Base model 2.5 TBI Voyager to Turbo project.

[ShelGame]

So, I thought it was about time to put a log of my Minivan project.

I bought this from Jason Hagger last spring with the intention of making it a daily driver (with no car payment!).

Here are the pics of it as it sat in Jason's yard. I pretty much bought it by the pics, since it's a 2+ hour drive over to get it. Unless it was rotted to hell, it was coming home with me. For a van originally sold in Maine, it's actually really clean underneath. The only rust is on the front of the RH rear fender lip.

The van is really for me to drive to work, but I will occasionally need to transport at least 2 of my 3 kids. The van had no rear seats at all in it from Jason. But, a quick Craigslist search turned up a 3rd row bench from a '91 Voyager for $10. It made for a real long return trip home, but I stopped and picked up the bench after picking up the van. The upholstrey isn't a match, but at least it's maroon, too.

[Sgt Craig]

What the hell is a fuel pacer.Ive never seen that.Your van is in great shape!

[ShelGame]

OK, so this was originally a 1989 2.5 TBI Plymouth Voyager. Of course, it will go turbo. However, the original trans was a A520 - not exactly up to the task of the 2.5 Turbo. Jason also happened to have a 3.77 ratio large spline A523 from a '90's Shadow. We made it part of the deal. He also threw in the shifter and cables from the P-Body.

The wheels/tires that came on the van are obviously not staying. Plus, Jason wanted the rims back (partially in exchange for the trans). So, the first order of business was to find wheels and tires to put the van on. I found a cool set of rims on Craigslist again (for $100). And a set of tires on eBay. Total price for the wheels and tires was like $200 with mounting and balancing.

The first pic is a 'concept' pic that vntodd whipped up for me...

[ShelGame]

2nd order of business was to get the trans and shifter swapped over. I only have a couple of after pics of the A523 hanging in there. I didn't get any 'in-progress' pics...

[ShelGame]

I picked up a Turbo Mini harness from TD.com. It needed to be cleaned and re-tapped. That was about a half days worth of work. But, well worth it. I found a couple of frayed wires that I'm sure would've caused me fits if I hadn't fixed them before trying it in the van.

Working in the auto industry has it's perks. I have several rolls of 2 different kinds of actual production harness tape.

[Captain Chaos]

New tow rig for the Daytona. Looks good. Plus its a like a at track junk yard to rob parts in case of breakage.

[ShelGame]

I actually hope to be able to tow my little trailer with it. I think it will do it. The trailer by itself doesn't weigh but maybe 800lbs (open deck, just 2 rails for the tires).

[Captain Chaos]

I have several rolls of 2 different kinds of actual production harness tape.

I have a part number for some cloth electrical tape thats used on our Audi harnesses. Kind of pricey but nice stuff.

[ShelGame]

Of course, one of the main reasons I was able to talk my wife into this project was the fact that I have a garage full of spare parts - blocks, cranks, heads, pistons, rods. Really, just about everything this van was missing I had in the garage.

So, next on the agenda was to get an engine built for it. I looked at all of my stock bore 2.5 CB's and picked the one with the best looking bores. Since the bores looked pretty good, and since I had a set of used stock bore Mahles, I decided I was just going to hone/ring it. Again, I didn't get any in-progress pics. But, I just used a ball hone to clean up the cylinders. I then degreased and stripped the block in the driveway. And took it to the car wash and hit it with the pressure washer. I dried it off and oiled it up good while waiting to assemble it.

I then went thru my 2.5 cranks and picked the one with the best looking/stock sized journals. Turned out to be the crank that came out of the block I was already using (both bought at a swap meet the year before, the guy had told me they were from his minivan - ah, it was meant to be). I polished a couple of the journals with 2000 grit and oil just because of some dis-coloration. I cleaned and re-used the rods that came with the pistons.

I picked the best head that I had. Unfortunately, only half of the valve guides had the circlips. So, off it went to the machine shop for new guides. 3 weeks later (and $200 poorer) I got the head back with new guides and a fresh valve job. Since I got a good deal on PT lifters on eBay a while back, this head will be the first time for me to try them (the 2nd set will go in the Daytona for next season).

