swellestgorgons rig

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swellestgorgon
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After 3 years and 10s of thousands of dollars building my 96 r33 skyline and actually managing to get it on the road for 6 months i decided i wasnt happy with it and back in the garage it went. At this time i needed a knew daily driver, seeming as a lot of my friends started getting 4wds to replace their sports cars i decided id look for something with a swb.

As my fiance needed her car back for uni i had just a few weeks to find something that fit my criteria, after deciding on a suzuki jimny or seirra i couldnt find anything in my price range that was practical as a daily or wasnt completely clapped out. On the verge of giving up and settling for a small hatchback i stumbled across a 1.6 litre swb silver pajero io on gumtree for the pricely sum of $4000 and picked it up the next day.

After getting the io on monday afternoon, I drove it to work on tuesday and realised i had the queerest car in the car park other than the smart car which turned up occasionally, that afternoon i organised with a mate to go for a quick drive in the bush out the back of his house in the mud so we could figure out what sort of a base we had to play with.

My mate having a lifted ranger with 33" mt's had no issue getting through the 100 metre mud run and i got through ok as well, then we tried to come back, after the ranger had so kindly ripped up the track i got caught up on my diff and highway terrain tyres probably didnt help my cause. Off we went back to my mates house to get the snatchy, but on trying to take an alternative path to get in a better position to snatch me out we managed to get the ranger stuck as well, FML. So we called our soccer coach knowing he had his turbo v8 troopy and figured he'd be able to give us some assistance, not knowing it didnt even have an lsd in it and him also getting stuck we now haad 3 people bogged and getting dark. Being stuck for 3 hours isnt fun and left us with know choice but to call in the nissan patrols and wait another hour for them to turn up only to listen to their crap about real 4wds etc etc lol.

So my journey started on giving my little 'soft roader' the ablity to go the majority of places the bigger 4wd's can go.

 

My first step was a new set of federal couragia at's (225-75-16 all round) for the front and putting the slightly worn at's off the front on the back at the expense of the ht's and a full service of all engine and drivetrain fluids replacing them with nulon synthetic oils and adding nulon g20 additive, which i'd recommend for all driveline parts as it has had the same effect as using redline shockproof gear oil in mine and mates diffs and gearboxes. I followed this with some 25mm strut top spacers which brought the front a bit more level with the rear.

this made quite a difference and on a trip up to landcruiser mountain at jimna got me through most of the intermediate tracks that a lot of people didnt expect me to do and allowed me the satisfaction of pulling a mates patrol out of a mud hole on a track that i made it through easily.

 

Seeing a few shortfalls on my setup, on my return i decided it needed some love. I started researching lifts and saw that some people had questioned the possibility of outlander struts, hilux rear shocks and ba astina springs with adjustable commodore panhad rod, so i started by getting the springs and panhard rod which was easy enough, i think the springs cost me about $70 complete with the shocks as the wreckers wouldnt allow me to seperate them and the panhard rod came from ebay seller suzuki super 4x4 for $85 posted.

 

swellestgorgon
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seeing no one had actually

seeing no one had actually tried the outlander shocks yet i found some ultima branded ZE outlander front struts on sale for $180 with free postage from seller Autoteconline and decided to fing out what would be needed to make them fit. When they turned up it was quite easy to see a couple of differences but it didnt put me off giving it a go. The first issue is mounting them to the stock pajero io strut top bearings. the pajero io item is bigger than the outlander one

this is the top of the pajero strut

 

this is the top of the outlander strut, see my problem?

 

this is how much extra space is left over with the pajero io strut top bearing on the ze outlander strut

 

my solution was to get some tube i had lying around, drill out the inside to the size i needed and cut it down to fit. this looks a bit crude in this picture but it was finished off a lot neater than this. from memory the spacer had an ID of 12mm and OD of 15mm which i hand sanded a little bit to get into the strut bearing, so you'd need a wall thickness close to 1.5mm

this is the strut top with the 25mm spacer fitted sitting on the ze outlander strut, very nice fit with the tube spacer fitted.

 

this is all thats required to fit the strut to the bearing.

swellestgorgon
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the other problem with

the other problem with fitting the outlander shocks is that the bolt holes where it mounts to the hub are 14mm as compared to 12mm in the pajero io (from memory, i could be incorrect but its close), for the sake of fitting them to see how it went i test fitted them anyway but the offset of the bolts is all wrong and gives you a lot of positive camber somewhat resembling the back wheels of a baja bug.

 

As i was going to fix the issue any way i took out the top bolt so the strut was just sitting on the bottom bolt on the hub (the car needs to be jacked up for this)  and pushed the top of the wheel in where it needed to be and marked where the bolt should be going to avoid positive camber. I then slowly hand filled the top bolt hole inwards towards the car ovaling the bolt hole until i could adjust the camber to be where it needed to be. i dont recomend this but after 6 months of driving it hadnt moved.

