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Between 485 & 705 SQ/FT Mid-Century Moto Mecca Makeover

Workspaces between 485 and 705 squarefeet.
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sakurama

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I tried to send you a PM but for some reason it doesn't show in my profile this morning. So if you didn't get it: I live in Nashville. Let me know how I can help.

So I wanted to thank Zippercat for his huge help. I have been looking for a van for about four months now - but as you might imagine I had a very good idea of what I was looking for. I want to replace my truck with something that could better tow the trailer but could also haul my photo gear and bikes inside. Sort of like the Sportsmobile concept but not really a camper.

My goal was a Ford E350 with a 7.3 diesel, extended body and hopefully a high roof. I wanted windows because, like my house, I wanted lots of windows. Because, you know - windows! So every day I'd search CL nationwide. Several times I'd find a van but be a day or two late. Several times I found a van and would try to put a deposit down and have it sold out from under me.

Anyway, I found one - so cheap it was probably a scam. Everything about this deal said I was going to be scammed. I wasn't about to lose another one so I sent half the money via Western Union (first clue, or maybe the second or third) and then reached out to see if someone here was able to at least go there in person so I would only lose half the money.

But Dave took the rest of my cash and went to this completely sketchy junk yard and recovered the van, delivered it to a local mechanic I found and a few days later I flew in and drove it home.

i-P4Ww2Tv-X2.jpg


The van will be converted to 4x4 and, in a rare fit of common sense, I won't be doing it myself. The pickup will be sold to pay for the conversion and this will become the family adventure van. I'm pretty excited.

Zippercat - thank you soooooooo much. There's no way I'd have gotten this thing without your help. While it looks like you should have a tetanus shot to drive it the van has turned out to be in near perfect shape underneath all the dirt and grime. Zero rust and a super strong engine. Even got 20mpg on the way home.

Gregor
 
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gasgas17

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Those are great vans Gregor. I have owned 2 over the last 10 years for work. A v10 and a 5.4 v8. Both e350's. Take some time and adjust all the hinges and door latches on the rear side and back doors. The only service parts we have ever had to replace are ball joints around 150k Kms. And brakes every 60k kms. We pound them around the city with a thousand pounds of tools full time. You can also fill them 3 feet deep with lumber and still safely drive them. Try that with a truck. We have also hauled dirt bikes in them all over eastern Canada and Atlantic Canada. You can squeeze 800 Kms out of a tank on the highway with the gas vans with out a trailer.
 

gasgas17

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I also did a fly and drive on the last one. Picked it up in Brandon Manatoba on Friday afternoon and back home in Dartmouth Nova Scotia on Sunday night. 3800 Kms. Really should have taken an extra day.
 

Huxley

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All it needs is some wood paneling - on the outside.

Good luck finding someone competent, trustworthy, speedy, **** to do the conversion.

Use those Google powers for good, not evil.
 
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sakurama

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All it needs is some wood paneling - on the outside.

Good luck finding someone competent, trustworthy, speedy, **** to do the conversion.

Use those Google powers for good, not evil.

The outside. Ha, I like that.

I actually do have a person who is great on tap. We're talking now.

Gregor
 
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sakurama

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Who will do the 4x4 conversion?

I'm talking with Michael of MG Metalworks. He's local which is good, but he's also developed the most slick and thorough conversion of anyone out there. Ujoint was the standard I think but Michael uses coils instead of leaf springs so the ride is better and the geometry is tighter. If you like this sort of thing and want another epic build thread to peruse he's put a new 6.7 Cummins into a newer E350 that he installed his kit onto: http://forum.expeditionportal.com/threads/96155-MG-Metalworks-Van-Build

I will probably start (another) build thread for the van as there's a bit I'd like to do to it but I am going to do my best to out source van work as much as possible because I don't like working on cars/trucks. I do like fabrication so it's possible I'l make my own bumpers and such if I can't find something I like but the goal is to get this thing ready and spend a summer in it. So that has to happen pretty quick.

Gregor
 

mr_magicfingers

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Catching up after a few weeks away. Loved seeing all the show photos on instagram and then seeing them in larger size on here. Brilliant work Gregor, thanks for sharing with us.

Very much looking forward to following the van build. I did an old VW camper years ago, on the cheap and in a hurry but it was a hoot to live in for a while. Still have a hankering to build up an adventure van one day that can take the wife and the dogs and go fun places.
 
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sakurama

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You keep this internet going. May I ask why you didn´t mention anything regarding portal axles on the Van. You will need it...i think. Portals are cool.

http://forum.expeditionportal.com/threads/37713-An-expedition-truck-on-portals

Btw. You are working to much. More updates...we need the flow.


ps: Did you use the 250 exc or 200 exc/xcf...

