Thinking of a Silver and Black Once all my parts come in this week, I will start posting many photos. I have it jacked up and ready to pull the entire front suspension off
Have a small dent, rear left (Driver Side) tail light was hit in, just a bit. I can probably bang it out, but going to try to find something at a junk yard I can cut from another van Also, I dont have any rear windows. I would like doors with windows, so going to be looking for that
I plan on a clean look, clean build, nice looking and running van.
Here is a link to a previous build I made a few years back.
Had a busy weekend. Went to a local junk yard, first time in about 10 years and found some really cool things Found back doors with windows, little dirty, but will come clean. The back corner has a dent, so will fix so doors close properly. Also found the back light corner, and cut it out from another van, just need to weld in place. Never done that before, but will figure it out. Also, and this is a big wow, found seat mounts with the spinning function. I was excited about that, wanted to be able to rotate the two front seats. Looking forward to all the work coming ahead.
Also spent the weekend tearing down the entire front end
Doors
Front End Before
Front End After
This is after one week owning this thing. Have lots to do
Had a little time after work today. Found the rotors I ordered from Amazon and inner barring's and seals were incorrect. Re-ordered from a local place, should be here by tomorrow.
Almost done with the front, just need to change the pitman arm, and need a puller for that. Tomorrow
These are 2.5" drop spindles, new stock springs, new upper A-arms, new lower ball joints, and new brake hoses. Waiting on a few more parts. Should be done by the weekend, hopefully. Then I can drive it, rear breaks next, then the real fun begins.
Finished smog, all ready to start measuring and cutting. Visited a junk yard after work to get a couple of parts, so exciting. Also, I don't like the back sticking way out, so photoshopped a sample of what Im going to do. Take about 44" off the center, and 9" off the back to make a Shorty Short Short.
Im not that good at welding, been so many years Don't know much about body work Not a painter
But have lots of enthusiasm.
Here is the final render. In about a week, I will start pulling fuel tank, brake lines, wires, driveline and anything in the way.
Finished smog, all ready to start measuring and cutting. Visited a junk yard after work to get a couple of parts, so exciting. Also, I don't like the back sticking way out, so photoshopped a sample of what Im going to do. Take about 44" off the center, and 9" off the back to make a Shorty Short Short.
Im not that good at welding, been so many years Don't know much about body work Not a painter
But have lots of enthusiasm.
Here is the final render. In about a week, I will start pulling fuel tank, brake lines, wires, driveline and anything in the way.
I am the same way....didn't know a lot about welding, bodywork, etc but I read a lot, asked a lot of questions from people who knew how and then practiced and both of my two vans are turning out nice. Keep up the enthusiasm and good work!
So sprained my ancle, so haven't touched the van in a little bit. But was finally able to hobble around changed the rear brakes. Haven't done drum brakes in a long time, so took me a little while. Didn't have all the tools as well, but got through it.
Now its time to start measuring the entire thing and figure out where I'm going to cut. Should be interesting.
Tranny - Fix oil leak - Done Front Suspension - Done Rear Brakes - Done Cut Van and tack weld together - Next Shorten Driveline - Shorten Brake Lines - Shorten Fuel Tank Lines - Rear Air Bags - Under carriage Clean and Paint - Lots of welding - Body Work - Primer - Paint - Misc. Exterior - Interior Front - Interior Rear -
I've still been limping because of my ankle, but have been able to do some work. I cant do the cutting at my house, it's too loud and would end up with lots of complaints. My friend let me do this at his house, so here we go.
First, jacked the van up just a bit, and built a stand to go under the tranny mount. This carries the weight of the back half, and added a couple of small jack stands under the front frame. Added a few jack stands at the front and rear of the back axle, not sure which way it was going to go.
Had to deal with ABS, pulled all the lines and pump which sits just under the side door entrance. Pulled the fuel tank, lines, and exhaust
Wow Wee Kaah Zowee !! FEARLESS Super Dave ! Rock on Dude . ( Is your next door neighbor's house for sale ? ) Keep the pics coming. Appreciate them for sure.
Been so busy, haven't had too much time to work on the van So today, continued to cut and trim the edges and corners. Cleaned off the point where I'm going to weld.
