The Lunchbox Build... 4x4 chevy shorty van

Lunchbox2

Explorer
Annnnnnnnd we're back....:D Working on a van for 4-5 months straight and not maintaining your business can be detrimental to your pocket book, so I had to play a little catch-up! I had withdrawals from not working on the Lunchbox though, so I had to get back at it.

I'm ready to bring the van to the house, I need it sitting here staring me in the face every day or that "out of sight out of mind" mentality really starts to set-in. So I went out to the shop to tidy a few things up on it, so we can tow it back to the house.

I don't have a welder at home, so I wanted to make sure all my major fab work was done. I can plumb brake lines, and measure drivelines here at the house, then it's driveable and I can go back out the shop if need-be. It's only going to cost $150 to have both driveshafts shortened and re-balanced, so I'm not even going to attempt that one....

I ordered up some shorter u-bolts to remedy my problems out back. I was able to clock the caliper brackets back up where they were supposed to be, and I can get the caliper bolts in and out now that my u-bolts aren't a mile long. So that's a relief, I thought I was going to have to make new caliper brackets...



Everything else was in pretty good shape, I had completed more than I remember. I wanted to raise up my tranny crossmember a few inches, but I don't think I'm going to mess with it right now. I will have to cut out braces under the floor to move the tranny/t-case up any more, so I'm just going to build a skid plate for it and hopefully it won't drag too bad. I will mess with it at a later date if I find that it's causing me problems on the trail....

This picture was taken level with the bottom of the rocker panel. I think the transfer case hangs down too low, especially for going up a ledge or something, but other people say I'm overthinking it.... IDK. I mean it is a bohemoth van, so it's not like I'm going to be able to put this thing where a jeep would go, we'll see....



The one thing I hate when I see other 4x4 vans, is how the tires aren't centered in the wheel-well, they are always sooo close to the bottom corners. I won't tolerate any rubbing under full-flex, and I wanted to make room to upgrade to 37's later (which I now regret not buying in the first place). Once the bottom of the front of the fender is trimmed, it will look right. The wheel is also turned slightly to the right...



Then I filled up the diffs with 80w90 and we hooked the wrecker to her and pulled her to the house!





She's home! My son can't wait to ride in it. Every time we leave the house it's... "Can we take the van daddy??" soon kid.... soon....

 
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Lunchbox2

Explorer
I've been fixing cars to flip lately, so once the two trucks that I have are sold, I'll buy brake parts and get driveshafts built. I did a video gig for a fabricator buddy a week or so ago, so my labor for bending up bumpers/sliders is paid for. I just have to buy the tubing and get him down here to start bending things up....Back in the saddle!
 

Lunchbox2

Explorer
I spoke with Chris at Offroad Design and he got me hooked up with the braided stainless brake lines I needed for my axles. Basically, there's 2 lines coming from the calipers that meet in the middle of the axle at a TEE, and then there's a 30" long hose that shoots up to the chassis. Then it will have hard lines from the master cylinder, down to those 30" hoses, annnnnnd done....

I'm going to try the stock master cylinder first, so I may need a proportioning valve for the rear brakes. They are now discs, and I don't need them locking up every time I hit the brakes. The hoses show up in a week or so, so we'll just have to wait and see....
 

Bikersmurf

Expedition Leader
I'd order the proportioning valve now from Summit Racing or one of the other reputable suppliers. I've been running a Willwood one for about 18 years.
 

chiliVANilli

Adventurer
I have the Wilwood, too. Good stuff. I put stainless all the way around on mine, too, but from 4wheel parts. So many choices for Chevy stuff out there, it's hard to choose. Which disc conversion did you use?
 

Lunchbox2

Explorer
I have the Wilwood, too. Good stuff. I put stainless all the way around on mine, too, but from 4wheel parts. So many choices for Chevy stuff out there, it's hard to choose. Which disc conversion did you use?

My buddy had an old kit from his rock-crawler days still sitting on the shelf, so I just bought it because it was there and it was cheap. They are the straight brackets that require a spacer between the brackets and axle, not the newer style that are bent. I've read nothing but ****ty reviews on caddy calipers, so I used 81-ish 3/4 ton 2wd chevy truck front calipers. The plan is to make a transfer case brake out of a Wilwood spot caliper and a homemade bracket, and I'll probably pony up the $125 for the rotor instead of try to make one.

 
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Lunchbox2

Explorer
Well.... brake lines showed up today.... After 2 phone calls and several questions, I still don't have the brake lines I need. There were supposed to be 6 lines total, 3 for each axle. I got the lines for the rear axle, but I am missing the drop line w/tee for the front axle. I can still use these if I'll run a hard line out to each front corner on the chassis, but the plan was to have all of the lines contained on the axle with only one "drop line" going up to the master cylinder. So I guess I'll have to call ORD on monday and wait another week before I can work on brakes....

On the plus side, I'm very happy with the lines themselves, very well-built...

 

Lunchbox2

Explorer
Not a lot to report back.... ORD sent me the missing brake line, and I got them mounted to the calipers and ran on the axles.

The van "frame" is wider, so the leaf springs are pushed way out on the axle, and it doesn't leave much room in-between the springs and brake calipers. I had to do a little grinding on the calipers to get the lines to "clock" to where I needed them to, but nothing crazy...









Being that the axle is a few inches wider than the truck axles, the brake lines didn't fit like stock. No biggie, I just need to relocate the mounting bolt(s), and weld on a couple tabs to hold the lines in-place.







Same with the front axle, I need to weld on some tabs to hold the lines in place..







I'm really happy with the lines. They are high-quality, and should give me years of trouble-free service....

I'm going to make an order with Rockauto.com this week and get all my tune up stuff (plugs, wires, cap/rotor), fuel pump & filter, & brake master cylinder. Then I'll go to my local advance auto and get some hard line, and I'll be ready for brakes!
 

Lunchbox2

Explorer
When I was crawling around under the van doing the brake lines, I noticed something..... There was ATF leaking out of my transfer case.... After a little bit of research I learned that the seals in the adapter are bad, and allowing ATF to flow into the transfer case. So I'm just going to pull it and put new gaskets all throughout.

The plan was to then install a clocking ring while it's out and gain some more ground clearance. That also involves new shifters....UGH.... After some deliberating, I decided that I can just cut out/rebuild one of the cross-braces in the floor, and move the entire transmission/t-case up a few inches. I can also re-do the crossmember to tuck it up a few inches as well, so I can gain another 6" of clearance. BAM.... problem solved for very little money.

So that's going to save me $400 because no clocking ring or new cable shifters, and I'm going to need it because the next thing I'll need is DRIVELINES...

I have all different size yokes everywhere. The 14-bolt has a 1350, the dana 60 has a 1330 I believe, and my np205 has 1310's. So it looks like I'm going to be buying some yokes and building new driveshafts. I was going to try and work with the front 1310 cv shaft I have, and factory rear drive shaft, but again.... why put it together with inferior parts? I spent the time/money buying all the other good ****, it would be stupid to skimp now.

I have a local custom driveshaft shop that I'm going to go and talk to, and see what he can do for me. If I feel he can't give me what I want, I'll call Jesse at High Angle Driveline and have him put a couple driveshafts together for me. I just know that that's going to be a $1200-$1500 day... It's only money right?! haha fuuuuuuuuuuuck
 

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