Vannin' Home

Tuner4life's 1985 Chevy G20 4 Speed Build Thread

Posted By: tuner4life

Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 17th 2014 11:00 am

I am so excited right now. I have been lurking on here for a while. I needed something to pull my drift car to events among other things. I was initially looking at a pickup, but came to realize that a van might be a better option. So after a lot of "keeping an eye open for what I want" I stumbled on this van on craigslist.

It's a 1985 G20, 305, 4 speed manual (PO tells me they only made around 500 of these?), only 64k miles, correct amount of windows. There is no rust, and besides a few dents, is in very good shape. Has mid 80s Pickup wheel setup. The only things that it really needs is a paint job, and the A/C converted to R134. I am picking it up tonight and can't wait to start on it!

The idea is to make from the rear axle forward lounge area, and behind that will be tool/parts/etc area for race events.. Hopefully the start of a long and fun build.

Pics:

[Linked Image]
[Linked Image]
[Linked Image]

cheers
Posted By: MACE

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 17th 2014 4:10 pm

Nice!!
Thats gonna make a sweet car hauler man.
Nice stance
Nice Van!!
When you get a sec post a pic or 2 of what the van will
be hauling.....
I kind of like the patina.
Score!!
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 17th 2014 4:16 pm

Looks like a nice van you got there.Congrats .
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 17th 2014 4:36 pm

Thanks! I do kind of want to lower it some.. And it definitely will be getting painted. I want to keep it rust free.


Here's the car it will be pulling, It's a 1991 Toyota Cressida with a Lexus 4.0 V8 that is set up for drifting.

Here's the build thread for those interested: http://jzxproject.com/bbs/index.php?showtopic=9332

[Linked Image]
Posted By: MACE

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 17th 2014 4:40 pm

Stuntrider alert!
nice pic man.
Post up some pics when you get the Van
and welcome to vanning
Posted By: 86ed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 12:09 am

Congrats on the van. Sounds like you have some cool ideas for it. Good luck
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 2:44 am

Have some real fun, turbo charged 350 in the van and drift it ! Lol

You got a great looking van there, enjoy !
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 12:32 pm

Haha! Corners are scary enough in this thing, I couldn't imagine trying to drift something this tippy.


[Linked Image]


Got it home late last night! It is definitely different than the smaller cars that I normally drive. It will take some getting used to, especially the clutch and shifting.

I also drove it to work this morning (about 35 minutes) and it did fine.


[Linked Image]


Maintenance will come first, then paint. I haven't had a chance to really go through it and inspect everything yet, but I started a list of things I know for sure that I will need to do:

-Rebuild carb (I'm new to carburetors, but how hard can it really be? It has some hesitation and I think something is wrong with the accelerator pump. When you floor it it is about the same as half throttle. Whatever, it's cheap to do and I want to learn carbs)

-Hitch.. Again, never owned a large vehicle. Where's the best place to get a hitch, brake controller to work with the van, and the necessary wiring for 7 pin?

-Vacuum A/C, convert to R134, replace any leaky parts in the process

-Basic tune up, replace all vacuum lines

-Adjust switch on clutch pedal (cruise control quits when you hit a bump, pull up on the clutch pedal, hit resume, and it takes off again).

-Paint.. I really can't decide on color, I like the original color, wife doesn't.. Maybe original color with some sort of graphics.. Idk.. What do you guys think?


I love this thing so far!
Posted By: Captain_E

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 1:54 pm

Congrats on the new van. 4 on the floor is definitely rare for a van. You may not have anything wrong with the acceleration. It may just be the 305. I always found them to be extremely sluggish. Check out Kurk's van at customvan.com. He works and camps out of his and if I remember correctly has his tools/drawers etc. at the back of his van. Might give you some ideas. Good luck with that pretty Chevy.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 2:54 pm

Thanks, That is a cool website!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 3:11 pm

I just figured out that this van already has swivel bases on both front seats! My question is how are you supposed to use them? If you turn them inwards, the back of the seats hit the door frame, and if you spin them all the way around the long way, the seat belts get wrapped around the seats since they mount to the seat itself.. What am I doing wrong?
Posted By: Reed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 5:29 pm

Only use them swiveled when parked, to clear the door frame slide the seat forward on the base, wrap the seatbelts around the back of the seat so you don't sit on them.
Posted By: OMIWYTCIMA

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 7:25 pm

Nice van
Posted By: kursed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 18th 2014 8:11 pm

Loving it. Subscribed to the thread. smile

When you get to the carb give me a shout. I'll throw some tips and tricks your way.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2014 12:17 pm

Well, I started doing work. First things first I did a coolant flush to get the dex-cool junk out of there and also replaced the thermostat. Glad I did as I could already see where the dex-cool was eroding the gasket and starting to seep a little.

Then I pulled it inside. It really takes up a big chunk of the garage space lol.

[Linked Image]


I found a great tutorial and rebuilt this thing with no real issues. I found the power issue too, one of the suction tubes for the secondaries had fallen into the bowl. It is a ton better now! Also replaced every vacuum line I could get to.

[Linked Image]


You can tell it's been sitting for a while because there are a lot of dry seals and gaskets. No major leaks, but several seeping spots. On the positive side though, the body and underside are very solid.

[Linked Image]


While it was all apart, I ditched this mess. The pump was seized up anyways. Also deleted the EGR. It is slightly easier to work on stuff now...

[Linked Image]
[Linked Image]


By the end of the weekend I had it running again. I can definitely tell a difference in the rebuilt carb. I also replaced all the filters and did an oil change. The engine seems a bit noisy to me, hoping it quiets down after some use.. But I'm also used to smaller smoother import engines, so it might just be the way it is. Time will tell.

Next up will evidently be the brakes because when I got back from the test drive, I noticed that a rear wheel cylinder was leaking.. Luckily, nothing looks rusty and it should all come apart fairly well. I'll also repair the seized parking brake cables while that's apart.

I am not used to buying parts this cheap. It's kind of nice.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 14th 2014 12:23 pm

It's been a while since I messed with drum brakes.. What a pain! But I won. I'm replacing the leaky wheel cylinders, shoes, hardware, adjusters, and e-brake cables all in one shot in hopes that I won't have to mess with them again for a long time.

[Linked Image]


There is also a tapping coming from the top end of the engine on the right side. 95% sure it's just a lifter needing adjustment. That project is coming next. Never had to do this much work inside of a tunnel before. Working on the engine in a van is definitely an experience!



Also I had another question. What side steps are used on a van like the A-team van? Something like this maybe?

[Linked Image]

I want to add flares, chin spoiler, visor, etc.. I love the look of side pipes, but since I do plan on using this van in the rain it's probably not a good idea. I really don't like the fiberglass running boards, or the older aluminum steps. But I can't seem to find any like the picture above for sale anywhere. I want a solid step like this that I can color match. Any information on where to get something like those?
Posted By: MACE

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 14th 2014 1:36 pm

Yeah that lifter sounds collapsed....taking off the intake and all that, youy might as well go for it and buy all new lifters/pushrods soak the lifters overnight in Lucas oil and inspect the rest of tha crap in there.
Not that big of a deal tho but you will need a friend to help hold the intake over the engine as the new seal is a bitch to set right
at least that is my experience doing that in a yard to my friends old jeep
good luck, good work and keep the pics coming!!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 14th 2014 1:49 pm

Yeah, hoping it's not collapsed. I had a couple of people listen to it and they said that it sounds like the adjustment on the rocker arm is just a little out on one cylinder. They said to try adjusting that and if it doesn't work, then dig deeper.

Thanks for the info!
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 14th 2014 4:02 pm

Originally Posted by tuner4life
Haha! Corners are scary enough in this thing, I couldn't imagine trying to drift something this tippy.


I "drift" my red van alot in the desert, I know its not pavement but its ADRENALIN BY THE GALLON. Just get the tires spinning & control the slide. My 454 still has way more motor than tire.

Even drifted the white van in the park, had a little water on the ground, punched it and away we went, side ways all the way around the island circle taking up 2 lanes. The Ranger came over and that was that. Man there is nothing more fun than seeing your rear end passing you.....LOL
Posted By: Chadsci

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 2:09 am

Very cool van and the drift machine is killer too.

Posted By: c1run1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 12:31 pm

(Also I had another question. What side steps are used on a van like the A-team van? Something like this maybe?)

Find a good sheet metal or welding shop to bend you a set up . or if you know some one with an eight foot sheet metal brake you can make your own . The brackets you can hand make with angle iron and a welder . You seem like the type thats not affraid to try new things and venture on to other areas .
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 1:01 pm

Thanks, I figured I could fab something up if I needed to, I was just curious if something was out there. I was kind of thinking about making them out of thickish sheet aluminum and then coating both sides in rhino lining, but I wasn't sure how ugly it would end up..

lately I have been really considering some side pipes instead of steps.. Either way, the mechanicals will come first.

Update:

Adjusted the rockers, all is well now. still fiddling with the carb secondary spring, but it keeps getting better the more I screw with it.

I am slowly going through everything and fixing what isn't up to par. Things that I still need to do are:

-Hitch/wiring

-Speedo cable (makes the most annoying noise, tried greasing, didn't work)

-Clutch/u-joints/carrier. Clutch shudders some, the rest is cheap preventative maintenance. Not sure about the rear end, it howls some, but with the low miles I can't imagine it needs to be rebuild already, not sure what's normal with these vans or if it's just normal noise resonating inside. I'll check it out when I change the fluid.

-Suspension. It isn't horrible, but it's all a bit loose. I'm just going to do everything at the same time so it will be new. Probably do the steering box too. Doesn't return to center quite like I feel it should. Also doing drop knuckles while I'm at it. This project may not happen until spring.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 1:05 pm

Side note, drove it through a massive rain storm the other day and there were no leaks that I could see. All window and door seals will be replaced when I paint it anyways, but good to know that it's safe for now.
Posted By: wookee

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 2:35 pm

These rears can be noisy in these vans.
My 85 I bought brand new was noisy from day one.
When not driven much the outer bearing tend to dry out.
I had one rear quiet down after a two hour or so road trip.

I had a nice set of steel running boards bent up at a local steel supplier who is equipped with a cool press brake, along with an operator who knows how to use it.

[Linked Image]
my plan is too color match these boards when i hang them.

Hopefully they will look this good when I am done

[Linked Image]

Van Crazy Customs also made this set out of steel.

.........wookee
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 04th 2014 2:42 pm

Awesome! That's about what I had in mind!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 19th 2014 11:56 am

Starting to collect parts...

[Linked Image]


Although it is becoming painfully obvious that the front suspenion, steering, and brakes should be the first priority!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 24th 2014 12:01 pm

Got this installed.. Only running standard 4 wire for now, but prewiring for brake controller in the near future.

[Linked Image]


I'm trying to come up with a list of all the things that I want to prewire the van for before I enclose the walls/roof. It's going to be more work than wiring a house! lol.

Where do you guys run your wiring from the dash to the back? Up an "a" pillar, and down the roof? Under the front flooring? Through the drivers side wall? What is the best path for it?
Posted By: wookee

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 24th 2014 1:19 pm

At least the wires for the brake controller is different colors.......

......Wookee
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 26th 2014 6:45 pm

So the van did it's first work for me today. Pulled home another project/toy. 1985 Celica GTS. The cleanest rust free-est, chassis I've ever seen on one of these cars. Picked it up for next to nothing and towed it home with the van. That's all for today...


[Linked Image]
Posted By: c1run1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 26th 2014 6:51 pm

Originally Posted by tuner4life
So the van did it's first work for me today. Pulled home another project/toy. 1985 Celica GTS. The cleanest rust free-est, chassis I've ever seen on one of these cars. Picked it up for next to nothing and towed it home with the van. That's all for today...


[Linked Image]


Im keeping my eyes open for a disc brake rear end solid axel Ae85-6
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 26th 2014 7:36 pm

Good luck. Unless you are in California, or in the south where stuff doesn't rust, you're going to have a very hard time finding anything for an AE86.
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 27th 2014 4:39 am

It figures... There's an AE86 sub-culture here and all I have is an AW11.
LOL!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 02nd 2014 2:32 pm

It may not look like much, but there is quite a bit of time wrapped up in this. I needed to extend the trailer wiring harness so that it would reach into the body of the van. But being OCD like I am, I was worried about water/moisture/etc messing with the wiring.

I used heat shrink connections, covered in a longer piece of heat shrink, then wrapped each one in 3M electrical tape, then the whole harness is covered in split loom.. That should about take care of it! lol

It's routed through the same path as the license plate wiring and comes up through a grommet in the floor right next to the licence plate wires. Should be very solid and last a long time.. Took me several hours of fighting with it. Now I have to actually hook it all up inside the van..


[Linked Image]
[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 24th 2014 12:23 pm

Not much going on right now. Just fixing small things and tinkering while I save for the paint and suspension.. Probably next year sometime. I have been driving it a few times a week just to keep it fresh. So I'll just leave a pic of it sitting at work.



[Linked Image]
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 24th 2014 1:54 pm

Whats up neighbor! Think I will put mine away for the winter next week, since it is supposed to be so nice around here this weekend going to have to out for a cruise.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 24th 2014 3:49 pm

Yeah, I hear ya. Winter's almost here.. I've been driving the van while I do some work on the winter cars.. As soon as the winter beaters are ready, the van and other toys are going into storage. It won't be seeing any snow if I can help it.

Posted By: EagleDave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 27th 2014 11:04 pm

Nice Hualer you got there.

For the Flares, Spoiler, and Visor I got the ones for Eagles Nest from Mark Hann. I have photos on my Readers Ride page. He has two types of flares for our years Chevy/GMC vans. The ones I got are the for a running board but Mark customized the fronts for me for no running boards. We decided to leave the rears original since we thought it would look better.

Good luck on your van I'm looking forward to your updates.

We need more long vans on here. Most of these guys love shorties for some reason.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 28th 2014 12:36 pm

Thanks Dave! I do like the flares/spoilers that you have. I am still up in the air about steps vs. side-pipes though. Once I get ready for body work, I'll definitely look into Mark's flares.

I agree. I can appriceate the shorties, but for what I need, it just wouldn't do. I would have gotten a lwb, but I couldn't find one like I wanted.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2014 4:18 pm

Nothing going on with the van lately.. It's safely in storage for the winter..

But the main server and phones were down for the first couple of hours at work today.. So I sketched this up of kind of what I want mine to look like. No sketching, all freehand.


[Linked Image]
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2014 5:26 pm

Much better than I can draw, and pretty cool looking too. . . . Best of luck on the build up ! Now I have to reread 4 pages of post to see where you are on this so far, damn the luck, FORCED to read about a van ! LOL
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2014 5:40 pm

Haha, thanks. Really not much done to it right now.. Just catching up on all the maintenance and such. It'll be a painfully slow build.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 28th 2015 1:39 pm

Just came across this really cool picture of a Ford E350 Van that my late grandfather had back in the '70s. Didn't realize that he ever had a van. He did the conversion himself I guess, and used it for camping alot. Just thought I'd share.


[Linked Image]
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 29th 2015 4:25 am

Cool old pic & great work on your van.
Posted By: Reese

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 31st 2015 3:28 pm

Originally Posted by tuner4life

Where do you guys run your wiring from the dash to the back? Up an "a" pillar, and down the roof? Under the front flooring? Through the drivers side wall? What is the best path for it?


Basically, yes, up the A pillar. On the driver's side, I found and unplugged the factory dome light connector. I attached a length of nylon twine to it with black electrical tape, and used the wire to pull the twine through. Removed the tape, pulled several feet of twine up the A pillar, re-attached dome light wire to middle of my new "pull line" and pulled the wires back through the pillar, and re-connected it.

I used the pull line to pull wires for my overhead console, overhead lights, rear lighters and rear speakers. In my case, I used the roof channel the conversion company opened up to install my van's high top, to run the wires to the rear of the van. I coil the twine tightly and tuck it behind the under dash wires, in case I ever need it again, it's still there.

Hopefully this will give you an idea or two on how to do something similar for yours.

Love the van by the way, rare stick-shift setup for sure.

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 02nd 2015 1:46 pm

Thanks for the advice! I might have to use both pillars with all the electronics that I want to run.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 05th 2015 2:09 pm

Quick question, for those that run wiring up the "A" pillars on the Chevy vans, is there a trim covering the inside of the pillar that the wires can run behind? Maybe on a conversion van? I can't seem to find a good picture of one..
Posted By: Karson

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 10th 2015 3:44 pm

Oh sweet van, I was looking for one just like this but could only find a 3spd. Hoosier Vanner here too.
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2015 4:20 am

Have a bad feeling your ticking may be due to a lobe going bad on the cam, SBC rockers don't usually get loose on their own. and the 80s wasn't a good time for cams back when we had good oil much less now that we have low zinc in todays oils.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2015 1:09 pm

Actually I fixed the tick with a simple valve adjustment. This engine has less than 70k miles and is probably only going to be used less than 5k miles per year for a while. I'll just put some money aside and do a 5.3 or 6.0 swap if the 305 ever dies.

I think Hyperlube makes a zinc additive. I might put that in starting on the next oil change to help things last a little longer. It really runs good for a 305..
Posted By: Karson

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 15th 2015 2:01 pm

Where did you find your van?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 16th 2015 1:33 pm

It was on craigslist. A guy over close to Fort Wayne was selling it.
Posted By: Karson

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 16th 2015 4:23 pm

Dang and I missed it. I am always browsing Ft Waynes CL too. Awesome find Congratz.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 13th 2015 12:04 pm

I am a little disappointed. I haven't been able to start tearing into my van as a project yet. It truly has been a blessing as we have been using it to move to a new house about 30 minutes away. We've made several trips over a couple of months, but we haven't had to rent a truck, and that alone almost justified the purchase lol.

We did do a little "vanning" last weekend though. We took the van and the drift car to No Star Bash at Gingerman Raceway in South Haven MI. Our group had a car hauler, a camper, and my van set up in our camp. My wife is 7 months pregnant, so we stayed in a hotel nearby, but I did have a recliner in the van to use while we were at the track during the day.

Here are a couple pictures from the weekend:

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]



I can't wait until we are settled into the new place and I can really get to work on the van!
Posted By: Karson

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 06th 2015 3:50 pm

Truck-in close to you, CITA in Montrose IL
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2015 1:42 pm

Small update before winter. I went and picked up a real trailer yesterday.

[Linked Image]
[Linked Image]

Granted it was empty, but the van pulled it very smoothly and easily. I wanted to make sure to get it back before the snow fell (supposed to be tomorrow frown ). Should be the last outing this year besides pulling it in/out of the shop to work on other projects. Over the winter, it's getting a full suspension, brakes, clutch and drive-shaft overhaul. Not going to spend a bunch of $ on this 305, just run it until it's dead and replace with an LS, but I'll make sure to keep up with basic maintenance and things that could strand me. If I get real ambitious I'll fix the A/C and work on insulation too. Stay tuned.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2015 7:18 pm

Jason, must have picked that trailer up in Bristol, snow tomorrow yuk. Mine was out tailgating last weekend and now put away for the winter, time to make some changes!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2015 7:25 pm

Haha, The trailer was from Michigan, but the gas stop was at the castle in Bristol. First time I've been inside the place, it's impressive.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2015 7:31 pm

It is crazy, you could live there.....:)
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2015 8:23 pm

Originally Posted by tuner4life
I am a little disappointed. I haven't been able to start tearing into my van as a project yet. It truly has been a blessing as we have been using it to move to a new house about 30 minutes away. We've made several trips over a couple of months, but we haven't had to rent a truck, and that alone almost justified the purchase lol.

We did do a little "vanning" last weekend though. We took the van and the drift car to No Star Bash at Gingerman Raceway in South Haven MI. Our group had a car hauler, a camper, and my van set up in our camp. My wife is 7 months pregnant, so we stayed in a hotel nearby, but I did have a recliner in the van to use while we were at the track during the day.

Here are a couple pictures from the weekend:

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
I can't wait until we are settled into the new place and I can really get to work on the van!




Is that a 90 or 91 Cressida ? I have always loved those cars ! Yours looks great by the way. . .

Also, van projects always seen to take 3 or 4 times as long as you planned
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 23rd 2015 1:38 pm

Thanks Uncle Fester, It's a 1991. There's a link to the build thread on page one of this thread if you're interested.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2015 1:27 pm

Did a trial run with the car on the trailer. I think I can move the car back on the trailer a little bit, but definitely needs some overload shocks on the van. Maybe custom leafs in the future, but we'll see how it sits after the suspension overhaul this winter and the front gets lowered.

[Linked Image]
Posted By: RIVER1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2015 1:55 pm

I had air shocks on mine and it made a big difference. Try just adding 1 leaf to your springs.
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2015 5:00 pm

We installed Hellwigs 2500 series overload springs on our '95 G20 Chevy for towing the TT. I can highly recommend them. Easy to install, adjustable and they make sway bars totally unnecessary. (I think it rides better unloaded than it did before.)
A little more with the install kit than air shocks but worth it. And they don't have to go with the van if you trade.
My2%

Linky: http://www.sdtrucksprings.com/index.php?main_page=product_info&products_id=1599
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 01st 2015 8:05 pm

I like that idea Catfish, but I was worried about them being too close to the frame under compression. If you've used them successfully that settles that though.

I am also curious about getting a set made at a reputable place locally. Maybe de-arched a little bit but with an extra leaf..
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 02nd 2015 12:23 am

With the rear door mounted spare on the van I have to run an 8" extension in the receiver hitch to add clearance between the vans spare and the trailer jack on both our trailers. The Hellwigs more than overcome the extra leverage caused by the extension. I had 'em on in less than 30 mins.
(and I am slow as molasses in winter blush )
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 02nd 2015 12:48 pm

Sounds like a good plan. I'll probably go with those Hellwigs then. Do you just run normal shocks then? or something heavier?
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 02nd 2015 5:44 pm

It has standard issue shocks but I'll be upgrading before next towing season. The only issue we have is that, on the right concrete highways, it will "porpoise" slightly. If you know what I mean. It's only on the expansion joint type of road but it can be distracting. I believe most of that's caused by the extra length from the extension. It increases the distance from the ball to the rear axle almost like it was an extended van. Plus our little travel trailer is a single axle which can cause that too.
Looking at that picture it appears you have quite a bit of trailer/tongue weight. Does the 305 pull it OK? Our 350 has to work it's azz off in the mountains to lug just 2200# or so. (and it only gets about 9 mpg) eek
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 02nd 2015 9:07 pm

I get what you are saying about the porpoising. With the helper leafs I shouldn't need the "coilover style" overload shocks, probably just a set of heavy duty Bilstiens or something will likely work fine if they dont have to deal with the extra weight.

There is a bit of weight at the tongue in the pictures, but the next time I load the car, I can and will load it a further back. It is right at the front in the pictures. Honestly the 305 struggles to break 60mph pulling like this, but I do have the advantage of a manual trans so I can control RPM much better. I'm just going to use the 305 until it's dead, then probably swap to a newer 5.3 LS engine.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 04th 2015 1:27 pm

I had told myself that I was done with the van and trailer until spring when the overhaul is complete, but a friend wanted me to do some work on their Blazer and we didn't trust it to make the trip to my house. Since they haven't started salting the roads around here yet I went and picked it up.

I loaded the Blazer more evenly on the trailer and it helped a lot with the squat at the back of the van. Still needs some helpers, but I think getting the tongue weight right is key.

I am also confident now that the 305 will be ok pulling the race car longer distances. I towed this Blazer about 30 min back to my house at 55mph with no significant issues. Was even able to use overdrive on flat stretches of road, just had to downshift to 3rd going up hills. It's not going to go much over 55 loaded up, but considering that this Blazer is significantly heavier than my car I am optimistic about it.


Another picture of the thirsty van satisfying it's drinking habit.

[Linked Image]
Posted By: westonboege

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 24th 2015 9:05 pm

Nice van dude! race car looks sick too! I def gotta get a trailer setup for mine!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 22nd 2016 1:49 pm

It has begun!


[Linked Image]


I have had several other things pop up lately that have needed attention, but I am finally getting a chance to work on the van. Over the weekend we had some good weather so I cleaned the undercarriage thoroughly to see what I was working with, then pulled it into the shop and got the front off the ground.

I will be replacing the entire steering system, all bushings/joints, 2.5" drop knuckles, and new brakes/wheel bearings. I will also be coating/painting everything that needs it while it's apart.


Here's what I'm starting with (looks 100% original):

[Linked Image]


I was also at a different junk yard over the weekend and found a 1978 Chevy with some cool goodies. I got this Lund visor for $20. It's dirty, but the fiberglass is perfect!

[Linked Image]


They were getting ready to close up, but I am going back this week to get the old style taillights with chrome trim rings, and the porthole windows.


Posted By: 86ed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2016 3:34 am

Nice find on the visor.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2016 5:34 pm

Thanks!

Alright, I'm working on ordering the parts for the front suspension. I thought that I had read somewhere on here to avoid polyurethane bushings on these vans (squeaking/not holding up if I remember right). (The forum search function doesn't seem to work anymore so I can't find where I saw that). I have used Energy Suspension Polyurethane replacement bushings on many of my other projects (tuners/imports) with no real issues as long as they are lubed properly. Never had a van like this before though.

I see that Energy makes poly bushings for the upper/lower control arms and sway bar. Is anyone using these? What's the consensus? Should I just go with the original style Moog instead? Is the ride/handling actually going to be improved with poly, or is it in vain to try to make a van like this handle?
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2016 8:56 pm

Here is the search thread ....

https://www.vanning.com/threads/ubbthreads.php/ubb/search

I have the Red polyurethane bushings on my 4X & they work & hold up well.
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2016 1:07 am

OMG!! I totally LOVE the Cressy!! I had an 83 mkII Supra for almost 10 yrs. Went through a total rebuild,God I miss that car. I was trying to get a Cressy for years but never found one worth having or priced reasonably.. Here is a pic of her before we parted ways.
[Linked Image]
Sorry for getting off topic.
As far as the poly bushings Id figure they should be fine. With a 4 speed a lower,stiffer stance and some fat deep dish wheels and your swinging into the Dajiban movement lol. Would go well towing the race car.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2016 1:31 pm

Thanks for the comliments! Nice supra too!! I've Definitely got a soft spot for these old Toyotas. While it's not quite the same thing, I've got a 1985 Celica GTS also. It's currently in storage waiting on a full restoration.

[Linked Image]



Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2016 1:39 pm

Well I spent most of the evening dealing with snow, but I managed to start working on the van some. It is weird to be using the odd sockets with fractions on them. I mostly work on imports, so they are all nearly brand new still lol.

In just over an hour, I removed the sway bar, steering linkage, shocks, and calipers are hanging (not going to remove these until I have new ones). Everything so far has come apart relatively easily considering they are all original parts from 31 years ago.

[Linked Image]
[Linked Image]


Energy suspension upper/lower control arm bushings, sway bar bushings, and bump stops are ordered, as well as the 2.5" drop knuckles. Should have the $ for the rest of the parts in a week or so. In the meantime I'm going to be cleaning and coating the chassis. Every wear part is getting replaced, and the few things that aren't are getting sand blasted and painted.
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2016 5:23 pm

Sense we are showing off our old (past) toys, this is what I had (pics are NOT of my cars)

first: 1982 Datsun SX-200 Couple 5spd, mine was silver color
[Linked Image]

second was my 1980 Toyota Celica GT coupe 20R w/5spd, same color as this one
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2016 6:03 pm

Those are some cool rides Uncle Fester!
Posted By: Mike M

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 26th 2016 3:20 am

Good luck w your front end rebuild. I would like to follow your progress. I'm going to rebuild my 89 G20 front suspension as soon as the harsh San Diego winter is over. It's been 20 years since did the same w coils, shocks, bushings, ball joints, etc.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 26th 2016 1:19 pm

I got the rest of the front suspension apart last night. Everything came apart fairly easily. Going to work on removing the bushings and joints from the arms tonight. Also need to remove the steering gear box and pump as I am changing those too.


[Linked Image]


The underside is in very good shape. While all the parts are removed, I'm going to clean it up and POR15 any rusty areas, then cover everything with 3M Rubber undercoating.

[Linked Image]
[Linked Image]


There's a part of me that want's to remove the crossmember and have it sand blasted and repainted before I put it all back together, but I'm not sure how to support the engine while it's out. Usually I would support it from above, but the lack of a normal hood makes that hard.. Any ideas?
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 28th 2016 3:21 pm

Use an engine hoist through the passenger door to hold the engine and a jack stand and a block of wood under the front of the pan as a safety support. That's how my uncle did it when he replaced the front end of my grandmas van.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 29th 2016 1:30 pm

I managed to make a "cradle" out of wood that supports the engine nicely with jack stands, then I pulled the crossmember out with a transmission jack.

[Linked Image]
[Linked Image]



There is only minimal surface rust on the frame of the van which will be easy to clean up and stop. Going to clean those spots up then coat with POR15 also and then 3M rubber undercoat.

[Linked Image]
[Linked Image]


I also managed to get both lower control arms completely stripped down. Those bushings suck to remove!! No good way to use a press, and my air hammer died. I may have to Pick up a new air hammer tonight because after 2 hours of hammering I am having zero luck removing the bushings from the upper arms frown .

[Linked Image]


Anyways.. Once I get all the parts that I am reusing stripped down, a friend is going to sand blast them for me and I'll coat all of them in POR15 and rebuild (crossmember included). Should look nice when it's done. I have about a 2 week window to get this project done.. Probably won't happen, but I can hope.

Also, I went back to the junk yard that had the 1978 Chevy van and grabbed these taillights. They are not perfect, but should clean up nicely.