I forgot to take photos of them, but I welded two 2.5" square tubing stacked on each other to make 5"x2.5"x2 feet long One for each side, slide each one foot into the frame in the front, drilled and bolded 1/2" bolts to hold on the front Slid the back half in, and bolted the back. There kind of like sleeves for the frame, but inside. After doing this, the frame held itself together without jack stands, so its pretty solid. Now its ready to weld.
Had a little time to work on the van today after work.
Drilled and added more bolts to the frame to add strength, not its sitting on its wheels, no more jack stands.
Here are a few photos to show the progress
1st - Here is a picture showing the driver side. I cut a 4" pice from the section I removed and added it as a band aid on the inside. This is showing how well it fits together with some small sheet metal screws. Now it's ready to weld.
The next picture shows the inside, you can see the small piece of metal binding the two half's together. This shape fits perfect on the curves, so all I had to do is clean the paint off on the outside so I can weld later
This is showing the inside floor. I had a 2" overhang so all I had to do is screw it together. Ready to weld now
The last one here is showing the roof. Again a 2" overhang put together with screws. All ready to weld.
Van is all put back to together, as far as the body and frame, not just welding
Today's task was to lower the back to even out the ride
Removed the 2" lifting block, the overload spring, and the 4th spring as well
Now the leaf springs have only 3 springs
Here is what I removed
Not is all put back together, lowered and ready for the rest... Have to get a level to adjust the angle of the rear axle, then measure the driveline to have it re built.
Thanks SDMickey, I wish I had more time, but try to do as much as possible when I can.
I don't know if I mentioned, but this has ABS, so Im kind of hopping I can put it all back together. It was mounted directly under the sliding door, so I have to re-locate to about just in front of the rear axle. Hopefully all the lines go back together.
I'm sure you'll figure it out. Brother; in such a short time you've done a lot. The pics are greatly appreciated . They motivate us all. You are Fearless Dave !
You should have a T-Shirt done in the style of Big Daddy Ed Roth with a pic of your van and you with a GNARLY BLOW TORCH !!
Was able to do some welding today, little more body panel adjustment and fixing few holes in the floor. Guy before me had a bunch of cleaning equipment, and didnt know how to just make one hole to bolt things, he made a bunch. Took some pieces form what I cut out and patched the floor for support and keep things out...
Also, cut and shortened all three fuel lines, changed all o-rings, fuel filter and re-mounted fuel tank. Fuel side is done...
Cut the exhaust up, going to try and re-build tomorrow, hopefully I can get it to fit, then weld it back up.
Lastly, hopefully I can get the ABS and all brake lines re-mounted without having to re-size too much.
Then hopefully be driving this thing home so I can get going on the air bags, shocks in the rear and all the welding that still needs to be done...
Well, its drivable now. Brakes and all ABS are done.... Took so long trying to put it all back. Took forever to bleed the brakes. They are good enough for now
Been super busy with life, but still managed to get a bunch done. I was able to drive this thing around a bit Finished some stuff in the rear suspension.
I originally wanted to put air bags, but after ordering them, they were too big, so I just ordered air shocks. I haven't received them, but as soon as they get in, Ill put them on Removed the rear leaf springs, and added a new center bolt, painted everything and put back together I cut up the entire exhaust, and was able to weld all back together as short as I can get it, it fits. Just need to finish welding the hanger and tail section. It runs great with not a lot of noise.
I was able to get most of the seams welded today. Came out pretty good. Just need to bind the hard to fit places, like lower sections and corners that didn't match up 100% Lots of grinding now, then the body work.
Here is a photo of the rear doors I purchased with windows. There is a dent in the left tail light section, so had to cut partially, and use a bottle jack to straighten the left column. Doors close now. Still need a little adjustment.
One good thing, 4 day sale this weekend at local Junk Yard Found Lexus black leather seats with heater and cooler and all electric. Hope I can figure out how to wire them Also took the speaker system and seat belts from the Lexus Really nice stuff.
Mine isn't that bad, but I just want to add some filler over the welded spots to level. Its not going to be as good as yours, but it should be okay Not going for the perfect look, you will see when Im done painting. I am not going to be adding huge amounts, but just enough to make it look smoother.
