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  1. #821
    Join Date
    Mar 2004
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    Mid-Michigan
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    Thanks Joe, Once I get the chassis to roller stage I will finish up the bottom of the body. Dropping it on the chassis will be party time!

    I got motivated after dinner and went back out to the shop and got the front rotors cleaned up. A wire cup brush on a drill motor and a D/A and we're almost ready for paint. I sprayed the rust I couldn't get off, like down in the vents, with rust converter. This turns the rust black and makes a good base for paint.
    They weren't in real bad shape to begin with but knocking off the surface rust sure does help.



    After some time spent with the D/A.

    After a dousing with the rust converter. The inside face.

    The outside was clean enough after sanding I will just wipe it down and spray it with the black caliper paint.

    These cleaned up very nice and will look "almost" as good as the spendy coated ones once installed.

    This is the rust converter I use.
    DupliColor Rust Fix

    I'll get these painted tomorrow and start working on the rears.
    Thanks for looking!
    Mark

    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/


  2. #822
    Join Date
    Mar 2004
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    Got a lot done tonight. Front rotors painted, rear rotors cleaned up and rust converted, upper ball joints bolted in and the RH steering knuckle hung. I think the rotors look pretty good and I am really leaning toward black calipers as well...









    I also got the v-belt lengths figured out. Both Alternator and A/C belts are 51.5 inches long. The PS belt will be about 32 or so.



    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  3. #823
    Join Date
    Mar 2004
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    I got the rear rotors painted tonight. It was raining yesterday, not painting when the humidity is stupid high...
    Hung in the sun to dry they set up pretty quick.



    Waiting for the rotors to dry I started hanging the LH Lower Control Arm. This bolted up easily as well as the shock.



    The only snag is I couldn't find the LBJ boot... Looked for a while but no boot. So, off to the auto parts store... I'll find it AFTER I get a new one.

    Thanks for watching.
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  4. #824
    Join Date
    Mar 2004
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    Mid-Michigan
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    Haven't done to much with the van the past weekend or this week. A big two day car show in Flint, a lot going on at work and then a funeral yesterday has taken up all of my time. I have been gathering parts though. I have a 36.5" long v-belt for the PS hook up and I have lower ball joint boots to wrap up getting the front suspension together. I hope to get that done tonight along with putting on all of the belts and starting to work up a lower radiator hose that will route between the A/C Compressor and the Alternator right above that. I'll post up some pics tonight after I get things put together.
    In the plan also is getting the brake calipers and abutments cleaned up (sandblasted) and painted so I can get all of that installed before the rolling stock goes on...
    Thanks for following!
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  5. #825
    Join Date
    Mar 2004
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    Ordered the LBJ boots through O'Rielly's last week and got the left front suspension together.

    With the rotor installed.

    Sunday morning I got out into the shop early, before it got to hot, and blasted the brake abutments and got them painted. I went with the silver caliper paint.
    Before and after blasting.


    The silver paint went on great and it baked in the sun all day...



    Here are the "grey" Grand Sport calipers.



    I got these and the Hydro-Boost cyl. painted with the black caliper paint today. I'll post up pics tomorrow. I have all week off for GM Shutdown. I hope to have this chassis rolling around by the end of the week...
    Thanks for following!
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  6. #826
    Join Date
    Aug 2002
    Location
    Waleska Ga.
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    2,380
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  7. #827
    Join Date
    Mar 2004
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    Mid-Michigan
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    Thanks David! It looks like we could be kindred spirits the way we drag out builds like we do... Any updates on yours? I hope the shop is complete and the car is in there being worked on!
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  8. #828
    Join Date
    Aug 2002
    Location
    Waleska Ga.
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    Quote Originally Posted by astroracer View Post
    Thanks David! It looks like we could be kindred spirits the way we drag out builds like we do... Any updates on yours? I hope the shop is complete and the car is in there being worked on!
    Mark
    Life happens to some of us and our projects get stalled,
    I like to come in and check out all the build threads here when i get a chance, especially the ones like yours!
    Getting real close on finishing up the Garage ,The power to the building should be on next week sometime. I got my Split Heat and AC unit to install, then empty the conex trailers out of tools and parts fiq. out were the welders, tables and tools are going to be in the shop then the camaro and the elcamino are on the list first thing !
    Thanks for asking ! Keep up the work its looking good and motivating me

  9. #829
    Join Date
    Apr 2001
    Location
    The Netherlands
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    1,484
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    Looks good Mark!
    1st 2nd
    Pro-Touring outside the USA !
    Martin's Camaro Page