[Linked Image]


Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 29th 2016 8:06 pm

Originally Posted by tuner4life
I
I also managed to get both lower control arms completely stripped down. Those bushings suck to remove!! No good way to use a press, and my air hammer died. I may have to Pick up a new air hammer tonight because after 2 hours of hammering I am having zero luck removing the bushings from the upper arms frown .


it seems to me, last time my Dad and I did control arm bushings, we BURNED them out with a gas welding torch. . . . EPA or some other such place would probably scream doing that today !
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 01st 2016 7:09 am

Wow good job on that front end restore...

How hard was it to get the whole front end and crossmember out...? How lucj time do you figure you have into it, and are you using air tools for removal...?

I'm considering a full rebuild like that, too...
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 01st 2016 1:52 pm

It actually wasn't all that bad. But keep in mind that there is very little rust on my van. Rusty/stuck bolts would have really made this a giant pain.

I haven't really kept track of time but I would say only a few hours.. Probably 4-5 or so to get everything including the crossmember off the van. I did use air tools. (Impact gun, air ratchet, and air hammer). Also make sure to have a good ball joint/tie rod fork, and a big hammer.

The hardest part so far has been removing the bushings from the control arms.. What a giant pain, and I even have a shop press. I probably have 2-3 hours in getting the lower arms stripped down, and I spent an hour and a half on the uppers and only got the ball joints out. No luck with the bushings.. Although I did break my air hammer in the process.. Maybe it will go faster once that is replaced.. If you are short on tools, it might be best if you took the arms to a shop to have the bushings removed/installed.



So I might have a cool deal going on for my parts. My friend who was going to sand blast the parts for me so I can use POR15 said that his business works hand in hand with a powder coating company. I'm hoping that I might be able to work out some sort of sponsorship deal for the racecar in exchange for having these parts powder coated.. I'm excited, but we'll see what happens.



Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 02nd 2016 12:56 pm

So I got confirmation yesterday that I will for sure be getting all of my reused suspension parts as well as the large crossmember powder coated. A good friend of mine is getting me the hook up in a big way. Super excited, but I need to get the rest of the parts torn apart and to him tonight. Gonna be busy!


Also these showed up yesterday! Ended up going with MaxTrac 2.5" drop. They seem to have good reviews for a very good price. We'll see how it goes.

[Linked Image]
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 02nd 2016 6:25 pm

Hey stranger! Hell yeah dude you are going for it, you need anything you know where I'm at. Nice score on the taillights, was it at LKQ?

Scott
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 03rd 2016 1:26 pm

This is about how last night went..


[Linked Image]



Had to burn the bushings out of the upper arms to get them apart. Once I did that I was able to easily press the sleeves out. All of my parts are at the powder coater now. I'm hoping to have them back by the beginning of next week. I have some other parts that should be in around that time, hopefully I can get it mostly put back together next week.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 04th 2016 2:11 pm

A-Arm bushings were such a pain in the ass I said screw it and took them to the shop and them do mine. cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 04th 2016 5:10 pm

Haha, I probably should have. Live and learn I guess.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 07th 2016 12:59 pm

Got the first batch of powder coated parts back over the weekend. They look very nice. I'm hoping to have the rest back early this week.


[Linked Image]



Over the weekend we had company and I didn't get a whole lot done, but I managed to remove the steering pump, steering lines, and steering gear box. The new parts should be in at the local parts store on Tuesday and I wanted to have the cores ready. On top of that, I replaced the engine mounts while I was in there.

I also degreased the fender wells and front frame rails, removed as much rust as possible, and treated the areas with rust converter. I will be painting these areas with black paint and then liberally coating everything with 3M rubber undercoating.
Posted By: apo234

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 08th 2016 1:25 am

WOW those parts look great! JEALOUS
Posted By: 86ed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 08th 2016 2:24 am

Lookin real good!
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 08th 2016 3:26 am

The powder coat is sweet, real nice bow cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 11th 2016 1:14 pm

Thanks everyone!

I've been slowly refinishing/gathering replacement parts. Getting a little frustrated with the slow progress, but it should be worth it. I had a little bit of time last night. I got the surface rust taken care of on the chassis and painted, then liberally coated the inner fenders/frame rails with 3M rubber undercoating. Should hold up and keep everythying covered nicely. Then I got the crossmember bolted back in and reattached the engine mounts and brake lines/shields. Also the bracket for the idler arm. Hoping to get the steering gear and some other things reinstalled this weekend. Expecting another batch of parts early in the week.

[Linked Image]
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 12th 2016 12:57 am

LOOKING GREAT BROTHER !

van van van van van
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 12th 2016 1:39 am

Nice work.


Looking good.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 12th 2016 6:28 pm

Originally Posted by apo234
WOW those parts look great! JEALOUS


No kidding. I'm used to seeing those with a lot of rust and grease on them.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 14th 2016 1:07 pm

Thanks guys! Since I am using this van in the summer only and it will likely never see salt I want to make sure that everything is done 100% correctly so that I never have to do it again. I hate doing stuff like this twice so I'll gladly put in the extra work now.


I didn't get a whole bunch done over the weekend. I am still waiting on the second batch of powder coated parts to come back. (Part of the deal I am getting is that they are low priority). Hoping to have them this week. Over the weekend I installed the new steering gear box, pitman arm, idler arm, and got the new steering pump ready to go back in as soon as the new pressure line gets here. I'm expecting the new coil springs and steering pressure line to get here on Tuesday, and I am picking up rotors, pads, calipers, brake hoses, wheel bearings, and seals tonight or tomorrow also.

I think after that I will have everything on hand to put it all together.
Posted By: Deathorvictory

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 23rd 2016 1:08 am

As a fellow blue lwb manual g20 owner, love this thing and project direction! I wish I had a garage to keep mine and really dig in as much as you are. I've managed a lot parked on the street but you're taking yours to the next level by really getting under there. Going to look better than new I bet you. Looking forward to the rest of the work you do.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 24th 2016 11:58 am

Thanks Deathorvictory! Manuals are the best! So much fun!

So I have all of the parts for the suspension now! Time to start putting it all together. I only worked on it for a short while last night, but here are a couple of teaser pics:

[Linked Image]

I'm going to work on that sleeve a little more tonight. When pressing the other end in, this one popped out just a little bit. It's still in there solid, but it bugs me.

[Linked Image]
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 24th 2016 6:49 pm

Looking good Jason, brings back memories! cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 25th 2016 12:01 pm

Thanks Scott!


So this is my life right now: Race car and van both!

[Linked Image]



Made a bit more progress on the van last night too. Finally got the control arms built. I'm so happy there should be no more pressing to do! Here is what the arms looked like:

Lowers: Powder coated arms, Energy suspension bushings, Moog ball joints, Moog bump stops.

[Linked Image]


Uppers: Powder coated arms and pivot rods, Energy Suspension Bushings and bump stops, Moog ball joints to be installed after arms are on the van.

[Linked Image]


And where I stopped late last night. sleep


Right side: Upper arm installed, Moog idler arm, Powder coated bracket, powder coated center link, undercoated chassis.

[Linked Image]


Left side: Upper arm installed, Reman steering gear, Moog pitman arm, Undercoated chassis.

[Linked Image]


Sounds like we will get out of work at 1pm today so I will have the entire evening to work on stuff! Need to do some work on the race car too, but I may be able to get both projects done.. Time will tell.

cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 26th 2016 4:11 am

And here is the progress from today.. Got sidetracked by several other things that needed done, but made decent headway. New steering pump and lines are installed and fluid filled/bled. All control arm assemblies, springs, and knuckles are installed.


[Linked Image]
[Linked Image]
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 26th 2016 4:49 am

Im driving there tomorrow so you can do the ft end on the '92 .... what a good job you are doing.... I love new parts & paint.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 27th 2016 4:14 am

Thanks frscke! It's an art that most people don't get.

It's amlost done! Somewhere in my gathering of parts I forgot to grab the brake hoses.. I'll have to grab those ASAP then it will be done pending an alignment.

It's late and I'm tired, I'll get some better pics when I'm completely done, but here is where I'm at so far.

[Linked Image]
[Linked Image]
Posted By: Deathorvictory

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 27th 2016 8:20 pm

I cant wait for a ride report with that new set up, it's going to be such a difference.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 28th 2016 1:06 pm

Complete!

[Linked Image]


And here is the stance. I'm sure it will settle a bit. I just dropped the jack and rolled it back and forth a couple feet.


[Linked Image]
[Linked Image]


After a short drive up and down the driveway: (didn't want to go too far, it was raining)

[Linked Image]
[Linked Image]


Not a very good test yet, but my initial reaction is that it felt a lot more firm and stable.

Still needs an alignment as well.

The other issue that I was kind of aware of already is that with the drop knuckles, the wheels do come VERY close to the suspension components (steering arm, and lower control arm). Pictured below..


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


The clearance to the steering arm seems good enough and shouldn't be an issue, but the lower control arm clearance (even after grinding the arms slightly) was still tight enough to knock the wheel weights off the back of the wheel at full lock..

I'm going to grind the arms a little bit more and have the front wheels rebalanced with sticky weights on the inside. I'm confident that will take care of it. It's getting there slowly.

Also since the front track is wider now, I am thinking about picking up some of those 10" wide rally wheels from Summit for the back to match the width of the front a little better.. Hmm....
Posted By: 86ed

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 30th 2016 2:18 am

The fresh parts look sweet, and not a bad stance
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 30th 2016 9:46 pm

I did not have issues with the control arm or tie rod but the caliper mount got into my sticky weights.

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 31st 2016 12:16 pm

Last night I made small notches in the rolled part of the lower control arms, and reinstalled my wheels (now with sticky weights out of the way). Everything seems to be good now. Made circles in each direction in the church parking lot down the road from my house and all seems fine, nothing is rubbing.

The other neat thing that I noticed is that after replacing the engine mounts (factory style), and the trans mount (Energy Suspension), there is slightly more vibration at idle, but the clutch chatter issue that I was having has all but gone away, engagement is much smoother and consistent now.

I'm getting an alignment on Saturday if all goes well.


[Linked Image]


I am still a little bugged by the narrow track at the rear compared to the front now.. Very seriously looking at getting the 10" wide rally wheels from Summit as a temporary solution until I buy nice wheels.. Gotta figure out my priorities lol.


Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 31st 2016 1:00 pm

I did end up having an issue on the highway (bridges/dips in road) with fender getting into tire, put bags in the springs and solved the problem for less than $100.

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 31st 2016 2:20 pm

I believe that my tires clear the fenders. I think they are a little narrower then yours.. I rolled the fender lip a little bit just in case. We'll see how it goes once I get flares and different wheels, but the helper bags are a good idea. Where did you run the line to fill them?
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 31st 2016 3:35 pm

I put the valves in the core support, just pop the hood and they are right there.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 04th 2016 12:57 pm

Got the van aligned on Saturday. Everything is now in spec and centered. It really feels great! I drove down some crappy country roads and the tires only rubbed the fenders on a couple of severe dips/bumps.. Not enough to worry about at this time.


Post-alignment on saturday.. Yes, it was snowing here on April 2nd. mad

[Linked Image]

And this morning, It's settled noticeably already.

[Linked Image]
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 04th 2016 4:40 pm

Congrats on a great job...! Looks so much better than 30 years of rust and gunk, better than the factory ever did, too...!

I'll be dong something similar when it finally warms up around here (yeah, Buffalo had snow this weekend, too) with my new '90 extended van - I'm going to convert it to 5 lug, and I plan to restore/replace with MOOG parts and POR-15...

What did you come up with to leave the engine & trans in the van...?

As for wheels - I would definitely do the 10's in the back, and maybe some 7's on the front with a slightly smaller tire now that she's lower, just in case... When you're weighed down with the trailer it might rub more...
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 04th 2016 5:03 pm

Thanks! Definitely check into having the arms and other various parts powder coated. Not knocking POR15 at all (great stuff), but the cost of having the parts blasted and powder coated might be worth the cost vs all the labor of doing it yourself. Definitely go with all Moog stuff for sure. I am used to working on imports and Euro cars, so I may have gone a little overboard when I found out hoiw cheap parts are for the van lol.

I took a couple of jack stands (one on each side of the engine, and ran (2) 2x4s across the lowest part of the pan right behind the crossmember I had some rags between the pan and the 2x4s to protect the pan. Then I was able to remove the crossmember using a transmission jack. Definitely a bit of labor but well worth it in my opinion.

The wheel/tire situation is up in the air right now.. Leaning towards doing the paint/body work first and getting wheels and tires later. The wheel situation is going to change with flares anyways. angel
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 08th 2016 12:09 pm

Not too much to report, but I got the trailer brake controller installed last night. Should make things more stable/less sketchy.


[Linked Image]


Posted By: SonnyLada

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 08th 2016 7:25 pm

this project is real awesome, and inspiring!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 13th 2016 12:31 pm

Been 2 weeks since being back on the road and this is the first real sunshine we've had. Figured I better take a couple pictures before it rains or snows again..


[Linked Image]
[Linked Image]


Gonna do an oil change tomorrow and then put it to work this weekend. Gonna be towing the race car around for a total of about 10 hours to 2 different events.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 13th 2016 2:09 pm

Looking good! Where you drifting this weekend?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 13th 2016 3:43 pm

Thanks! Going to be in Xenia Ohio at Kilkare Speedway on saturday, and Baer Field Raceway in Ft Wayne on Sunday as long as nothing goes wrong on Saturday.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 18th 2016 12:56 pm

Had a great weekend! The van made it the whole time pulling the car/trailer. The 305 is a total weakling lol. It strained to keep 65 mph highway speeds and had no chance maintaining speed going uphill, even when downshifting to 3rd. Also makes funny noises under load. I need to try to retune the carb again and see if I can get anywhere with it. Despite it's flaws, overall it did great and the chassis handled the load great. It wasn't really a chore to drive like it used to be.

Got some work to do, but likely going to pulling the car to St. Louis in a couple weeks.

Here are the pictures from the weekend's festivities. Even managed to get a few rolling shots!


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


And a bad quality highlight video of Saturdays drifting:


Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 26th 2016 2:57 pm

First picture in a long time of the van nearly empty of all contents. There is usually a bunch of crap in the back, but I cleaned it all out the other day. I added load adjusting shocks in the back and they really help with rear end sag when pulling the trailer. Also give it a bit of rake when unloaded.


[Linked Image]


Then I went home and loaded up with tires that needed to be dismounted..


[Linked Image]


Tonight's project is to build/fabricate a mounting system for the bench seat that I picked up over the weekend. Pics of that will follow as I progress. Need to have it ready by the weekend as we will be racing in St. Louis this coming weekend and need to take more than 2 people.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 27th 2016 12:02 pm

Alright, I worked on the rear bench seat project last night. The bench seat I picked up is a 3rd row from a Suburban. I chose this over some others because it has integrated seat belts, so it is basically self contained.


[Linked Image]


I'm going to mount this slightly behind the front seats as a 2nd row. The only issue is that, being a 3rd row seat, the mounting latches make the seat way too low if I was to mount it directly to the floor. So I have been working on a mounting platform using 4"x 4" square tube steel. I'm going to add hooks so that the seat can latch and be modular like it was designed to be originally. So far it weighs a ton, but it needs to be safe before anything else. This is a temporary solution until I can get around to completing the full interior project.


[Linked Image]
[Linked Image]
Posted By: Chadskitt

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 27th 2016 2:22 pm

Nice work on the Suburban seat. I've thought of doing the same for a 3rd row when I get to the point of doing my interior. I'm very interested in seeing the end result.
Posted By: apo234

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2016 1:50 am

Nice work! The van is looking great! and it looks great pulling that trailer!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2016 11:57 am

Thanks!

Well I ran myself out of welding wire last night after all the stores were closed. I'll have to pick some up tonight to finish the seat mounting bracket. Fail..

So I temporarily moved on to another project. I ran the wiring and added some power ports on the left wall. One by where the 2nd row seat will go, and one at the very back for a powered cooler, or tire pump, or whatever.


[Linked Image]
[Linked Image]
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 29th 2016 4:01 am

Those are nice looking seats, The mount is strong looking, that seat won't move lol bow cheers
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 29th 2016 6:18 pm

Hell yeah Jason, did you go out to the swap meet/car show Sunday? I took 1st place in the 80's class cheers

Let me know if you looking for any van stuff, remember also I yanked those swivel seat bases also if you need some.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 04th 2016 11:48 am

No, I didn't go. We were drifting in St. Louis on Sunday. Congrats on the First place though! It is well deserved!

My van already has swivel bases in the front, but I will keep you in mind. I'll be after some fiberglass by this winter if all goes well ;)


I had to finish the seat mounting in a hurry at the end of last week in order to leave on Saturday morning for St. Louis. The mounting bracket is very heavy and crude, but it is solid and does what it was supposed to do. And the seat latched down to it like it is supposed to. I was out of black paint, so silver it is. Again, this is only temporary until I do the full interior project.


[Linked Image]
[Linked Image]


Overall the van was a champ all weekend. Logging close to 1000 miles with the car/trailer in tow for most of them. It is still slow and the 305ci has to work pretty hard to maintain highway speeds, especially on hills. But on flat ground it would usually maintain 65-70mpg. Can't complain too much.

[Linked Image]


The car did decent Sunday considering that it was underpowered for the large track we were racing at. I had to over-drive the car in order to keep up with some of the big power cars and unfortunately I got over ambitious in late practice and got in a fight with a tire barrier. Thankfully the damage is all cosmetic and limited to the right doors and fender. (Already in the process of getting repaired). It's still mechanically 100% and continued to race through qualifying. Unfortunately I did not qualify for the top 16 elimination rounds, so I packed up early and watched the rest of the event with the family. There are a few things that I need to tweak on the car, (not including the body), but I had a good time and learned a lot. Can't wait for the next event which is closer to home and at an easier track.

[Linked Image]
[Linked Image]


And the damage back at home:

[Linked Image]


Posted By: SonnyLada

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 04th 2016 3:35 pm

outch.... dude that sucks.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 10th 2016 9:47 pm

Damn Jason, I did not know your a body man also......
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 11th 2016 11:49 am

I don't like doing body work, but I know enough to be able to fix my own boo-boos. Gonna have to become one I guess lol.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 24th 2016 12:26 pm

I've got 3 drift events in the next 3 weeks, the first is tomorrow. Woot!

The A/C in y van hasn't worked since I bought it and I can't justify fixing it at this time with plans to change the engine in the next few years anyways. So I started looking for other solutions. Driving on the highway isn't usually too bad because there is ample airflow, but when parked at the track, it would be nice to be able to cool off some.

I ended up building a little swamp cooler last night and it works surprisingly well. This is the only foam cooler that I could find in the area. Nobody is really selling them anymore. I wanted a bigger one, but beggars can't be choosers. I also bought a small 12v fan and a harbor freight solar panel just in case we get some sun this weekend I can try to make that work. Worst case I'll bring my spare deep cycle which should run that little fan all day if need be.

There are 3 holes in the lid which can be easily plugged by milk jug caps. The swamp cooler sits inbetween the front seats. When the side holes are plugged and the center hole points backwards, it can cool the rear seat area (where the baby will play), and if I spin the cooler around, cap the center hole and remove the side hole plugs, it blows a decently refreshing amount of cool air on both front passengers. It's not real A/C, but it works surprisingly well and should run for several hours on a large bag of ice. I bought an extra cooler that I left uncut to hold a second bag. Not sure how that will work. Might just have to send someone out to grab more ice part way through the day if it all melts. It's definitely an experiment, but will be neat if it works out.


[Linked Image]
[Linked Image]
[Linked Image]


Directed to rear:
[Linked Image]


Directed to front passengers:
[Linked Image]





Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 24th 2016 5:20 pm

Nice Jason, I love it! Good luck this weekend, let me know when you have a race close to home. I will be heading down to the Drag strip tomorrow, Lane has their big deal this weekend, $10,000 to win tomorrow.

Scott
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 24th 2016 6:50 pm

Cool cooler, cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 24th 2016 7:08 pm

Thanks Sammy!

Scott, unfortunately there isn't much going on close to here. Good luck at the drag strip!
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 24th 2016 8:02 pm

A yr ago I used 2 Omaha Steak coolers & the same fan ..

https://www.youtube.com/watch?v=xgh7EVb6DdM

https://www.youtube.com/watch?v=Bo1qiyee348
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 25th 2016 5:10 pm

frscke1 love the sound tracks on the vids. 😎 I am currently about to make one of these for my van as well for the baby. Tuner4life good luck on the event and the cooler looks great. Let us all know how well it worked out for ya.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 1:11 pm

Friske, your cooler setup looks great!! I was hoping to find a cooler more that size, but the small one that I got was all I could find around here. The swamp cooler worked well all day saturday, however, I could see the benefits of having a larger box to hold more ice. I ran it all day on my deep cycle battery with no effect on the battery at all. It didn't cool the van down a bunch (no insulation yet), but it was nice to be able to get in and let it blow on your face for a few minutes. I'm going to try to find a bigger cooler next time.


As for the racing, it went much better than last time. The track was more suited to the lower power cars and was much more technical. The better of my 2 qualifying runs landed me in 13th qualifying spot out of about 40 cars. My goal for the year was to qualify top 16 in an event. (only the top 16 move on to tandem battles) So I am super stoked for that. In the tandems I was up against a very experienced driver in a turbocharged LS powered Nissan 350Z with over twice the power that my car had, I felt good about my follow run, keeping up fairly well considering the power difference. But on my lead run he put tons of pressure on and I got fazed for just a second which threw off my line and gave him the win. He went on to finish 2nd so I don't feel too bad about that. I had tons of fun and can't wait for the next event!


[Linked Image]


And here is a potato quality video of my good qualifying run:

https://www.youtube....h?v=gwZr4pqi74Y




As for the van, I don't have any pictures, but it did good. I might just fix the A/C.. I was waiting to fix it until I could swap to a 5.3, but the 305 has been a champ so far so I might invest a little in maintenance and do the water pump, timing chain, and A/C... We'll see.

The only issue we had was one that I figured would be an issue, but somehow hadn't yet. We went over a largely unkept set of railroad tracks on a 60mph divided highway. This was enough to slam the tires into the fenders and take a nice chunk out of them. I figured that it would happen eventually as I have had minor rubs over large dips before, but for some reason it was way worst this time. Maybe the suspension is finally settling or something. I don't know, definitely hit the bump stops. Luckily the tires didn't blow and we made it safely home.


[Linked Image]
[Linked Image]



It has 225/70/15 on pickup rallye wheels now. Could I go to a 225/60/15 and be ok on the fitment? Would I need to go wider since I know the width will vary based on the height? I'm trying to figure out a good size to replace the front tires with, but I can't find a good size calculator and I'm unsure of the correct math to figure it out. Any advice?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 2:34 pm

Edit: After some research. It would seem that the width would not change going from a 225/70 to a 225/60, however the sidewall height would be a total of ~2" shorter effectively (1" lower ride height and 1" extra room between the tire and fender).. Would that be enough to avoid contact with the fender? Should I hammer the inner lip of the fender more than I already did to gain clearance?
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 4:26 pm

Originally Posted by tuner4life
Edit: After some research. It would seem that the width would not change going from a 225/70 to a 225/60...


Right, the first number (225) is the tire's width in millimeters.
The second number is the aspect ratio (the tire's height compared to width), which is shown as a percentage.
So a 225/60-15 tire is:
225 millimeters wide
Is 60% of 225mm tall (135mm)
and of course, fits on a 15" wheel

So you have to base your tire selection on width first and then figure height, since the aspect ratio is not a consistent measurement across different widths.
I hope that makes sense.






Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 4:31 pm

Yeah.. I did some more digging and the 255/60 would have the same width as the old 255/70, but be around 2" smaller total radius (~1" more clearance between the tire and fender). That should be good enough. I'll hammer the lip of the fender a little more too to try to help the situation.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 5:02 pm

I used the bottom of 2 coolers & pined them together with wood slats. Put a blade in the top one inside to direct the fan air flow to the back. Also put a hose fitting on the bottom section near the top so if the ice melted it would run thru the hose & out the side of the van or into my cup for ice cold water.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 5:20 pm

Now that's quality engineering ^
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 8:10 pm

Jason, I think I told you before that I put bags in the front springs and it just stiffend it up enough and do not have a problem with rubs any more and still rides great. I also never had a problem until I hit the highway and the dips at RxR, bridges, etc.

The video link did not work for me but good job on the qualifying.

Scott
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 27th 2016 10:27 pm

https://www.youtube.com/watch?v=gwZr4pqi74Y
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 28th 2016 11:38 am

You did mention the airbags Scott. I like the idea, but thought I was going to be able to get away without them.. Oh well. I wanted to get new front tires anyways. I've got 2 new Cooper Cobras on order in 255/60 instead of 255/70. That should help some for now, and also give it some more rake. Also going to work on the fenders some more. clearancing fenders is very common with the type of cars I'm used to, so shouldn't be a big deal..


Here are more pics from the weekend's festivities.



13498031_1179467792074868_38686499595706
FB_IMG_1467055859435_zpsewpzgrmz.jpg
FB_IMG_1467077458597_zpso62cfnsj.jpg
FB_IMG_1467077477858_zpsxtcdui0k.jpg
FB_IMG_1467077534017_zpsdvbg8yh5.jpg





This was at the end of my follow run in the tandems. Stock power 1UZ Cressida vs LS swap Turbo 350Z. I'm a little surprised I was able to maintain even this proximity.

13512244_10100289772871054_8912720740709
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 28th 2016 11:39 am

You did mention the airbags Scott. I like the idea, but thought I was going to be able to get away without them.. Oh well. I wanted to get new front tires anyways. I've got 2 new Cooper Cobras on order in 255/60 instead of 255/70. That should help some for now, and also give it some more rake. Also going to work on the fenders some more. clearancing fenders is very common with the type of cars I'm used to, so shouldn't be a big deal..


Here are more pics from the weekend's festivities.



[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]




This was at the end of my follow run in the tandems. Stock power 1UZ Cressida vs LS swap Turbo 350Z. I'm a little surprised I was able to maintain even this proximity.

[Linked Image]
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 28th 2016 2:41 pm

Great site here for checking differences in tire size and you can set the offset and width on a set of wheels compaired to the ones you have and it tells you how much closer or farther away from the suspension it would be.
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 28th 2016 2:41 pm

http://www.rimsntires.com/specspro.jsp
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 29th 2016 11:06 am

Thanks! That is a great link!


While getting the wheels off the van last night, I realized that the passenger wheel had significantly more brake dust on it than the driver's side. (closer wheel has more dust than the further)


[Linked Image]


The pads seemed to be wearing evenly so It would seem that I caught it pretty early, but I'll be replacing the 6 month old caliper under warranty while the wheels are off. I believe it's hanging up slightly. Debating about replacing the hose too just in case We'll see how things go. Time is an issue this week. It was weird because it wasn't pulling to the right or anything.. Who knows.


Also got some help from my son. At only 11 months, he already prefers my tools over his toys.

[Linked Image]
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 29th 2016 12:30 pm

Good job Jason, and Fam! Great track action! Plus the fun of the Van rides. Enjoy every minute.

Billy's first words were "Truck Tire..."
Keep those priceless memories rolling on
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 30th 2016 1:53 am

Great pics shift

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 30th 2016 12:29 pm

I got the 255/60 Cooper Cobras mounted and installed last night. The front stance is much better now. It's a little bit lower and has more rake as well as having about an inch more room between the fenders and the tire. I might pull them back off tomorrow and hammer on the fender lips a little bit more just for peace of mind, but I think all will be good with these.. Plus the white letters look sweet! It's really making me want to pick up a set of 10" rally wheels for the back and get another wider pair for back there!


I'll try to get better pictures in the daylight.


[Linked Image]
[Linked Image]
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 30th 2016 2:31 pm

Yea hoses are cheap insurance, I need to do all three on mine.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 30th 2016 3:27 pm

I had done the calipers and hoses 6 months ago, but the one caliper went bad. You can check which item is bad. pump the brakes a few times. (The stuck side should be significantly harder then the other side to spin even after letting off the pedal). Then loosen the bleeder on the caliper. If it frees up immediately, then the hose is bad. If there is no difference and is still stuck, then the caliper is bad. I was prepared to warranty both if needed.
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 30th 2016 11:23 pm

The new tires look great, cheers
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 02nd 2016 3:48 am

Tuner I was going to tell you the same test..lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 05th 2016 12:37 pm

Quick update.. Not much to mention about the van. It did what it is supposed to do. Pulled the car to and from the track and gave us a place to setup base camp.

[Linked Image]



The car on the other hand had it's share if issues from chassis parts, to cooling fan relays, to the transmission.. Yep, had to swap out the transmission at the track on Sunday. Despite all the issues, I was able to get a bunch of track time throughout the weekend and had fun. Now I need to fix all the issues with the car before we go back to Indianapolis next weekend..


[Linked Image]
[Linked Image]
[Linked Image]




Also think I have nailed down the paint color for the van. Just working out some details at this point. Hoping to paint it this winter if I can stop spending money on the race car..
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 12th 2016 9:47 pm

Are you going to have any races in or near Oklahoma City any time in the semi near future ? I would love to ride out , meet you and see that green toy run.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 13th 2016 11:56 am

Unfortunately we don't usually get that far west. St. Louis is about as far west as the midwest series goes. Once I get the van done and capable of being camped in for a few days at a time, then maybe I'll travel a little further. There is some good drifting in Texas!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 16th 2016 11:31 am

Forgot to post about last weekend. This was the 3rd of 3 weekends of racing in a row. This was just a test day at Lucas Oil Raceway in Indianapolis. The drift car did great, got tons of practice and really feel comfortable with this track. Bonus, it wasn't eating tires and I only used 3 pairs all day.


[Linked Image]
[Linked Image]
[Linked Image]




The van did pretty good as usual. The 305 is actually being a decent engine (despite being slow and underpowered) and showing no signs of blowing up as I expected it would after being abused. So I might have to actually do some maintenance.

