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Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #777955 June 20th 2021 5:14 pm
Joined: Apr 2007
Posts: 249
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G Van Man
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G Van Man
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Have not been able to get too much done lately working 6 day work weeks. However I did get the rear-view mirror wired and the harness reloomed. Front end is back together and I am about to have it on all 4 wheels again. I decided to do an exterior LED conversion and update the look of the rear with some aftermarket tailights. Will update once I get them installed and the LEDs and LED electronic flasher installed.

Attached Files
Screenshot_2021-06-19-14-52-57-1.png (732.87 KB, 65 downloads)
Last edited by 1983G20Van; June 20th 2021 5:16 pm.

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
AdSense long
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #777956 June 20th 2021 5:17 pm
Joined: Feb 2002
Posts: 32,696
Likes: 172
Old Timer
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Those are nice!


Jim & Lucy Newkirk
1965 Chevy Bad Influence
1981 Chevy-the Love Shack
2012 Chevy Van , 2020 chevy van
2020 Chevy van Sapphire Sweet.
Club Vannerz.
vanninvanner@comcast.net
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778005 June 21st 2021 4:49 pm
Joined: Apr 2007
Posts: 249
Likes: 59
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G Van Man
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G Van Man
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LEDs arrived yesterday afternoon. Tailights shipped today, should have them in my hands on the 24th. Spending some time at my shop today on my only day off this week. Took apart all the trim to get access to the tailight mounting points and swapped over the LEDs. Took a couple of pictures after swapping the high mounts and the RH side bulbs to LEDs. I forgot that the reverse lights are 1156s and ordered 1157s. Ordered a pair of 1156s and going to keep the extra pair of 1157s for spares. These stock flasher seems to flash these LEDs just fine with only the rear turn signals in place. Guess that makes sense because I have towed all kinds of trailers without the flashing speed changing. I also forgot that I had put Silverstar bulbs in the back about 8 years ago. The hazy blue coating the apply had peeled off the RH side bulbs. The Silverstars are already brighter than normal 1157s. Even still the LEDs are much brighter than the Silverstars.

Attached Files
20210621_150317-1.jpg (173.01 KB, 133 downloads)
20210621_150231-1.jpg (205.83 KB, 134 downloads)

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778031 June 22nd 2021 1:49 am
Joined: Apr 2007
Posts: 249
Likes: 59
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G Van Man
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G Van Man
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Played around with the lights some more this evening. Updating every exterior bulb on the 97 Chevy to LED. Also going with the 4 HI mod that keeps the low beam headlights on with the high beams. With around 30,000 lumens of 6,000k light per side (more when I install driving lights in the factory holes in the valance) I will not be the one to play lets leave our brights on coming at me on a two lane road with. Also will not be the one you want to tailgate. The brake lights and turn signals are much brighter than the running lights. The replacement projector style tailights should make them even brighter. I also forgot the front turn signal and running lights required two pairs of 1157 amber bulbs. Ordered another pair of them to go along with the 1156s. Also ordered a LED bulb to replace the burned out factory underhood trouble light bulb. It has cost me a little under $200 to swap out every single exterior bulb to LED including the headlights and IMO well worth it. Those extra long ones with the heatsink or fan will not fit.

As you can see in the headlight picture, huge difference between Silverstar headlight bulbs and a decent LED headlight bulb. The composite headlight Express vans use 9005 and 9006 headlight bulbs. I found some that fit within the dimensions of a stock bulb externally.

I also spoke too soon on the flasher. When I put the front bulbs in place the stock unit hyperflashed. Took about 5 minutes to change to the $17 LED flasher. Its located under the column and you can reach it and remove it without taking anything apart. New LED style replacement has it working properly again. One flasher runs the turn signals and the hazards on the 96+ Express.

Would have gotten more done but a couple of buddies of mine were working at their shop across the street. Helped them troubleshoot a no start on a LY6 6.0L swap into a 90 R30 crew cab. Ended up being a cam sensor connector with the signal and 12 volt source wire swapped and the fuel lines swapped between the sending unit and the fuel filter on the Vette fuel filter. Vette fuel filter will not flow fuel through it if you try to push fuel into the internal regulator return port. You also do not get fuel or spark without a cam signal on the newer gen 4 58x engines.

