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2002 Safari Van, rusty.

926 Views 12 Replies 7 Participants Last post by  chinaman4u
I wanted to thank everyone's post(s) and picture(s)...have proven invaluable.

I recently bought my 4th Astro/Safari van. I thought I would posts pictures as I fix her up, since everyones' pictures helped me a lot in the past.
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After purchase, I drove her home 2 hours. Drives nice, but I took back roads and never went over 40mph. These are pictures taken by the previous owner that she posted in the classified. Located in Pennsylvania, so she is rusty/rotted. I hope some of my 'fixes/photos' will help others, as others' threads, has helped me.

2002 AWD with towing, rear AC, rear heat, plus standard options. 151,000 mileage.
Tire Automotive parking light Wheel Automotive side marker light Car

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I was midway through this first repair, and decided to share...radiator support! At first, I tried lifting the body, but pulled the frame up with it. It worked, on my past vans. This time, I had to chain the bumper rails to the bottom of my engine lift, in order to raise the body to proper height.
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I knew what I was getting into. This is only the beginning, much more damage will be shown.
Note: i just found out ODB port power is same circut as the rear cigarette lighter power(blown AUX fuse). I also have the front cig lighter stays on(this is likely normal) but the rear heat/rear air blower power remains on as well, not sure why, could drain my battery one day.
Welcome! Im partial to the color, i find it hides the rust on mine
I was shocked to find spray paint costs $18! But Walmart saved the day, with matching paint to boot! The paint is very close, depending on which viewing angle, maybe a different primer, can get it closer. I use tape to prevent overspray(notice straight lines), this is just a quick paint over rusty spots.
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(Krylon 7519 gloss classic red closely matches 2002 Astro paint code 307D)
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Didn't as much as I wanted this weekend, cut out some of the rust and made some brackets to bolt into bushings....
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.....then I reassembled the front end to check height and alignment. I probably will make new pieces, using sheet metal to replace what I cut out. The brackets will have holes drilled and bolted in, I'll have to wait for new bushings in order to finish.
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