 

The better option in my opinion, which i just did is to take the pajero io struts and outlander struts to a welder or machine shop get the outlander bolt holes welded up and get them re drilled to be the same sze and in the same place as the pajero io items. i dont know how much this would cost you as i had it done by a mate of a mate for a carton of rum.

the difference in height of the outlander and io spring perch

 

when fitted they dont seem much stiffer than my 13 year old standard high perch shocks and ride hight sits where it did with the 25mm spacer on the standard springs, when i fitted the outlander shocks i didnt use the 25mm spacer until i got my astina rear springs as the front was heaps higher than the back when fitted

swellestgorgon
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so i fitted the adjustable

so i fitted the adjustable panhard rod which was a straight bolt on, the outlander front shocks which was a small amount of work (with standard high perch io front springs), this gave the front a lift equal to fitting a 25mm strut spacer. Fitted the front shocks with my 25mm spacer for a further lift, fitted the 323 ba astina front springs into the rear which gave around 40mm of lift. and then ordered some pro comp shocks.

i have hilux es3000 pro comp shocks and i find them really good. i used part# - EXP-324506 to suit 81-85 4wd hilux or surf. these do need to use 323 ba astina front springs and either bigger bump stops or 1 inch 80 series front spring spacer as without the spacer they only just get to being fully compressed as they're made to suit a hilux with 2.5-3 inch lift.

extended length 24.84 inches (656mm)

compressed length 14.82 inches (376mm)

travel length 10.02 inches (254mm)

$141.30usd for the pair shipped from USA to brisbane through Summit Racing

 

for just 323 springs or king/dobinsons then the EXP-322506 seems alright, in hindsight i would have gone these

extended length 22.58 inches (573mm)

compressed length 13.74 inches (348mm)

travel length 8.87 inches (225mm

 

search what part number and size you want and put the part number into summit racings website and see what price you can get them for.

 

check what size your eyelets are on the shocks, if the centre is 24.5mm the same as the pro comps i fitted then fit the superpro part numbers below for a correct fit on the pajero io. they were approximatey $15 a pair.

spf 2178 12k

spf 2178 16k

some shock companies seem to use the same shock part numbers for triton, hilux, rodeo, ranger so if the different branded shocks all use the same size eyelets then the above mentioned bushes are what's needed.

 

Ive got mine mounted with the body at the bottom extending upwards and have no problem fouling anything even before putting in the coil spacers.

 

ive also searched for some 15x7 inch wheels but not being able to find any i came across some 16x7+17 ford falcon rtv steel rims which do need a 5mm spacer to clear the brake caliper. once they turned up i purchased some simex centipede mt's in 245/75/16 (i think 30.7 inch) and had them fitted although they do sit outside the guards and do require the removal of the front mud flap and its bracket being bent up a bit for clearance at full lock. i dont think you could go any bigger without some serious work or bigger lift

 

Claude io
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nice work

Very well done yes

You must have done a lot of reading on the forum :) It is good to see that you used the info wisely, and added some new info....fantastic.

You may have to change the diff ratio to have the compensate the bigger tyres, Glen recently done it on his car...not sure if it is suitable for your 1.6 litre engine.

I have a few question....

Where did you get the spacer to fit on the top of the strut, they don't look "homemade" 

What advantage did you find by using these strut instead of the io strut with a bigger spacer ?

These 2 door io are great....

Happy io

bob_oz
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awesome work!!

i looked at the outlander strut but the stroke travel was the same, hust 25mm longer total, and the spring angle was a bit weird so I left it.

the mazda tribune/ford escape strut is 30mm longer when compressed but has an extra 45mm stroke overall - i was going to grab one from u-pull-it and dummy it in, mazda runs smaller diameter coils too so more wheel clearance.

very inspiring to see your build man!!

.

swellestgorgon
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Sorry can't tell you it came

Sorry can't tell you it came off the internet from somewhere outside aus, it wasn't to suit an io but had the same measurement on the bolt holes, a higher drive would be nice but funds have dried up at the moment although I did see a chinese gen 1 pajero air locker on ebay for $850 posted, don't trust it though

swellestgorgon
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After fitting the outlander

After fitting the outlander struts it gained an extra 40mm travel, 30 up and 10 down, which isn't much but every bit counts. The strut top does sit a bit higher on the outlander stut as the way it was fitted, could quite easily fit a 32 inch tyre under them

natsterrr
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Chinese locker

I've been reading up on those chinese lockers, and from what I've read they are pretty decent for the most part. Just have to be lucky I guess.

The ARB comparison video floating around youtube makes them look crap, but when you look at the numbers, the chinese one took nearly 90% of the breaking strain of the ARB one I think... Or maybe 70%.. Either way, with a 4 cylinder petrol engine I doubt there'd be an issue.

Just be careful with your 1.6litre rear diff - I'm not sure if it is the same as the 2.0litre which will accept the ARB RD05 rear locker. Incidentally, ARB have changed their numbering system to throw off the chinese copies - I think they are an RD210 or something now.

 

Size is not important; it's how you use it that matters!

fordem
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The new numbers have nothing to do with Chinese copies

natsterrr wrote:
Incidentally, ARB have changed their numbering system to throw off the chinese copies - I think they are an RD210 or something now.

ARB numbers are different because the actual locker is different - they switched to a two piece housing with "timed" gears and got rid of the plastic piston - if the part number starts with a 2 it will be the newer, stronger version.

bob_oz
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outlander struts

the outlander struts had the same stroke, they were longer overall but the actual stroke was the same from memory:

Koni pajero insterts were 593mm-424mm (169mm stroke)

Outlander insterts were approx 613mm - 444mm (169mm stroke) 20mm longer but no increase in travel

my next option was to try this:

http://pajerio.com/forum/coilover#comment-15481

.

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