I also had decided that this will not be a stock-class legal van. So, it will get a Garret and an I/C. I traded Bigbrudda some cal work for a VNT I/C, and I bought/built a T1/T2 conversion turbo. For what I plan to use the van for, I think it will be more than adequate. It'll certainly be better than a Mitsu. Unfortunately, no pics of the head with the turbo/manifolds installed

[ShelGame]

I have a part number for some cloth electrical tape thats used on our Audi harnesses. Kind of pricey but nice stuff.

Mine were 'samples' from our electrical department.

[ShelGame]

While the head was out at the machine shop, I decided it would be a good time to tackle a couple of other things the van needed. I installed a walbro 255, put new rear shocks on it, and relined the head liner.

When I got the van from Jason, the headliner had been pulled down. It was just the backer board with some old nasty gooey foam on it. I bought some maroon headliner material on eBay for like $40 shipped (for reference, 3 yards is just enough to do a SWB van...). The color is not a good match at all to the original headliner, but it is a near perfect match to the color of the interior plastics. The only problem is the sun visors don't look right anymore. I have a little material left over that I'll use to try and cover the visors.

Al in all, this was a very rewarding part of the project. I had never done a headliner before (never done any kind of upholstery at all), so I was a little concerned. I think it came out very nice. It doesn't relly look factory-new, but it does look really good. Certainly 1000x better than gooey foam...

[ShelGame]

After I got the head back, I got the engine all assembled and last weekend, I put it in. My preferred method is to install the shortblock, then install starter, starter harness, P/S pump - basically all the stuff that's near impossible to get at with the head on. Then finally install the head complete with turbo and manifolds.

Again, no in-progress pics. I was too busy, and the camera batteries crapped out on me again.

Since this pic, I've got the engine timed and the timing belt installed, and the fuel hoses replaced. I still don't have the alternator harness cleaned up. So, that's next on the list. Also, the P-Body crossover shifter cable is WAY too tight. Jason was just by tonight to pick up his wheels and 520 trans. He dropped off a set of Daytona cables. So, I'll have to swap over the crossover cable before I get to much more installed. Then I have to mount up the old racing exhaust from the Daytona (it dumps to the ground right after the muffler - might be a little loud ) and then see if it starts. After that, I still need to fab up mounts for my rad/cond/intercooler combo. I'll make sure to take good pics of that as I think it will be pretty unique.

[ShelGame]

What the hell is a fuel pacer.Ive never seen that.Your van is in great shape!

The 'Fuel Pacer' was the upshift indicator they put on the TBI vans to help you get better fuel mileage - basically by short shifting...

[Sgt Craig]

The 'Fuel Pacer' was the upshift indicator they put on the TBI vans to help you get better fuel mileage - basically by short shifting...

Interesting.I guess now it be a good place for a high RPM shift light!

[ShelGame]

Interesting.I guess now it be a good place for a high RPM shift light!

I was thinking about using it for the knock indicator, actually.

[Sgt Craig]

I was thinking about using it for the knock indicator, actually.

Another good use.Ill keep on the lookout for one.Van is looking good!

[raccoon]

man i wish I had will power to do things, great work!!! van is going to be killer.

[DBB mini]

Nice progress.

[ShelGame]

I guess a little bit about future plans is in order.

I have a set of Daytona struts (only OEM style monroes, nothing special). And, I'd like to get the rear springs de-arched. And, at 140k, the van could use polybushings at all corners. I'd also like to add a rear swap bar. But, I think I've run out of time and money this fall. Maybe next spring.

Also, the van could really use some paint. It's just a van, so a stock re-paint is order. Probably a Maaco special. Maybe in the spring.

Though, this van will have a flashable computer and one of my USB cable setups. It will be a rolling laboratory for Turbonator. Something I've really been missing this year since I didn't take the race car out.

Finally, it will definitely get a reciever for towing the race car to events.

[blk86trbo]

Looks great Rob, thanks for sharing!