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Thanks Dave. There is probably about as much foot room as there would be in a narrow cowl "A", you are right. There is some work to be done with pedal placement but I won't do that until the front wheel wells are rebuilt.
I am forming the blend area out of cut and bent strips and welding them together. I was planning to make a hammerform to do this work but was unable to cut the glued up MDF. The "little" wood bandsaw was not up tot he task and the big saw broke a lower blade guide...
http://images33.fotki.com/v1138/phot...MVC001F-vi.jpg
Back to the drawing board. We basically wasted 3 hours dinking around with saws.
We made some flat paper templates and cut out the steel strips with my beverly shear. After some tacking and bending you wouldn't believe how strong this piece is. And it's not even fully welded.
http://images12.fotki.com/v20/photos...MVC018F-vi.jpg
Added the drop side down to the floor. The floor radius still needs bending but you can see what it will look like.
http://images16.fotki.com/v377/photo...MVC022F-vi.jpg
Here it is with a little more trimming and fitting. I decided to move it down a bit to smooth the transition with the original flange.
http://images12.fotki.com/v335/photo...MVC007F-vi.jpg
Here is a bit of development on the right hand side. This is a little simpler then the drivers side. It's all flat.
http://images58.fotki.com/v279/photo...MVC001F-vi.jpg
That is a "flexible" ruler in the pic. It is bendable and retains it shape. I'll use it to layout the flat stip for the flange.
Check out my shifter "console" :)
http://images57.fotki.com/v1354/phot...MVC003F-vi.jpg
I will be doing a lot of measuring and mocking up to get a comfortable shifter location AND workable cable route.
http://images54.fotki.com/v627/photo...MVC005F-vi.jpg
Got a lot of stuff coming together. I hope to have most of this doghouse rebuilt this weekend.
Thanks for looking
Mark
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These posts are from last month so read them as "past tense". Got some done last night and today. Spent yesterday afternoon and evening making the "S" shaped piece I was developing the other night.
Made a template using the bendy ruler and cut the piece out with the beverly shear.
http://images52.fotki.com/v637/photo...MVC002F-vi.jpg
Cutting it out. If you haven't used one of these shears you are in for a treat. Very nice to use and so much quicker than snips...
http://images51.fotki.com/v103/photo...MVC003F-vi.jpg
Did a little bending and hand forming to get the flanges rolled over. I made this out of one piece rather then two like the drivers side. This piece is flat so it was a little easier to work the radii. The drivers side went uphill while transitioning into the "S" shape. Pretty tough to form off-hand.
http://images44.fotki.com/v220/photo...MVC010F-vi.jpg
http://images58.fotki.com/v279/photo...MVC012F-vi.jpg
Mel was out today and we got a lot done. I was working on the drivers side filler piece while he was cleaning up and fitting the doghouse pieces together. I got the drivers side piece trimmed and fit well enough that I could start welding it in.
This was during the fitting process.
http://images61.fotki.com/v218/photo...MVC014F-vi.jpg
Doing some tacking...
http://images50.fotki.com/v1557/phot...MVC009F-vi.jpg
We added some extra length to the doghouse piece to fill the gap back to the floor brace.
http://images51.fotki.com/v102/photo...MVC018F-vi.jpg
We carried the floor ribs up into the doghouse piece.
http://images56.fotki.com/v362/photo...MVC004F-vi.jpg
These are all welded up now and I have a little grinding left to do to finish it up.
http://images56.fotki.com/v362/photo...MVC017F-vi.jpg
The new floor piece, as you see it, will be removable for engine and trans access. I drilled holes and installed 10-32 threaded inserts into the floor brace and the cover is bolted in right now. I will finish developing the passenger side filler pieces tomorrow....
Thanks for looking.
