Rally Van Build (More Pics)

"Long_Voyager, Now With More Caravanny Goodness" (long-voyager-2nd-edition) 09/17/2019 at 06:18 • Filed to: Voyager, Engine Swaps, Off-Road, Mopar

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figured I’ll do a quick write up on my van’s journey.

This is the day I brought her home, roughly 6 years ago (parked next to our 95 SW):

It was in great shape other than needing a coat of paint (yay paint peel) and valve cover gaskets.

So I started in:

Started sanding her out, smoked out the lights, and had my friend airbrush a set of Spirit wheels I had painted to match:

I kept on with body work, getting everything prepped, then built the push bar and laid on the black:

With the black laid on, I finished prepping and pulled her in to finish the paint work:

Believe it or not, the paint was originally Ford Shadow Gray and Jet Black. We added Blue pearl to the clear coat, which completely changed both colors.

Then got my bar back on, cut down the roof rack cross bars, and painted it to match:

Then I (the wife actually) decided it needed a snorkel to complete the look. Not being one to have anything that isn’t functional, I set to building my Snorkel:

Made a “mold” out of hardware cloth, then wrapped it in parchment paper, and coated it with fiberglass (I will use fiberglass mesh instead of filler next time):

Snorkel was sorted out, so I got it mounted:

I don’t have a good pic of the intake, but it was routed like this, minus the cone filter:

I drove it like that for over a year, daily to work, out on weekends, beating on trails, etc when the transmission finally started acting up at 195k. I was going to have it built, but then I stumbled across this (107k original):

So I tore the driveline out, freshened it up with some newer top end parts (more power), mild porting, all new gaskets, and a new look:

With the drivetrain ready, I set to work tearing mine apart for the transplant:

Which also required swapping the complete engine bay harness (which we did not save from the donor):

Got the harness swapped and set to work installing the new drivetrain:

I completed the whole drivetrain swap in a day. I drove it to work Monday, took Tuesday off, drove it to work Wednesday!

Since then we’ve been enjoying driving it. It’s an absolute riot with it’s newfound power, while still being a perfectly reliable daily. I’ve been adding things here and there ever since, most recently adding lights:

I still have to rebuild my snorkel, as my old setup won’t work with the new drivetrain, but I already have a plan for that.

Started into rust repair this fall:

While I was at doing body work, I needed new tires, so I decided to get my wheels redone before having tires mounted:

I used this to get them stripped, worked like a dream:

Then I started laying down color:

Once they were dry I got my new tires mounted:

This is the current state of her for the winter.

Had a local shop do some dual exhaust for me, which took some sorting to get the sound right, but now it’s done and sounds perfect:

Also working on building a 2" lift after looking at her “lifted” at my friend’s garage:

So come spring I’ll be installing the Spacers I’ve designed/built for the front, adding a leaf+Spacer to the rear. Once the suspension is out of the way, I’ll be finishing up body work, then getting her resprayed.

1/14/19 Update:

Got ambitious last week while I was slow at work, so I designed and made up my strut spacers for my lift:

Then I ended up off Friday, so I decided it was the perfect time to dig into the lift. I started with the rear:

Got everything tore apart, then added 2" blocks:

I was planning on adding a leaf at this point too, but my springs are looking a little sketchy, so I decided on just getting new rears instead. Here it is with the rear all done:

Then I set into the front:

Got the strut out, compressed the spring so I could pull the top mount, then knocked out the studs and welded in longer bolts:

Got everything back together:

So far I like it, drove it around some this weekend and to work this morning. It’s a little tighter than it used to be, but not overly tight/harsh, I think I’ll be very happy with it.

Now with that done I just have to finish up sanding once it warms up and get her repainted.

Update:

Drove her most of the winter until a random oil issue caused my motor to let fly. So I picked up a different motor from MasterMario and went to work on that. I tore it down and checked all the tolerances, did some porting/polishing, then put it back together with all new seals/gaskets.

With the motor ready it was time to put it in:

With the new motor all in and sorted I set back into the body work I got cut off on last winter:

Got my bar all redone while it was off:

And I got the body completely ready for paint:

Now I’m working on getting my new hatch ready. I’ll hopefully be putting that on tonight. I plan on laying down the black for the 2-tone tomorrow night, weather permitting.

