Sparkydog's 2003 Safari AWD

Forum rules
Build topics only! Members are allowed one topic per vehicle in this forum. Topics may only be started by the vehicle owner but all are welcome to reply to the authors project thread.

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

Sent from my SM-N950U using Tapatalk
User avatar
cowgirlcullen
Fueling (1/8 tank)
Fueling (1/8 tank)
Posts: 19
Topics: 3
Joined: December 2020
Gender: Female
Alias (AKA): Jennifer
Van Model Year: 2003
Van Make/Model: Chevrolet Astro
Extra Info: AWD

  • Similar topics
    Replies
    Views
    Author
  • 2003 AWD Safari Overlander
    by Vanteriors » April 21st 2021, 7:09am in Projects/Builds
    1 Replies
    92 Views
    Last post by sixsix View the latest post
    April 21st 2021, 12:42pm
  • 2003 extended astro van
    by sumtingbig » March 15th 2021, 2:31pm in Projects/Builds
    3 Replies
    264 Views
    Last post by domsan View the latest post
    March 15th 2021, 4:11pm
  •  
    5
    79
    Last post by AstroSafari.com View the latest post
    April 23rd 2021, 1:16pm

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.
002.JPG


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
004.JPG


After the cuts:
005.JPG
006.JPG


With wheels back on:
007.JPG
008.JPG
Original Poster [OP]
User avatar
Sparkydog
Firing on 1 Cylinder (L1)
Firing on 1 Cylinder (L1)
Years of Membership: Sparkydog has been a member for 1 full year
Posts: 138
Topics: 12
Joined: July 2019
Location: SoCal & SoOre
Alias (AKA):
Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

Re: Sparkydog's 2003 Safari AWD

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

Boy! - now that is Clean.
.

I Love Peaches also & Wolverines and Gophers
User avatar
sixsix
Firing on 8 Cylinders (L5)
Firing on 8 Cylinders (L5)
Years of Membership: sixsix has been a member for 6 full yearssixsix has been a member for 6 full yearssixsix has been a member for 6 full yearssixsix has been a member for 6 full yearssixsix has been a member for 6 full yearssixsix has been a member for 6 full years
Posts: 4850
Topics: 39
Images: 1359
Joined: May 2014
Location: Edgewood, Northern Ky.
Gender: Male
Alias (AKA): Mike
Van Model Year: 1992
Van Make/Model: Chevrolet Astro
Extra Info: LT W CPI - RWD 200K

Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » March 8th 2021, 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.
022.JPG


Over the weekend I sealed up the areas in the front wheel wells with more metal, seam sealer and paint.
018.JPG

023.JPG


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

003.JPG


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

008.JPG


All done.
010.JPG

011.JPG
Original Poster [OP]
User avatar
Sparkydog
Firing on 1 Cylinder (L1)
Firing on 1 Cylinder (L1)
Years of Membership: Sparkydog has been a member for 1 full year
Posts: 138
Topics: 12
Joined: July 2019
Location: SoCal & SoOre
Alias (AKA):
Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

Re: Sparkydog's 2003 Safari AWD

Postby stent » March 8th 2021, 5:19pm

so many great ideas!!!
your jack mount & air box brackets are my faves so far!
001.JPG
sparkybracket
User avatar
stent
Firing on 2 Cylinders (L1)
Firing on 2 Cylinders (L1)
Years of Membership: stent has been a member for 3 full yearsstent has been a member for 3 full yearsstent has been a member for 3 full years
Posts: 283
Topics: 2
Images: 188
Joined: May 2017
Alias (AKA):
Van Model Year: 1999
Van Make/Model: Chevrolet Astro
Extra Info: rwd cargo

Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » March 8th 2021, 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

014.JPG
Original Poster [OP]
User avatar
Sparkydog
Firing on 1 Cylinder (L1)
Firing on 1 Cylinder (L1)
Years of Membership: Sparkydog has been a member for 1 full year
Posts: 138
Topics: 12
Joined: July 2019
Location: SoCal & SoOre
Alias (AKA):
Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

