65' chassis swap

Finished the chassis swap for a full tubed rails, IFS front and C-notched rear. All scratch built suspension. This is the first time on wheels since undertaking the project.
Custom four link

That looks real nice. What size engine you putting in it?

Inline six from a trailblazer. Adding some boost with a turbo kit

That van is sure going to be a helluva lot different than when you bought it!!

Way Cool

Welded up the panard bar to locate the rear left and right. Scratch built except for the bar itself. Some of you die-hards will recognize it as the original steering link. Thought including it would be a little tip of the hat to the old school.
This van project has tested and bettered my TIG welding skills. Trying to hold the project up to a tight final piece has forced me to make every part clean fit.

Installed.

Looks fantastic!  

Those are some skills to have. Its looking good. Its going to be nice to have a vintage van with modern handling.

I got the steering brackets back from the waterjet and welded them up last night. decided to drill and tap the attachments to the lower member just in case they need to be relocated for the engine. The angle to the steering box is just about right.

That is some pretty fancy bracket fabbing ! Loving the build.

While i am waiting for my engine mounts to be cut i thoguht i would try and tune up the door latches. The striker on the driver side was sagged and had worn through at both the latch and the striker plate. The hard plastic wedge that puts tension on the assembly inside the door striker was worn to nothing. I debated cutting a new one out of Delrin or casting one in epoxy resin, but then decided to see if i could improve the design with a tighter tolerance aluminum.
Start with some bar stock.



find the critical measurements


the radius edges really arent necessary to fit or working but makes for a better looking finished piece.


squaring up using alot of cutting fluid and higher speeds for that finished look. once the pieces were square, i drilled and countersunk the spring setting


taking shape


the most difficult step; cutting the slope. My mill is manual so this was a three step process and then smoothed by hand.


finshed by hand. I went a 1/64th bigger so the piece has less slop then the original, i think the hardened alum will wear better and once the door isnt sagging, it should be a nice tight fit.


good thing im not getting paid by the hour, these took me two hours start to finish. Id be broke

Looks awesome! Watching this build closely for sure.

Superb SKILLS!!!   

Reinstalled the bead blasted strikers and machined bumpers.

Laying out the motor mounts. The inline six makes a nice mounting point on either side of the narrow block (only 11" at the mount plates). I cut up some heavy wall DOM that fit the 4X4 rubber mount kits i bought. I miter cut the arms and TIG welded the two pieces together. The plate was heavy enough i could really sink in some filler along the uprights. I thought they looked too plain so i cut a sleeve and machined in a pattern. I think i will braze this sleeve on before i cut the angle that meets the rail. I want to be able to unbolt the mounts so i cut some 1/4" 4"square plates with mounting holes. I will go all the way through the rail for strength. I hope to get the whole enigine( turbo snail included) under the larger of the two doghouses that came with the van originally but i am a realist and know it will probably end up 3/4 of an inch too short in several spaces and i will have to remake the whole thing.

long time since last update, updated my thread in "between the seats "G"" as well. Life comes at you fast some days (or months or even years) I have put some time into the project in the last few months. took a welding cert class at the college and made an intake for my final project. got the new engine hung, worked out the steering box, made a fuel cell, and figured out how the brakes are going to fit.( a remote booster behind the drivers seat about 4' long actuating rod). Hoping to get a floor bead rolled and installed this summer. I am considering making the exhaust headers myself due to lack of any real aftermarket options. the engine I ended up with just isn't a popular hot rod piece so nobody really supports it with any aftermarket add-ons. I ended up having to machine the intake flange myself and that really tested my machine and 8th grade math skills. This van/rod has become my lifes work and my mid-life crisis all rolled into one. enjoy;

WooooooooW its gorgeous!

had some time this week and installed the IDIDIT steering column. Matched up nicely to the steering gear box and sat at the correct length and orientation. I wasnt as pleased with the aestetics of the drop itself and set about making a "stronger" looking sub mount for the under dash.



Started with a nominal sized billet aluminum block and drilled out the pockets to mount this piece to the current dash mounting points (4.25" on center if anyone is interested). I cut a .50" trench that accomodated the IDIDIT drop itself and centered it between the mounting points. Radiused the ends and edges for a finished look.





the drop fits nicely

happy with the fit and finish. Plan on mounting it up tomorrow after work.

Nicely done. I like that look a whole lot better as well.

the after shot; much better IMO. The angle improved just by moving it down that 3/4" and it looks "tougher" now i just need to patch the two errant holes in the under-dash. man i hate drilling or cutting into that old steel. especially when it turns out to be unnecessary



bought all the brake lines and most of the fittings. decided on stainless lines and fittings as they wont get any paint. borrowed a nice flair tool and watched some YOUTUBE so i am basically an expert now. should be a piece of cake!

Brake lines are a snap. Once you do a few practice flares on an old piece of brake line to perfect the double flare, it will be done before you know it. I did find that stainless was a bit tougher to flare without cracking. But practice a patience prevailed and they turned out great.

I have to mount an Isuzu box in a similar manner, but I haven't been able to locate the right spline to DD u-joints.  Do you remember where you found them; part #, spline count, or anything else that might help me locate a set?  Appreciate the help!
Jim

66e100pu wrote:I have to mount an Isuzu box in a similar manner, but I haven't been able to locate the right spline to DD u-joints.  Do you remember where you found them; part #, spline count, or anything else that might help me locate a set?  Appreciate the help!
Jim

The spline is specific to a Chrysler application. The ones I have were made by borgeson but sold through SO-CAL speed shop. I took my box in and stabbed it in the display until I found the right ones. Sorry I don't have a part number for you.