Update, Paint Done/Buffed:

Since the last update, I got her painted/wetsanded/buffed, got my basket reinstalled with custom fairing, and got my dash pieces done and reinstalled:

Now I just have to find a pair of rock sliders and finish rebuilding my snorkel and she’s complete.

More Pics:

themanwithsauce - has as many vehicles as job titles > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 07:51

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Lee Iacocca woke up this morning and smiled, despite not quite knowing why. Meanwhile, also in America, some glorious bastard is letting freedom ring with a rally inspired Plymouth Voyager.

MM54 > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 08:22

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Cool, looking forward to seeing what the future holds for the rally van

boredalways > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 08:42

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Wait, so is this Voyager one of the rare AWD models?

Either way, I salute you!

Long_Voyager, Now With More Caravanny Goodness > boredalways 01/08/2019 at 10:04

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No it isn’t, but the tire upgrade makes it pretty unstoppable anyway. Honestly the only times I’ve been stuck have been due to high centering, not from lack of traction.

I am however looking for an AWD model to swap the AWD parts onto mine so I can get stuck even further in than I should be....

Long_Voyager, Now With More Caravanny Goodness > MM54 01/08/2019 at 10:07

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As it stands now:

1. 2" lift with beefier rear suspension for towing when needed.

2. Fresh 2 tone paint, charcoal grey and black.

3. Rebuilding the snorkel to mate to the 3.8L.

In the future:

4. Possible AWD conversion if I can find an AWD donor.

5. 4.0L/6-speed swap for better parts availbility/more power/torque , or newer 3.8L top end swap for same reasons.

Akio Ohtori - RIP Oppo > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 10:33

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This is good oppo.

ITA97, now with more Jag @ opposite-lock.com > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 10:47

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This is great Oppo. 

boredalways > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 11:14

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dew eht!

i86hotdogs > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 11:31

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I was gonna ask how you were going to do an AWD conversion. F rom what I recall there is little to no tunnel for a transfer case and driveshaft to run through.

DipodomysDeserti > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 11:31

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There’s quite a few dead Wrangler 3.8s out there you could pull the heads off.

Long_Voyager, Now With More Caravanny Goodness > DipodomysDeserti 01/08/2019 at 12:04

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Quite a few dead 4th gen vans too.

I’d want the complete van, so I have all the parts I may need anyway.

From what I’ve researched thus far, it requires some rewiring, but it’s good for something like 250hp/300ft-lbs just by swapping the newer top end on the old style lower.

Long_Voyager, Now With More Caravanny Goodness > i86hotdogs 01/08/2019 at 12:05

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It’s basically a ladder frame underneath. They came factory with AWD, the only real changes were a different differential housing, adding a driveshaft, and the rear axle. Otherwise it’s just different exhaust routing from what I can see.

Long_Voyager, Now With More Caravanny Goodness > boredalways 01/08/2019 at 12:06

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I have a search saved, I check it weekly.

boredalways > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 14:05

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Good, because my Autotempest search was an utter failure 

Long_Voyager, Now With More Caravanny Goodness > boredalways 01/08/2019 at 14:34

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I’ve been looking for almost 2 yrs now, yet to have anything pop up locally, and I’m not willing to drive cross country for a donor.

DipodomysDeserti > Long_Voyager, Now With More Caravanny Goodness 01/08/2019 at 16:41

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What’s different about the old blocks? I have a 2011 Wrangler and it’s rated at around 200hp at the crank. Good amount of torque for an N/A (237 lb-ft), though.

Long_Voyager, Now With More Caravanny Goodness > DipodomysDeserti 01/09/2019 at 06:53

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The old engines ran domed heads with domed pistons, the newer engines run flat heads with flat top pistons.

Putting the new top end on the old bottom end nets something like 11.5:1 compression, which in turn nets more power/torque.

The van motors were also rated for more power/torque than the Wrangler from 01-07 where they made 215hp/245ft-lbs.

DipodomysDeserti > Long_Voyager, Now With More Caravanny Goodness 01/09/2019 at 08:29

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Gotcha. Good to know!

WilliamsSW > Long_Voyager, Now With More Caravanny Goodness 01/09/2019 at 10:16

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This thing is awesome, and it looks like it will be getting even better soon! Great work!

