Squares Chevrolet G20 camper , 4x4 swap

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This is my G20, I got it a year ago after a trip to the US and deciding I couldnt live without one. Originally I looked at importing one as I wanted something 4x4 but alot of the conversions looked pretty shit and I didnt fancy my chances of getting one road legal here, that and the 12k odd shipping cost put me off. There were a few for sale here but mostly newer with TBI engines and just werent quite right. Then I found out a mate down south had one, road legal, diesel 2wd, 84, RHD, cheap, you beaut ! main issues were the colour and it smelt like soup kitchen, some dude had been living in it apparently, and sounds like he enjoyed a dart or 10 

 

Plate I wasnt allowed 

 

 

 So I drove it home and started planning, gutted the inside and got it over to the painters, similar colour to and old car I had and made new kitchen and beds etc, drove the shit out of it last summer, so good having a bit of space and sliding door. I drives good, stops good, steers good 

 

 

 

 

 

 

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So it needed a bit of work, the RHD conversion hasnt aged well with leaks and the wiring was just flat out shit, tape covering soldered joints everywhere, 3 feet of extra loom in the engine bay where the fuse box and AC had been moved, then leaks around the windscreen from the AC box install etc. And the roof had just been chopped out for the glass top.  So I got the shits with it and listed it, figured Id sell it and get something newer and dump some cash into a pointless but fun fwd rx323 which will now be on hold for a bit

 I had a guy. lined up then took it in for a wof and it failed on sketchy details around the RHD conversion and cracks in the filler / sealant around the roof. I got upset for about 3 seconds then decided Id keep it and fix it. This was on friday 

Friday night / sat morning : 

Sunday night :

 

 

I wanted it 4wd but couldnt find axles wide enough in NZ ( 66" ) , the conversions Id seen mostly used Dana 44s and 60s and leaf springs up front, not ideal from a handling and turning perspective but easy enough to fit. I have a 460LE with transfercase from a suburban which I planned to use but was going to have to import axles, not keen.

 

So off down a google hole I go and the widest diffs I can find were 80 series cruiser at 63". Theres room in the fenders for a narrower front end and itll fit and turn 15x10s I reckon ( see below ) 

 

I found pair of axles, engine ( 1HDT ) and trans close to home ish for a good price so got it all home ( sunday before pulling van motor ) 

6.2 dinosaur after 110ks :

 

1HDT after 300ks , I did timing belt etc yesterday and it all looks clean as inside 

 

I probably run a modified pump but these things and a piece of cake to get running, needs alternator wiring and power to fuel cut solenoid. Ill rewire the whole van, have a harness on the way. 

Back axle will go back on leaves, ill just weld new perches on it 

 

 

Front is the fun bit. The van has a big crossmember which holds the motor and upper and lower arms, spring hats are in the right places but new diff will hit the crossmember so ill cut it right down to clear the diff and put the new ( offset ) engine mounts in. Im rebuilding the swivels now, one of the hub bushings / bearings had disappeared so will get those done this week. 

 

Ill run coils on the chev upper mounts and cruiser axle mounts, im pumped on the coils. Then trailing radius arms with some mounts with vertical adjustment ( lots of holes ) sio I can correct caster while Im sorting ride height. 

 

So this static rollover threshold with LVV for lift limits might be an issue but once I sort the crossmember itll give me some space to drop the engine and get crank down.

 

The van is over getting the rust etc done now, meantime Ive put new vent windows and frames in and will make up the roof stiffeners itll need for cert 

 

 

 

 

 

 

 

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so it should fit 15x10s at -44p, 33x12.5 MTs and poke out 15mm so ill run plastic fenders , omg Im good at photoshop 

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I got the front axle rebuilt and ready to sling in. All new bearings and seals etc, just waiting on the brake hoses. One thing I didn't know that I didn't know was that 80s are full time 4wd, but some clever dingo sausage figured a mod to lock the centre diff gear and use it to throw the front driving gear and make it 2wd / 4wd so I got the kit and put manual hubs on the front.

 

I made so some radius arm mounts too, plan is to use them for mock up / alignment then maybe get some snazzy triangular ones profile cut, or add triangles and black paint to these ones 

 

 

Wiring harness and a few other bits showed up, also ordered a super cheesy LCD instrument cluster which I'm pretty excited about, sort of like the nasty old Dakota digital ones that tried to look modern but ended up quite the opposite.

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I went and visited the panel shop today, they are right into and and have blanked off the AC hole, remade the screen gutter bit and are most of the way through the screen pinch weld, outside of a pillars are done and insides have been replaced. There were some real nasty old repairs in there, dunno if it was earlier rust work or what.

