Project Base Camp

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Project Base Camp

Postby slipperychicken [OP] » June 14th 2012, 2:56am

Hello,

After lurking on AstroSafari.com for a few months, I finally pulled the trigger on my first Astro. Today, I purchased a 2000 Astro Cargo van from a fleet sales auction. It's a former telephone operator's van, and it has about 300 pounds of telephone junk in its wire racks and bins. 4.3L, AWD and A/C are all I know so far about the mechanicals, although it drives pretty well.

My plans for this van are to transform it into a fishing and hiking base camp vehicle. I will install a high top and rack, modest body lift and slightly larger tires. I will fit the interior with a small sink, stove, convertible bed, and storage space for my gear.

An ambitious undertaking for my first project, to say the least. Wish me luck!!
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Re: Project Base Camp

Postby chevymaher » June 14th 2012, 3:03am

Welcome. You had duplicate post, please repost the picture of your van.
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Re: Project Base Camp

Postby slipperychicken [OP] » June 14th 2012, 3:09am

Thank you sir!
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Re: Project Base Camp

Postby Duck Hunter » June 14th 2012, 3:38am

Great! you know I am an out door guy too.. fishing and camping..
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Re: Project Base Camp

Postby chevymaher » June 14th 2012, 11:58am

slipperychicken wrote:Thank you sir!


I am not Sir. Call me hey you, Dillweed, Dork but don't call me late for supper. And your welcome, good to have you here.
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Re: Project Base Camp

Postby StanVan » June 18th 2012, 3:34am

Looks like mine did. Mine belonged to an electrical shop. I put the bin assembly on wheels and it rolls around my shop and holds a decent amount of hardware. The barrier behind the seats kept the seats from moving all the way back. I guess that shop only hired short people!

Question. The pic doesn't show the rear. By chance, does it have the Dutch Door? Mine is one of a few cargos that I've seen with them.
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Re: Project Base Camp

Postby Jasen » June 18th 2012, 4:08am

I've got dutch doors on my cargo, I love 'em. I built cabinets that allow me to slide sheet goods in and they hang out the back about 8-10" and with the hatch pulled down it protects them during a light rain.
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Re: Project Base Camp

Postby slipperychicken [OP] » June 21st 2012, 2:50am

No such luck on the Dutch Doors...

My van is at a friend's house for storage. Wish I had the time and access to get to work on her... Patience is a virtue that I have a short supply of... :|
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Re: Project Base Camp

Postby slipperychicken [OP] » July 1st 2012, 5:18am

Got a few things accomplished today:

Bought an air compressor and air tool kit. So far, so good.

Removed most of the pipe rack- all but the four post bases. The air tools made the work much easier.

Cleared enough space in my buddy's garage to get it inside.

I attempted to find the problem in my a/c system. No cold air. I followed Tex Star Detail's post and inspected the plug on the resistor. No such luck, it looks brand new.

viewtopic.php?f=127&t=8306&hilit=driver+door+hinge

Any other suggestions as to my A/C problem?

All in all, a decent day's work
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Re: Project Base Camp

Postby Phantom » July 1st 2012, 5:32am

slipperychicken wrote:I attempted to find the problem in my a/c system. No cold air. I followed Tex Star Detail's post and inspected the plug on the resistor. No such luck, it looks brand new.

Any other suggestions as to my A/C problem?

That is only for the blower fan motor ,, if your fan is blowing but just not cold air ,, check fuses under hood and verify that you have enough r-134a in the system , if not the compressor will not turn come on , you can jump the contacts on the connector mounted on the refrigerant line to see if the compressor will come on , if it does then you low on r 134a , if compressor cycles on and off frequently it means you are low and and a can or 2 will fill it up
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Re: Project Base Camp

Postby Sailing_Faith » July 1st 2012, 6:18am

slipperychicken wrote:....

My plans for this van are to transform it into a fishing and hiking base camp vehicle. I will install a high top and rack, modest body lift and slightly larger tires. I will fit the interior with a small sink, stove, convertible bed, and storage space for my gear.

An ambitious undertaking for my first project, to say the least. Wish me luck!!


My plans are similar, look forward to seeing how yours progresses.