The clutch has always been kind of skechy and I think it is on it's last legs. It seems to slip excessively in first gear sometimes, jumpy/shaky engagement despite having all new engine mounts and poly trans mount, etc. I know I've smoked it pretty bad a couple of times trying to get started on a few hills. The problem is that everyone shows several options for sizes, so I'm going to have to pull it out and match it up I guess.. Also I would love to convert to a hydraulic setup instead of the over-complicated linkage clutch, but that may be another project for when it gets an engine swap in the future.

Also wouldn't mind fixing the A/C, but again, that may be a next year thing. I've only got 1, maybe 2 more events this year, so I may just wait on all of it. It's going to be torn apart and painted over this winter anyways. I'm already shopping for flares and spoilers ;)


For now, here is how it sits. The new smaller front tires seem to have cured the rubbing issues.


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 1:04 pm

Well, good and bad news.. I was helping a friend move a tractor that he just bought to his property last week and the brakes failed on the tractor while loading it and it hit the back doors of the van. We got very lucky as the damage was completely limited to the doors. The rest of the body, windows, hinges, etc are all ok. Even the spare tire and bracket are still 100% even though it pushed the bracket through the left door. I can't be too upset, I was helping a good friend, and he is insisting on making it right. Since I am planning on painting the van over the winter anyways it isnt the end of the world. Plus I have a lead on a full conversion parts van with good doors and all the power options to swap into my van!

(No damage to the tractor of course)
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


The doors still open and close even..


So on a positive note, I will be using a friend's truck to haul the race car to the rest of the events this year (the season goes through mid September), which will give me an extra month to work on the van (body work, paint, assembly/disassembly, swap parts over from conversion parts van, refresh transmission/clutch/driveshaft, engine maintenance. etc..). Since I won't be using it the rest of the season, it's time to start this big project!
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 4:53 pm

Ouch!
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 5:36 pm

OOOooops .....

Want to get rid of the pop out windows ?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 5:42 pm

Nope! I'm keeping the pop-outs and transferring them to the new doors. Thankfully they were open when it happened because they won't shut now the doors are too bent. I'm sure they would have broken if they were latched.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 5:44 pm

Know where I can get 2 of the hinge's for the pop outs ?

Found out the JY gave me a set of Dodge hinges not chevy. The windows are Chevy but the hard ware is dodge.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 7:20 pm

I'll keep an eye out at the local yards here. Most are fixed window around here though. It'll probably be like those pillar trims lol
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 7:39 pm

Originally Posted by tuner4life
I'll keep an eye out at the local yards here. Most are fixed window around here though. It'll probably be like those pillar trims lol


I sure hope not! LOL
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2016 9:28 pm

Originally Posted by tuner4life
I'll keep an eye out at the local yards here. Most are fixed window around here though. It'll probably be like those pillar trims lol


Oh guess what I called my guy Carlos @ A & B, A chevy conversion van just came in & it has pop out windows.

It may also have the A pillar trim .....
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 09th 2016 12:23 am

Bad news the van was a "Family Camper" conversion, low end build. No trim. I see that my neighbor's RV has them its a 88. that may be another source.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 09th 2016 12:15 pm

I think I have the pillar trims nailed down. I should know something about them within the week, and if they don't work out, I have a second possible source.


Well, since the van is now not going to be responsible for race car transport for the rest of the year, I've decided to start taking it apart to prep for body work/paint. It's going to be a long hard project, but I'll have all winter to complete it and if I chip away at it an hour or 2 a night, then it should all work out well. Honestly, the biggest obstacle I'm up against is where to store all the parts that are removed.. The shop is already pretty full.

[Linked Image]
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 09th 2016 11:41 pm

Oooooo looky looky you must be a Toyota man. I see you have yourself a Celica and by the flares I'd say a GT or GTS. That Cressy though... Lol
I find myself to be pretty partial to just the older Toyotas and anything Mopar.
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 10th 2016 3:34 pm

I hope I find Toyota guys like you when my '85 MR2 goes up for sale.
smile
Posted By: Doc 2% of Canada, EH!!!!

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 10th 2016 11:50 pm

Keep the tuners off the page please...this is a van site
Posted By: nautic1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 12:00 am

I do agree with the above statement. While you may be proud of your other rides, this site is a vans only site. Thanks for keeping it that way.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 12:54 pm

Really? While I fully understand that this is a van site, I didn't realize that we were so picky about what an OP posts in their own build thread.. I wasn't spamming a technical/info post, and I wasn't cluttering up someone else's for-sale thread. I was continuing a relevant conversation about cars that I own in my own thread. It's fairy petty to make an issue about it. I'm a member of several other automotive forums, and they all keep fairly active by having friendly dialogue about whatever comes up between build updates. It keeps the forum active. Van's aren't exactly an up-and-coming thing, I would hate to see this place turn into a ghost town as I've seen several other forums do when moderators start to micro-manage build threads. I can tell you that the other forums I have build threads on are more then interested in updates about the van, just figured it went both ways.

Whatever though, I don't own the site.. From here on, I will keep this thread strictly about the van and won't post about anything unrelated, sorry for the offense.



Anyways..

I had another free hour last night so I took the van apart some more. Started sorting all the nuts and bolts into ziploc bags labeled as to where they go. Here's how it sits currently. It really is therapeutic to work with non-rusty fasteners.


[Linked Image]


Trigger warning. There are import parts in the background, sorry if this is not appropriate. I can crop them out if it's a problem. rolleyes
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 3:44 pm

I don't even know what to say...
I thought this place had a laid back, keep on truckin' kind of atmosphere.
I didn't know we were restricted on what we said in our own threads.

Am I in the wrong place?
Posted By: nautic1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 3:55 pm

I was not trying to chastise but I received a complaint that there were cars posted on the site and they thought this was a vans only site. I kept my post civil and to the point and did not try to wage a war on anything or anyone. I like cars just the same as you and yes this is a laid back site. But it is a site for vans.
There is no problem with saying what you want in your own threads. You can talk about work you have done on your van, car, go kart, dune buggy, hot wheel, bar stool, etc. But when it comes to posting pictures, please keep it to vans only. Although a motorized bar stool would be cool. lol.
I hope this makes sense.
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 4:15 pm

Sure, it makes sense.
Except the part where somebody complained about Tuner posting pictures of his other cars... in his own build thread.

I actually enjoyed him sharing that stuff with us.
I understand that this is a van site, that's why I'm here, but I think he should have a little more creative freedom in his own threads.
This guy uses his van to tote his race car to the track.
I'm guessing that his racing hobby is pretty important to him. The segue was simple. He has a van that totes his race car, he races an import car, he drives other imports, someone showed interest in them.
If someone complained, that's just them showing a lack of flexibility.
That lack of flexibility is the kind of stuff that turns younger users away... Something that seems to be against this particular hobby's goals.
Can we afford to turn people away?

Besides, if he builds that motorized bar stool, somebody's going to say, "Pics or it didn't happen".
Then what do we do?
LOL lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 4:24 pm

I get the "van only" concept at a meet or show or something but lets be honest, the complainer was being a bit petty. This place has always had that "come hang out and shoot the shit" type of feel about it, seems strange that we're ordered to stop just because of 1 complaint. There are pictures posted all over this forum about stuff that isn't even related to vehicles at all.

Phil, I didn't mean to come across as snappy this morning, it just rubbed me the wrong way first thing in the morning before I had coffee. Honestly, it still kind of does in the afternoon, but if the rules are pictures of van stuff only, then I'll abide. Not trying to start a war or step on anyone's toes. Van pics only from here on out.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 4:27 pm

Rusty, If you want to chat about the other cars I guess we can take it to PM.
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 4:53 pm

It wasn't even me that was interested in the first place.
I was just tagging along and enjoying the scenery.
Which simply means you had more people interested than offended.

I came to your defense because the whole thing got me wound up.

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 4:57 pm

Haha, It's all good. Appreciate the support. I got all wound up about it too, but in the end it is what it is. I don't own this place. There are build threads on other sites that I can link people to if they ask from here on out.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 6:31 pm

Hey Jason,

Nice pics all. But ouch! on that hard Tractor hit from the rear. You can't write this stuff...
It will all be funny in time...

Certainly can appreciate how deep you had to go into that car at the race. Keep up the good work and happy wrenching on the G20 rebuild! Thanks for posting.

Just wanted to let you know much I enjoyed the cars.
Posted By: Astro

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 7:46 pm

ok, it's a van site, lets keep it about vans.
that being said, the OP was about his van, the tuner pics were what he hauls with the van, they weren't the main subject of the post, and were more about what he does with the van, so I'm ok with it.
let's just keep things civil please.
Posted By: nautic1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 7:47 pm

Ok there. In that respect we have heard from the boss who I consulted. Figured it best this way.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 8:00 pm

cheers

Thanks Astro. We're all good here, not trying to make waves. I'll keep the automotive ADHD to a minimum.
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 8:01 pm

Hi Jason, I agree with what Rusty said, I enjoyed that you shared your Toyota's with us in your own build thread, This is Van and family site, and their are things that should not be posted, But with only one complaint, does not seem to justify the censorship of a couple photo's worms cheers
Posted By: nautic1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 11th 2016 11:40 pm

So are we all good here now?
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 12:48 am

Wow I had no idea that this would go 2 more pages of rants on our constitutional right to post lol. Yeah I got the formula drift of it right from the start. Nice progress on the G20 there Tuner. Must have found some extra storage you didn't see the first time.
Posted By: Deathorvictory

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 4:31 am

Can't wait to see more pics of the tuners, I mean van. This'll look great with some paint on it!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 11:39 am

We're all good Nautic.

MidwestB200: I've started storing small parts on boxes in the back of the van, larger parts like bumpers and stuff can lay along the wall and the window glass is being taken inside the house and stored deep in the basement for safety sake. I have a toddler roaming around, so everything is under lockdown.

The tuners will have to make their appearances in the background of the van pictures. As demonstrated below angel


I had about 2 hours to play last night, so I got the core support out and completely gutted the passenger front door (except for the latch). The manual Window regulator is a gigantic pain to remove. Holy crap I must have spent 45 minutes trying to get it out once all the bolts were removed. The parts van that I have my eye on has power windows, so I'm going to try to swap those over to my doors since my doors are in better shape. I remember there was a thread about that somewhere on here, I'll have to find it.


Core support out. Do you guys paint those body color or something else? Mine was silver originally to match the grille. I want to go to a chrome tubular grille, so not sure on painting the core support or not. In a perfect world I'd just have it chromed lol.

[Linked Image]


And the gutted passenger side door.. No imports to see here. lol

[Linked Image]
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 2:57 pm

Ive been following along for awhile. I like your cars but I like your van more, mostly I like that you get things done.
No screwin around for you.

I will throw this out there, A black core support, etc. will make for good contrast behind your chrome tube grille. The grille will stand out much more.
Posted By: MidwestB200

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 4:29 pm

I have to agree with 1959 on the blacked out core support. It would make the chrome grill POP way more. I myself want to make a phantom style tube grill for my tradesman but funds go to family before fun lol. I totally understand the toddler situation mine is just starting the trying to walk and getting into everything so all car parts stay hidden lol. The boxes in the van are pretty genius. Never been a fan of removing the regulators in the Chevy vans. There just never seems to be enough room in the holes they give you to work with.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 12th 2016 8:49 pm

Thanks guys. After looking around, I think the core support might look best chromed since it will be partially visible between the grille and the hood.. Idk, I'll worry about that after the paint is done. Chrome is expensive. Either way I do it, I'm probably not doing it body color, so it can go in a different pile.

Posted By: Don_F

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 13th 2016 1:02 am

I liked the variety of the cars on the OP's own thread, it wasn't overwhelming to where the intent of the build got lost. I agree with the others posting here that the one complaint was very petty at best.
Posted By: nautic1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 14th 2016 3:04 am

Ok we can move past this now please.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 16th 2016 12:33 pm

Back to regularly scheduled programming.. I had another couple hours to work over the past couple of days. Both front doors and the side barn doors are completely gutted, windows out, ready to be prepped. I also took the important parts that I will reuse out of the damaged back doors.


[Linked Image]



I did find just a tiny bit of rust starting at the bottom inside corners of the side barn doors where the door skin is folded over. I'm really hoping that I can grind it out and get it neutralized easily, but I have a feeling that I am going to have to cut out some metal which I'm not looking forward to. I'll grab pictures of those spots later.
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 16th 2016 1:40 pm

For the core support, have you looked at Spectra Chrome?
https://www.facebook.com/spectrachromeusa/
Got a friend that had some control arms done with Spectra Chrome and they looked great. Of course, that van didn't work for it's living.
(Way Back) When I used to race we always considered chrome as bad luck, even though that was usually the cheapest thing we put on it!! lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 16th 2016 3:02 pm

That Spectra Chrome is fascinating, however from what it sounds like having something done might be nearly as expensive as just having it plated..

The race car doesn't have a ton of chrome, but the van most certainly will get it's share of brightwork. While it is a "working van", it will only see reasonable weather (no winters), and will probably see a few shows here and there. It's got to look good.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 17th 2016 12:11 pm

Had a few minutes last night so I took the rear bumper off. Pleased to find no rust or damage down here. I do need to source some more of the chrome-capped bumper bolts though because I destroyed a couple removing the bumper.


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 19th 2016 12:19 pm

Only had a half an hour last night, so I removed the rear doors, marked everywhere that needs "body work" attention (dents pulled, holes welded up, etc..), Also test fit the junk yard visor I picked up over this past winter. I am thinking about adding a small orange LED marker to the outer ends of the visor facing forward. It would be kind of like a subtle version of the lighted visors that are out there.. I'm undecided on this.


[Linked Image]
[Linked Image]
[Linked Image]
Posted By: apo234

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 20th 2016 5:04 am

I say go for the lights on the visor, or some nice cab lights, but that is my opinion as I love lights!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 01st 2016 12:17 pm

My glass guy came out yesterday and pulled the windshield.


[Linked Image]


I am pleased to say that there are no major repairs needed to the windshield frame. There are only a couple small spots of surface rust that are nowhere close to being through the metal, should be easy fixes. The glass guy said that he was very impressed because usually these vans are rotten away to nothing under the windshield especially on the glue-in models. He is going to source me a new gasket-mounted windshield and gasket to install in the spring when all of this is done and reassembled.


Here are the couple of places that need touched up. No holes whatsoever though!


[Linked Image]
[Linked Image]


While the windshield is out, I'm also going to add welded-in nuts or threaded inserts for the visor to mount to. I'm hoping that if I can do that and have them sealed and painted with the rest of the body, as well as using thread sealant, I should be able to completely stop any water intrusion and potential rust spots caused by using sheet metal screws like how many visors are mounted.


Also, I am heavily debating repairing the right front fender vs. just replacing it with fresh metal. seeing as the whole van is taken apart, I can access all of the spot welds, however I do not have any experience with drilling spot welds and rewelding them. I'm not sure what direction I'm going to go. Maybe I'll cut the front half of the fender from the parts van that I'm going to get before winter and just replace the front half, but i don't know how well splicing it would go.

Posted By: Lunchbox2

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 4:55 am

I love the 4-speed van, that thing is dope. I can honestly say I've never seen one before. Then I wanted to compliment you on the Cressida. I have a soft-spot in my heart for those older toyotas, one of my best friends has a 2JZ swapped MK III supra (big single) that I fell in love with. But I guess we can't talk about that, so...

Anyhoo...good-luck with the build man, hope you're bangin gears again in the van soon!
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 12:27 pm

The windshield will (probably) be an #853. The gasket and the windshield will most likely carry the same number. That is, whoever the manufacturer, it will usually have #853 in the part number somewhere. At least, the ones I've had were that way.
[Linked Image]

I have both glue-in and gasket types and I too favor the gaskets because they're not as bad to trap the dirt and moisture.

Edit: I used the "top-hat" expanding nuts for our visor and have had no troubles yet. Welding in studs sounds like a better idea if you're painting anyway.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 12:36 pm

Thanks Lunchbox!

Catfish, I'll have to see when he installs it. I would imagine there aren't too many different sources for that windshield anymore. In talking with my glass guy, he did agree with what you are saying. The gasket windshield is the way to go. He showed me the drain holes under the window and how the original glue in window clogged those holes and a couple other spots where the glue wouldn't let trapped water out. I'm just happy its getting taken care of now before it gets any worse.
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 12:49 pm

One of the afore mentioned drains:
[Linked Image]
There's another on the other side....
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 12:53 pm

Yep! Those drains! The glue on mine was completely clogging both of my drains. I'm going to wire wheel any remaining glue away and refinish the frame to original and paint it with the rest of the body. Should be good for a very long time.


Another question. I've got several holes in the floor where the previous owner had plywood screwed down. The screws are in the holes plugging them, but I want to coat the floor with truck bed liner and I would like to weld up the holes first. The problem is that some of the holes are above the fuel tank.

My question is, should I remove the tank to weld up these holes in the floor? It seems like a lit of work, but I don't want to die in a fire either. How risky is it?
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 4:06 pm

My opinion, I would err on the side of caution. Compared to what you have to lose !!,,,, pulling the tank is not that bad. Besides you can replace the pump screen for about 9 bucks or the pump too if it's the original.
The tank ain't bad with a floor jack and a homemade "saddle". I cut out a saddle to match the shape of the bottom of the tank outta scrap 2x4s, spaced to miss the support straps. Then bolted it down to the jack and replaced the pump and screen on a half full 33 gal tank as a one-man job.
[Linked Image]
Removing and replacing the damn trailer hitch is actually more work!

Better safe than sorry......
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 02nd 2016 7:41 pm

Hey Jason, I have not been around for awhile busy fkn summer! Sucks about the tractor but looks like youe are hard at it and somebody will be doing some shows next year! shoot me a text sometime and we will get together cheers

Scott
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 03rd 2016 4:45 pm

Dude, love the rebirth, totally looking forward to what you're going to do since you were so thorough in the front end...

I totally agree with those drain holes, my van had them both plugged up with the urethaned in windshield, and the passenger side one was the cause of my rot...

Maybe over the gas tank you could use some 2 part epoxy or urethane sealer to fill them in so you don't have to worry about causing a fire...?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 28th 2016 11:56 am

When you're getting tired of messing with body work, but the the UPS guy shows up...

The Norcal wing should be here soon as well. drool


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 28th 2016 12:56 pm

Another question. I have most of the replacement weather stripping figured out as far as where to buy it from, but on the side and back door hinges, there are seals for the hinges. A sort of flat foam rectangle seal for the body side, and a more visible rubber type seal for where the hinges go through the doors.

The only place I have found that can seem to get these is steelerubber.com, and they want $39.00/set of 4 body side seals and $43.70/set of 4 door side seals.

Spending $165 just on these hinge seals seems a little ridiculous. Is there anywhere else that you guys have found to get Them? Also, it looks like the originals were painted over from the factory. Since successfully painting rubber is nearly impossible, how bad would they look just being left black?
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 28th 2016 3:52 pm

You mean these ....

[Linked Image]

you can go to Home depot or Ebay & for $3 get a 12x12 sheet & make them your self like I did for my '93.

3/16 peel & stick 12 x 12 sheet

http://www.ebay.com/bhp/adhesive-backed-foam

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 28th 2016 4:01 pm

Good call! Thanks for that!
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - September 28th 2016 4:15 pm

I made 18 of them & still have 1/2 the sheet left over. It would cost more to mail you the other half than you getting a whole sheet.

Just use a new sharp razor blade.
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 04th 2016 12:56 am

Nice work, I'd pull the tank and check the sending unit, ethonol doesnt seem to be playing very nicly with older pickup screens . alot of folks are pulling out black gooey messes.I know the one in my tan van had to be stopped up because i was getting bad starvation issues on the highway there in texas at abut 65-70 mph . you can inspect the inside of the tank too, do you know if you got the larger 33 gallon tank? be a good time to upgrade and increase the range.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 05th 2016 12:53 pm

Got my Customvan.com Norcal wing yesterday.. Unfortunately the Fedex folks in this area are as worthless as they come and damaged it in shipping. I contacted Kirk right away and he is handling replacement. He has been great to work with so far and I would recommend to anyone.


Here is what Fedex managed to do to the spoiler:

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]




I might work on this thing again this week. Still banging dents out and working on the mounting of the fiberglass parts.

May pull the tank out just for kicks.. Planning on doing a fuel injected swap at some point in the next couple of years, so Not sure if I'll mess with that part yet or not.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 05th 2016 11:12 pm

Oh wow...FedEx really hammered on that thing.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 06th 2016 12:10 pm

Yeah, the Fedex drivers around here are horrendous. If it's not delivered to the wrong place, it's usually damaged.

Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 06th 2016 2:21 pm

I ended up with a free set of damaged side pipes due to Fed Ex, not sure what their hiring policy is but they have issues. Can't wait to see more progress.....good job!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 17th 2016 2:15 pm

Got the replacement spoiler. Still has minor stress cracks where the halves are bonded, but they are minor and I think I can take care of the minor imperfections fairly easily.

Overall it fits well and looks great! Currently working on a waterproof solution to mounting it and running wiring inside.


[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 19th 2016 12:51 am

yay
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 25th 2016 12:19 pm

I've had some other things to get done around the house recently, but I finally got a chance to work on this again.. It's going to be a big project and probably take most of the winter, but I'm in it for the long haul now.

Currently working on mounting the fender flares. I want to make any necessary holes now before paint so that they will be sealed up and won't rust as easily later.

The metal fender may need a bit more work, but I got the right front flare on last night:

[Linked Image]
[Linked Image]
Posted By: crazyvanman

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 25th 2016 7:38 pm

looks like a good fit so far.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 26th 2016 1:23 am

Nothing looks better on these vans than fender flares.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 26th 2016 12:26 pm

I love the way it's looking so far! All of the flares seem to fit relatively well except for the front right. After doing a little tweaking I think it will look ok. It was warped a little bit.

After getting the front flares mocked up close to where they need to be, I discovered that they didn't line up well with the front lower lip spoiler. I spent last night working on mounting that. I've come up with a system using 6 screws with a "knob" type head to mount the lip so that I can remove it easily if extra ground clearance is needed.

Here is the mock up of the front lip when I called it a night. (I only get about an hour per night to work on the van right now). It needs to be moved to the rear about 1/2" but it's close.


[Linked Image]


Also just found out that the parts van that I thought I was getting isn't going to work out.. So I am going to be looking for a later 3rd gen conversion GM with good back doors and all the power features (locks/windows/mirrors) among other things.. If I can't find one for cheap enough I'll be forced to scrounge the parts wherever I can find them..
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 27th 2016 5:25 pm

Alrighty, last night I was able to finalize the mounting position of the front chin spoiler. It is centered as good as it's ever going to be and mounted solid.. I also mounted the right front flare to check the fit and it is decently close. I still have a little work to do. I think if I massage the little up-turn at the ends of the chin spoiler just a little, it should all fall right together as that is the only piece keeping them from mounting flush.

[Linked Image]


It does look mean though so far!

[Linked Image]


I am probably going to have to take Bikertrash00's advice and get some airbags for the front springs to help with the load. I finally got it to quit rubbing by changing tire size and clearancing the fenders a little bit, but the flares will likely be contacted by the wheels if I hit a large dip or bump. Either air bags, or I will need to make a riser block so that the bump stops hit sooner.

Posted By: Chadskitt

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - October 27th 2016 5:33 pm

Looks great so far! Thanks for posting pics it's making me wish that I was to the same point in my build. Maybe by summer .
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 06th 2016 5:56 pm

The junkyard finally had a conversion chevy! I was able to grab all the lock actuators, wire passages into the doors, and door jamb pin switches as well as some trim pieces and hardware that I needed.

[Linked Image]

[Linked Image]


I was also able to find a pair of rust free back doors someone was selling from an Arizona van.

[Linked Image]


I've decided to buy the aftermarket power window kit instead of messing with transferring OEM ones over. So all that leaves are power mirrors which I can find later. I'm getting stoked to get this all together.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 06th 2016 6:16 pm

I love hunting in a Bone Yard ...
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 06th 2016 6:36 pm

Way to go Jason. Thanks to you and all the other Vanner's on here that are Going Deep. Good job! shift
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 07th 2016 1:35 pm

Thanks guys, I love junkyards! It is just rare around here to find stuff that is actually usable.


I didn't make much progress all week, but I am continuing to work on mounting the fiberglass parts. I want to make any holes before paint so that they will be painted and sealed and hopefully not rust.

Here is a rough mock up with all my fiberglass installed. I love it!


[Linked Image]
[Linked Image]


I'm going to be doing a little rearranging of the shop in the coming weeks to make more space for working on the van. Storing a couple of the other future project cars offsite. My work just informed me that I still have 96 hours of vacation to use up before the end of the year or else I lose it.. Guess who is taking the second half of November and first half of December off! Maybe I'll get somewhere with this thing.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 08th 2016 1:30 pm

Last night I got the replacement back doors stripped of all glass, seals, etc. and mounted them up. Everything looks good as far as fitment goes!


[Linked Image]


Being that the doors came from an Arizona van, I need to figure out how to get the fully cooked striping off. I'm not sure if an eraser wheel will work.


I am also trying to find some shallow metal boxes of some sort that can mount inside of the back doors and provide a little bit more storage for tools and supplies.. Having a hard time finding anything though and I would prefer not to use wood..
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 08th 2016 6:34 pm

Looking Good! Just a thought....I was originally looking for a type of box also and all I could find was wood conversion stuff and decided not to cut for boxes and instead just cut and installed 6X9's and put some foam in the door cavity which turned out great with awesome sound quality.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 08th 2016 6:58 pm

I thought about that too, unfortunately the used doors I got were already cut for the conversion wood boxed (that were in pretty bad shape). I think I might be able to fab up something nice out of aluminum or maybe diamond plate or something. Felt-line the inside and have another storage spot. I've got a couple of ideas.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 08th 2016 9:48 pm

Rivet some ammo cans inside the door.. The small ones should work.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 09th 2016 7:59 am

Looks like you got that front spoiler fitting pretty well.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 09th 2016 2:02 pm

It's looking Baaadddaaass...

Especially the angled shot of the entire Van. Pow! Looks like a scene from the Batman TV show. Bam!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 11th 2016 1:23 pm

I am a couple days away from rearranging the shop so I didn't want to dive into a big project just yet. So instead of mounting more fiberglass, I played around with the back up camera. Previously it was mounted to the license place bracket and was really too low to be useful. I had toyed with trying to mount it to the norcal spoiler, but couldn't wrap my head around how best to mount it and run the wiring. Plus it looked pretty gaudy up there. I settled on mounting it just inside of the rear window on the door. This way it's fairly invisible, not in the way of getting damaged, and high enough to actually be useful. I did check and it will clear the glass and seal. I ran the wiring inside of the door and used a grommet to finish the hole. I'm satisfied with how it's turning out.

[Linked Image]
[Linked Image]

Posted By: Lunchbox2

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 17th 2016 3:15 pm

She's coming together man, lookin' good!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 21st 2016 5:32 pm

After all the headache finding the windshield pillar trim a few months ago, over the weekend I stumbled on a Rallye van in a junkyard that I don't normally go to.. Had the full set of trim. I bought all the pieces I thought I could ever use for $35.

Can't beat that!


[Linked Image]
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 21st 2016 7:21 pm

OH MY ! Glad you finally found the set & in your color also SCORE ! & for $35 THATS STEALING !
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 22nd 2016 12:12 am

Your van is really looking good.
Posted By: OutlawZ

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 26th 2016 11:09 pm

Def keeping tabs on this build!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 30th 2016 2:06 pm

Been working on projects inside of the house more than expected the last couple of weeks, but finally making some forward progress. I put a couple of the other long term project cars in storage offsite and rearranged the shop so I have some more space to work on the van. So far the flares and chin spoiler are mounted. Still need to mount the spoiler and visor. The chin spoiler still needs a little massaging to meet up to the flares correctly, but it's close.

I think I have sourced a van and a junkyard that will let me bring in power tools, so I should be able to cut a couple of pieces that I've been trying to source for a while. We'll see how it goes this weekend. Plus I scored a 20v lithium Porter Cable sawzall black Friday. Hopefully I'll get to try that out.


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 07th 2016 1:42 pm

I was able to cut out the pieces that I needed at the local junk yard. Going to work on patching them in tonight starting with the extra fuel door.



[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 08th 2016 1:22 pm

I got the fuel door patch panel cut and tacked in last night. It sis about an inch further forward than the real fuel door on the driver's side, but is the same height and position otherwise and measures up to being straight. I think it's time to look for a real welder though.. I've been using this old Harbor Freight Flux core welder that I got for free years ago. It works pretty decent for most projects, but I cannot seem to make it work with sheet metal such as patching in this panel. It just wants to blow holes in it, even with the power on minimum and the wire speed at various different positions I couldn't make a consistent spot weld. Might have to bite the bullet and actually get a MIG..

But for now, Here is where this project stands. I'm happy with the positioning and am confident that (after completing the welding in of the piece) it should finish nicely.

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Lunchbox2

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 08th 2016 3:30 pm

Lookin' good man! I need to do the extra fuel door thing, to fill an auxiliary tank that will feed my main tank. These shorty vans don't have enough room behind the axle to run a good-sized tank.

I had a Miller 175 welder that was great for everything from sheet metal to 1/4" plate steel, and I think I had right around $1100 in it, WITH buying the big argon tank. The smaller 135-140 welders are great for sheet metal, but don't have enough ass to weld 1/4", so they don't work for me.... Keep an eye on craigslist and the like, there's always somebody that needs money and selling their toys. I've seen good welders in the $500-$700 range pretty consistently....
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 08th 2016 3:51 pm

Now you have to install a 454 to drink all that gas .....lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 08th 2016 4:10 pm

Yeah. I'm eventually going to find a decent mig welder for cheapish, but for now I think I can borrow a friend's. The bigger issue is that I need to run 220v out to my shop. Yay for projects on top of projects crazy

The funny thing is that this extra gas door isn't even going to be used for gas. I plan on having an electrical hookup behind it. I just wanted a cleaner install than a random port mounted to the side of the van.
Posted By: Lunchbox2

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 10th 2016 2:54 am

That's a great idea! I haven't even begun to think about shore power, house batteries, and power inverters yet... I've been painting and pulling transmissions lately...ugh Although we did get to go wheeling yesterday, for the first time in a month!

