Converting a 1986 G30 Van for Expeditioning

[Perro Viejo]

Here is the importance of doing preventive maintenance vs waiting for an actual breakdown.   What you're seen below is the old harmonic balancer.    Not changing this would had cause my engine to go to pots.  Here are some pictures so you can see what a bad one look like.

Thanks for sharing the details of your work. I also am USAF surplus and I have recently acquired a G30 HiCube 1993 with 6.2L and 4l80e trans with a full floating rear end. Mine has relatively low miles. Mine has had a hard life. The doors are really beat-up, all of them! I`ve had it for about a month now.
I`ve got to get my brakes sorted out and harmonic balancer replaced before I can really do anything with it. You inspire me to leave mine Blue. Un fortunately I can`t include any photos of mine as I haven't down-loaded them from my phone to my pc and that's what I`m putting this note together on. Thanks again for sharing your thoughts and actions. I` try to get sorted out with regard to personal info soon.

 

[arctic cat]

Thanks for sharing the details of your work. I also am USAF surplus and I have recently acquired a G30 HiCube 1993 with 6.2L and 4l80e trans with a full floating rear end. Mine has relatively low miles. Mine has had a hard life. The doors are really beat-up, all of them! I`ve had it for about a month now.
I`ve got to get my brakes sorted out and harmonic balancer replaced before I can really do anything with it. You inspire me to leave mine Blue. Un fortunately I can`t include any photos of mine as I haven't down-loaded them from my phone to my pc and that's what I`m putting this note together on. Thanks again for sharing your thoughts and actions. I` try to get sorted out with regard to personal info soon.

I would replace all the belts.  Also if the rear heater is inoperative or you have no plans for it   Take of those hoses off and replace the with hoses without connection straight to the firewall and the engines to avoid any future leaks

 

[arctic cat]

Well I put those solar panels in top of the van and mileage per gallon went to hell I have to find a way to make that thing more aerodynamic

 

[Kirby]

Hey there! i just purchased this same van!
But I'm not exactly sure what the common problems are with it, I was wondering if you had any insight for what to check for? preventative and otherwise. yours is coming along great! can't wait to see the finished product! (and also cant wait to hear your solar panel conclusion, i was gonna mount a couple on mine as well, but after that I don't think that will be in the cards)

~Kendra

 

[highdesertranger]

so you have the 6.2 diesel? the most important thing to check is the harmonic balancer. they get old and the rubber will fail allowing the weight to slip or come off this almost always has disastrous results for the crankshaft. there are tons of options for balancers from junk to great. I prefer the fluid dampener brand. pricey but the best. if you have any questions about your engine don't hesitate to ask. I have a lot more tips. highdesertranger

 

[Kirby]

so you have the 6.2 diesel?  the most important thing to check is the harmonic balancer.  they get old and the rubber will fail allowing the weight to slip or come off this almost always has disastrous results for the crankshaft.  there are tons of options for balancers from junk to great.  I prefer the fluid dampener brand.  pricey but the best.  if you have any questions about your engine don't hesitate to ask.  I have a lot more tips. highdesertranger

I do have the 6.2 diesel. thanks so much for the advice I'll make sure and have the mechanic check out the harmonic balancer. :f she starts making any odd noises I'mma come running back here asking all the things.

 

[arctic cat]

Hey there! i just purchased this same van!
But I'm not exactly sure what the common problems are with it, I was wondering if you had any insight for what to check for? preventative and otherwise. yours is coming along great! can't wait to see the finished product! (and also cant wait to hear your solar panel conclusion, i was gonna mount a couple on mine as well, but after that I don't think that will be in the cards)

~Kendra

Based on my experience.    Like highdesert said Harmonic Balancer, not that expensive so just replaced it and keep checking it.    The box fuel filter on mine was an issue.   I replace it with a more modern version and if you can put it toward the front against the firewall    Take it to the an auto part store and check the alternator and the starter, I ended replacing both.  I also replaced the injector pumps and put new injectors.   The injectors are relatively cheap in comparison with newer diesel.  I finish my van and did about 2,800 miles.   Because is an older diesel they the injector pumps come on 2 versions.  The High altitude version and regular altitude.  Since I operate mine mostly in Texas, when I go up to the mountains it will smoke like Army Tank in retreat. so be ready to get the middle finger at anything over 5,000 vacuum line as the rubber was all ***** and all the rubber fuel line between the injector. most of them were having small leak.

 

[VintageVan]

Love the rig.

 

[linaa13]

Based on my experience.    Like highdesert said Harmonic Balancer, not that expensive so just replaced it and keep checking it.    The box fuel filter on mine was an issue.   I replace it with a more modern version and if you can put it toward the front against the firewall    Take it to the an auto part store and check the alternator and the starter, I ended replacing both.  I also replaced the injector pumps and put new injectors.   The injectors are relatively cheap in comparison with newer diesel.  I finish my van and did about 2,800 miles.   Because is an older diesel they the injector pumps come on 2 versions.  The High altitude version and regular altitude.  Since I operate mine mostly in Texas, when I go up to the mountains it will smoke like Army Tank in retreat. so be ready to get the middle finger at anything over 5,000 vacuum line as the rubber was all ***** and all the rubber fuel line between the injector. most of them were having small leak.

