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Nicely done best way to do it if you've space
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Astravan Epic!
- Thread starter Johnthesparky
- Start date
Johnthesparky
Club Member
Not done much, lockdown and all that...
the estate is tucked away on a farm I’ve got some storage (it’s so tucked, had to take the wing mirrors off it to get it into the shed
)
I got a spare set of struts though so I can refurb them in readiness of stripping the estate down
Lockdown meant we sorted some junk out, and means that I’ve now got a small workshop space which is lovely! So pressed the old hubs and bearings out, used the tig to fix a bolt to a broken wheel bolt and heated that up, then just undid it
also bought a cheap engine crane, it’s a Chinese thing so hopefully it will last long enough to swap some engines about, I can only see the ram being a problem long term
And got back to tidying up the GSi brakes ready to swap them in at some point.
I’ve also got another Isuzu to swap in later on
its got a ported and polished head, Garrett GT2056 turbo, pump mods, tubular manifold etc
I’ve known about it for a while, so when it came available I bagsied it for the future (when I’m not using it every day for work)
Also have a plan to run it on airbags, that should happen towards the end of the summer.
I don’t really want to drop it much lower. But it would be good to be able to raise it up on occasion on some sites.
And since I have a complete estate for spares, any modifications needed are easily undone with the spare set of struts and a spare beam.
I picked up a secondhand Elevel management last year
The good thing about it is the sensors will maintain the set rideheight, so it will compensate for me loading it up with tools and kit
the estate is tucked away on a farm I’ve got some storage (it’s so tucked, had to take the wing mirrors off it to get it into the shed
)I got a spare set of struts though so I can refurb them in readiness of stripping the estate down
Lockdown meant we sorted some junk out, and means that I’ve now got a small workshop space which is lovely! So pressed the old hubs and bearings out, used the tig to fix a bolt to a broken wheel bolt and heated that up, then just undid it
also bought a cheap engine crane, it’s a Chinese thing so hopefully it will last long enough to swap some engines about, I can only see the ram being a problem long term
And got back to tidying up the GSi brakes ready to swap them in at some point.
I’ve also got another Isuzu to swap in later on
its got a ported and polished head, Garrett GT2056 turbo, pump mods, tubular manifold etc
I’ve known about it for a while, so when it came available I bagsied it for the future (when I’m not using it every day for work)
Also have a plan to run it on airbags, that should happen towards the end of the summer.
I don’t really want to drop it much lower. But it would be good to be able to raise it up on occasion on some sites.
And since I have a complete estate for spares, any modifications needed are easily undone with the spare set of struts and a spare beam.
I picked up a secondhand Elevel management last year
The good thing about it is the sensors will maintain the set rideheight, so it will compensate for me loading it up with tools and kit
Johnthesparky
Club Member
Other than driving it around, up until the weekend I’ve fitted a GTE wheel
But the long weekend has been spent on the engine and running gear swap, some photos
But the long weekend has been spent on the engine and running gear swap, some photos
Attachments
Johnthesparky
Club Member
The low blow was getting fairly sick, lots of blowby and oil everywhere
Isuzu is in now, wiring next and it’s (hopefully) nearly done
Isuzu is in now, wiring next and it’s (hopefully) nearly done
Great work from you and Tom, looks like you made the most of the weekend, you’ve just made a good van into a cracking van
Johnthesparky
Club Member
Done!!!
Sorted the wiring, mostly pulling one engine loom from the green socket on the n/s strut and adding a different one, the Isuzu also has another loom that plugs into that for glowplug control.
only real head scratching was for a couple of ghetto repairs for the alternator, some extra wiring (I assume from it’s time on the railway), and the differences in the wiring.
The van has an extra fuse box in the engine bay (I assume because it’s the late (‘97 on) wiring and the estate was ‘94 to ‘96 wiring
But removed the van engine wiring with a few cuts and the Isuzu wiring replaced it. The wire for the old glowplug feed I coiled up out of the way and pulled the fuse. Everything else was removed.
Worked through the list of jobs, went to start it and then found out we hadn’t tightened the engine earth. Sorted that and it started!
spent the afternoon buttoning things up, drove it home and promptly replaced the wheel bearing that we noticed was dodgy on Saturday and got delivered on Monday.
today I’ve driven about 65 miles for work. Topped up the coolant when I got to first job, checked the oil, and also had a knock which was a loose anti roll bar link.
It feels so much nicer to drive than the low blow, and feels so much stronger (but then it is 20% more powerful, but the low blow was obviously poorly so a bit more I guess)
Really happy with it and definitely worth the effort
Sorted the wiring, mostly pulling one engine loom from the green socket on the n/s strut and adding a different one, the Isuzu also has another loom that plugs into that for glowplug control.
only real head scratching was for a couple of ghetto repairs for the alternator, some extra wiring (I assume from it’s time on the railway), and the differences in the wiring.
The van has an extra fuse box in the engine bay (I assume because it’s the late (‘97 on) wiring and the estate was ‘94 to ‘96 wiring
But removed the van engine wiring with a few cuts and the Isuzu wiring replaced it. The wire for the old glowplug feed I coiled up out of the way and pulled the fuse. Everything else was removed.
