[DRZ]

Wow Kenny, I've never seen that van dusty.

 

[kennyj]

Wow Kenny, I've never seen that van dusty.

I know! But I couldn't find the car wash at Yosemite.

I did have to hit the car wash a few times trying to keep it clean...

because this trip I did a lot of off-pavement miles,

and I also added a lot of pinstriping. I still need to get on this with the power buffer.

 

[kennyj]

Since I haven't updated this thread in a while I want to play catch-up and write about the newest changes in the van. I'd like to keep this thread active because before next spring I hope to have it completely remodeled. Instead of shared duty as a work van I'll be doing a dedicated camper van build. More on that later…

In spring of 2012 I bought this 3.73 ring and pinion, and G80 locking differential to replace my stock 3.23s and open diff.

I procrastinated about trying to install it; I tried to line up a shop to install it; finally with travel plans approaching I dove in and did my first rear-end build. I'm not going to detail the job, there's plenty of great write-ups out there. I'll just say the first time was as difficult as you might think. I was really nervous about buttoning up my work and hitting the road for 5,000 miles.

But later I opened it up to change the oil and checked it out, everything was right on the money. And now I've put over 12,000 miles on it. I would feel pretty comfortable doing the job again.

The changes were totally worth it; the G80 has worked to get me out of plenty of tough situations, and the 3.73s seem perfect for the type of driving and travel I do. As far as mpg, I didn't do the swap for better mileage. On straight interstate driving it probably hurts, but for the kind of miles I put on it might be a wash. The benefit is my motor operating in a much better range and not feeling like it's straining around town, on hilly roads, and especially mountain driving. I'm sure my tranny is happier now, not constantly hunting between 3rd and OD.

So, G80s and 3.73s: :handgestures-thumbupleft: :handgestures-thumbupleft:

 

[kennyj]

I was missing a rear axle bump stop which would occasionally let the axle bottom out doing nasty things to my tire. So at the great midwest Junkyard Meet of 2012, (or the, "what are all those Astro guys doing in the Furd section?" gathering)...

I went after the mother of bump stops...

The mounting cups for these things were welded to the frame so I had to chisel and pry them off the donor. then I had to weld up a mount to install them on the Astro axle.

Here is one installed, it's like my poor-man's Timbrens. At normal ride height they are just in contact with the frame, as I load up they take up some of the load and limit bouncing in the rear end. I really like these things.

One of them blew out after a season; I tried to find them in GM parts, Gm calls it an "aux spring", and the bumpers alone are like $80 each. Back to the junkyard, I found 3 good ones for a whopping $4 each ('because they're kind of big") so I replaced the bad one and have a spare set.
:rockon:

Coming next, my 12 volt power system with inverter, and never finding the cheese swimming in cooler water, ever again.

 

[SilverBullet1997]

<snip>
Coming next, my 12 volt power system with inverter, and never finding the cheese swimming in cooler water, ever again.

I hate when my cheese takes a dive in to the abyss....

Looking good. Where'd you get the 3.73's with the G80... I already have the 3.73, but I want to put the G80 in.

 

[C11MAN]

looking very nice, jealous of the trip and the terrain! wish I got 3.73 and a g80 but I don't see myself being able to do a rear end anytime soon...

how does the road ahead look?

 

[kennyj]

I hate when my cheese takes a dive in to the abyss....

Looking good. Where'd you get the 3.73's with the G80... I already have the 3.73, but I want to put the G80 in.

I bought my parts from this seller on ebay. All he does is diffs, and based on my one transaction I would recommend him. The parts I got looked great.
http://www.ebay.com/sch/mrboss429r/m.ht ... =12&_rdc=1
To do the build I bought this Motive Gear install kit, with Timken bearings. Comes with absolutely everything you'll need. Order online from Advance and use a coupon code, you can get it for about $80 or less.
http://shop.advanceautoparts.com/webapp ... l+bearings

 

[kennyj]

looking very nice, jealous of the trip and the terrain! wish I got 3.73 and a g80 but I don't see myself being able to do a rear end anytime soon...

how does the road ahead look?

