Thread: Bad Ast Astro Van Build

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It's funny that you mention that... mel and I were talking about that last weekend. There are very few parts in this build that we have had to do twice... I think we take our time on some things and others we just got lucky. I know I am having a blast!

Here are some pics of a little handle I designed last night in the shop. The need for this handle is to access a Dzus button at the front of the dog house. It is right under the duct for the HVAC. No way to reach it other than with this little "extension".
I roughed it out in steel, took those numbers to work and modeled it up in UG. I then sent the file to my pal in the fab shop and I had parts in my hand at lunch time!!!!
Here is the handle as I modeled it in UG. It's about three inches long.
http://images50.fotki.com/v1515/phot...mage001-vi.jpg
A few hours later I had parts in my hand.
http://images50.fotki.com/v393/photo...MVC002F-vi.jpg
After I got home from a VERY long day at work I put a bit of a bend on the handle.
http://images34.fotki.com/v1126/phot...MVC003F-vi.jpg
http://images51.fotki.com/v93/photos...MVC004F-vi.jpg
I ground a flat spot on the button (mostly to remove the galvanizing) and spot welded the handle in place.
Prior to welding.
http://images54.fotki.com/v77/photos...MVC007F-vi.jpg
After welding and a little clean up with the grinder. This position is the open position
http://images30.fotki.com/v41/photos...MVC010F-vi.jpg
Here is a shot with the button closed. With the handle like this it will be tucked up under the air duct, out of sight.
http://images114.fotki.com/v970/phot...MVC013F-vi.jpg
And one with it open for removal. This is easily reached as it sticks out past the duct. I'll get some more pics later.
http://images51.fotki.com/v747/photo...MVC014F-vi.jpg
This makes it real simple to get the buttons out for doghouse removal. I plan to add this handle to all of the buttons on the cover. They will get painted black and most of them you won't be able to see anyway. I think they look pretty cool...
Mark

Out in the shop at 7 Sunday morning. Modifying a dzus plate to weld to the new reward location and bending up a couple more of the handles. Mel got here at about 8 and we finished covering the doghouse with material.
This is a pic after the first coat of resin. This stiffened up the material enough that we could start laying some 'glass on.
http://images45.fotki.com/v148/photo...MVC010F-vi.jpg
http://images38.fotki.com/v1217/phot...MVC012F-vi.jpg
We let the piece cook in the sun for a few hours, did a little grinding to start smoothing things out and then bolted it back into the van so it can cure in the shape it needs to be...
We also mocked up the seats where they need to be, threw in the column for driver position and also worked out the shifter position. The shifter is going to live up on the back edge of the doghouse.
http://images49.fotki.com/v1458/phot...MVC005F-vi.jpg
I thought we would have to be VERY creative with the cable routing but I came up with a very easy route. We will be building the shifter into the top of the cover. This will all have to come out when the cover is removed....
See the "divot" in my leg from the band of steel in the doghouse? We cut that down a bit before we glassed it. Let me tell you there is NOT a lot of room over here for feet and legs.

Design-wise I will drop the shifter into a pocket, built into the cover, so the cable comes out level with the top of the doghouse, I will run the cable straight forward, over the top of the doghouse. I will then make a closeout panel to cover the cable (and wiring) which will pull off with a couple strips of velcro. Making the closeout panel out of the same carbon fiber that I use on the cover will make it all but disappear...
Mounting the shifter with some quick release pins will allow me to easily remove it and set it on the floor or in a seat to pull the cover.
Here is the solution in a nut shell...
" While looking at photos of the cover installed, I noticed, on the right side of the engine cover flange, there is a square hole which was the old computer connector pass-thru. I can route the cable in a big loop over the doghouse, vertically down thru that hole and then rearward toward the tailshaft. This will be one huge loop, no tight bends at all. I will route some romex along it tonight ,if I get time, but I thinking I may be able to get away with a 10 foot cable. I plan to hard mount the cable as much as possible to keep loss of travel to a minimum."
added a quick photoshop for cable routing
http://images42.fotki.com/v1314/phot...routing-vi.jpg
When I got home last night I ran the short cable I got with the shifter along my "path".
Up on top, the cable naturally falls down thru the pass-thru.
http://images58.fotki.com/v154/photo...MVC007F-vi.jpg
http://images57.fotki.com/v139/photo...MVC008F-vi.jpg
Underneath it sweeps right back toward the rear of the van. Mind you this is all natural, there are no forced bends in the routing.
http://images33.fotki.com/v1187/phot...MVC005F-vi.jpg
This routing will work perfectly and it tucks the cable right alongside the old frame rail, well away from the headers and exhaust heat.
Thanks for looking!
Mark