Lose Weight For More Action: Van Hack - 4-Wheel & Off-Road Magazine

131 1105 Lose Weight For More Action Van Hack Ford Econoline Van

Add a bumper, winch, big tires, running boards, a rollcage, dual batteries, recovery gear, toolbags, coolers, and spare parts to your 4x4 and you're ready to go, but you've also just given your drivetrain more work to move all that stuff over every obstacle on the trail. The argument about weight versus strength will never be decided, but if you don't think about weight when you're building your next 4x4 project then you may just be sending your truck Titanic-style to the bottom of every mud hole and hillclimb.

131 1105 Lose Weight For More Action Van Hack Van On Computerscales

We needed a cheap 4x4 to chop up for this study in off-road weight loss, and before we knew it we were dragging home Ivan the Off-Road Van. Ivan had lived a life of use down at the beach so rust was more than prevalent. Though it has four-wheel drive, it doesn't have low range and it's heavy (starting weight 6,002 pounds), thus it should really benefit from weight loss.

We needed a cheap 4x4 to chop up for this study in off-road weight loss, and before we kne

If you read our sister magazine Hot Rod you may have caught the story "Vette Hack" (Nov. '10), where they took a mid-'80s Corvette and cut it up just to show how a lighter vehicle can go faster around in circles. That got us thinking: If weight is an issue for going in circles, how does it affect our trail rigs that need to climb stuff, descend steep hills, and race over rough terrain? Thus Van Hack was born.

The goal was simple: Build a van into an average off-roader, then take it wheeling, and after every run cut off weight and see how it affects the ability. We sourced a set of heavy-duty Computerscales from Longacre Racing for the test and some tools from Harbor Freight. The rest was all for science.

Two Front Diffs?
If these photos have you scratching your head and wondering "WTF?" you're not alone. Ivan the Off-Road Van is as oddball as they come. The basic 1-ton '79 Ford van is nothing special, but underneath is an unusual three-output transfer case that sends power to the Dana 60 rear axle and two tiny front differentials that look to be Dana 30-size but in fact are a special Dana variant.

Developed by Dana back in the '70s, this V-drive system was designed to add four-wheel drive to vans, SUVs, and even station wagons, but none of the OEMs picked it up. A few entrepreneurs put together the Vehicle Engineering and Manufacturing Company (VEMCO) out of Fort Wayne and started doing 4x4 van conversions, but the company folded in the '80s.

131 1105 Lose Weight For More Action Van Hack V Drive Front Differential

The van has 3.50 ring-and-pinion gears, and the front differentials each run a spool, with the actual differential unit located in the transfer case. The worst part is the lack of low-range, requiring full-throttle launches up obstacles.

The V-drive system never really caught on, but if you ever come across one of these units (found in both Ford and GM vans) you can get parts for it from Burrel's Service in Keego Harbor, Michigan, 248.682.2376.

To make it realistic we added big knobby Boggers and a winch. The Boggers have the benefit that they make any vehicle look like an off-road superstar, as they are the epitome of aggressive tread. We wrapped the tall skinny 35x10.50R16 Interco tires around a set of Mickey Thompson 16-inch wheels we sourced through National Tire & Wheel.
To make it realistic we added big knobby Boggers and a winch. The Boggers have the benefit
The winch is an 8,000-pound Road Shock winch from Harbor Freight. This inexpensive winch combined with a winch mounting plate and the Boggers pushed the Longacre scales up to 6,196 pounds.
The winch is an 8,000-pound Road Shock winch from Harbor Freight. This inexpensive winch c
We welded the winch plate to the frame and cut off a bunch of metal with a Millermatic 211 MIG welder and a Miller Spectrum 375 plasma cutter. Then we pulled one of the bench seats from the back and trimmed the sheetmetal to clear the Boggers. We made it back to 5,965 pounds.
We welded the winch plate to the frame and cut off a bunch of metal with a Millermatic 211

We headed to our top-secret test facility (and pig hunting ranch) to begin the research. The van, in full glory with a full tank of gas (and a high-performance racing paintjob), weighed in at a hefty 6,035 pounds.
We headed to our top-secret test facility (and pig hunting ranch) to begin the research. T
The Longacre Computerscales work with four-wheel scales attached to a small digital display. We weighed the truck in the same spot after each reduction (weight-hack) on a section of hard-packed dirt road to get as close a comparison as possible. The readout shows each wheel's weight and the total, or percentage, of weight biased to front, rear, or side-to-side.
The Longacre Computerscales work with four-wheel scales attached to a small digital displa
Our opening run ended on the cable. Fat Ivan just didn't have the grunt to climb the first hill, and its diving board rear bumper stuffed in the dirt and stopped us from backing down.
Our opening run ended on the cable. Fat Ivan just didn't have the grunt to climb the first

