Sparkydog's 2003 Safari AWD

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Re: Sparkydog's 2003 Safari AWD

Postby cowgirlcullen » February 23rd 2021, 8:27pm

Thanks for the info and quick reply! Trying to get stuff ordered to get my project underway. I think I might skip the blocks and just leave it on the ground. I do have a hoist, but that's about it besides a floor jack, so I'll have to get some jack posts and jack stands. I just found this thing though (link below) so this might be the way the go I think. It will be interesting figuring out where exactly to connect the hoist to the van though.


https://www.amazon.com/dp/B00LQVZG8I/re ... UTF8&psc=1

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Fueling (1/8 tank)
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Van Model Year: 2003
Van Make/Model: Chevrolet Astro
Extra Info: AWD

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Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » March 2nd 2021, 5:33pm

Time to cut up the rear wheel wells.
The stuff to make a cardboard template:
001.JPG


Deciding on the shape of the curve and marking out on the template.
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Transferring the cut line onto both fenders. The right side will cut through more complex metal as it's tight in this area due to the sliding door opening.
003.JPG
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After the cuts:
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With wheels back on:
007.JPG
008.JPG
Original Poster [OP]
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Sparkydog
Firing on 1 Cylinder (L1)
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Van Make/Model: GMC Safari
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Re: Sparkydog's 2003 Safari AWD

Postby sixsix » March 3rd 2021, 3:25am

Boy! - now that is Clean.
.

"Ban gerrymandering" out 1 side, then says, "We really need to get rid of the electoral college for starters, there is no way in hell that the person that receives fewer votes wins, simply crazy."
So only CAL, ILL & NY Elects??
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Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » Yesterday, 4:53pm

Thanks sixsix!
This past week I started driving the van to work. I'm wanting to regain my trust in it before I make my next trip to Oregon near the end of the month. It was unusually cold for SoCal so the e-fan hasn't had to do much - yet. I was immediately bothered by a noise coming from the front of the van that sounded like a failed wheel bearing, or a stuck brake caliper, or something bad from the front diff. But a guy I work with went for a ride with me and he says it's just the noise from the bigger, more aggressive tread on the tires off the Burner Tahoe. For now I am hoping he's right and will continue to just drive the van.

In fact today I'm using the van in semi-cargo mode. The 2nd row seats are still in the van but the giant cargo shelf/bed is out of the van so I could stick my engine hoist into the back and load an automatic transmission I'm selling to a guy. I also am hauling off some scrap metal.
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Over the weekend I sealed up the areas in the front wheel wells with more metal, seam sealer and paint.
018.JPG

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I also installed the wheel jack kit from the Burner Tahoe. The jack is bigger than the stock van and more importantly for me, it has the long rods so you can run the jack without having to be near or under the van. :snooty:
I started the mod by cutting out the stock mounting bracket.
002.JPG

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Then shaved off some of the Burner Tahoe bracket in order to get the base portion to tuck into the fender area better.
005.JPG


Came up with a scheme to build a small wing on the base and allow me to weld it into the van side.
006.JPG

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All done.
010.JPG

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Original Poster [OP]
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Sparkydog
Firing on 1 Cylinder (L1)
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Years of Membership: Sparkydog has been a member for 1 full year
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Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

Re: Sparkydog's 2003 Safari AWD

Postby stent » Yesterday, 5:19pm

so many great ideas!!!
your jack mount & air box brackets are my faves so far!
001.JPG
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Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » Yesterday, 5:20pm

Just for S&G's I grabbed the tow hooks off the front of the Burner Tahoe and dove under the Safari to see how I might attach them. Much to my surprise, they sort of fit up into the subframe holes without any special work. I'm going to embellish things a bit so that the hooks sit square-er but for now it's darn near a direct fit!
013.JPG

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Sparkydog
Firing on 1 Cylinder (L1)
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Years of Membership: Sparkydog has been a member for 1 full year
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Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

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