I got some more arm brackets cut locally, took the guy minutes 

Also got the local certifier to go over it, nothing unexpected and he's happy with my plan with diff mounting and my obsession with caster. 

I need to plate under the seat mounts and come up with a source for the seat swivels, and add some belt floor anchors, the pillar ones are stock.

I've got some work to do reinstating the roof structure where it was hacked out for the glass highroof so I can run a third seat in back but there's plenty of space in there and upholstery will cover the bars, all ahead full ! 

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I got the van back from the painters, they done a heap of work and I'm stoked with how the pillars came out,.nothing that'll be seen once it's back together but no more leaks and they pulled a heap of filler and silicone patches out, and a big one held in with liquid nails 

 

It fits in the shed, sort of, I had to push it in and roof only just clears which might make things interesting getting it out, I might get some little travel wheels for it 

 

 

Then I got excited and pulled front suspension out, had to cut 2 ball joints,.no fun. Then had an hour before misso got home so took to the front crossmember with the sawzall

 

Then dummied front axle. Radius arm mounts will work good, I can plate up one of the existing crossmembers to mount them

Spring hats sit way too low, I'll unbolt them and cut them down, then try them mounted another 7 inches up on the side of the chassis rail, then I can run the long cruiser springs hopefully. 

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I got the spring hats unbolted, bit of time removing the factory solid rivets off the top, shit of a job, I drilled out 80 of them on the last C10 frame I did, no fun 

I got them sitting in place and they look much better up high and there's plenty of surface to glue them on 

 

I've used a set of g30 springs for mockup, they are way overkill but trying to estimate sag is a bit of a job so I can cut them down if needed. The axle is now sitting where it should. I'll get some more steel tomorrow and get it fully mounted and welded over the weekend hopefully.

 

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I slipped in a half-day today. I went a visited the machinist this morn to sort a plan for the steering crossover shaft, he's going to cut a 21mm Metric fine left thread onto the chev steering output link and I'll be able to screw it all together and run a damper, easy as.

 

I made up the Radius arm mounts, I've stood up and down 90 times this avo measuring and whacking and tacking etc.

 

Slapped them in, lined everything up again, then again, then again etc. The whole car seems really straight, I've had mixed luck with the last few, up to 15mm off square with one of them. Van is good though, unibody obvs holds strength.

Got happy, fully glued them in, plenty of attachment, I'm happy 

 

 

I got not that happy with the upper spring hats, I pulled them back off and moved the axle centre forward 40mm for guard clearance then welded them on as well.

One thing that displeases me is the bottom corner, it's a big stress riser and I've had issues with this corner cracking on bagged cars before ( albeit with the older top hat frames ) so I need to brain how to apply triangles or brace it from above, through floor maybe ? Idk 

 

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I had a pretty productive weekend on this pig. I got most of the wiring done, just need to add speaker cables and trace a couple of the back ones. I've got a generic Aeroflow GM harness, all coloured and labelled, great but of kit. I've used painless ones etc before that are sold as vehicle specific but they are just generic ones with add ons.

 

In a wave of steamed genius in the middle of last night I decided I needed and engine template to get the mounts and sump figured out, i wish I'd thought of this last time with the Cummins.

Mounts are offset between sides but it fits in just fine and gives me 150mm or so of clearance with sump 

I drew up crank centreline as well to calculate the " Static stability factor " for cert which need to be over 1.1,  it's at 1.28 as is which is great as ive got no engine, so in theory it can be raised still but it's up 8" on what it was and I still need to be able to get in it.

With the spring hats etc I'll weld in a couple of 100 X 50 beams and brace the shit out of it, that'll take care of the spring mounts, and give me somewhere to mount engine, Panhard bar mount and steering damper, I'll try and get that done this week.

Also made up and offset gauge for the wheels, right side is going to be a problem with 33x12.5 tyres and -44 rims. I might get some bigger offset wheels made, I'm not keen on spacers and want space to run 35s. 

 

 

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I haven't had much time in the shed this week, got a few jobs knocked off.

My guy cut threads onto the steering crossover shaft to adapt the chev output rod to the Toyota crossshaft, it'll work but be tight with the Panhard bar so I need to.brain that some more, also need to make a bushing for the centre hole to take up the slop between the tapered bore and the mount stud on the steering damper to mount that.

I got the back diff sitting in place,it's narrow but will work

I flipped the shackles and ditched the blocks that were in there which gives me 5" of lift or so, I'm thinking I'll match the front to this, I want to add some airbags or gas riser shocks as well for driving when the boat is on and water tank full.