Hey, I'm not sure if you'll ever see this but I've been trying to research 1986 Chevy G30 Hightop vans, and I came across yours. First off, amazing work you did here. Totally inspirational! I was wondering since you seem pretty experienced with the process if you'd be willing to check out the van I'm pondering on. It's pretty beat up, definitely don't think it's worth $2000 - though it does have low mileage, it's old and it's exposed to New England weather which in the winter SUCKS for vehicles because of the salt that ends up corroding the undercarriage. I'm not sure the specifics of what mechanical repairs have been made over the years or where it's been stored (especially in the winter). But I was hoping you'd be so kind to take a look at it and  give me your honest opinion. I plan on redoing the inside completely (though not so much with the sink and the bathroom) and most certainly repainting the exterior. Was it difficult for you to fix the rust spots yourself? If I ever hear back from you, thank you. If not, hope all is well and you're still happy with your creation! - Lina

https://nh.craigslist.org/cto/5959091923.html

 

[highdesertranger]

Lina the add says no title. big red flag. be careful with this one. batteries are just sitting there not hooked up, if they have been like that for any amount of time they are junk. if you are going to own a 6.2 diesel you should be mechanically inclined after all it's 31 years old. btw go over to the Newcomers corner and introduce yourself, we will give you the official welcome. highdesertranger

 

[arctic cat]

Hey, I'm not sure if you'll ever see this but I've been trying to research 1986 Chevy G30 Hightop vans, and I came across yours. First off, amazing work you did here. Totally inspirational! I was wondering since you seem pretty experienced with the process if you'd be willing to check out the van I'm pondering on. It's pretty beat up, definitely don't think it's worth $2000 - though it does have low mileage, it's old and it's exposed to New England weather which in the winter SUCKS for vehicles because of the salt that ends up corroding the undercarriage. I'm not sure the specifics of what mechanical repairs have been made over the years or where it's been stored (especially in the winter). But I was hoping you'd be so kind to take a look at it and  give me your honest opinion. I plan on redoing the inside completely (though not so much with the sink and the bathroom) and most certainly repainting the exterior. Was it difficult for you to fix the rust spots yourself? If I ever hear back from you, thank you. If not, hope all is well and you're still happy with your creation! - Lina

https://nh.craigslist.org/cto/5959091923.html

Hi Lina; Thanks for the compliments.  Like high desert said,  The no title may be an issue, unless you are planning to tag it in the same state.   Now this van are notorious for getting rusted, just like any other 31 year vehicle may be. I'm assuming that purchasing a vehicle from the northeast that may be more of an issue.   My vehicle was a military vehicle that never left Texas, so rust was minimal.   The way I dealt with interior rust was technically using fiberglass which you can mold to the desired shape.  I did remove all the rust before applying it.   In some other areas I just cut the rust out area and replaced with sheet metal.   Like high desert said it's an old vehicle, parts are readily available available, but it's a diesel and usually younger diesel mechanics are not willing to work on this vehicles, so having knowledge of diesel is extremely helpful.   The great news that by been an older diesel they it's actually fairly easy to work on,.   I got to see the picture and it appeared that the person who have it have done a lot of connections here and there and would be very leary about that.   Additionally by the age you have to assumed that person who had it have not done a lot mechanical maintenance work, such as replacing anything and everything that is rubber in the engine.

I have my own shop and have tools.  I paid for my van a $1000. and perhaps spend about $3,500 to $4,000 restoring.  I was worth it to me because I know the conditions of the van.  Most of the repairs that I did were done out of precaution, so things that were working but I found to be questionable I replace, to avoid dealing with on the road.  I would take my van pretty much everywhere.  If you need specific advice just give a shout

 

[Ballenxj]

I just read through all ten pages of this build. WOW! What a nice van that is, and I'm sure you're going to enjoy it a lot!  
PS, what a cool little trailer you have for the bedroom.

 

[arctic cat]

So the plan now is to actually sleep inside the van and carry a trailer to place the motorcycle with the idea of parking the pank and use it as a base and the use the motorcycle to get around.  In order to do that I have to make a space for bed.  Well after some planning a bed it is.  I have to eliminate one small rack and rearrange some cabinets and this is the final work.

 

[AbuelaLoca]

That looks great!!!

 

[arctic cat]

More pic

 

[AbuelaLoca]

What's the blue thing? With all the buttons?

 

[highdesertranger]

very nice. is that a store bought slide for the ARB? what kind of MPG are you getting out of the 6.2? highdesertranger

 

[AbuelaLoca]

Fridge/freezer??

 

[arctic cat]

Fridge/freezer??

Yes an ARB Fridge freezer

 

[arctic cat]

very nice.  is that a store bought slide for the ARB?  what kind of MPG are you getting out of the 6.2?  highdesertranger

Yep the slide is from ARB.  Mileage?  not too crazy on a good day about 15 MPG in high altitude terrible and it smoke.  I was wondering since the pump is DB2 Manual if there is any adjustment that can be done to make it more efficient in High Altitude.  The military call for 45 PSI all around in the tires but the side label call for 45 psi in front and 75 psi in the rear so I'm retesting to see if that (lower psi) would had cause me low mileage.  Maybe you have a tip or two.