1976 US Air Force Chevrolet P20 5.7L Step Van

[Tinstar]

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.


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

I got that joke instantly!
Kids today…………

Maybe that’s what I’ll call it…….”Pinto”!

 

[Tinstar]

Found more wiring damage due to mice and have fixed that.
They also chewed the windshield washer fluid hose at the door jam, so have to find bulk hose since that piece is at least 6 feet long.

This area was particularly bad for wire damage.
Multi colored wires in bottom left of picture is the wiper motor wiring they chewed in half.
Waiting on proper color and gauge of wire to fix it.





Cleaned up the rusty fuel fill.
Will make new gaskets since unable to get replacements.
New cap on the way.




Tried the rivet approach to patching two holes on top of passenger side fender top.
I don’t like how it turned out and will just use structural adhesive in the rest.
The loctite structural adhesive is expensive and not that easy to find. I use the H8100 and will order some this week.



Just some old and new tank shots that I used to make sure tank was correct.




Drove Step Van around ranch only to blow out the right rear brake cylinder.
New ACDelco parts ordered yesterday for full rebuild of rear brakes.

New coffee bean sack seat cover is working well.
Actually using it since I’m in and out of truck so much and don’t want to tear up seat anymore that it already is.
The auction yard left the door open of course for a year at least.

Realized I do not have brake lights and located a NOS GM brake light switch. It’s ordered.
Not 100% sure it’s a faulty switch, but the one in it is original so it’s time anyway.



Lots of parts still inbound and more will be needed. Still need to order heater core.
Still need to remove driveshaft and get new ujoints and a new carrier bearing installed.
Forklift driver lightly dinged the rear section of drive shaft. So that will need a new tube.
It’s not bad enough to collapse tube under normal load, but will definitely cause vibration issues at speed.
That alone will cost almost as much as I paid for truck. Has to be done.

No luck finding new window gaskets so far.
Search continues.
Lots of places claim to have them but they’re not the correct ones.

It’s a process. But worth it I think.

Like I mentioned before, goal is to get it as reliable as possible for future use.
I believe this Step Van is deserving of it.

 

[marchplumber]

Found more wiring damage due to mice and have fixed that.
They also chewed the windshield washer fluid hose at the door jam, so have to find bulk hose since that piece is at least 6 feet long.

This area was particularly bad for wire damage.
Multi colored wires in bottom left of picture is the wiper motor wiring they chewed in half.
Waiting on proper color and gauge of wire to fix it.

View attachment 959877



Cleaned up the rusty fuel fill.
Will make new gaskets since unable to get replacements.
New cap on the way.

View attachment 959874
View attachment 959875

Tried the rivet approach to patching two holes on top of passenger side fender top.
I don’t like how it turned out and will just use structural adhesive in the rest.
The loctite structural adhesive is expensive and not that easy to find. I use the H8100 and will order some this week.

View attachment 959873

Just some old and new tank shots that I used to make sure tank was correct.

View attachment 959872
View attachment 959871

Drove Step Van around ranch only to blow out the right rear brake cylinder.
New ACDelco parts ordered yesterday for full rebuild of rear brakes.

New coffee bean sack seat cover is working well.
Acrually using it since I’m in and out of truck so much and don’t want to tear up seat anymore that it already is.
The auction yard left the door open of course for a year at least.
Starts right up in cold weather and runs fantastic.

Realized I do not have brake lights and located a NOS GM brake light switch. It’s ordered.
Not 100% sure it’s a faulty switch, but the one in it is original so it’s time anyway.

View attachment 959876

Lots of parts still inbound and more will be needed. Still need to order heater core.
Still need to remove driveshaft and get new ujoints and a new carrier bearing installed.
Forklift driver lightly dinged the rear section of drive shaft. So that will need a new tube.
It’s not bad enough to collapse tube under normal load, but will definitely cause vibration issues at speed.
That alone will cost almost as much as I paid for truck. Has to be done.

