1987 Suzuki Samurai Build: Inside Bryan Blehm’s Allied Fab Trail Machine

AS SEEN IN OUR JULY/AUGUST 2026 ISSUE – Buy Now!

Far From Stock

In a world where bolt-on builds and catalog parts dominate the off-road scene, a rig shows up every once in a while that reminds you what true fabrication, persistence, and passion really look like. Bryan Blehm’s 1987 Suzuki Samurai is exactly that kind of machine—a purpose-built crawler that has evolved over decades, refined through experience, and crafted with the kind of detail only a machinist could appreciate.

Hailing from Brush Prairie, Washington, Bryan isn’t just another weekend wheeler. By trade, he’s a machinist, and it shows in every inch of this build. This Samurai isn’t about flashy trends or social media hype. It’s about function, durability, and a relentless pursuit of performance on the trail. Built over the course of years dating all the way back to 2003, this rig represents multiple iterations, countless upgrades, and the kind of hands-on development that only comes from time behind the wheel and under the hood.

At the core of Bryan’s build is a 2009 GM Ecotec 2.4L inline-four, an engine known for its balance of power, efficiency, and aftermarket support. But this isn’t your average Ecotec swap. Bryan stepped things up with a 50 mm turbocharger paired to a stainless exhaust system, creating a compact but potent powerplant that delivers far more punch than the Samurai ever dreamed of from the factory. To support the swap, the setup includes a standalone harness and a Radium fuel surge tank, ensuring consistent fuel delivery even at extreme angles on the trail. It’s a smart combination that prioritizes reliability in harsh off-road conditions, where fuel starvation can quickly end a day. Breathing out through a 3-inch exhaust, the system is built for performance and durability. It’s clear this performance package wasn’t thrown together—it was engineered.

While the engine may be the heart of this project, the chassis is the backbone. This stage is where Allied Fab’s influence really shines. The Samurai’s frame has been heavily modified using 1.75-inch DOM tubing, creating a rigid, trail-ready structure that can take serious abuse. With a 105-inch wheelbase, this isn’t your stock short-wheelbase Samurai anymore. The stretched stance improves stability on climbs and descents, while also giving the suspension system room to work more effectively over rough terrain.

Speaking of suspension, Bryan didn’t cut corners. Up front, the rig runs dual Fox 12-inch shocks, while the rear features Fox coilovers paired with 2.5 x 14 bypass shocks. This combination delivers a balance of articulation and control that’s crucial for technical rock crawling while still being capable of handling higher-speed trail sections. Skid protection is handled with 3/16-inch aluminum armor, protecting the vitals without adding excessive weight. It’s a thoughtful approach that keeps the rig nimble while remaining trail-ready.

A build like this demands a drivetrain that can keep up, and Bryan delivered. The Samurai runs a Toyota transmission paired with a short shifter for quick, precise gear changes. Behind that sits a Toyota transfer case with a 2.3:1 low-range gear, giving the rig the crawl ratio needed to tackle serious obstacles. Custom driveshafts built from 2-inch .250-wall tubing and upgraded Toyota U-joints ensure strength where it matters most. When you’re bound up on a rock ledge, that extra durability makes all the difference. Axle duty is handled by RuffStuff housings, front and rear, both equipped with Toyota outers. With 4.88 gears on both ends, the setup is optimized for the tire size while maintaining usable power across the rev range. Traction is handled with a high-pinion Grizzly locker up front and a V6 spool in the rear—an aggressive combination that ensures power gets to the ground no matter the terrain.

Braking is equally well thought out, with Toyota IFS calipers up front and matching rear brakes, all controlled by a Wilwood master cylinder. It’s a simple, effective system that delivers consistent stopping power. No off-road build is complete without the right stance, and Bryan’s Samurai sits exactly how it should. Wrapped in 36×13.50 Interco TSL SX tires mounted on Trail-Gear 17×9 wheels, the rig has the footprint needed to grip and claw its way through tough terrain. With 3.5 inches of backspacing front and rear, the setup strikes a balance between clearance and stability. It’s aggressive without being excessive—a theme that carries throughout the entire build. Fuel is handled by a 15-gallon Fuel Safe cell with an internal pump, providing safety and reliability for long trail days.

Inside, the Samurai keeps things simple and purposeful. PRP seats provide comfort and support, especially when the terrain gets rough. There’s no unnecessary fluff here—just what’s needed to stay planted and in control. The exterior follows the same philosophy. Finished in factory teal paint, the Samurai retains a bit of its original identity while clearly showcasing its transformation. Custom aluminum work including the roof and door skins adds strength while keeping weight down. Additional lighting comes from a KC Gravity light bar, ensuring visibility when the sun goes down and the trail keeps going. And in true trail rig fashion, the remaining body panels show signs of use—“smashed up,” as Bryan puts it—because this rig is built to be used, not babied.

When asked about the cost of the build, Bryan’s answer says it all: “My wife can’t know.” It’s a humorous reminder that builds like this aren’t just financial investments; they’re personal ones. Time, effort, and passion are poured into every weld, every component choice, and every trail run. This Samurai wasn’t built overnight. It’s the result of years of evolution, learning, and pushing limits. It has been refined through real-world use, not just garage speculation, and that’s what makes it special.

Bryan Blehm’s Allied Fab Samurai is a testament to what’s possible when skill meets dedication. It’s not about having the biggest budget or the newest parts; it’s about building something that works, something that lasts, and something that reflects the builder behind it. From the turbocharged Ecotec to the fully fabricated chassis, every detail serves a purpose. It’s a machine designed to conquer terrain, withstand abuse, and keep going long after lesser rigs have called it quits. In a scene full of trends, this Samurai stands out by staying true to the roots of off-roading: build it yourself, fine-tune it, and take it where others won’t.