By the way, Im a computer tech, just doing what seems correct.
Don't sweat it. Proceed. When I am as brave maybe, I will be following in your footsteps with all of the sheet metal, door, and tools frscke1 gifted me with to repair all of the Church van driver carnage inflicted upon my G30. 32 year old GM paint too!
You would be very impressed at the effort he put in bringing all that sheet metal to Texas. His motto is, "If it drips a drop, it's in the shop." Also "Adrenaline by the Gallon." Hard to achieve perfection with an imperfect product, but when frscke1 builds it, it is as close to it as it can be.
I'm his Tilesetter, if anything goes wrong you can just blame it on the Tile Guy.
Shhh. The guys at the body shop did the Bondo after he left. Let er rip!!!
The only major damage in this thing was the left tail light corner, had a pretty big bang. This messed up the doors, they wouldn't close properly. With a bottle jack and a 2x4, I was able to get it streight so the doors close properly. Problem, the dent was still there.
A quick trip to the junkyard, and I found a nice van with the corner intact, so I cut it out and now Im ready to fix this.
This made me more nervous than cutting the whole thing in half. Maybe because this is the main support for the back doors, or whatever. Anyway, I cut this out, and replaced. Doesn't look too bad, still need to do some body work.
Not bad for never doing anything like this, and not welding for 10 years, and a $120 mig welder from Harbor Freight.
What do you think
I cut the light section out first to allow me to set the new piece over, then cut them both together which gave me a true size. I used some pliers, hammer and was able to get in place.
I know not as good as someone who actually knows what they are doing, but here is my attempt
Wow Dave, that looks great! Don't sell yourself short. No Fear!
Can you tell us what you are welding the the sheet metal with, settings, rod? MIg, Tig, Gas or Arc? Probably not Arc, I think. Too thin. to severe. LOL
Great build thread . That thing is just so ridiculously cute! Keep the Red! Little Red Riding! Wheelie Bars!!
Dont laugh, I purchased this little welder from Harbor Freight for under $200 It works great. Finally finished one spool, and just added a new one when I fixed the tail section.
Still have a few little things to weld, but will start stripping it to get the body work done and premiered. Hopefully you will see it premiered this weekend.
Yes, I plan on painting this myself I have the primer on order Currently doing all the body work myself. Just doing the best I can Believe it or not, Im a computer tech...
As for chopping, no, no chop top I think it will look good as is Im 6'5" - Chop Top would not be good for me. I don't like that look
Thanks all, it has been fun. Lot easier now that its not 110 outside
Here is the progress from today I was able to finish welding a bunch of little things on the drivers side, and started the body work I played with bondo today... I figured out, not to put too much of the red stuff in it, it dries really fast. Had to move quickly.
2 of the nuts you can get to from the engine side it is the last one that is a problem. I had to take out the side vent and that was the only way I could get there careful not to drop the nut otherwise its gone for good. Mine uses a 3/8 socket to get there.
Does anyone know what rear bumper alternative I can use instead of the stock? I would like one that goes all the way across, no license plate cutout, and Im not putting a trailer hitch. Just a simple, solid bumper
Is there a C10, or another year bumper that would match?
Cant tell too much from the photos, but if you do body work, you know that it is very time consuming... This I am new to and learning as I go. As Im finishing on the center section (where I cut this), Im finding little things that needed to be taken care of, little dents, holes, and lots of other stuff, so taking a long time But Id rather not rush, because once its painted, Im not going to go back, its done at that point
Here is a picture of the Junk Yard doors I found. They had lots of holes where the ladder was bolted. The previous owner just made a bunch of holes. I used a piece of copper behind the holes to assist in welding them up.
Also, spent a couple of hours stripping the front, getting it ready to paint. Removed as much from the firewall, top radiator brace, and lots of other stuff, including the wiper assembly and so many other things. Its ready to clean, a little sand, then primer
Was also able to remove the rear door windows so I can weld up a bunch of little holes. I also found that the bottom of the right rear door has a bunch of body filler, and many holes where the ladder was bolted, again with the holes I plan on taking a piece from the old doors which were in better condition and skinning the one with the holes. That way I have new metal, not body filler.
