1976 US Air Force Chevrolet P20 5.7L Step Van

[Tinstar]

Picked up this about two weeks ago.
The older ones are getting hard to find I'm told.
5.7L 350 small block with the Turbo 350 transmission.
70,000 original miles.
No power steering
It went from the USAF to the OK Forestry Dept, who then gave it to the Rural Fire Department. You can still see the USAF Blue under the puke green paint in some areas.
They did have a generator installed inside the box, but it was removed before auction.
I was very lucky to find two sets of ignition and fuel cap keys. Door keys are missing but will worry about that later.
It does have some rust and the only rot I can find is the front lip of the hood.
Not bad at all but it's there.
The small amount of body damage looks like was mostly caused by the typical surplus yard forklift driver.

Didn't need it but it was almost given away and thought it was cool so I was fortunate to get it.
It's complete and hasn't run or been on the road in 21 years.
Fluids look good, but of course I will change them.
Fuel tank is most likely a loss. Fuel in there now smells horrible
Will drain when it's warmer and see if any leaks develop.

Spent a ton of time removing all the emergency equipment wiring and lights. All were old and went into trash.
Engine was seized, but I did the Vice Grip Garage trick and now engine rotates freely.
No water in either the trans or engine oil.
Have new plugs, plug wires, water pump (Old one is crunchy), cap and rotor, fuel pump and other small items to install before trying to start it. It will need a new alternator but that can wait until I see that it actually runs.
No cracks in block or busted freeze plugs that I can see.
Had to make up new ground and positive battery cables as the original ones were junk and corroded.

Lots of mice remnants and some wire damage. Two spark plug wires were completely chewed in half.
Nothing cool was left except some old airline seats. Their possibly old Greyhound bus seats, don't know.

Thanksgiving and cold weather has slowed work, but will start back to work in it today.

It's Different for sure.

 

[Tinstar]

 

[Tinstar]

 

[Tinstar]

It has the dreaded 16.5” tires/rims but will be an easy fix with 16” rims/tires.
Surprisingly all these hold air and the tire date codes are from 1991 if I remember correctly.

I have the original teardrop style marker roof lights ordered.

Will also remove the rooftop antenna and plug all the holes from miscellaneous emergency equipment.
The interior is insulated so I want to keep it as dry as possible.

Let the fun begin……..

 

[M813rc]

That's pretty neat! And useful too. Will it go back to Zoomie...I mean Air Force colours?

Cheers

A couple of 1968 dated pictures, but they haven't changed much over time.

 

[Tinstar]

That's pretty neat! And useful too. Will it go back to Zoomie...I mean Air Force colours?

Cheers

A couple of 1968 dated pictures, but they haven't changed much over time.

View attachment 958670 View attachment 958671

Oh most certainly it will get painted back to AF Blue.
Finding pics online of AF Step Vans is difficult so thank you for the pictures.

If anyone else has more pictures of these, please post them.
The more detailed the better.

 

[Tinstar]

Today I installed new spark plugs and wires, cap and rotor, and fixed alternator and distributor wiring due to poor electrical work.

Also filled carburetor with seafoam and will let it sit and clean the internals for a few days.
No leaks and accelerator pump still works.

Very tempted to try a start, but it’s not ready yet.
New Fuel pump and new fuel line yet to be installed and water pump also.

Master cylinder was empty and somewhat nasty.
Cleaned up the inside and filled with new fluid and slowly pumped brakes.
So far the pedal feels great. No leaks.

Will change oil and filter before start attempt also.

 

[SCM35A2]

Subscribed for updates!

 

[Tinstar]

This style of marker light is rare now. (Cat Eye Style)
I did find a USA company that makes them overseas in LED.
Will go ahead and install them since new paint will be this summer.

 

[Evil Dr. Porkchop]

Here’s a 1984 I had a couple years back. We bought it at auction after seeing one terrible pic of it. It had been used as a storage shed and hadn’t run in probably 20+ years, but being off the road kept the body and frame in nice shape for a northeast vehicle.

We changed the fluids and filters and it fired right up. 6.2 Diesel and TH400. Did the brakes, belts, put some tires on and it was driving. It was pretty unmessed with and even had the gas card on the keychain. Fun vehicle but ended up selling it since I didn’t really have a need for it.

 

[Tinstar]

Wow
That is in really great condition!
Thanks for the pics.

 

[Tinstar]

My P20 was severely abused by the fire department.

This is just the positive battery cable.
What’s left of it.
Gives you an idea of what I’m dealing with.

Didn't take pics, but the starter looks to be original and bench tested fine.
The negative battery cable was also junk and too small.
Have new one installed already and new body ground wire installed also.
Will install one more additional ground to engine once final connections are done.

