Project BigB... a 1977 Dodge Van 6x4!
- Thread starter Keyblazer
- Start date
Keyblazer
Adventurer
Thanks for that Kelster, I did in fact find reference to that stuff and it may be useful!
Thanks Camit, yep, I get ya!
Not sure if I posted this before but a Buddy of mine who I sent pics to when I got it, never really liked it in reality... and he said as much. But a few months ago he swang by when I was working on it, and after looking it over, going inside etc, he suddenly changed his mind, and proclaimed that he totally gets it and what I am aiming for!
So, I am trying to figure out what the deal is with these roof caps.
When i was at the Junk yard the otrher week I saw a Dodge van with the "High Roof" version, and I was thinking about that van...
I am thinking that I could pull the roof off the rear, and move it to the front, and find a high roof to put on the rear. As the rear roof would be taller, I could cut the profile of it to sit over where it meets the front section(the drop section of the front roof would be removed).
I need to go to the JY and take some measurements..
Until then I am trying to figure out how the roof attaches to the steelwork, and after the rusty section is removed, what will be left to attach to!
huskyfargo
Adventurer
It's kinda like a baby skunk...so ugly it's cute!
This looks like an amazing project!
This looks like an amazing project!
Keyblazer
Adventurer
I have been looking at how to fix the rust issue...
It seems that this is a weakspot on all Dodge vans..
On BigB its made worse by the fact that the Cap does not follow the roof shape, and they "fixed" this issue by putting sealant in the gaps... which held more water, and made it worse!
Here is the extent of the issue... its pretty bad, but the repair and solution is a big improvement!
Roof rust..
From inside you can really see how bad it is!
Drivers side gutter..
Now, here is the basic plan...
The current roof cap will be coming off to repair the rust.
I plan to cut out the front roof section, where I need to, make repair sections for the rusted areas. Then I will make a tube that runs around the whole inside of the roof gutter to replace the lost strength, and this will have 6 legs that extend to the floor with foot plates, forming a chassis stiffener/roll cage. I think 3 cross beams as well.
The current roof cap will be remounted at the front, adding headroom, and I am gonna find a suitable "Taller" cap for the rear.
I have already been searching junkyards for the new roof cap.
The two caps will be modded to fit together and I think I will cut and glass them into one.
This plan will give me increased headroom, better chassis stiffness and solve the rust issue!
It seems that this is a weakspot on all Dodge vans..
On BigB its made worse by the fact that the Cap does not follow the roof shape, and they "fixed" this issue by putting sealant in the gaps... which held more water, and made it worse!
Here is the extent of the issue... its pretty bad, but the repair and solution is a big improvement!
Roof rust..
From inside you can really see how bad it is!
Drivers side gutter..
Now, here is the basic plan...
The current roof cap will be coming off to repair the rust.
I plan to cut out the front roof section, where I need to, make repair sections for the rusted areas. Then I will make a tube that runs around the whole inside of the roof gutter to replace the lost strength, and this will have 6 legs that extend to the floor with foot plates, forming a chassis stiffener/roll cage. I think 3 cross beams as well.
The current roof cap will be remounted at the front, adding headroom, and I am gonna find a suitable "Taller" cap for the rear.
I have already been searching junkyards for the new roof cap.
The two caps will be modded to fit together and I think I will cut and glass them into one.
This plan will give me increased headroom, better chassis stiffness and solve the rust issue!
007
Explorer
I don't hate the whole van, just the part that extends past its normal footprint. I think the color is making it really hard to look at. I wonder how it would look with olive green on flat black, like a military truck?
adventureduo
Dave Druck [KI6LBB]
I dig it. I like different rigs instead of the same old same old i see everyday.
