Thread: Bad Ast Astro Van Build

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Originally Posted by rspears

I'd love to see a high of 88F in mid-afternoon!! Yesterday we were at 103 to 105F, with humidity in the 30-35% range which is pretty high for that heat. Inside the barn/shop was pushing upper 90's. A fan helps, but when it's pushing 100+ air it's kind of like a blast furnace. Just glad I'm not in AZ in the summer! That place is brutal.

Yes Sir, We had a string of triple digit temps here and that is what prompted the A/C buy. Can't get anything done when I can't breathe...

Nope no beer here just cool air

yep 4 or 5 days triple in a row and we'er at 6 at 90s+

Very nice! I wouldn't mind taking a ride in that V...

Originally Posted by astroracer

Very nice! I wouldn't mind taking a ride in that V...

the v has only one seat. caddy may be around

I blew apart the old cluster. This sure did bring back memories! I did the initial cluster design for these back in '83-'84... I had forgotten how much **** we packed into these...
http://images42.fotki.com/v664/photo...MVC011F-vi.jpg
With the lens removed.
http://images52.fotki.com/v637/photo...MVC013F-vi.jpg
What I am going to do is remove all of the original gauges and light pipe and replace them with a flat panel and Autometers' Pro-Comp 5" speedo and tach.
Here is the back of the light pipe where all of the gauges are mounted. Once this is removed the cluster case itself is an empty shell...
http://images24.fotki.com/v874/photo...MVC017F-vi.jpg
I took everything off the back and used the light pipe as a pattern to make a foam board blank. I used that 5 dollar saw to cut this out...
http://images55.fotki.com/v268/photo...MVC010F-vi.jpg
I used the scroll saw again to cut out some more foam core to make the speedo and tach. I used these to mock up the gage positions in the cluster.
http://images16.fotki.com/v377/photo...MVC011F-vi.jpg
As you can tell I am not going to have a lot of room for the fuel level gage so I may make a tunnel in the upper shroud so I can push the gage higher in the cluster. there is nothing up there so there is plenty of room as long as I don't block the gage with the upper bezel.
Here is the basic layout of the instrument cluster and center stack gage cluster.
http://images55.fotki.com/v608/photo...MVC013F-vi.jpg

Lots going on in the Bad Ast shop this week! I brought the tank home tonight. Should be good to go after a couple of pressure testing sessions and fixing a few pinholes. Jesse did an excellant job welding this thing up. There is a bit of warpage but it is all in areas that will not be visible so it is all good.
Sitting back in the van as a one piece deal this time.
http://images24.fotki.com/v798/photo...MVC016F-vi.jpg
After I cleaned it up a bit. Sitting on saw horses in front of the shop.
http://images52.fotki.com/v639/photo...MVC004F-vi.jpg
There is a butt-load of welding here. To do all of this and have only three pinholes is incredible in my book.
http://images15.fotki.com/v588/photo...MVC003F-vi.jpg
http://images21.fotki.com/v840/photo...MVC005F-vi.jpg
You can see a bit of warpage on this long flange. This is the upper bolt flange.
http://images55.fotki.com/v608/photo...MVC011F-vi.jpg
I will fill it with water and let it sit for a while to see if it weeps any.
I am thinking I will get the inside coated, just for piece of mind. Gas Tank Renu is right here in Swartz Creek so I think I will call them.
I am also thinking about having it powder coated black. What do you think?
http://images110.fotki.com/v1539/pho...MVC015F-vi.jpg
Mark

