Jezza's SK410 Van Build

[jezzza]

Hi to those who still lurk on the forums!

Its sad how socials have made forums redundant these days. I find socials very hard to document a build/share it with others
So this is basically a way for me to document each step of my build for myself.. but enjoy anyways

A bit of history with my van:
I bought the van around 12-13 years ago just as a random purchase. The car sat around ~130k kms, now sitting on around ~184k kms
White, F10a with a 4 speed in pretty good nick! Only thing aftermarket it came with was a little sound system
Fast forward to 2021/2022, no real major work was done in between then and now, but the van needed some TLC due to some surface rust, scratches and dents

This is the list of work so far: (29/03/2022)
Engine and transmission
- Full transmission rebuild - new synchros, bearings, seals etc.
- New Exedy clutch
- Machined flywheel
- New transmission mount
- Engine machined, re-bore (slight oversize), decked
- New pistons, rings, gaskets, seals
- Carby rebuilt
- New radiator + hoses + thermostat
- New headers + exhasut (to be fabricated)
- New coolant and fuel lines where required

Suspension, brakes and wheels
- Lowered springs
- Lowered blocks
- New brake master cylinder
- Watanabe 13x6
- New black wheel nuts
- New black tyre valves

Interior
- Everything else painted black
- Black roof carpet
- Fabricated roof supports
- Black door carpet
- New interior light cover
- New wooden steering wheel and boss kit (doesnt fit!)
- New carbon fibre gear knob
- Leather seats fitting to factory rails
- Kicker speakers
- JVC headunit

External and body
- New headlights
- New taillights
- New sliding door window metal inserts + rubber
- Closed door respray in white
- Rust repaired and treated
- New windshield
- Tint all around

Late 2021, I decided to start repairing some of the surface rust and getting ready for paint

[jezzza]

Engine removal and clean up
The engine had been leaking coolant and some oil - when it was taken apart, the headgasket fell out in three pieces lol
Coolant had leaked into the bores

[jezzza]

Just some parts I purchased

The radiator I bought was supposedly for a SK410, but later found it isnt the same size. Apparently its from a ST90
The boss kit - SAAS BK134L also doesnt fit

[jezzza]

My roof lining was sagging, and I had the roof "popping" in when the wind pressure was too much. The roof supports were slightly kinked, so decided to fabricate some bigger and better ones!
Was a massive pain trying to remove the foam backing stuck to the roof
I used some high temp adhesive (130*c) to stick the roof lining on
I have to mention a big thanks to my wife who calmed me down and helped me glue the lining on! It was not a fun job...

[jezzza]

Fabricated a mount for the radiator to fit. It looks like the hoses should still fit *fingers crossed*
The inlet and outlet are a few cm to the passengers side. The stock shroud fits for now, but will need to make something custom to fit better
Im planning on make an air tunnel straight to the filter - hence the bracket design

[jezzza]

Mock up of seats (Hyundai i30) and steering wheel setup
The seats were fitted to stock rails. They sit higher than stock, which does feel a bit odd as you sit higher. But with the steering wheel + boss kit, the driving position is almost same distance as stock, just a little higher

[jezzza]

Van stripped and ready to go for paint!

[jezzza]

Engine machined and being rebuilt - the machinist didnt have a tool small enough to bore!
We ran into lots of issues with the rebuild kit I bought.. the bearings didnt seem to be standard
Had to buy piston and rings because of it being bored

Carrys massive clutch

Painted the rocker cover in wrinkle black - came out really well

[jezzza]

Some progress on the prep work of body ready for paint
The aerial got deleted and smoothed

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[jezzza]

Van painted! There are a few small areas which need a touch up, but painter said he is happy to take care of it later - only picked up some areas when I started assembling the van
Overall im happy with it

[jezzza]

Assembly of the van
How good do new headlights and taillights make the car look?!

[jezzza]

Decided to make the van a little more luxury with carpeting the floor and wall
Ill be making little custom floor mats as well

[jezzza]

Replaced the brake master cylinder due to leaking
I had to weld on a little tab for the proportioning valve <?> .. the blue thing. The overly expensive master cylinder didnt have the mounts for it
I didnt bother repainting the booster because its under the dash. and I was a bit concerned about overspray getting on the exterior of car

[jezzza]

My mirrors have deteriorated to a point of no return. I tried to refurbish them, but after sanding them I realise it jsut wasnt going to happen.
I purchased some retro style dome mirrors and will be installing them soon
Ive modelled up some mirror mounts and my bro in law 3d printed it for me

Modelled up wiper covers

[jezzza]

Putting back together the dash etc.

I refurbished the cluster plastic as was pretty scratched up. I used 1000/2000 grit wet sand, then sprayed over with clear - but failed!

I had to re-sand it down, repeat 1000/2000 sanding, and then polished with plasticx which came up way better