GLHS hybrid project, 10+yr build and counting

[GLHS320]

The cables came in a lot sooner than expected but the other parts that were supposed to be in today didn't make it. Today's progress took twice as long as it should have because nothing is bolt on. I bought these cables from a name brand aftermarket company and had to modify to get them to work. The springs were too long so was the compression clips.





This is how it looks after I cut the spring and holding clip.



Then the adjusting screws wouldn't fit on the e-brake shoes and had to widen them with my cut off wheel.

[IMG][/IMG]

Here's the finished product with what I have for parts. Hopefully the rest comes in tomorrow so I can work on it over the weekend.

[2.216VTurbo]

By any chance are you keeping track of your labor hours invested? Nah, I wouldn't either Gonna be one Clean S car

[Reaper1]

I have run into the "too long of a spring" issue on the parking brake cables before...when I converted my '90 Daytona to rear discs the factory ones were too long and even with correct adjustment did not engage the parking brake. I snipped them just like what you did and it worked fine.

[GLHS320]

By any chance are you keeping track of your labor hours invested? Nah, I wouldn't either Gonna be one Clean S car

I didn't, If I did it would have been embarrassing. I can say I have over 40hrs in the intake not including the welders time and over 8 hrs total in the valve cover. The cover includes grinding off some of the letters,media blasting it twice, making a jig to fit it in the oven, polishing what numbers were left and 1 1/2hrs to outgass it before I powder coated it.

The rear trailing section is taking longer than I expected but it doesn't help when you're a little ocd on making everything look a nice a possible. On a side note I'm impressed with the durability of the Chassis Saver paint on the bolt head's. The down side is it's a time consuming process. The rest of the parts came in yesterday and just have to go out today to find some adapter fittings for the master cylinder.

[GLHS320]

Installed the rear calipers, glad I painted the spindles or it would have stuck out like a sore thumb with the rust.







I hit the intermediate cable with a wire wheel under the car and painted it so it blends with the rest.



The sending unit had more rust on it than I thought so I cleaned it up and painted it with Chassis Saver. While I was at it I took a few more parts off the rear section and painted them. It never ends...

[Johnny]

Simply amazing!

[tryingbe]

Project looks great!

Is the fuel sock used. If so, I'd change it.

[GLHS320]

Simply amazing!

Thank you. The pictures make it look better than it really is but it should be decent.

[GLHS320]

Project looks great!

Is the fuel sock used. If so, I'd change it.

The sock doe's look scary but I'm only using the sending unit to plug the whole and for the fuel gauge. This is the pump I'll be running with a filter before and after.

[GLHS320]

If it wasn't for the Tapatalk app and my smartphone posting would be very little. It saves a ton of time.

Bought rebuilt Caravan 60mm calipers. Being in the automotive parts business for so long I've always wondered what a new reman caliper looks like on the inside. Do they really clean them and do a quality job. I ended up with calipers from two different manufacturers one of which has been out of business for a few years. They both media blast the piston bore and was surprised to see the piston seal on one was seated maybe half way. That was the company that closed. I ended up chasing all the threads on both because one of the bleeder screws was pretty tight and seems like they don't clean the threads unless they need to.







This is the one where the seal wasn't seated all the way before I used my shop air to get the piston out.




I smoothed them a little with a 4 1/2 grinder with sanding flapper wheel. I wasn't going to get crazy, this took long enough and just wanted it a little better.



Media blasted them.





Outgassed them for an hour in the oven to burn off any oil contained on the casting. Cleaned and coated with high temperature powder. Now I have to assembly them with the rebuild kits I bought.

[GLHS320]

Work was crazy this week and made little progress. Installed the fuel sending unit, plugged the vent hole on the top of the tank and made a new mat out of rubber for the top of the tank. The old one was tore up on removal.







Installed the tank and filler neck then ran into problems on other suspension components that might cause a delay in getting it back together. I thought what I bought was different than what it is now I'm looking into something different.









There's a few things I still can do but I need to figure out what I want to do with the suspension so I can get it ordered. The braided brake lines for the calipers didn't make it in as expected but that ended up being a good thing. Our regional tool & equipment rep rode with me the other day and had the latest and greatest brake line flaring tool. He knows I'm over the top with tools so they're sending me a demo to show-sell to the customer's and see of they want to roll it out to the company. This is an industry exclusive that I expect will sell extremely well in the rust belt regions. I'll post pictures and a review next week after I play with it

[GLHS320]

Finished assembling the power coated 60mm front calipers.







I noticed the caliper brackets I bought on eBay don't match the calipers or brake pads I bought. The calipers and pads are for a 1989 Dodge Caravan with single pin 60mm piston calipers. Does anyone have the correct brackets they want to sell me or able to tell me what these brackets go to? I can use a lifeline on this so I don't waste time researching it instead of getting this done.















The bracket is about 1/8" to big. Any suggestions will help. Thank you.

[GLHS320]

A few more shots if it will help.

[cordes]

What knuckles are you using? Which "vehicle" did you get the pads for?

[GLHS320]

They're the original Glhs knuckles. The pads and calipers are for a 89 Caravan the caliper brackets I bought on eBay was supposed to be for a Caravan but it's about 1/8" too narrow.

[cordes]

I don't have a definite answer for this one. I know that the later big brake calipers (R/Ts) are different than the ones that came on the earlier big brake cars like the 89 TII cars. They can't be interchanged. I know there is a difference in the pads for each version and they can't be interchanged either. I can only assume you have some mix up of the two styles.

[GLHS320]

One huge advantage with my job is I have full access to our parts catalog as well as other vendors on my company laptop. Spent some time this morning doing some research and seems the caliper bracket is for a 54mm single pin caliper. I found a member that had the correct brackets and bought them. Here's a few pictures to show what I ran into. The bracket is about 1/8" to small.

[GLHS320]

Found the correct caliper brackets from Ajakeski, great seller had them in the mail Monday morning and only took a few days to get them.



I didn't like the way the e-brake brackets came out with the rust craters.



Blasted them and then cleaned them up better.



Powder coated them again.



The caliper hoses came in from FWD and got a little creative with the hose brackets I received with the rear brake set up I bought on eBay. This picture was the mock up to make sure it would work.





Black oxided the bolts, powder coated the hose brackets to match the trailing arm and ran the brake line.









Here's the the FlareForce brake & fuel line flaring tool. It takes less than 10sec to do a double flare. This thing is amazing.







Installed the trailing arm brackets.

[Wastelands Warrior]

Quite an awesome job of engineering.

[Johnny]

You have had that bushing kit a LONG time!