Attached Files
20210621_230402-1.jpg (402.28 KB, 125 downloads)
20210621_230609-1.jpg (310.01 KB, 123 downloads)
20210621_230500.jpg (261.58 KB, 123 downloads)
Last edited by 1983G20Van; June 22nd 2021 2:12 am.

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778080 June 23rd 2021 12:56 am
Joined: Jul 2019
Posts: 11,241
Likes: 412
S
Post Junkie
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S
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Posts: 11,241
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Nice upgrade. ( wish I had some buddies that had a shop across the street ) chevy

Last edited by SDMickey; June 26th 2021 1:37 am.
Re: 1997 Chevy Express Cobra Conversion
SDMickey #778134 June 23rd 2021 11:40 pm
Joined: Apr 2007
Posts: 249
Likes: 59
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G Van Man
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G Van Man
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Originally Posted by SDMickey
Nice upgrade. ( wish I had some buddied that had a shop across the street ) chevy

Buddies having a shop across the street is cool but I am extremely fortunate to be able to lease a place of my own.


1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778199 June 24th 2021 9:12 pm
Joined: Apr 2007
Posts: 249
Likes: 59
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G Van Man
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G Van Man
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Posts: 249
Likes: 59
With parts becoming hard to find I went after alot of what I needed to finish the van. I now have probably close to a full months worth of shop time to work on the van parts wise. Ordered an android head unit with a 10.1" screen, rockford fostgate front speakers (rears to come soon), all the AN lines and fittings to do the trans and power steering as well as a Derale 24" frame mount oil cooler for a power steering cooler that is going under the radiator core support in the stock location of the vans that had the factory tube and fin p/s cooler. Still have to button the 383 back up with a new crank seal and install it. Still have some pressure washing to do in the engine compartment. Also have to finish putting the LH front suspension and brake system back together. Finally have a broken shift cable to change. Working 60+ a week I have so much to do and so little time to do it in. I also found the connector that matches my Bosch Marine T-Map sensor so that I do not have to adapt the van map sensor as well as a connector kit that has the matching connector to the $20 AEM EV6 fuel injector harness I picked up. I got a whole mess of additional weather proof connectors to build whatever quick disconnect I want for the cost of a single pigtail. I have a radiator and e-fans to mount along with the fan harness and the a/c pressure sensor harness update. Have to crimp the ac pressure sensor connector fitting into the discharge side of the a/c manifold hose. I have HPS red silicone hoses to change out all the heater hoses and the matching stainless silicone hose clamps. I have both the front and rear plastic heater control valves to change. Have a rear expansion valve and front orifice tube to change as well as flush the a/c system. I have one of the new wafer thin style CSF parallel flow condensers and a new UAC Sanden SD7H15 compressors. I have all the GM seals to reseal the heater and evaporator case as well as a new OEM heater core. Also have a hydroboost and Redhead steering gearbox to install. I have exterior door handles and all the power window and power lock switches to change. Might do the window motors while I am at it. I also have a +3qt aluminum trans pan and a HD2 shift kit for the 4L85E. I have an Trutrac and 4.56 gears for the 10.5" along with the install kit. I am looking at a license plat bracket, rear door handle with the built-in backup camera they make. Tired already just from thinking about it all. I have been gathering parts for this build for 6+ years.

Attached Files
Screenshot_2021-06-24-19-45-44-1.png (246.02 KB, 102 downloads)
Screenshot_2021-06-24-19-46-17-1.png (253.62 KB, 107 downloads)
Screenshot_2021-06-24-19-46-34-1.png (214.31 KB, 103 downloads)
Screenshot_2021-06-24-19-46-59-1.png (192 KB, 103 downloads)
Last edited by 1983G20Van; June 24th 2021 9:26 pm.