Mark
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This work was done over the xmas holiday. I did get a little shop time over the break. :)
The passenger side is done and I'll have the drivers side wrapped up tomorrow. This was a LOT of work!!! I still have a bit of cleanup work to do but the passenger side looks great and it all unbolts for easy engine access. Read that plugs and header bolts.
http://images44.fotki.com/v301/photo...MVC012F-vi.jpg
Some "during" shots.
http://images60.fotki.com/v778/photo...MVC013F-vi.jpg
http://images41.fotki.com/v195/photo...MVC012F-vi.jpg
http://images59.fotki.com/v112/photo...MVC019F-vi.jpg
The drivers side will have the same removable panel. I will fab up the rivnut tabs tomorrow and get that stuff welded up. Should have a complete doghouse flange by noon.
http://images16.fotki.com/v377/photo...MVC009F-vi.jpg
Thanks for looking.
Mark
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This series was done over New Years weekend.
What with my 34th wedding anniversary and New Years Eve being the same night I killed two birds with one stone, so to speak.
We had a party Saturday and another on Sunday but I got a few hours in each day along with helping to clean and set stuff up.
Actually got a lot done. The doghouse removable panels are done, both sides. Everything is bolted up and fits very well so I am happy. Having these panels removable makes for easy working clearances around the plugs and headers.
http://images44.fotki.com/v220/photo...MVC018F-vi.jpg
http://images59.fotki.com/v255/photo...MVC019F-vi.jpg
http://images51.fotki.com/v628/photo...MVC020F-vi.jpg
I still have to finish up a short flange for the rear part of the floor but that is easy and I'll get that wrapped up this afternoon.
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I also finished up a short flange for the rear part of the floor Monday afternoon. It was fairly simple. A flat sheet formed around the front of a floor rib and welded to the removable half of the doghouse flange.
http://images44.fotki.com/v301/photo...MVC011F-vi.jpg
A little trimming and bending and it fit very well.
[img]http://images56.fotki.com/v124/photos/5/904975/10310642/MVC013F-vi.jpg/img]
The piece is welded on and bolted down with a bit of grinding left to do. Once this is finished and painted it will look great.
http://images12.fotki.com/v20/photos...MVC014F-vi.jpg
The floor and doghouse areas are very sturdy now.
Thanks for looking
Mark
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This post will get you all up to date as of yesterday.
Did some much needed cleaning during the week. It's hard to believe how many c-clamps and vice grips we used doing the engine cover rebuild. I am back to working 56 hrs so I don't get much time in the shop during the week. I'll do a little bit of work but most of the fab time will be on the weekends.
We got the rear wheel wells trimmed and cleaned up today and we also cut out the old rear rails.
Because I am re-using the old wells we needed to square up the cuts I made when I removed them. We squared them up on the table and used my height gauge, with a marker hose clamped to it, to mark a line around them. Worked nice.
http://images51.fotki.com/v628/photo...MVC003F-vi.jpg
The wells all marked up and ready to trim.
http://images61.fotki.com/v777/photo...MVC005F-vi.jpg
After an hour or so of cutting, grinding and sanding we have some cleaned up wheel wells.
http://images44.fotki.com/v301/photo...MVC007F-vi.jpg
The pass. side clamped into it's approximate position. This is just a look see. You can see the original rail still occupying space under it.
http://images61.fotki.com/v777/photo...MVC013F-vi.jpg
Mel starting the first cut on the rear rails. These are welded into the unibody of the van.
http://images57.fotki.com/v300/photo...MVC015F-vi.jpg
After removing both rails there is a lot of room in there for tires.
http://images12.fotki.com/v20/photos...MVC016F-vi.jpg
http://images56.fotki.com/v362/photo...MVC018F-vi.jpg
http://images60.fotki.com/v778/photo...MVC023F-vi.jpg
Did a little mocking up with the rear tires. Looks sweet doesn't it.
http://images50.fotki.com/v1524/phot...MVC005F-vi.jpg
Lots of room for tire here.
http://images12.fotki.com/v335/photo...MVC008F-vi.jpg
This week I am going to work on getting the tire mocked up correctly and possibly cutting some tin for the wheel well extensions.