[Linked Image]

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 12th 2016 2:22 pm

Looks like fun! While it's not really something I would do with my van, I would love to pick up an FJ80 Landcruiser for a winter daily/trail rig.


It snowed here over the weekend, so I spend most of Sunday shoveling/snowblowing which left me too tired to cars about doing body work. But I did manage to get the front fender patch tack welded in on Saturday before the weather killed my mood.

It may not look great in the pictures, but I was able to cut the patch to include nearly all of the damaged metal on my original fender. The edges all line up and are level, should finish up nicely once I can complete the welding. I am so glad that I went this route instead of continuing to try to repair the original fender as I kept making it worse.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 14th 2016 2:33 pm

I went to harbor freight and picked up the best wire wheel tool I have ever owned. I was using a standard 4.5" wire wheel and it wasn't doing much to the seam sealer in the gutters, and wasn't even touching the windshield glue. Well this twisted style wire wheel is a whole different animal. It removed the windshield glue in about 30 minutes. Got the whole frame down to bare metal very easily.

[Linked Image]
[Linked Image]




I'm not exactly sure what my plan should be for this seam at the top, there is no severe rust here. Should I just grind it clean and fill with some seam sealer?

[Linked Image]



And here is the only rust issue on the windshield frame. There are 3 very small holes at the bottom near the middle. What should I do with this? I'm thinking that I'll just weld them up and grind smooth. Then use just a tiny bit of body filler to smooth the area out before painting. Would that work best or should I leave the area filler-free? I don't think it's bad enough to warrant cutting the whole area out. Thoughts? Being below the windshield seal, it doesn't have to be pretty, but I don't want the rust to come back.

[Linked Image]




And here is the progress on the gutters, only got the drivers side done for now (chipped the sealer out, haven;t cleaned with the wire wheel yet). The wire wheel is great for final cleaning, but I am having to chisel the thick pieces of seam sealer out with a hammer and chisel first. Going to be a job that's for sure.

[Linked Image]
[Linked Image]
Posted By: Lunchbox2

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 15th 2016 3:38 am

Hell man, I want to see the tool! haha It seems like I'm ALWAYS needing a wire wheel for something...
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 15th 2016 1:35 pm

Oops, I thought I posted a picture of that yesterday. Here it is:


[Linked Image]


It was about $6.



Also, the 220v is getting hooked up in the shop tonight and I will be borrowing a MIG welder from a friend for the weekend. I'm stoked to get the welding done.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 16th 2016 10:56 pm

looking good Jason, can't way to see that beauty painted, it is going to be a show stopper.......meaning I will stop bringing mine to the local shows if you are going to be there...hahaha.....cheers Keep up the great work!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 21st 2016 2:26 pm

Hell no! Your van is awesome! Well have to tag team some shows this year. There needs to be more vans around here.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 22nd 2016 4:18 pm

Absolutely dude, cant wait to do some local shows together! Get that beauty ready for the Nationals this year!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 28th 2016 5:59 pm

Alright, I am mostly done with the welding areas. The front fender is welded and partially done with filler. The rear gas (electric) door is basically done and ready to go. I also welded the couple of small holes in the windshield frame, all the emblem holes, holes that the PO drilled to run wires (in the wrong spot). Also dealing with the lower crimp seam on the side barn doors, there was just a little bit of rust. I argued with myself for a little while on how to handle it, but eventually decided to just do it right. I ended up using metal from the old crunched back doors to repair the side doors. I have the metal work done on the "60" door, just need to seam seal the crimp and smooth out the outside skin I just need to do the same on the "40" door then I should be done with all the welding. I need to return the welder that I borrowed.


Picture dump:


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 28th 2016 6:22 pm

Thats pretty slick Tuner !
Posted By: JIm_Rockford

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 28th 2016 7:55 pm

on all that Bare metal I highly suggest using 2k epoxy primer, as it completely seals out any moisture, Almost all other types of primers are porous and will absorb water and rust out behind the primer.
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 28th 2016 10:15 pm

Sorry I don't have anything to add but keep up the great work. You are gonna have a sweet van!
Posted By: OutlawZ

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 29th 2016 5:13 am

Damn this van is going to be awesome when its done!
Posted By: Sammy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 29th 2016 7:52 am

Looking Great Man, Going to be real nice when your done, your doing great work, Sammy cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 29th 2016 1:46 pm

Thanks guys!

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 29th 2016 1:49 pm

Originally Posted by JIm_Rockford
on all that Bare metal I highly suggest using 2k epoxy primer, as it completely seals out any moisture, Almost all other types of primers are porous and will absorb water and rust out behind the primer.



I do have some 2k Epoxy primer on the way, but due to the holidays it hasn't arrived yet. I had a can of self etch sitting around so I used that as a temporary solution (It's been raining/humid here, didn't want to take any chances). Is that going to cause me problems? Should I sand/wire-wheel all if the self etch primer off and recoat with the epoxy primer when it gets here?

Posted By: OutlawZ

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - December 29th 2016 11:31 pm

Originally Posted by tuner4life
Originally Posted by JIm_Rockford
on all that Bare metal I highly suggest using 2k epoxy primer, as it completely seals out any moisture, Almost all other types of primers are porous and will absorb water and rust out behind the primer.



I do have some 2k Epoxy primer on the way, but due to the holidays it hasn't arrived yet. I had a can of self etch sitting around so I used that as a temporary solution (It's been raining/humid here, didn't want to take any chances). Is that going to cause me problems? Should I sand/wire-wheel all if the self etch primer off and recoat with the epoxy primer when it gets here?



Cant see why it would other then if it was a different type ergo Acrylic vs Enamel for example...but if they are the same type i cant see why you cant just scuff the self etch and apply the epoxy over it.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 09th 2017 3:10 pm

Alright.. I didn't get any pictures, but on the "60" door, I bent the crimp back out a bit and filled the seam with epoxy primer after wire brushing away most of the etch primer. Then I used some POR15 on the inside of the panel to cover the welds from the patch and also let it run down to seal the inside of the door down in the crimp area. Hopefully this keeps the rust away for a long time.



On to the "40" door: I started with cutting out the one corner that looked bad, but then realized that the rust went all across the bottom of the door. ended up cutting the door skin away all the way across the bottom.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]



Made replacement piece for severely rusted area: There is some other minor rust that isn't really accessible, but it is only minir surface rust. I'm just going to neutralize and seal that. Shouldn't be an issue or visible.

[Linked Image]


Almost patched in:

[Linked Image]



And finished: Luckily the other side of the door shell wasn't rusted too badly. I will not need to cut/replace that part, just clean it up and coat with POR-15 before crimping new skin.

[Linked Image]


Maybe I'll work on the skin tonight..



Side note. I talked to my friend who is going to do the painting for me at his shop and he and some of his coworkers recommended that we should sandblast the body to get the rest of the loose paint off. It's nearly impossible to sand it off without going through the primer too, and they feel that this would be a more uniform way to get to bare metal without excessive sanding and the issues that go along with it.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 09th 2017 5:23 pm

Coming along nicely, Jason. Good work!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 11th 2017 5:18 pm

Thanks Wedgy.

I'm still not sure why I'm fixing this 40 door instead of just replacing it.. It's definitely fighting me more than the 60 door that I repaired previously. My patch panel keeps wanting to warp no mater what precautions I take to try to prevent it. I may just get the welding finished and try to shrink the metal where I can to get it close and Bondo it straight.

[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2017 1:38 pm

Last night I got the welding and crimp done for the "40" door. There is still some hammer and dolly work that will need done on the front around the weld seam and maybe some shrinking to get rid of some of the warpage, but a majority of the hard work is done. Also painted the inside of the door skin as well as the door shell with 2k Epoxy primer to seal up the crimp area. There are a few bare spots on the inside as well as the inside of the welds that I will paint with POR15 to seal them.

[Linked Image]
[Linked Image]
[Linked Image]



I also popped the crimp back loose on the "60" door and sprayed the 2k Epoxy primer down in that crimp as well (as recommended that the etch primer previously applied wouldn't be as good). Also fixed a couple of surface bubbles and painted the whole door bottom with Epoxy Primer. The inside of the lower door shell and the inside of the welds will be liberally coated in POR15.

[Linked Image]
[Linked Image]


I also have some seam sealer work to do on both doors.

I am very thankful that the front doors and back doors are in good shape! This is tedious work.
Posted By: relaxedvanner

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2017 5:20 pm

Great work on the van.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2017 6:00 pm

Hey Tuner Ive got a door for you to do with your EXCELLENT CRAFTSMANSHIP !
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2017 6:46 pm

Thanks Friske! Although if I was in your area I'm sure I could find some non-rusty doors!
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2017 8:28 pm

Whats the fun in that ...lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 13th 2017 1:29 pm

Spent a couple of hours last night grinding welds (had to redo some of them as I ground through), hammer/dollying, and shrinking metal on this "40" door to minimize warpage from the welding. Finally got it to a reasonable point and spread the first layer of filler before calling it a night. I'll block sand it tonight and see where I stand. I should be just about done with the metalwork now. Now comes an eternity of sanding.



[Linked Image]
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 19th 2017 2:17 pm

Damn Jason, your fabrication/welding skills are great! Awesome job! cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2017 1:47 pm

Had some other projects get in the way temporarily, but back to working on the van! I've determined that while I'm fair at welding and drilling holes, I am absolutely horrible at true body work (filler). Spent way too much time over this past weekend trying to get the barn doors and front fender straight and got marginal results. My painter is amazing at paint, but he admittedly doesn't really do body work either. So I will concede defeat and am in the process of lining up a body guy to take this from where it is to being ready to paint.. I had a guy a couple of years ago but lost contact. Unfortunately many that I've found recently that are good are also flaky and unreliable. I think I've got a decent one lined up now however. Hopefully!

Before that however, I needed to finish up a few other projects like any holes that will be drilled for accessories/body parts, seam sealer, etc..

Here's the list of things I need to do before I turn it over to an actual body guy..

-Drill holes for visor (actually did this last night)
-Figure out Nor-Cal Wing mounting (see issues below)
-Sand, epoxy prime rain gutters, then seam seal (3M 8307 self leveling), then epoxy prime over the seam sealer. Sand/epoxy prime bare windshield frame in the process.
-Seam sealer in a couple other spots and inside of lower barn doors where the new crimps are
-POR15 the inside of weld repair areas on fenders, extra fuel door, barn doors, etc..



Last night's work ended when I started working on the mounting of the Nor-Cal Wing. I'll probably need to call Kirk at Customvan.com to see what he recommends but I'll see if anyone here has any ideas too.. He mentioned some tips when I first ordered it, but I forget what all they were.. The issue that I'm having is that the spoiler comes down just a little too far at the sides and hits the gutter well before the mounting face sits on the roof. The driver's side is decent, but the passenger side is much worse. The wing actually sticks out over the side of the gutter by a little bit on this side. One of the things that I do remember Kirk saying is that I will probably need to apply some downward force to the wing for it to sit flat down on he roof. I tried this some and the small cracks at the corners seemed to open up a little which isn't good. So at this point the spoiler won't sit down flat on the roof surface which concerns me about water entry between the rather large gap between the wing and roof surface. If it sit flat down on the roof, I could use some good sealer around the mounting bolts, but the gap is too great now. I think the best approach at this point would be to remove some material at the lower side edges because I believe that if doesn't contact the gutter, it would sit flatter on the roof (or maybe from the outside surface so that it sits down in the gutter?). I just hope that there is enough material to be able to do this. I'll work on it more this weekend.


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2017 1:59 pm

Jason, something is not right, have no idea how you would take that much gap away. I would defiantly talk to Kirk before you start modifying this one. Hopefully somebody will chime in with a simple solution. Are you in the Autofest show next month?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2017 2:29 pm

I'm definitely going to call him after work today and before I mess with it at all. Considering that this is already the 2nd spoiler that was sent. I really hope that I'll be able to use it.

Not in the show this year. Going to lay low with the racing this year and work on a couple other projects (Van, old Saab, daily drivers).. Race car will hopefully be getting a bunch of work next winter in hopes to be able to keep up with more competitive cars. Is your van in the show?
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2017 6:19 pm

Yep I am registered for the show but just like you have other projects going and need to get back on the van to finish changes made before the show. Unfortunately I always start another project before I finish one! Aaaah. One of these days I will get back to posting pics of changes on vanning.com.
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 25th 2017 1:52 am

That sorta looks like a wing for a Ford.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 27th 2017 1:04 pm

While I don't have a ford to compare to, I can say that it fits my Chevy very well as far as the curve of the roof, the width, and even the recesses for the roof ribs are in the exact right spot. The only issue is that the sides come down too far and hit the gutter thus not letting the rest of the wing sit flat down on the roof.

I called Kirk on Thursday and sent him some pictures. Evidently he doesn't make these spoilers himself, but has them made through someone else. He was going to check with them and get back with me. I haven't heard anything yet. I would just cut the ends down myself, but neither myself or Kirk believes there is enough material to be able to remove it without causing bigger issues. I'll bump him about it again later this week if I don't hear anything.


On a more positive note, I feel optimistic about the prospective body guy that came and looked at it over the weekend. He is an acquaintance of my friend who will be doing the painting. He seemed confident that he could take care of the repair areas and get them to the primer stage without too much issue and gave me a reasonable quote to do so. I'm hoping to get it all ready for him in the next few weeks.


Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 16th 2017 12:56 pm

Kirk told me that i could just draw the wing down using toggle bolts and lots of sealant and it should be fine. I'm less confident in that method especially with it already being weak in the corners. Luckily, the guy doing the body work also specializes in repairing fiberglass, so it shouldn't be a big deal to modify it to fit properly. Also, I'd prefer not to drill holes in the roof, so I may weld some brackets to the roof that would go along the inner part of the arch and the screws could enter the wing from the inner sides.. Idk. We'll see how it goes.


Moving along to other projects, We got all of the doors and other loose parts sanded, and loose paint chips removed. Only the main body left now this will save us time later and also help the body guy out some. Last night I worked on drilling all of the wire passage holes in the doors and jambs. Every door will have electricity. Whether it's for locks, speakers, lights, whatever. The passages will be there. Wanted to get this done before paint. Also not pictures, but I cut out the large flat areas on the inner doors. I want to maximize storage space and some of that storage space will be inside of the doors. It also makes it easier to apply POR15 to the insides of the welds on the patch panels.


[Linked Image]
[Linked Image]


Just pictures of holes, but lots of measuring went into these lol. Especially the doors that don't have the locations marked.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: apo234

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 17th 2017 7:05 pm

I love the look of that wing very much and have one for my van, but mine has the same problems and I still have never put it on because that is to much work for something that will just crack apart in a couple of years. In fact just sitting on my shelf for like 5 years the cracks are still getting worse.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 27th 2017 1:14 pm

Update! If all goes well (and it's not raining), we'll have the loose paint all sanded off the main body shell by this weekend and the van will be delivered to the body guy. He is also very confident that he can make the wing fit and fix the small stress cracks in the process. I feel much better about him doing it then messing with it myself especially since he specializes in fiberglass for his job. He's also going to take care of any dents, damage, previous bad repairs by yours truly, etc.. I've got just about everything else ready. All of the door seals, weatherstripping, front door window sweeps and tracks, etc.. All arrived over the weekend as well as the pesky little door hinge grommets discussed in this thread here:

https://www.vanning.com/threads/ubbthreads.php/topics/721770/1


I also finished the POR15 application to the inside bottom of all of the doors. This is a 3 step process that I've used before in various applications with great success. Anyways, it took most of the weekend to complete as each step has to be completely rinsed and bone dry before starting the next. There wasn't any significant rust inside of the doors, but there were a few small sport of surface rust just starting. Now, that should be cured indefinitely and any water sitting inside of the doors can easily drain and if it doesn't, it won't cause rust issues at the lower pinch seams.

Pics of a back door, but the fronts, sides, and rears are all done this way.

(still very wet in the first picture)

[Linked Image]
[Linked Image]

Just a couple of small things to tidy up before sending it to the body guy this weekend!
Posted By: CatFish

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - March 27th 2017 8:32 pm

Ahhh...sweet progress.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 03rd 2017 1:18 pm

On it's way to body/paint! I can't post many pictures of it in progress due to where the work is being done, but I'll post plenty when it's done. Letting people who know what they are doing take care of everything and I'm just helping out where I can.


[Linked Image]


We managed to get basically everything sanded except the roof. We'll do that next weekend. All of the patina and failing paint is gone. Sanded down to bare metal in a majority of spots. It's going to be a long journey, but I'm stoked!
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 03rd 2017 4:22 pm

Awesome.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 03rd 2017 4:45 pm

Excellent! What colors for the fresh paint?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 03rd 2017 5:05 pm

It's actually a Kia Color. Corsa Blue. Code 4HO.

One of the prettiest blues I've seen on a car in person.


[Linked Image]






google the color, there are tons of good pictures of it.

Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 03rd 2017 6:50 pm

That's even more awesomer! LOL
Great color!
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 04th 2017 9:50 pm

Nice work man, you've sure come a long way with her...!
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 05th 2017 12:47 am

Nice work. That's a great color
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 05th 2017 12:34 pm

Thanks everyone!


Last night we sprayed primer on the first batch of doors/hood/etc. Going to do a few parts at a time in the evenings a couple times a week. After sanding all the loose paint off, the primer coat will really show where any dings and problem areas are. I was surprised at what all showed up once the primer was on.. Either way. Progress is progress!


First a light coat of etch primer:

[Linked Image]


Thick primer:

[Linked Image]
[Linked Image]

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 1:11 pm

Spent another evening watching someone who actually knows what they are doing work on the barn doors, there is still a small amount of body work that will be needed, but they are already leaps and bounds better than I was able to do. They are now in primer.


[Linked Image]
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 4:44 pm

Seeing this progress is really exciting, and actually has inspired me to finally get started on my van (now that I have a place to put it inside).
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 6:40 pm

I'm glad it's inspiring to someone! It feels like it's just dragging on and on to me.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 6:44 pm

Talkin about draggin on & on my '93 has been in the shop for a full restore for a yr & a half.


WAY TO GO JASON !
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 6:56 pm

Yeah Friske! You are in the same boat! I thought yours was almost done a couple months ago??
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 07th 2017 7:57 pm



Originally Posted by tuner4life
I'm glad it's inspiring to someone! It feels like it's just dragging on and on to me.

That's because you know where the project is, and are not able to drive it while it's down.
My POS Camaro project is kind of like that. Pulled the door panels off, ordered some switches and stuff... then waited two weeks for the parts to get here. The whole time, my 4 year-old son was asking me every day, "Can we ride in the "New Camaro" today? LOL
To me, every so often I see an update with progress on your van, and it makes this whole idea seem like it's actually feasible.
So the van's going inside fairly soon to get a much needed "Spa day" smile

Originally Posted by tuner4life
Yeah Friske! You are in the same boat! I thought yours was almost done a couple months ago??

That's what I was thinking too.
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 08th 2017 12:46 am

Those barn doors are looking pretty damn straight now.

I actually found this forum because of this thread. Google kicked it up when I was looking for info on rebuilding Van front suspensions.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 10th 2017 12:48 pm

Glad to have you Greenstreak!


Didn't do much over the weekend, but did acquire mint condition Old style taillights, and ordered some ebay chrome headlight bezels. Going to try to strip all the paint off so that they are fill chrome. They should be here this week.

Going to go up and put another evening in working with the body guy/painter. Maybe We'll get all the doors in primer? Maybe not.. Who knows beer
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 14th 2017 12:44 pm

Not much to update. Hoping to put in some more work this weekend and get the whole thing in primer. Then the body guy will give it a once over and make it all straight and stuff.

These showed up in the mail yesterday from ebay. They are really pretty nice, and as others have suggested, they are fully chrome under the silver paint, so I'm going to work on removing the paint to let the chrome shine.

[Linked Image]
[Linked Image]
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 14th 2017 6:59 pm

Wow, those do look nice.
Good luck on the de-painting... I hope it's easier than it is hard.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 17th 2017 1:24 pm

Over the weekend, we finished sanding all of the old loose paint off. What a giant pain! Even with 2 people and professional equipment it took more hours than I cared to count, but we finally got done. There are some spots that were still in good shape, but a vast majority of the body went down to bare metal. The scaffold in the pictures came in very handy to do the roof (although my knees aren't as appreciative).

[Linked Image]
[Linked Image]


Then we treated the minor surface rust spots and applied the self leveling seam sealer into the gutters. The 3M 8307 stuff worked great and leveled out wonderfully. There are a few places that I know aren't perfect, but it should get the job done. Also, pro-tip. I bought 3 qty of the seam sealer and it was just barely enough for my mid-length van. Like, I may have applied it just a little thin towards the end.. I would recommend that anyone doing this job buy 4.. Anyways. I'm satisfied with how it turned out

[Linked Image]


Then taped it all up and cleaned any/all dust off:

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


Spraying primer. Again, the scaffolding came in handy. As the painter would finish a section, I would push the whole contraption back another few feet. I couldn't imagine painting the top of this thing without it.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


And in it's current state:

[Linked Image]
[Linked Image]


It's going to the body guy sometime this week to have the front fender and a few other dings/dents fixed, but he asked that we have it in primer before taking it to him so that it wouldn't just be exposed metal. Once we deliver it to him, he should have it for a week or 2 and will be doing the following (I wrote him a list):

-Fix front fender. Grind out my crappy bondo repair and fix it right
-Fix any other dings/dents/etc. from body and doors. Any metal parts.
-He is going to drill and supply specialty mounting parts for the visor and spoiler.
-Modify spoiler to fit and fix any stress cracks (he has a lot of fiberglass experience so I'm confident he'll handle it).
-Check all other fiberglass parts for issues and get them ready.
-Re-prime any repair areas


Once he's done, all we'll have to do is smooth sand the primer and paint it!! It's been a long road so far, but I can, just barely, start to see the light at the end of the tunnel.






Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 17th 2017 3:30 pm

Looks good in primer! A ton of work, and it really shows. Good job Jason and Friends!

My 60 year old Tilesetter knees say, "Dude... Next time you pass by Harbor Freight, pick up a couple pairs of knee pads for yourself and your painter."

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 17th 2017 4:28 pm

Thanks! We had the same thought about the knee pads, but couldn't find any laying around and Harbor freight wasn't open at midnight on Good Friday sleep
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 17th 2017 8:36 pm

Man, that's coming along really well.
I just pulled an old car of mine out from under a tree yesterday, for its 50th birthday... Maybe I'll send her your way. LOL!
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 18th 2017 7:01 pm

Yo Tuner4life, I know I may be a little bit late to the game, but im doing something very similar to my van that you did to yours, in terms of front suspension overhaul. I was originally just going to grind the front crossmember down with it on the van, but am now considering dropping it down and supporting the engine, so I can really get it nice and clean. My question for you is how did you support the engine with the crossmember out? And where did you support it from? Oil pan with a floor jack and a block of wood? And was it difficult to get it down and out, or fairly simple?
I wanna do it right the first time, but I also don't want to make any stupid mistakes.
Thanks man.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 19th 2017 12:38 pm

Originally Posted by Fakieghettobird
Yo Tuner4life, I know I may be a little bit late to the game, but im doing something very similar to my van that you did to yours, in terms of front suspension overhaul. I was originally just going to grind the front crossmember down with it on the van, but am now considering dropping it down and supporting the engine, so I can really get it nice and clean. My question for you is how did you support the engine with the crossmember out? And where did you support it from? Oil pan with a floor jack and a block of wood? And was it difficult to get it down and out, or fairly simple?
I wanna do it right the first time, but I also don't want to make any stupid mistakes.
Thanks man.



Hi there! The engine was supported by a couple of 2x4s and 2 jackstands. Once all the suspension is removed and you are dealing with the bare crossmember, you set a couple of 2x4s (or 1 4x4 if you happen to have one) on your floorjack and lift them up against the lowest part of the oil pan (rearward of the crossmember, the wood should be going side-to-side). It's a good idea to put a couple of rags between the wood and pan. Then unbolt the engine mounts and give the jack a couple pumps to relieve the engine weight from the crossmember and raise the engine an inch or so. be careful not to dent the pan by trying to lift it too far. Then position 2 jackstands under the wood supports and lower the floorjack and remove it. The engine should now be supported by the wood/jackstands and the crossmember will be free to remove. You just need to undo the bolts and any other parts attached to it. I know there are some lines attached to it but don't remember what else. As long as your bolts aren't too rusty, then it should come out no problem. There are 4 bolts that go horizontally through the framerails and 4 or 6 bolts that go vertically into the frame. You will need to have the control arms removed to access the vertical bolts. Overall it's not too hard if the suspension parts are already removed. Definitely worth the time.


EDIT: I used a transmission jack, not a floorjack to remove the crossmember. I'm sure it could be done with a floorjack, but it's very heavy and the transmission jack makes it much easier to control.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 19th 2017 12:48 pm

Also, on that same topic, I had "dwaynedomi" PM me with some questions about the goofy rubber filled LCA shaft on the G20's. He had a Vixen RV with the same front suspension and was looking for some info on the shafts. He initially contacted me a couple months ago, but just the other day he messaged and said that while he had his suspension apart, he modified the crossmember to accept more readily available G30 style Lower control arms which don't have the rubber shafts. I don't have a thread or description to reference, but here is a link to the pictures of his work. It's pretty self explanatory. I hope he's ok with me posting this.

https://goo.gl/photos/xHGf5nzjcti3f2wV6


I have no desire whatsoever to drop my crossmember again, so I'll probably be going the "machined solid shaft" route, but this might be very useful for someone who is planning on removing the crossmember and wants to improve the design some.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 19th 2017 12:53 pm

Dropped the van body off to the body guy last night. Should have it back all straightened out in a couple of weeks and ready to paint. We'll have to make a few more trips to deliver the doors and all the loose parts. It takes about 4 station wagon loads to deliver all the doors, hood, and fiberglass parts.. Don't expect much in the next couple of weeks until I get it back.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 19th 2017 7:30 pm

No guts no glory, ha ! Good you young guys thought about that though. Safety first in the paint booth too, there eh!

Mine got thicker over the years. My grouchy old Leatherneck Marine Boxer Boss, who could make a grown man cry, said, "Those aren't knee pads, they're stilts..."

My final work pair have broad leather pads with felt lining on the bottom. A pair of hard cap knee pads over that. Then 2 hydro sponges on top in each. I had to Duct tape them in because the helpers would snag 'em for grout sponges. That way they could still muscle out one if need be. Gotta back the help, goes a long way. Good timez

Good info on the Chevy LCA, thanks! And keep up the good work Jason, looking good there in the Heartland Sir!

Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 19th 2017 7:52 pm

Originally Posted by tuner4life
We'll have to make a few more trips to deliver the doors and all the loose parts. It takes about 4 station wagon loads to deliver all the doors, hood, and fiberglass parts..


Or 1 trip in a EXT Chevy van ! LOL
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 20th 2017 12:22 pm

Haha! We've been joking that I should have bought a second van to handle restoring the first!
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 24th 2017 6:58 pm

Word on the lower control arms man, those things have been a major PITA while doing this rebuild. The slightly narrower g30 arms are available everywhere for pretty cheap, but GM and any aftermarket supplier discontinued production of the g20 arms who knows how long ago. Got some decently clean ones shipped from a junkyard in San Diego, and I had a guy at the shop I work at press the bushings out, and I got them back with the ears bent, so now I've got to figure out how to bend them back to spec to fit the shaft and new bushings in. Not fun.

Would be nice to just cut out the control arm mounts on the g20 crossmember and weld or rivet in the g30 ones. Would make it a whooooole lot easier. And most likely sturdier.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 25th 2017 12:13 pm

I totally agree. I wish I would have thought about doing this while it was all apart. Since I don't want to pull the cross-member again, I will probably end up having someone make custom solid shafts for the G20 style control arms.


Also. Trying to source a tubular grille. The round bar style. The only ones I can seem to find are the more modern style with the square/rectangular tubes. I really would like to find a round tube grille. I've looked at the options for pickups too. I know that some of them fit the vans too, but still can't find one like I want. Am I stuck trying to find a NOS one from the 70s? Or are there other options available? Where should I be looking?
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 25th 2017 1:01 pm

Maybe you have already inquired but talk to Glory Grilles. I think they started out making grilles for vans.
Posted By: Reese

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 25th 2017 10:08 pm

I found a mid 1980’s Chevy pickup version of a round tube grille on the bay of E. Cost? Thirty bucks. The width at 50" was just about perfect, but the height of 10" just wasn't filling the opening to my satisfaction.

[Linked Image]

Construction is pretty simple. Three 1/4" sections of channel material with holes spaced as needed. A trip to Lowe's netted me some new 1/4" aluminum channel. A little hacksaw work and I soon had three 12" high sections to work with. All I have to do is space the holes further apart and I'll have what I need. Each screw goes into a clip that slides along the length of each tube and the hole in the channel is bigger than the screw diameter for additional "wiggle" room.

[Linked Image]

I took some Chevy Caprice signal lights, rotated them vertically and mounted them to the radiator support. The OEM "quarter turn" lamp sockets fits these perfectly, so I can always change back to stock if I want. When I held my new 12” high version in the opening, there was about a 1/4 inch gap on the top and bottom, which was what I was aiming for.

