1976 US Air Force Chevrolet P20 5.7L Step Van

[M813rc]

It's like they have no spatial awareness, nor comprehension of the concept of measuring - "Just drill holes 'til some of them line up!!"

And the wiring usually looks like the ramblings of a drunken spider....in technicolour...

I spent quite a bit of time welding up the M715 bed. Fortunately, the cab wasn't overly molested.

Cheers

 

[marchplumber]

They had a drill and lots of drill bits and enthusiasm.
What they apparently didn't have were a tape measure and a straight edge.
It's really bad inside, I just haven't shown the dash or the overhead panel yet.

Now I get to weld all of the holes up.

Weld? Maybe a filling compound/adhesive? MFG are using adhesive agents quite a bit these days....i've seen van doors "glued on" at hinges.....amazing

Would save a poop-ton of time AND effort..... quality would still be there....(Plumber humor)

Ya know the story....."Your Truck, your project". Thats what makes em fun, but suggestions can be life savers......like "Pull that D-ring!" LOL

 

[Tinstar]

Ha
I totally forgot about structural adhesive!
I’ve used it a lot in the past and thank you for reminding me.

Definitely doing that!

Was really dreading the welding idea.

 

[Tinstar]

Still waiting on some parts but went ahead and drove it around the ranch a bit.
Did the YouTube fuel tank special. Looks stupid but works.

Step Van starts right up and idles smooth.
Smoked lightly for about 30 seconds then cleared up.
Not gonna lie…., it’s pretty fun driving this.
Speedometer works and put about 3 miles on it today

All the gears in the transmission work and the brake master cylinder gave out so a new one inbound.
My suburban is thankful the parking brake works.
Very close call

Alternator sounds like it’s going to explode at any minute and obviously doesn’t work anyway. New one should be here Monday.
Fixed some more wiring and cleaned up the spark plug wires a bit.

Once everything was nice and hot I changed the oil and filter.
Still need to do the trans and differential.

Went to the tag agency and got my tag, title and registration. It’s legal now.
I am the first civilian owner in its 49 year old history. Pretty cool I think.

Once brake master cylinder and new fuel tank arrives and are installed, I’ll get it out on Route 66 for some fun.


Progress is being made.

 

[FarmingSmallKubota]

Still waiting on some parts but went ahead and drove it around the ranch a bit.
Did the YouTube fuel tank special. Looks stupid but works.

Step Van starts right up and idles smooth.
Smoked lightly for about 30 seconds then cleared up.
Not gonna lie…., it’s pretty fun driving this.
Speedometer works and put about 3 miles on it today

All the gears in the transmission work and the brake master cylinder gave out so a new one inbound.
My suburban is thankful the parking brake works.
Very close call

Alternator sounds like it’s going to explode at any minute and obviously doesn’t work anyway. New one should be here Monday.
Fixed some more wiring and cleaned up the spark plug wires a bit.

Once everything was nice and hot I changed the oil and filter.
Still need to do the trans and differential.

Went to the tag agency and got my tag, title and registration. It’s legal now.
I am the first civilian owner in its 49 year old history. Pretty cool I think.

Once brake master cylinder and new fuel tank arrives and are installed, I’ll get it out in Route 66 for some fun.


Progress is being made.

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At least you found a use for those stupid EPA gas cans. mine are decorations around the garage as i only use Scepter Military cans now

 

[Tinstar]

At least you found a use for those stupid EPA gas cans. mine are decorations around the garage as i only use Scepter Military cans now

I have quite a few Scepter fuel cans also but they’re all filled with diesel.
I was going to buy more from you but forgot once I was there.

The rigging will work for now.

 

[FarmingSmallKubota]

You get that step van really nice and come visit again since you know where i live. we could fill it up with all kinds of surplus treasures. Although a fall drive would work best probably a little warm in there without AC

 

[Tinstar]

Just the thought of that long of a trip in a step van, without modifications for overnight comfort, makes me cringe.
Taking nothing but backroads would make it doable.
Probably wouldn’t be that bad with the doors open. Loud but airflow at least.

My plan is to get van as reliable as possible, so it can handle spur of the moment trips that my wife and I like to do.

Really looking forward to painting it.

 

[Tinstar]

Interior shots of more holes drilled haphazardly and a fine welding job back where they had a generator mounted.

Usually it’s the rodents that wreak havoc on wiring.
Nope
They only destroyed two spark plug wires.

The wiring on this vehicle is a mess everywhere you look.
At least it’s fairly simple to chase the gremlins and make repairs, a lot of them.

Would like to know why they parked this.
All the mechanical stuff works.
Wiring issues possibly. Lack of need?
Too old a vehicle for dumping resources into?