Whoa, that's cool and I'm so unhappy to know about it. No. I'm going to stay strong and ignore portal axles. Part of the reason for going with a Ford van is the simplicity and reliability.

And you're right - I have been working a lot but it's also nice to not be broke for a change. So I'm not complaining. We used to joke that the only worse than no work is work. Although you can flip that and it's just as appropriate.

I have work scheduled for the end of May and I'm hoping to get time on the house as the weather improves. That's a big hold up on the closet - lots of rain and the boards I need to stain/finish are pretty long and take up a lot of space so the best thing is to work on them outside.

Gregor
 

Zippercat

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Gregor,

You're most welcome. Glad I could help. Did you save any of those pounds of Tennessee topsoil as a souvenir? You should post a before pic. This van is not remotely like the one I picked up and test drove.
 

fergus

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Totally awesome man. I have to admit...I am slightly jealous. I think with a young family, the adventure van is an awesome way to go. I'd like to be able to do something along those lines in the not too distant future...I see a decent number of Sportmobile conversions in my area...and start daydreaming.
 
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sakurama

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Gregor,

You're most welcome. Glad I could help. Did you save any of those pounds of Tennessee topsoil as a souvenir? You should post a before pic. This van is not remotely like the one I picked up and test drove.

I took some "before" photos of the van tonight and it's headed for a detail on Monday. Once the grime is removed I think I'll be better able to assess the situation. Then it will get a stereo install which I wish I'd done before I drove it home but at least for the rest of the summer there will be tunes.

Totally awesome man. I have to admit...I am slightly jealous. I think with a young family, the adventure van is an awesome way to go. I'd like to be able to do something along those lines in the not too distant future...I see a decent number of Sportmobile conversions in my area...and start daydreaming.

I thought I was getting a great deal but costs are adding up quick to do the whole conversion. I'm sure I'll still be ahead a bit compared to picking up a used 4x4 van and it will be dialed in for us. I'm really looking forward to actually taking it off road and Ben and I are planning some 4x4 family outings so it should be a lot of fun.

Michael is now looking for the parts and with any luck the van will start it's transformation in a few weeks or so. I'll be sure to photograph that as it happens.

Gregor
 

ruffryder

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sakurama,

I am curious why you chose the van instead of something already 4x4, like a Ford Excursion. I guess you mainly wanted the height that the van would offer? You going to be finishing the van off with sinks / stoves and stuff too?

Sounds like a great project!
 
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sakurama

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sakurama,

I am curious why you chose the van instead of something already 4x4, like a Ford Excursion. I guess you mainly wanted the height that the van would offer? You going to be finishing the van off with sinks / stoves and stuff too?

Sounds like a great project!

Yes, it's mostly for the ability to put a motorcycle inside. I have been contemplating what would replace the pickup since before I bought my pickup. I saw a Sportsmobile maybe 20 years ago and thought it was so cool but it was (and still is) far beyond my means. The pickup served me well but it can't carry stuff securely like a van can. A Sprinter can carry stuff and has it great space but can't really go offroad. It's not like I go wheeling that often - I have dirt bikes for that sort of thing - but it was a big part of growing up for me and I think that is probably what's really driving this van project. I want to take the kids up in the mountains, on a road that looks impossible, high above timberline and let them experience the same mechanical epiphany that I had as a kid. Machines can take you to amazing places.

Honestly it's probably that more than anything. The van will be able to that but also carry a bike inside when the need arises. Like Friday. When I put my first bike inside for a race this weekend!

So my apologies for not keeping up here. I have wanted to do work on the house but I made a commitment this year to race a full season of the OMRA Cross Country series. Riding has really fallen by the wayside for me since taking on this house and I needed to reconnect in a bad way. The start of the series was delayed and then we've had a couple of races close together and now more on consecutive weekends. I miss racing and it's a wake up call to get back out there and see how much speed I've lost. Well, I think I could get a lot back but not without riding over my self imposed 70% limit where I don't feel like I'm at risk of crashing.

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This was last weekend at the China Hat ISDE race. Despite training since back in November the first race kicked my *** so hard I could barely walk the next day. I got fourth in my class 50 Am and so I doubled down on my training hoping to do better in the next race... and got 11th. At least I wasn't as wiped out and could almost stand for the entire two hour race. That's an improvement.

So with preparing the bikes, training and work taking time and the rain preventing me from laying out lumber to finish the closet, work on the house has sort of ground to a halt. But since this thread is home to many a diversion I thought I'd at least take some photos of a recent tool I made. Besides, I like the excuse to shoot photos for this thread - it gives a reason to practice.

