New project: The White Buffalo (Chevy Express AWD)

[zuren]

One of the issues with the trucks, that may be the same with the vans, is the factory shocks are too short. The shocks limit travel, before the suspension reaches the lower travel stops.

When the torsion bars are cranked, the suspension has nowhere to go. Sometimes this looks like it has no effect. There is also a difference in the bars. The heavier bars will respond better to cranking, but they will also ride stiffer.

Try removing the nut on the upper shock mount. Then jack up the van, under the cross member, and see if the suspension travels further down than the shock does.

Hey Photog - I wanted to revisit this comment of yours. Once it gets warmer out I plan to do as you suggest and check the suspension travel with a shock disconnected.

If travel is being limited, then I need shocks that can handle a <3" lift or something like this right?:

http://www.bilsteinus.com/products/off-road/5100-series-ride-height-adjustable.html

The van has 120k miles and the shocks look to be original. I don't feel anything strange but I'm sure I may be due for replacements on all 4 corners.

While on the topic of shocks, it looks like my van has a stem top mount but most shocks for trucks have the eyelet design. It appears I would need a stem-to-eyelet adapter?

Thanks!

 

[zuren]

Update: Facelift

I like the composite headlight look on Chevy's better than the standard work van/truck front ends, so I decided to change it.

Before

After

This also opens up more options to run different wattage bulbs. I was running the Hella H4 upgrades but still wanted the updated front clip. I took some pics during the install if anyone is interested in a short write-up.

 

[Photog]

Hey Photog - I wanted to revisit this comment of yours. Once it gets warmer out I plan to do as you suggest and check the suspension travel with a shock disconnected.

If travel is being limited, then I need shocks that can handle a <3" lift or something like this right?:

http://www.bilsteinus.com/products/off-road/5100-series-ride-height-adjustable.html

The van has 120k miles and the shocks look to be original. I don't feel anything strange but I'm sure I may be due for replacements on all 4 corners.

While on the topic of shocks, it looks like my van has a stem top mount but most shocks for trucks have the eyelet design. It appears I would need a stem-to-eyelet adapter?

Thanks!

When you jack up the front end, you will be able to determine how much more shock-length is needed. 1" of movement at the shock is about 2" at the wheel. You should be able to get a good Bilstein, that has the proper mounts, without having to use that converter piece.

 

[TroySmith80]

lol, I keep bumping up all these AWD threads...

Zuren & Photog: I don't think the shock could be what is keeping zuren from seeing an increase in ride height, because the shock is not fully extended when the van is just sitting there. So if he cranks on the torsion bar, he should get an increase in ride height. However, i can't imagine how it's possible that he can turn the bar and not get a change in ride height... something is weird here.

PS - Photog, is your Roadtrek a chevy? 2WD, 4x4 converted?

 

[Photog]

lol, I keep bumping up all these AWD threads...

Zuren & Photog: I don't think the shock could be what is keeping zuren from seeing an increase in ride height, because the shock is not fully extended when the van is just sitting there. So if he cranks on the torsion bar, he should get an increase in ride height. However, i can't imagine how it's possible that he can turn the bar and not get a change in ride height... something is weird here.

PS - Photog, is your Roadtrek a chevy? 2WD, 4x4 converted?

Mine is 2X4 Chevy 3500, with lift springs and blocks. 4X4 later, but it will be a straight axle.

I don't know if Zuren or the PO has already cranked the bars, and it now sits with the shock fully extended. That is why doing a lifting test, and taking some measurements is so important. Without this info, we are all speculating on problems & solutions.

 

[ben2go]

I finally seen a AWD Express the other day.Most all I see around here are the 2wd.The one I seen was a conversion van and appeared to be a factory unit.It was a sweet ride.

 

[zuren]

Update - Sofa bed has arrived!

It is basically a tri-fold with what the manufacturer called an "add-a-back" and an additional cushion. It is a manual fold, manual slide frame. Total bed platform is 50"W x 74"L. I still need to bolt it in. There are a couple issues that I need to sort out with the manufacturer before I can install it but overall, I'm mostly pleased. The quick release brackets arrived without directions and there is a larger issue of it being wider than I ordered (ordered a 48"W sofa, received a 50"). The extra cushion was made to the correct 48"W dimension, so there is a mismatch. I plan on keeping the larger sofa and press them to send me a new matching cushion.

This also makes the available space down the passenger-side narrower than I was planning so I'll have to get creative with that. The interior paneling and rear AC/heater unit (that I want to retain) limit how far I can move this to the driver-side to try to give myself more room. Maybe if I elevated the frame to get the cushions over the paneling on the driver-sider, hmmm????

The down side to this option is that underseat storage will be minimal. The frame is decently complex with a lot of cross members, etc. under there. The nice thing is the larger bed platform will be more comfortable and I'm confident it will be safe for carrying belted passengers.

 

[Herbie]

Looks great! Is that from DiscountVanTruck.com or a different manufacturer?

If not DVT, please share the name as there are too few offerings for sofas that I'm aware of!

 

[zuren]

Looks great! Is that from DiscountVanTruck.com or a different manufacturer?

If not DVT, please share the name as there are too few offerings for sofas that I'm aware of!