Good luck!
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Re: Project Base Camp

Postby slipperychicken [OP] » July 5th 2012, 3:19am

Got to work on the van today. Removed all of the shelving and racking from the cargo area, as well as the bulkhead and the rubber floor matting in the cargo bay. Slowly but surely...
DSCF0071.JPG
Before...
DSCF0080.JPG
... And after.
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Re: Project Base Camp

Postby slipperychicken [OP] » July 8th 2012, 8:05pm

Pulled the driver's side door and fender this weekend. The bottom door hinge was broken in half, and it appears that someone tried to tack-weld it back in place- about 10 times to be exact. Because of the door sag, the fender and door are both creased and bent.

We went to a few salvage yards yesterday to find the replacement items, but with no success. I did find an under-seat storage bin, so all was not lost.

If I can't find a replacement door, I may take the original one to a good auto shop and have the broken hinge welded back on correctly. The door spring was missing altogether, so I'll need to purchase a new one.

The fender also had a large hole and 4 screw holes in it. Was this from an antenna? The van was a phone service vehicle in its former life.

Thanks for reading.
P1070025.JPG
Bent door and fender
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Door & fender removed
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Body door hinge
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Fender and door removed
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Re: Project Base Camp

Postby PJorgen » July 12th 2012, 6:01pm

Great thread! I'm planning a similar project, although I started with a passenger model as I wanted all the windows. So far I'm still working on the mechanicals, making sure it's safe and reliable for the back country. Changed most of the fluids and filters, am debating changing the diffs and transfer case oil. Next up are shocks, brake pads, brake fluid and a rear sway bar.

I intend to replace the rear carpet with a mat from a JY cargo van. Then I'll build a raised platform in the back for a bed with storage underneath. Will post pics if I ever get that far.
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Re: Project Base Camp

Postby slipperychicken [OP] » July 13th 2012, 3:09am

Thanks, PJorgen! I've decide to do a 2" body and 2" suspension lift next. Still no luck finding replacement fender or door... The search continues. I'll be sure to check out your build as well. Cheers!
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Re: Project Base Camp

Postby Birdshake » July 13th 2012, 4:11am

I had the same problem with my climate control. I followed the same thread and inspected the plug for the resistor and the plug was fine just like yours. But I also checked the resistor and it was fried so I replaced it and everything worked again. My 2003 had the older styled resistor and replaced it with the newer designed one which is the same one tex star detail showed.
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Re: Project Base Camp

Postby icebrrg3rd » July 13th 2012, 5:22pm

chevymaher wrote:
slipperychicken wrote:Thank you sir!


I am not Sir...


Ma'am? :poke:

Around here there are more 2nd gens in the junkyards than 1st gens, so I don't think there would be a problem with finding a fender/door. What yards have you looked in? White is popular with work vans so you think there would be a good chance of finding a white one. Hope you stumble across one soon.

And nice pics, keep them coming as the van evolves. I would love to do the "camper van" thing but with wife & kids, I can only live those dreams thru others. My camper van would have to be a Class A motorhome, Class C at a minimum.

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Re: Project Base Camp

Postby slipperychicken [OP] » July 15th 2012, 6:25pm

Thanks everyone for the words of encouragement and comments. I took the weekend off from the van build and went fishing yesterday near Vail. No fish, lots of rain, but a great way to recharge the batteries...
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Re: Project Base Camp

Postby slipperychicken [OP] » July 20th 2012, 4:00am

Got my 4" OLV lift kit ordered today. Having spent a ton of time on the Lifted Suspensions forum, I decided that it might be worth the extra $$ to buy the complete kit with hardware included. Seems like it can be a PITA to track down all of the parts and pieces separately. Now comes the "waiting patiently" part...
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Re: Project Base Camp

Postby Don1806 » December 28th 2012, 9:50pm

That hole that you thought might be from an antenna looks more like it was either a Kussmaul type charging system where the van is plugged into AC when not in use to charge equipment on board and on some systems it will also trickle charge the battery. If none of the equipment is still on board then it's an ideal location to install a shore line connection to whatever equipment you may want to keep charged such as a second battery, etc.

Since it was a fleet vehicle, it could have also been a fleet key safe that contained a set of keys to the van. When a company uses those, all of the safes are keyed alike, and each safe contains a backup set of keys to the respective vehicle. It keeps key costs down allows for keys to (almost) always be available if the primary operator of the van isn't available to provide them.
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