[Linked Image]

I’m not finished yet, but thought I’d pass along my own low-buck approach to getting the vintage round tube look I wanted.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 25th 2017 10:32 pm

Hey Reese thanks for makin that for me ......lol

What a good job !
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 25th 2017 10:56 pm

I thought he made it for me. LOL

That's cool.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 26th 2017 1:37 am

I was gonna ask you how you got the lower control arm bushings out without bending the ears on the arms actually. The ones I had the shop press out got bent too far for me too feel safe putting them back on, so I found another pair and having them shipped to me in a few days. I think I'm gonna do it myself, just to be sure that I don't have to through this again, lol. Did you burn the lowers out? Or just put a spacer in between the ears to prevent bending and press them out? I've heard a bunch of different methods but all of them kind of conflict each other.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 26th 2017 12:08 pm

Nice grille! Making something neat like that on your own is always more satisfying. I might try to get creative if I can't find anything I like for a reasonable price.


For the control arms, I ended up burning the rubber out and then using a mix of a sawzall and a grinder to notch the metal sleeve so it would come out easier. The arms did bend slightly when putting the new sleeves in, but it was minor and seemed to come back to the correct shape with some prying/hammering and a big vice.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 27th 2017 10:39 pm

Cool. I was going to collapse the bushings by either burning them or drilling the rubber out and then going from there with a sawzall and air chisel.

I don't mean to probe you with questions, lol, but I'm of the school of thought that you "do it right, once", so just want to be sure I'm not going to have to go back into the suspension/steering anytime soon. I ordered a reman PS Pump and Steering Gear, A-1 Cardone, and am kind of reluctant to install them after reading some reviews on the overall "hit and miss-ness" of cardones reman'd stuff. Did you use a cardone unit? Or something else? And how did it work out?

I noticed on the reman gear box I got from Cardone, the input (stub) shaft splines are much more worn then the original box I pulled off the van.
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 1:07 am

Originally Posted by Fakieghettobird
Cool. I was going to collapse the bushings by either burning them or drilling the rubber out and then going from there with a sawzall and air chisel.
I don't mean to probe you with questions, lol, but I'm of the school of thought that you "do it right, once", so just want to be sure I'm not going to have to go back into the suspension/steering anytime soon. I ordered a reman PS Pump and Steering Gear, A-1 Cardone, and am kind of reluctant to install them after reading some reviews on the overall "hit and miss-ness" of cardones reman'd stuff. Did you use a cardone unit? Or something else? And how did it work out?
I noticed on the reman gear box I got from Cardone, the input (stub) shaft splines are much more worn then the original box I pulled off the van.


Unrelated to this application specifically but I can confirm the hit or miss nature of Cardone stuff. I barely trust anything Dorman these days as well.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 1:11 am

Originally Posted by Greenstreak[/quote
Unrelated to this application specifically but I can confirm the hit or miss nature of Cardone stuff. I barely trust anything Dorman these days as well.



I second that !
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 2:54 am

Originally Posted by Greenstreak

Unrelated to this application specifically but I can confirm the hit or miss nature of Cardone stuff. I barely trust anything Dorman these days as well.


Seriously. All I've read are stories of replacing a gearbox 3-4 times to get a decent one. Was it in a gearbox specifically, or just another reman'd part? And is there any other brand that you'd recommend?

Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 3:12 am

https://www.redheadsteeringgears.com/
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 3:23 am

Originally Posted by frscke1


Haha, I was just on their website actually. Can I send them my gearbox and have them rebuild it? Would that be cheaper than just getting into a rebuilt one? Or is sill upwards of 300$?
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 5:04 am

That $300 is probably with your core ... lol
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 1:12 pm

I chanced it with a Cardone steering gear and lucked out. It seems to be working great. Although I did tighten up the "play" adjustment slightly when I first installed it.

I do agree though, it's hard to find good parts anymore. Even from more "reputable" brands. They all seem to be getting the same Chinese garbage anymore.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 3:50 pm

Originally Posted by tuner4life
I chanced it with a Cardone steering gear and lucked out. It seems to be working great. Although I did tighten up the "play" adjustment slightly when I first installed it.
I do agree though, it's hard to find good parts anymore. Even from more "reputable" brands. They all seem to be getting the same Chinese garbage anymore.


Think I'm going to roll the dice with a company called BBB Industries. NAPA used to use cardone gears, but due to massive warranty returns, switched to BBB and supposedly haven't had any issues since.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - April 28th 2017 6:38 pm

Originally Posted by Fakieghettobird
Originally Posted by tuner4life
I chanced it with a Cardone steering gear and lucked out. It seems to be working great. Although I did tighten up the "play" adjustment slightly when I first installed it.
I do agree though, it's hard to find good parts anymore. Even from more "reputable" brands. They all seem to be getting the same Chinese garbage anymore.

Think I'm going to roll the dice with a company called BBB Industries. NAPA used to use cardone gears, but due to massive warranty returns, switched to BBB and supposedly haven't had any issues since.


Let us know how it goes. Always looking for good brands.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 06th 2017 3:44 am

I hope you don't mind me probing you for more questions, lol. I've run into a little issue. When replacing my upper ball joints with the moog bolt in replacements, I've noticed a small gap between the flange of the balljoint and the control arm. Is this an issue? When you did yours did you have this gap? Here's a few photos.

[Linked Image]

[Linked Image]

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 06th 2017 11:57 am

It looks like your arm got bent a little bit. Probably when removing the old ball joint. As long as you can get all 4 bolts tightened down it should be fine. It's not a pressed fit, so it's just relying on the bolts to hold the ball joint, not the arm itself.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 06th 2017 1:56 pm

Yeah, I was thinking the same thing. Those rivets were not fun. I'll just persuade the arm back into shape, and be done with it. Did you install the boot on the ball joint stud, and then put it through the control arm and bolt it? Or did you put the ball joint through the arm, and the bolt the boot to the underside of the arm?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 08th 2017 12:42 pm

I put the ball joint in from the top and the boot on from the bottom. I don't think the boots will fit through the hole correctly.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 10th 2017 10:49 pm

Originally Posted by tuner4life
I put the ball joint in from the top and the boot on from the bottom. I don't think the boots will fit through the hole correctly.


For sure. That was my plan too. Just wanted to double check. Also, I'm pretty sure these vans didn't come with coil spring insulators/isolators, but not 100% positive. Do you know if they did?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 11th 2017 12:29 pm

Mine didn't have any isolators or anything on the springs.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 15th 2017 11:23 pm

Cool man, appreciate the experience you've shared. If all the parts arrive on time, I should have it off jackstands in a little under two weeks. I'll post some photos if you're interested
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 16th 2017 12:29 pm

Originally Posted by Fakieghettobird
Cool man, appreciate the experience you've shared. If all the parts arrive on time, I should have it off jackstands in a little under two weeks. I'll post some photos if you're interested



Definitely post some pictures! The more info out there the better. You should start a build thread to document what all you are doing.
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 25th 2017 3:55 pm

What was your method for installing the new LCA bushings? I was gonna start the bushing in the second hole with an impact, and then maybe use a shop press, but it'd be nice to hear from you how you got it to work. Thanks man!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - May 26th 2017 12:36 pm

It's hard to get those in without bending the arms. I don't remember the exact method I used, but there was a shop press involved and numerous variations of shims/spacers/etc to keep the arm in shape while pushing the bushing in. It also helps to put the bushing in the freezer for a day before you try to install it. It'll make it shrink ever so slightly and will make it easier to push in.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 06th 2017 7:15 pm

Looking good Jason, keep up the great work! Stop by for a beer sometime!
Posted By: Fakieghettobird

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 07th 2017 12:01 am

I was testing out the pitman arm travel before I tightened it down on the gear and noticed that the pitman arm hits the frame about 10 degrees before it hits the internal stop in the steering gear. At a loss as to what it could be, because I'm certain that the steering box, and intermediate shaft are aligned properly, and that the pitman arm is also aligned properly. I'm also using a Moog K6220 Pitman Arm, so I know it's good. Could it be that the steering is limited by external stops, like the knuckle hitting the control arm? Did you notice this problem? I don't have the rest of the suspension or steering hooked up yet, so I haven't tested it all together yet
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - June 07th 2017 11:35 am

Originally Posted by Bikertrash00
Looking good Jason, keep up the great work! Stop by for a beer sometime!


Thanks! I will hit you up in a week or so. Personal goal this summer is to not be a hermit and actually have a social life. We'll see how that goes.


Originally Posted by Fakieghettobird
I was testing out the pitman arm travel before I tightened it down on the gear and noticed that the pitman arm hits the frame about 10 degrees before it hits the internal stop in the steering gear. At a loss as to what it could be, because I'm certain that the steering box, and intermediate shaft are aligned properly, and that the pitman arm is also aligned properly. I'm also using a Moog K6220 Pitman Arm, so I know it's good. Could it be that the steering is limited by external stops, like the knuckle hitting the control arm? Did you notice this problem? I don't have the rest of the suspension or steering hooked up yet, so I haven't tested it all together yet


My van has been at the body shop for a month or so now, so I would need to refresh my memory, but I believe there are stops where the knuckle contacts the lower control arm.. Don't quote me on that though.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 06th 2017 12:28 pm

Progress!! Still having some delays with the guy doing the body work, but we do have almost all of the loose parts back. Just waiting on the main body and the roof wing to be completed. (hoping to have them back in another couple of weeks, we'll see...)

Since we have all of the doors back, the painter wanted to go ahead and spray the insides of the doors so that part was done and then we would hang them to paint the outside. Plus we were itching to finally spray the color! I am stoked!!!

I only have some low quality cell phone pics for now..


[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 06th 2017 5:05 pm

OH!

MY!

GOD!

That's incredible!
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 06th 2017 9:26 pm

Yep, that's a great looking color.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 08th 2017 1:21 am

Jason,

Just Wow.
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 08th 2017 3:53 am

Wow man. That's nice.
Posted By: Bikertrash00

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 09th 2017 1:19 pm

Good looking color Jason! That van is going to be BadAss!
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 09th 2017 5:15 pm

Dude that's coming along great...! Good for you...!

How did you resolve the NorCal fitment issues...?
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 09th 2017 9:39 pm

Hell yeah! Great color choice. I can't wait to see this project all reassembled.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 10th 2017 1:10 pm

Thanks for the compliments everyone.



Originally Posted by Keep_On_Truckin_WNY
Dude that's coming along great...! Good for you...!
How did you resolve the NorCal fitment issues...?


I haven't seen that part in person yet, but the body guy seemed to think that it wouldn't be a big issue to take care of with some fiberglass work. I'm actually going up to his shop tonight to inspect the progress. Hopefully I'll know more then.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 11th 2017 12:16 pm

Went to look at the van last night and I am stoked at how good it looks. despite taking longer than originally planned (he ended up in the hospital for a while), he is making sure that every inch is straight and done right. Even to the point of grinding away all of my previous filler repairs back down to metal to be sure that there wouldn't be any issues with them popping out later and to make the panels straighter before using filler to reduce the filler depth. I am really happy with what he has done. There are panels that I thought were perfectly straight that are straighter now.

Here is that troublesome front fender after he removed my sketchy repair, straightened the metal and refinished it.

[Linked Image]


The only thing he has left to do is one small area on the drivers door and finish the spoiler. We have come up with a way to mount it without drilling holes in the roof and without having to grind away too much of the fiberglass on the wing. He's also going to repair and reinforce those pesky cracks in the corners. Finally seeing the light at the end of the tunnel and I'm excited about it.
Posted By: Rusty_Pancelode

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 11th 2017 5:35 pm

That fender looks great!
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - July 11th 2017 9:33 pm

Looking great man...!
Posted By: Vanereal_Disease

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 07th 2017 4:05 pm

How's this coming along.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2017 1:53 pm

It's getting there. As has been my experience any time I've gotten body work done, those guys kind of work at their own pace and there's no sense trying to rush them. I did go see it in person recently and what is done looks very good so far. I am happy with the quality of the work and I know that the body guy has had some of his own setbacks along the way, so I'm trying not to get too worked up over the long timeline. Plus I have several other projects that I'm trying to finish at home so even if I had it back right now it would be a little while before I could mess with it. At this point I'm happy to have the open shop space at home and until I finish a couple of other things in that space I'm not complaining.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - August 08th 2017 3:06 pm

All good things in time. Stay safe working Jason. Getting closer!
Posted By: semihippie

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 18th 2017 10:43 pm

Any closer? I can't wait to see that paint.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - November 20th 2017 3:22 pm

Ran into a few scheduling issues, but we should be doing the paint over Christmas break. The body is completely done and ready to go with the exception of the spoiler mounting brackets I'm working on.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 2:16 pm

Finally making some serious progress on thing thing. Got almost everything painted over Christmas break, just a couple pieces left. I won't bore you with too many details, but the paint code is 2012 Kia Corsa blue over a metallic black base boat. The remaining pieces will be finished and the whole thing will get set sanded and buffed later this week. I am beyond excited to finally see this thing in color. It's been a long time coming.

Large picture dump in no particular order:


[Linked Image]
[Linked Image]


Did the roof first separate from the rest of the body:

[Linked Image]
[Linked Image]


Also did the cowl cover and piece behind the front bumper:

[Linked Image]


Money shot of the color:

[Linked Image]


Roof covered, all taped up. Last picture in primer!

[Linked Image]


Spraying the metallic black base coat (My friend who made all this possible, not me):

[Linked Image]


Base coat: (there was actually 1 more layer of base after this one)

[Linked Image]


And with the clearcoat!!

[Linked Image]


My camera had a hard time getting this color right especially in the booth where all the light is fluorescent. In person it is absolutely stunning. I can't wait to get it home and start putting it all together.

Special shout-out to Friske1 for sending me a set of good door strikers in a rush so that we can get the doors hung and adjusted!
Posted By: Lettercraft

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 2:32 pm

Looks Great Tuner.

I went back to page 1 on this thread.
WOW, you are a dedicated van man.


Thanks,
Mike
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 3:06 pm

Looks great! Love that color. I too would be anxious to start reassembly. Get it ready for the Nats.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 3:15 pm

Originally Posted by 1959
Looks great! Love that color. I too would be anxious to start reassembly. Get it ready for the Nats.


The Nats are only an hour away from me this year. I wouldn't miss it for the world!
Posted By: Gladiator

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 3:21 pm

Looks killer, color is definitely better suited on the van than any 2012 Kia.
Posted By: Uncle_Fester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 7:25 pm

That looks KILLER man !
Posted By: RockinRoger

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 02nd 2018 9:20 pm

nice job looks good .
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 03rd 2018 12:07 am

Love that color!
Posted By: Infopro

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 03rd 2018 3:11 am

Really a nice blue.
Posted By: oldskool73

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 03rd 2018 4:18 am

Great color.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 03rd 2018 1:10 pm

Thanks guys! We were back at the shop last night and started doing the wet sand and buff. Got most of the driver's side done. The pictures still aren't great because of the lighting, but I am so happy with it!

I also finished un-masking while the real pro was buffing (I am mostly just moral support at this point in the process lol). Seeing it un-masked just reminds me how much more work is still needed on the interior and engine bay to make it presentable.

More pictures in no particular order.

[Linked Image]

[Linked Image]

Cool shot (roof is just dusty)
[Linked Image]

Artist at work:
[Linked Image]

[Linked Image]

[Linked Image]
Posted By: oldskool73

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 04th 2018 2:12 am

Jealous.
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 04th 2018 2:33 am

Beautiful color choice. I can't wait to see this thing assembled and out in the sun.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 04th 2018 5:31 pm

Forecast. Shiny!
Posted By: Grey20

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 05th 2018 8:08 am

This is going to be a nice towing rig !!
Posted By: lukester

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 06th 2018 4:18 am

Way cool man.
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 08th 2018 9:48 pm

Tuner you are doing such a good job on this van ! !


Wedgy says I was near you this last 2 weeks in Levelland Tx ... your just up the road a few hundred miles.

Next time Im comin by to visit !
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 09th 2018 1:08 pm

Come on by! Although TX is nowhere close to anywhere in Indiana lol. Plus I'm at the very top of the state. 30 min from MI.

The Nats are only an hour away from me this year. You coming?
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 09th 2018 8:08 pm

Just got word that the van body will be coming home tonight! There is still a good amount of buffing that needs to be done, but the space needs to be freed up at the paint shop. The buffing will be finished at home and I can start on everything else!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2018 2:18 pm

Loaded up the body on Tuesday and brought it home. Thankfully the roads were clear and it wasn't raining. Probably the nicest evening this week..

Not pretty in the picture. The whole thing is sanded to 3000 grit, but not cleaned off or buffed in the picture.

[Linked Image]



Now that it is home, my painter is going to finish the buffing in my shop. I am happy to have it back home because I can now start on some of the rest of the project. The first thing I am going to do is the Dashboard and everything behind it. Going to do all preventative maintenance and everything I don't want to deal with again later. Here's the to-do list:

-Heater core
-A/C evaporator (and the rest of the A/C system revamp)
-Wiper motor since it's such a pain to get to
-Replace all Vacuum lines and HVAC controls
-Maybe custom gauges or at least add wiring for them
-Completely redo the dashboard and panels custom
-New speakers
-Add all wiring for stereo, switch panels, power options, security, etc..
-Route wire passages @ A-pillars to roof


Anyways, Last night I got the dash out and brought it inside the house. It was super easy. Radio is already MIA so nothing to do there. Remove console and doghouse, remove a handful of screws at the top, a handful of screws and bolts at the bottom, remove cluster panel and cluster itself, unplug or remove headlight switch, unbolt HVAC control and push back inside dash, loosen 2 nuts holding the column, then ta-da, comes right out.

I guess now's the time to learn how to do Upholstery!

[Linked Image]

I'm more excited about this. Now I can plan how to wire up all the gadgets I've been saving.

[Linked Image]





Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 12th 2018 5:26 pm

Enjoying the bold build! Good job Jason, and Friends. Love your drivetrain. Going to be a unique and beautiful Van. Work safe and enjoy the ride.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 15th 2018 1:34 pm

Thanks Wedgy!

While I wait for the rest of the paint/buffing to be done, I started working on some ideas for the interior. Where I work, I can get marine grade upholstery vinyl at cost so i bought a yard to play around with. If these parts turn out well, we may work on some larger ones. Anything to complicated for my wife and myself to tackle may have to be handed off to an upholstery shop. We'll see. Anyways the first piece we did was from the pillar trim set that I scored from a Bellevue in the junkyard. I got the A-pillar trims, the piece across the top of the windshield, as well as the passenger B-pillar trim and the part over the side barn doors. This is the piece over the side barn doors. I think it turned out acceptable.

We used Weldwood brush on contact cement per some recommendations online, and while it seem to have worked well, it does take quite a long to set-up before you can put the pieces together. I am probably going to pick up a couple cans of 3M Hi-Strength 90 spray adhesive because I have had good experiences with it and it sets-up much faster.

Here is the first completed piece:

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


I also need to start working on ideas for the overhead console..
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 16th 2018 2:48 am

Interesting. I was thinking of prepping and painting all of those trim panels but they look damn good wrapped.
Posted By: oldskool73

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 16th 2018 6:06 am

Looks great so far.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 16th 2018 1:44 pm

Thanks!

They do look good wrapped, but wrapping them takes absolutely forever and is very tedious! I managed to get 1 more piece done last night, the passenger side "B-pillar" cover. It looks ok, but there are a couple flaws in the tight corners. I think I could have done better but I am not redoing it at this point. Each piece has taken over 3 hours to complete. I'm sure I could do them faster as I improve, but for now anyways, it's very time consuming.

I forgot to take pics of the second piece.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 1:57 pm

Started mocking up the overhead console last night. Probably going to build it out of MDF and then pad and wrap it in leather, but just working on the basic shape for now. It's going to house a CB radio, some switches and possible some gauges and speakers. May also utilize the space to hide some electronic modules/wiring.

[Linked Image]
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 2:53 pm

Looking good Jason, very nice work on the upholstered trim panels!

On your overhead console, I'm not tall, but I notice my seating positions in the Vans, leaves little headroom.

Campervan is very close, but I can wear a hat and lower the seat. Lol. Even in the Chevy, I have to lean forward to see the hanging stoplights. No Visor, for sure. Ha!

You may not be old enough to remember, but check your "Max Headroom!"

"Better too much, than not enough."
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 3:09 pm

Looking good, nice work on the upholstered trim panels. On your overhead console, I'm not tall, but I notice my seating positions in the Vans, leaves little headroom.

Campervan is very close, but I can wear a hat and lower the seat. Lol. Even in the Chevy, I have to lean forward to see the hanging stoplights. No Visor, for sure. Ha!

You may not be old enough to remember, but check your "Max Headroom!"

Better too much, than not enough
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 4:22 pm

Thanks Wedgy! I am a nice and short 5' 8" and I don't wear hats so I do have an advantage in the headroom department.

I am slightly concerned about impacting my head in an accident so I will probably reduce the front to back depth a bit. I have a Cobra CB radio that I want to mount in the center and I don't want it to stick out, so it is going to come out at least that far,but no more. As for the height, my very high tech cardboard mock-up is perfectly level with the top edge of the windshield which seems to be about the standard height. We'll see how it turns out I suppose.
Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 4:58 pm

That interior is going to be so custom, great thing about doing it yourself! "Make it so, Number 1!"

My B250 O head console has a center pod for the radio that drops down a bit in the middle. The design is similar to what you describe, which leaves additional driver/passenger room overhead.
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 5:23 pm

I too would be concerned with a too tall console. I had one in my Suburban years ago and took it out cuz it was just too low. I'm sure you will make it great and then the rest of us will have to copy your design.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 17th 2018 6:19 pm

Haha Thanks! I'll try to remember to trace all the parts so they can be re-created.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 18th 2018 1:09 pm

I had my wife take a look and give her thoughts on the overhead console, and she agrees that the height is fine, but it does stick too far back. I've got a few ideas and am going to get some MDF over the weekend and try some things out. I am excited about this thing more than I should be.

Here is the wife modeling the head -> cardboard clearance:

[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 19th 2018 3:35 pm

I think I found a solution for a scratch built headliner and wall paneling. FRP (fiber reinforced paneling). This stuff is used for shower walls and is all plastic so it should be immune to moisture and humidity unlike wood. It is textured on one side, but very smooth on the other. Should be able to easily attach whatever material I want to this stuff. It is also fairly lightweight and also flexible so it should make the headliner arch no problem, but it's not so flexible where I think it would flap around between mounting points, if it does, it should be easy enough to attach some supports to firm it all up.. We'll see I guess. Looks promising anyways.

It's sold at Lowes in 4x8 sheets for $25.

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 22nd 2018 1:36 pm

MDF acquired. I'm going to start the construction of the over head console tonight.

Here is the rough mock up in cardboard of what I'm going with.. The CB will fit in the middle panel. and on the driver's and passenger side, the console will lean away slightly so the panel is angled down. Then at the outside edges, there will be pods for some 6'5" speakers. The upper edge of the console will be straight across.

The main construction will be MDF, but there will be some fiberglass work to tie in the odd shaped areas.

[Linked Image]
[Linked Image]

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 23rd 2018 1:18 pm

Last night I got the main bottom board of the overhead console cut out. I should have gotten much more than that accomplished, but I spent quite a bit of time being confused as to why the center line of my board was not matching up with the center roof rib of the van. After a bunch of measuring and confusion, I figured out that quality control in the 1980s wasn't really a thing, and the center rib was actually about 3/8" off center. Once I redid my measurements and redrew my center line, everything fit much better.

Here is the revised center line on the roof:

[Linked Image]


And here is the main board for the console. The ends will probably end up getting cut completely off when I build the speaker pods, but I'm not sure yet. I'm waiting for the speakers, MDF rings, and some cheap speaker pods I found online to show up. Going to play around with a few things and see what works best. Tonight, the plan is to get the hinges mounted and hang the main board so I can work on the rest of the mounting and front panels.

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 24th 2018 1:39 pm

I work slow. Much slower than I would like to..

That being said, I got the hinge system mounted for the overhead console. I used 1/4-20 T-nuts pressed into the wood instead of just wood screws. I did make a small error on the leading edge of the console. It sticks slightly forward of the hinges so when you hinge it down, the front edge does hit the edge of the windshield frame and I'm positive that it will contact the windshield, or at least the seal once the glass is installed. I am going to trim the front edge up tonight which should solve the issue.

[Linked Image]
[Linked Image]
[Linked Image]



I held the back edge up temporarily with bungee cords and test fit the CB radio. It will fit just fine. I also started looking at how I want to mount the 6.5" speakers on the outer edges of the overhead console. It will be tight, but I think they will fit with a little persuasion. These are the Marine speakers that I'm going to mount in the side and back doors that I'm using for a test fit.

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: frscke1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 24th 2018 4:21 pm

I love using those cleats (nuts in the wood) .... makes the job cleaner than just using screws.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 24th 2018 5:20 pm

Originally Posted by frscke1
I love using those cleats (nuts in the wood) .... makes the job cleaner than just using screws.


Yep! And they won't pull through after taking it on and off several times.
Posted By: cornfarmer

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 24th 2018 10:18 pm

Cool build cheers
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 25th 2018 1:44 pm

Thanks!

Last night I worked on a design for the center mount/latch for the console. Gonna hit up the hardware store after work and grab some parts. Should be interesting.

I did manage to trim the front edge of the console so it will hinge down all the way now. Also cut and mounted the center face panel where the CB will mount. I know it's still a little tall, but I'm going to trim it down once I can make sure the console fits level.

[Linked Image]



Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 26th 2018 2:02 pm

Ok, the original plan for attaching the console was going to be to have screws going up through the bottom into brackets, and a hinge at the leading edge. My wife triggered my full OCD when she mentioned that I should find a way to do it so that there are no screws showing from the bottom. I think I found a solution for this after staring at it for a while last night. The hinge at the front will remain. I'm using T-nuts to attach it which won't be visible from the bottom, so that's good to go. Then I needed a good way to attach the rear edge. I mulled that over for quite a while. While digging through the spare parts/junk box in the shop and found a strip if thick steel with holes in it. this is very rigid and will work excellent for a bracket. I also found a weird steel bracket in my junk box. Not sure what it came from, or would normally be used for, but it's going to work perfect for this project. The Idea is that I am going to make a small glove box compartment on the passenger side. Inside of that compartment, there will be a false wall on the left that will flip down. With that wall flipped down, I'll be able to reach up inside above the CB and take 1 bolt out which will let the console hinge down. There will still obviously need to be attachments at the outer ends as well, but I'll deal with them once I make the speaker pods.

Here is what I've mocked up: the bracket for the CB radio will attach to the bottom with T-nuts as will the 2 feet of the strap bracket. The funky parts-box bracket bolts to the top of that. See the captive nut and cross bolt to attach to an upper bracket that I haven't designed yet.

[Linked Image]
[Linked Image]



I also started making some of the internal walls for the console and ran into another problem. I am using 1/2" MDF for this project instead of the 3/4" that I usually use. i did this because of the weight and since it isn't a subwoofer box, it doesn't need to be quite as thick. The problem with that is the MDF keeps splitting when trying to screw into the end grain, a problem that I don't usually have with the 3/4" stuff. It didn't matter now big I pre-drilled the hole either. It got to the point where the screw was barely biting into the wood before it finally quit splitting and I wasn't comfortable with that. I am using Spax screws and pre-drilling as recommended with no success

Here is the solution I came up with. In the area where the tip of the screw will be after being screwed in, I drill a 1/2" diameter hole through the wood and insert a 1/2" long section of 1/2" wood dowel. I then drill a small hole through the MDF and the dowel. That hole should be the recommended size for the screw to bite into the wood. Then I remove the dowel and run a slightly larger drill bit through the hole. Big enough that the screw barely catches in the MDF at all, and would easily thread in with your fingers. Last I countersink the face for the head of the screw. Once you have all the holes drilled, I put glue on the dowel and put it back in the hole (make sure the holes you drilled all line up). And put glue on the mating surfaces, then I install the panel with the screw. Since the dowel is actual wood and not pressed like MDF, the screw will grab into the dowel tightly and you can then tighten up the screw without risk of splitting the MDF. I still tightened the screws by hand so I didn't over-do it, but I installed 2 of these in each side panel and didn't split anything.

The empty holes are for access to the mounting screws for the CB to the bracket.

[Linked Image]

Posted By: BudVanBeer1

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 29th 2018 12:05 am

Nice work going on here, Tuner! A few pages back you were going to "de-chrome" the headlight bezels. I hadn't seen an update on that. I know the '78 - '82 rectangular bulb chrome bezels were sprayed silver (argent) around the perimeter and that was able to be removed. I thought the "chrome" on the later (stacked headlights) models was a Stainless Steel piece. ...but I've been wrong before! Just curious...
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 29th 2018 1:51 pm

Originally Posted by BudVanBeer1
Nice work going on here, Tuner! A few pages back you were going to "de-chrome" the headlight bezels. I hadn't seen an update on that. I know the '78 - '82 rectangular bulb chrome bezels were sprayed silver (argent) around the perimeter and that was able to be removed. I thought the "chrome" on the later (stacked headlights) models was a Stainless Steel piece. ...but I've been wrong before! Just curious...



I'm definitely keeping the chrome. In fact the plan is to remove the silver paint which should actually expose more of the chrome! The bezels (on my 1985 anyways) are all chrome plated plastic but a majority of the surface area is painted silver over the chrome. Here is what they look like. These are the aftermarket ones from Ebay. I haven't bothered messing with them yet because I have so much other work to do first lol.

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - January 29th 2018 2:15 pm

So I found a solution for the center mounting latch overhead console! Working in the marine industry, I am exposed to a wide variety of random stainless hardware that isn't common in automotive applications.

I found this quick release latch (bottom) which is used to attach a bimini top to a boat. It's quick release, stainless, and pretty strong. It's made by Accon. (Also, in the picture is the neat little stainless lift ring latch that I'm going to be using for the glove box door in the overhead console).

[Linked Image]


And here is a video of how it works now that it is installed.




There is going to be a glove box on the passenger side with a false wall to access the latch. It's not the most convenient thing to get to, but I really didn't want it to be.