Long_Voyager, Now With More Caravanny Goodness > WilliamsSW 01/09/2019 at 10:17

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Thanks.

DipodomysDeserti > Long_Voyager, Now With More Caravanny Goodness 01/09/2019 at 10:42

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Also, I wonder if those pistons have something to do with the perceived reliability difference between the 3.8 in Jeeps vs vans.

Long_Voyager, Now With More Caravanny Goodness > DipodomysDeserti 01/09/2019 at 12:12

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The engines all changed in 1996, and again in 2001, so I would assume the van 3.8 and J eep 3.8 are the same internally.

benjrblant > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 07:15

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I really admire the work you’ve put into your projects. It’s impressive!

random001 > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 07:25

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GET LIFTED!

That is awesome!

HoustonRunner > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 09:04

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This is what makes Oppo great.  I have no real interest in the platform, but I look forward to your updates and read them thoroughly.  Great job on the van and write-up.

Wild > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 09:35

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Rsearch for my (slumbering) 92 woody project has led me to believe the awd rear subframe will lower the back 2 inches if you don’t use the awd springs, shocks ect.. also transmission or motor has an external flange diffenence (can’t remember which way) full pump and computer have different part listings. The trouble with the awd vans is the pinion gear for the awd goes bad and there made from unobtanium.

You're l lucky man. My spouse hates mine.

Hamtractor > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 09:59

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This is why I come here....

Long_Voyager, Now With More Caravanny Goodness > Wild 01/14/2019 at 10:03

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You have to use all the awd parts to make it work. The trans has a different diff housing.

From what I’ve gathered the awd setup has no issue handling major power/torque, it’s far more stout than the fwd setup.

My wife loves our vehicles by default, they’re cheap, so she’s in.

Long_Voyager, Now With More Caravanny Goodness > HoustonRunner 01/14/2019 at 10:04

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A lot of people don’t get it. I love them because they’re easy to modify, take mods well, and are cheap.

E92M3 > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 10:31

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Something’ s missing....

Oh there it is!

CarsofFortLangley - Oppo Forever > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 10:38

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What’s your next mod plans?  

Wild > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 11:12

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everyone smiles, old couples stop and hug each other, Gentlemen a generation older then me corner me at gas stations to reminisce and tell theyre stories. To me its an awesome mobile lazyboy that sometimes transports 4 kids. They have just become unpopular for the moment. I love mine. Everything was built and designed right. Last drive I got 24mpg from the old 240k 3.3.

I too plan on buying another complete unit (this would make a third because fuel rail, yep) to upgrade light to light. Though I worry about going too new because the security is integrated into the dash and I love the full digital display.

I was contemplating daytona struts and awd rear subframe to lower it 2 inches then add an airbag setup for MN snow days. They’re good fun projects, parts are cheap and there are a million available.

ITA97, now with more Jag @ opposite-lock.com > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 11:57

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This is what makes Oppo awesome. I don’t have to get it, but that you’re into to them and take the time to write em’ up and share it with us makes this place special .

Long_Voyager, Now With More Caravanny Goodness > Wild 01/14/2019 at 12:05

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With the 3.8L under the hood of mine it has enough to surprise a lot of people, plenty of power/torque to have fun.

The fuel rail is a simple repair kit or simple fix to take care of, mine failed a while back, I slapped the repair kit on and problem solved. I did pick up another rail to remove the leaky endcaps and replace them with elbows/high-pressure hose to fix the issue right, but I’ll save that for a later date.

I had Daytona struts on the front of this before I went off-road style with it, it was ok. Rode rougher than I would have liked, but it handled quite well. I had Daytona struts with the big sway bars and de-arched rear springs on my other van and it was amazing, tore up corners like no van should.

I enjoy all the attention and stories from people when I take it to shows, it gets a lot of attention and draws a lot of good conversation.

Long_Voyager, Now With More Caravanny Goodness > CarsofFortLangley - Oppo Forever 01/14/2019 at 12:11

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Find new shocks for the rear as they are now maxed for travel.

Paint this spring.

Rebuild s norkel.

Do more trail riding/camping/etc.

Drive/enjoy until something major fails.

3.8L top end swap or 4.0L/6-speed swap in the distant future.

CarsofFortLangley - Oppo Forever > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 12:13

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- drive to BC for PNW meet?