No luck finding new window gaskets so far.
Search continues.
Lots of places claim to have them but they’re not the correct ones.

It’s a process. But worth it I think.

Like I mentioned before, goal is to get it as reliable as possible for future use.
I believe this Step Van is deserving of it.

Ton of work, glad it is moving forward.....
The Journey is part of the adventure, but can be frustrating and disheartening when the end keeps pacing back on ya....
You'll have a great vehicle when you're done and the satisfaction of knowing you made it possible.....

 

[Tinstar]

I’m also finishing up mechanically restoring a 1995 S10 4.3L that was also purchased by the USAF for around base use.
Dept of forestry gave it to Oklahoma State University/USDA and they abused it. Cow manure was 6" thick, coating everything underneath.
Frame rails were packed.
Front steering and suspension were absolutely worn out along with a host of other issues.
About 98% done with this one.
Only 75K miles and runs like a top.
Only paid $500 for it and it saved me thousands by not needing a side-by-side, which are insanely priced.
This truck is Farm Use only.



Also finished restoring a 1995 CM Trailers all steel 5X10 cargo trailer.
It made a flawless 4500 mile trip right after completion.





The 1998 Suburban LT I also just finished at same time.
Had all the leather seats recovered and did a ton of mechanical work.
She purrs like a kitten and is extremely comfortable on a long trip.

The Step Van is coming along nicely and no big surprises yet. Hopefully never.
It’s a learning process for me as I’ve never been inside one of these before, let alone working on one and bringing it back from the dead.
I buy the best parts I can afford and it really pays off in the long run.

Part of me wants to keep paint as is, to show its history of public and military service.
Part of me wants to make it almost like new again.
Time will tell and appreciate all suggestions/ideas.

Obviously I’m not afraid of hard work and really looking forward to driving this.

Thanks everyone for all the support and comments!

 

[marchplumber]

I’m also finishing up mechanically restoring a 1995 S10 that was also purchased by the USAF for around base use.
Front steering and suspension were absolutely worn out along with a host of other issues.
About 98% done with this one.

View attachment 959888

Also finished restoring a 1995 CM Trailers all steel 5X10 cargo trailer.
It made a flawless 4500 mile trip right after completion.

View attachment 959889
View attachment 959890

The 1998 Suburban LT I also just finished at same time.
Had all the leather seats recovered and did a ton of mechanical work.
She purrs like a kitten and is extremely comfortable on a long trip.

The Step Van is coming along nicely and no big surprises yet. Hopefully never.
It’s a learning process for me as I’ve never been inside one of these before, let alone working on one and bringing it back from the dead.
I buy the best parts I can afford and it really pays off in the long run.

Part of me wants to keep paint as is, to show its history of public and military service.
Part of me wants to make it almost like new again.
Time will tell and appreciate all suggestions/ideas.

Obviously I’m not afraid of hard work and really looking forward to driving this.

Thanks everyone for all the support and comments!

THAT is some wrenchin! =)

 

[M813rc]

Too bad about the driveshaft, expensive.

I like your Suburban. My POV is a 2001 LT Suburban I bought last year after my wife slew my beloved 2004 Tahoe. The Suburban was a garage kept, one owner vehicle with 154,000 miles on it, a friend of a friend sold it to me because she was moving to Hawaii. She is a competition wakeboarder, and only used the Suburban on trips to events.
The Tahoe had been my experiment - just how long would it last? I bought it with 9000 miles on it in late 2004. It had 436,000+ miles on it and was still going strong when my wife hit a 60 pound piece of steel C-channel someone had dropped in a curve on the highway. Blew both left tires (which were all of two weeks old! ) veered and slid into the ditch, rolled the truck. Wife was bruised, but fine, the Tahoe was totaled though. Still had the original 5.3 engine, and the original transmission was rebuilt at 270,000 miles. Still on the original A/C compressor, which was amazing, considering that I went through three in three years on my 2001 Tahoe. The front end had been redone a couple or three times. Two weeks before the wreck, I had put four brand new tires and shocks on it, had it inspected, and renewed my registration for the year.