Thanks for looking
Mark
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Lots of good work, Mark, tires and wheels are going to look great and have lots of room back there!
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Mark,
I looked through all of your pictures and the van is going to look great with those tires! We had a couple of Astro's years back, and I always liked their lines. Yours is going to be super cool!
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Thanks guys, I have owned an Astro van since 1986. With two usually in the stable.
Have a couple of updates.
I'll get some pics of the Harwood 12 gal fuel cell I got off Ebay mocked up in the back. It's ugly. No room for the drag style fuel pickup and the tank just doesn't fit so I have decided to build an aluminum tank. I modeled this up in UG last night and started developing the tin work around it tonight. The tank volume is a little over 25 gals right now.
http://images56.fotki.com/v362/photo...altank2-vi.jpg
The tank will drop down into the space between the frame rails right behind the axle and wrap up over the frame and existing floor.
http://images56.fotki.com/v362/photo...altank4-vi.jpg
The tank will actually "plug the hole" in the floor you see right now and seal with a welded flange along the new tinwork right over the shock xmbr.
http://images60.fotki.com/v662/photo...altank3-vi.jpg
I am getting prices for a sheet of .090 aluminum and will try to weld this up myself.
Mark
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I have a "two day" weekend thanks to MLK. Mel and I were out in the shop at 9:00am this morning. We made a game plan on the floor and tub work and got busy.
After I cut out all of the stuff that's in the way of the tire....
http://images44.fotki.com/v301/photo...MVC012F-vi.jpg
Here is the pile of "stuff"
http://images57.fotki.com/v300/photo...MVC011F-vi.jpg
And here is the tire at the correct ride height.
http://images61.fotki.com/v777/photo...MVC006F-vi.jpg
Inside... I made a little gage block to mark the inner fender were I needed to remove it. Sets the pen at four inches from the tire. That gives me 3 inches of jounce and some room for a taller tire if need be.
http://images44.fotki.com/v220/photo...MVC017F-vi.jpg
here is a shot with the old inner clamped in position. It'll look pretty good once all of the tin is replaced.
http://images27.fotki.com/v972/photo...MVC002F-vi.jpg
While I was dinking around with the van Mel was cleaning up and trimming the floor so we can replace the stuff we cut out. We are putting back most of what was cut. Just reorienting it and cleaning up the cross members underneath to clear the new frame.
http://images61.fotki.com/v384/photo...MVC009F-vi.jpg
Marking for the trim line. This will butt up to what is still in the van. The holes you see are spot welds to the original crossmember Mel cut out. The crossmember will be plug welded back in place to carry passenger seat load and give me a place to hang mufflers.
This next pic shows how the flange was welded to the old floor. This will now slide under the old floor and we will plug and stich weld it back together.... A little grinding and some seam sealer and we'll be good.
http://images57.fotki.com/v300/photo...MVC004F-vi.jpg
http://images34.fotki.com/v1081/phot...MVC018F-vi.jpg
There is a lot of work to do under the floor. We need some shallow notches to clear the new K member and the ends of the original crossmember need to be plated in for strength. I'll get pics of that tomorrow.
Mark
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It's all those little details that nobody ever sees that eats up all the time and makes for a quality build. Then the unknowing wonder why it takes so long to get a project done!!!! Nice work, Mark.
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Isn't that the truth! Thanks Dave!
We got a lot done today although, like Dave says, it doesn't look like it. I spent two days cleaning out all of the old sheetmetal to make room for the new tires... Couldn't believe it. TWO DAYS!
