Suzuki Samurai Suspension Upgrade - Project Sami Supreme

After some careful bending, a new front tube fender and grille were taking shape. The front winch-mount bumper is now complete with the steering box securely mounted. This snug setup will provide exceptional strength and a 90-degree approach angle.

Our optima yellowtop battery once resided on the passenger-side inner fenderwell (prior to removing the factory fenders and grille). A new mount was fabricated on the inner rear framerail to distribute more weight to the rear while promoting a lower center of gravity.

Unlike many vehicles, the sami's framerails continue to angle apart toward the rear of the vehicle. This will be an issue for mounting the air shocks, so the framerails must be narrowed. Welding in a temporary brace to keep things square, each framerail was notched and angled inward.

Similar to the front bumper, a rear bumper was constructed to provide a home for the new jaz 12-gallon, foam-filled fuel cell. The extension will take full advantage of the space afforded by the additional wheelbase while offering a 90-degree departure angle.

The new rear addition will eventually allow for a removable third passenger seat while reinforcing the existing "sport cage."

A custom heavy-duty front axlehousing was ordered from Diamond axles to bring the axle up to par with the new heavy-duty suspension setup. This toyota-based housing was ordered a couple of inches wider on the shortside to allow the use of a Landcruiser shortside inner shaft. Ultimately, this will make narrower pre-1985 front-axle assemblies match the width of our later-model rear toyota axle.

After swapping over the components from our stock toyota front housing, the Diamond axle was built, and the all-Pro lower link mounts were temporarily tack-welded to the housing.

The only things needed to complete our front suspension were the shocks. A set of 14-inch, 2.0 sway-a-Way racerunner air shocks were ordered to bring the new front suspension to life.

With the all-Pro off-road three-link setup and sway-a-Way air shocks tacked into place, the new front suspension was cycled using a hi-Lift jack to check clearances.