Thanks, C11Man. This year was an epic trip. I'm trying to work up a trip report on ExPo, but I'm still sorting through the 7,000 pics and like 150 hours of dashcam video.

Before it gets too cold I just want to get some bike riding done, thinking about Chequamegon National Forest, but I may just get in a ride heading north on the Mississippi River route.

 

[C11MAN]

looking very nice, jealous of the trip and the terrain! wish I got 3.73 and a g80 but I don't see myself being able to do a rear end anytime soon...

how does the road ahead look?

Thanks, C11Man. This year was an epic trip. I'm trying to work up a trip report on ExPo, but I'm still sorting through the 7,000 pics and like 150 hours of dashcam video.

Before it gets too cold I just want to get some bike riding done, thinking about Chequamegon National Forest, but I may just get in a ride heading north on the Mississippi River route.

are you kennyj on ExPo also? I am C11MAN over there too. if you ever need another Astro on a trip, I am only 25 miles north of you

I would like to see some of that dashcam of the particularly interesting bits...

never been to Chequamegon, but hear its quite nice

 

[kennyj]

are you kennyj on ExPo also? I am C11MAN over there too. if you ever need another Astro on a trip, I am only 25 miles north of you

I would like to see some of that dashcam of the particularly interesting bits...

never been to Chequamegon, but hear its quite nice

That's so cool, finally another A/S member out in this neck of the woods! Maybe we'll work up another spring meet, since all the Milwaukee guys bailed. :lol:

Yes, I'm kennyj on Expo, though I'm not much of a poster. I thought I remembered seeing your nick there, talking of running the TW*T; I was on my way west when that was happening. Someday I'd like to put together a local route; I know some pretty interesting roads from here and up into southwest WI.

 

[kennyj]

In the beginning of 2012 I bought a deep cycle battery to power led lights, and the roof vent fan, and charge the laptop and camera. Later that summer I decided to bite the bullet and go for an onboard refrigerator. I looked into the Engel and Edgestar 12 volt fridges; they have some advantages but they are really expensive. I decided to go with the trucker solution and get a 12v to 120v power inverter and a 120 volt compact refrigerator. This solution would also provide 120 volts for other uses.

I had to come up with a system to keep the battery charged. After reading a lot about charging systems I zeroed in on this thread on Expeditionportal.com
http://www.expeditionportal.com/forum/t ... tup-for-50
The basic idea is that when the vehicle is running, power from the alternator is sent to an auxiliary, or house battery via a heavy duty relay/solenoid. The length and gauge of the wire that charges the battery can be chosen for an ideal charging current. I didn't want to charge too fast, hurting the life of the battery, but wanted to fully recharge in a typical day of driving time.

Here is the charging relay mounted under the hood. It's on with the ignition on, power is supplied from a fused upfitters power lug in the fuse/relay box.

Here is the space getting ready for the power system. The charge wire is in; I started with 20 feet of 10 gauge, shooting for max of 30 amps charge current. This location was chosen to move the weight of the batteries ahead of the rear axle since I was planning on carrying a motorcycle out back.

Here is the inverter ready to go in. The battery to inverter cables are I believe 2 gauge wire with hydraulic crimped lugs. This is a pure sine wave inverter; most inverters are modified sine, and are not suitable for starting a refrigerators compressor. The 1,500 watt size is roughly equivalent to a single 15 amp household circuit, plenty for the compact fridge, or a coffeemaker or microwave.

Here is the inverter mounted. I chose this location to save space, but I need to relocate it for better fresh air flow so it will cool better. It works fine, but the internal cooling fans run so much they are robbing battery charge.

Here is everything wired up and batteries installed. I ended up using two batteries to extend charging intervals. These are the biggest deep cycle from Walmart, about 110 amp/hours each and pretty cheap, being flooded lead acid.