Your box trailer is really nicely redone too.

Cheers

 

[marchplumber]

Too bad about the driveshaft, expensive.

I like your Suburban. My POV is a 2001 LT Suburban I bought last year after my wife slew my beloved 2004 Tahoe. The Suburban was a garage kept, one owner vehicle with 154,000 miles on it, a friend of a friend sold it to me because she was moving to Hawaii. She is a competition wakeboarder, and only used the Suburban on trips to events.
The Tahoe had been my experiment - just how long would it last? I bought it with 9000 miles on it in late 2004. It had 436,000+ miles on it and was still going strong when my wife hit a 60 pound piece of steel C-channel someone had dropped in a curve on the highway. Blew both left tires (which were all of two weeks old! ) veered and slid into the ditch, rolled the truck. Wife was bruised, but fine, the Tahoe was totaled though. Still had the original 5.3 engine, and the original transmission was rebuilt at 270,000 miles. Still on the original A/C compressor, which was amazing, considering that I went through three in three years on my 2001 Tahoe. The front end had been redone a couple or three times. Two weeks before the wreck, I had put four brand new tires and shocks on it, had it inspected, and renewed my registration for the year.

Your box trailer is really nicely redone too.

Cheers

Ouch! Glad wife was ok!!

 

[Tinstar]

This suburban has the 5.7L and does great.
The previous owner had the cheapest parts installed and like the O2 sensors, were the wrong part number for the truck.
Did the normal plugs, wires, cap, coil, hoses etc.
Love the 44 gallon fuel tank, Which I installed a new Delphi fuel pump in.
Blistein Shocks, brakes, rotors, drums, fuel pump, ubolts and plates on new rear springs, and even added AirLift air bags.

She really performs and while I don’t drive it often, Doesn’t hesitate to start
Great vehicle.

Cargo trailer even has electric brakes and a torsion axle.
Tows fantastic!!

I’ll get there with the Step Van, will take a little longer since so much work needs done.
Look forward to it.

Just tested the brake light switch.
It’s working fine.
Installed some new hardware on the fuel tank brackets and installed new cotter pins also.
Originals were almost completely rusted away.

 

[Tinstar]

Too bad about the driveshaft, expensive.

I like your Suburban. My POV is a 2001 LT Suburban I bought last year after my wife slew my beloved 2004 Tahoe. The Suburban was a garage kept, one owner vehicle with 154,000 miles on it, a friend of a friend sold it to me because she was moving to Hawaii. She is a competition wakeboarder, and only used the Suburban on trips to events.
The Tahoe had been my experiment - just how long would it last? I bought it with 9000 miles on it in late 2004. It had 436,000+ miles on it and was still going strong when my wife hit a 60 pound piece of steel C-channel someone had dropped in a curve on the highway. Blew both left tires (which were all of two weeks old! ) veered and slid into the ditch, rolled the truck. Wife was bruised, but fine, the Tahoe was totaled though. Still had the original 5.3 engine, and the original transmission was rebuilt at 270,000 miles. Still on the original A/C compressor, which was amazing, considering that I went through three in three years on my 2001 Tahoe. The front end had been redone a couple or three times. Two weeks before the wreck, I had put four brand new tires and shocks on it, had it inspected, and renewed my registration for the year.

Your box trailer is really nicely redone too.

Cheers

Glad she’s ok
That could’ve been much much worse

Your wife was very lucky and that truck most likely saved her.

 

[jeffhuey1n]

Awesome project! Brings back many memories! Couldn’t tell you how many miles or how long I spent in the back of one of those trucks. Flight line expeditor truck. Lots of memories and stories. Shucks, I wouldn’t mind finding one of those for my own use!

