Air ride on sad pimped 92 Astro!!

[andyfanshawe]

This could be a long thread with an even looooonger story behind it!!
This is a 1992 2WD Astro in the UK that has been “pimped” badly and has deteriorated since then. My mission was/is to resurrect it and have a bit of fun in the meantime!!

The whole story from the dark beginnings can be found here
http://www.amvo.org/forum/viewtopic.php?f=3&t=4920
Make sure you have plenty of time to read it though!!!

But, since this is a suspension thread, I am going to relate my attempt to fit air suspension to it and get it really low. Luckily it has a gfx kit fitted, so the task to get it to sit on the floor is far easier than it would have been.

Before I start here, I must thank SoCalliV8 for his help during this saga. Without his assistance this van would be in a British scrapyard pushing up daisies.

Anyway, here we go; As bought on ebay uk in Dec 2006



This van is so low that the 255/35 -20’s rub even when going straight! Lock to lock is optimistic and consequently so is parking the damn thing.





So, alternatives are
1. raise the ride height and don’t look so cool,
2. Change wheels and tyres
3. Modify the van to fit the wheels and f it air ride.

Number 3 it is then!!

Shockwaves and LCA air arms at the front should sort the suspension side out. And a 4 link at the back should suffice with C notched frame and a great big slot cut out of the floor.

Here is a photo of the new belltech dropped spindles installed and the spring removed. This is as far up as it gets



Not far off (2")

Better view with the fender removed and a rough black line to show where the cut should be.



Here we go with the cutting at the front right.







More update soon.

Andy.

[SoCalli V8]

Thankyou for your 'props' Andy, I enjoy to share my knowledge and mechanical skills with all the ASV members here in the US and in Europe.

You know how to find me if you have any further Q`s....

[andyfanshawe]

Thanks SoCalliV8.


More cutting today, and preparing for it's new wheel arch.







It certainly won't rub now!!

The van is about an inch off the floor now. That should take care of any bumps on the floor when it sinks down. Don't want any gfx shattering

Panels fabricated next and all need welding up. Then it's over to the other side.

Andy.

Now, where did all those wires connect to?

[andyfanshawe]

Mocked everything up today to see what it looks like and get some measurements for the shockwaves I need to order. i.e LCA lower shock mount to top shock mount at proposed ride height and full body drop. If anyone has to go through this, 10" when van is down on the floor, and 12" when it is at ride height.

Few photos for ya
First two are at full drop





Here's the proposed ride height. A lot more sensible than before.



Metalwork time.

Card template made



Then I ran out of steel and MIG welding gas!! At the same time. Shopping trip tomorrow then.
In the meantime, passenger side suspension has been stripped out ready to clear engine bay on that side of coolant pipes, AC and heater and everything else necessary.

More to come.
Andy.

[Someone]

looks like it is coming along great

[andyfanshawe]

Yep, quite pleased with it so far.

Had an interesting chat to Darren at Air Ride Technologies (http://www.ridetech.com).

He has recommended this one (http://www.ridetech.com/products/Chevy_ ... 57-60.html), but with a change of stroke of the damper from 2.6" to 3.5".

http://www.ridetech.com/images/products ... kw1011.jpg

Andy.

[andyfanshawe]

Decided to try to go a bit lower So, out with the saw.......

Before



After




Starting to fit up the new smoooooth wheel arch.


Hmmm, is this low enough????


More soon.
Andy.

[ihatemybike]

Cool, keep the pics coming.

[andyfanshawe]

More photos

Had to re radius the wheel arch and take it further out towards the door.
Here all the flanges are bent up and clamped to see how it all fits.



Here we have an exact join to the original



Views from engine bay and interior





Welding tomorrow and a lot of filler panels to fabricate.

Andy.

[SafariRob]

Superb work, Andy. I'd love to be helping out on this one. What a daunting task to undertake.

[andyfanshawe]

Superb work, Andy. I'd love to be helping out on this one. What a daunting task to undertake.

Hi safariRob.
I'd love you to help with this one as well

I always forget how long it takes to do good bodywork. It's not just the fab and the welding, it's the painting and the full rust protection afterwards. Especially here in the wet UK. I don't want to be doing this again soon!!

Thanks for the support though.

Andy.

[andyfanshawe]

More pictures.
2 brackets made up to reinforce the third side of the A post (fourth side will be the curved wheel arch).





Welding in place with a dedicated spot welder (piggin heavy as well).



All welded in





Andy.

[andyfanshawe]

More progress for anyone still following along

Difficult brackets to fab next. This one goes under the floorpan at the rear of the wheel arch to attach the new rubber splash curtain to. Flat sheet first, then the lip turned over at right angles. The a pair of mole wrenches to "corrugate" the lip so it makes the plate curve round. Then a shrinking hammer to flatten the lip and,....well,.....shrink it The marks you can see on the top of the lip are from the sharp points on the shrinking hammer. Won't affect the spot welder though.



Here is a photo of the new wheelarch spotwelded at the front;


Some plug welding and spot welding


Another view


Andy.

[andyfanshawe]

Finally finished the bracket that goes under the floorpan at the rear of the wheelarch.





Tomorrow it will be spot welded in, but not before hitting the back of it with some epoxy primer.

Then it's close it all off and get it sealed and painted. Onto the other side.

Andy.

[SoCalli V8]

Pictures no worky m8, go back and check how they are hosted....?