I’ve worked with a LOT of volunteer fire departments and they’re all great guys and gals.
This VFD I’m sure is the same.
They did the best they could, with what they had, where they were.

Now it’s mine and I have the time and resources to fix it.
Not a full blown restoration, which would be great, but very expensive.
Just to get the truck 100% operational, sealed up and looking as close as possible to its original USAF configuration.

These old step vans are few and far between, especially with Air Force history.
Luckily this one was saved from the crusher or rotting away parked, never to move again.

 

[marchplumber]

Interior shots of more holes drilled haphazardly and a fine welding job back where they had a generator mounted.

Usually it’s the rodents that wreak havoc on wiring.
Nope
They only destroyed two spark plug wires.

The wiring on this vehicle is a mess everywhere you look.
At least it’s fairly simple to chase the gremlins and make repairs, a lot of them.

Would like to know why they parked this.
All the mechanical stuff works.
Wiring issues possibly. Lack of need?
Too old a vehicle for dumping resources into?

I’ve worked with a LOT of volunteer fire departments and they’re all great guys and gals.
This VFD I’m sure is the same.
They did the best they could, with what they had, where they were.

Now it’s mine and I have the time and resources to fix it.
Not a full blown restoration, which would be great, but very expensive.
Just to get the truck 100% operational, sealed up and looking as close as possible to its original USAF configuration.

These old step vans are few and far between, especially with Air Force history.
Luckily this one was saved from the crusher or rotting away parked, never to move again.








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That last one looks kind of scary might need to do something about that possible rust remediation chemical treatment?

 

[Tinstar]

That last one looks kind of scary might need to do something about that possible rust remediation chemical treatment?

Plan is to remove side panel, held on by clutch head screws, and cut off excess, treat any rust still visible, paint the area and patch that panel.
This Step Van is insulated, so I will add/replace any damaged insulation as needed.

Once the engine/trans/brakes are squared away, then that spot in particular is next for attention.
I keep the spare tire leaned up against it so I don't rip open any flesh.

Whatever they had there, it affected that spot, the top of fender and where the generator once rested.
I already cleaned the 1" thick oil/dirt cake that was there.
Not only did they love drilling holes, they had a field day cutting the floor up for the generators exhaust and wiring.

The truck is smelling normal again.
It used to smell like a greasy oil change bay floor.
I mean really bad.
Now it smells like clean old truck, if that makes sense.
I used the pressure washer and sprayed the interior, roof included, only bypassing the dash panel.
Then left everything open for several days in the sun.

 

[Tinstar]

So added a few new parts and this thing now runs and starts even better.
Good oil pressure and engine temp stays where is supposed to be. New temp sensor installed.
The new fuel tank should arrive today.
Still trying to find a fuel pickup and sending unit.

Brakes are still an issue but I’ve narrowed it down to a bad proportioning valve.
Will get that ordered and on the way.

I added the LED clearance light bars front and back and have those wired up.
Had to remove one ceiling panel and found a huge mouse nest and wire damage.
Entire interior needs removed and cleaned, but will do that later.
Van does not smell like mice at all, but finding evidence of them was not a surprise. It’s been sitting for the last 21 years.

I removed and disassembled the instrument cluster. Cleaned as best I could and replaced a missing bulb.
Weird seeing that they used real glass back then.
Reattached the gear selector light connector. It works now. It’s also nice to be able to see the turn signal lights again.

With the exception of installing the remaining three spark plug wire heat shields, I’m pretty much done with the engine.
Two motor mounts have to be removed to install the front heat shields. Oh fun.

Still need to install ground cable from engine to battery.

I put the engine cover back in place and step van is much quieter inside now. Also keeps the cats out. Truck has been open enough and sat here long enough, that if there were any mice left, they’re gone now.

Lots of little things to do and slowly making progress.

 

[marchplumber]

Tha

So added a few new parts and this thing now runs and starts even better.
Good oil pressure and engine temp stays where is supposed to be. New temp sensor installed.
The new fuel tank should arrive today.
Still trying to find a fuel pickup and sending unit.

Brakes are still an issue but I’ve narrowed it down to a bad proportioning valve.
Will get that ordered and on the way.

I added the LED clearance light bars front and back and have those wired up.
Had to remove one ceiling panel and found a huge mouse nest and wire damage.
Entire interior needs removed and cleaned, but will do that later.
Van does not smell like mice at all, but finding evidence of them was not a surprise. It’s been sitting for the last 21 years.

I removed and disassembled the instrument cluster. Cleaned as best I could and replaced a missing bulb.
Weird seeing that they used real glass back then.
Reattached the gear selector light connector. It works now. It’s also nice to be able to see the turn signal lights again.

