Thread: Bad Ast Astro Van Build

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Thanks Charlie, yea it never seems to end.

We hit it pretty hard today. Mel started setting up the battery brackets to get them welded and I started figuring out how to cut the holes in the aluminum panels for the radiator shrouds.
Here are the brackets as Mel was figuring out how to clamp this mess together for welding.
http://images58.fotki.com/v696/photo...MVC003F-vi.jpg
He made some small angle iron brackets to get everything clamped up. Once it was clamped up we tacked all of the pieces together so we could mock it up in the van.
Here are the tacked brackets set in place on the fender mounted straps.
http://images108.fotki.com/v1623/pho...MVC020F-vi.jpg
http://images55.fotki.com/v585/photo...MVC021F-vi.jpg
Once we got everything squared up I tacked the brackets to the fender straps.
http://images58.fotki.com/v132/photo...MVC005F-vi.jpg
It's amazing how strong these little guys are! They shouldn't have a problem holding up a battery.
http://images51.fotki.com/v1586/phot...MVC007F-vi.jpg
While Mel was building stuff to build stuff, I was building a top for my router table. I used a piece of 1/4" plywood and clamped it to the top of the table. I used this to spin the aluminum panels around a center hole to cut out the fan openings.
http://images55.fotki.com/v605/photo...MVC009F-vi.jpg
I used some Castrol stick wax to lube the 1/4" carbide cutter in the router.
http://images108.fotki.com/v613/phot...MVC010F-vi.jpg
In order to "keep" the center of the hole from falling out, I had to stop short on 3 of the cuts. You can se the end of the first cut at the top of this pic. The bit is set in the next hole and the stick wax is spread on the cut line.
http://images49.fotki.com/v1511/phot...MVC016F-vi.jpg
I drilled 1/4" starter holes at 4 points and ran the router up till it was a 1/2" or so shy of the next hole.
This was pretty noisey but it worked well and I got both openings in the radiator shroud cut along with the one for the trans cooler.
http://images15.fotki.com/v792/photo...MVC003F-vi.jpg
Once I got the holes cut I worked on the trans cooler shroud. I laid out the shape and bend lines and did some off hand cutting on the verticle band saw.
http://images59.fotki.com/v426/photo...MVC008F-vi.jpg
http://images16.fotki.com/v220/photo...MVC009F-vi.jpg
I bent the .090 aluminum in the 3 in 1 tool. It was kinda tuff but it did the job.
http://images20.fotki.com/v422/photo...MVC011F-vi.jpg
All bent up and sitting nice and flat... I like it when it comes together like planned...
http://images108.fotki.com/v1623/pho...MVC013F-vi.jpg
I had to set the mating components in place just to test the fit. Perfect!
http://images15.fotki.com/v1626/phot...MVC017F-vi.jpg
http://images108.fotki.com/v1623/pho...MVC018F-vi.jpg
http://images109.fotki.com/v144/phot...MVC020F-vi.jpg
I'll try to get out in the shop after work this week to get the rest of the trans cooler shroud pieces made. They are pretty simple and shoud go quick.
Thanks for looking!
Mark

Lots of neat stuff, great work as always Mark!

Thanks Dave! Don't look too close at my welding skills in this next post... Pretty rough but I will get better!

I got the trans shroud finished up this weekend. Mel worked on the battery brackets. Drilled holes for the battery tray and ran all of the pieces through the sand blaster and got them primed. I worked on the rest of the pieces for the trans shroud. These are the upper amd lower closeouts that will weld to the plate I made last weekend.
http://images109.fotki.com/v158/phot...MVC001F-vi.jpg
The layout lines you see in the above pic are tangent points for the bends I had to put in them.
http://images14.fotki.com/v390/photo...MVC012F-vi.jpg
This pic is of the back plate that closes off the back of the trans cooler. It tapers out from the fan to help direct airflow thru the cooler (I hope...).
http://images50.fotki.com/v1571/phot...MVC013F-vi.jpg
This is the first time I have done any REAL aluminum welding other then in a few classes I have taken. I was pretty leary as I hadn't done any aluminum welding with my Tig. I did a few practice beads and got back up to speed.
http://images9.fotki.com/v114/photos...MVC011F-vi.jpg
I did okay. The welds are serviceable and I only blew two holes which I filled with some 1/8th inch filler rod. By the time I was finishing up I wasn't doing to bad and actually had some okay looking beads. At least my consistancy was getting better...
http://images57.fotki.com/v496/photo...MVC001F-vi.jpg
I had a few heavy spots that I sanded down but for the most part I was happy with my first effort...
http://images50.fotki.com/v1571/phot...MVC013F-vi.jpg
http://images14.fotki.com/v218/photo...MVC014F-vi.jpg
http://images16.fotki.com/v363/photo...MVC015F-vi.jpg
I got the fan mounted with some AVK's and mocked up the cooler for a look see....
http://images54.fotki.com/v883/photo...MVC006F-vi.jpg
http://images52.fotki.com/v640/photo...MVC009F-vi.jpg
The back side
http://images107.fotki.com/v70/photo...MVC011F-vi.jpg
I will be picking up some black oxide button head cap screws for the real mounting bolts. I'll get the cooler mounted to the shroud also. I need to redrill the holes for the cooler. The ones pierced in the end channels are not centered well.
Thanks for looking!
Mark

The welding just comes from lots of practice Mark, they're looking good right now and will improve with time. That is unless you start going blind like me and have to resort to welding by Braille!!!!!