Both sides are opened up now so I can actually get back to building...
http://images61.fotki.com/v777/photo...MVC015F-vi.jpg
I still have a lot of work to do to get the new tubs fit in but we'll get there. All of the dirty work is done so this next step is fun.
http://images12.fotki.com/v20/photos...MVC018F-vi.jpg
Here is a pic of the drivers side tire at ride hgt.
http://images51.fotki.com/v628/photo...MVC003F-vi.jpg
Mel got the floor patch almost ready. He made the end plates and got everything fit up and clamped
http://images16.fotki.com/v382/photo...MVC008F-vi.jpg
After the fit up.
http://images57.fotki.com/v300/photo...MVC013F-vi.jpg
A lot of work here also.
http://images61.fotki.com/v384/photo...MVC014F-vi.jpg
This piece will get welded back into the floor and that original crossmember will give me a place to hang mufflers and stuff.
http://images12.fotki.com/v335/photo...MVC020F-vi.jpg
We still need to get it set into the floor so we can mark it for the K member notches. Lots to do, so little time...
Thanks for looking
Mark
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I have been following this build I realy like the idea to not change the outside. a lot of guys just cut out and put in bigger tires I like your taking your time and realy like the pictures Thanks
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Really nice work Mark!!! Large wheels and tires can still give the impression of a subtle mod when the work is done correctly! Yours certainly do fit in there nicely! Well done!
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Thanks Charlie, Thanks Dave! It's great to have someone watching the build AND seeing the vision! This van has been done in my head for years... I know what it will look like and I am feeling really good about the final product. It will be done right AND done well.
Thank You for the compliments.
I have been chomping at the bit all week to get out to the shop. We got about 3 inches of snow last night so I blew off drining 65 miles into work today. Stayed home and worked on the van. (After shoveling walks and driveways of course...)
TechRod, by all means get a thread going! Some of the computer and electrical stuff you are doing is crazy!
Mel came out after I called him. He worked on the floor patches, notching the old xmbr so it will fit over the K braces and making plug weld flanges. he layed out the notches and cut them out with the sawzall and plasme cutter.
http://images50.fotki.com/v1530/phot...MVC006F-vi.jpg
He cut a piece of 2" DOM down the middle and fit the halfs into the notches he made.
http://images57.fotki.com/v505/photo...MVC012F-vi.jpg
All welded up and grinding down the high spots.
http://images51.fotki.com/v102/photo...MVC016F-vi.jpg
While Mel was working on all of that I was building this contraption to set the height for the top of the new inner wheel houses. This gives me a hard reference point for height AND a place to clamp too.
http://images35.fotki.com/v1154/phot...MVC004F-vi.jpg
It will stay in place while I build both sides.
http://images30.fotki.com/v479/photo...MVC009F-vi.jpg
I used posterboard to make the RH pattern. This is the difficult side because I have to work around the bottom of the slider door track. It is directly behind the inner sheet metal and protrudes into the wheel well about an inch and a half.
http://images51.fotki.com/v102/photo...MVC023F-vi.jpg
This pic is from underneath so you can see the track and how I had to jog the panel around it.
This is the fit I am looking for. It won't be welded to the outer. The inner panel will get welded and this gap will get filled with seam sealer.
http://images45.fotki.com/v1310/phot...MVC022F-vi.jpg
http://images57.fotki.com/v505/photo...MVC019F-vi.jpg
Once the pattern was made I could start cutting steel. I cut a hunk of 18ga with the old Pexto. That machine handles the heavier gage a bit easier than the 3 in 1 does...
Laid out the pattern, cut out the shape, put a bit of a bend on it to conform to the old inner well and set it in place for a look see...
http://images32.fotki.com/v1090/phot...MVC003F-vi.jpg
After a couple more ins-n-outs I had the shape real close.
http://images12.fotki.com/v20/photos...MVC006F-vi.jpg
This is the fit-up underneath. I wanted to keep the new steel away from the outer by about an 1/8th inch. It's real close to that and it will seal up nice.
http://images60.fotki.com/v361/photo...MVC009F-vi.jpg
There is a little more finagaling to do but I think it's real close right now. I put in a few Cleco's and called it a day.
http://images56.fotki.com/v362/photo...MVC007F-vi.jpg
The Cleco's are half an inch from the edge of the inner. The new panel will get trimmed to this edge and welded in once I have all of the fabricating on both tubs complete.
http://images54.fotki.com/v104/photo...MVC008F-vi.jpg
Thanks for looking
Mark
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Looks great Mark! Can't imagine doing any fab work without posterboard and cleco's!!!!!