Lots of work, but I think its worth it. Ill do this tomorrow, hope it comes out good.
What do you think so far? I think once I primer it, I is going to look awesome. Cant wait to start driving this thing
Oh yeah, And I figured out how to remove the front Chevy emblems. So not easy. After I removed the grill, there are a couple of little holes, big enough for your arm to fit in. I was able to get aa 3/8 wrench in with a couple of fingers and just turn. Finally was able to get them off.
I am going to polish them and add a little paint. They are going to look great, I hope.
Ive been so busy last couple of weeks, pretending I know what Im doing. Fixed the back door, but wasnt too happy with it, it will have to be good enough until I can find another door.
Did the best I can with the body work, and lots of sanding. Finished stripping the van, glass, chrome, everything. Found a neat idea for the windshield. You can just shove a rope under the edge of the rubber seal, which lifts it enough to sand and paint under it, then just pull the rope out. Worked great.
In the meantime, another hobby I have is Roasting Coffee Beans Love Coffee, been roasting for several years My cooler is actually a modified car intake tube, a cake pan and a heater motor all going to a vacuum dust collector
In the meantime, another hobby I have is Roasting Coffee Beans Love Coffee, been roasting for several years My cooler is actually a modified car intake tube, a cake pan and a heater motor all going to a vacuum dust collector
I don't have time, really need a third vehicle, so this will be my daily driver. Just in time, my daughter is taking over my other vehicle, so I had to get this done asap. I will be, hopefully adding the second color tomorrow. Hope it goes well.
As you can see, its been a back yard adventure, no booth, carport or anything, so who knows when the weather changes or something else. Now that Im almost done painting it, I can take it home at take my time finishing the inside.
After all this time, I can finally said, it's down hill from here. I have been so excited working on this project, it's been quite a challenge. Now I need to move a little faster because I need to start driving it. So....
U-POL Raptor Tintable Urethane Spray-On Truck Bed Liner Used a bottle and half for the top alone using a heavier spray, just to make sure it seals good. Then lightened up the spray to have, not such a rough surface, but a smoother look and feel. The flat color looks pretty good in the sun.
Again, I am not a body man, or painter, so this is the cheating way to make it look descent. Can't believe this was two pieces last month...
Thanks everyone, It has been a lot of fun I cant wait to start working on the inside. Sad thing is, I will not be ready for the Van Show in King City this weekend. Im about a week from ready. Next Time...
Still need the rear windows, some missing bumper bolts, and the front grill Ordered a new grill, but came broken, they said keep it and refunded my the entire bill
Was finally able to drive it, so smooth. Tomorrow I will finish the windows, and lots of little things. Ohh, need to put some seat belts So love this Van. Drives really good on the road and smooth. Cant wait to get more of it done, should be easier at home
Also, forgot I only finished the exhaust up to the rear axle, so a bit of the smoke was coming into the cab
At lunch, was able to weld the tail pipe on, and also routed the air shocks properly Added the air shock valve next to the license plate in the rear bumper
Well now that I have it here at home, I can do little things without having to get all my tools in a bag Just run out, get some stuff done and get back to work. Really nice. Hope to finish the seatbelts and seats. Have to modify the parking brake, rear brakes are making a noise, so have to get it all fixed And a million other things
So for the last few days, have been working on lots of little things. I was able to replace all the windshield washer hoses and fittings, installed along with the top air valance. Was able to get all the new door seals installed. Front grill is finally installed Finally removed the stock drivers seat, and installed the Lexus seats. Got them temporarily wired, very nice with all the functions working Installed the swivel mounts, but didnt like them. Just tightened up all the bolts instead, dont think im going to be using that function Pretty much finished most of the outside stuff. Still have a few little things to do, like parking brake cable and wheel well trim
Still need to order new wheels and tires Get the AC fixed, hopefully this week Alignment as well.
Here are the new seats. Really comfortable, especially because Im tall. I can see out the front, nut having to squat a bit.
