Thread: Bad Ast Astro Van Build

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Originally Posted by pat mccarthy

make sure to take one of you rod ends or a set up block so we have the right spacing for the brackets what size is the bolt holes we will need set up bolts if 5/8 i do not have any bolts /nuts for setup

Okay, cool. I'll be bringing the bushing spacers and hardware. Everything is 9/16th's.

Originally Posted by astroracer

Okay, cool. I'll be bringing the bushing spacers and hardware. Everything is 9/16th's.

ok 9/16 bolts/nuts are a no go for me and any thing open around the shop could be very hard to find around here ...do not leave home with out them

Just a bit of an update. Haven't been getting a lot done because the build is to a point where things just don't go as quick. Today and last Sunday were spent working with Pat McCarthy of McCarthy Performance in Kawkawlin, MI. (I think everyone here knows who Pat is). We have been installing the 4 link brackets on the 9" and getting it ready for narrowing. His shop is an hour and fifteen minute drive north for me so we do as much as we can in a day. It took two full days to get all of the brackets installed but I'll tell you right now they are right and won't be falling off any time soon.
Here are a few pics from the two days we spent on the brackets.
Last Sunday we got the two sets of upper brackets installed and called it quits about 4 or so.
http://images15.fotki.com/v235/photo...00_4091-vi.jpg
I had cut all of the brackets for the 3.25 dia. tube.... We had to do some "finagaling" with the two inside plates to get them on the "square" shoulder of the punkin.
http://images51.fotki.com/v103/photo...00_4097-vi.jpg
This took some time as they also had to sit square and still line up with the outer plates.
http://images59.fotki.com/v684/photo...00_4089-vi.jpg
We did good. After welding the bolts slide out easily.
http://images108.fotki.com/v191/phot...00_4095-vi.jpg
Today was spent sticking on the lowers.
http://images58.fotki.com/v154/photo...00_4256-vi.jpg
These went pretty quick compared to the uppers. No "finagaling" to do...
http://images107.fotki.com/v780/phot...00_4267-vi.jpg
http://images108.fotki.com/v360/phot...00_4269-vi.jpg
http://images59.fotki.com/v222/photo...00_4270-vi.jpg
Here is a couple pics of the 3rd member. Yukon case and gears, TrueTrac, HD pinion support and a 1350 yoke
http://images59.fotki.com/v255/photo...00_4258-vi.jpg
http://images110.fotki.com/v630/phot...00_4260-vi.jpg
Things are coming together. Just slowly...
Thanks for looking
Mark

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

Originally Posted by Dave Severson

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

Hey Dave,
Nope, no fires other than the one on the end of his torch...
http://images56.fotki.com/v1602/phot...00_4087-vi.jpg
Thanks for the compliment, although I have to give Pat most of the credit. Working with him those two days taught me a lot! He is very talented and knowledgable and it was a pleasure working with him. Yea, Pat, I'm talking about you!!!
Thanks for the help and hard work you put in on the housing...
Mark

Originally Posted by Dave Severson

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

no i am quiet sure you could of but did not. i find after being burnt up sitting for over 3 month waiting for skin to grow back so i can try to get back on my feet to make a living i find it more funny if i start the burn jokes about my self and welding.. Thanks nice try

Mel was over today and we got most of the rear suspension brackets fabricated. We left them in a rough state for the most part. I really don't want to finish them up until I have the housing back in the shop and get it hung on the 4 link.
These are the frame brackets for the panhard bar. We still have to cut the clearance pockets (the white layout lines) for the rails but we won't do that till the rear is actually in place. Because these brackets "live" on the frame kickup the cuts need to be in the right spot to control height.
http://images15.fotki.com/v2/photos/...MVC001F-vi.jpg
These are the housing brackets. They will be welded to the left side lower bar/shock/panhard bracket after the housing is hung.
http://images54.fotki.com/v77/photos...MVC002F-vi.jpg
This is the outer frame gusset for the panhard bar. It is "kind of" fit to the bottom of the rail but there is room to play. You can see my layout lines on the rail. These were laid in from the front 4 bar mounting hole to establish the panhard bar bracket location.
http://images116.fotki.com/v618/phot...MVC003F-vi.jpg
Here is a mock up shot of the housing bracket. The round tube will eventually pick up the housing itself to triangulate the PHB brkt.
http://images108.fotki.com/v205/phot...MVC009F-vi.jpg
Inside the PHB brkt is a box section to help carry the loads generated by the triangulation bar. This whole mess will be welded directly to the lower bar bracket.
http://images110.fotki.com/v629/phot...MVC011F-vi.jpg
We got a lot done. Mel is heading to Florida tomorrow for two weeks so I'll be going it alone for a while... Lots to do though.
I will start building the 4 link bars tomorrow. I will keep you all updated.
Thanks for looking
Mark

And more good lookin' brackets!!! Anxious to see the entire assembly setting in place, Mark! Definitely going to be a some nice working and looking suspension!