Lol

Long_Voyager, Now With More Caravanny Goodness > E92M3 01/14/2019 at 12:15

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No, no, no, those are too hard to mount up, this is the correct version:

The Ford M90 is way, waaaaay easier to adapt.

Long_Voyager, Now With More Caravanny Goodness > CarsofFortLangley - Oppo Forever 01/14/2019 at 12:17

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I don’t think a 27+hr drive is in the cards.

It would be a great time though.

Long_Voyager, Now With More Caravanny Goodness > ITA97, now with more Jag @ opposite-lock.com 01/14/2019 at 12:17

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Agreed.

Wild > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 12:27

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How does one cure the 1 inch or so “sag” in the roofline on the rear, and how much does altering spring arch cost? Mine are pretty flat

Long_Voyager, Now With More Caravanny Goodness > Wild 01/14/2019 at 12:32

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The sag comes from the springs de-arching over time, the only real fix is to install new springs.

IIRC it cost me $250 to have my rear springs de-arched, any spring shop should be able to do it.

Wild > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 12:52

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Sweet. Thanks for the info  man. Matching trailer is also on the someday list. Will need springs for that too.

MattHurting > Long_Voyager, Now With More Caravanny Goodness 01/14/2019 at 13:17

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You, sir, are a madman. I mean that as a compliment.

Long_Voyager, Now With More Caravanny Goodness > Wild 01/14/2019 at 14:23

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Not a problem, always happy to give insight to a fellow Mopar vanner.

Otto-the-Croatian-'Whoops my Volvo is a sedan' > Long_Voyager, Now With More Caravanny Goodness 01/16/2019 at 17:19

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Nice post, I enjoyed that.

What are the plans for repainting? All n ew color or just a refresh?

Long_Voyager, Now With More Caravanny Goodness > Otto-the-Croatian-'Whoops my Volvo is a sedan' 01/16/2019 at 17:23

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Charcoal Gray and Black 2 tone like it was supposed to be originally.

Debating whether or not I want to use Matte clear, but it’ll likely end up gloss.

Rainbow > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 08:04

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Goddamn, you've put more work into this than my entire family has put into any of our cars, ever. I'm impressed.

TheRealBicycleBuck > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 09:09

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I love updates, but I’m a bit disappointed in the way Kinja handles them. There’s no way for us to give additional stars when the post is moved forward in time as an update. I think a better way to do this is to create a new post, link to the original post , and add the new content. That gives us a chance to give additional kudos for work well done.

Long_Voyager, Now With More Caravanny Goodness > TheRealBicycleBuck 05/20/2019 at 10:03

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I can definitely start doing that!

Long_Voyager, Now With More Caravanny Goodness > Rainbow 05/20/2019 at 10:09

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I love it too much to part with it, so it will continue getting fixed/upgraded until the chassis rots out from under it.

VincentMalamute-Kim > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 10:56

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You have more time or energy than me. Probably the latter. Enjoyed the update - you inspire me to get off the internet and do something.

I was wondering how you find non-rusted away vans in Wisconsin.  Then I saw the rust repair pictures.  Good job with the repair but I have a sinking feeling about it.

Long_Voyager, Now With More Caravanny Goodness > VincentMalamute-Kim 05/20/2019 at 12:04

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Energy is key. I work 10 hr days and have a family, time is not something I have an abundance of.

Honestly, this body style is pretty easy to find in decent shape. The rockers and sliding door skin are the problem areas, both of which they actually make repair panels for. The rest of the van is pretty much spotless, it still has the factory undercoating on most of the bottom.

VincentMalamute-Kim > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 12:26

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I figured it was energy. I’m envious.

My 93 Caravan also rusted away along the entire upper wind shield / roof junction.  I caulked it.

Long_Voyager, Now With More Caravanny Goodness > VincentMalamute-Kim 05/20/2019 at 12:30

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Other than the rockers and a spot on my hatch, my van is clean. I figure it’s in great shape for a 25 yo WI vehicle with 245k on the body. I see much newer cars in much worse shape.

VincentMalamute-Kim > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 12:31

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It is in amazing (surprising ) shape for a WI car and for a Chrysler product. I think it’s you.

