Thread: Bad Ast Astro Van Build

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Anyone interested in some updates? I couldn't believe it has been almost two years since I last posted in the thread!
I have been picking away at the project since this last post. I got a lot done in early 2017. Front and rear stab bars made and mounted, brake lines ran, lots of work getting the front suspension ready to go. Painted the frame and all of the suspension parts and then it all ground to a halt.
Fast forward to a couple of weeks ago and I am back at it with the intent to have the frame done and rolling around by spring. getting the body ready to put on is the goal once it warms up a bit. Still have to finish up the tubs and floor but that work is easy compared to what's been done.
Here are some pics to bring you up to speed. Just ask if you want to see anything in detail.
https://static1.pt-content.com/image...VC002Fvi-1.jpg
https://static1.pt-content.com/image...VC014Fvi-1.jpg


Sand blasted everything.
https://static1.pt-content.com/image...VC004Fvi-1.jpg
Prepped and cleaned for Rustoleum Silver Hammered.
https://static1.pt-content.com/image...VC002Fvi-1.jpg
I mixed a little enamel hardener into the Rustoleum and it got as hard as a rock after about an hour dry time.
https://static1.pt-content.com/image...VC004Fvi-2.jpg
The control arms and spindles have already been repainted and I need to repaint the rear housing and get the stab bars painted but this was a big one!

A couple of weeks ago some friends came over and we pulled the frame off the rotisserie.
https://static1.pt-content.com/image...KNx9EDKg-1.jpg
https://static1.pt-content.com/image...cnx9EDKg-1.jpg
https://static1.pt-content.com/image...Rnx9EDKg-1.jpg
https://static1.pt-content.com/image...iyx9EDKg-1.jpg
https://static1.pt-content.com/image...Cdx9EDKg-1.jpg


Working on getting the driveline bolted together. Ran into a snag with the old gear vendor unit. it is sold and gone and a new one is on it's way from GV.


I am designing an AC compressor bracket that I can fab, just need to get the pulleys sorted out so I can get the placement nailed down.
https://static1.pt-content.com/image...Rqx9EDKg-1.jpg
https://static1.pt-content.com/image...Pdx9EDKg-1.jpg


I worked on the trans itself this afternoon. Putting on a deep sump pan that I picked up at a swap meet. The new pan is an inch deeper then the rusty stocker and I had to order the extension for the filter pick up tube. I made a spacer for the filter bolt today. I turned the spacer out on the lathe. Faced it off to shine it up and bored it out for 5/16ths bolt to pass through it and cut it down to about an inch long. It will bolt between the filter and the valve body. The pan is like brand new. A little dusty but it has never had fluid sitting in it...
Need to order 1" long bolts for the new pan as the stock ones are to short. McMaster Carr here I come!
https://static1.pt-content.com/image...GWx9EDKg-1.jpg
https://static1.pt-content.com/image...Jnx9EDKg-1.jpg
https://static1.pt-content.com/image...Z5x9EDKg-1.jpg
https://static1.pt-content.com/image...LNx9EDKg-1.jpg
https://static1.pt-content.com/image...qnx9EDKg-1.jpg
https://static1.pt-content.com/image...5yx9EDKg-1.jpg
https://static1.pt-content.com/image...8Gx9EDKg-1.jpg
It's getting there! Pulling together all of the fasteners seems to be a full time job! During the build and mock ups I have been getting by with an odd assortment of bolts and nuts but, now that it is going together for the last time I am finding a lot of stuff I need to order!
This is where things are at as of yesterday. Thanks for looking!
Mark

Welcome back. We love updates!

Times 10.. we love updates with photos!

Good to see you posting again too.

Ditto some really great progress and very nice work!

This is a pretty cool project! I’m glad to see you’re plugging away at it.

https://www.youtube.com/watch?v=-j0H...tbChannel=null

Not quite what I am going for but that is a bad ast van!
Got some work done the last few days. And another step backwards as well!... The water pump has zero outlets for plumbing the heater or by-pass hoses...
https://static1.pt-content.com/image...rFx9EDKg-1.jpg
https://static1.pt-content.com/image...sFx9EDKg-1.jpg
The pump was on the motor when I picked it up, figured to re-use but it's no good to me without the heater outlets. I will need the suction side for the heater and the by-pass hose is a good thing right? Options with this pump? Drill and tap? Bite it and buy a new pump? I got a new pump...

New pump came in from Summit, I went with cast iron so I have some work to do.
https://static1.pt-content.com/image...pRx9EDKg-1.jpg

https://static1.pt-content.com/image...3Dx9EDKg-1.jpg
This one has some real nice heater and bypass hose fittings on it. Should work just fine

I have also been working out all the fittings I am going to need. I ordered almost 400 bucks worth of -4, -6, -10, & -12 Push-Lok hose and fittings yesterday as well. Pipe plugs, bolts for the trans pan, etc., etc. I knew this day was coming so I have the money. Kind of exciting to be at this point!