This past week we worked on a few things. The seat frames, the shifter cover and the instrument cluster. The seat frames are well on there way. Both are ready for welding and all we are waiting for are the front and side braces. I dug out a small sheet of 10 ga I will be taking to work to have all of this stuff cut out on the laser... Much faster and neater. I will also have them make a set for the rear seats for when I get around to building/adding those.
http://images42.fotki.com/v664/photo...MVC003F-vi.jpg
With the mockup seat brace. The front brace is laying on the floor.
http://images15.fotki.com/v588/photo...MVC005F-vi.jpg
This is a rear view of the pass side.
http://images49.fotki.com/v1510/phot...MVC002F-vi.jpg
Mel did the brunt of the work on the seat frames, After we got them bent up and designed last week he has been mocking them up and drilling holes. I spent most of my time working on the shifter cover and getting that fit and smoothed and primed. It's not done by any means but it is well on it's way.
This is after a couple applications of bondo. Starting to smooth out quickly.
http://images107.fotki.com/v71/photo...MVC003F-vi.jpg
The cleco in the lower right corner is holding the two halfs together. Just to the left of the cleco is a verticle seam between the two parts... Can you see it? I think not...
http://images60.fotki.com/v661/photo...MVC004F-vi.jpg
The upper cleco is doing the same work but that seam is more visible because it I have sanded down thru the bondo on the removable piece to the 'glass so you can see the transition... It goes away in primer.
http://images50.fotki.com/v406/photo...MVC013F-vi.jpg
http://images14.fotki.com/v218/photo...MVC014F-vi.jpg
The seat braces and gage cluster face are in for laser cutting. I took in the steel for the braces yesterday. I hope to have the parts tomorrow or Monday.
Thanks for looking
Mark

I brought home a bunch of steel tonight. Four sets of seat frame reinforcements, the center stack gauge pane piecesl and a little box full of my Dzus handles.
The reinforcements mocked up on the frames and a box of parts.
http://images55.fotki.com/v648/photo...MVC004F-vi.jpg
I think these will look real good when they are done.
http://images57.fotki.com/v139/photo...MVC005F-vi.jpg
The fit on the front pieces isn't quite right as I have to do some trimming to get them where they need to be
http://images14.fotki.com/v384/photo...MVC006F-vi.jpg
http://images54.fotki.com/v461/photo...MVC008F-vi.jpg
Tomorrow will see smoe complete seat frames.
The gauge panel will need some cleanup and a good polishing but it will work great.
http://images57.fotki.com/v256/photo...MVC011F-vi.jpg
The small piece gets overlaid onto the bigger piece to give it a 3D look.
http://images59.fotki.com/v420/photo...MVC002F-vi.jpg
I am thinking about making CF panels to fill the "cutouts" and add some interest. I haven't decided about finish yet. Polish it, scotchbrite it or powder coat black... Have to wait and see what happens with the rest of the interior.
http://images57.fotki.com/v1614/phot...MVC003F-vi.jpg
That's what I worked on tonight.
Mark

Looking good! Having access to that laser is a real blessing. I especially like the gauge panel, with the 3D overlay. Seats should look good, too.

Good looking work ...It just keeps coming ..What is your ETA for driving it??

Originally Posted by cffisher

Good looking work ...It just keeps coming ..What is your ETA for driving it??

yep i like to know that to i here some guys has your engine ... i think i may know him? what color on the block ????

Originally Posted by pat mccarthy

yep i like to know that to i here some guys has your engine ... i think i may know him? what color on the block ????

Yea, a good friend of mine has it held hostage in KAWKAWLIN of all places! He is building it into a runner... And I think it needs to be painted a hammertone med silver. Will look real close to aluminum if we do it right. I have three cans of it here at the shop. When do you want me to bring them up?

Originally Posted by astroracer

Yea, a good friend of mine has it held hostage in KAWKAWLIN of all places! He is building it into a runner... And I think it needs to be painted a hammertone med silver. Will look real close to aluminum if we do it right. I have three cans of it here at the shop. When do you want me to bring them up?

there was a sale on deer green i pickup 3 cans of that just for you ??? . short block will be ready for paint this coming week end

Originally Posted by pat mccarthy

there was a sale on deer green i pickup 3 cans of that just for you ??? . short block will be ready for paint this coming week end

LOL! That would go great with all of the Chevy engine orange parts! I will call it the JastRO-Lantern!
That's pretty funny Pat! I will bring something with me when I come up to paint the block Saturday... You will get a kick out of it.