Once the sheetmetal work is done, what's next on the build plan????
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Mark forget the flames.........ya I hate them too,but this gives you a idea what a shaved slider would look like:
http://i172.photobucket.com/albums/w...ellar/1024.jpg
The other idea is one the from ASV Socalli V8 Darren Cole on face book did,He Gull winged his.Looks pretty slick.Darren also shaved everything and built a custom cowl that hides the wipers.
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Mark here is a pic of Darren's Gull wing.What brings about these suggestions is you saying your working around the slider track.
http://i172.photobucket.com/albums/w...61990_2607.jpg
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Thanks Gary but shaving the slider was never an option. Working around the track is done now and I think it's a lot LESS work than shaving or gull-winging. I want the slider to be functional so any mods are out.
Dave, Once the rears are done the fronts will get cut out, raised and widened for the 275/40's. I will dry fit the front suspensions, run them through jounce and steer and keep the new wheel wells an inch or so away at worst case.
Mark
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Sounds kewl Mark, eagerly awaiting the next round of pics!!!!!!! I really like the direction your build is going, subtle and wild all at once!!!!
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Very nice work, Mark, and your photos are well done, too. Makes it easy to follow your process of getting those details out of your head and onto the van. Looking forward to the next installment!!
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Thanks guys! I aqm pleased everyone is enjoying this as much as Mel and I are! Roger, I find it is good to FINALLY get this stuff out of my head and onto the van!
We got a LOT done this weekend. Mel worked his ASS off on the floor patch. We had an issue where the two pieces we are welding together were mis-matched.
http://images12.fotki.com/v20/photos...MVC004F-vi.jpg
One section had floor ribs and the other didn't. Mel made a forming die from some 1/4" plate and made a couple of ribs that we welded into the floor to "terminate" the other set... Incredible. Here is the die and the 1st test "stamping".
http://images57.fotki.com/v1613/phot...MVC006F-vi.jpg
The lessons learned from that were applied to the die block. A little bigger radius at the back and some blending on the corners gave him the 2nd test stamping.
http://images16.fotki.com/v368/photo...MVC010F-vi.jpg
That's a winner!
http://images59.fotki.com/v111/photo...MVC021F-vi.jpg
He cut and fit them to the patch panel. Once these are weleded in you will never know.
http://images60.fotki.com/v778/photo...MVC005F-vi.jpg
Tacked in and looking good. Thanks Mel!
http://images51.fotki.com/v102/photo...MVC007F-vi.jpg
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While MEl was finagaling with the floor stuff I was making patterns for the front of the Pass side wheel tub. Yesterday I got the back half done.
Pattern and wheel tub.
http://images45.fotki.com/v148/photo...MVC013F-vi.jpg
After a bit of rolling and hand bending I had it fitting well enough I could put a couple of cleco's into it.
[img]http://images51.fotki.com/v103/photos/5/904975/10358292/MVC022F-vi.jpg[\img]
Had to do a bit of trimming at the lower right front corner. Three pieces of steel came together here and the outer jamb for the slider protruded inside as well so there was some work to do....
http://images56.fotki.com/v362/photo...MVC018F-vi.jpg
Both halfs are fitting fairly well right now. I still have abit of forming to do but I will take care of that when I start welding them together.
http://images56.fotki.com/v371/photo...MVC017F-vi.jpg
I also made the rear inner piece that wraps around to the side. This piece will get welded to the old tub and I will build a flange to recreate the floor that was cut out.
http://images44.fotki.com/v220/photo...MVC015F-vi.jpg
http://images16.fotki.com/v369/photo...MVC014F-vi.jpg
Still have a lot to do to wrap up the passenger side. I hope to get this done next weekend and have a good start on the drivers side.