Long_Voyager, Now With More Caravanny Goodness > VincentMalamute-Kim 05/20/2019 at 12:44

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It had over 150k when we got it, at which it was totally rust free , so it’s not just me.

I like cars: Jim Spanfeller is one ugly motherfucker > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 15:01

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Look what I found at a junkyard last week:

with these sweet wheels:

Long_Voyager, Now With More Caravanny Goodness > I like cars: Jim Spanfeller is one ugly motherfucker 05/20/2019 at 15:32

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That van actually looks pretty decent?!?!

I like cars: Jim Spanfeller is one ugly motherfucker > Long_Voyager, Now With More Caravanny Goodness 05/20/2019 at 15:54

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I agree. I didn’t see much by way of body rust, but I didn’t poke around too much. I’ll likely be back there this weekend more likely than not. The interior was roached and I didn’t look under the hood.

Long_Voyager, Now With More Caravanny Goodness > I like cars: Jim Spanfeller is one ugly motherfucker 05/21/2019 at 07:09

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Why am I not surprised the inside was junk? Those T&C’s always seemed to go to hell, I think because people didn’t take care of the leather.

Going to bet it’s a 3.8L, where exactly is this at?

I like cars: Jim Spanfeller is one ugly motherfucker > Long_Voyager, Now With More Caravanny Goodness 05/21/2019 at 07:22

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It’s at Grade A Auto in Dayton, so,a little out of your way. They don’t post inventory online I don’t think.

Yeah, not taking care of interior, also not clesning after kids. We wrecked our T&C (1994) when I was a youngun. 

Long_Voyager, Now With More Caravanny Goodness > I like cars: Jim Spanfeller is one ugly motherfucker 05/21/2019 at 07:37

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Thankfully both of mine were taken good care of prior to me getting them. I take care of my stuff, so the inside of both of mine still look great. The vinyl on the driver’s seat side is finally starting to crack on my 94 after 245k mi of in and out.

Ya I think an 8 hr drive is outta the question when I don’t actually need anything.

I like cars: Jim Spanfeller is one ugly motherfucker > Long_Voyager, Now With More Caravanny Goodness 05/21/2019 at 08:53

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Yeah, it’d be a little excessive. But their inventory turns around super slow (and it’s a huge yard, bigger than any other I’ve been to. I had to walk ten minutes to get to the VWs) so if you had plans to come down this way for Midwest Oppo Rally, it may still be there. I don’t doubt you’ll need parts by the fall. I know I will.

Long_Voyager, Now With More Caravanny Goodness > I like cars: Jim Spanfeller is one ugly motherfucker 05/21/2019 at 10:07

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Guessing there’s not really anything on it I’d need. If the inside is that rough, I wouldn’t pull anything drivetrain related off it...

Rusty Vandura - www.tinyurl.com/keepoppo > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 09:33

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This seems like such an unlikely vehicle to do all of this to, but I admire your perseverance . So, you have a 3.3 in it now, again? Did you have to swap the wiring harness again?

How much power do you think you are making, versus how much power stock?

How harshly will you, do you, rally it? Like, exploring, or like having a co-driver and getting air from bumps?

Long_Voyager, Now With More Caravanny Goodness > Rusty Vandura - www.tinyurl.com/keepoppo 06/24/2019 at 10:11

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It is a 3.3L again. It was originally a 3.0, then I swapped in the 3.8L at 195k when my original trans was starting to slip. I did not have to swap anything other than the engine as the 3.8/3.3 use the same wiring. I may have to swap the ecm though as I’ve found out the 3.8L ecm shouldn’t even run the 3.3 ( despite the fact that I’ve been driving it like this for a couple months now ).

I would guess with the mods, maybe 170 hp/205 ft-lbs? Which is far less torque than my 3.8, which was around 175 hp/235 ft-lbs. The 3.0 that powered it originally was 141 hp/173 ft-lbs.

I’ve done a few random rally-x events. They were geared towards everyone, so they were pretty mild. Can’t say I’ve ever aired it off-road, but there are a few roads around that I’ve had tires off the ground. I generally do more “overland” style off-roading where we’re just taking crap trails to get to a hot-spot.

Rusty Vandura - www.tinyurl.com/keepoppo > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 10:35

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The whole thing blows my mind, using that car for anything but getting groceries or hauling a washer/dryer.

