First, the old dash was discarded.  The new 1.6 16v fuel injected motor had a lot more wires to stash under the dash and I wanted a wide open area to work in.  Next, the motor was installed and then another couple weeks went by as I figured out how connect the mound of wires :)  Along the way I rigged up my fuel tank to work with a hi-pressure fuel pump, re-used my stock instrument cluster, and moved the radiator so it would work with the 1.6 fan. The steering problem was solved by going to full hydraulic steering. This entailed mounting a high pressure pump, filter, cooler, reservoir, orbital valve and 2" bore steering ram.  Once everything was mounted, custom high pressure lines were made.   

Next, the entire back end was removed from the spring mounts back on the frame and up to my flat bed deck.  From there the rear 4 link suspension grew. 

With the rear suspension in place I made a few body panels to give the rig some character.  The last thing I did was cut off the front hoop and replaced it with a more refined grill and small front hoop to give the front bumper a little shape.

After nearly 4 months of non-stop work the Suzuki was finally heading back home.

I had some bugs to work out, but between the new rear suspension, hydro steering, bigger motor and fuel injection it was like a whole new rig.  So far I have climbed everything I pointed it at. The rig is stable on climbs (Annihilator shown in 2nd picture above) and off camber. On the road the coilovers soak up bumps like you wouldn't believe. 

It took me a while but I finally stopped at a weigh station on our trip to Colorado in July 2004 to get the zuk weighed.  With a full tank of gas, all my tools and spares but no cooler the rig tips the scales at 3,127 lbs.  A few weeks later I weighed all the tools and spares I carried, everything came to 212lbs.  This puts my rig at 2915lbs.

So the big question I always get asked , "Are you done?".  I'll let you know.