'99 Chevy Astro Van build thread ~ Goal 30 mpg

[ChopStix]

'99 Chevy Astro Van ~ Goal 30 mpg highway

So in order to show progress from stock to aero mods I reset my van back to stock form in my "winter tires" fuel log. It shows basically the EPA mileage measured over numerous tanks of gas. Then the fuel logs progress to show ever increasing mpg ratings as mods are applied. Those fuel logs are based on the entries below. Progress steps are dated and lists the mods applied, etc. However in reading this you have to remember that I measured these first 2 fuel logs with the van loaded while using it in work conditions. This is why my best mpg is very different than my "Kumho Sense" fuel log. Empty van verses loaded van. So when I log my empty van mpg later on, the numbers will shoot way up by comparison.

02/01/16
I removed the roof rack which turned out to be worth 1 mpg towards my goal. I saw this same result using both the Winterforce tires and the Kumho tires.

02/25/2016
I picked up a couple mods towards my goal of 30 mpg highway out of my old van. I got an electric fan conversion which has been claimed to be worth a couple mpg. I also purchased a set of Jet power pulleys to slow my accessories which has also been claimed to be worth a couple mpg. But I want to test some aero mods before installing them.

03/25/2016
205/75R15 Kumho Sense tires. Which is a narrower size, low rolling resistance spec, and lighter weight tire than stock. I also picked up a set of 15x7 steel rally wheels, and a set of chrome moon hub caps. These steel wheels and tires weigh 10lbs less each over my winter tires on the factory aluminum wheels.

04/04/2016
Winter tires on stock wheels:



04/04/2016
Summer tires on lite weight wheels:



So thus far the results speak for themselves. As shown in my Kumho Sense fuel log, the wheels, tires, and roof rack removal equaled a solid 5 MPG gain from my Winterforce fuel log. However this new setup has not equaled my previous best measured MPG when empty. As remember we are comparing a loaded van mileage to an empty vans mileage in this fuel log.

On the tire subject I suppose the claimed .7 inch smaller diameter difference is a culprit of why the mileage has not been equal to my previous measurements. Well that and the fact that my old tires were worn out. But I used an online RPM calculator and it says I gained roughly 200 RPM's from the slightly shorter tire at interstate speeds. So obviously this a tiny step backwards. Well at least until these tires wear down which always helps with mileage gains.

Summary:
Specter Reusable Air Filter
Synthetic Oil
Stock Computer W/Low Altitude Program
Roof Rack Removal
Lite Weight Rally Wheels
LRR Skinny Tires
Moon Hub Caps
= 32% over EPA, or gained 5 mpg!

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'99 Chevy Astro Van build thread

[ChopStix]

Ok change of format. From this point on I will be measuring the fuel logs with the van empty unless defined otherwise on the fuel logs individual entry's. So I created a new fuel log "Aero Mods" to track these changes.


05/22/16
I designed some spats for my van today. This picture shows what I'm hoping to accomplish with out increasing my frontal area.



06/10/16
I got the chin spoiler installed and the spats installed. I still have one more front filler panel to install. After a couple days for the spoiler to get used to being mounted in that shape, I fixed the warped upper edge. I upped the Kumho tires to 50 PSI, which is higher than the side wall advised. The rolling resistance was significantly reduced, with no tire wear effect.





06/13/16
Today it was suppose to rain, they got that one wrong again! (-lol)
I took the opportunity to make some rear bumper filler panels. Since I have many feet of lawn edging left over I cut a couple rectangles and Z bent them in my brake, then taped them on.

Before:


After:


You guys should consider buying one of these cutters which is made for cutting plastic plumbing pipe. It works amazing for cutting lawn edging, etc.





'99 Chevy Astro Van build thread

[ChopStix]

I have (more or less) sold this van. The guy is still making payments, or he claims to be..... Anyway it dawned on me that I didn't post all the pic's of this project, plus I have a few more to move over and post.