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778386 June 28th 2021 11:26 pm
Joined: Apr 2007
Posts: 249
Likes: 59
1
G Van Man
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G Van Man
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Joined: Apr 2007
Posts: 249
Likes: 59
Managed to get some more work done today. Couple of before and afters. Tailights are installed. Also installed my Rockford Fostgate front speakers and tweeters. The main speakers installed right into the OEM brackets but I still have to mount the tweeters. I measured the rear overhead speakers and they are 5x7s. Then I discovered working on the tailights with the music playing that the rear doors have a 2nd pair of rear speakers down low on them behind a fabric covering on the door panels that I never realized were there. Guess I get to order 2 more pairs of Rockford Fostgates for the rear. I know the name is twisted but with the OEM door panel and factory speaker grille over it, nobody will see it. I also mounted the Derale 13224 under the metal support that holds the radiator core support and started plumbing the cooler and the AN lines for the trans and power steering. Forgot to take pictures of that progress.

[Linked Image]

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Last edited by 1983G20Van; June 28th 2021 11:32 pm.

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
1 member likes this: Jimkinmd
Re: 1997 Chevy Express Cobra Conversion
1983 G20 Van #778556 July 02nd 2021 8:24 pm
Joined: Apr 2007
Posts: 249
Likes: 59
1
G Van Man
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G Van Man
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Joined: Apr 2007
Posts: 249
Likes: 59
So I just started the next project on the van and it is quite an undertaking. First I removed the OEM radio and cd player. Fitted a 10.1" touch screen Android head unit. I still have to route and mount the backup camera, GPS antenna and the bluetooth hands free microphone. I hooked the GPs and Microphone up and they work very well. The GPs antenna grabbed 5 satellites laying on the dash inside my shop. I connected the radio to the hot spot on my phone and downloaded the Texas map and then downloaded OBDLink that ties to the OBD2 Elm327 device I have. I have swapped out the front speakers and the tweeters. I have the rear 5x7 and 6x9 speakers on order. Rockford Fostgate Punch line all the way around. The 5x7s are 3 way and the 6x9s 4 way. The internet based apps play very clearly off my hotspot. I will need to cut the radio craddle, reinforce it and find a way to mount the ac controller in the former CD player opening. The electrical connections and vacuum hoses need to be relocated to the lower opening in the dash behind the craddle but they are plenty long to reach. I will seal the upper opening off with a piece of textures ABS plastic cut to fit the opening. I used a Metra harness and the radio harness and spliced then together with solder and heat shrink before wrapping the wires with 3M harness looming tape to make a plug and play conversion harness. Still have to route a wire to the parking brake switch and the reverse input to the cluster. Finally have a dead Clifford alarm to remove out from under the dash and a new Metra power antenna to install to replace the failed OEM power antenna. I also installed the relay setup to give me 4 HI on the headlights in that the low beams turn back on with the high beams. With 6,000K LEDs the sucker is bright. Finally I ordered a flush mount dual USB connector to keep from having random USB cables hanging out from under the dash. You may notice I have yet to drop the 383 back in. That install is coming soon. Still have a few minor things to do and it is much easier to access the wiring and under dash without the engine in the way.

Head unit installed in the dash using a Metra adapter.

[Linked Image]

A/C controls now hidden behind the unit

[Linked Image]

Opening where the factory CD player resided and the a/c controls will be located.

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Unit powered up and a Bowtie boot screen

[Linked Image]

Just some random playing around. It is capable of running apps in a split screen.

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USB connector that I am moubting in the glovebox section that bolts on behind the engine dog house. Will install it next to my wideband afr gauge and my exhaust cutout switch.

[Linked Image]

Finally 4 HI on the headlights after the relay mod.

[Linked Image]

Last edited by 1983G20Van; July 02nd 2021 8:31 pm.

1983 G20 Conversion Van, 350 TPI, Reed Hydraulic Roller cam, Ported 906 Vortec, Edelbrock 3817 TPI-Vortec Base, Doug Thorley Tri-Ys, Dual 2 1/2" exhaust, Speed Density 7730 ECM tuned by ME, 700r4 by ME, Stock 1,600 rpm converter, Rebuilt Stock 10 bolt with posi by ME, 3.08 gears, 358 RWHP @ 5,200, 384 RWTQ @ 3,400, 14.66 @ 95.43 w 2.28s 60'
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