How Does a Lightweight '86 Sammy Handle 42s on the Rocks?

Justin Crawford’s ‘86 Suzuki Samurai buggy rolling on 42" tires isn’t your typical weekend warrior build. This Tracy, California wheeler has created something that sits perfectly between a traditional Samurai and a full-blown buggy, and the results are pretty impressive for anyone who appreciates the art of building something unique.

Starting with an 86 Samurai chassis, Crawford swapped out the original 1.3 liter (0.34 gallons) (0.34 gallons) mill for a 16-valve 1.6 fuel-injected engine. He kept the stock 5 speed manual and transfer case to save some cash, but added Trail Tough’s 6.4:1 gears to help turn those massive 42s in the rocks. The axles are 1st Gen Toy units with 1550 u-joints, and he stretched the frame about 18" to accommodate the longer wheelbase that now sits around 102".

The suspension setup tells an interesting story about this build’s priorities. Crawford runs coils in the rear and nitrogen shocks up front, though he’s planning to swap the rear coils for 14" travel nitrogen shocks soon. This isn’t a speed demon setup - it’s built for methodical rock crawling where precision matters more than pace.

What really sets this rig apart is how Crawford approaches his wheeling. He’s all about slow-motion rock crawling, keeping it in low gear and letting the rig work its way through obstacles (as opposed to smashing the skinny pedal like some people we know…). The full hydraulic steering he installed has become his favorite modification, giving him the precise control needed to place those 42s exactly where they need to go.

The tire choice creates an interesting dynamic with this build. Those massive 42s absolutely dominate in snow conditions, where the weight-to-tire ratio creates incredible traction. Crawford says the rig can go anywhere in snow, but admits the rocks present more of a challenge with the current gear ratio. It’s a trade-off that shows how different tire choices can completely change a rig’s personality.

Reliability has been solid for this Samurai buggy. Crawford hasn’t broken much beyond ripping out a diff drain plug during some aggressive rock dragging. He had to get creative and fill the differential through the breather tube, but that’s the kind of problem-solving that comes with pushing boundaries in the rocks.

The build process wasn’t just a solo effort. Crawford worked with his mom to create the side canopy shade pieces, cutting netting and stitching everything together. Those pieces turned out to be his best value modification, providing essential protection during long days on the trail while creating some quality mother-son build time.

Looking ahead, Crawford knows the 42s need more power behind them. He wishes he’d gone with a bigger motor from the start to better match the tire size. The 1.6 gets the job done, but more HP would help the rig perform better with those massive meats.

The Samurai community has been crucial to this build’s success. Crawford emphasizes reaching out to companies like Trail Tough and connecting with Samurai groups where experienced builders share knowledge freely. The community aspect of Samurai building is strong, with wheelers eager to help newcomers avoid common mistakes and find the right direction for their builds.

This rig represents something deeper than just another modified Samurai. Crawford got a tattoo of his Samurai buggy, cementing his commitment to never selling it. Instead, he plans to keep evolving the build through different phases, constantly improving and adapting based on what he learns on the trail.

The reaction from other wheelers is always the same - they immediately notice those 42s mounted on Toy axles and wonder what happens when something breaks. It’s a valid concern, but Crawford’s approach focuses on smart wheeling rather than just hammering through obstacles.

This build shows how the classic Samurai platform continues to evolve. Crawford has created something that honors the original’s lightweight philosophy while adding modern capabilities through axle swaps, engine upgrades, and suspension improvements. It’s not the fastest rig on the trail, but it’s built with purpose and passion - exactly what makes the off-road community special.