Thanks for looking!
Mark
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Always a big day when the fitting is done and the welding begins!!!!! Some very nice work, ever thought of renting Mel out????????:LOL::LOL::LOL:
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As always realy nice work
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Mel is retired and just wastes away waiting for the weekends...
Thanks guys.
I worked all day yesterday at the real job so we didn't get out in the shop until this morning. Mel worked on the floor sections, doing a lot of grinding and cleaning up (read that making LOTS of noise and dust...)
http://images61.fotki.com/v390/photo...MVC005F-vi.jpg
http://images51.fotki.com/v282/photo...MVC012F-vi.jpg
He pulled out all of the engine cover panels and cleaned those up, finished some grinding and welding and got all of them primed. They look pretty good with some paint on them.
http://images16.fotki.com/v369/photo...MVC019F-vi.jpg
http://images12.fotki.com/v335/photo...MVC020F-vi.jpg
I made the template for the RH front filler panel
http://images12.fotki.com/v335/photo...MVC002F-vi.jpg
http://images109.fotki.com/v785/phot...MVC006F-vi.jpg
and got that cut out and fit in. Put a roll in it for the corner and put a little dink in it to finish a rib that was in the old panel.
http://images60.fotki.com/v778/photo...MVC010F-vi.jpg
Got it tack welded in and did a little cleanup grinding. I need to pull the tub out to finish the "dink" but this is well on it's way.
http://images27.fotki.com/v990/photo...MVC017F-vi.jpg
http://images60.fotki.com/v361/photo...MVC016F-vi.jpg
http://images60.fotki.com/v661/photo...MVC003F-vi.jpg
Getting the LH side set up for fabricating.
http://images12.fotki.com/v20/photos...MVC018F-vi.jpg
After the set up I got the rest of the old tin removed off the inner wall. To mark the outline I ran a straightedge across the gap and marked out the cut line with a marker.
I made another template out of the greenboard.
http://images61.fotki.com/v390/photo...MVC010F-vi.jpg
Fitting it to the outer sheetmetal.
http://images16.fotki.com/v382/photo...MVC011F-vi.jpg
This is where we knocked off for the day. We went in the house, had some cake and Mel headed home. Thanks Mel!
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Mark I use a retired guy too.
Oh wait......................that's me.LOL
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Another good weekend's work Mark! Coming together quite nicely.
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Thanks Dave, after a month or so of Over Time I finally got a full weekend off from the money job and got some stuff done on the van.
Saturday I worked on the front half of the left rear tub, getting that cut out and fit to the outer wheel well.
Here it is on the bench after I had run it through the rollers. I found it was easier to put a bit more bend into the panel then it actually needed and then sneak up on the fit by slowly unbending it...
http://images112.fotki.com/v386/phot...MVC001F-vi.jpg
Things went fairly smooth and it was clecoed in quickly.
http://images61.fotki.com/v390/photo...MVC010F-vi.jpg
You can also see the lower "skirt" piece is made and clipped in at this point.
Mel worked on the front brake hubs.... This was a job. He used the trusty sawzall to remove the rotor from the hub.
http://images16.fotki.com/v378/photo...MVC009F-vi.jpg
http://images60.fotki.com/v370/photo...MVC008F-vi.jpg
All cut down and ready for the lathe. These need to be reduced in diameter to 6" so they will fit in the Corvette front rotors. They will be shortened up quite a bit also.
http://images61.fotki.com/v390/photo...MVC017F-vi.jpg
Once this is done we will verify caliper positioning and drill out the spindle for the 7/16-20 bolts that hold on the abutmemnts.
http://images55.fotki.com/v659/photo...MVC015F-vi.jpg
Doesn't look like a lot but we made some progress.