This one is from Superior Seats Inc. located in Elkhart, IN. They have quite a few options at different widths. The guy I spoke with was very nice and helpful. Calling was better than emailing. I read too many less-than-glowing reviews about DVT so I tried to avoid them.
http://www.superior-seats.com/

Another that was recommended to me on the SportsmobileForums site were these guys located in Idaho. I probably would have gone with them but they would only go to a 52" sofa, too wide for my purposes. Their site is sparse on van information but they do make seating for them.
http://www.home-style.com/flash_content/index.html

You are correct that there isn't much out there and the models that are, are not advertised very well. I have actually found more van conversion shops by searching "quick release sofa brackets" than any other search string.

Also look into Atwood Mobile Products.

 

[ben2go]

If you can find a seat that you like,an RV or auto upholstery shop should be able to cut it down.Widening a seat is a little more complicated and usually requires two seats and recovering.

 

[zuren]

Update:

- Van now has a 1" body lift
- Sofa bed is bolted in
- Light bar for front bumper has arrived (may take a while on this one; mounting won't be as straight forward as I hoped)

I'll post some pics tonight.

 

[ben2go]

Sweet!Can't wait for pics.To bad on the light bar mounting.It be great once it's on there.

 

[zuren]

I was delayed over the weekend getting these up. Enjoy!

Before 1" body lift

Body lifted 1"

Front gap (and light bar sneak preview)

Rear gap (not bad, exhaust pipe needs to altered so it isn't hanging down so far)

Sofa bolted in

Sofa frame attachment

Bed configuration - Front view

Bed configuration - Rear view

Showing the support arms for the extra cushion (removable)

Storage space underneath

Bed platform butts against rear doors

Back in sofa config., Support arms and cushion stowed

So I had to sit and think about the light bar for a while. It comes with mounting hardware but no instructions. I think I figured it out! The top of the Chevy Express bumper is a plastic cap with foam underneath. I took a hole saw and cut 2 insert holes for the top arms to set into. There are some reinforcing brackets on the back side that interfere so I removed the bumper to get a closer look. This is as far as I've gotten.

I need to order up some more electrical bits to move forward on house power and sort out some driveline noises. I just replaced a bad wheel bearing assembly (that was fun). All 4 shocks need replacements (all are severely rusted/beat up, I have a suspension thump in the rear) and it sounds like one of the u-joints from the 4x4 conversion is failing (whirring noise at my feet when moving). I will probably go with KYB Gas-Adjust shocks since I cannot really confirm that Bilsteins will fit (thread here). I plan to replace the u-joints on the rear driveshaft as well. The rear u-joints and shocks have 128k miles on them as far as I know. I have some PIAA 510s waiting to go onto the light bar once I have that bolted together.

Cheers!

 

[fike]

tire sizes on AWD express van

what size tires tires are you now able to fit on that van? I am trying to figure out how much bigger you can go without needing a body or suspension lift. I am considering an AWD van like yours, but I know the suspension lifts are generally complex or unavailable. Of course, to get some more clearance under the differential, bigger tires are the only solution and that 1" body lift may help that.

Stock 245-70R17 30.5" diameter
upsize 1 255-70R17 31.1" diameter, limited choices
upsize 2 265-70R17 31.6" diameter, more choices
upsize 3 265-65R17 30.6" diameter, no meaningful increase in clearance, but wider​

[EDIT]
After looking back over your thread, I see that you are running 265-70R16 30.6" diameter. So I would assume that 265-65R17 should also work. Neither of these increases clearance under the rear differential though. Do you have any sense if you have the room to go a bit taller?

 

[zuren]

what size tires tires are you now able to fit on that van? I am trying to figure out how much bigger you can go without needing a body or suspension lift. I am considering an AWD van like yours, but I know the suspension lifts are generally complex or unavailable. Of course, to get some more clearance under the differential, bigger tires are the only solution and that 1" body lift may help that.

Stock 245-70R17 30.5" diameter
upsize 1 255-70R17 31.1" diameter, limited choices
upsize 2 265-70R17 31.6" diameter, more choices
upsize 3 265-65R17 30.6" diameter, no meaningful increase in clearance, but wider​

[EDIT]
After looking back over your thread, I see that you are running 265-70R16 30.6" diameter. So I would assume that 265-65R17 should also work. Neither of these increases clearance under the rear differential though. Do you have any sense if you have the room to go a bit taller?

The 265/70R16's that I have on it now rub the mudflaps I installed just slightly at full lock with the 1" body lift. It's tolerable. Before the body lift they rubbed the flaps badly. There was no rubbing at all before the flaps or before the lift. You might be able to do the 31s but the area that gets tight is the rear, lower portion of the fender/rocker panel. On my van, that is a fiberglass piece so it doesn't react well to being banged or rubbed.

The only other person I know of to push the envelope of what will fit is dwalt (search his user name). With 2" lift blocks in the rear and fully cranked torsion bars, he was able to fit 33's with a little rubbing but the tires he used rode like garbage. I think he is down to 31s or 32s now.

My end goal was to get a little more traction while maintaining a good highway ride since this van sees mostly pavement so I didn't stray too far from stock. I also didn't want to get into speedometer adjustments and it has 3.42 gears so it wasn't going to react well to bigger changes.

Hope that helps!