Also to note, there are going to be 2 other mounting points on each side out by the edges, those screw heads will be visible, I just didn't want to have the visible screws right in the center. I've got some nice finish hardware for the other mounting points. While the latch is pretty strong, I would not trust it to be the only thing holding up the entire console. The idea here is that if I need to service the wiring or anything in the overhead console for that matter, I can remove the fasteners and be able to support the console with 1 hand while releasing the latch with the other and slowly let it down. That way, I'm not having to try to muscle it in/out potentially without help.

With the console now able to be locked into position, I was able to mock up the side face panels in cardboard. These are obviously going to be a little interesting to shape correctly, especially at the edges where they need to be cut at an angle to match up with the bottom panel as well as at the top where it will meet up with the eventual headliner. I borrowed a router as well as a jigsaw with a tilt-able foot so I can make those angles (which luckily come out to being about 31 degrees). I'm hoping to get those panels formed tonight. I am still waiting on the speaker rings to show up in the next day or so, then I can start working on the speaker mounting pods as well as the switch panels and glove box.

[Linked Image]



Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 02nd 2018 1:52 pm

Well, the entirety of my family was sick earlier this week, so I was stuck in the house, but managed to get back out last night and make some good progress.

First I made some more mounting brackets around the front edge of the console to keep it steady and level while making the face panels:

[Linked Image]

My local hardware store has these nice stainless fasteners that I'll be using. Yes, they will be visible, but they aren't right in the middle of everything, only out on the edges. They won't be an eyesore:

[Linked Image]

Then I made the bracing, made the face panels, and attached everything on the passenger side together. I have a bit more to do to strengthen it up, but I'm pleased with how it looks. I also doodled the speaker location and the rough shape of the glove box door.

[Linked Image]
[Linked Image]

There are a few places in the middle corners that aren't held together very well. I'm going to pick up some wood dowels so I can "pin" some of the pieces together in areas where using a screw isn't ideal.


Lastly, I picked up these neat little light up speaker rings from work (I mentioned earlier that the marine industry gets all the neat little trinkets). Obviously I won't be able to use them while driving, but they should look pretty neat when parked. I tested them out last night. Neato!

[Linked Image]


I'm hoping to make some significant progress this weekend!

Posted By: Wedgy

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 02nd 2018 4:21 pm

Hey now!

Console coming along nicely, looking pretty sharp there. Really enjoying seeing this build.
The "Bar," is going to be pretty high once this Van's on the road. To the Nat's!!!

Kudos to your Painter, whose work will be more appreciated once unveiled. And to Mrs. Tuner for sure, who sure looks like she's lovin every minute of it. Voted best Wife on the Planet, I'm quite sure.

Not sure why I thought ya'll lived in OKC, but it sure did cheer frscke up, so, lol.

Vannin, living, and working up in Indiana in the Marine industry's, not bad duty in the Heartland.

Work safe, Van On!
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 02nd 2018 5:54 pm

Thanks Wedgy! I'm having more fun with this than I usually do with other projects. There's just so much real estate to play with! I'll definitely be at the nats even if I show up without the doors installed yet!

I am super proud of my painter! He is one of my best friends and we've been returning favors for a couple years now, but he has really outdone himself! I feel bad for how much work he's done, but I couldn't be happier with how it's turned out! He is even hoping to be able to come with me to the nats. We'll see how it goes. Also, I'm not trying to keep it "veiled", but it is partially sanded, partially buffed, none of it is assembled. The doors are all buffed and done, but they are leaning up all around the shop. i couldn't get all of it in one picture if I tried lol.

My wife is very understanding, I couldn't ask for better. I have 9 cars, and this isn't the only one that is in the middle of a full restoration. And somehow she hasn't killed me yet! She's pretty awesome really. In fact, just yesterday she let me know that she has scheduled a photo shoot with one of my favorite automotive photographers once the van is done!

This area of the country is crazy. Between the RVs, boats, and manufactured housing, the production level around here is off the charts. We have record high pay for basic factory work just because there are no more people available to work. In Elkhart county, the unemployment is only about 3%. On top of that there is a super low cost of living, property values are low, and there is minimal government regulation on everything. The only real problems are winter/snow/gray sky, and the fact that they salt the bejesus out of everything in the winter. I can only drive the toys for about 8 months of the year. Other than that, I like it here lol.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 05th 2018 2:08 pm

I made a bunch of progress on the overhead console over the weekend! It's completely assembled, braced, mounts are all made and installed, and the body filler is well underway!

Here is it installed in the van and completely fastened after checking all the dimensions, clearances, etc.

[Linked Image]


I wanted to strengthen the top/middle of the console a bit to reduce flex and keep everything solid under the body filler and vinyl. Also wanted to avoid any cracking later on from bouncing along the crappy roads here. First, I added some metal brackets between the center panel and the side face panels. They don't look like much, but they are pretty stout:

[Linked Image]

I also added some of these wood wafer things I found at the hardware store. Evidently they are commonly used in furniture making to help brace up end-grain to end-grain connections. I used my angle grinder and made a nice little notch across both pieces. filled with wood glue and gently tapped the wafers in. They added a surprising amount of rigidity to this area. They were then trimmed flush once the glue dried.

[Linked Image]


I added the outermost mounting points to the body. There are going to be 2 fasteners visible on each side, but they aren't much of an eyesore. and they will easily hold the weight of the console if for some reason the center latch fails.

I may look for some smaller diameter stainless washers in place of the rather large ones I used to mock it up:

[Linked Image]

Mounting brackets and what I had to cut out of pillar trim covers to make everything fit:

[Linked Image]

I also cut the holes in each side panel. The passenger side will have a glove box door wrapped in the same vinyl as the rest of the console. The driver's side is going to have a switch panel. The picture makes them look funny, but they are pretty straight and symmetrical in person. The drivers side hole opening is slightly smaller overall, but I used a 45 deg router bit and the outer edge of the routered area on the left is exactly the same size as the cut out area on the right side. It looks better in person I swear.

[Linked Image]

I also took my 3/4" speaker rings and cut them in half at an angle. They were then attached to the face of the console. They are rotated so that the speakers will aim slightly up (from the 30 deg downward angle of the face panel), and slightly inward. They did hang down below the console just a little bit, so I trimmed up another set of speaker rings and made these neat little pods to make them look more integrated:

[Linked Image]
[Linked Image]

Another picture of the pods as well as the filler pieces and end plates I made to cover around the pillar pods.
[Linked Image]

Once all that was done and the wood glue was dry, I started the body filler. This will be the biggest headache of the whole thing lol. It's not terrible, and I'm not doing anything crazy, just smoothing everything out so it looks good covered in leather vinyl. Here is the first application after light shaping/sanding. I'm hoping to work on it more this week after work.

[Linked Image]
[Linked Image]






Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 05th 2018 2:14 pm

Maybe the first project tonight will be cleaning up the shop and blowing the saw dust off of everything..

[Linked Image]
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 05th 2018 3:42 pm

Man you are killing it. Looks great!
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 06th 2018 12:38 am

Damn man, that overhead is looking great...!!!


Good job on it man, the whole van is coming along nicely...!
Posted By: DadsVan

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 06th 2018 1:12 am

these would sale....fiberglass mold it....sale sale sale......very nicely done
Posted By: Lettercraft

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 06th 2018 11:26 am

With the craftsmanship of your project, there’s no doubt you got everything right.
That’s the cats ass.

Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 06th 2018 1:22 pm

Thanks guys! I want nothing to do with molding fiberglass lol. But it does sound like a neat idea if someone wanted to make a mold if it, My only request would be to give be one of them once they are made.
Posted By: cornfarmer

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 06th 2018 6:49 pm

thumbs up.jpg
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 12th 2018 1:33 pm

the overhead console is 99% done. Just a couple tiny pinholes and screw heads that I need to smooth over. I'm happy with how it's turned out. I am going to wait to vinyl wrap it until after the windshield is installed that way I know if I need to trim any more off the front edge or not. I also need to cut the hole to mount the switch panel above the CB radio. I'm going to be using Carling blue LED switches with custom rocker covers from rockerswitchpros.com. Should be neat.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


Also cut the glove box door. Still working on a hinge and latch solution for that.

[Linked Image]


I've also been planning out the routing of the wire harnesses for all of the stuff I'm adding. For being such a large open vehicle, there is limited space to run wires especially between the engine bay and cabin, as well as between the dash and ceiling. I have a set of A-pillar cover trims from a Bellevue which are nice and cover the ends of the dashboard, as well as have a space behind them that can be used for hiding wires along the pillar. I did need to drill some holes in the ends of the metal dash support for the wires to pass through into the pillars. I drilled 3/4" holes which I should easily be able to find grommets for so the wires don't chafe. I was able to fit 3 holes on the driver's side and 2 on the passenger side. They will be nicely hidden by the pillar cover trims.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


Later in the weekend, it was disgustingly cold and I didn't feel like walking outside to the shop, so I stayed inside and worked on the headlight bezels. I've had them for a while, and finally got around to de-painting them. These are aftermarket bezels from ebay that I got for around $65. They are chrome plated plastic, but the majority of the part is painted silver to match the factory look. However, under the silver paint they are fully chrome plated. I used 100% acetone nail polish remover and paper towels to remove the silver paint and underlying residue. Then I finished cleaning them up with Windex and some old t-shirt rags. They turned out amazing for the small time investment in them.

Right is before, Left is after:

[Linked Image]
[Linked Image]
[Linked Image]

And both completed:

[Linked Image]
[Linked Image]
[Linked Image]


This week will consist of vinyl wrapping more pillar and window trims, POR-15 application in a few spots under the cowl and in the engine bay that I forgot about previously. Also going to start looking at how I want to modify the dash and center console if at all..


Posted By: Lettercraft

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 12th 2018 5:02 pm

Looks Great.

The '76's are not as hard to reach. I hit them with a buffer.

https://www.facebook.com/lettercraft.signs.9/videos/197365134338038/
Posted By: Mike M

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2018 3:59 am

Awesome job on the headlight bezels! I have to go out and stare at my 89 G20 bezels and wonder what's hiding under there!
Posted By: Lionvan

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2018 4:02 am

The ones on my 90 g20 aren't chrome under the paint they are original equipment.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2018 1:22 pm

Original bezels likely won't be fully chromed. These were cheap replacements from ebay



So the next couple weeks will probably just be slow methodical progress. I'll try to accomplish at least 1 small project in the shop each evening and/or upholstery vinyl wrap one more interior trim part. So with that in mind..

Yesterday, I received my switch panel for the Carling rocker switches I plan to use. I don't have the switches yet, but I can fit the panel while I wait for the switches.

Here is the panel I got:

https://www.banggood.com/8pcs-ARB-C...EAQYAiABEgIOFvD_BwE&cur_warehouse=CN

It's a well designed piece that is completely modular. Sections can be added or removed to hold as many/few switches as you want. I bought the 8 switch panel, but ended up only using 6 sections because I didn't want to remove any more material from the console than I already was. This switch panel will hold all of the switches for the mood lighting inside and outside.

[Linked Image]


Then I went inside the house and got to work on one of the A-pillar trim covers. Wrapped it in black marine grade vinyl using 3M super 90 adhesive. Everything went smoothly (although very time consuming), but as you can see, there are always a few spots where the glue seems to need just a little "help" staying put until it dries.

[Linked Image]
[Linked Image]

Hopefully I'll work on the other side tonight.


Posted By: cornfarmer

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 13th 2018 6:46 pm

Looking good.
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 14th 2018 3:28 pm

Nice work man...!

I'm a fan of the Beauville interior trim - A-pillars, B-pillars, side door window trim... I've added some to other vans that didn't come with them, when I've found them of course...
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 14th 2018 4:28 pm

Originally Posted by Keep_On_Truckin_WNY
Nice work man...!

I'm a fan of the Beauville interior trim - A-pillars, B-pillars, side door window trim... I've added some to other vans that didn't come with them, when I've found them of course...


For sure! Makes the interior look so much more finished.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 14th 2018 6:53 pm

Console is nice. Headlamp bezels look great! I did the same thing with the wheel centers on my '95. Why GM put flat silver paint over beautiful chrome is beyond me.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 19th 2018 1:01 pm

Alright everyone. It looks like my photobucket account is on borrowed time. I thought that I may have missed the massive screwing that they gave the internet because I had been paying $2.99/mo for their upgraded storage account, but I received this email from them over the weekend:


Hello Jason ,

This message is to inform you that your Plus20 subscription has been discontinued. You will continue to keep all of your plus benefits until your expiration date. In order to stay current post expiration, we ask that you upgrade to one of our latest plans.

We've been working on some exciting new stuff for 2018, including a new plan which offers additional benefits at a far greater value.

Thank you for your continued business and please do not hesitate reaching out with any questions.
-Sebastian

Have questions? We are happy to help! Email plus@photobucket.com



Needless to say I'm not paying them several hundred dollars a year for picture hosting. I'm pissed and won't post the email that they received in return. They had a good thing going and they got greedy. Looking forward to watching their business implode in the near future. That being said, I would expect that most of my posted pictures will disappear sometime in the next few weeks. My dad is working on setting up a dedicated picture hosting server for himself and I will be hosting all of my stiff from there as well. I have already done a mass download of my entire photobucket account and have it saved, so that is a relief. Unfortunately this isn't an immediate process and it's going to take a few weeks, possibly even months to get up and running correctly. Once it is working I will work on replacing all of my picture links throughout all of my build threads (several cars, several forums). I'm obviously not uploading any more pictures for the time being, but luckily there isn't anything too amazing happening with the van yet. Just slowly getting it all buffed and working on some of the interior upholstery and wiring a little bit at a time. I'll keep the thread updated if anything interesting happens, but no more pictures for a while.

That being said, if anyone wants to follow, I'll probably increase my Instagram activity which can be followed @ team.turner.
Posted By: Dyno_Dave

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 19th 2018 9:47 pm

If you decide not to use the dedicated server, check out Flickr. After struggling with the bucket for years, you WILL NOT BELIEVE how fast and easy Flickr is, and like 100x the free photo storage. It loads so fast compared to the bucket, it won't take you any time at all to move in. "How to" here...

1971-1974DodgeCharger.com
Posted By: cornfarmer

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 20th 2018 6:21 pm

Another alternative is imgur.com.
Posted By: Keep_On_Truckin_WNY

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 22nd 2018 6:49 pm

I’ve been changing my build thread here over to Flickr, and it’s just as easy as photobrokit...

I’ve been slacking here, and I need to post weekly - Astro that runs the site is a good guy and he deserves our support...!
Posted By: 1959

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 22nd 2018 8:39 pm

Allright I gotta chime in. Not trying to complain, just voice an opinion. And tuner4life I am sorry that I am posting on your thread but I think it is appropriate because you seem to be one of the few that post photos. I love your van and admire your vision and determination. I hope to meet you at the Nats this year!

Posting photos on this site is overly difficult.

Why must I first have to set up a hosting account? Why cant I just post photos directly from my files? I have never posted a photo here but I am a member on other auto and non-auto related sites that allow direct photo uploading and have done so many, many times. Part of the requirements of posting thru the common photo host sites is that the images become theirs and I give up all rights to my images. F that. Then they want to charge umpteen dollars to subscribe. F that too. Then they up their fees and if you dont pay, all of your past images get wiped out. F that three.

I take lots of photos both for business and pleasure and I manage them all on my laptop without the need for an outside cloud host. I can post photos on forums, email, text, whatever any quantity I want just about anywhere I want without an issue. Everywhere but here.

I have seen other posters on this forum state that "no one updates here anymore". Me thinks that it might be because there is little traffic and people are posting elsewhere. I get it, forum users want to see pictures hence the "pictures or it didnt happen" response.

I dont have a f-book or insty-g account but lots of folks do and those are the places to go if you want to see and hear about VANS. Maybe not old Chevies or trucks from the 30s but most definitely for VANS.

I dont know if the forum administrators (Astro?) will see this post but if so, why not make it easier to post photos here? I know I would post if I didnt have to go thru a third party site.

Sorry to vent but just my 2%.
Posted By: Greenstreak

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2018 1:06 am

I started following you on IG, Tuner. Username is 0zerohour0



I would bet we can't just attach files because it would increase the cost to host this board. Only a guess.
Posted By: tuner4life

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2018 2:00 pm

1959. I see your point, (and keep in mind that I am not a computer guy at all. I can get around online, but don't understand most of the behind the scenes stuff). But this is not uncommon at all. I am a member on several different forums for the various vehicles and there is only 1 or 2 that have the capability of copy/pasting photos right into threads. While it is a very handy feature, I do imagine that it could cause headaches for the website host because they now have to have the storage space to holds the pictures. And since, up until recently, off-site photo hosting was basically free, it wasn't that big of a deal and was common practice for many years now. While Photobucket seems to have gotten greedy and ruined a good thing for a lot of people, there are many other hosting sites available that are still free. I just don't trust any of them to be free forever and would like to organize all of my pictures onto a personal server/website. I am very lucky as my Dad is very technologically inclined, so he thinks he can get this all set up pretty easily. It's just a personal preference at this point (and probably the OCD talking). But if we can get it set up right, it should be a long term solution.

On top of that, it would seem that forums are slowly going the way of the dinosaur. Instagram and Facebook groups (even the van groups) seem to get 20x the traffic that a forum does. Plus you can upload directly on those platforms. I much prefer a good forum build over everything else and will keep mine updated as long as the forums are still around, but it's hard to stay relevant if you don't keep the attention of those with a tiny attention span. And anymore with the drifting I'm doing, and the upcoming build for the drift car, I basically have to keep the social media accounts active to stay relevant. Potential sponsors don't even give you a second look if you don't have tons of followers online. It's not a perfect system, but it's the way the world is going whether we like it or not.

Anyways, I'm hoping to have it all going in the next few weeks. There really isn't much to see right now anyways. Just more buffing, minor assembly, installing doors etc. I just realized that I grossly underestimated the amount of Lizard skin insulation and sound deadening that I will need, so I need to save up for that now lol.

Hi Greenstreak! Thanks for the follow! Glad to have you!
Posted By: Lettercraft

Re: Tuner4life's Big Ballin, Racecar Haulin, 4 Speed Manual G20 - February 23rd 2018 9:27 pm

I agree,

I posted 8 vids of my grill changeover last Saturday on FB which I opened specifically for my van.

Hope it gets worked out.
Some of you are missing alot of great stuff.

Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 3:23 pm

Well I have been in overdrive since back in February. Between working lots of overtime and spending every extra waking minute not at work or with family working on the van. The last 6 months or so have flown by and I apologize for not keeping this updated. I have not gotten around to getting my new picture hosting solution worked out yet, but since photobucket seems to have realized the error of their ways and re-linked everyone's pictures. I'm still not thrilled about doing it, but I decided to go ahead and upload a large number of pictures so I could go ahead and post an update here before heading to the nats on Thursday.

Here's a massive update to this build!

So. Starting back in maybe February sometime, the van arrived back at home and I immediately started re-assembling the exterior. Picture dump in no particular order:


[Linked Image]
[Linked Image]
[Linked Image]


Windshield going in:

[Linked Image]


Old style seal:

[Linked Image]


Somewhere in the midst of the re-assembly, I changed the water pump and revamped the complete A/C system.

[Linked Image]

This hose has to be custom made as it doesn't exist anywhere to buy

[Linked Image]

Looking good under the hood!

[Linked Image]


More reassembly:

[Linked Image]


Visor on:

[Linked Image]
[Linked Image]
[Linked Image]

The batch of parts that had just come back from powder coat:

[Linked Image]


Terrible picture, but the reflective shine of this paint is insane. I had a hard time getting pictures while inthe shop because all you see if the messy shop, not the van.

[Linked Image]


I found this conversion van NON-POWER bench/bed at the junkyard. I'm going to re-upholstery it and utilize it when i get around to finishing my interior. I wanted the manual version so that I could fit tool boxes and other supplied underneath it. I had been looking for one for a while.

[Linked Image]
[Linked Image]


More parts installed. Mirrors, bumper, etc..

[Linked Image]


Finally sometime in April or so, the weather was not crappy and I was home at the same time, so I pulled the van out into the sun for the first time and was absolutely stunned. My painter did absolutely amazing work on this thing! The pictures don't even do it justice since it's pretty dusty from being in the shop.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


I had back wheels ordered from Wheel Vintiques that were 10" whide versions of the truck Rally wheels I already had. Unfortunately after several delays and finally was told that they weren't available anymore. I was already scrambling to get the van ready for Gridlife Festival - Midwest on June 8th, so I made an impulse buy and got a set of polished Torque Thrust IIs 15x8 and 15x10. They were the only wheels I could find in the exact sizing and backspacing that I wanted without being stupid expensive. This turned out to be one of the best purchases that I've made for the van and I couldn't be happier with them!!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


Fitment is exactly how I wanted it. I thought about going out another 3/4" or so with the fronts, but I am very close to having rubbing issues as-is. This is as good as it's going to be and still be drivable.

[Linked Image]
[Linked Image]


The van now has power locks, mirrors and windows. When converting to power windows there were some issues that I ran into. I have resolved them now. Everything regarding swapping one of these to power windows is detailed in this thread:

https://www.vanning.com/threads/ubbthreads.php/topics/735938/swapping-to-power-windows-1985-g20#Post735938https://www.vanning.com/threads/ubb...ing-to-power-windows-1985-g20#Post735938


Same boring angle inside the shop, but now with even more parts installed.

[Linked Image]

Then we started tackling the interior. I had previously chipped/peeled all of the original vinyl off the parts (huge PITA!!) My wife only has a basic sewing machine, but despite that we were able to make patterns and she sewed some nice seams with blue thread that matched the paint pretty close.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

Reinstalled the dash (console and overhead is not wrapped yet in this picture)

[Linked Image]



Maiden voyage to the gas station! It was midnight in the small town I live in, but I was still stuck there talking to people for 20 minutes. Literally everyone at the station had to come over and check it out lol

[Linked Image]

First wash:

[Linked Image]


Drove it to work and was smiling like a kid the whole time!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

and for nostalgia sake:

[Linked Image]


We have a PDR guy at work who agreed to work on a couple areas that were dinged during re-assembly.
[Linked Image]
[Linked Image]
[Linked Image]



More picture

[Linked Image]


First rain: I was chasing leaks all over.. The windshield guy came out and reset the seal with some sort of sealer at the top which fixed this issue:

[Linked Image]
[Linked Image]

There are still some leaks that I'm chasing, but more on that later.


Gridlife Midwest Festival 2018!! One of my favorite events every year. It's a big racing/concert/parts event. I was not racing this time, so I just brought the van up and camped in it.

[Linked Image]

I also entered it on the car show and much to my surprise I won something! Even with no interior and the grille that hadn't shown up yet. Judges choice! The trophy is pretty cool too and is now mounted on the front bumper!

[Linked Image]
[Linked Image]
[Linked Image]


Later Saturday evening, our whole group was invited to go out on the track and do a parade lap for photography purposes. I wasn't sure they meant the van too, but they insisted. It was freakin awesome! Just driving through the pits, everyone loved it. Even several of the pro drifters that I have idolized for years came up and complimented me on the van!

[Linked Image]
[Linked Image]

The trip to and from Gridlife was a little stressful as the carb had developed an issue where somehow a lever had broken and gotten jambed so that any time I hit the gas, it would close the choke. The solution until I go LS is a manual choke kit and a carb rebuild (it set for 2 years so I figured it was due). All is well now.


After Gridlife was over, my brother and I did a really nice photoshoot around the area. Grille still missing in action, but these turned out amazing!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


The grille arrived!!

[Linked Image]
[Linked Image]


A couple weeks after Gridlife, My brother and I went to a nice little cruise-in / show at my best friend's church. It was super hot, but a nice turnout:

Washing the night before:

[Linked Image]

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

Random pic at the gas station:

[Linked Image]

In early July, I put the van in a small benefit car show in my hometown and was super surprised to meed another vanner who evidently lives in the same town as me! It's a 1978 (I think) original conversion. Cool guy and neat van!

[Linked Image]

I also won "Peoples Choice" at that show and got a plaque!

[Linked Image]

The van still puts in work, it just looks a lot better doing it now.

[Linked Image]

Had a nice sunset! I'm not against murals, but my mural is whatever I park next to and I like it that way.

[Linked Image]


I have still been chasing rain leaks in various areas. The dash was removed again so I could address them.

-Driver's side floor: ended up being the kick panel vent (the manual one with the rod). That whole housing was leaking water in around the seal. Fixed now

-Passenger side floor: HVAC box to firewall. Had to fix various places here. I did seal the box correctly when I reinstalled, but there were several other places. With the help of RTV, Flex Seal, and a couple homemade shields, I believe I have it fixed now

-back door pop out windows: They didn't fit quite right since the doors are originally fixed glass versions. I tweaked the mounting, got new special seals that I'm trying out, and reinstalled and those seem to be better now.

-Back door seal right at the top where the doors meet: Still working on this one. I think it may be due to cheap aftermarket seals.


While the dash was out, i decided to finish up the overhead console and lower console as well. Lots of time in upholstering these parts, but I am stoked on how they are turning out.

Here is the bottom of the overhead console: The woodgrain panel is also going to be used for the table tops on the lower console (explained below) There will also be lighted speaker rings and Infinity Kappa speakers up there.

[Linked Image]
[Linked Image]


A friend had an amazing idea for an interior theme. I am going to do it with luxury in mind but themed Japanese VIP car style (google it if you don't already know). One of the features of those ridiculously posh builds are the custom tray tables. The center console in the van is the perfect place to build a VIP table. This is obviously not finished yet, but you get the idea. The whole interior will be kind of a mix of classic van/muscle and JDM VIP. Should be lots of fun!

Lower console wrapped (the center will be custom panels)

[Linked Image]
[Linked Image]

And the table mock-up: (Not finished yet). The tops will be the same gray wood seen in the overhead console, and the tables will be trimmed out with chrome. The cup holders are also lighted and there will be multiple charging ports hidden as well.

[Linked Image]




So......

I believe that brings us to current.

Things I still need to finish before Nats:

-Reinstall dash, piller trim, overhead console, etc
-Finish table and wire up lights/charging ports
-Transmission oil and differential oil changes
-Pack
-Sleep?

I'll be hustling on these things after work today, and taking all day off tomorrow. We'll be convoy-ing to the Nats on Thursday with Bikertrash00 and a couple others. Can't wait to see everyone there!!


cheers shift








Posted By: 1959

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 3:54 pm

She's a beaut Clark! You did an awesome job. I look forward to seeing you and it later this week.
Posted By: frscke1

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 3:54 pm

OUTSTANDING ! ! ! LOVE THE COLOR ! ! ! Now there is a face to this van .... super job well done ! ! !
Posted By: Gladiator

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 4:08 pm

Awesome update, it looks killer!
Posted By: frscke1

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 4:16 pm

" but I was still stuck there talking to people for 20 minutes. Literally everyone at the station had to come over and check it out lol"

Get used to it ...
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 4:34 pm

Absolutely Beautiful job! Well done Jason. Thanks so much for the in depth update too. Enjoy the Ride!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 4:35 pm

Haha! thanks everyone! My experience is the same lately Friske lol. I plan an extra 15-20 minutes for almost any short trip now.

Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 4:59 pm

Man that sure turned out beautiful. And I love the stitched dash and console covers. You do some wonderful work sir.
Posted By: Bikertrash00

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 24th 2018 8:29 pm

Originally Posted by Dyno_Dave
Man that sure turned out beautiful. And I love the stitched dash and console covers. You do some wonderful work sir.


I had the pleasure of seeing it in person and man it does look great, I agree he is doing a great job! Can't wait till Thursday!!!!beer
Posted By: oldskool73

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 25th 2018 1:48 am

Been enjoying following along. That's a beautiful van. I think I need to get a visor.
Posted By: Rusty_Pancelode

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 25th 2018 3:39 am

Oh my god!
It's beautiful!

Honestly, I must have said that a hundred times looking through those pictures.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 30th 2018 12:44 pm

Thanks guys! The last week has been a whirlwind but I got done with the projects I wanted to and made it to the Nats Thursday morning!


First, Here is a look at the finished VIP table up front:

[Linked Image]
[Linked Image]
[Linked Image]


Here is a picture of the whole setup along with the overhead console all lit up:

[Linked Image]

The rest of the pictures are from the Nats. Bikertrash00's Brown '82 are in some of them as well.

[Linked Image]
[Linked Image]
[Linked Image]

Show field:

[Linked Image]
[Linked Image]
[Linked Image]



Overall I had a great time at the Nats! I met and hung out with so many great people and saw so many awesome vans! I now have so many more ideas for when I start completing my interior. I'm going to take a short break from building the van and work on a few other projects I've been neglecting, but can't wait to keep building this thing!




Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 30th 2018 1:45 pm

Good job Jason!

That Van was cool when you got it. Turning out quite well. Defines Quality Craftsmanship.

Wow...
Posted By: Astrocreep66

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 30th 2018 7:14 pm

Wow...talent. Nice ride..guess I need to break out my George Barris "custom van book "..No B.S looks Great
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 30th 2018 8:38 pm

Nice work.

What do you use for the chrome trim around the edge of that wood tray?
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 30th 2018 9:02 pm

Thanks everyone!

Originally Posted by Dyno_Dave
Nice work.

What do you use for the chrome trim around the edge of that wood tray?


It's Cowles stick on chrome trim in varying thicknesses to match the thickness of the table.
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 01st 2018 2:51 am

Thanks. It's a very good looking result.
Posted By: Uncle_Fester

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 01st 2018 7:00 am

That van is H O T ! and that drink tray. . . . .WOW! You have done a great job on this whole thing, hard to believe it is the same van.....
Posted By: Bikertrash00

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 01st 2018 12:27 pm

Hey what color is that? LOL cheers
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 01st 2018 1:47 pm

Originally Posted by Uncle_Fester
That van is H O T ! and that drink tray. . . . .WOW! You have done a great job on this whole thing, hard to believe it is the same van.....