Also, made new seat belt mount brackets The entire seat belt, 3 mount points are on the wall, not the seat. Didn't like that they were tied to the bottom of the seat. Oh, and all the electrical functions work, including lumbar support Didn't connect the heat, don't need here in the valley
Dropped off my van at the shop to get the AC repaired, going to call him "Bluey" now, Too many people have been calling it The Mystery Machine.... I don't like that
Bluey now has Cold AC running... Yeah!!!
Front Alignment is scheduled for Saturday, then I can get the new Rims and Tires. Awesome
Thanks SDMickey, so much to do and so little time Spending my evening looking at YouTube videos of how to install my alarm It's been years since I have done this, and want to get it installed before putting the dash back in Alarm is more for keyless entry Also will be wiring in the stereo.
Actually, don't have much time, been taking every minute available to get as much done as I can. Been so busy with so many other things, wish I could dedicate some actually full days This has all been a couple hours here, a couple there.
For today's project, I actually spent some time with WOOD!
Took about an hour to build this cool piece of wood. As you can see, not the most perfect lines, I suck at wood working almost as much as welding and body work
So as you can see, the original dash was a light gray, so I removed, and painted a charcoal gray. Painting things now as I go
After wiring the alarm, or keyless entry, I started to wire the stereo. Its pretty much done up here, just need to run wires to the amps and start building the back of the interior I also ran wires to the back for ceiling lights, and door lights, you will see soon
Here is the dash so far. Ordered new hinge pins for the little glove box, and painted the wood thing now, will install tomorrow and show you that.
For the stock stereo hole, I actually purchased a small cubby pocket thing to put there. I can use for a cell phone, or whatever I want to store there.
The dash looks awesome! I have the same headunit. So, jealous how easy it went into your van. I went and got a few things I need to get my dash to the next step this morning.
Thanks guys, appreciate it SafariTim, would love to see your dash Today, I was able to finish the dash, for now and installed the stereo and cleaned up a bunch of wires Also wired some interior lights that run on the door switch. Will install them permanently after the interior is done
Its amazing how you find so many little things that need to get done When you do get them done, you feel satisfied they are finally complete, but you have nothing to take pictures of
Today, had some time so was able to get the rear doors adjusted, greased the lock so it all works with the alarm now Was able to get lots of welding finished, some holes on the floor, brackets for the seat belts, removed the original spare tire bracket, and a few other things I cant remember.
After all this, was able to put the insulation on the walls. Will be cutting the side panels, hopefully tomorrow, so it should be quieter inside
Yes SDMickey, they are a Junk Yard find I pulled them out of a Lexus car Everything but the heater element work, I just didn't need it here in the valley, its rerly needed as the weather is usually hot here
All motor functions work, and very comfortable Still need to add the button on the dash for the internal coolers and have to re-install the back and bottom covers. I just haven't got to it.
Today at lunch, I started installing the floor, and building the side benches. They will have subwoofers and amps. Im also going to have a bit of storage for jack and jumper cables, etc...
Sorry I havent posted much lately, still working on the van when I get a chance, just nothing too exciting yet. I finally fixed the parking brake cable. Having to cut 3 feet of it was a chalenge, so what I did was pulled it way back to the front left wheel, re-routed under the frame instead of thru the frame, welded a tab on the outside of the frame with a hole for the cable mount. This holds the outer cable, then the center part of the cable can move freely. I didnt have a crimper for the ends, so I just used tinny u-clamps to link both cables together. Its working properly now.
Also bled the brakes again, just in case, and adjusted the rear. All working properly
I ordered and received the front carpet, looks good. I should have time next week to install
Also, found some really nice rims on Facebook Marketplace... Now looking for the tires. Coming soon!!!
New Black Carpet from Rock Auto
New Rims - 15x8
So much more in the works. Im hoping to have some time next week to get a bunch done. Cant wait to show you all!!!
These are 15x8, not sure the backspacing. Found them on Facebook Marketplace Just $320 for the set...
Cant believe you bought those without checking the back space ... since the van was made for 15x6 tires any pos BS will interfere when turning and spacers are not a good idea ...
Is the lug pattern for a Chevy 5x127 ?
Cause if they for a Dodge or a Ford they are different even thou they are 5 lug.