  10. #830
    Join Date
    Mar 2004
    Location
    Mid-Michigan
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    Thanks guys! Appreciate the kudo's!
    Didn't get out to the shop to work on my stuff today. Cleaning out gutters and repairing some on my mom's barn and running to get some 1 x 3's for the relamping project in the shop. The 8' 220V cold start fluorescents I put up in '05 are on their last legs. They were well used when I got them and now I have to jiggle the switches to get them to light up. Pretty frustrating and they need to be replaced.
    I ordered some Hyperion 70w LED's to put up in place of the fluorescents so I will mount the new lights to the strapping and put them up two at a time.
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  11. #831
    Join Date
    Mar 2004
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    One thing I have decided to do is to replace the hydro-boost and master cylinder I got off a '95 Astro I stripped. I pulled them apart to clean them up for painting and there is quite a bit of rust on the inside of the hydro-boost unit. I don't know if a little bit of rust is anything to worry about but I do not want to be replacing stuff that doesn't work after I get this thing put together...
    Another question, and I'll ask this in the brake section as well, is there a better M/C to use for disc/disc? The '95 had disc/drum.
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  12. #832
    Join Date
    Mar 2004
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    Worked on the front brake corners this morning. Everything is bolted up and it looks like they will work. I will still need to blow everything apart for grease and thread locker but it's much easier to work with clean parts if I have to take it apart for any reason. And I still need to throw some more paint on the hubs. The van is a still a long way off from drivable. I should have a rolling chassis tonight though.
    I'll get back out into the shop later when it cools off a bit.
    Right front assembly.


    Left front assembly.


    Thanks for looking!
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  13. #833
    Join Date
    Mar 2004
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    Back out in the shop this evening after it "cooled off" a bit. Still damn hot and muggy...
    I assembled the right rear brake corner tonight. Just bolting things together for the umpteenth time... I like the black rotor and caliper. I think it will look good behind the polished rims.





    Also got the left front tire and rim bolted on... What do you think?





    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  14. #834
    Join Date
    Aug 2014
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    328
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    Quote Originally Posted by astroracer View Post
    I like the black rotor and caliper. I think it will look good behind the polished rims.


    Mark
    It looks great. Once you get all the wheels on, take pics, because they don't stay that way. lol. I really wish they would. Especially with slotted rotors, the black surface looks awesome.

  15. #835
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    Mar 2004
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    Yea, the pads will wear a path thru the paint, that is unavoidable. The rest of the rotor should stay black though which is what I am after...
    I am thinking I will leave the "CORVETTE" script black as well, what does everyone think?
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  16. #836
    Join Date
    Apr 2001
    Location
    The Druid City
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    14,238
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    I would leave the Corvette script black. Amazing progress.

    Andrew
    1970 GTO Version 2.0
    1967 Cougar build
    GM High-Tech Performance feature
    My YouTube Channel Please Subscribe!
    Instagram @projectgattago

    "You were the gun, your voice was the trigger, your bravery was the barrel, your eyes were the bullets." ~ Her

  17. #837
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    May 2010
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    British Columbia
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    419
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    Ditto

  18. #838
    Join Date
    Mar 2004
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    I think that's going to be the plan. Everything black except the caliper brackets. Nice thing is that plan can change anytime with a different color paint...
    I've had a few people asking about the aluminum abutment adapters. I got those from someone here on Pro-Touring back in 2011 or 2012. I have no clue who made them.
    With the modified spindles there was no room for a bolt head on the upper adapter mount so I used 1/2-20 x 2" LG socket set screws.


    Adapter brackets mounted to spindles. You can see the clearance between the nut and the caliper. I had to use short lock nuts on the caliper side to clear the caliper bracket.


    All of this was figured out during mock up so it was a simple matter of bolting everything up.

    The Corvette abutments take metric bolts and I ordered these flange head bolts (14mm-2.0 x 45 long) and, as with every other part on this van, I had to do some modifying to get them to work.

    I had to turn the flanges down by 0.2 inch to get enough clearance between the bolt head and the spindle. I spun them in the lathe and cut 0.2" inches off the OD of the "washer" to let the bolt pass by the spindle as the caliper bracket is bolted on. A stock bolt is at the bottom.


    The spindles are highly modified 2" drop Astro pieces. Leaving as much material around the bolts as possible I still had to grind out a bunch to get bolts to fit during the mock up phase.
    I also ground a full thread off the length to give better clearance to the rotor.

    A bit of a trick getting the Corvette stuff to work but it all bolts up and the calipers align with the rotor so I think we are good to go...
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  19. #839
    Join Date
    Mar 2004
    Location
    Mid-Michigan
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    Worked on the rear brakes this morning. The RR was mostly done, bolting up the brake hose was the only thing to do. The LR needed to be assembled but that didn't take long, and with everything put together, mounting tires and wheels was a most do...
    To get the front wrapped up I need to take the front tires and wheels to Discount. The valve stems are on the inside of these rims and the stem is too long. It hits the caliper as it rotates, not a good thing. :( I will not set the chassis on the ground until that is done... I may take them in this afternoon.






    Thanks for looking!
    Mark
    Mark:
    "Bad Ast" Astro Van. Just because I did it... Doesn't mean it's possible...
    This my Bad Ast thread...
    https://www.pro-touring.com/showthre...roject-Faze-II
    This is my Fotki album...
    http://astroracer.fotki.com/

  20. #840
    Join Date
    Nov 2006
    Location
    Ma.
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    4,994
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    I haven’t had a chance to check in lately , nice progress.
    Wayne
    Car FINALLY home !!!!!! lol
    Project FNQUIK https://www.pro-touring.com/showthre...ghlight=FNQUIK

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