1963 GMC Step-Van 7

[Aberdare]

Progress is progress, even if it is slow going. I decided to fabricate new steps for the van, and as you can see... the right side original step is as functional as a screen door on a submarine. The left side is in worse condition. So, the 2nd picture is the new sub-frame and the space the new step will fit into, and the 3rd picture is the raw materials I will be using for fabrication... an old steel shelf and the remainder of the section of the bed that was cut off previously.

So here we go...

[Aberdare]

So, I began with cutting the pieces... the step back was fabricated from the steel shelf to fit, including the rise and taper as well as the forward angle taper. Next up, I cut the step bottom and step back... followed by the forward angle taper to complete the step. So, with 4 pieces ready to assemble, I did a test fit and did a little trimming... then began tack welding the pieces together. Once all tacked, I did a test fit. Hard to believe it fit perfectly the first time, but it did... all that's left now is finish welding and grinding.

Now to do the same for the left side... Using the leftover bed floor cut-off makes it look like it belongs there and the corrugated steel adds a little extra strength to the step.

[Aberdare]

Things have really gotten busy in the workshop during the last few weeks, so very little time spent on my project... however I did stop out with the P/O, to start getting the parts trucks ready for transportation, now that spring is here. I brought a set of tires with me, knowing that at least one of them has no rear tires. Had to jack-up the '65 and put it on blocks, so that the brake drums can be pounded off later. The '64, I put the set of tires on. I collected 6 tires & rims from the trucks, as well as several boxes of loose parts & Pieces from the '66. I also scored the steering box from the '66, as I noticed it has the same casting number as the steering box on the van. The '66 is basically a frame, with the Cab, Doors, Hood, Fenders and Box... the original engine and transmission are long gone.

I spent more travel time, to and from, than I did actual work time to start getting them ready for transport... but that's how it goes sometimes.

[Aberdare]

I know it has been a while, but things have been crazy stupid in the workshop with no time for any personal projects. But I am one step closer to moving the Parts Trucks... the car hauler just needs a Deck, Wheels, Fenders & Lights, after welding the whole frame together... check it out.

Once I have the parts trucks all moved, It'll be time to get back on the Van Chassis.

[cornerstone]

That's gonna be stout! Any progress is good.

[Aberdare]

Originally Posted by cornerstone

That's gonna be stout! Any progress is good.

Thanks!... here's what I used to build it:

Materials List
HSS 4 x 2 x 0.125 - Qty 2 x 192"
HSS 4 x 2 x 0.125 - Qty 5 x 71"
HSS 4 x 2 x 0.125 - Qty 2 x 75"
C3 X 1 1/2 - Qty 4 x 71"
C3 x 1 1/2 - Qty 2 x 62"
HSS 2 x 2 x 0.125 - Qty 2 x 188"

and additional parts:

Qty 2 - 2000lb 89in Axle - 74in spring centers
Qty 4 - 1750lb 4-leaf double eye spring
Qty 2 - 2000lb axle U-bolt kit
Qty 1 - 5000lb A-Frame trailer jack
Qty 1 - 2 5/16 A-Frame trailer coupler

So, all in... a 4,000lb - 16ft Hauler. Just needs Lights, a Deck, Fenders and Tires & Rims to finish it off.

[Aberdare]

It's been a slow week in the workshop... more time on the trailer so that I can have things ready to move the parts trucks. Suspension done, wheels and tires installed, lights installed... just fenders and deck left.

I'll be using qty 3 - 2x4 16ft and qty 1 - 2x6 16ft on each side, leaving the center open.

[knomadd]

What do you think the trailer will weigh when you're done? It looks good so far.

[Aberdare]

Originally Posted by knomadd

What do you think the trailer will weigh when you're done? It looks good so far.

Duane:
While the trailer will be rated for GVW of 4000 lbs, I expect a curb weight around 600 lbs. I will be having it weighed prior to certification.

Today was another light day for retail in the workshop, so I managed to get the decking boards all installed and screwed down, in addition to installing the safety chains. The only thing left now is fenders... not sure if I'm just going to buy some prefab ones, or make a pair from scratch.

[knomadd]

Wow, that'll be pretty light. Looks good too!

[Aberdare]

Well, it was another light day for retail in the workshop, so once again... work on the projects. Today, I installed a 2000lb electric winch on the trailer. I had some left over 2x2 HSS and a piece of 2 inch angle iron. I cut the 2x2 HSS into qty 2 - 4 inch pieces, and the angle iron into qty 2 - 10 inch pieces. I cut the ends of one piece of angle iron to weld the 2 pieces of HSS onto them, so that the winch is raised off the deck after it is mounted. I welded the pieces together so that the winch is offset slightly forward of the front deck cross member. While I am not a welder, I didn't do too badly.

Check it out... So Total Cost; Winch - $60.00 (new in the box from Kijiji), Materials - $0.00, Labour - 5 Hours. Going to add a Battery Tray from one of the Parts Trucks.

The Trailer still needs Fenders...

[Aberdare]

Well, with or with-out Fenders... actually, with-out... 320 km's round trip for the first run with the trailer. The trailer tracked perfectly straight and didn't bounce too badly empty... alot better with the chassis on the deck. As you can see in the pictures, the trailer is the perfect width. Other than a small mishap loading, I cracked the left lamp lens. Good thing I had a spare one, so it was easily changed out.

I picked up the chassis for the 1966 Fleetside Longbed... Now, it resides next to the Step Van Body. Next trip will be for the Cab, Box, Doors, Fenders and Hood. Loading with the winch was a breeze, and the ramps made it even easier. My little Ram-50 managed things quite well, considering I wasn't hauling a complete vehicle. Going to be using the PO's mid 90's pick-up to haul the trucks at a later date.

