through Grimm Jeeper and my FPS speed was a difference of .07.

It’s not ideal. I could run 34’s or 33’s even. I just know I’m hanging up all the time with these 32’s. I just need a little more to help this short wheelbase.

 

[FleshEater]

Yota axles gusset diff/and/or Vitara dig and keep it on the 32s, beat on it extensively?

That’s the first step. I want to add a front locker and Yota CV’s to see if this let’s me pick better lines to keep from hanging up so much.

I’ve got another year on these 32’s or more so I’m not concerned on rushing to a bigger size. You can still have all my CV’s if ya want them after this.

 

[Byro]

Full flat skid front to rear. Cover that with 1/4” HDPE and slither over everything.

 

[2big bronco]

Full flat skid front to rear. Cover that with 1/4” HDPE and slither over everything.

Yep, the frame rails are perfectly flat for the whole belly and already the lowest point. With lockers and full skids it would slide/crawl over anything

 

[FleshEater]

I’ve got a 1/4” steel plate under it right now.

My problem is losing traction in the front and then high centering on my frame rails with the front tires in the air.

 

[YotaAtieToo]

I did not envision an aluminum cage, I meant a steel one similar to what keeps the samurai tcases alive.

Basically just build a shell that grabs as many bolts as you can, then rubber bushing off of that. I'm very certain it will solve the aluminum diff issues.

 

[Byro]

I did not envision an aluminum cage, I meant a steel one similar to what keeps the samurai tcases alive.

Basically just build a shell that grabs as many bolts as you can, then rubber bushing off of that. I'm very certain it will solve the aluminum diff issues.

I like this. I installed a dirty snatch on a guys Sami case years ago. It was definitely impressive and I dont think he broke it any more after that.

 

[FleshEater]

I’m not sure how I could build a steel cage and make it strong on this diff. Wuz has an idea for it and said he’s done aluminum housings in the past for Miatas. Using steel there’s a lot of distance to cover from all the bolts and not a ton of room.

Anyways, I went back through this thread and remembered that Sami thirds swap over. So I pulled the rear third out of the rotted up pile out in the driveway and test fit everything.

26 spline side gears fit in the Sami carrier.

26 spline shafts fit in the Sami carrier.

Now all I need to order is the Spartan and the can to capture the pins on the Sami carrier. Then I guess I’m setting up gears…again.

Pretty stoked about getting this done in an affordable manner. Kind of the point of these things.

Next up is welding up the bracket on the Sami third and then the Toyota CV adapter and Hagen mod after Wuz ships back my housing.

I really should be swapping an FJ t-case into a 4Runner right now, but this is more appealing.

Ready to start.

 

[FleshEater]

Does anyone know if a solid spacer for a Sami pinion will work in a Track/Kick? I can’t see why it wouldn’t if pinions swap.

Also, thanks for whoever provided the information about the Sami pinion flange being used for an SYE. It works and I’m going to add that to the list. Then rebuild spare driveshafts to carry for it.

 

[Byro]

My crazy ass idea I had at one point was use a SxS diff, cut down SxS shafts and SxS outers with double A arm.

Then I realize it’s a Tracker and I’m not rich.

 

[FleshEater]

Tidbit I found from the old place:

Rear Sami 3rds are 26 spline side gears and all 4 pin.

Front Sami 3rds are 22 spline side gears and only early models are 4 pin.

If anyone else is looking for Samurai parts to swap, this should help.

 

[FleshEater]

Took my buddy and his girlfriend out tonight. Didn’t fare well. Time to pull the interior panels out and bang this shit out.

 

[2big bronco]

Took my buddy and his girlfriend out tonight. Didn’t fare well. Time to pull the interior panels out and bang this shit out.

Try a plunger first

 

[FleshEater]

I ordered up the pin retaining can and a Samurai solid pinion spacer today from Trail Tough.

I’ll get the locker from ECGS.

Anyone want to take a guess how long this survives on stock CV’s with a front locker?

 

[YotaAtieToo]

I ordered up the pin retaining can and a Samurai solid pinion spacer today from Trail Tough.

I’ll get the locker from ECGS.

Anyone want to take a guess how long this survives on stock CV’s with a front locker?

Depends on how you treat it. If you wedge a tire in a hole and keep going with an open diff, it will just not power that tire. With a locker, a broken cv is pretty likely. But you're now going to be way more capable and may be able to make stuff easier than before.

I'd still bring a few spares

I’m not sure how I could build a steel cage and make it strong on this diff. Wuz has an idea for it and said he’s done aluminum housings in the past for Miatas. Using steel there’s a lot of distance to cover from all the bolts and not a ton of room.

My thought was that you'd have to probably cut all the stock mounts off the frame and build new ones off the steel shell.

Anyways, I went back through this thread and remembered that Sami thirds swap over. So I pulled the rear third out of the rotted up pile out in the driveway and test fit everything.

26 spline side gears fit in the Sami carrier.

26 spline shafts fit in the Sami carrier.

Now all I need to order is the Spartan and the can to capture the pins on the Sami carrier. Then I guess I’m setting up gears…again.

Pretty stoked about getting this done in an affordable manner. Kind of the point of these things.

Next up is welding up the bracket on the Sami third and then the Toyota CV adapter and Hagen mod after Wuz ships back my housing.

I really should be swapping an FJ t-case into a 4Runner right now, but this is more appealing.

Ready to start.

Having a sami 3rd in there should help quite a bit, just need to brace the "ling side tube" on the diff. Even with whatever aluminum you're adding, I would somehow try and tie the steel mounts together side to side.

Although it's been a while since I've been under one of these and that may be easier said than done.

What are you doing to weld to the Sami 3rd? Anyway you could just clamp around the pinion snout with a big u bolt? I'd be a little nervous about warping the bearing area on that tiny 3rd.

 

[FleshEater]

Depends on how you treat it. If you wedge a tire in a hole and keep going with an open diff, it will just not power that tire. With a locker, a broken cv is pretty likely. But you're now going to be way more capable and may be able to make stuff easier than before.

I'd still bring a few spares


My thought was that you'd have to probably cut all the stock mounts off the frame and build new ones off the steel shell.



Having a sami 3rd in there should help quite a bit, just need to brace the "ling side tube" on the diff. Even with whatever aluminum you're adding, I would somehow try and tie the steel mounts together side to side.

Although it's been a while since I've been under one of these and that may be easier said than done.

What are you doing to weld to the Sami 3rd? Anyway you could just clamp around the pinion snout with a big u bolt? I'd be a little nervous about warping the bearing area on that tiny 3rd.

I know these slick moss covered rocks are not easy without a front locker. My spooled rear constantly kicks me off my line and the front just gives up the minute a tire is in the air.

Since I’m jumping up to 26 spline CV’s I have no spares. So I’ll need to order some aftermarkets for backups. I’m going to rob the CV off the 96’ Tracker and swap in a less than optimal aftermarket.

Thoughts on the Sami 3rd are the same as welding the truss on the Toyota axle. Increments. I’ll take it nice and slow and not overheat it. Should be fine.

 

[YotaAtieToo]

Would it make sense to stay 22 spline then? Isn't the cv the weak point either way?

Then swap to 26 spline when or if you go toyota CVs