Thanks for looking
Mark
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Got to do some tack welding on wheel tubs today! Once we were satisfied with the fit to the outer wheel well all of the new panels were clecoed in place. On the underside I marked the cut lines to trim the new panels for butt-welding to the original wheel well.
Once all of the trimming was done we used those blade style welding clamps to set the gaps and hold the edges of the panels in alignment. You can see a couple in the top of this pic.
http://images51.fotki.com/v299/photo...MVC015F-vi.jpg
They work very well. After a few tacks they come out and we move on to the next panel
http://images51.fotki.com/v103/photo...MVC001F-vi.jpg
This is the right rear.
http://images15.fotki.com/v588/photo...MVC009F-vi.jpg
The right front. We also made the piece to fill the hole from the slider door frame.
http://images54.fotki.com/v101/photo...MVC012F-vi.jpg
Once the tubs were one piece we removed them for finish welding.
http://images55.fotki.com/v659/photo...MVC017F-vi.jpg
This pic shows all of the contouring invloved working around the slider door track...
http://images16.fotki.com/v383/photo...MVC001F-vi.jpg
The finish welding will happen later. We were pretty well done in at this point. After a month or so off we lost some stamina...
Thanks for looking. More to come later.
Mark
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Mel just sent me these pics of the hubs. He took them to a local automotive shop yesterday and lined them up on turning down the O.D. to fit inside the Vette rotors and they also pressed in new bearing races and swapped out the 7/16 lug studs to 1/2".
http://images61.fotki.com/v777/photo...nthubs2-vi.jpg
The bigger studs are Astro van pieces. The one on the right still had the spindly 7/16ths in it...
http://images56.fotki.com/v371/photo...nthubs1-vi.jpg
These will clean up nice in the blast cabinet and look great with some gloss black paint on them.
Thanks again guys!
I hope we can keep moving forward!
Mark
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The wheel tubs came out great Mark! Looks like the brakes and hubs are going to be well up to the task of motivating the Van!
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Mark, you're doing some great fab work and your pictures are well done to help understand your process. It's a huge project, but one that's gonna get lots of attention down the road. Thanks for posting all of the details.
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Don't you just wish you had more time to put in on your project?
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THANKS A TON GUYS! I am glad you are enjoying the build. I DO wish I had more time to devote to it but I wouldn't be able to pay the bills that way. :( I haven't updated the thread for a while so here is what we've been up to. Just kind of picking away at things, lots of little things need doing to get the bigger stuff taken care of...
Got some work done the past few weekends. Welding and grinding on the wheel rear tubs last weekend with Mel getting the spindles set up for the brake abutment adaptor brackets.
http://images55.fotki.com/v648/photo...MVC003F-vi.jpg
http://images51.fotki.com/v103/photo...MVC008F-vi.jpg
Drilling and tapping holes for those. We had to do some plugging to relocate one of them for better caliper positioning but the other was a straight drill and re-tap for both holes.
http://images51.fotki.com/v299/photo...MVC014F-vi.jpg
Today I put off doing any welding. Worked on the alternator brackets. The brackets that came with the engine are set up for the drivers side. I have NO room for an alternator over there so it has to go on the pass. side. The pulley is out of alignment on this side so I made up a couple of spacers to push the whole bracket forward 3/4's of an inch.
http://images55.fotki.com/v585/photo...MVC002F-vi.jpg
http://images45.fotki.com/v1257/phot...MVC008F-vi.jpg
http://images60.fotki.com/v367/photo...MVC010F-vi.jpg
You can see the spacers behind the bracket. The belt lines up beatifully now. The next job is getting an adjuster plate down there. It is getting fairly close to the lower rad. hose but I think it's do-able.
Thanks for looking.
