Bedford Astravan MK2

[3cav3]

53 hp was quite reasonable in the 80's
We are all spoilt now by the rediculously powerful engines.
Bear in mind that engines back then were not hindered by catalytic converters or emissions control.
True raw power back then.

I am sure it is a relief to be getting another job boxed-off, especially when they fight you all the way.

You can say that again, I was beginning to doubt my sanity. Until I started on the struts of this van I had only ever changed one other in my life. I now feel I could do the job blindfold, the amount of times I've stripped these ones out.

I'm sure the 53bhp will be adequate to trudle along in, however having driven quite a few non turbo diesels back in the day( a 1.5 VW caddy, and a Citroen BX 19rd amongst others) I always found the lack of acceleration for overtaking was the biggest bugbear. I was mearly commenting that the lack of vented discs shouldn't be a concern as with such little power I'm unlikely to cook them.
No power sapping emission controls and a lack of sensors and electronics in general are a big plus point in my eyes.

[Envoy CDX]

Loving the progress on this one. Those bearings can be a pain in the hoop, not done many in my life, but the last few I've done have tested my sanity and the little press at my friends place as well as my shoulder trying to smash out the remains.

[Robsey]

I find that as long as you start off straight, it usually goes without too much drama.
As soon as it goes the tiniest bit out of square, it simply locks and jams.
Either that or I have been lucky.
I have done loads of bearings over the years.

Only ever used a fly-press once, when assembling the Cavalier mk3 legs in 2016.

A good old fashioned hammer and pin-punch, out on the car park at all other times.

[3cav3]

Between last night and lunchtime today I have just spent 4 hours getting the O/S wishbone bolt out! And if that wasn't taking the pee enough I found once removed that, the wishbone had been hiding 2 holes in the floorpan! At times like this it best to shut the tent up and walk away!

I've spent half my adult life getting bits of metal to move that didn't want to, but this was one of the worst I'd ever had, there just was no room to gain access. Its out now though. Guess I know what I'll be doing on the weekend! Probably be about 7-8 hours to replace one wishbone by the time I've repaired the floor.

[Robsey]

I am sure at the back of your mind, you knew that there would be more welding to do.
A quick and easy task for a man of your caliper.

But yes these things can be very frustrating and annoying. Still - after all this, it looks like you are more or less on the home straight.
Mainly putting bits on, than stripping or cutting off.

[3cav3]

With this Van I think ill be welding it till the day I die! At least thats what it feels like.

Heres the offending bolt, who'd of thought that something so small would cause so many problems?



It was a combination of rust and the rubber collapsing around it.

Had to be a bit brutal with the Old Wishbone too.



Pleased Ive got a new replacement.



Above is one of the holes



Not quite sure how I missed the second one. In my defence though there is nothing visible on the otherside. Once welded both front floor pans will be rubbed down, rust treated, then undersealed, like ive allready done to the rear chassis and inner wings.

[3cav3]

Went fairly early to the unit this morning to try and beat the heat, didnt work as it was far too hot for welding by 8 but had to carry on.



Finally got the wishbone bolted into place. Has ended up taking about 8-9 hours just to replace a pair! The last ones I did on my Wifes Panda was about 45 mins a side!

[3cav3]

After all the fight I thought I would do a nice simple Job and fit the refurbished Steel Wheels and new Uniroyals that I'm pleased I purchased before lockdown as tyres in general but particuarly oddball sizes like these have gone through the roof price wise.





Here she is finally sat on matching rubber all round. Probably for the first time in years.





Next job is going to be to give the canopy a proper tidy up, then rub down the floor pan and underseal it before trying to sort out replacing the brake lines and fuel pipes.

[Robsey]

Maybe it is just me,
but I would have fitted the tatty old wheels and tyres, until after the van had been painted.

I just expect lots of dirt and muck will be created as body preps and fittings are worked upon.

It is a nice mile-stone to reach, getting the van on it's four wheels.

[3cav3]

I've been toying with leaving the old ones on, however I'm trying to keep chipping away at the jobs to keep the motivation going as I'm starting to run out of steam again with this project as it just seems never ending- For example looking back its taken me nearly 6weeks to get the front suspension done!
The plan is to bag them up with a few handfuls of silca gel sachets in each to hopefully stop the new discs rusting.

[Robsey]

I can understand how the motivation and focus can stall.

I have periods of focus and longer periods of despair when I do not feel like I am getting anywhere.
Looking back to when my van saga started in May 2012... and I still have 80% of the van to fix.

Keep focussed my friend - you are making great progress. Even if you do not think so.

[3cav3]

I can feel for you. When I first purchased this Van I genuinely thought it would be about 6months, just sills, rear arches, a pair of wings and a few other little patches. Little did I know...
Now getting towards five years later I still feel like I've a mountain to climb before its finished.

[3cav3]

Due to a combination of hurting from head to toe, and the extreme heat I had a slight change of plan this morning and instead of fitting the brake and fuel lines which would need me to lie on my back, I started to panel up the van. Still need to tweak some of the gaps slightly, but am heading in the right direction.









As can be seen I'm using the old bumpers for the time being, so if i clip them with the sander or get overspray on them it wont matter.

[Robsey]

This is where your van physically takes shape.
It must give a buzz seeing it come together.

Brake pipes, fuel lines, and other stuff under the van make progress, but being out of sight they don't give that visible emotional boost.