Long_Voyager, Now With More Caravanny Goodness > Rusty Vandura - www.tinyurl.com/keepoppo 06/24/2019 at 12:09

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Just adding the Grabber tires made it extremely capable off the beaten path. I wanted something smaller than the truck to take to our fishing spots, had the van, and thought “ why not?”, so I installed the Grabbers and gave it a shot. The limited slip setup is quite good, so between that and the tires, I’ve never been at a loss for traction. We regularly take it down trails that generally only get use by lifted 4x4s.

Back when it was still 3.8 powered I also took it down the strip just for fun. It laid down a 15.2 in the quarter on those Grabber ATs:

Rusty Vandura - www.tinyurl.com/keepoppo > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:27

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Limited slip?

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:30

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What a journey! Errrr... W hat a voyage, I should say.

Wonder what an SRT4 swap would set ya back?

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 12:35

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If I was going to swap anything other than a 3.3/3.8, it’d be either a boosted 3.0 or a 3.8L Mivec, either of which would blow an SRT4 out of the water for far less coin.

Or I could just boost the 3.3L, make around 300 hp/330ft-lbs, and still cost less.

Long_Voyager, Now With More Caravanny Goodness > Rusty Vandura - www.tinyurl.com/keepoppo 06/24/2019 at 12:36

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Differential. The Mopar unit is quite good stock, so long as you do blow out the shear pin.

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:36

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Sounds like a plan my good man!

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 12:39

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Sorry, I just get tired of the “SRT4 swap it” crap. The original drivetrains in these are easily capable of 300+ whp with loads of torque to boot, why would I pull that out for a smaller engine?

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:43

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Beats me. I had been erroneously advised that the, and I quote: “SRT4 can nevAr l0 s3 !!!!1!1!1!!!"

Seemed legit, but I’ll take your word on any and all matters Mopar. You know what's up.

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 12:47

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I feel it’s a “more money than brains” kinda swap.

The 3.0 can easily handle 3-500 whp on stock internals and fuel, and people have already discovered how to boost them for under $1k. The 3.3L uses almost the same ecm/fuel setup, so they can handle boost as well with little issue.

The 3.0 also has a lot of slop from factory that can be easily cleaned up to make quite a bit more power than stock for little to no money.

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:55

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500whp Voyager sounds about right to me! Even at 3, few would argue with it. Being able to do it on a reasonable budget, all the better! Sorry to rattle your cage. Your van rocks as-is.

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:56

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Loving it! Personally I think I have always liked the look of the Caravan front grill, rear taillights and headlights more than the Voyager. They look a bit....meatier...if that makes sense...?

Rusty Vandura - www.tinyurl.com/keepoppo > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 12:57

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Limited slip is not a term I associate with front-wheel drive vehicles.

gettingoldercarguy > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 13:14

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Any news on the engine development?

Boost or no?  LS swap?  I kid, I kid.

TheRealBicycleBuck > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 14:05

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“Now I just have to find a pair of rock sliders and finish rebuilding my snorkel and she’s complete.”

Yeah, right.

You were just complaining about the power, so I expect to see another engine-swap update sometime soon.  

Long_Voyager, Now With More Caravanny Goodness > TheRealBicycleBuck 06/24/2019 at 15:59

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I clearly meant the outside is done ;)

I’ve found out a few things about the engine, so hopefully I can get them sorted.

Long_Voyager, Now With More Caravanny Goodness > gettingoldercarguy 06/24/2019 at 16:10

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I was just planning on doing a post about it.

Here ya go: https://oppositelock.kinja.com/woes-found-some-things-1835816370

Long_Voyager, Now With More Caravanny Goodness > Rusty Vandura - www.tinyurl.com/keepoppo 06/24/2019 at 16:12

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FWDs have differentials too...

Long_Voyager, Now With More Caravanny Goodness > RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars 06/24/2019 at 16:13

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I like the Voyager nose better, IMO the Caravan is too bubb ly/plastic looking.

I like the Caravan tails better though.

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 16:16

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Even with my mild 3.8 she’d put down a 15.2 in the quarter on her Grabber ATs.

That was maybe 175-180 hp/230-240 ft-lbs. It really helps that they only weigh 3200lbs....