Mark
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We also started cutting up the pass side front wheel well. The whole front corner was removed in the process and there is a huge gapping hole in the floor and firewall now. You can see some of the carnage here.
http://images18.fotki.com/v438/photo...MVC011F-vi.jpg
We did this so we can get the tire wheel into full jounce and steer to set clearances and rebuild the wells.
We also started assembling the front suspensions. Pressing in the lower ball stud and bolting in the uppers, we actually assembled the front pass corner on the van for the first time!
http://images51.fotki.com/v299/photo...MVC009F-vi.jpg
http://images60.fotki.com/v361/photo...MVC014F-vi.jpg
The amazing thing to me was that it actually went together and looks right!
http://images60.fotki.com/v778/photo...MVC016F-vi.jpg
Even the calipers bolted up as designed. I was feeling pretty good by the end of the day! Even though we have a long way to go, things are coming together and it seems we are doing something right. Moving forward is good!
http://images17.fotki.com/v374/photo...MVC003F-vi.jpg
http://images50.fotki.com/v1530/phot...jpg?1332153347
I tried bolting up a front rim but the studs are too short (I knew they would be and I have longer ones from Summit on the bench) I need to change those out so I can get a wheel on.
Thanks for looking
Mark
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Thanks guys, work is progressing slowly. We are into a stage where there is a lot of little things to do before we can get big things done. Last week was spent pulling together all of the parts for the trans build. Runnning the trans and rebuild kit up to Fred in Bay City after work Thursday night. I got home at 5:00pm to a flooded shop (TONS of rain) and spent an hour getting that swept out. I will have to mop and clean the floors before I do any painting this year.
Saturday was spent working on the hubs. Sandblasting, priming, painting.
Before blasting...
http://images17.fotki.com/v284/photo...MVC002F-vi.jpg
After blasting... Cleaned up real nice.
http://images16.fotki.com/v378/photo...MVC003F-vi.jpg
I painted them the same hammer black as the spindles. Looks okay. Not that you will see them after they are assembled anyway...
http://images61.fotki.com/v384/photo...MVC007F-vi.jpg
We pressed in new, longer 1/2 inch studs today and stuck it back on the spindle.
http://images112.fotki.com/v113/phot...MVC015F-vi.jpg
We also spent some time working out the new alternator bracket design. Took a lot of measurements and I designed the new bracket last night.
http://images55.fotki.com/v585/photo...RNATOR1-vi.jpg
http://images53.fotki.com/v249/photo...RNATOR3-vi.jpg
This will move the alternator up about two inches which will get it out of the way of the lower rad hose and still clear the engine cover. I will talk to the fab shop at work about laser cutting these for me...
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Getting the hubs done with longer studs let me get a rim and tire bolted on.
http://images16.fotki.com/v382/photo...MVC021F-vi.jpg
This pic is with the fender in place. What you see here is full jounce
http://images55.fotki.com/v659/photo...MVC015F-vi.jpg
We also mocked up the steering rack so we could get an accurate lock to lock on the tire.
This is full right lock/full jounce. We developed all of our trim lines from this position.
http://images51.fotki.com/v103/photo...MVC004F-vi.jpg
This is from the pass side door before any extra trimming. We trimmed enough to give the tire a full inch of clearance.
http://images17.fotki.com/v62/photos...MVC002F-vi.jpg
This is full left lock/jounce.
We'll build a new inner fender to cover the suspension and tie into the firewall and new front structure.
http://images55.fotki.com/v585/photo...MVC005F-vi.jpg
Mel got the old inner wheel house cleaned up and we'll use that as a base to rebuild the new one.
http://images112.fotki.com/v113/phot...MVC020F-vi.jpg
We got a lot done today. Everything went together very well and we don't have any real issues other then the lack of time...
Thanks for looking! I think this van is going to look BAD AST... What do you think?
http://images16.fotki.com/v258/photo...MVC012F-vi.jpg
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Yeah Mark-it is coming together nicely.You think your going to driving it by the end of the summer??.