[3cav3]

This morning i turned my attention to the fllor extension/rear bulkhead(the bit that turns this from a car into a van. Originally I was going to fit rear seats for my Son but as this project has taken so long he rarely wants to come out with his parents, so as insurance for seat conversions is a bit of a minefield , I finally got round to welding it back into place. From the photos it doesnt look like much progress, but another few hours have gone by the time it was attached solidly.





As an added bonus Ive now got somewhere to fit some speakers under the floor pointing into the cabin.

[Robsey]

That is looking great.

Any thoughts about interior trim?

Ply-lining or plywood panels covered in grey carpet type stuff?
Carpet-lining would give the best sound deadening against the bare outer shell.

[3cav3]

That is looking great.

Any thoughts about interior trim?

Ply-lining or plywood panels covered in grey carpet type stuff?
Carpet-lining would give the best sound deadening against the bare outer shell.

I've already got a box of stick on sound deadening, as when I first purchased this van it was a bit like sitting inside a drum particularly with the old diesel chugging away. Then the back, sides and roof will be ply lined and carpeted throughout. But at the moment I can't afford the timber. I will also be doing a thourgh job of covering the arches in sound deadening as on my mk5 Van this is where the most road noise seems to come from.

With the front of the cab, along with the stick on pads, years ago I purchased a very good condition carpet out of a hatchback that someone was breaking as the vans original had gone thread bare in places.

[cavalier1990]

I can feel for you. When I first purchased this Van I genuinely thought it would be about 6months, just sills, rear arches, a pair of wings and a few other little patches. Little did I know...
Now getting towards five years later I still feel like I've a mountain to climb before its finished.

It's so easy to plan everything in your head and in there it only takes a few months, I've done the same, my diplomat has had to take a back seat due to the senator and the pressing need to overhaul the cavy LS, alongside all the rolling fixes I've done to it, but I origially thought a year should see it back on the road, that was in 2016 when I took the senator off the road for a "quick refurb". It's too easy to get consumed in those car SOS type shows where they totally rebuild a car in a couple of weeks, difference is they have a team of about 10 professional body repairers working on it all day and probably at night too, and they have all the specialist tools and ramps.

Looks like you're making some really good progress on it and can really see it all coming together now!

[3cav3]

I can feel for you. When I first purchased this Van I genuinely thought it would be about 6months, just sills, rear arches, a pair of wings and a few other little patches. Little did I know...
Now getting towards five years later I still feel like I've a mountain to climb before its finished.

It's so easy to plan everything in your head and in there it only takes a few months, I've done the same, my diplomat has had to take a back seat due to the senator and the pressing need to overhaul the cavy LS, alongside all the rolling fixes I've done to it, but I origially thought a year should see it back on the road, that was in 2016 when I took the senator off the road for a "quick refurb". It's too easy to get consumed in those car SOS type shows where they totally rebuild a car in a couple of weeks, difference is they have a team of about 10 professional body repairers working on it all day and probably at night too, and they have all the specialist tools and ramps.

Looks like you're making some really good progress on it and can really see it all coming together now!

Thanks for the words of encouragement. I think part of the time has gone due to the extreme amount of rust hidden in this van, It has also at times eaten into my enthusasim aswell, theres been times when Ive gone months without touching it, Covid also didnt help the motivation front.

I know with those programes that they are proffesionals with a properly equiped workshop and also unlimited funds. I'm working mainly outside and with a budget of nearly zero for the foreseeable future.

[3cav3]

One job ive been trying to do on and off for ages is to change the steering wheel. Said wheel just did not want to move however!

As can be seen its not in great shape, very worn and also pitted.






durring Lockdown1 I purchased this one out of a low milage Petrol car



No matter what I tried I couldnt get the wheel off the splines. The lad I work with said hes never been beat yet, but also couldnt get it to budge.
In the end I had to resort to buying this puller, Its a bit annoying as it will probably never be used again, but at least the wheel is now removed.

[3cav3]

After the disaster with my Cavalier last week, I ordered a NOS Radiator(aftermarket but not chinese crap), for it. Today it arrived, when unpacked however it didnt appear to be for the Cavalier but instead for an Astra mark 2 1600 Diesel. A hell of a coincidence but for a chnge all worked out well.




Date stamped 1999, but never used.


Lines up a treat.

[Robsey]

That is a canny occurance.

Did you need a rad for the Astra?.
It does make you wonder how the seller got it so far off.

Or are they just gifted with a sixth sense?...

[3cav3]

That is a canny occurance.

Did you need a rad for the Astra?.
It does make you wonder how the seller got it so far off.

Or are they just gifted with a sixth sense?...

Yes, i had mentioned it on page 36 of this thread. The one on the van was the original from 1988. Although it appeared to be holding water, the fins were starting to crumble. Was only going to be on there temporary.
I'd had in stock for years a brand-new one, but the fan didn't fit, I was considering adapting it, however the fins were so weak that breathing on them wrong was enough to badly desort them-chinas finest i guess.
Its great the wrong supplied one fits, although it does leave me still short of a radiator for the Cav, and at present I just cant afford any more money on "toys". It almost does seem too freaky a coincidence, I must be one of the few people in the country who actually has a need for a diesel one for an Astra mk2. The box simply said Vauxhall, so I've no idea where the cavalier bit came from.

[3cav3]

I dug the original radiator out today and as can be seen its getting worse, the front side is just crumbling more and more by the day. Looks like its a good job that the wrong one arrived.

[Envoy CDX]

Its coming together nicely.