I also worked on the deep sump pan yesterday. Drilled and tapped for the temp sender.
This is the spot. I am putting it at the back of the pan and deep enough that it should never be uncovered.
https://static1.pt-content.com/image...qVx9EDKg-1.jpg
Spot faced and pre drilled.
https://static1.pt-content.com/image...5Dx9EDKg-1.jpg
Ran a tap drill in for the 1/8th pipe tap.
https://static1.pt-content.com/image...jTx9EDKg-1.jpg
All done!
https://static1.pt-content.com/image...8Sx9EDKg-1.jpg
https://static1.pt-content.com/image...MVx9EDKg-1.jpg
https://static1.pt-content.com/image...zhx9EDKg-1.jpg
Mark

I got the new water pump painted yesterday.
https://static1.pt-content.com/image...tmx9EDKg-1.jpg
Bolted it up and tried the pulleys on for size... Guess what, yea... The old pump shaft was 5/8th's. The new one is 3/4. Now the pulley won't fit. Is that par for the course or what?
https://static1.pt-content.com/image...7Sx9EDKg-1.jpg
So! What to do?
Get out the step drill man!
https://static1.pt-content.com/image...shx9EDKg-1.jpg
Chucked the drill into the drill press and ran a dummy hole into a sacrificial piece of wood. Then used the 5/8th's step on the drill to locate the pulley and clamp it down while I screwed it to the wood to keep it from moving.
https://static1.pt-content.com/image...Vhx9EDKg-1.jpg
Ran the step drill in to the 3/4" step and it was done.
https://static1.pt-content.com/image...CLx9EDKg-1.jpg
Did the same thing with the spacer
https://static1.pt-content.com/image...GTx9EDKg-1.jpg
and now it all goes together like it was supposed to.
https://static1.pt-content.com/image...qVx9EDKg-1.jpg

I have all of the pulleys now and am working on a bracket design to get the AC compressor mounted underneath the alternator. I don't want to make the bracket until I get the engine and trans in place. Just to confirm the placement. I have a TON of parts coming in this week, the Over Drive was shipped Friday so this is starting to come together.

Originally Posted by astroracer

I have a TON of parts coming in this week, the Over Drive was shipped Friday so this is starting to come together.

I thought I heard that big cash register in the sky ringing up a sale!! And it said, "No Change!"

Thanks for the update and pics.

Great simple fix. I have all the above tools and would have never thought to try that. Sometimes the simple solution is the best and fastest/ cheapest!

Yes Sir, sometimes the simplest solutions never come to mind. I was thinking about what I was going to do when the step drill idea hit me. I went out and got it done.

Got a pile of boxes today. Fittings and hoses.
https://static1.pt-content.com/image...Ehx9EDKg-1.jpg
Swapped out the adapters on the trans for these push-loks.
https://static1.pt-content.com/image...HCx9EDKg-1.jpg
https://static1.pt-content.com/image...phx9EDKg-1.jpg
-10 heater fittings. These are equivalent to the 5/8th's hose usually plugged in here. This is the draw side to the heater core.
https://static1.pt-content.com/image...6nx9EDKg-1.jpg
-12 heater fittings are equal to the 3/4 inch hose used here. This is the suction side which draws the water from the heater core.
https://static1.pt-content.com/image...wLx9EDKg-1.jpg
I moved the fitting I took out of the pump up to the intake for the by-pass hose.
https://static1.pt-content.com/image...RCx9EDKg-1.jpg
All of the new brackets will be satin black and I will be blasting the pulleys and painting them satin black as well.
https://static1.pt-content.com/image...5gx9EDKg-1.jpg
I think that will look better then the chrome, what do you think?
Mark

The new GV Unit comes in today! I want to have the trans ready to go tonight. Setting up the OD adapter should go pretty quick. Getting the converter bolted up is the last big thing before engine/trans marriage. I plan to have the engine and trans in place this weekend.
I knew there was a lot to do and I have been thrown a few curve balls. The little things are what takes the time and getting them right just adds to it.
Thanks for watching!
Mark

Missed a few installments over the last few days, nothing major though. Just picking away at this thing.

Did a lot of picking up and cleaning. Got the trans and GV unit set down on a cart so I can get them bolted to the block.
https://media.fotki.com/2v2EAVM7gx9EDKg.jpg
I'm going to need some help to do that. Everything is just to big and cumbersome to handle by myself.
https://media.fotki.com/2v2EAVMiFx9EDKg.jpg

I rolled out the blasting cabinet tonight and got the engine mounts cleaned up and painted.
https://media.fotki.com/2v2EAqPcWx9EDKg.jpg
About 5 minutes worth of work right here...
https://media.fotki.com/2v2EAqPenx9EDKg.jpg
Some black hammered paint and we are good to go.
https://media.fotki.com/2v2EAqPQFx9EDKg.jpg
https://media.fotki.com/2v2EAqPpgx9EDKg.jpg

Getting stuff done, kind of slow but I try to do something every day.
Thanks for watching
Mark

Lookin' good Mark. I like the look of the hammered paint myself. I use it whenever I get the chance on things like brackets / bolts / pulleys.