The best training for riding a motorcycle is to ride a bicycle and mine has gotten rather crunchy lately. It needed new bearings in the bottom bracket and the steering stem and Sean hooked me up with the crank tool and bearings I needed so I thought I'd do the work. The bearings are rather large and thin so pressing them in with a hammer wasn't going to cut it. I needed a bearing press.

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I had a length of Acme threaded rod and some nuts that has been sitting idle for ever. And of course I have a whole bunch of 7/16" stainless leftovers from my kitchen cabinet pulls. With these scraps I figured I could make a bearing press in less time than it would take me to drive down town and buy one. Well, less time than it would take to walk there. Slowly.

Acme thread is a stronger thread form that evolved from the first square threads. It's ideal for transmitting power and load so it would be perfect for a bearing press. You have Acme thread in your shop too: your vise uses it and so do all your C-clamps. You can buy it from McMaster.

So I cut a few scraps of the stainless rod to the same length preserving the 45° mitre cut on one end and then transferred them to the lathe to finish the ends.

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Then I dusted off my welding helmet and welded the stainless rod to the steel nuts with 308 stainless rod.

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Okay, they're not perfect but they'll do. Then a couple of aluminum slugs are turned to offer steps matching the ID of the bearings I'll be pressing in. I can always make more later for other projects.

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And finally in use. It worked great and is now a part of my drawer of homemade tools which is fun to look at because you can certainly see the evolution of my skills as a fabricator and machinist improve over time.

The next thing on my agenda is to make another tool for my son's birthday and I'm not sure what that is yet. I think he needs a tool box but I can't find a design that I like and one of my constraints is that it be something he can't outgrow but also something he likes to play with now.

In a couple of weeks we're going to have a break in the racing and if it coincides with the weather I'm hoping to knock out those closets. I'll admit that the thought of attacking that project is pretty intimidating to me and probably why I've been dragging my feet. I need to get a few days to finalize the stain choice and just go for it...

Gregor
 
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Huxley

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The master (of all) returns!

<bow down>

Amazing photos & great update. Thank you.

Get back to CO so we can ride together!
 

azcanc

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charlotte nc
Is that a carbon seat stay version of the cannondale bike? I had one and cracked it. Same colors - sold to so guy on eBay and he fixed carbon for additional use.....fun bike. Ps - do you still ride vertigo cycles bike?
 
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sakurama

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The master (of all) returns!

<bow down>

Amazing photos & great update. Thank you.

Get back to CO so we can ride together!

I think we're going to head back this summer in August. We're going to need to test out the van's 4x4 worthiness. I'll be bringing a dirt bike for sure.

No way. Worry a lot Gregor. Put into your clever head how much we are waiting.
;)

Have you been talking to Judiaann? She's worried that we're going to end up like one of those houses with many cars in the yard. There's already lumber stacked outside and a motorcycle under an awning so maybe she's right.

Is that a carbon seat stay version of the cannondale bike? I had one and cracked it. Same colors - sold to so guy on eBay and he fixed carbon for additional use.....fun bike. Ps - do you still ride vertigo cycles bike?

No, it's a Cannondale Rush with a USA built aluminum frame. It's older but it wasn't too expensive and I've updated it with 650B wheels as I love the 27.5 wheel size and they just fit. It's like three generations behind which suits me fine since I'm now at least one or two behind myself. I've come to terms with the fact that I don't really like new stuff but would much rather fix up something a little older and make it mine. How's that working out for me...:lol_hitti

He's welcome to borrow a Vertigo bike whenever but seriously...how long do you think it'll be before he just makes his own bike?

A while. Hopefully a long while. I love the idea though. Gotta finish some motorcycles first. Oh, and a house.

And now a van...

Gregor
 

BoilermakerFan

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So, many years ago when you started your thread Gregor, I probably followed along for a few pages... I've been a member here for a long time, but never really posted. I noted you built motorcycles and moved to Portland... and then life happened and I lost track of it.

Now fast forward these few years, I find the thread again, and now I'm on the hook!

I now have project motorcycles of my own and I'm mostly on Instagram so I followed you today. I follow most of the motorcycle pages that focus more on the vintage Japanese and European customized bikes. I follow builders like Mike Le at Kinetic, Sofi at GT-Moto, Evan at Speakeasy Motors, Andre at BBCR Engineering, Voodoo Vintage, J.Webster Designs, Jtec Moto, Evan at Cognito Moto, Gabe at After Hours Choppers, PJ at Ranger Leather, and Craig Rodsmith. I have purchased or will be purchasing components from most of them for my builds. Your photos from the 1 Show this year are awesome! I didn't realize that was your work. I had no idea how strong the vintage and custom motorcycle and bicycle scene was in Portland until recently. Now I'm really envious you're out in Portland.

