Project: Chevy Van G30

06.01.2008planning the floor - 17.01.2008wheelhouse isolation - 03.02.2008various work - 09.02.2008finish bottom plates - 20.02.2008checker plate, Binford and slatted frame - 25.02.2008laying the PVC-floor - 01.03.2008installation of the checker plates - 29.03.2008bed legs and a bit of electronics - 05.04.2008mounting bed legs and starting with furniture - 05.05.2008progress with furniture - 19.06.2008furniture, electronics, lock and towbar - 10.07.2008electrical box and various small stuff - 07.08.2008Ok, push the button - 27.09.2008luggage net and bolted electrical box - 26.10.2008storage, leatherette and advertising - 15.11.2008start of the winter project - 04.01.2009preparing the upholstering of the leatherette - 21.01.2009cutting the leatherette - 08.02.2009finished cutting the leatherette - let's start upholstering! - 01.03.2009stapling and painting - 15.03.2009engine cover and sun visors - 29.03.2009dashboard painted and ceiling partly done - 05.04.2009ceiling, checker plate and rosewood - 09.04.2009installing the dashboard - 26.04.2009final spurt side panels, furniture re-installation and stereo - 10.05.2009door panels and cabinets - 31.05.2009carpet, window sealing, stereo and cutting fabrics - 23.08.2009various work during sommer - 06.09.2009installing stereo, part 1 - 27.09.2009installing stereo, part 2 - 20.10.2009front mud flaps and hifi switch - 24.10.2009installing the loudspeakers - 07.11.2009Loudspeakers, mud flaps and upholstery bandpass-box - 20.12.2009upholstery, shoe cabinet, sun visors and sidemarkers - 31.12.2009shoe cabinet and back door finished, carpet opening started -

various work

During the last few weekends, we have worked on various construction sites. We started with cutting the wooden boards. They're not quite finished, and now we have to wait for nicer weather. The large 2 boards are already cut out and treated.

Bodenplatte links 1
Fits...
Bodenplatte links 2
...very good!
Bodenplatte rechts
The 2nd board fits too!

unknown cables and relays

Actually we wanted to take the dismantled fog lights back in operation after the registration process. But once again we discovered old severed cable under the hood, and this time these orphans should not be ignored!

We suspected that some cables, relays and switches in the interior were used for signal lights and horns back in the time when the van was driving for the Zurich police. But it's a big cable mess. So Markus and I tested systematically all possible combinations of cables and relays with the switches.

Result:

  • Switch found for fog lamps
  • Relay for fog lamps is broken
  • unwired, functioning and structurally identical relay as the above found
  • Fog lamps and switch hung on working relay
  • Extremely suspicious relay (the only plastic one and made in Italy) is wired with 2x positive and 2x cut off cables, control signal we are missing altogether, the relay is almost permanently under power, no switch effect...

The plastic relay was branded with FIAMM. Back at home I did a google: FIAMM manufactures automotive batteries, antennas, and especially horns. So the police just didn't removed anything when selling the car.

I will replace the old (and rusty and broken) fog lamps in the future. Hansen Styling Parts have some really nice big lamps!

Elektronik messen
wiring and testing
Relais Nebelscheinwerfer
left: broken relays, right: working one, perfect...
Fiamm Relais für Signalhorn
Remains of the horn

Sidemirror on the wall...

One of my achievements from last year's van slaughtering are 2 gigantic side mirrors.

From my experience, I know: If you disassemble something make a photo before. If you have 2 parts, disassemble only one at a time and keep the other one assembled. You will save an incredible amount of time and leftover screws when assembling later.

In the following pictures, we see a completely dismantled side mirror. All parts are carefully cleaned and rust is removed, treated, demossed (!!!) the mirrors and replaced all the screws, nuts, washers, threaded rod with new parts, including internal and all plastic parts and rubber seals with silicone grease made supple.

Seitenspiegel
backside
Seitenspiegel Auslegeordnung
spreading all parts