I'll bolt it in tomorrow but won't weld the perches and shock moints in until engine and trans are in and I can set pinion angle 

 

I also got the front crossmember beams in. This was a bit of a job but I'm much happier with the spring hat strength now.

Problems solved :

- spring mounts stiffened

- place to mount Panhard bar 

- ties front frame rails together again instead of just relying on core support

- place for engine mounts to attach

Problems created :

- panhard bar sits at an odd angle with beams, needs brain

- engine will sit too high to clear beams so I'll have to notch into them a ways then beef it up again after 

 

My welder was farting around a bit so have that a birthday and went back over a couple of beads too 

Next job is probably sort out the seat and belt mounts and frame up the roof for cert 

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I tried getting the seat mounts and belts sorted this week but it got boring pretty quick, I've got the plates cut and a few in but need to rivet in the belt mounts.

So I got to getting engine mounts sorted, the ply template gave me a rough idea of the sump clearance so chopped a bit out of the crossmember and sat it on place. Major issue is getting it in, the firewall sits midway along the engine, so I have to take 2 grabs with the crane, easy as long as the windscreen is out lol

Once in it fits fine, I've given it 25mm of clearance between fan and radiator and it looks ok at the back for getting the trans in and out. Then i got straight into losing sleep over how to brace it all and mount engine and came up with this 

 

Which Im pretty happy with, I'll add the Panhard bar mount next then will get some paint in there and put motor in for good. 

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I got another good weekend in the shed, snow is shit and trails are muddy.

I got front rails and engine cradle painted and engine in, no dramas, plenty of space around it 

 

I got the steering arm back from the machinist, he reshaped it for me and drilled out the centre taper, then made me a press fit bushing to take the metric ball joint on the steering damper, it works great and gives me plenty of space for the Panhard bar. I got the Panhard bar mounted and track set too and it sits good

I stared farting around with the roof braces. The gist of it is when the glass roof extension went in they just hacked all the braces out so I need to reinstate the structure. I got one finished which braces the pillar belt mounts  and mocked up the others, I need to speak to the certifier again tomorrow before I attach them for good, he's against welding them in so I'll bolt and glue them.

Then I put the seat doublers in and read the info sheet again and realised they need to be riveted, rivets on the way.

 

 

I also sold a 4L80e and transfer case to a fella from down south who rocked up in this weapon, home job turbo 5.3 with a big ol cam, looked and sounded like a shitload of fun 

 

 

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I've had a good bit of progress last week, got a good chunk of wiring sorted, shout out to my favourite tools, my hydraulic swager for 0 gauge cables and my temu Deutsch plug kit 

 

 

I got the heater in, it's just a universal Summit one, I got rid of the distribution manifold and everything and just plumbed it straight into the demister rather that trying to revive a heap of vacuum operated valves and nasty old crap 

 

I also got the dash fired up, pretty pumped on it 

 

I got the dump pipe made up, its nice not having a firewall to argue with, it's 45 degrees out of the turbo so I didn't bother with steam pipe, it's basically full lobster back tif welded SS, except with mild steel, and a mig, and out of combo bends 

 

it fits good 

 

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The roof bracing is mostly done, I won't attach it until certifier has seen it again, he was talking adhesive and rivets, I want to use bolts. It's definitely a bit tidier, before :

 

After 

 

This will all be upholstered over anyway 

 

I also got the floor and front lined, roped the grommet into it for the corners, up under the pedals, worst $10 she's ever earned

 

 

And the wheels showed up, it's just how I pictured. Plenty of clearance inside at front, and close to flush with guards, out back I might have to space them out a touch, theres not much clearance with inner fender, will see how it goes with flex.

 

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Bit more progress last few days, I got the dash back together, the instrument panel cover bit is pretty fucked, I might try and make a new one or try find one on eBay. But the new cluster work good and mounted ok 

 

I made up the front shock mounts, shocks are some ones I had, Google says Hilux, Torana and a few others so will see how they go for dampening. I think I'll use limiting straps aswell for top out, it'll be a heap of weight on the shock shaft otherwise 

 

 

 

I also farted around with springs. I got a set of cruiser ones but they are way too big so I chucked in some g30 ones I had, I know they ride good and have lifted it another couple of inches which it needed.

Im stoked as fuck on how it looks, big feet and stock body. I live in a town infested with late model Japanese 4wd utes covered in every accessory know to man, this brick will stand out.

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I'm still waiting on the trans, hopefully next week then I can fire it up and get shafts made.