I just finished reading through every page in this thread. Normally I would skip a few pages at a time, and I started to on this thread, but then I realized I was missing way too many cool posts and pics so I had to go back to page 1 and go through it page by page. The video for the Gear Patrol tour was awesome! I'm looking forward to your continued updates. This thread is one of my favorites on GJ, mostly because of your attention to details, the quality of your work/pics... and the varied posts on the garage, the house remodel/renovation, on tools, on the motorcycles, the bicycles, the trailer, the van!

But that does bring me to one question... I thought you were getting one of Vertigo's 27.5s?
 
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Vertigo Cycles

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But that does bring me to one question... I thought you were getting one of Vertigo's 27.5s?

Dunno. Gregor is already one of the coolest people I know and a Vertigo might put him way over the top.

He already has the ability. He just lacks the appropriate tools and time. We've chatted about him coming over for a "class" in building frames and I think it's just a matter of time* before he builds one of his own.

*some period between a year and a half century.
 
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sakurama

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I just finished reading through every page in this thread. Normally I would skip a few pages at a time, and I started to on this thread, but then I realized I was missing way too many cool posts and pics so I had to go back to page 1 and go through it page by page. The video for the Gear Patrol tour was awesome! I'm looking forward to your continued updates. This thread is one of my favorites on GJ, mostly because of your attention to details, the quality of your work/pics... and the varied posts on the garage, the house remodel/renovation, on tools, on the motorcycles, the bicycles, the trailer, the van!

But that does bring me to one question... I thought you were getting one of Vertigo's 27.5s?

Dunno. Gregor is already one of the coolest people I know and a Vertigo might put him way over the top.

He already has the ability. He just lacks the appropriate tools and time. We've chatted about him coming over for a "class" in building frames and I think it's just a matter of time* before he builds one of his own.

*some period between a year and a half century.

I am beyond glad that the audience here finds the many diversions of my life and this thread entertaining. Not everyone in my household shares the opinion and it is precisely because none of you all live with me that this is entertaining. Much like the entertainment value of Nascar I can assure you that when you're the one strapped in the flying car that diversion is probably not appreciated.

But ha! It's warm and sunny and the summer is fast approaching. I am in a rush to get some stuff done while I can work outside. Especially things for the summer.

So while I should be working on the closet we've already committed to some camping trips and the point of the van was to tow the trailer. The point of the trailer was to do some trips with the kids who are now at a great age for travel.

So I shifted priorities.

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Does that look familiar? Yup, I'm up on the roof of the trailer trying to seal up the remaining seams.

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I had to pull off a small piece of the Eternabond sealing tape and it's impressively sticky.

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Peel the plastic backing and lay it down after all the old sealer is scraped and cleaned away...

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It's pretty flat laid down but it needs to be rolled to really make the seal.

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Next on the list for the trailer is a new seal for the refrigerator, replacing the broken clearance lights and hopefully attempting to reseal the windows.

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The trailer went from blistering UV in the high altitudes of Colorado to the swampy moss-grows-on-everything winter of Oregon - it's not pretty. At the races this weekend I found myself admiring the the new Airstream of a fellow competitor - so clean, so carefree. So expensive.

Well, I'm hoping to make progress tomorrow and then take a day off to go ride with Sean. Can't spend every nice day on projects.

Gregor
 
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sakurama

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BoilermakerFan

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Well, if you're really a glutton I've started a thread for the van. I'm not quite sure it will be as entertaining as I hope to farm out the conversion for my sanity but I also hope to build some things for it as well.

http://forum.expeditionportal.com/t...Satisfaction-Guarenteed?p=2296932#post2296932

Gregor

Cool. I've been following U-Joint for years on Facebook. Love his ambulance conversions. Please feel free to add van updates to this thread too. I don't even remember if I'm a member on EP... I probably am, but it's easier for me to keep up with the build here.
 
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sakurama

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Cool. I've been following U-Joint for years on Facebook. Love his ambulance conversions. Please feel free to add van updates to this thread too. I don't even remember if I'm a member on EP... I probably am, but it's easier for me to keep up with the build here.

Ey Ey Captain. One more tank for the shark to jump.

Gregor
 

Vertigo Cycles

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Great ride today Gregor. Let's do it again soon.