Here is the fridge. It's just a 1.8 cu ft dorm fridge, but I selected it for the Energy Star rating. In typical summer weather I can run lights, fans, laptop and camera charger, and the fridge for easily 48 hours with the batteries staying above 50% state of charge. That 50% is a good number to get the maximum life of recharge cycles from the batteries.

Still on the to-do list is a digital readout to monitor battery charge, and a time-delay relay for the ignition line to the charging solenoid. I have all the parts, just need to install them. Also I would like a second, switched charge wire that I can use to boost charge current; this for the occasional day that I won't be driving enough time to get a full recharge.

System cost was about $90 x 2 for batteries, $200 for the inverter, about $100 for refrigerator, and about $50 to $75 for solenoid, wire, lugs, etc., so about $550 total.
Never again seeing cheese floating in the cooler water = priceless

 

[SilverBullet1997]

I posted this on another thread, and it may be relevant here for you. It does cost a little money, Alarm/Remote start system and the Havis IdleRight2. But I do see you have some toys there and an alarm might be something you want to think about...

Haven't done this mod yet, but been thinking about it for when I really go to start camping in my van.

I in the future want to put a remote start on the van for two reasons, one I hate going out to a super cold van in the morning, and two, I want to install an IdleRight http://idleright.havis.com/ control Module

Save Fuel and Reduce Idle Time

The Havis IdleRight Fuel Management System is a purpose-built idle reduction system designed to allow emergency vehicles to be parked with warning lights flashing continuously while minimizing engine idle time and decreasing fuel consumption.

The IdleRight2 is the next generation of Havis Idle Reduction systems. It is designed to work with many popular after-market remote starters, which greatly simplifies installation. The IdleRight2 also features an LED diagnostics system and Return on Investment (ROI) calculator, as well as a new, lower price.

Which I think could be great for running electronics in the van all night long when camping. If the battery gets to an undesired level, the van will start up recharge the battery and then shut off. Also I have 'Emergency Flashers/Strobes' installed on my van and if I were to leave them running for an extended period of time I would want the system to start/stop my van.

Designed to work with many popular after-market remote starters, the IdleRight2 monitors the battery's voltage while the vehicle is turned off and your electronics are still on. If the voltage of the battery drops below a pre-set level, it triggers the remote starter to idle your vehicle. The system then runs the engine to charge the battery, turns the vehicle off, and begins the process again.

The simplicity of the new Havis Idle Reduction System is what makes it perfect for any fleet. Once installed in your vehicle, IdleRight2 will use your light bar or other electronic component as a signal to engage. So, all you have to do is turn the light bar switch on, turn your vehicle off, and walk away -- IdleRight2 will take it from there.

I think this would be good if you liked to listen to the radio at night, or had a small plug in heater on board, or a fan for the hotter climates, maybe a small TV and game console. Who knows, but I am sure it could come in handy with the right applications.

IdleRight Systems are Compatible with these Remote Start Models

VIPER Model 5101 Two-Way System
Python Model 1401/4102P Two-Way System
Clifford Model 4203X Two-Way System
Avital Model 4113 One-Way System

Might be something up your alley might not, I don't know.

But anyhow your system looks pretty awesome.

 

[C11MAN]

I don't post all that often their either, I feel like most of them have fully built rigs and spend like 2/3's of the year out, while I am like, "I have a van, and I like to drive in dirt sometimes". plus they mostly have Toyotas......

I never did make it very far up the TW*T, my long trip got canceled due to family health issues.

so I have to wait till spring for you to spill about the interesting roads around here?

 

[SilverBullet1997]

Happy Birthday Kenny!
ccasion-balloons: ccasion-birthday: ccasion-birthday: ccasion-birthdaymulticolor: ccasion-cake: ccasion-candle: ccasion-clown: bscene-smokingweed: ccasion-gift: ccasion-gift: ccasion-partyblower: ccasion-partyangel:

 

[HotWire]

I know it's an old thread, but a good one! I'm building my van for similar trips; and if you ever want someone to ride Chequamegon with, let me know. I try to ride there every Summer. I'm in Madison WI.