Worked through the list of jobs, went to start it and then found out we hadn’t tightened the engine earth. Sorted that and it started!
spent the afternoon buttoning things up, drove it home and promptly replaced the wheel bearing that we noticed was dodgy on Saturday and got delivered on Monday.
today I’ve driven about 65 miles for work. Topped up the coolant when I got to first job, checked the oil, and also had a knock which was a loose anti roll bar link.
It feels so much nicer to drive than the low blow, and feels so much stronger (but then it is 20% more powerful, but the low blow was obviously poorly so a bit more I guess)
Really happy with it and definitely worth the effort
Johnthesparky
Club Member
Been just over a month, starter motor decided to start playing up, after being sent a low blow one I got a replacement... swapped that over (which is much easier on the Isuzu than the low blow at least
Think I’ve finally sorted the air leak on the low pressure diesel, found the pipe from the filter to the pump was perished, so cut down the one from the low blow
Fixed the trailer electrics, with a new buzzer box and used the towbar in anger for the first time to tow the Fugitive to Santa Pod for a test day
And rebuilt some track arms, need to fit then and get an alignment
Think I’ve finally sorted the air leak on the low pressure diesel, found the pipe from the filter to the pump was perished, so cut down the one from the low blow
Fixed the trailer electrics, with a new buzzer box and used the towbar in anger for the first time to tow the Fugitive to Santa Pod for a test day
And rebuilt some track arms, need to fit then and get an alignment
Johnthesparky
Club Member
Got the alignment done, fitted the 16” steels back on
been trundling round with no real issues but can brakes started squealing on n/s rear, rather than play about with the adjusters it was time to fit the discs
had some assistance
flexies had seen better days!
Was definitely due a fluid change
Got the rears sorted, but it took most of the day with rusted in hard lines and having been sent the wrong flexies. Will do the fronts another day. But all bled up fine and no longer squeals
been trundling round with no real issues but can brakes started squealing on n/s rear, rather than play about with the adjusters it was time to fit the discs
had some assistance
flexies had seen better days!
Was definitely due a fluid change
Got the rears sorted, but it took most of the day with rusted in hard lines and having been sent the wrong flexies. Will do the fronts another day. But all bled up fine and no longer squeals
Johnthesparky
Club Member
Just coming up to 20k miles now
few shots from out and about
and another van down at the RetroRidrs Weekender @ Goodwood
few shots from out and about
and another van down at the RetroRidrs Weekender @ Goodwood
Well done John. Great to see my old van looking increasingly better.
Johnthesparky
Club Member
No, I had already bought a handbrake cable so just swapped it over.
the one I got was a cheap one from ebay and seemed a bit short (it’s right on the end of the adjuster) but works fine, just a bit of a faff to get on the adjuster to start with
the one I got was a cheap one from ebay and seemed a bit short (it’s right on the end of the adjuster) but works fine, just a bit of a faff to get on the adjuster to start with
Love this van, especially the fact its still being used as it should be as well.
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The other van is a chap called Pete
Johnthesparky
Club Member
Do you know anything about it?
we were on the morning sprint in the fugitive, I think he had a problem so didn’t get to have a proper look or speak to him.
but it was caged and looked really good (but I may be biased )
we were on the morning sprint in the fugitive, I think he had a problem so didn’t get to have a proper look or speak to him.
but it was caged and looked really good (but I may be biased
)
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caged, xe on carbs i think
One of my fave pics of the van -
One of my fave pics of the van -
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Loved the van at retro rides really is a nice one
Johnthesparky
Club Member
Thanks
I think it looks good when parked up with builders transits and relays etc, but wasn’t sure it would make the grade when parked in a field of retros. But it got quite a few nice comments
I think it looks good when parked up with builders transits and relays etc, but wasn’t sure it would make the grade when parked in a field of retros. But it got quite a few nice comments
Maybe it deserves a run up the road back to Scotland to see me next Summer. BVAC Classic - Festival of Motoring at Thirlestane Castle | Thirlestane CastleThanks
I think it looks good when parked up with builders transits and relays etc, but wasn’t sure it would make the grade when parked in a field of retros. But it got quite a few nice comments
Johnthesparky
Club Member
Not updated for a bit.
swapped the front brakes to the GSi ones
Gave it a service at the same time, as it’s driven 5000 miles since the engine swap.
Dropped the sump and checked the pickup as it’s still got a 3sec oil light
was very clean and no issues so happy it’s just the thing that the Isuzu’s do.
Van has just rolled over 24k miles since I got it, some days it trundles round locally, last week I went to Harwich for the day to move supplies on a weighbridge
And towed the Fugitive to the Retro Rides Gathering and parked on the show field whilst we took the Fug up the hill
saw Pete going up the hill in his van too
swapped the front brakes to the GSi ones
Gave it a service at the same time, as it’s driven 5000 miles since the engine swap.
Dropped the sump and checked the pickup as it’s still got a 3sec oil light
was very clean and no issues so happy it’s just the thing that the Isuzu’s do.Van has just rolled over 24k miles since I got it, some days it trundles round locally, last week I went to Harwich for the day to move supplies on a weighbridge
And towed the Fugitive to the Retro Rides Gathering and parked on the show field whilst we took the Fug up the hill
saw Pete going up the hill in his van too