I figure if I post here instead of txt you'll have to post a bunch of photos of whatever you're working on when you reply. I hope it's van stuff.
 

BoilermakerFan

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Gregor

I started a camper thread in the Free Parking area. Be sure to post pics of your camper over there after you get it further along. I can't wait to see what you do on the inside once the bug bites and you decide you are going to remodel it after all. We know it's just a matter of time. I figure you'll get the van done, then a bike, then you'll jump into the camper again after a season or two of use.
 
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sakurama

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So between work and family I've been trying to hit work on the trailer. To my great surprise that last round of sealing I did seems to have finally stopped the remaining small leaks. If the weather is rainy I try to attack an inside project and then when the sun comes out I hit the outside stuff. None of it is finished which is why I haven't posted anything. I'm feeling like everything lately is one step forward and two back.

This marker light is on by the way - it's the only one working...

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The rear marker lights on the trailer leave something to be desired.

I'd ordered some LED replacements a while ago but just didn't want to tackle that in the fall. I found them and tested them out to make sure they worked.

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Once I tested one I realized the actual LED's were probably different colors instead of just covers and it's a good thing I did as the LED's were five red and five orange - bullet dodged there. From there I had some gray butyl tape - similar to what I'd used on the vent caps a few pages ago. This ribbon version is used to seal windows and narrow things. It seemed like a less messy way to seal them to the surface than Sikaflex or some other version of caulk.

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Then I gathered my collection of wiring tools. The two on the left are worthy of note if you're not familiar.

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First are these:

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I first saw these at the electronics desk of an engineering firm a friend worked at. They struck me as the most magical Rube Goldberg pliers that could ever exist. They basically cut and strip in one squeeze. To this day they give me pleasure to use. Cheap versions can be had on Amazon for $7-8 and I got mine from McMaster who never tells you who makes what they sell but it's always very good quality. Mine are 20 years old at this point and are still going strong so that extra $20 was worth it I think.

Next up are the crimping pliers. I was never a fan of crimping because in college I worked at a high end hifi shop and we silver soldered everything and used color coded shrink tube and it was pretty. Pretty made sense to me, I was a photographer. Chris, at my old shop, explained that crimping was in fact a better connection because it was mechanical. Much like wire nuts in home wiring. Like wire nuts it's also faster. I still don't like it but I accept it.

The key however is that you need the right crimping plier for the right connection and they're all different. These pliers are for crimping many different connectors by virtue of changing the jaw clamps. If you've ever used the cheap pliers that come in the little kits of auto connectors (similar to the yellow pliers above) you know that you can crush the plastic insulator and then gently tug on the connector and it slides right off. It's the curse of the cheap tools.

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I still don't find that as pretty as a soldered connection with shrink wrap over the base but I'm standing on a ladder in the driveway so soldering isn't an option. I also don't have as much love for this trailer at the moment.

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I used self tapping stainless screws, cleaned as much of the rust off the aluminum that was left from the old marker lights off and then tested each light as I installed it. Each one worked perfectly right up to and including the last one. I installed all the caps and then went to do one more final test to bask in the glory of five LED marker lights and...

I now have no lights.

Not just the markers but no tail lights now either. I guess that should be funny in an ironic way. The front markers that I haven't replaced are still working - figures - and they should be on the same circuit as the other markers so I'm sort of baffled. That's another one step forward and two steps back thing that's been plaguing me lately.

So I'll try to sort that out tomorrow, make some other progress and try to update this again soon.

On the van front axels have been found and are en route. I ordered tires and wheels today as well deciding that I'd rather get new wheels of the correct size than try to make the other ones I already bought work - another step backward but at least two forward. It's looking like June should be a busy month for the van. Nothing to really take photos of at the moment so I'm not doing much with that thread yet.

Gregor
 

bunks-tj

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Next up are the crimping pliers. I was never a fan of crimping because in college I worked at a high end hifi shop and we silver soldered everything and used color coded shrink tube and it was pretty. Pretty made sense to me, I was a photographer. Chris, at my old shop, explained that crimping was in fact a better connection because it was mechanical. Much like wire nuts in home wiring. Like wire nuts it's also faster. I still don't like it but I accept it.

The key however is that you need the right crimping plier for the right connection and they're all different.
Gregor

There is a happy compromise here. i dont like crimped connections anyplace where moisture might work its way into the sleeve (and never scotch locks...anywhere). When we make a connection that might be exposed to the elements, say a trailer wiring harness, we sometimes push the crimp sleeve out of the plastic sleeve crimping only the metal sleeve. we then shrink tube that connection. you have the advantages of the mechanical connection with the water proofing that shrink tube creates.
 
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