I did check, actually, they do rub just a bit, but not too bad. I will be using a small spacer I've used them for many years without any problems. I will probably put under 10,000 miles a year on this, and my office is about 5 minutes away from home, so Im not really worried about it. I know if it was a 4x4 with lots more weight, it would probably be more of an issue, but Im sure it will be fine. Thanks for your concern frscke1, appreciate it
Friends worry bout friends & their van. Seen lots of money lost for parts not fittin and horror stories bout spacers puttin more stress on the hubs that werent designed to stick out another inch. But under that inch and you say you have small GLAD it works out ..
Appreciate it frscke1, thanks. I have spacers coming tomorrow to test things out. If I do go this way, Ill just keep an eye on things to make sure not wearing other parts out. If I find these wont work, I can trade these rims, or just get others. Thanks for the concern.
Like everyone else here, been super busy but found a little time to get a few things done
Been wanting to replace the DogHouse carpet, this things was really bad Finally pulled off, and replaced with that cheep stuff you find at Autozone for speakers.
It came out okay, not the easiest to work with, but the parts you actually see are pretty clean I first cleaned and lightly sanded the fiberglass dome
And, finally was able to install the new carpet Not so easy either, had to get just right, and used the seat mounts to hold in place. Still need to add the trim, and cut near the throttle peddle, so it wont get my foot stuck.
Did a bunch of other stuff, but will post later. Still working to get it drivable again so I can drive to work tomorrow.
Yeah, It probably would, but I kind of like the big square look. I get lots of looks because people try to figure out what's different with my van. People love asking questions, that's for sure.
Its my daily driver.... Looking forward to some time during winter break to be able to work on the interior. First though is I need to get some mud flaps. These tires stick out just enough to spit up some water on the sides, looks pretty awful.
I thought about it, but you don't actually see too many like mine anyway, so I think I will stick with it for now. It's a huge expense to try to get it to look older, when its already 30 years old, and looks pretty cool I wish I could find LED headlights for it, but not much of an option for these little square things. I am trying to get the interior done before I do anything else. I would like to do a 4 link for the rear with coil overs for a better ride, but for now, just trying to get what needs to get done first.
In town, Ive only seen 2 other vans, and those guys went crazy when they seen mine Not many vans around anymore. I do get lots of looks, especially since I put the new wheels and tires. Mud flaps are also in, look good and keep the mud off my sides.
Havent had so much time to do stuff because of work and the weather, that's why I was so in a hurry to get it drivable. I knew I wasn't going to have time in the winter
But, I have had a little time for some stuff.
Here are a couple of photos of the two speaker boxes I built for an 8" woofer. Built two, to go behind each seat.
And have been doing little on the inside. Was able to cut all new door panels Carpeted and installed with all new window and door switches Also made some small doughnuts as spacers for the door speakers. Finally some music up front.
Hi guys, seems like winter has really slowed down the progress
As weather is finally starting to warm, I have lots of plans to finally finish the interior. I've been enjoying my van every day, and look forward to cruising all summer with the stereo cranked. I will hopefully have some updates soon.
Nice work Dave! What brand of speakers are you running in the front doors? They have a nice clean and simple look. Might get a pair too if you vouch for them sounding good!
Hadn't looked at your thread in a while. Love those door panels. The fabric, the chrome trim, the speaker mount. Very clean look. Maybe I'll run speakers in my doors after all when I build the panels.
Nice work Dave! What brand of speakers are you running in the front doors? They have a nice clean and simple look. Might get a pair too if you vouch for them sounding good!
If you blow up the pictures, speakers say SKAR audio
Subwoofers are 8" Skar, have two of those The rear speakers came out of a Lexus, really nice 3 way. The doors are actually 6.5" Kickers I don't like the Kickers very much, they don't have much bass or mid's, mostly highs I think when I have time, I will make some longer door pods that will have three separates like the back. I didn't want to cut holes in the doors, so there is no movement of air, sound. I think I will have to so I can get a better sound. Boom Mats, I think thats what they are called. Its a foam insert that will protect from water, and acts like a small speaker box inside the door. Not sure if I want to do this. But it does sound really good right now. Get to crank my Classic Rock!
