Suzuki Vitara Offroad Build 'PJ'

Check out my cheap 4x4 challenge. Seeing how far I can take a cheap 4x4 with minimal investment and lots of DIY.

35 Pins

8mo

DIY Metal Fabrication

the front end of a truck with an orange cord attached to it's bumper

Part 5 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

Time to add more reinforcement and an aluminum skidplate to our custom DIY winch bumper build! We also discuss lot of tips and tricks along the way.

the front end of a car with its hood up and some wires attached to it

Toyota Truck

Armor Ideas

Part 2 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

Time to whip out the plasma cutter and finish reinforcing the winch mount! In this post we add two additional attachment points and cut out the winch plate and fairlead mount.

the front end of a truck parked in a garage

Tube Bumper

Custom Trucks

Part 7 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

Finally, the last part of the front bumper build for PJ. Today we tie it all together by adding reinforced tubes to finish out the sides of the bumper. Be sure to check the completed pics at the end!

the front end of a truck parked next to another car in a driveway with grass and trees behind it

Part 3 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

Time to weld the winch plate together, make some mounts for the winch solenoid, and get everything permanently attached to PJ our Suzuki Vitara offroad truck!

the front end of a vehicle that is being worked on

1st Gen Tacoma

Truck Ideas

Part 4 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

This ain’t no bolt on bumper so the madness continues! Time to reinforce the winch mount and start making a skid plate.

Offroad Trucks

Sliders

Off Road

Part 1 - Mini Boatside and Rock Sliders on Vitara Tracker - DIY METAL FABRICATION .com

Time to remove PJ's rusty rocker panels and build some rock sliders from scratch. Rock sliders are great for protecting your doors offroad and providing a pivot point around trees and rocks.

there are many different tools in this garage

Part 2 – Mini Boatside and Rock Sliders on Vitara Tracker - DIY METAL FABRICATION .com

Today we cap the giant hole we just made from cutting off the rocker panels and reinforce the rock sliders. Then we reattach the fenders using some race car parts.

an image of a car engine with the oil in it's tank and hoses attached

Automotive Electrical

Bull Bar

A Bull

Bending

Part 6 – Front Winch Bumper Build with Receiver Hitch for PJ - DIY METAL FABRICATION .com

Today we bend up a bull bar / hood protector for the bumper and wire up the winch with a quick disconnect safety switch.

a man standing in front of a truck with the door open and looking at the camera

Explaining My DIY 4x4 Air Locker Setup: Parts, Wiring Diagram, And Demonstration - DIY METAL FABRICATION .com

This is a full walkthrough of my entire offroad 4x4 air locker setup covering the physical location of all the components, wiring, and air parts. First I lay it all out on the whiteboard, then show where everything is located and how it is wired up. I also cover the air compressor, air tank, air regulator and fittings then demonstrate the differential locked and unlocked while up on the lift.

a man in a garage working on an air lock install with the caption'99 and newer vitra / tracker

Lockers

Chevy

Installing An Air Locker In A 1999-2003 Chevy Tracker Vitara Is Possible! (With Some Modifications) - DIY METAL FABRICATION .com

Full installation guide and details on the modifications needed to fit an RD209 air locker into a 1999-2003 second generation Tracker or Vitara. I took the risk and tested this out then documented it so you don't have to!