Re: Sparkydog's 2003 Safari AWD

Postby Sparkydog [OP] » March 29th 2021, 5:46pm

This past week I did a 1600 mile round trip to Oregon and back. The van was in cargo/truck mode for this trip. The area under the giant package shelf was full of totes. I left the 2nd row seat in the van but filled it with a bike, luggage and some smaller totes. And I towed a trailer. Going up to Oregon the trailer had some patio furniture in it and coming back it had a zero turn riding lawn mower.
I got about 13-14mpg at 65+ mph after accounting for error in odometer/speedometer due to larger tires.
002.JPG

003.JPG

004.JPG

005.JPG


The good news:
The motor and transmission did not fail.
No coolant leaks.
I made it back.

The bad news:
New oil leak - probably the power steering pump tank. A slow leak but now the under side of the van, the rear of the van and the front of the trailer are covered in a sprinkling of power steering fluid.
HVAC blower stopped working on the way back. Then started working again a day later.
I hit a giant pothole on I5 north of Sacramento and lost cruise control for some reason. Got to wear my right foot out for the next 9 hours.
There were several sections of I5 and LA freeways that were so broken that I destroyed most of my aging suspension bushings. So now I have a bunch of new things to repair.
The V6 + bigger tires + 3.73 diff + trailer + cargo is not a good combo. This van needs that LS V8 to wake it up.
Last edited by Sparkydog on March 30th 2021, 12:29am, edited 2 times in total.
Original Poster [OP]
User avatar
Sparkydog
Firing on 1 Cylinder (L1)
Firing on 1 Cylinder (L1)
Years of Membership: Sparkydog has been a member for 1 full year
Posts: 138
Topics: 12
Joined: July 2019
Location: SoCal & SoOre
Alias (AKA):
Van Model Year: 2003
Van Make/Model: GMC Safari
Extra Info: AWD

Re: Sparkydog's 2003 Safari AWD

Postby Rod's Trucks » March 29th 2021, 6:20pm

Be glad you didn't have the 3:42 gearing!
Rod's Trucks
Firing on 6 Cylinders (L1)
Firing on 6 Cylinders (L1)
Years of Membership: Rod's Trucks has been a member for 1 full year
Posts: 643
Topics: 36
Images: 57
Joined: January 2020
Location: Issaquah, WA
Gender: Male
Alias (AKA): Rod and/or WE7X
Van Model Year: 1998
Van Make/Model: Chevrolet Astro
Extra Info: Forest Green LS AWD

Previous

 
  • Related topics
    Replies
    Views
    Last post

Return to Projects/Builds

It is currently April 23rd 2021, 1:16pm

Projects/Builds Forum
Projects/BuildsEach members' project build thread. Post details and photos, past and present, of your projects coming together. Restorations, modifications, or customizations of a vehicle and a sequential history of the progress. Build-up threads only!
To create a new topic in Projects/Builds, click this button:
Previous topic Next topic
Recent Image Attachments
Attached by:
backinabox
in Projects/Builds
Views: 2472
Comments: 49
Date: Yesterday
Time: 11:19pm
» Read last comment
Attached by:
Attached by: LumaWJ
LumaWJ
in Projects/Builds
Views: 1133
Comments: 35
Date: Apr 21 '21
Time: 4:05pm
» Read last comment
Attached by:
Vanteriors
in Projects/Builds
Views: 92
Comments: 1
Date: Apr 21 '21
Time: 6:52am
» Read last comment
Attached by:
backinabox
in Projects/Builds
Views: 2472
Comments: 49
Date: Apr 20 '21
Time: 3:24am
» Read last comment
Attached by:
backinabox
in Projects/Builds
Views: 2472
Comments: 49
Date: Apr 20 '21
Time: 2:38am
» Read last comment
Sponsors

Who is online

Users browsing this forum: No registered users and 3 guests