James Carter has been part of Zuks of Arizona since around 2010. Back then, he was wheeling a Suzuki Samurai that was almost as overbuilt as this Grand Vitara. Over the years, he’s built just about everything — sand rails, drag diesel cars, race UTVs — you name it. From building wild Suzukis to helping other members get theirs back on the trail, James has done a little bit of it all.
He’s served as club president, helped organize runs, and has always been the guy you can count on when something breaks or you need solid advice. We’re lucky to have him as part of the community — and this Grand Vitara build is a perfect example of the kind of creativity and attention to detail he brings to everything he does.
Scroll down for the full build list, photos, and a walk-around video of one of the most capable Grand Vitaras we’ve seen out here.
Follow James for more builds, trail runs, and behind-the-scenes content.
Custom Off-Road Body & Exterior Components:
- T&B Fabrication 1.5″ x .120 wall mild steel rock sliders for maximum underbody protection
- T&B Fabrication 1.5″ x .120 wall mild steel rear bumper with integrated tire carrier and ZOR swing spindle
- T&B Fabrication 1.5″ x .120 wall mild steel front bumper with integrated Warn 8000lb winch
- RodLouver custom hood louvers for improved engine cooling
- Auxbeam LED light bar for off-road visibility
Off-Road Tires & Custom Wheels:
- 33×12.50R15 Falken Wildpeak ATW4 All Terrain tires
- American Racing Ansen AR969 custom wheels
Turbocharged Engine Build & Performance Upgrades:
- 2.5L V6 engine with 160,000 miles, upgraded with MLS head gaskets
- Custom turbo setup: T3/T4 turbocharger running 10 PSI boost
- Aftermarket intercooler for improved performance
- Premier Power Welder alternator with onboard welding capability
- TC power steering pump conversion
- 4-core aluminum radiator for enhanced cooling
- AEM FIC 6 Fuel and Timing Piggyback ECU tuned by T&B Fabrication
Heavy-Duty Transmission & Drivetrain:
- Rebuilt 03-72LE automatic transmission with upgraded Mitsubishi 23-spline output shaft
- Mitsubishi NP transfer case adapter plate
- T&B Fabrication custom transmission crossmember and mount
Transfer Case & Crawl Ratio Setup:
- Jeep NP231J transfer case from 1990s Cherokee
- Slip yoke eliminator (SYE) kit installed
- 6-pinion planetary gears for strength
- Terra Flex 2:1 low range shift fork
- 2.71:1 low range crawl ratio
- 1350 U-joint rear output yoke
- 1310 U-joint front output yoke
- JB Custom Fabrication transfer case shifter
- Dakota Digital speedometer conversion box for Jeep to Suzuki compatibility
Custom Driveshafts:
- Arizona Driveshaft custom front and rear driveshafts
- Double-cardan (CV) joints at transfer case
TTB Front Suspension & Axle Build:
- 1990 Ford TTB (Twin Traction Beam) Dana 44 front axle conversion
- Full frame section from firewall forward with 6-bolt spindles
- Motive Gear 5.13:1 ring and pinion gears
- Spartan mechanical locker for improved traction
- T&B Fabrication plated and reinforced TTB beams with cut-and-turn modification (built with Nate Morgan)
- Desolate Motorsports uni-ball beam pivots
- T&B Fabrication 2″ x .250 wall DOM radius arms with 7/8″ FK heim joints
- T&B Fabrication 1.5″ x .120 wall 4130 chromoly engine protection cage
- Minhworx modified steering gearbox with heavy-duty ambulance tie rod ends
- King Racing 3.0″ Internal Bypass coilovers with 12″ stroke
- Fox Racing 2.0″ hydraulic bump stops with 3″ stroke
- 16 inches of front wheel travel with bump stops and limiting straps
Ford 8.8 Rear Axle & 3-Link Suspension:
- 2001 Ford F-150 8.8″ rear axle with redrilled axle shafts for 5×5.5 bolt pattern
- Motive Gear 5.13:1 ring and pinion gear set
- Spartan mechanical locker
- Iron Rock Off-Road axle truss for added strength
- Custom 3-link suspension with Panhard bar (track bar)
- 2″ x .250 wall DOM steel tubing for lower links
- 1.5″ x .250 wall DOM steel tubing for Panhard bar
- 7/8″ FK heim joints on lower links
- EMF spherical joints on upper link and Panhard bar
- Fox Racing 2.0″ coilover shocks with 14″ stroke
- Fox Racing 2.0″ hydraulic bump stops with 3″ stroke
- 15 inches of rear wheel travel
Functional Interior & Expedition Equipment:
- Fully operational air conditioning and heating system
- 2000-watt power inverter for tools and equipment
- Icom IC-8000 50-watt two-way radio for trail communication
- Polk Audio 6.5″ speakers throughout vehicle
- 10-pound CO2 tank for air tools and tire inflation
- Onboard angle grinder and drill
- Yeti 45-quart premium cooler
- Complete spare parts kit, fluids, hand tools, and mobile welding equipment