I haven’t even attempted a start yet because of this.

Will pull the valve covers and make sure no valves are stuck.
Also bought NOS plug wire heat shields.
Original ones are missing.

 

[Tinstar]

Finished installing the new battery cable and the possibly original starter.
Installed the NOS plug heat shield above the starter also.
Will install the rest this week.

Couldn't resist and gave it a try.
Engine was turning over slowly and connected a jump box to the battery.
That worked.

SHE LIVES!!!
First start in 21 years

Smoked a lot burning off all the penetrant and lots of smoke, acorns and such came out of exhaust pipe.
Marvel Mystery oil really smokes.
Carburetor did great with the seafoam added a week ago and the engine idled.
Engine sounded great and oil pressure was really good also.
Had the fuel line disconnected from the carb and the fuel pump is trash.
Already have a new one and it will also be replaced this week.

Turned off engine and did a restart after filling the carb bowls back up.
Engine turned over (without jump box) normal this time and started right up.

Transmission also works in forward and reverse.

Very relieved.
Now that I know I have a good engine, I will order additional parts that are needed. (alternator, hoses, thermostat, heater hoses, etc.)

Really looking forward to driving this now.

NOTE----The SF97 arrived and the VIN number was wrong on one digit. Emailed the appropriate person and a correct one was sent out today.

Pic is from a screenshot of a video of the first start after 21 years

 

[marchplumber]

Here’s a 1984 I had a couple years back. We bought it at auction after seeing one terrible pic of it. It had been used as a storage shed and hadn’t run in probably 20+ years, but being off the road kept the body and frame in nice shape for a northeast vehicle.

We changed the fluids and filters and it fired right up. 6.2 Diesel and TH400. Did the brakes, belts, put some tires on and it was driving. It was pretty unmessed with and even had the gas card on the keychain. Fun vehicle but ended up selling it since I didn’t really have a need for it.
View attachment 958812View attachment 958813View attachment 958814View attachment 958815View attachment 958816View attachment 958817

Plbg truck?!? Hahahah.....Rigid 270 too! Nice, with oiler....gee whiz!

 

[Tinstar]

I knew the fuel tank had really bad varnished gas in it but didn’t expect what was actually in there.

Fuel tank must have been full when they parked it 21 years ago.
You could knock on the bottom of tank and it was just a thud.
Removed drain plug and nothing came out.
Used a screwdriver and broke through what seemed like two inches of goo
Removed screwdriver and it was coated with a tar like substance and looked like BlackStrap Molasses in the winter.
It’s what was left over from the fuel that evaporated long ago.
Worst smelling stuff ever.

It was oozing out of the drain small blobs at a time.
I even added 3 gallons of fresh fuel and that didn’t even thin it. Not one bit

So new fuel tank it is.


A few extra pics.
Keeping the negative battery cable off when I’m not working on it.



Forgot to tidy up the plug wires.
Will do that tomorrow.

Ordered lots of stuff today.
New alternator, brake hoses, radiator hoses, filters, etc.
Also ordered NOS GM starter support bracket. Cheap insurance.

Just in time for the really cold weather headed this way.

 

[sbgarage]

Sounds and looks like a fun winter project

 

[Tinstar]

You hear the phrase “they don’t make them like they used to “ a lot.
Well, that is especially true when it comes to the way they used to make clearance lights.
Either solid aluminum or galvanized steel.
Built like tanks.

The Cat Eye ones are original to the step van and the others were wired to act like emergency lights.
That VFD loved drilling holes.



Installed new Optronics LED Cat Eye clearance lights.
They will work.
Im not doing a restoration, just functional and legal.




Painted the new water pump.
I know it’s not “true” GM Blue, but it’s what I had on hand.
I hate rusty new water pumps






Not going to do a part by part thread, but thought the vintage clearance lights were very interesting.

 

[M813rc]

That VFD loved drilling holes.

While working on my former-VFD M715, I quit counting at 47 extraneous holes in the bed, most of which defied logic in their location That is when the Mad Driller was created...




Those clearance lights are cool. I'm glad you found new ones the right shape.

Cheers

 

[marchplumber]

While working on my former-VFD M715, I quit counting at 47 extraneous holes in the bed, most of which defied logic in their location That is when the Mad Driller was created...

View attachment 959080


Those clearance lights are cool. I'm glad you found new ones the right shape.

Cheers

Thank GOODNESS it was a VFD not a dentist! LOL (UGH!)

 

[Tinstar]

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.

Edit: Will be sealing up the holes with structural adhesive instead of welding.