Step one: Lose the back and passenger doors and the rear bumper. Again Harbor Freight came to the rescue with a giant drop tarp, 7hp generators, pry bars, a drill, and a reciprocating saw. Some people may think Harbor Freight's tools are cheap, but cheap doesn't mean junk. Sometimes cheap is just inexpensive. We're here to say the generator and saw got put through the paces on this science project and worked flawlessly (plus many issues of this magazine contain a 20 percent coupon in the Harbor Freight ad).
Step one: Lose the back and passenger doors and the rear bumper. Again Harbor Freight came
The van without doors was a healthy 5,700 pounds on the Longacre scales. We could definitely notice the dropped pounds. The first climb was now possible with a good run, and the second, steeper climb was accomplished with judicious pedal to the metal. Departure angle was greatly improved sans bumper, and visibility was a tad better.
The van without doors was a healthy 5,700 pounds on the Longacre scales. We could definite
At this point we learned of a new sheetmetal cutting tool, the double-bit axe. With a strong Viking swing, an axe will decimate body panels as quickly as a sharp Sawzall blade.
At this point we learned of a new sheetmetal cutting tool, the double-bit axe. With a stro

Back to the chopping, and now it was going to get ugly. This round lost the roof, driver's door, engine hood, and rearward sheetmetal. We also crawled underneath and buzzed off the exhaust in front of the cat and muffler. We're not sure if this helped engine performance, but it sure sounded better. The Longacre now read 5,351 pounds.
Back to the chopping, and now it was going to get ugly. This round lost the roof, driver's
At this weight the van came alive. The tired 351M V-8 was uncorked, the Boggers were hucking, and the van had slimmed down enough that our fear of snapping its little driveshaft joints was diminishing. To put it bluntly, Ivan was fun to drive. Climbs that before required momentum could be crawled, and rough riverbed speed runs were smoother with less sprung weight.
At this weight the van came alive. The tired 351M V-8 was uncorked, the Boggers were hucki
It was time for the final act of automotive surgery. Axes, prybars, saws, and hammers all came out as we hacked and whacked, the van down to a svelte 4,843 pounds-nearly 1,200 pounds off the initial weight.
It was time for the final act of automotive surgery. Axes, prybars, saws, and hammers all

With less that proper protection around us, helmets were donned as we headed for the test track.
With less that proper protection around us, helmets were donned as we headed for the test
The first hillclimb was a joke to our slim trim supervan. Ivan climbed it and then some with ease.
The first hillclimb was a joke to our slim trim supervan. Ivan climbed it and then some wi
Our new post-apocalyptic battlewagon was ready for nearly anything we threw at it. This clapped-out $400 surf van had been reborn into a family go-kart that rivals even the highest-dollar trophy truck when it comes to fun. By the end the van was far from safe, and we could feel the whole thing twisting as we worked through ditches and over obstacles, but visibility was sure great.
Our new post-apocalyptic battlewagon was ready for nearly anything we threw at it. This cl

The weight loss program taught us a lot. If your vehicle doesn't have a lot of power or gearing then you may want to remove parts, not add them. We're not saying go chop-crazy like we did, but maybe unbolt the doors, consider using thinner steel for your homebuilt bumpers, and ask your local 4x4 shop just how much weight those bigger wheels and tires would add to your ride. And finally it doesn't hurt to eat some veggies and slim down your own chubby belly. Every ounce counts.
The weight loss program taught us a lot. If your vehicle doesn't have a lot of power or ge
As for Ivan, he has taken a load off and he'll be living the good life from now on, whether taking the kinfolk to town for ice cream or hauling the boys through the woods on the next hunting trip. He's a happy healthy van now.
As for Ivan, he has taken a load off and he'll be living the good life from now on, whethe

SOURCES
Miller Electric 1635 W. Spencer Street Appleton WI 54912 920-734-9821 www.millerwelds.com	Longacre Racing N/A AK 800-423-3110 www.longacreracing.com
Mickey Thompson Tires & Wheels 4600 Prosper Drive Stow OH 44224 330-928-9092 www.mickeythompsontires.com	National Tire & Wheel Wheeling WV 800-847-3287 www.ntwonline.com
Harbor Freight 3491 Mission Oaks Blvd Camarillo CA 93011 800-444-3353 www.harborfreight.com	Interco Tire 2412 Abbeville Highway Rayne LA 70578 337-334-3814 www.intercotire.com