Originally Posted by Dave Severson

That is unless you start going blind like me and have to resort to welding by Braille!!!!!

I know what that's like firsthand!

Yea, that is scary. Mel has some macular degeneration in his left eye and it has him a little down.

Originally Posted by astroracer

Yea, that is scary. Mel has some macular degeneration in his left eye and it has him a little down.

Tough deal there, as I understand it, not a lot can be done for that disease? A lot of my sight deterioration comes from years of abuse (don't need a helmet just to tack), and most lately some meds I'm on, one for kidneys, one for arthritis, that both cause a gradual loss of some vision... Given the choice between good eyesight and dialysis it wasn't a real tough decision to make!!! Now I just have to get new glasses a couple times a year...

Another thing about welding by Braille, the gloves sure don't last very long!!!!!!

Guess if we can't laugh about our health problems a guy could wind up depressed or something!!!!!

Best thing for flash is raw potatos

Can't wait to see this ASTRO completed! Great thread, thanks for all the pictures

While Mel was working on the wheel well stuff I was getting the fan shroud ready to weld on the flanges. I had to cut some clearance holes to go around the hose outlets. Because the holes were real close to the edge I used one of the wood blocks I cut to guide the hole saw as it cut the aluminum sheet.
http://images109.fotki.com/v83/photo...MVC017F-vi.jpg
I used a 2 1/2" dia hole saw mounted in my Milwaukee 1/2" drill to cut the holes. Only took a minute.
http://images57.fotki.com/v81/photos...MVC018F-vi.jpg
After the cut.
http://images20.fotki.com/v681/photo...MVC021F-vi.jpg
I will get the shroud welded up next weekend. AFTER I get gas... And pull a few more practice beads.
See you then
Mark

Thanks Dave, Thanks TG. Mel is doing okay and both of us can't wait to get this thing done!!!

Got a lot done this weekend! Mel painted the battery brackets and they turned out great!
http://images15.fotki.com/v1626/phot...MVC019F-vi.jpg
I spent a few hours acquanting myself with my tig welder. Playing with settings and getting to know how the pulse and freq settings affect the weld. I was starting to get the feel for it and pulled some real nice beads today. I am almost out of gas though so I need to get a new cylinder this week.
We worked on the left wheel well and got it fleshed out real nice. We ended up re-making the piece I had fabbed a month or so ago. Needed it about an inch wider and didn't want to scab in a piece.
http://images15.fotki.com/v1624/phot...MVC020F-vi.jpg
We quartered up a piece of 3" dia. muffler tubing to make the rolled edge.
While I was playing with the welder Mel remade the pattern for the new wheel well. Here is the new piece all fit in and ready to weld to the tubing.
http://images49.fotki.com/v572/photo...MVC004F-vi.jpg
http://images49.fotki.com/v572/photo...MVC004F-vi.jpg
Here is a pic from underneath. This provides PLENTY of room for the tire at full jounce/full steer.
http://images28.fotki.com/v121/photo...MVC006F-vi.jpg
Here it is after tacking.
http://images46.fotki.com/v319/photo...MVC009F-vi.jpg
We pulled it out and finish welded it. After a bit of sanding we clecoed it back in and started making the inner skirt.
http://images28.fotki.com/v122/photo...MVC012F-vi.jpg
This is how it looks underneath right now.
http://images58.fotki.com/v156/photo...MVC013F-vi.jpg
The pattern (in white) for the inner skirt.
http://images49.fotki.com/v571/photo...MVC014F-vi.jpg
Mel finishing up the inner skirt in steel.
http://images15.fotki.com/v1626/phot...MVC016F-vi.jpg
The skirt clamped in place. We have a little trimming to do yet and are planning to run a bead around the bottom edge to add some strength.
http://images52.fotki.com/v1564/phot...MVC004F-vi.jpg
A look under the skirt...
http://images51.fotki.com/v731/photo...MVC005F-vi.jpg
I think this looks great! Once we get the skirt finished up it will be very strong also!
Thanks for looking
Mark

It all looks great and should work just as well!!! Lots of good progress Mark! Always good to get a bunch of the little jobs done, they eat up so much time!!!

Thanks Dave, this weekend was good one. The thing is, being that we got the left side patterns made we already have the bulk of the work done for the passenger side. We have to fix a few things and redo some of the inner because of the accident damage we found but that has already been looked at and figured out.

Here is another little piece I am working on. I modeled up some scissor style hood hinges and the fab shop cut these parts out with the laser.
http://images14.fotki.com/v384/photo...MVC015F-vi.jpg
These will be for the hood. I want to put some sort of cowl scoop on the hood and extend it back to the windshield. If you know how the astro hood opens, you know I can't do that using the stock, single point, hinge.
The scissor style will let the hood open more vertically and "should" keep it out of the windshield. I need to do some mock-ups to figure out positioning.
This is the hinges closed. I will make some mounting blocks to lock down the hinge pivot points and get some pics.
http://images14.fotki.com/v373/photo...MVC014F-vi.jpg

Man you are moving out now keep it up GOOD WORK

Looks killer, Mark! GM should have offered a V8 in these.