Thanks!

Originally Posted by Bikertrash00
Hey what color is that? LOL cheers


What you don't remember? Haha!!! I think we got asked a hundred times!


(2012 Kia Corsa Blue for those few that don't already know)
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 20th 2018 1:11 pm

I suppose after sitting for a couple years during the resto, I can't be too upset that the calipers were sticking. It is the 3rd time I'll have replaced them, but the calipers and pads are still under lifetime warranty through Oreilly's so I wasn't out anything besides some paint and brake fluid. They look nicer now anyways.

[Linked Image]


I drive this thing to work any day that there isn't rain in the forecast. It's so fun!

[Linked Image]









Posted By: Rusty_Pancelode

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 21st 2018 1:44 pm

You had me wondering if you were actually going to keep using it.
It looks like something that would be on the trailer rather than pulling one.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 21st 2018 4:06 pm

We're absolutely going to keep using it! (Although we did recently get a 2003 Lexus LX470 for the wife which can also tow the racecar if necessary).

We're going to a drift event on September 8th and will be using the van as tow vehicle and base camp in the pits. Should be a good time.
Posted By: H20Toie

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 21st 2018 9:53 pm

That rig is just beautiful, i have been trying to decide the direction i want to go with my van and figuring out what kind of stripes or graphics, but yours has such a timeless and classy look to it i may have to rethink and go with a single color.
Posted By: Rusty_Pancelode

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 21st 2018 11:27 pm

Originally Posted by tuner4life
We're absolutely going to keep using it! (Although we did recently get a 2003 Lexus LX470 for the wife which can also tow the racecar if necessary).

We're going to a drift event on September 8th and will be using the van as tow vehicle and base camp in the pits. Should be a good time.


Right on!
Posted By: OutlawZ

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 26th 2018 8:27 pm

Van turned out awesome! Took me an hour to get all caught up again but it was worth the read! That Kia color turned out great, may need to try it on my van once i finally get the dang thing home. It was blue to start with so going with this color would blend well with the interior!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 27th 2018 12:35 pm

Right front caliper is starting to hang up again after a longer drive.. This is getting old. I cracked the bleeder but it still did not release which would rule out the hose.. Are O'reilly calipers that crappy? I am lubing everywhere that I'm supposed to and the fluid is clean and fresh. Maybe I'll try some calipers from Napa this time...
Posted By: Greenstreak

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 27th 2018 12:41 pm

Sadly I've had a pretty bad track record with any of the parts stores remanned calipers over the years.
Posted By: Rusty_Pancelode

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 27th 2018 1:30 pm

That seems to be the direction things are going.
I haven't been pleased with any remanufactured part I've bought in the last 10 years or so.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 12:49 pm

OCD strikes again! I pulled the back wheels off as well to check the drums out and turns out they were hanging up a little bit too. Went to bleed some fluid and it was pretty brown/murky. So now it's getting everything replaced. I think sitting for the 2 years during restoration was hard on the brake stuff.

-Calipers again (Napa Eclipse this time, hopefully they will be better) Getting painted Red of course ;)
-New hoses again (All 3, rear was original))
-New rear wheel cylinders
-New rear axle hard lines (found 1 was bent a little from when we were towing it around during the restoration)
-New Master Cylinder (original)

I also checked the front wheel bearings and re torqued them accordingly, also checked the adjusters on the rear shoes and made a couple adjustments.

If it still has issues after today, then I'll be fresh out of ideas..


[Linked Image]

[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 1:03 pm

Also got featured on VanKulture's website. They got my name wrong (Josh is my brother who took the pictures).. I think they are fixing that, but still cool to have the van noticed by what is primarily an import van page!

https://www.vankulture.com/single-post/2018/08/02/Spotlight-Joshs-1985-Chevy-G20-Van
Posted By: Don_F

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 2:32 pm

Originally Posted by tuner4life
OCD strikes again! I pulled the back wheels off as well to check the drums out and turns out they were hanging up a little bit too. Went to bleed some fluid and it was pretty brown/murky. So now it's getting everything replaced. I think sitting for the 2 years during restoration was hard on the brake stuff.


I have a reverse bleeder from Phoenix Systems. I flush the brake system in the van every few years. Its old, but made me a lot of money when I had my shop. It will get air out of systems that a regular power bleeder will not. They have cheapie ones now made for DIY. They will probably do just a good a job and replacing the fluid completely every few years is a good thing.
Posted By: H20Toie

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 4:04 pm

Originally Posted by tuner4life
Also got featured on VanKulture's website. They got my name wrong (Josh is my brother who took the pictures).. I think they are fixing that, but still cool to have the van noticed by what is primarily an import van page!

https://www.vankulture.com/single-post/2018/08/02/Spotlight-Joshs-1985-Chevy-G20-Van


That is beautiful

Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 4:21 pm

Originally Posted by Don_F
Originally Posted by tuner4life
OCD strikes again! I pulled the back wheels off as well to check the drums out and turns out they were hanging up a little bit too. Went to bleed some fluid and it was pretty brown/murky. So now it's getting everything replaced. I think sitting for the 2 years during restoration was hard on the brake stuff.


I have a reverse bleeder from Phoenix Systems. I flush the brake system in the van every few years. Its old, but made me a lot of money when I had my shop. It will get air out of systems that a regular power bleeder will not. They have cheapie ones now made for DIY. They will probably do just a good a job and replacing the fluid completely every few years is a good thing.



I usually flush brake fluid every couple years for good measure. I just use the wife and use the old fashioned method (pump/hold/bleed/again) This was last done about 2 years ago, but I think that the sitting mostly undriven for 2 years in a non climate controlled warehouse caused this issue.. That being said, I'm underwhelmed by the Oreilly caliper that started to stick again after just a week.

Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 28th 2018 4:22 pm

Originally Posted by H20Toie
Originally Posted by tuner4life
Also got featured on VanKulture's website. They got my name wrong (Josh is my brother who took the pictures).. I think they are fixing that, but still cool to have the van noticed by what is primarily an import van page!

https://www.vankulture.com/single-post/2018/08/02/Spotlight-Joshs-1985-Chevy-G20-Van


That is beautiful




Thank you!
Posted By: markdh

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 29th 2018 2:21 am

man what a cool van well done I love that blue
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - August 29th 2018 12:28 pm

Originally Posted by markdh
man what a cool van well done I love that blue


Thank you!


So I got all the brake stuff mentioned above done and installed last night. It does stop much straighter and more confidently again now. I feel like the back brakes are doing more work now and the fronts are less likely to lock up. I did a few aggressive stops from highway speeds and *knocks on wood* everything seems to be working great. Once I got back home and in the shop, I was able to push the van just by leaning against it. So hopefully that means that my sticking caliper issues are solved.

Going to a cruise in tonight at our local church if the rain holds out. Should be a good time. My photog brother will be there so might get some more good pictures of the van!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - September 10th 2018 1:16 pm

Knock on wood the brakes are still working like they should. Evidently 4th time's a charm..


So we took the van to the drift event over the weekend and got some pictures beforehand and on the way. My brother has become quite the good photog lately and I'm lucky he likes practicing on my hoopties.


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: oldskool73

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - September 10th 2018 8:46 pm

Nice pics.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 12th 2019 1:19 pm

[Linked Image]


So I've been working on a thousand other things over the winter, but it's now time to attack the van project with a fury! I need to have it ready for the Gridlife Festival Show Field at the end of May. I just re-arranged the shop to allow maximum space around the van so I can work! Here is what I've got to do:

-Pull dash out and rebuild HVAC box again, It has a minor rain leak, new heater core is now leaking, and A/C has lost most of the freon from last summer (suspect evaporator). Warrantying out the A/C compressor too as the clutch bearing is starting to fail.. I bought the best stuff I could find and am generally disappointed. At least it's all under warranty still.

-Pull transmission and check clutch issues. I suspect it's the throw out bearing making noise, but we'll see. The trans is starting to wine too, but that's gonna have to get taken care of after the show.

-Weld up previous holes in the floor

-Fab new seat bases and any other permanent fixtures

-Bedliner floor front to back

-Dynamat portions of the walls and ceiling that will benefit the most (around speakers and wheel wells, front of roof, etc.)

-Insulate the rest with a combination of sound deadening closed cell foam and Reflectix for thermal insulation

-Build custom wall panels, headliner, door panels, etc. I have a lot of interesting ideas. Not giving too much away at this point in case it doesn't materialize.

-Reupholster different front seats and make the cushions for the rear. The wife is learning auto upholstery so this will be an adventure for sure!

-Run all wiring for the various lights, modules, and equipment that still needs to be installed. (CB, alarm system, stereo system, interior lights, shore-power wiring, on-board charging system, etc..) I plan on utilizing a conduit system with a pull-string to make future wiring easier

-Complete cut/buff/paint correction with ceramic coating.

-Replace side markers (again). the chrome rectangles keep jumping ship frown



I have a bunch of things in mind for this project. I'll detail them all as I go on here as well as social media.
Posted By: 1959

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 12th 2019 3:01 pm

You have an ambitious list and I'm sure you will get it all done. Your van looks great and all this will just make it better!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 13th 2019 12:24 pm

Thanks! Getting a little stressful for sure lol!


Going to try to get the swivel bases out tonight, but need to find a friend to hold my nuts from underneath... the van of course..
Also going to try to get the dash back out tonight as well..

So much room for activities!!

[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 18th 2019 1:22 pm

Alright, after this weekend, I think I am going to change my entire interior layout plan..



I had a little help stripping the rest interior. Seat bases, dash, overhead, etc..

[Linked Image]


My original plan for the interior was going to be to have a fixed driver's base and make that 1 piece with a long side seat base. Basically there would be a rear-facing lounge seat that backs up to the driver seat. This could be the wife's "area" for long trips, cozy with reading lights, cup holders, power hookups for a phone, etc.. Then a rear bench that would be able to slide up and touch the end of the side bench, or slide back against the back doors. Also flip down into a bad. The front pass seat would swivel. This is how I have envisioned the layout since I bought the van. Well over the weekend, I finally started to prepare for the interior build. I threw some subs about where I would put them, put the bed/bench in the "forward" location, and mocked up the seating where it would need to go..

[Linked Image]
[Linked Image]
[Linked Image]


Needless to say, I am disappointed in how it turned out. in my mind the backrest for the side lounge seat would have been further forward. Unfortunately it sits much further back then I imagined and makes that weird triangle between the backrests almost center stage when the side doors are open. I've had a few friends come look and they agree that the idea was good, but it's not really going to work out how I wanted it to..

So I think I have decided to change it up and do what I have seen in so many other vans. I am going to ditch the side seat idea, and build a minibar in that spot instead. The back bench will still be adjustable up against the back doors and flip to a bed, or side forward up against the minibar to allow cargo behind. The front seats would stay the same, although I want to find a way to retain the swivel driver's seat. It was already hard with the stick shift being there, and would have been impossible with the side bench, but I want to angle the front end of the bar enough to allow that seat to swivel.. There will also be a TV mounted to the wall above the mini bar. I think I can fit as large as a 32" there. I may even look into a mechanism that can retract it down into the countertop.. I want to finish it in a similar style to the VIP tables I have already built up front.

With this new idea, I will be able to run a bigger TV, bigger fridge, and probably have more storage. I will lose 1 seat, but that' snot the end of the world. It will still hold 5 people. The TV will be on the opposite wall from where I originally wanted it, but I think I can probably get over that. Maybe I'll just have 2 tvs.. Idk.


I came across this and like the overall design of the bar. I may do something similar to this. Still looking for more ideas.

[Linked Image]

Anyways, so now I am rethinking everything.. Fun fun. coffee
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 22nd 2019 8:54 pm

Like reading a good novel! Your stuff makes me want to rethink mine interior plan, which is just plane naked cedar strip for now.
If you want your front seat to swivel then you'll have a challenge. I have my seats swapped from Monte Carlo and grinded down stoppers to swivel 180 deg instead of 90 deg originally. That was the easy part. The hard part was that the front of the seat was hitting door pillar while turning, so I had to make my seat non adjustable forward/back, but adjustable sideways to clear door pillar. That was the hard part of passenger's seat. The driver's seat had an extra hard part... When turning, back rest of the seat was hitting steering wheel as well. Non adjustable forward/back didn't work this time coz to clear steering wheel it was too far back to reach my pedals:) So I had to weld double seat sliding brackets criss cross for it to be adjustable 4 ways and have the right height to sit. I'll have few pics in my thread in a day or so but first page has pics and info about passenger's seat.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 25th 2019 11:44 am

Thank you! I re-think this project all the time. I've put so much more time into planning the inside than I ever did on the rest.. The hard part is actually getting started lol.

My van had vintage swivels in it when I bought it. I'm going to keep those as they work great. The passenger side isn't a big issue, but since there is a stick shifter next to the driver's seat as well as the steering wheel, it is kind of a process to get it turned around. Move it a little, slide forward, spin it a little more, slide back, swivel a little more, lean the backrest forward... and so in. Worth it if you are parking or camping for an extended time though!

Also to note, I have ditched the idea if using the Saab Aero/Recaro seats I had mentioned before. There was too much wrong with them internally, and they are going to be a huge pain to get re-upholstered.. That, along with the size preventing them from being able to swivel, I have decided to use the leftover seats from my 1991 Toyota Cressida. They are in very good shape, and all power functions tested good the other night. They are a lot simpler design to upholster and should allow enough room to swivel..

[Linked Image]


Also hoping to pick up the supplies for the flooring, mini-bar, and headliner this week!
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 26th 2019 3:16 am

Supplies for mini-bar... hm... I know where I would start on mini-bar:))
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 26th 2019 2:52 pm

Originally Posted by RoboforcerX2000
Supplies for mini-bar... hm... I know where I would start on mini-bar:))


We are probably on the same page.. lol. I'm researching good 12 volt refrigerators. I found this unit on Amazon and I really like it, plus the dimensions are perfect for where I want it to go..

https://www.amazon.com/dp/B07DNNMY5...VAH83&psc=0&ref_=lv_ov_lig_dp_it
Posted By: frscke1

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 26th 2019 3:14 pm

I like that book markin the site.....
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 27th 2019 1:14 am

Me too! I don't like that price but idea is really cool, I'll consider having one.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 27th 2019 12:17 pm

It is a bit more expensive than some of the others I've seen, but supposedly this one is designed more like an actual fridge than a cooler and will get colder and use less power. It also has better than average reviews for what it is and isn't $1000 like an ARB..
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 28th 2019 1:37 pm

My wife has been practicing for the upholstery work and I think we have settled on this design for the seats. We will be using the 1991 Toyota Cressida seats posted previously, and redoing them in this style:

[Linked Image]


This is just a test on scrap material, so do't mind the random colors and marks, but the seats will be black leather overall and the diamonds are going to be a dark Charcoal leather. All visible stitching will be blue as will be the piping around the perimeter. I'm pretty stoked for these!

Planning to work on the HVAC box tonight..
Posted By: roadrunner212

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 28th 2019 5:50 pm

Your wife did a good job! And she is just getting started? wow
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - March 29th 2019 10:14 pm

Those test panels look great!
Posted By: Uncle_Fester

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 6:07 am

You might want to give this article a read, before you decide as it has a ton of great information on 12v refrigerators....

https://www.thewaywardhome.com/12-volt-refrigerator/
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 12:26 pm

That's a good article! ^ I've read through it a couple times now. Lots of good info!



Here's where we sit after this weekend. The HVAC box is out and i'm waiting on the replacement parts to arrive. Warrantying the heater core that started leaking after less than a year, also the Evaporator core while I'm in there. The A/C compressor is also getting replaced because the Clutch bearing has started making noise. Going to replace all the seals while it's apart. On top of that, I'll be wire-wheeling the firewall where the box mounts and completely refinishing that surface and resealing to avoid rain leaks that I was getting before.

What is the best sealant/adhesive/whatever to use between the HVAC box and the firewall to prevent rain leaks?


[Linked Image]




After getting the HVAC out, I started working on the sound deadening. Using Noico Deadener from Amazon. It's pretty good stuff for a fraction of the cost of Dynamat. I have friends that have been using it with good results. Anyways, I got the left wall and right wall behind the barn doors done so far. Going to be doing the roof skin tonight. I am pretty impressed with the results so far. Before when you would knock on the sheet metal walls, it would resonate and echo badly, but after putting this stuff on, that effect is greatly reduced.


[Linked Image]
[Linked Image]
Posted By: roadrunner212

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 7:28 pm

totally non related to HVAC... but what size speedo and tach are you using in your van?
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 8:21 pm

Just stock gauges for now..



[Linked Image]
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 9:23 pm

3M came to mind in answer for your firewall heater box seal. So here's an overview that looks like that which you seek for sealant. Always admire your Family Hauler, Team Turner! Just. Beautiful.
Your business card should say Quality Craftsmanship. Chevrolet should take notice!

http://multimedia.3m.com/mws/media/305437O/tecnologias-de-sellado-3m.PDF?fn=33.PDF
Posted By: 67Econo Guy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 01st 2019 11:12 pm

great pics, van looks bad ass, going to van nats. ???
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 02nd 2019 12:26 pm

Originally Posted by Wedgy
3M came to mind in answer for your firewall heater box seal. So here's an overview that looks like that which you seek for sealant. Always admire your Family Hauler, Team Turner! Just. Beautiful.
Your business card should say Quality Craftsmanship. Chevrolet should take notice!

http://multimedia.3m.com/mws/media/305437O/tecnologias-de-sellado-3m.PDF?fn=33.PDF



Thank you so much Wedgy! I'm just trying make the best improvements I can for the $ and make it more enjoyable to live with. OCD is a blessing and a curse. There are definitely a lot of things that Chevy could have designed different/better, but they never intended it to be a Rolls Royce. It's so bare-bones, it maximizes the effect of anything I do. Part of what makes it so fun!

3M is my go-to for stuff like this and that ducting link is helpful, Might look into the "Sealant 540" further. Seems like the closest thing to what I need. It's just a plastic housing to the metal firewall, but I don't want to be doing this again. It's such a pain.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 02nd 2019 12:27 pm

Originally Posted by 67Econo Guy
great pics, van looks bad ass, going to van nats. ???




Thanks! I wish I was. I went last year and had an absolute blast! Unfortunately it's just not in the cards this year. Maybe next time!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 02nd 2019 4:59 pm

Doing some more research on the topic, I can't find much of any info about sealing a HVAC box to the firewall. It seems that most applications would call for a foam/rubber gasket material like what I linked below. It would be cut to shape.

https://www.ebay.com/itm/Evaporator...1655075?_trksid=p2385738.m4383.l4275.c10


The other thing that seems to be highly recommended is 3M Strip Calk. That seems to be about the best option so far.

Not sure which direction to go, or if I should use both...I absolutely do not want rain leaks lol
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 03rd 2019 11:54 am

Finally got done with the sound deadening and foam. My arms are jello. I used Noico products and am very impressed with the results. There is a HUGE reduction in the resonance, boomyness, and echo effect inside the van. I haven't driven it yet, but just by tapping on the panels from the outside the result is dramatic. The doors also close much quieter

First picture is with the mat only, the second picture is with the foam installed over it.


[Linked Image]
[Linked Image]
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 03rd 2019 1:46 pm

Originally Posted by tuner4life
Finally got done with the sound deadening and foam. My arms are jello.
laugh I'll bet.

Looks nice. Very nice!
Posted By: Vanereal_Disease

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 04th 2019 2:07 pm

Butyl tape might be a good inexpensive fix for the Hvac seal. It’s flexible and won’t dry or crack.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 10th 2019 12:46 pm

Alright, I took my time and over the last few days I pulled the HVAC box out, then I took a wire wheel to the firewall where it mounts and got rid of all the old sealer and crud that had been built up. I repainted the area matte black to match the rest of the bay. Then I went through the HVAC system. I replaced the defective heater core, A/C evaporator, Accumulator, and orifice tube and all related seals. (All under warranty). I also warrantied the compressor because the clutch bearing was making noise. Then I put all the pieces back together and used 3M strip caulk to seal every possible leak area. I also replaced the foam between the heater box and the interior side of the firewall with new closed cell sealing foam. Then for the A/C box on the front side, I used generous amounts of 3M strip caulk and thoroughly sealed the entire assembly together against the firewall. Rain should never leak in that area again!

All apart and the firewall restored:

[Linked Image]


And back together:


[Linked Image]

Heater box partially re-installed:

[Linked Image]





My wife has been working on the upholstery while I've been dealing with the HVAC. She is still working on patterns and pieces so nothing too exciting yet, but she did finish these panels that will be part of the rear bench. I'm getting excited for how this will turn out!


Don't mind the marks, that's just excess marking chalk that needs to be cleaned off:

[Linked Image]

[Linked Image]



I'm trying to work on the headliner now.. I wish I could flip the van over and work on it upside down lol. 4 friends had a hard time holding the 12ft long panel in place to try to get it trimmed correctly!
Posted By: Reed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 10th 2019 3:16 pm

Wow, very nice work! It will look and work great when you get it finished.
Posted By: H20Toie

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 10th 2019 10:13 pm

Wow can't wait to see the outcome
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 11th 2019 1:46 am

Damn, that's some quality upholstery!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 15th 2019 12:38 pm

Worked on the headliner a bunch this weekend.. Got several cool ideas for it which I will detail once it's done and actually works like it's supposed to.. Also got the rear door panels cut and got riv-nuts installed in the doors to mount them. I am going to try to find some shallow compartments with doors that can flush mount in the back doors. Not having much luck yet.

Also, last night it was raining a bit so I rolled it partially outside to see if my heater box refresh/reseal worked.. The good news is that I did not see any leakage from the heater box.. The bad news is that there was still water on the floor. This time I was seeing the water right in the area indicated below:

I checked the windshield seal and that is bone dry, the HVAC box also seems to be sealing up fine. At this point, I suspect the fresh/recirc blend door housing that is mounted into the kick panel.. I'm going to pull that out and reseal it and see if that gets me anywhere.

It's supposed to rain more this week and I fully plan on camping out inside of the van with flashlights until I am confident that there is ZERO water coming inside.. I'm not sure why this is so difficult. Does everyone's Chevy leak this much?? I just want to install my flooring ugh..


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 16th 2019 1:56 pm

I am not sure if the leak was coming from that blend door housing or not, but it was cracked so it was definitely suspect. I decided to just remove it completely. Side note, it will not come out without removing the heater box. I was not doing that again, so since the blend door housing was already cracked, I just finished it off and removed it in pieces. The cavity behind that blend door was filled with wet leaves and junk so I am glad that I was able to clean it out. I then plugged the vacuum line that went to the actuator and made an aluminum block off plate. I made a seal with adhesive-backed closed cell foam and installed it. If it was leaking before, it shouldn't be now!

The only time that this blend door moved to pull air from inside the van was when the controls were set to "MAX AC". The rest of the settings pull fresh air in.. So now it is permanently going to pull fresh air.. No big deal for me. I rarely had to use MAX AC last summer when the van was bare inside. Now with the insulation it should be even better. A fair trade-off if it fixes the leak. That being said it actually didn't rain last night so I didn't get a change to leak test. We'll see how tonight goes.

[Linked Image]



Also, my wife finished up the first cushion late last night! This is the backrest for the rear bench/bed. We are super excited about how it turned out!

[Linked Image]
[Linked Image]
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 16th 2019 3:22 pm

Seats look epic!!!!
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 16th 2019 9:30 pm

Absolutely! yeah
Posted By: H20Toie

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 16th 2019 10:18 pm

Simply stunning
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 17th 2019 12:20 am

That is some serious, professional caliber work right there. Nicely done Mrs. t4l.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 22nd 2019 12:06 pm

Thanks guys!

I spent most of the weekend planning the routing paths for all the wiring and working on the headliner. I don't want to go into too much detail about it until it's done in case it doesn't work out, but I'm super excited about how it's going so far. Stay tuned!


[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 12:28 pm

Last night we got a pretty decent rain, so I polled the van out into the driveway and set inside with an army of flashlights for over 30 minutes and I am pleased to report that there are no rain leaks anywhere! Both front footwell areas were bone dry, the rear door seals pop-out window seals, everything! I may still replace the rear door seal because I don't like the way it sits when the door is closes (gets rolled/pinched a little between the doors at the top), but for now it looks all good!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 1:09 pm

I was going to wait to post about this until I had the project done, but I have over 35 hours in it at this point and I'm getting to excited to keep it to myself!

Starting with a cargo van, there was no headliner. I had a bunch of ideas for what I wanted to do with it, but it eventually came down to this. I am replicating the fiber optic "Starlight Headliner" option that is a $12k option on some Rolls Royce models. Obviously I am not spending this much, but after the amount of time this is taking so far I can see why it is so expensive.

Anyways, I used plastic vapor barrier sheet and strong magnets to stick it to the ceiling ribs, then I trimmed around the perimeter to give me a pattern for the headliner. I wanted to make this 1 piece and as seamless as possible, no ribs or exposed fasteners, so I was lucky enough to have someone in the "know" who was able to get me an oversized piece of FRP plastic sheet to work with. This will allow me to make the entire 12' headliner as 1 piece. It is a little floppier than I would have liked, but it will work fine for the application.

I searched for a couple weeks for a way to attach this to the ceiling that would be strong yet still removable if needed as well as be invisible from the bottom side. What I eventually came up with is a mounting track system for drop ceiling tiles of all things. I found this at Menards. It is designed for low profile, surface mount applications of drop ceiling tiles. part of the rail mounts to the ceiling, and the other part snaps into it to hold the tiles in place. After inspecting this stuff in person, I determined that it will work great. It holds very well, but is still able to be separated if you pry the pieces apart with a screwdriver. It will also drop the headliner panel down about an inch from the ribs allowing space the for fiber optics as well as other wiring

I ended up using some rivets and 3m double sided tape to hold the tracks to the headliner panel, The rivets are shallow enough that they are invisible under the suede headliner material, You can feel them if you know where they are, but completely invisible otherwise. The other half of the tracks are attached to the roof ribs using the shortest tek screws I could find. There are over 40 up there though so they aren't doing anywhere. Plus 3M double sided take on the mounting surfaces.

Here is what the track looks like.

[Linked Image]


And here are the (4) 8 ft long pieces of track mounted to the headliner panel and to the van:

[Linked Image]
[Linked Image]


The perimeter of the headliner panel will be mounted with a combination of industrial strength velcro and some plastic fasteners. It is definitely tedious to install (take 4+ people). But it works, And I'm running wiring for everything I could ever think of installing above the headliner before it gets installed. Ideally I'll never have to remove it.


The next step is to flip it over and install the 1/8" foam backed suede material. I ground the heads of the rivets slightly just to smooth them down a little, and then scuffed the surface of the board with a scotch brite. I used 3M industrial headliner adhesive and stuck the material down:

[Linked Image]
[Linked Image]


Suede finished and trimmed. It was nice to see this part finished. I was tired!

[Linked Image]
[Linked Image]


The next step was to flip the headliner back over (put a few layers of cardboard and plastic underneath to protect the material and the tables below). Then I used a yellow paint marker and marked 800 dots in a random pattern over the visible portions of the headliner. There is no way I would have been able to keep the pattern evenly scattered freehand, so I drew a grid over the area where the fiber optic strands will go. Each square is about 11" square, and there is 13.3 dots in each square. I started with 10 dots in each in random patterns, then filled in the extra 3 in each square where they were looking sparce. I then added the remaining few dots as needed until I had 800 total painted.


[Linked Image]



After that,, I spent another few hours drilling every one of those dots with a 0.75mm drill bit. Yes, it sucked.

Once that was done, I started running the fiber optic strands and poking them into the holes and finishing with a dab of hot glue on each. I pre-trim each strand so that it's closer to the correct length, and then leave a few inches hanging out the bottom just in case they get tugged a little. The strands get trimmed flush with the headliner once installed in the vehicle. I could go on for hours about the techniques and routing, etc.. but I'll space you all that mess. Just know that I am now over 30 hours just into poking the strands through, gluing them in place, and then wrapping/taping them down to keep them somewhat tame for when we install, and I have over 200 still to do. Hoping to have it finished this weekend.

Here are some more pictures:

[Linked Image]
[Linked Image]



And here is a teaser of the lights. This will do white or just about any color, and they twinkle. It's pretty sweet!! This is the top obviously, but once installed you will only see the dots from the inside of the van.


[Linked Image]



Stay tuned.. More to come as this slowly progresses.




Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 1:44 pm

Nice!!! i ordered all my fiber optic engines last month, also go shooting star engines for mine if i ever get there lol i cant wait to see how this turns out!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 2:42 pm

Originally Posted by Juntao_DW
Nice!!! i ordered all my fiber optic engines last month, also go shooting star engines for mine if i ever get there lol i cant wait to see how this turns out!


Awesome! I looked at the shooting star models as well as trying to draw out some constellations.. Forget that, this is complicated enough as-is lmao.
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 3:43 pm

well, i think the vans have too much real estate to make constellations lol. are you using one engine or multiple? i was going to do 3 rgb twinkle engines, but after seeing this i may have changed my mind wanted it to twinkle at different rates, but after seeing this i may swap over to one larger one.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 6:35 pm

I was going to use 2 engines on 2 separate panels, but the issue of them getting out of sync wasn't going to work for me so I ended up with a single engine 800 strand system
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 8:49 pm

This is going to be so COOL!
Posted By: Perches

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 9:24 pm

This is unreal bud, can't wait to see it installed, and hopefully in person soon!
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 9:48 pm

CAN'T WAIT to see the finished product! Going to look killer. I always wanted to do fiber optics in a headliner to look like night stars.
Posted By: frscke1

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 26th 2019 10:33 pm

Tuner you just have tooooo much talent in your hands ... WELL DONE ! !
Posted By: Vanereal_Disease

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 27th 2019 2:33 am

Where is the “LIKE” button?!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 27th 2019 12:53 pm

Thank you so much everyone! I can't wait to get this part done! lol


Originally Posted by Perches
This is unreal bud, can't wait to see it installed, and hopefully in person soon!