 

[M813rc]

Thanks, gentlemen. Yes, if you're going to roll a vehicle at 60mph, a Tahoe or Suburban is a good one to be in. Lots of sturdy metal around you, and a well designed safety system.
I do like that vast fuel tank on the Suburban, even with those cushy leather LT seats, my tail usually mandates a stop before the fuel quantity does.

Back to the step van - despite seeing them in just about every service's colours over the years, Air Force blue just seems to be their natural state of being. In other colours one is inclined to say "Oh! The Marines/Army/Navy drive those too?"

Cheers

 

[marchplumber]

Thanks, gentlemen. Yes, if you're going to roll a vehicle at 60mph, a Tahoe or Suburban is a good one to be in. Lots of sturdy metal around you, and a well designed safety system.
I do like that vast fuel tank on the Suburban, even with those cushy leather LT seats, my tail usually mandates a stop before the fuel quantity does.

Back to the step van - despite seeing them in just about every service's colours over the years, Air Force blue just seems to be their natural state of being. In other colours one is inclined to say "Oh! The Marines/Army/Navy drive those too?"

Cheers

I dont remember seein a "green one"....blue? Hell yeah, LOTS

 

[Tinstar]

Never seen a green one.
Only AF Blue.

If I paint this like a true Air Force Step Van, everyone will think I used to be in the Air Force.

If I paint this the Glossy OD Vietnam Green, most people will think it’s a UPS truck.

If I knew the right paint person, a standard issue 3-Color Camouflage CARC paint job would be…….interesting.
(I know they NEVER painted them like that.
EDIT: Wrong……New photographic evidence proves they did.)

If I leave it as is, then I’ll need therapy.

Good news is I have a LOT to do to it before it’s time for paint.

Treated the rust at the roof seam today.
Some areas are rough, but no rot
As soon as that’s dry/cured, I’ll seal it up and the roof line will finally be sealed again.

The window gaskets are hard as a rock and leak a bit.

Whatever type of paint they used, it doesn’t come off easy.
Had to burn off the paint on the fuel fill plate.
Worked well and it’s already primed and painted.
Pic is while it was cooling down.
small wire brush worked wonders

Before…….



After……..



Still moving forward.

 

[marchplumber]

Better "green" than "blue" but Im prejudice! Lol

 

[Tinstar]

I think it would look silly in 383 green, but think the glossy OD they used during the Vietnam War would look great.

I can see the difference between UPS Brown and that green but most could not. Most wouldn’t care about it either way.

Also want to preserve its AF heritage, but I wasn’t in that branch.
I think my Army Aviator Wings would melt if I did that.

Time will tell

 

[sbgarage]

Try millsupply.com for window gaskets? They're a step van supply outfit

 

[Tinstar]

Try millsupply.com for window gaskets? They're a step van supply outfit

They do not have the correct ones for this model Step Van.

Will be going by an auto glass shop and seeing what options are available.
They usually have sources unavailable to most of us unless you’re in that business arena.

 

[Tinstar]

[QUOTE
Shucks, I wouldn’t mind finding one of those for my own use!
[/QUOTE]

These old Step Vans are very hard to find now.
Especially the ones with Air Force history.
Most were crushed or are sitting somewhere used as a storage shed.
Most that have survived are heavily modified to suit owners taste.

I wasn’t looking for one at all.
But it popped up on GSA auction and received almost zero attention.

I paid a whopping $523 for it and it was an hour away.
If it had a junk engine or transmission, it would be now sitting on the ranch somewhere as a small cabin. Complete with wood burning stove.

I gambled and was lucky.
Especially with the engine being seized initially.

 

[M813rc]

$523??!!???
Outstanding!!

We did have some green ones on Marine bases, semi-gloss Marine Green with yellow markings. I don't remember seeing them on the flightline though. We always felt pampered if we flew into an Air Force facility - they'd send one of those vans or something similar to pick us up from the aircraft. On our own base, you'd figure out where your helo was parked and take off walking!

Cheers

 

[Tinstar]

On our own base, you'd figure out where your helo was parked and take off walking!

Boy that’s a fact!!