[Aberdare]

Well, another light day for retail in the workshop... so I spent the day on the Van Body. Would you believe 5 hours labor and close to qty 100 - 5/16 inch bolts holding the roof on? (Check out the small box full of nuts & bolts) The sealant holding things together just didn't want to let go, but some gentle persuasion with a couple of prybars and it came off. The roof is now perched on top of the '66 Long Bed Chassis. And it looks like tomorrow is going to be another light day for retail, so my next step will be to remove the rear door header as a complete assembly. I guess I'll find out how badly it wants to come apart...

Here's a few pictures from today's progress.

[Metaldoc]

So 5 inch chop?

[Aberdare]

Originally Posted by metaldoc

so 5 inch chop?

noooooooo... Lol

[Metaldoc]

10 inch section and a 5 inch chop

[Aberdare]

Originally Posted by Metaldoc

10 inch section and a 5 inch chop

Thanks Doc... I needed a good laugh.

[Aberdare]

As expected, today was another light day for retail in the workshop. I removed the rear door header as a complete assembly, and also removed the forward cab section. In order to accomplish removing the forward cab section, I started with removing the pocket door rails, then simply lifted out the doors. I set them aside with the rear door header assembly. I located the top header joint and made a cut with a reciprocating saw on each side, leaving behind what was left of the floor and sidewalls.

Check out what is now a pile of rubbish...

[Aberdare]

Tuesday Continued...

Remember the nice forward floor sub-frame assembly I constructed back in April? Well now is the time it comes into play as a structural component. With the assistance of the lads in the workshop, we hoisted the forward cab section back onto the chassis. I welded on the door opening rear uprights, joining the upper header to the forward floor sub-frame. I also test fitted what used to be the inner door pocket panels to what will become the partition wall between the cab area and the cargo area.

Check it out...

[Aberdare]

It was another light day for retail in the workshop... It's starting to be a trend as we get ready for summer's end. We should start getting busy again middle of September. So with not a lot else to do, it was another project day. I took a couple of heavy gauge steel shelves and fabricated them into a two piece forward floor cover. It was a fair bit of fabricating, but it did make the day go by with something to do. Pictures to follow later.

[VWNate1]

Wow, what a great project ! I just found this thread to - day, 8.15.2018 .

I lived in Rural New England when this rig was new, very few made it beyond 5 or 6 year old before they completely rusted away ~ that yours is still so intact is amazing .

Question : the little black car in the back ground of posts # 53 and 67, is it an Austin A55 derivative ? . I love it .

You should post photos of exactly where the chassis VIN is to be found .

[Aberdare]

Originally Posted by VWNate1

Wow, what a great project ! I just found this thread to - day, 8.15.2018 .

I lived in Rural New England when this rig was new, very few made it beyond 5 or 6 year old before they completely rusted away ~ that yours is still so intact is amazing .

Question : the little black car in the back ground of posts # 53 and 67, is it an Austin A55 derivative ? . I love it .

You should post photos of exactly where the chassis VIN is to be found .

Thank you... but everything below the belt line on the van body is just rotten... A testament to how cheaply made the Union City Van bodies were made. Putting it back together again is going to take some time and a lot of fabrication.

To answer your question; The black car beside the trucks is a '55 or '56 Austin Cambridge.

In keeping with Legal Requirements, as a Licensed Journeyman and certified to do Vehicle Safety Inspections... Posting photographs of the exact location of hidden identifiers for motor vehicles is a criminal code offense in Canada - so I will have to respectfully decline.

[VWNate1]

No kidding .(about the hidden VIN)

You must be younger than I as I well remember rusty vehicles in the 1950's and 1960's, dangerous ones often .

Using S & H green stamps in lieu of the safety inspection sticker, paying $15 for an illegal sticker, brake lines parting under sudden stops, putting my foot on a four year old Ford Galaxy's rear bumper and having the FRAME break away ~ this on a car that was running and driving, for sale for $350 at the time .

On and on .

I'm not saying your van isn't rusty and in dire need of the works you're doing but I remember far worse .

[Aberdare]

Originally Posted by VWNate1

I'm not saying your van isn't rusty and in dire need of the works you're doing but I remember far worse .

Rusty sometimes hides far more dangerous conditions, hence why I decided to lift the body off the chassis and start with a good solid foundation.

As promised, here's a few pictures of the new forward sub-frame floor and I also refitting the engine cowls to see how well I did fabricating the sub-frame. I didn't do too badly with the forward outriggers higher by 1/8th of an inch on both sides... I can easily make an adjustment for that with some spacers between the frame and the forward cab mounts. I had a couple of leftover pieces of steel shelf that will work perfect as bottom anchors for the partition wall. I will need to fabricate the driver side step, then install both the left and right steps onto the sub-frame, before I fold over the ends of the steel floor and screw them all together.

... but check it out! New Floor! Just need to fabricate a new shifter cover and make sure I leave some room for the PTO control lever to be installed later.

[Aberdare]

Well, once again... another light day for retail in the workshop, so it was another project day. Made some headway on the partition wall as well as getting the right side step mounted that I fabricated back in April. On Friday, I pulled all the glass. Turns out there's a local company that distributes Automotive Lexan (Polycarbonate) which has an impact strength 250 times greater than glass... and it's CHEAP, considering I only need a single flat sheet to make all the pieces for the Van... but more on that later.

... Check out today's progress!