 

Meantime i got the steering stabiliser on, I need to drop the mount angle down a bit to give the inboard ball joint some more movement but position wise it works through the travel without hitting anything. I just got old mate to turn a tapered bushing up and I stuck it together with some plate etc 

 

 

I also got it outside, it looks mean as, but too high in front, static stability ratio is at 1.03 so I'll put stock springs back in which will drop it 40mm and it'll be good.

 

Chevy fleet is on point 

 

One thing I do need help with is the glow plug relay, is there a vehicle I can get a combination timer and solenoid out of ? Running a solenoid triggered but a timer is being harder than it should, i just fried a $160 one and I'm not keen to do it again 

 

Any advice appreciated

 

https://oldschool.co.nz/index.php?/topic/87859-squares-g20-pest-van/

 

 

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I finally got the trans back for this, it's a hydro a442f and i got it ( rebuilt ) from A Automotive in Auckland, first in the phone book which hasn't been of any use for some time. But anyway it looks good and the parts list says it has a good going through.

I got it in place, had to reshape one crossmember which was fun lying on my back in the driveway

It's sits good and high, the whole thing looks much better with the transfer case hanging out the bottom 

 

I filled it through the dipstick hole by pressuring the jug, not smart but it worked a treat 

 

Then I made a dummy shift linkage out of rebar, I hate shift cables in autos, and it worked so good that I threaded it and painted it and in she goes 

I think I've got a plan for the centre diff lock motor, it turns both ways like a window motor and has a limit switch in the motor body.

So I made a box of wires with a couple of relays 

 

I also got the pinion angle set in the back and welded on the leaf perches and shock mounts, and got diff painted, will make new back brake lines as I'd rebent the stock ones and they look shit 

 

 

Hopefully I'll get it fired up tomorrow, then finish the trans wiring and then all I'm waiting is the gearbox rubber mount and a driveshaft, I'm planning on taking it camping next weekend but that may be dreaming 

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Well she runs, it needs a shot of ether to fire for some reason, I think either fuel is bleeding back and I'm losing prime and it needs a lift pump or theres a big hole in vacuum system maybe ? I also need to read up on how auto choke works. Glow plugs seem to be working fine 

It runs fine once it's fired and restarts like it should. I got the front shaft in and went for a circle round the lawn, happy days 

My relay box for 4wd didn't work straight away so I packed a shit and tore it out, and have just put a momentary rocker switch putting power straight onto the transfer case actuator for now, I'm sure thisll screw the motor long term but it works.

I got a basic exhaust built, it's not loud with no muffler so will.try it and see, I didn't have enough bends to get over the diff and also couldn't be bothered so out the side she goes 

 

I also made a new trans crossmember,.Ive left the mounts mocked up for now until the new rubber centre mount shows,. hopefully Monday 

Also got most of interior back in and engine bay tidied up 

 

 

it just needs rear driveshaft and gearbox crossmember finishing now. 

 

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Few more odds and sods this week, the starting issue ended up being a fuel / air leak, these don't run lift pumps so lines are normally in vacuum. I stole an idea from some clever sausage and used clear tube to watch fuel flow 

 

Before  ; 

 

After ( sans bubble ) :

 

 

I got the trans crossmember done, ordered 2 mounts, neither showed So I just used a couple of big bobbin mounts for now 

It hangs below the transfer case and seems to work good 

Also got sway bar mounts made, they are on chunks of 50x25 and pivot point is level with radius arms mounts so hopefully it doesn't move forward and back enough to snap them, I cycled it a few times and it seems ok 

So here she is, just waiting on back driveshaft which should be here tomorrow avo, I might still get away in it on weekend if I can get some miles on it Thursday / Friday 

 

Close to concept I think 

 

 

 

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I got driveshaft in and got it driving good enough to start putting miles on it last week, calibrated Speedo, sorted some leaks and other small stuff and took it away over weekend, fuck it was good, electrical system and batteries etc worked a treat, it kept.charged all weekend with fridge running and lights on.

Went to mavora lakes for some fuckstickery, 30 odd grown men racing around on 100cc kids bikes, some of the best fun Ive had 

 

So it ran sweet, 250 odd ks then a thought I heard a noise coming back into Queenstown and pulled over, then heard a big noise. I assumed it was big end but got under it and I could move the flexplate with my hands. So called in a tow and got it home, I have to let the tyres down to get it on my trailer 

 

Pulled the trans, which I wasn't in the mood for after a big.weekend, and found loose flexplate a 5 sheared bolts.

 

I don't really know what's going on, 2 things are that theres no dowel in the counterweight and there should be one, and there's a spacer in the parts listing that wasn't in there. 

When I measured it all up the torque converter engagement all seemed right so I'll do it all again and see if I can nut out what's going on.

 

I can't see any damage to torque converter or trans so far thank fuck