GREEN GOBLIN: 1996 GMC Savana Conversion Van

1996 GMC Savana 1500 with a Gulf Stream Conversion

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I got a van! After many years of owning and building adventure travel vehicles I have decided that I am ready for a conversion van (again). Based on my past overland adventures and journeys I realized that I spent 99.9% of my time and mile in 2WD and with careful route selection and ground clearance I only use 4x4 only for fun not that I would but I could lines or trails. So 2WD will be absolutely adequate for all my adventure needs.

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My priorities for this new toy were: headroom, I want to be able to stand up and be able to dress without doing a serious yoga workout. Ground clearance enough to conquer trails where Honda Civics and off the showroom floor Suburbans rip their bumpers off. As close as I can get to 20 miles per gallon and 500 miles on a single fill up without spare fuel cans. Ample interior room to sleep 2-4 adults and store all the toys and gear without encroaching on interior space. Price: as cheap as I can find without the vehicle crumbling apart from rust. Affordable repairs which can be done with a quick reference on YouTube and parts that can be found in any auto parts store or junkyard. Finally something that's reliable enough to buy it, put gas in it and drive it as far as any road will take me in any direction as is with no worries .

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20 years ago I had a 1990s Dodge B250 conversion van, it was amazing. After 200k miles I got bored of it and sold it for more that I originally paid for it. Couple years later I wanted another one and in a hurry picked up a early 2000s Ram Van 1500. it was fun but a little shorter than my B250, less room, less cargo capacity and less miles per gallon and shorter driving range. I sold it and have not looked back on getting a replacement until this spring.

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I knew I wanted a 2500 chassis, Dodge or GMC, however I came a cross a 1500 Savana high top conversion van with 5.7l small block and 85,000 miles. Price was right and I pulled the trigger. Some of the plastic trim was cracked from the sun and age, paint was faded and peeling in places. Shocks were original and leaked out years ago providing with a breath holding boat like ride with over exaggerated yet gentle sway and lean in every turn. The final point in this decision were the brand new tires or so the owner claimed. DOT sticker read 18th week of 2021 but the owner claimed he only had 200 miles on them since he bought them. As I carefully inspected everything that could possibly be wrong with a 30 year old van the owner came out with a receipt for tires: 3 peak snowflake M+S AT tires installed 142 miles ago. I was sold.

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Now I have a new to me van. I am going to run it as is on as many adventures as possible adding, removing, rebuilding it as I see fit based on lessons learned from past adventures and my perceived future adventure needs. Based on my past adventures I know interior will be rebuilt, 35" tires and a lift kit will come sooner than later.
 
First mod! I added a light bar!

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Front bumper has a pseudo step built in but all I see it as the perfect spot to mount a curved light bar.

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Light bar mounted, relay installed, wiring ran and switch connected. Ideally a 36" curved light bar would fit this space perfectly, however I settled for an eBay 32" curved light bar. It works way better that the headlights!
 
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The day after after acquiring the van it went on a little 3,000 mile shake down drive.

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Rt 50 does not disappoint being the loneliest road in America.

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Very interesting how Desert and Oasis are only two miles apart.

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Only 22,223 miles until I see all ones!

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Lake Tahoe is breathtaking as usual. Very tempting to drop the kayak into the snow-melt freezing cold water.

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Driven past this little gem many times but this time decided to take a short walk and check it out.

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South Inyo Crater. Pretty cool place and only two miles up a snow covered forest service road and another mile hike.

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Pictures do not do the steep walls justice. Would be fun to ski if there was a little more snow.

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Tree stumps in the Sierras are pretty huge. My lab is 80lbs for reference.

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Van did great at 11,990 foot Loveland pass, going up and back down.

I averaged 18.5 mpg and between 450-510 miles per fill up. I pulled the middle seats out for the drive and had a 42" dog kennel for my puppy. There was so much room in the van that we would go on our morning walk without stepping outside. Rear bed got a 4" tempurpedic mattress and I fit on it comfortably both lengthwise and transversely.

Couple minor issues with the van that will need to be addressed in the near future:
  • Thermostat is stuck open. I either have full blast AC or high heat, nothing in between and engine temp does not go up above 120F. Got a new thermostat ready for an emergency roadside repair, did not need it yet, should replace it sooner than later, bet it runs better at normal operating temperature.
  • Front rotors are original and are slightly warped, cheap metallic brake pads look relatively new Replacement rotors and ceramic pads are in the near future.
  • Weird front tire tread wear consistent with loose ball joint. Need to find the bad ball joint and replace, until then: higher tire pressure and more frequent tire rotations.
  • Van pulls to one side, also consistent with ball joints in control arms or tie rod ends. Alignment to come soon.
  • Front shocks are pogo sticks, one is leaking other one already leaked out and dry. Upgrade to Bilstein 5100s in the near future all the way around.
 

ThundahBeagle

Well-known member
The day after after acquiring the van it went on a little 3,000 mile shake down drive.

cDh3O6J.jpg


Rt 50 does not disappoint being the loneliest road in America.

lxcudLC.jpg


Very interesting how Desert and Oasis are only two miles apart.

R8gLtzS.jpg


Only 22,223 miles until I see all ones!

rbV8dF0.jpg


Lake Tahoe is breathtaking as usual. Very tempting to drop the kayak into the snow-melt freezing cold water.

FdJgqCJ.jpg


Driven past this little gem many times but this time decided to take a short walk and check it out.

iBYaTD9.jpg


South Inyo Crater. Pretty cool place and only two miles up a snow covered forest service road and another mile hike.

iC7xMMQ.jpg


Pictures do not do the steep walls justice. Would be fun to ski if there was a little more snow.

Gk94fo6.jpg


Tree stumps in the Sierras are pretty huge. My lab is 80lbs for reference.

rgQxyg0.jpg


Van did great at 11,990 foot Loveland pass, going up and back down.

I averaged 18.5 mpg and between 450-510 miles per fill up. I pulled the middle seats out for the drive and had a 42" dog kennel for my puppy. There was so much room in the van that we would go on our morning walk without stepping outside. Rear bed got a 4" tempurpedic mattress and I fit on it comfortably both lengthwise and transversely.

Couple minor issues with the van that will need to be addressed in the near future:
  • Thermostat is stuck open. I either have full blast AC or high heat, nothing in between and engine temp does not go up above 120F. Got a new thermostat ready for an emergency roadside repair, did not need it yet, should replace it sooner than later, bet it runs better at normal operating temperature.
  • Front rotors are original and are slightly warped, cheap metallic brake pads look relatively new Replacement rotors and ceramic pads are in the near future.
  • Weird front tire tread wear consistent with loose ball joint. Need to find the bad ball joint and replace, until then: higher tire pressure and more frequent tire rotations.
  • Van pulls to one side, also consistent with ball joints in control arms or tie rod ends. Alignment to come soon.
  • Front shocks are pogo sticks, one is leaking other one already leaked out and dry. Upgrade to Bilstein 5100s in the near future all the way around.

"When this baby gets up to 88,888 miles (per hour), your gonna see some serious sh ! t."

Great scenery. I'd love to get out that way some day
 

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