Back when I made the side skirts and spats.




Installed


Rear Spats





'99 Chevy Astro Van build thread

[ChopStix]

reserved for future updates

[ChopStix]

This post is reserved for future updates.

[ChopStix]

Here's a list of available mods for Chevy Astro Vans, 1996-2005 4.3L ENGINE.
All information I believe to be correct.
If in doubt, always contact manufacturer. Use at own risk.


AIR FILTER OEM REPLACEMENTS
1) Holley Powershot,#221-1
2) K&N Filtercharger, #33-2225
3) Jet Performance, #4122
4) Accel Kool Blue, #KP2348


AIR INTAKE KITS
1) Volant, #25743
2) JET Performance, #63290


MASS AIR FLOW SENSOR
1) Granatelli, #350116 (normal intake)
2) Granatelli, #350116C (aftermarket intake)


Throttle Body Spacer
1) Jet #62107
2) Transdapt #2564


COMPUTER REPROGRAMMING
1) Jet Power Control Module | Stage 1 #20015
2) Jet Power Control Module | Stage 2 #20015S
3) Jet Performance Programmer #15024
1) Hypertech PP3, #390202 (1996-1999) #360202
2) Hypertech PP3, #30001 (2000) #30024
3) Hypertech PP3, #30008 (2001) #30023
4) Hypertech PP3, #30012 (2002) #30012
5) Hypertech PP3, #30019 (2003) #30019
6) Hypertech PP3, #30022 (2004-2005)
7) Jet Performance, #2004 (stage 1)
8) Jet Performance, #2004S (stage 2)
9) Superchips GM Max Tuner, #2565 (98-00), #2575 (01-02)


THERMOSTATS
1) Hypertec 160 temp, #1013
2) Jet Performance 180 temp, #10171
3) Duralast 195 temp, #15119
4) Stant 195 temp, #45119


IGNITION ITEMS MSD
1) 6 Series, #6420 (6AL)
2) Wires, #32389 (98-00), #31649 (90-97)
3) Coil, #8231


IGNITION ITEMS ACCEL
1) Truck tune-up kit, #TST-1 (includes plugs, cap, rotor, wires – 9000 series)
2) Wires, #9044
3) Coil, #140024
4) Cap, #120142
5) Rotor, #130141


EGR MOD FROM MDW PERFORMANCE
1) EGR Restrictor Plates, #10GM9602, $74.99
2) EGR Restrictor, #44GM9602, $48.99


INLET AIR TEMPERATURE SENSOR RELOCATOR/ SIMULATOR
1)Jet Performance, #61620
2) Radio Shack Resistor 4.7K Ohm, #271-1330


THROTTLE POSITION SENSOR CONTROLLER
1) Casper's Electronics, #102017


SUPERCHARGING
1) Powerdyne, #K10526-101


UNDERDRIVE PULLEYS
1) March, #4460 (2pc)
2) ASP, #841001 (2pc), #841051 (3pc)
3) JET Performance, #90105 (2pc)
belt for Jet pulleys - 060935


ROCKER ARMS
1) SLP Engineering 1.6, self align type


SHOCKS/ SUSPENSION
1) Edelbrock IAS, AWD (1995-2005) – Front #3303, Rear #3438
2WD (1985-2005) – Front #3338, Rear #3438

2) Bilstein B6 Performance Series Shocks Front (1985-2005) 2WD #24-011044
Rear (1985-2005) 2WD and AWD #24-010474


EXHAUST SYSTEMS
1) Gibson, Dual Sport, #5607 (Aluminized), #65607 (Stainless)(2000-2005)
2) Gibson, Extreme Dual Sport, #5609 (Aluminized), #65609 (Stainless)(2000-2005)
3) Gibson, Split Rear, #5608 (Aluminized), #65608 (Stainless)(2000-2005)
4) Gibson, Swept-Side, #315560 (Aluminized), #615560 (Stainless)(2000-2005)
5) Gibson, Swept-Side #315500 (Aluminized), #615500 (Stainless)(1996-1999)
6) Gibson, Swept-Side, #315553 (Aluminized), #615553 (Stainless)(1995)


