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If you are really concerned about the long term of moisture/rust then put down a good coat of POR-15 or take it down and have it Line-X'd. You can put anything on top of either of those products and not worry about it again..

I'll probably modify the lower ducting some...the upper ducting will do most of the work...and it too will get relocated a bit during this project.

Nope, it's going to stay, it works too well to mess with..

some progress on the base structures

I'm running Blue Sea switches for my battery system, I agree they make good stuff. With the 24" top I have some space on the backside that I played with the idea of a small window unit...if not that then I'll probably put at least one max-fan back there. I'm already just shy of 10ft tall so...

Yep; something very much like that. I saw a picture of one on an express that was made from aluminum square tube, it was a larger plaform but had the drop down built into it...was just wondering if someone else had run across it. Not a huge deal, it's not a complex piece to build either way..

I'm considering moving the cooler from under the galley cabinet to in front of the rear side barn door. I've seen some pictures of building a little sub-floor in that area to create a larger flat surface but can't find any now. Does anyone have a picture of something like that?

I was looking at maybe an 8k unit as those appear to be the most available, 6k would be fine if available, I haven't looked that hard yet and I'm not even 100% I'm going to do it at all. I've lived without a/c in this house for 25yrs...it would be just mostly be to take the edge off the heat in...

Hadn't seen the smart plug...looks like well made stuff! I am leaning toward a portable/roll-around a/c unit, I can get some use out of it in the house the few times it's hot enough here in Oceanside to want one! Stopped out at the metal supply and picked up 200ft of square tube(went with .065"...

A couple things I'd like recommendations are: a good 30amp shore power receptacle set up, (I have a 30amp shore power extension cord from the motorhome) ideas for portable air conditioning (my girlfriend isn't as heat tolerant as I am) when we have access to power awning reviews, I'm leaning...

After reading on porta-pottys a bit more yesterday (not something I thought I'd ever say) I went with the Thetford 345 https://www.amazon.com/gp/product/B07CHNB6TS/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1 for a larger seat and deeper bowl (no I'm not bragging..) both it and the cooler...

hyperlink in my signature may not be active on your phone, build thread here: https://www.dieselplace.com/forum/76-speciality-forums/218-vans/925338-2000-express-3500-hightop-lbz-allison-sas.html

Thanks for the kind words; you are correct the headroom issue is something I noticed, I'm going to pull those side panels off and see if there's any "easy to get" clearance, I doubt the hardtop installer went out of his way to get rid of any excess so I'm hopeful I can pick some up, but, if...

I'd just sell what you have and buy what you need, you don't want to find out that it didn't work after you've completely reassembled your front end...that's a lot of work..

all aluminum L33 5.3 and 4l65e swap would be easier and depending on the year of your astro(and PCM choice) may work with your stock dash cluster..

I've got about 1200miles on my Duramax/4x4 conversion and I'm satisfied I've got the bugs worked out, details for all of that are on the DieselPlace site, link in my signature. I'm going to start the rear build out now. I'll probably do this in two phases. First Phase: Buffet/booth seating on...

I was wondering the same...maybe a torque bias viscous AWD / locked center diff selection? Pretty interesting bit, I didn't realize GM and Ford worked together on the 10speed development: https://www.caranddriver.com/features/g15377492/ford-10-speed-automatic-transmission/ Looks like first...

Definitely a "wait and see" situation, when they actually release the specs to the public I guess we'll get to pick it apart then... I'd love to see a 5 to 1 first gear ratio and some specs on the transfer case bias and torque capacity. Some options for something taller than a 3.31 axle ratio...

You're not going to ever build this in enough quantity to worry about forming vs weldment, and just from looking at the make up of the pieces you wouldn't see much advantage to try and start from extruded shapes. I'd stick with jet/laser cut plate with alignment tabs and weld relief notches...

I'm a huge diesel fan as well...but...I'd go with the ecoboost for this anyways, the 3.5 has massive aftermarket tuning support and can make a lot more power than the current 5cyl diesel offering and likely the same for the coming 4cyl diesel that will replace it..