Inside the Wild Build: Suzuki Samurai Goes Ultra4 Racing at KOH

When you think about the most unlikely Ultra4 race rigs, a Suzuki Samurai probably isn’t what comes to mind. Most folks picture big-dollar buggies with massive V8s and suspension travel that could swallow a small car. But one builder decided to take a different approach entirely, proving that sometimes the best builds come from thinking outside the box.

This particular Ultra4 Samurai started life as a bone-stock ‘88 that had already blown its engine. After a rebuild and a few years of daily driving duty with modest 30" tires and a small lift, the transformation into a full-blown race machine began. The builder had a simple philosophy - see how far you could push a Samurai while keeping it fundamentally a Samurai. That meant keeping the lightweight, nimble characteristics that made these little rigs so fun in the first place.

The 1.3 liter (0.34 gallons) (0.34 gallons) 4 banger might seem laughably small for Ultra4 competition, but it’s been built up with more compression, a cam, head work, and a Holley Sniper EFI system. At 68 HP to the wheels, it’s not going to win any drag races, but that’s not the point. The real magic happens when you consider the power-to-weight ratio and how that translates to technical rock sections.

After bending both original Samurai axle housings in the dunes, the builder switched to hybrid Sidekick housings with 5.13 gears and Lock-Right lockers front and rear. The steering setup uses a Toy IFS truck steering box with a custom pitman arm, all engineered to work with the track bar geometry.

The suspension is where things get really interesting. Up front, a 3 link setup with 2.0" FOA coilovers provides 14" of wheel travel. The rear runs 16" with a wishbone-style 3 link. These FOA shocks cost about half what you’d pay for Kings or Fox, and they’ve proven reliable through over 100 miles of King of the Hammers punishment without a single issue.

Speaking of King of the Hammers, watching this little Samurai tackle Turkey Claw is something else. While other rigs muscle their way through with brute force, the Samurai picks its way through with finesse. The light weight and short wheelbase that would be disadvantages in the desert sections become serious advantages when threading the needle between boulders.

The interior keeps that original Samurai dash for authenticity, but everything else is purpose-built race equipment. Corbeau Forza seats, Crow belts, and a full Switch Pros setup handle the electrical duties. The body has been channeled hot-rod style, bringing the roof down to the frame to lower the center of gravity as much as possible. All the bodywork is eighth-inch Lexan with vinyl wrap, and UHMW skid plates protect the undercarriage.

One of the coolest modifications is the Howe 1.5-to-1 steering quickener. With such a short wheelbase, you need to be able to react fast when the rear end tries to come around. The builder is even considering switching to a 2-to-1 ratio for even quicker steering response.

But this isn’t just a rock crawler. Watching the Samurai get air in the Oregon Dunes shows how versatile the platform can be. The long-travel suspension that helps it float over rocks also lets it soak up sand dune landings with surprising composure. The builder mentions the suspension keeps getting better and better as he dials in the setup.

The 22 gallon fuel cell and 8,000 lb Warn winch round out the package, along with proper venting systems required for Ultra4 competition. BFGoodrich 33x10.50 tires on 15x8 Ultra wheels provide the grip, while chromoly axle shafts and RCV joints handle the power delivery.

During the King of the Hammers attempt, he completed 109 miles with zero mechanical issues. The weak link wasn’t the little engine or the Samurai running gear - it was simply running out of time. The 10-hour time limit comes fast when you’re not running a big-HP desert machine.

The beauty of this build is how it proves you don’t need a six figure budget to have serious fun in Ultra4 racing. While everyone else is chasing more power and bigger tires, this Samurai succeeds by being different. It’s nimble where others are clumsy, light where others are heavy, and affordable where others break the bank.

Sure, a turbo is in the future plans, and there’s always room for improvement. But right now, this little Samurai is doing exactly what it was built to do - proving that sometimes the best approach is the one nobody else is taking. When you’re threading your way through the rocks at King of the Hammers with Vaughn Gittin Jr. hot on your tail, HP numbers become a lot less important than having the right tool for the job.