Like everyone else, weather, busy, lots of other stuff going on... So here are a few photos of a few little things Ive done
From the back, you can see I made some rear door panels. Simple with just some carpet from Lowes Ive also managed to put some insulation on all the walls and roof. Added 1/8th inch, not sure what type of cardboard wood stuff. There it is
Also, was able to build some nice wedge speakers for the rear. These have the Lexus 3 way speakers I was able to pull from the Junk Yard. They sound really good. I will arrange them better when I finish the back. This is kind of where they will go
You can also kind of see the Subs, and center console I found on Amazon. It works really well, especially for the cup holders.
I want to do a 4 link rear, with coil-overs. I think this will give me a way better ride, and control. Then some helper bags in the front to give it a bit more tight feeling
Anyone have any information on this? Especially the rear
Then to make the ride a bit better, added some air bags to the front I decided to pull the springs, and put the lines going up, instead of down the way it is recommended. I didnt want to accidently hit something and damage the bags. It was really easy to just pull the bottom A-Arm.
Then, finally had the courage to tackle the power steering pump. Surprisingly, it wasn't too difficult. Had to pull the upper, and lower shroud to move just a few inches to the left, Then rented a puller for the pully, and finally was able to remove the pump. Reverse the process to install. Works great
Oh, and the best part Finally was able to get a new muffler Need one with inlet and outlet on the same side This thing is so short, needed to completely build a new exhaust
Don't laugh, I know my welds aren't the prettiest, but no leaks and sounds great. Ill show some installed pictures later, got dark.
Started to work on my portal windows and corner trim
My wife gave me an old cutting board, so I made a jig to make perfect circles with my router. I wasnt going to buy one, so just did some measuring and tada
And the finished interior round portal trim, or window sill, or whatever you want to call it. Used a little Bondo and lots of sanding to make them look like plastic
Still have to put some paint on the screws, but its now pretty much complete inside. Soon, going to go to the Junk Yard to find some rear seats. I wasnt going to put any, but find I really want some.
I dont really want to use it for a sleeper. I plan on maybe putting some bucket seats, and still have room in back for camping stuff. I will remove the seats when me and my wife travel alone. I have really nice cots that fit, so I can just use those if I plan on sleeping in there.
Because of MPG, and speed, I decided to get some bigger tires for the back. Had to remove the spacers and jack the frame up to lower the axle as low as possible to get these in 255/70/r15 They don't look too bad, kind of inexpensive but I get the speed and MPG back to where it should be.
You can also see the exhaust sticking out from the drivers side
Anybody in Central California going to the Paulsen's Haul'n Assets? It will be my first Van show ever. Don't know what to expect, this van isn't show quality, but just entering to be part of it.
Left at 6am for the 2.5 hour journey This thing was running so smooth and fast on the freeway. 75mph, no problem 1 hour from home, we stopped for some breakfast. When we got back on the freeway, I noticed smoke coming from behind, so I quickly pulled over to check it out My tranny front seal was gushing...
I was able to turn around and get to Autozone Got a quart of stop leak, and 2 quarts of tranny fluid, and a big can of brake clean The stop leak worked, but the back of this thing was covered in tranny fluid
So we decided to not risk it, and turn around and go home. First thing was to get to gas station, and fill up again I filled up before we left, marked my millage, then filled up when we returned, did the same Then subtracted to see how many miles we drive, and divided by how much gas we used Looks like we were almost at 17mpg... not too bad
Then car wash, scrubbed the back and unders clean, and back home to rest.
I will pull the tranny next week and hopefully its just the seal. Going to replace the torque converter while im in there, and a full tune up as well.
It was a good test, but wish I could have made it.
Lots going on Took Bluey to the Tranny Shop, they said it was leaking from the front pump housing, so they are currently working on fixing all leaks I will be glad to get it back, and hopefully no more leaks. The intake manifold has a small oil leak at the back, and looks like radiator at some point was leaking as well Hopefully no more break downs this summer, and I will fix these things in the winter.