Thanks man! Hope to see you soon! Maybe if I ever finish this up I can leave the shop again.. Can't wait to see yours finished!
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 27th 2019 1:45 pm

Cant wait to see this done! i hear ya about the lights being out of sync, kinda the look i wanted to go for but after seeing this.... going to rethink this lot more to figuring out routing and patterns than i initially thought.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 29th 2019 11:44 am

I feel like I've been spinning my wheels the past week, but I did manage to finally get all of the fiber optic strands installed into the board on Saturday night. Here are a couple of terrible videos of it in action. this is just the top side, so the strands won't be visible once installed, just the dots. My camera was having a hard time focusing:

White lights:

https://www.youtube.com/watch?v=duPs9naxmMw

Fading through the colors:

https://www.youtube.com/watch?v=v9xZHWDgzVw

With that done, I've started on the wiring. I'm focusing on getting any wires ran that will go over the headliner. I never want to have to take this thing back down so I want to make sure that everything is there. Even running a few extra circuits for good measure lol. I Didn't take pictures of that yet. Maybe I will once I'm done.. Maybe not..

I am just still in shock at what the wiring is costing. I new it wouldn't be cheap, but I have so far underestimated the lengths if almost everything I would need.. This thing is huge compared to every other vehicle I've worked on lol. It's getting expensive!
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 29th 2019 12:49 pm

holy crap dude looks awesome!!!! yea i saw how quickly the dollars flew away when ordering my stuff and i havent started yet
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 29th 2019 6:35 pm

Looks killer man, keep it up.
Posted By: DontComeKnocken

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 30th 2019 12:13 am

That's awesome man. Headliners/ceilings suck to make in my opinion probably the biggest pain in the ass but that looks sweet. Way less than $12k for the Rolls Royce headliner, and cooler too since its in a van.
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 30th 2019 5:22 am

I want them!!!
Damn, that so cool, how I didn't think of that?:)) My roof will have 25 sunroof windows and I have 3mm LEDs for in between waiting for my interior project, but looking at your roof makes me feel not cool enough... LOL That looks awesome bro, can't wait to see finished lights.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 30th 2019 12:51 pm

Thanks so much everyone!


I have been struggling the last couple days with wrapping my head around the wiring. Wiring has always been my nemesis and this is no different, but I am still going to make sure it's done right. My dad is good with that stuff and came out last night and was able to clarify my thoughts on a few of the circuits and had a few good ideas of his own. Stay tuned for that mess.. At this point, I'm still just trying to make sure that I have every wire I'll ever need ran over top of the headliner before I install it. Ordering more wire yet again.. This is getting a little ridiculous lmao.. Also going to order a some distribution blocks as well as fuse blocks to get this mess moving forward.



Also, Last night, I helped my wife finish up the cushions for the back bench/bed. I am so exited for how this turned out! She has learned a ton and I am blown away at how good it looks for being her first time. Today is her birthday so I'm going to take it easy on her ;) She'll be back at it later in the week starting on the front seats.


[Linked Image]
[Linked Image]
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 30th 2019 7:59 pm

Seat looks gorgeous man, she really knocked that out of the park.
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - April 30th 2019 11:41 pm

yeah Absolutely.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 01st 2019 12:13 pm

Thanks guys!


I ran some more wires inside the van last night and started mounting the underglow.. I'm more excited about this than I should be lol..

Don't mind the mess..

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 01st 2019 12:39 pm

This is such a great project, and you and your wife are doing amazing work. Dad too!

When the Alcantara headliner in my van starts to fail, I may have to think about adding a few fiber optic accents here and there. I'm telling you, my back hurts after 15 minutes of washing dishes. I cannot imagine being bent over that headliner for that many hours. I'd be in a hospital after all that.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 02nd 2019 12:29 pm

Thanks guys! I didn't get any pictures last night, but I got both sides and the front underglow mounted. Still need to run the wires, but they are mounted! I need to get it out of the garage and get some good pictures..

I spent most of last evening running wires and getting everything I could think of that needs to cross from side to side routed along the ceiling. Once I get this headliner in, I never want to have to take it back out!

I'll get more pictures as we build, but the basics of the electrical system are going to be this:

On the left wall cavity right behind the driver's seat, there will be the main electrical panel. This will contain fuses, terminal blocks, relays etc, I'll be running a 0/1 gauge power cable along the frame and up through the floor to a distribution block in that area. All of my switch panels up front, and all of the modules and control boxes will get mounted in that area. I am also running another 0/1 gauge cable over the ceiling to the other side where there will be a similar panel in the wall cavity right behind the 40 door. There will be a mirrored terminal block for switched accessories like mood lights, power outlets, lighted speaker rings and cupholders, etc.. That way I can just hook up things on the right side and not have to cross wires over later.. I have 20 primary wires in a twist running over to the right side for whatever I need. Also prewiring all the Speaker wires, RCA cables for amps and a TV, the CB radio antenna cable which runs from front to back (was going to do a pair of mirror mount antennas, but decided on a cleaner single mounted to the tire carrier). In the future, there will be a pair of group 31 deep cycle batteries in the right rear. One in front of the wheel well and one behind, They will be tied into the rest of the system with the starter battery on an isolator.. That is going to be a while later though.. Sorry for rambling.

I am hoping to finalize everything going over the headliner tonight, and then probably head in the house to help the wife with the upholstery. Hoping to get the headliner hung tomorrow. Wish me luck.
Posted By: oldskool73

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 02nd 2019 6:32 pm

Good luck ! Some amazing transformation !
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 06th 2019 12:18 pm

I worked on a variety of things on the van over the weekend which I will update as I complete them, but most importantly, I got the headliner installed and working!

Here are a couple pics of it freshly installed before I trimmed the strands up:

[Linked Image]


And here is what it looks like after I trimmed up the strands nearly flush with the suede: The completed rear seat also made an appearance!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

Here is the seat by itself: We need to adjust the cushions and foam just a little, but I'm stoked about how it turned out!

[Linked Image]
[Linked Image]


I am now working on the side boxes around the rear wheel wells, and the mounting of the battery charger and other equipment inside of them. Also hoping to have the rear part of the flooring and mounting for the rear seat done asap.



Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 06th 2019 4:13 pm

All your work is great, but that headliner is awesome!!! Congratulations on that.
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 06th 2019 4:56 pm

Everything looks gorgeous man, absolutely stunning work.
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 06th 2019 7:52 pm

Looks awesome man!!!! holy crap!!!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 07th 2019 12:36 pm

Thanks guys!

No rest for the wicked however, so I'm moving right into other things. While the back seat is in the van and available to measure, I started to make the patterns for the side boxes around the rear wheel wells. Started on the right side last night. This needs to be strong because if can potentially be sat on and kicked when sleeping, but also needs to be modular and easily removable because of the batteries that will mount inside.

First I made an aluminum bracket that goes around my false fuel door pod (where the electric hook-up is hiding), and this bracket holds my dual bank battery charger, This hides it mostly inside of the wall cavity and will only require a slight bump-out for the cover. There is also room for a power supply to mount to the left of the charger that will power everything when plugged in.

[Linked Image]


Then I started working on the design of the bottom box. The first issue that I ran into was the width of the seat. The flip bench came out of a newer Express conversion van, and the cushions are a couple inches wider than the wheel wells. I was going to build my boxes to completely enclose the wheel wells but had to revise the design and make them a little narrower. Here is the final shape I came up with: I am going to be using some heavy gauge aluminum to make these and the visible part of the wheel wells and lower vertical walls will be bedlined.

[Linked Image]


I have a lot of ideas regarding how this area will be built. Strong vs, easily opened vs, use of space, vs asthetic.. Stay tuned..
Posted By: Deathorvictory

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 07th 2019 5:13 pm

Wow, havent been on the forum for a good amount of time and HOLY SHIT. This van is amazing. I love chevy vans!
Posted By: roadrunner212

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 07th 2019 7:01 pm

what under glow kit did you use?
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 07th 2019 7:38 pm

Originally Posted by roadrunner212
what under glow kit did you use?


It's a set of strip lights I sourced through my job. They are generic LED strips that gets used on pontoon interiors.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 08th 2019 12:14 pm

I need to get the upholstery on this, but I finished the cabinet that will cover the battery charger, I decided to make this box out of 80 gauge aluminum instead of the 60 gauge I had been using for everything else, that way if we kicked it in our sleep it wouldn't bend or get crushed.. Definitely made it interesting to do the bends! Took several hours, but I did get it done.


[Linked Image]
[Linked Image]

And behind the access plate is the battery charger:

[Linked Image]



It was getting late, so I didn't get to finish this, but here is the cardboard pattern for the lower panel. It will be easily removable to access the battery behind. Hoping to get that part done tonight.

[Linked Image]
Posted By: Wedgy

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 08th 2019 2:08 pm

The Quality Craftsmanship continues!

I especially like the super crafty extra Gas door feature you installed on the passenger side for your shore power! smile
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 09th 2019 10:33 am

I'm really diggin' the charger access plate setup. Cool stuff!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 09th 2019 11:58 am

Thanks guys.

I didn't get quite as much done last night as I wanted to, but here is the current status of the right side. The bottom rear section comes out to access the battery and wiring in that corner.The piece that goes over the fender is mounted solid and I managed to do it without putting any holes in the wheel-well. It is attached at the wall, but rests on rubber bumpers. It is strong enough to set on.

Not sure exactly how I'm going to do the front section yet. I'll work on that tonight, as well as the left side which should be much simpler to make.

[Linked Image]
[Linked Image]
Posted By: newkirkinc1

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 09th 2019 12:23 pm

Awesome work your doing there.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 10th 2019 12:12 pm

Thanks!

Another day another piece of the puzzle...


[Linked Image]



Also a pair of these showed up yesterday. As soon as I finish up the rear boxes, the wiring shall commence..

[Linked Image]
[Linked Image]
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 10th 2019 12:48 pm

Sweet!

Is that black access port on the charger box one of those storage pods used on kayaks? Looks really familiar, but I can't put my finger on it.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 10th 2019 2:15 pm

Originally Posted by kursed
Sweet!

Is that black access port on the charger box one of those storage pods used on kayaks? Looks really familiar, but I can't put my finger on it.


It's just a universal 8" screw off access plate. We see them alot in various Marine applications.
Posted By: Deathorvictory

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 11th 2019 1:08 am

Wow, more excellent work!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 13th 2019 12:25 pm

I got a bit more done over the weekend..

First, I finished the left side wheel well box. Inside I made some bracketry to hold the OEM jack and crank and possibly some tools. Might also put the power inverter inside of that box, but that's another project for later.

[Linked Image]


Then I took everything back out and I dropped the fuel tank! I dropped the tank to be able to gain access to mount the rear floor. The rear floor panel is diamond plate and there are 4x L-Track rails that are mounted through the floor (hence dropping the tank). The rear seat will mount to these rails and they will allow the seat to be moved to different positions, even turned around backwards if needed..

Anyways, We then cleaned up the rear floor and gave it a good sanding and wipe-down with wax/grease remover.After that was a nice thick application of Raptorliner bedliner. I was impressed with this stuff. It sprayed out well and wasn't too much of a mess. It feels nice when dry too. Not sure if I would use it for an outdoor bed, but it will work just fine for what I'm doing here. Most of it won't be visible once the floor covering is in, but I wanted the OEM metal floor to be as protected as possible. I'll do the front parts once I get any and all holes figured out up there.

[Linked Image]

The interior sprayed.

[Linked Image]


I also sprayed the side box panels with the Raptorliner. It looks much more wavy than it is, it was still wet in the picture.

[Linked Image]


Then, I cut the diamond plate for the flooring and got it mounted. The boxes aren't in the picture, but they fit against the edge of the flooring nice and tight.

[Linked Image]

I re-installed the tank and buttoned everything up. We also got the 4th and final strip of underglow mounted behind the rear bumper while it was all apart. Tonight I'm going to work on welding up the mounting brackets for the rear bench seat.

Definitely feeling these late nights, but It'll all be worth it in the end.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 14th 2019 12:33 pm

I got the bracketry and mounting for the rear seat finished last night. Here is what I came up with: Don't mind the mess..


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]



To move the seat, I will have to remove the 4 hold-down nuts and lift the seat off the track, then reposition the mounting studs and re-install the nuts.. Not as easy as a simple slider but shouldn't be too hard. This also has the advantage of being useful as tie-down track as well if needed.

I'm hoping to finalize the rear setup 100% tonight. Finishing the hardware to mount the side boxes, mounting the seat, foam vibration tape, etc.. I want to get that completely done.

After that I'll be moving on to either the front seat brackets to accept the Toyota Cressida seats I'll be using, or maybe I'll work on building my electrical panels for inside the walls..
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 15th 2019 12:10 pm

I started working on the front seat adapters to mount the Toyota seats to the Swivel bases.. It's a little tight, but I think everything will work well. No pictures of that yet


Instead, here is the final fitment of the rear bench in the "all the way back" position. I layed out there and watched the ceiling for a while so I didn't get as much done as I would have liked.


[Linked Image]
[Linked Image]
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 15th 2019 12:38 pm

Originally Posted by tuner4life
I layed out there and watched the ceiling for a while so I didn't get as much done as I would have liked.


It's mesmerizing!
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 2:24 am

You're my DIY hero!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 1:19 pm

Originally Posted by RoboforcerX2000
You're my DIY hero!


Touche! I'm still drooling over your custom dash and how fast you get things done!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 1:31 pm

Don't mind the mess, but I last night I finalized the brackets to mount the original seats from my 1991 Toyota Cressida to the existing swivel pedestals in the van. The brackets ended up being surprisingly simple and everything lined up better than I ever imagined it would.. I'll get some pictures of the brackets tonight hopefully.. Driving position is perfect, and they are super comfy!

I hooked power to them and verified that when I lean the back forwards and slide them around a bit, they both swivel all the way around just fine!! That is a huge relief because I was worried they wouldn't be able to swivel. They are quite a bit bigger than the original seats, and the stick shift is kind of in the way.

These are going to be recovered to match the design of the rear bench.

[Linked Image]
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 2:55 pm

Looks good. That seat clears the shifter no problem? looks tight there.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 4:12 pm

I have to put it in reverse and slide the seat forward and back a few times, but it clears by less than an inch all around!
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 4:58 pm

Still looking awesome, keep it coming man. Love it.
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 5:19 pm

Originally Posted by tuner4life
I have to put it in reverse and slide the seat forward and back a few times, but it clears by less than an inch all around!

Seriously awesome, plus the fact the van is a manual trans, besides i doubt you'll be swinging while you're driving lol. Honestly one of the biggest reasons i'm super gun ho about restoring my pops old van was seeing pics of your van.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 17th 2019 5:40 pm

Thanks everyone!! I'm so happy to hear that this thing is motivating people to restore these old vans!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 20th 2019 12:35 pm

Wiring is underway! My dad is an OCD electrical guru when it comes to this stuff. He doesn't seem to think there will be any issues getting everything wired up in the next week or so.. Here's a quick example of his work in the Overhead console:

[Linked Image]



I also finished up the main electrical panel what will go on the left wall behind the driver's seat. This took longer than I would have liked, but I'm very happy with how it turned out. The back panel is 1" away from the sheet metal body so there won't be any dents or issues with that. The right side is an open cavity with a removable cover. In that area will be the fuse blocks and buss bars. This section of the panel is bumped out a few inches. The left side of the panel will be hidden behind the wall and the minibar will fit in that area so I had to make it shallow. Hope that makes sense. Inside of that will be wire paths and maybe a few small parts that won't need to be accessible often.. The cover for the fuse panel will be upholstered to match everything else.

There is also a small compartment on top of this that houses the light engine box for the fiber optic headliner. The depth of this whole panel was driven by the size of that part, and it fits perfectly!

Hopefully the pictures explain everything better than I did.. I'm exhausted lmao

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


I also finished up several of the wiring pass-thrus in the floor and was able to get the bedliner sprayed all the way up to the front seat area. That part will come a little later. Raptor liner is good stuff. Looks great and easy to use.. However, I don't think it is super heavy duty. I'd be cautious using it in a truck bed that will get abused, but it works great for my floor which will be mostly covered.. I guess we'll see how well it holds up in this step well..

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 20th 2019 12:58 pm

bow
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 20th 2019 1:52 pm

Looks amazing, wiring is such tedious work amazing that it looks so neat with that many wires, props to your dad and props van is coming along great.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 21st 2019 12:39 pm

I have some of the best friends in the world. A group came last night and helped with a variety of odds and ends mostly little things that will eventually be hidden later on.. Got wiring ran from the main electrical panel up to the front for the underglow, fan override switch, and others. Also got the wiring on the right side pulled through the floor and safely inside.

Painted all the plastic trims for the Toyota front seats:

[Linked Image]



Got the jack storage finalized in the left rear corner. I need to find a place for the lug wrench, but I may just clip that to the side.. We'll see;

[Linked Image]



We got the buss bar panel made which is located on the right side in front of the rear wheel well. These will be redundant buss bars from the left side to run switched accessories and whatnot. There is also a large power stud for the deep cycle batteries to connect to.

[Linked Image]


Lastly, I made mounts for the rear speaker pods. These are marine pods like would go on a ski boat. The brackets will be mostly hidden behind the wall panels once they are installed so they didn't have to be pretty. Just solid.

[Linked Image]



I will probably be inside tonight helping to fit the new skins to the front seats. They are turning out great so far!


Lots more to come soon! This is entered in a show that we will be leaving for on 5/30 so hopefully we can get everything done.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 12:44 pm

Last night we did a bit more of the wiring and got the final section of the floor bedlined. Happy to be done with that step. Now we can pattern and cut the floor covering.

[Linked Image]

[Linked Image]
[Linked Image]
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 12:49 pm

Also, I found this cool little trick I am so excited about!

I wanted to find a way to leave the barn doors open if we are at a show or something, but not have the dome lights run the battery down. I happened to have a spare door jamb switch from a Saab 9000 laying around the shop, and I remembered that these switches have a cool feature. If you push the pin in 3/4 of the way in and twist it to the right, it will stay put and the dome lights will be off, it will self-reset the next time the door is closed. I was hoping that the measurements would be close enough to work for my application in the van, and sure enough it does! And fits amazingly well!

All you need to do to make this fit is drill the existing hole at the top of the right B-pillar out to 9/16, and add a small hole underneath for the mounting screw. It fits well and almost looks factory. I figured I might need a shim or something on the door to reach the switch, but it reaches exactly the correct length already. No shims or spacers needed. I love it when a plan comes together!


[Linked Image]
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 2:04 pm

awesome thats a nifty little feature for a door jamb switch. Curious not sure if theres a major difference in wiring, but mine has switch on the dash to the right of the steering column to shut off the interior lights. I assume you're van isnt equipped with it, regardless this is a much easier way than having to remember to turn a switch on and off all the time.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 3:13 pm

Strange.. My van only had dome light switches on the front 2 doors originally no way to turn them off... This new switch is just 2 wires and (while I haven't actually done it yet) should be able to patch right into the existing wire under the dash..
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 3:43 pm

I'll snap a pic of it tonight when i hit the garage trying to button up my one s10 before i tear into the van, but i already sorta started with removing the fuel tank and such. I'm thinking because mines a passenger van not a cargo it was added.
Posted By: Bikertrash00

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 22nd 2019 8:24 pm

WOW!!!! Lookin great Jason, you better also build a dedicated shelf in the barn for TROPHIES!
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 23rd 2019 1:13 am

That jam switch is neat, never seen one like that before.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 23rd 2019 1:00 pm

Thanks everyone! Thanks Scott! I'm hoping I can collect a few trophies over the years! We'll see!


Last night, we got the main wiring harness going to the overhead console finished up and I installed it over the headliner and down the wall behind the driver's door. Lots more wiring to do, but that was a big chunk!

[Linked Image]
[Linked Image]


Then I went inside and helped the wife install the finished seat skins on the bottom cushions. It was a pain and took most of the evening, but I was amazed at how good they look! She is still working on the seat backs, but they are much simpler than the bottoms. They should be done soon! I can't freakin wait!

[Linked Image]


It's crunch time now - 1 week left! Lots to do and finish before we leave for Gridlife Midwest next Thursday!
Posted By: amcochrane

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 23rd 2019 5:03 pm

This build is amazing! thanks for taking the time to update the thread regularly.
Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 24th 2019 11:37 am

looking good man good luck with hitting the deadline its coming along real nice. This is that switch on my dash for the interior lights sorry didn't take a pic of it the other night
[Linked Image]
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 24th 2019 12:50 pm

Interesting. I've never seen that switch before..


Last night we got some more of the wiring done before running out of terminal connections.. Moved on to the floor. Got the main panel cut out. That was by far the hardest piece. Just need to anchor it down. Hoping to get nearly all of the rest of the wiring finished tonight, and finish the floor. Gonna be another late one!

The pictures are terrible.. it was dark and late...

[Linked Image]
[Linked Image]


Other things that are scheduled in the next week or so:

-Full exterior detail / paint correction / ceramic coating..Supposed to be tomorrow morning.. Supposed to rain. We'll see how that goes..
-Wednesday.. The day before we leave.. A/C is getting vacuumed and charged. Praying there are no issues or it's going to be a hot weekend for us.. Might get the diff fluid changed too.. It also might wait until we get back.. who knows..
Posted By: KeVan

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 24th 2019 5:35 pm

You're doing an awesome job on the van, it looks terrific!
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - May 24th 2019 11:55 pm

Those seat look amazing. Your wife is doing such impressive work on those...crazy to think she doesn't do it for a living.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 03rd 2019 3:51 pm

Sorry for the absence, I have been off work and mostly off the internet as well for the last week or so as I scrambled to get the van together.

This'll be a long post. Lots of random pictures. Nothing in any particular order, but the build stuff will be first and the Gridlife showcase will be after


Alright, so the floor panels got finished up and fit to the floor shape: There will be better pictures of the floor covering later on. I kind of forgot to take pictures as we finished some things.

[Linked Image]


It took a few of us to get the flooring glued down to the subfloor, but it turned out pretty good. So thankful to have good friends helping through this whole process

[Linked Image]


My dad doing more of his amazing wiring work in the main panel: (wiring isn't completely finished in the pictures)

[Linked Image]
[Linked Image]

This panel is on the passenger side and mirrors some of the switched features from the driver's side. For example, when I turn on the underglow, the right side and rear connect to this panel instead of having to run across to the other side. Everything is pre-wires to be modular later.

[Linked Image]


Got the CB antenna wired up and working

[Linked Image]


My wife found some cool pillows for the rear seat. They should tie in a little bit of old school with the modern JDM/VIP style of the interior:

[Linked Image]


Here's my wife being annoyed that I was taking pictures while she was trying to put seats together:

[Linked Image]


And the finished set: We didn't get the headrests done/on yet, but after this weekend, we're still a little torn on if we will add them at all. The seats look better without, but it would be nice to have them for long trips.. Anyways. I am so impressed with this being her first time doing any sort of auto upholstery!

[Linked Image]

Overhead console installed and wired up!

[Linked Image]
[Linked Image]

Here are some pictures as we finished up the assembly of the interior:

[Linked Image]
[Linked Image]

And pointing towards the rear: The rear speaker mounts are marine ski tower pods: We didn't get a chance to build custom wall panels inside, so we came up with the idea to cut up a couple of old black tablecloths and make temporary curtains that cover the walls. I was skeptical of the idea, but they look as good as I could have hoped for what they are. Way batter than the alternative, uncovered walls.

[Linked Image]

Here is the 2AM pic 2 days before we need to leave for Gridlife Midwest. The wiring is 90% done at this point, the seats are mostly bolted in, and there is still a bunch to do. Had to stop and get a picture of the UFO in the shop:

[Linked Image]

The next morning I got the seat belts installed and the A/C charged. No pictures of either activity, but trust me the A/C is cold, and there are now seat belts.

Here is a cool idea that my wife had. The day before we left, she made up sole quick temporary door panels to cover the side doors so that they could be displayed open. We decided to have everyone who helped with the project sign the 40 door. It's not complete yet, but I love the idea! Once we make the permanent custom panels, we'll hang this one on the wall.

[Linked Image]



I had a friend and one of the best local detailers in the area come and do a full job on the paint the week before the show. Full wash, buff, paint correction, ceramic coating, etc.. Granted we were chatting a bit, but he was working on it for over 12 hours! Here are a few pictures of the during and after. I was blown away. The finish is so smooth now that my phone camera will pick up facial recognition in the reflection..

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


__________________________

Thursday afternoon after a delightful 1.5 hour drive, WE FREAKIN MADE IT!!!

[Linked Image]


Shortly after my upholsterer got a well-deserved nap. She's gonna kill me for posting this:

[Linked Image]


There was a ton of stuff to look at and do at the festival, but I'll keep this strictly about the van..

There was a pre-show on Friday. We got staged up and had a ton of people check it out. Everyone loved it!

[Linked Image]
[Linked Image]

"Hey go pose"

[Linked Image]

A friend drove the drift car up there as well so after some sweet-talking we put it in the show too.

[Linked Image]




Saturday was the judged show. While we didn't win anything this year, they did love it so much that they parked it right between the main stage and the entrance to the show field. Took up 2 spots and everything.

We had so many compliments and everyone loved the lights. They were on all day!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]


Even many of the pro drifters and celebs came and loved the van. It was so exciting to have people who I have followed for years compliment my project!

We even had Nads and a few other guys from Hoonigan come and they were geeking over it. Made my whole weekend!!

[Linked Image]




The weekend wasn't completely without incident however, while moving the van into the show field on Thursday morning, we ran over a nearly invisible hole/dip in the grass and the front splitter smacked the ground. Luckily my "break-away" clips did their job and the splitter pushed up behind the flare a little bit. The flare has a very small crack but the splitter did not crack at all. The flare and splitter will both need some paint work, but it is very minimal considering the sound it made. I'll have it repaired soon enough. Could have been worse, the same hole also took out the super expensive carbon fiber splitter on a 5 series BMW.

[Linked Image]
[Linked Image]



I am so happy that we were able to get everything that we did done in time for the show. I am going to keep working on it and I have a ton more planned, but I'm probably going to take a week or so off and catch up on sleep and the other things that I have been neglecting the the last several weeks.


cheers

























Posted By: Juntao_DW

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 03rd 2019 5:55 pm

ouch sucks about the splitter on the van, but def better than the whole thing getting messed up. van turned out great looks great even with the temp wall coverings in it
Posted By: RoboforcerX2000

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 04th 2019 4:05 am

Damn, your van is just sex on wheels!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 04th 2019 3:35 pm

Thanks you guys!

Here's 1 more that my brother got as I was pulling back into camp after the show. Definitely my new phone background!

[Linked Image]
Posted By: Dyno_Dave

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 04th 2019 6:12 pm

You continue to knock it out of the park with this van!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 17th 2019 1:51 pm

Thanks Dave!

[Linked Image]


We went to car show at the IN state fairgrounds over the weekend. It rained the whole tine, but we had a good time anyways. The van got lots of attention. Even the hardcore import guys loved it! Gotta clean it up now for a cruise this Friday.

Also need to figure out why my Flexalite fan controller is keeping my fan on all the time.. I suspect the sensor is bad. When I unplug the temp sensor from the unit the fans turn off. Otherwise they run, even when first started and cold.
Posted By: oldskool73

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 17th 2019 3:08 pm

Since selling my van, I only check into this forum to follow your build. Awesome !
Posted By: MACE

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 17th 2019 3:10 pm

Dang.
you killed it with that van bro
Nice!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - June 17th 2019 4:05 pm

Thanks guys!!
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 08th 2019 1:53 pm

Haven't done anything significant to the van the last few weeks. We did do a handful of shows over the last couple weekends though.

The first was a nice little show at an old farmer's market near me. Let up with Scott (Bikertrash00) and had both vans there. I'm still waiting for some pics to surface of mine, but you've already seen enough of it anyways. Here are some nice pictures of Scott's van!

[Linked Image]
[Linked Image]


The following Tuesday, there was a nice little cruise-in at the same location so we met up again. A local news station was there covering that event and they loved the vans. They even wanted me to do a little interview about the show and the vans for the local news so that will be cool when it airs.

[Linked Image]
[Linked Image]


Then on Friday evening there was a large organized cruise-night in a local town so we took the van out. Got some neat pictures.

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

(I really need to find a matching spare tire...)


Then on Saturday morning we went to a local cars and coffee. Neat little show and there was a wide variety of cars. This is the only picture I got.

[Linked Image]


Need to chill out for the next few weeks and catch up maintenance on some of the daily drivers. I'm already planning out the next wave of projects to do on the van over this next off-season.

cheers
Posted By: kursed

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 09th 2019 12:32 am

GORGEOUS! bow
Posted By: lukester

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - July 13th 2019 2:21 am

Such an awesome van build. Keep it up man.
Posted By: tuner4life

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - September 09th 2019 1:10 pm

This past weekend we cruised over to the Indy-Van-A event in Monterey IN with Bikertrash00 and had a great time! The weather was pleasant on Saturday, we went canoeing and just relaxed most of the weekend. There were a bunch of cool vans out for the show and shine! I am so excited to have won my first award at a van event!

It was nice to see some of you again, and great to meet many more for the first time! Definitely putting this one on the schedule again next year!

[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
Posted By: Deathorvictory

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - September 09th 2019 8:51 pm

First of many I bet, nice work man. That’s a great looking line up
Posted By: Perches

Re: Tuner4life's 1985 Chevy G20 4 Speed Build Thread - September 17th 2019 9:37 pm

Logged back into this site just to catch up on your van since I started on mine again. Constant inspiration!
© 2019 Vannin' Community and Forums