Man, you build some great looking parts. This thing is really going to be sweet when it's done!

Thanks guys, I really appreciate the comments. I hope it lives up to mine AND everyone elses expectations...
The rear suspension is well on it's way. I have a few things to tidy up so I can get the rear hung and the frame brackets finalized. i am hoping to have a full suspension under the van by the end of the day Sunday.... we'll see how it goes.
Last Saturday was spent in Kawkawlin wrapping up the housing mods. This time Pat and I finished up the narrowing, getting the bearing ends welded back on and figuring out axle lengths. Pat wasn't feeling very well so I really appreciate him taking the time to get this wrapped up. Thank You Pat.
I will be ordering axles from Moser this week.
http://images58.fotki.com/v510/photo...00_4276-vi.jpg
We also borrowed his neighbors lathe to bore out the upper bars to except the weld bungs I got from Currie.
Bored out bars and bungs... The upper bars are 1.5" OD
http://images108.fotki.com/v191/phot...MVC008F-vi.jpg
Brought everything home Saturday afternoon. Finished housing and brand new Yukon 3rd member.
I stopped at Withers steel on my way home and picked up a 24 x 36 piece of 3/8ths steel to start building a "Big Boy" welding bench. I also picked up a 4 ft piece of 1 " OD x 1/8 wall DOM for the panhard bar.
Sunday I spent hurting my back unloading all of that steel. (If you have never juggled a freshly built 3rd member you are missing out on a fun time) I got the upper bars built. Cut to length, fishmouthed and tack welded.
Fitting the bushing sleeve.
http://images51.fotki.com/v103/photo...MVC004F-vi.jpg
Tonight I got the lowers cut out, fishmouthed, beveled and tacked.
http://images116.fotki.com/v618/phot...MVC009F-vi.jpg
That's a tape measure for scale...
http://images54.fotki.com/v104/photo...MVC012F-vi.jpg
Tomorrow afternoon I am taking the bars out to EVI so Brett can weld them for me. I REALLY need to learn this TiG stuff better...
Thanks for looking at my junk
Mark

Anxious to see the whole thing all welded up and ready to go!!!!! Nothing beats a really nice rear end!!!!!!!!

Nothing beats a really nice rear end!!!!!!!![/QUOTE]
I have to totaly agree

I wholeheartedly agree! Who doesn't like a nice rear end? This one is taking shape.
Got some work done on it this past weekend. We were making more brackets... Lower shock brackets and a couple of extensions that I added to the rear axle shock brackets so I can use my 6" inch travel Vari-Shocks in the rear.
We also got the rear axle mocked into place. Clamped some scrap tubing to the frame and set the axle on that to get the height established.
http://images58.fotki.com/v156/photo...00_4385-vi.jpg

http://images57.fotki.com/v256/photo...00_4386-vi.jpg
I cleaned up and painted the 4 link bars Monday night. I used Rustoleum primer and "Hammer" gray. I think they look pretty good for a rattlecan job.
http://images59.fotki.com/v683/photo...00_4367-vi.jpg
I masked off the monoballs rather than take everything apart.
http://images57.fotki.com/v81/photos...00_4368-vi.jpg
I'll get some better pics when they are dry and I can lay them down.
Thanks for looking
Mark

I got a UPS notice last night! My axles will be delivered "by end of day" TODAY! Odered them from Moser Thursday morning and they were shipped Monday afternoon!
I am going to start finishing up the welding on the chassis tonight and should be able to wrap that up tomorrow night.
I hope to have the rear suspension set up this weekend (painting the Bars so I can install the poly bushings is part of the plan). She is coming together, slowly. I am in the process of planning fuel, brake and battery lines. I need to get the chassis under the van to get the body brackets placed. That will start this weekend. Once that is done I will get a heavy coat of primer on the chassis and start building anti-roll bars. Lots to do! No lollygagging allowed!
Thanks for looking at my junk.
Mark

How about a quick update? I have no pics from today as BOTH of my camera batteries decided to die at the same time. I just ordered new ones tonight.
Mel and I got the rest of the rear suspension put together today. Here is some of the stuff we worked on.
* Made the upper 4 bar frame brackets.
* Tacked on the upper bar brackets
* Built the panhard bar housing bracket and tacked it to the housing
* Tacking that to the housing we could finish up fitting the PHB frame bracket.
* Tacked and then finish welded the PHB bracket.
* Once all of that junk was in place we could fit the upper shock crossmember.
* We used a piece of 2" x 1/8th wall DOM for that, drilled holes for the shock mount sleeves, notched the ends to fit over the rails and tacked it in.
* I cut a piece of 1" x 1/8 wall DOM to make the panhard bar. Got that weled up and in the chassis.
I will be making some filler plates for the ends of the shock crossmember and doing a lot of welding this coming week.
Got a lot done today! There is a functional rear suspension in the van right now. That is HUGE!!!
I will get pics as soon as I get batteries.
Thanks for reading about my junk
Mark