With the exception of installing the remaining three spark plug wire heat shields, I’m pretty much done with the engine.
Two motor mounts have to be removed to install the front heat shields. Oh fun.

I put the engine cover back in place and step van is much quieter inside now. Also keeps the cats out. Truck has been open enough and sat here long enough, that if there were any mice left, they’re gone now.

Lots of little things to do and slowly making progress.

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That is pretty cool! Got a "purpose" for her yet? Back to work?
Thanks for sharin

 

[Tinstar]

Tha

That is pretty cool! Got a "purpose" for her yet? Back to work?
Thanks for sharin

I initially thought (still undecided) to restore it to USAF livery.
But I’m former Army.
While seeing these on an Army base was extremely common, I don’t ever remember seeing one that was ordered specifically and spec out by the Army. They were clearly all civilian contractors.

I like the glossy OD green used during Vietnam era but it would look like a UPS truck.

My wife LOVES this Step Van and has already thought about camping with it.
Not a dedicated camper conversion, just throw some bunk beds and stuff in it and go.

Would be nice to use this for hauling large items from Lowes/Home Depot without having to mess with trailer, especially during bad weather.

That’s a very long winded “I don’t know yet”.

It’s a lot of fun to drive and rides surprisingly smooth.
Plenty of power.

Will definitely be keeping it.

 

[marchplumber]

I initially thought (still undecided) to restore it to USAF livery.
But I’m former Army.
While seeing these on an Army base was extremely common, I don’t ever remember seeing one that was ordered specifically and spec out by the Army. They were clearly all civilian contractors.

I like the glossy OD green used during Vietnam era but it would look like a UPS truck.

My wife LOVES this Step Van and has already thought about camping with it.
Not a dedicated camper conversion, just throw some bunk beds and stuff in it and go.

Would be nice to use this for hauling large items from Lowes/Home Depot without having to mess with trailer, especially during bad weather.

That’s a very long winded “I don’t know yet”.

It’s a lot of fun to drive and rides surprisingly smooth.
Plenty of power.

Will definitely be keeping it.

I drove one when I was an apprentice plumber...............MOONS ago. GOOD trk, carried a POOP ton of stuff. Drove well. What I drove had dual tires, so quite capable. I agree with UPS............LOL............Air Force Blue isn't "terrible" but I would probably go with the gloss Green! I'm a former Soldier also, soooooo.........
Several Posts I was stationed at were joint service, so saw "zoomy blue" quite a bit on the flight line. LOL
IF the wife likes it??? YOU GOT A WINNER!!!

 

[Tinstar]

Fuel tank arrived today and also took some night pictures.

This is the first time since the Air Force had owned the Step van that all the lights are in place and working.
You can tell that by the puke green overspray evidence on different areas where different lights were missing or broken and the VFD never fixed it.

I think it looks cool with the original clearance light locations working again.

Also found evidence that the USAF turned over truck to the OK Department of Forestry in 1987, and then promptly turned it over to the VFD that same year.

 

[marchplumber]

Fuel tank arrived today and also took some night pictures.

This is the first time since the Air Force had owned the Step van that all the lights are in place and working.
You can tell that by the puke green overspray evidence on different areas where different lights were missing or broken and the VFD never fixed it.

I think it looks cool with the original clearance light locations working again.


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Fuel cell up front brings to mind a Ford Pinto but mirror imaged! LOL

Seriously,.Dang GREAT work!

 

[Tinstar]

Fuel cell up front brings to mind a Ford Pinto but mirror imaged! LOL

Seriously,.Dang GREAT work!

I will be very happy to have the liquid bomb off
The front bumper!!
It’s working great but hate doing it.
If it was diesel I wouldn’t be worried one bit.

This thing is seriously a lot of fun.
Very easy to work on.
It’s definitely unique. Not for everyone I know.

Drove it down the dirt road 1 mile and back.
(FedEx delivered fuel tank to wrong address).
Rides much better than expected.

Considering that 4 weeks ago it was sitting in a tree row with a seized engine and hadn’t ran in 21 years and was only moved once to the auction lot, the old girl has shown a lot of life is still left in it.

 

[M813rc]

That's really coming along quickly, it's great to see it all lit up again!
So good watching an MV come back to life.

Fuel cell up front brings to mind a Ford Pinto but mirror imaged! LOL

A friend of mine saw the Pinto below at a car show, most of the young folks didn't get the joke.

Cheers

 

[Tinstar]

Fuel tank was done a very long time ago.
Good news is that the straps are just fine.
They’re galvanized steel and have zero rust on them.
Oil soaked strap pads are also still usable.

A Two-Tube fuel pickup and sending unit from a 1976 K20 passenger side fuel tank is identical to this one.
What's left that is.
It’s on order

Glad this stinky tank is gone.