Everyone with a similar van knows, The headlights on these suck The double light on both sides are a crazy size, so nobody makes an affordable updated bulb. The only LED lights available for these are very expensive
So I found somewhere online someone modified them, which gave me an idea.
I removed the bulb from the back, cut a bigger hole, and glued in some inserts. Now, I can take a new LED bulb, and just slide in. Sooooo bright!
See the difference? Can you guess which one the New bulb (on the right) compared to the LED (Left)
Also, today I had also purchased a hitch, forgot to take pictures of it installed, but It kind of scrapes on dips on the road, too low in the back, actually, since I removed 2 leafs from each side, needs a little more support So I added a leaf back on each side, with new center bolts Sooo smooth on the road now.
This is without air in the shocks Came up about 2", and about another inch with 100lbs in the rear shocks Looks a little more hot rod with the bigger tires in the rear, and up a little bit
Awesome build Dave. Your van is so nice. It has come so far in such a short time. Your hard work has paid off. Looks like you and your Family had a great time.
Been awhile since I've posted, lots of little stuff taken care of
First, my starter was going out during our camping trip, and finally did after our return, that's good it happened at home
Decided to get one of those high torque, little guys on Amazon It worked great, until it didnt. It fit and started perfectly, but was so close to the ring gear, it touched when I drove it. So went back to Amazon and ended up getting a new one locally.
Sorry, don't know why the images are upside down, but you get the point
Also, actually this weekend, since we are planning to go to the BYOB in Anaheim at the end of the month, don't want to go without a spare, so decided to make a spare tire carrier
Started with drilling and tapping my hinges, decided on the right door, since the body work is less than stellar. Didn't want to cover up the pretty left door, it looks too good.
Then, since I don't have an exact match spare rim, I used the stock rim that came with the van. Quick sanding, washing with ajax, and a little bit of paint
Been awhile since I've posted, lots of little stuff taken care of
First, my starter was going out during our camping trip, and finally did after our return, that's good it happened at home
Decided to get one of those high torque, little guys on Amazon It worked great, until it didnt. It fit and started perfectly, but was so close to the ring gear, it touched when I drove it. So went back to Amazon and ended up getting a new one locally.
I too got rid of those factory starters there huge N draw alot of currant. I went to the reduction gear starters for my 454's.... BEST thing I ever did !
GREAT WORK there Dave ....You cant be done ....there never done lol ...youll find something ....
It has been awhile, life keeps us so busy I drive my van every single day so it's hard to park and work on. Have to take advantage of non work days like today
I have been working on a few projects, so going to post them now.
The first is the lower A Arm Bushings Yes, just like everyone out there, have Googled everywhere, but nobody sells these rebuilt, have to replace the bushings yourself. So I did that.
You can see they are pretty cracked, but as I removed them, you can see how worn they were. It was definitely time for replacement
Was able to use a big hammer and punch, but was able to get them replaced.
Next on the list, well, since I had the lower A arm out, I decided to go Air Ride
I was able to get a kit from Switch Suspension It was a plate that bolts to the top where the spring goes, and a cup that fits on the bottom. Then you just bolt your air bag to these plates
Small problem, the bump stop metal bracket hits the airbag
Came out really good. As you can see, had to drill some holes at the top mount, then bolted the top plate But before this, I bolted the air bag to this plate, and ran my air line
Works perfectly
Of course painted everything as I was putting together. Looks pretty cool
Okay, so that was just the front. I am working on the plans for the rear, has to be just right, so stay tuned for that
In the meantime, I only have a schrader valve for each bag for now, so am working on a tank and valves. Eventually a compressor, but that's just more money, will wait.
Started with this little home air compressor I had laying around
Took it completely apart, welded up some holes and mounted a valve and stuff
Have to run the air lines and mount it, but not sure if Ill be keeping these small tanks, 1 gal a piece, or getting a 5 gallon from Harbor Freight. Actually, Tractor Supply has one pretty cheep.
Gotta say, this runs so smooth. Have only done the front, but wow what a difference in ride
My Heater Core started leaking so I bypassed temporarily Since I had time, took it out today, and ordered. It will be here tomorrow, so I will install it, and going to replace all hoses and valve as well, dont want to go through all this and still have a leak