INTERIOR ACCESSORIES
1) Autometer Gauge Pods, #15123 (Single, A-Pillar for 2-1/16” gauge), #15122 (Dual, A-Pillar for 2-1/16” gauge)(1996-2005)


EXTERIOR ACCESSORIES
1) Lebra, Hood Protector, #45111-01
2) Lebra, Front End Mask, #55535-01
3) Auto Ventshade (AVS), Ventvisor (Plastic), 92006
4) Auto Ventshade (AVS), Ventshade (Metal), 12215 (Stainless) and 32015 (Black)
5) Auto Ventshade (AVS), AeroVisor (Plastic, wider at mirror area), #95015
6) AVS, Bugflector (coverage stops at ends of hood), #22001 (Smoke) or 22001-C (Clear)
7) AVS, Bugflector II (coverage wraps around corners of fenders), #24616 (Smoke) or 24616-C (Clear)
8) AVS, Headlight Covers, #41535 (4 light – 4 piece)
9) Kleen Wheels, Brake Dust Covers, #1507 (15”-5 spoke wheels, stock)
10) APC, Clear Taillights, #404113TLR (1985-2005)
11) APC, Diamond Headlights, #403662HLD (1995-2005, composite style)
12) IPCW, Clear Taillights, #CWTCE314C (1985-2005)
13) IPCW, Diamond Headlight Corners, #CWCCE19 (1995-2005)
14) IPCW, Projector Headlights, #CWCCE20 (1995-2005)


GAS CAP
1) Stant, #10836
1) Stant Locking, #10506


BELLTECH SUSPENSION LOWERING KITS
1) 3.0 Front, 3.5 Rear, #770SP
2) 2.0 Front, 3.5 Rear, #768SP
3) 2.5 Front, 3.5 Rear, #769SP
4) 2.5 Front, 2.5 Rear, #772SP


REESE MULTI-FIT RECEIVER HITCHES
1) Class I/II 1 1/4" square #88001
2) Class I/II 1 1/4" square Invisi-Hitch #06227
3) Class III 2" #51029
4) Class III/IV 2" #37152
5) Class III/IV Premium 2" #37042
6) Class III/IV Professional 2" #44010

[Natalya]

Plan to do ABA testing on any of these mods?

[ChopStix]

I'm a total newb at this eco modding thing. So I would not trust my results in that kind of testing. My plan is to copy the mods of others to see some results as this is more about personal curiosity and learning over setting some kind of standard for aero mods on brick shaped vehicles. Because in my time of messing with hotrods I never gave any thought to aerodynamics. It was always about HP over MPG.

I've not seen many brick shaped vehicles displayed step by step on this forum going from no mods, to numerous mods with fuel logs broken down in stages. So that is what I'm trying to do. Maybe I won't get the most gains possible from no serious testing. But I know certain things work due to numerous people using them. And that is the angle that I am playing with my choice in mods to try.

[oil pan 4]

Low temperature thermostat will lower fuel economy and increase engine wear.
EGR restrictor will likely lower fuel economy.
Cold air intake will also lower fuel economy.
Air intake temperature simulators are guaranteed to lower fuel economy, they trick the engine into believing the air is cooler than it really is, encouraging the ECU to add more fuel.

[ChopStix]

Originally Posted by oil pan 4

Low temperature will lower fuel economy and increase engine wear. EGR restrictor will likely lower fuel economy. Cold air intake will also lower fuel economy. Air intake temperature simulators are guaranteed to lower fuel economy, they trick the engine into believing the air is cooler than it really is, encouraging the ECU to add more fuel.

Its a parts availability resource, not a parts suggestion. And its a work in progress so I'll be adding more info as free time allows.