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 16:22

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Mod for down the road? :)

TheRealBicycleBuck > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 16:25

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I’d like to know more about your painting process. I’m thinking about using my trailer to dip my toes in those murky waters. It’s starting to get surface rust on the interior panels, especially the rear gate.

I figured a cheap gravity-feed blaster would be best for rust removal. I’ve just never painted with anything but a spray can. I think it’s time to put the compressor to use for something other than filling tires.

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 16:35

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That’s actually pretty quick. Not bad at all!

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 17:05

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It’s only .4 sec slower than the new STIs.......and only .3 sec slower than a FoST, so it’s extremely quick for a 90s van on off road tires...

Long_Voyager, Now With More Caravanny Goodness > RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars 06/24/2019 at 17:11

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I have some laying in the garage.

See I have a Caravan and a Voyager, so I can drive one or the other depending on my preference that day. ;)

This is what we'll show whenever you publish anything on Kinja: > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 17:17

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Slackens some jaws, I’m sure! 

Long_Voyager, Now With More Caravanny Goodness > TheRealBicycleBuck 06/24/2019 at 17:17

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Sand, prime/seal, lay base coat, lay clear coat. That’s pretty much the jist of it.

I have to do the Caravan yet this year, so if you’re local I’d be down for some “training”.

Long_Voyager, Now With More Caravanny Goodness > This is what we'll show whenever you publish anything on Kinja: 06/24/2019 at 17:18

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The look on people’s faces when an old minivan pulls away from them off a light is priceless!

David Baker > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 18:04

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I love the idea of the Pentastar/6 speed swap.  Has anyone figured out the electronics yet?

RallyDarkstrike - Fan of 2-cyl FIATs, Eastern Bloc & Kei cars > Long_Voyager, Now With More Caravanny Goodness 06/24/2019 at 18:52

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I approve of your choices! :P

TheRealBicycleBuck > Long_Voyager, Now With More Caravanny Goodness 06/25/2019 at 00:12

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You’re too far away for any training. I was really wondering more about your setup. What kind of gun are you using? What kind of paint? I can sand the snot out of just about anything. It’s the equipment setup that I’m wondering about. Will an inexpensive Harbor Freight spray gun do a decent job?

Long_Voyager, Now With More Caravanny Goodness > TheRealBicycleBuck 06/25/2019 at 06:58

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My gun is an old Devilbiss HVLP unit ( guessing it’s 30+ years old, was a gift to my dad from my uncle ), which is in need of replacement . I usually get my paint from Napa, I believe it’s Martin Seymour brand, but they do it in house. I always use base coat/clear coat, although I have sprayed their single stage with good results as well, I prefer the longevity of base coat/clear coat.

I have sprayed with Harbor Freight HVLP guns, in all honesty if you set them up right, they spray fine.

In all honesty, tuning the gun/air pressure so it sprays nicely is the hardest part to get a quality finish without runs.

I usually regulate down to 30-40 psi at the gun depending on conditions, run the gun wide open for paint flow, run the fan wide open, and go to town. I am used to production painting though, so I’m used to moving. For a beginner I would suggest turning the paint flow down until you get a feel for things.

Many people lay a lot of light coats of paint/clear, I usually lay one light coat for a base then spray for shine on each successive coat. It’s dangerous because you have a higher chance of runs, but it generally gives me a great looking paint job without the need for wet sanding/buffing after ( unless your dad mixes your clear coats and causes a massive reaction ).

Hopefully this gives you some idea.

Long_Voyager, Now With More Caravanny Goodness > David Baker 06/25/2019 at 07:02

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Not to my knowledge.

I would actually prefer the 4.0L/6-speed combo. It’s down on HP, but makes more torque over a wider rpm range, which in turn makes it a quicker more livable combo all around.

TheRealBicycleBuck > Long_Voyager, Now With More Caravanny Goodness 06/25/2019 at 08:49

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Excellent feedback! When I worked as a painter’s helper, my job was to hand-paint all of the gloss work (cabinets, trim, baseboards, etc.) and move the drop cloths as the painter painted. He used an airless gun with the feed in a five gallon bucket. We never taped anything and he was good enough to paint without cutting anything in, even ceilings around fixtures and ceiling fans. The guy was amazing with a paint gun, but I didn’t stay with the job long enough to learn the trade. I was more interested in going to college.