Build-A-Better VAN GMC Safari AWD Part 1 

The only problem I can see with stuffing fiber insulation in the doors is now they will collect and retain moisture. Insulation in the lower panels is why a lot of trucks and vans rust out in the first place. If you ever looked in the cab corner on a early 2000’s Chevrolet Silverado you know what I mean. These trucks are rust magnets. I would never put anything it’s going to obstruct the drain holes in the doors or body. Instead I would concentrate on putting insulation on the inside panels of the doors themselves and leave the doors open. Give the inside of the doors a good coat of fluid film and let that stuff soak in to help prevent rust. I’ve been using this trick and inside of the panels on my 2006 Silverado and that has done the trick so far. Even if you don’t live in the Rust Belt this is important to at least leave those drain holes open. I can really appreciate the care and meticulous thought that you put into this van.

Those guys who built that roof rack did a lot of work to get it like that. Cheers to them

Wow. I'm a girl who checks out these videos for future van life...usually the hominess of the builds is what interests me...But this was SUCH a good video showing what else can be done. This must have cost quite a bit overall(?)...But I guess, good to have those special friends who know what they're doing! Gorgeous job!

Having had a ton of vans and having converted two tons the insulation makes a big difference. What you chose is now going to start to rot your doors from the inside out since any heat or cold inside will condense and then that rock wool or whatever will hold the moisture. You should have put adhesive sound deadener on first then just used a closed cell sheet foam or spray foam making sure the drain holes in the bottom of the doors are clear.

Good on you I put a 4.8 a 233 tranver case lift kit and off road ties i made my awd have low range and free wheel hubs keep Vining bro

This is madness!!! Your van looks amazing!! Have a great time with it! I took some notes as I will be converting my Astro van as well!

I have a GMC Safari cargo and use it every day. So good to see someone else love these vans as I do. A little money makes a huge difference. I also picked up an AWD Astro and got it for parts, but it runs so good, I am going to restore it as a backup for my GMC.

Love the colors/textures/simplicity...also AWD is a nice feature for boondocking plus all weather driving ANYWHERE. At 100,000 miles, these type of vans go easily to 250-300,000 miles all day long...so the entry level makes sense..not too pricey and still lots of life left. Very smart, understated, it inspires my build. You can easily change the interior without structural difficulty. I happen to be CRAZY about having a hot shower in the desert and would design a solar thermal tank integral to that rack and a shower head at the rear or side. That rack invites a lot of opportunity for experiment. Well done. Thanks! I would play a Steely Dan tune..(but then I am an old dude)..:)

As someone who built a Sportsmobile-knockoff Ford Econoline (LWB) 4x4 and did extensive travel in Baja California, two things I learned based on that build which I'll make likely apply to my next setup: solar just isn't as practical as it seems and just know that if you drill holes in the roof, it absolutely will leak. Water always wins. Would be extremely interesting to compare notes with you after a couple of years have gone by. (you can see some videos of my van on my channel)

I also have an Astro van and a 2000 GMC Safari I really like what you did your van looks really good bro congratulations

A friend of mine sent me a picture of a GMC Safari Van parked at a Trader Joes. I responded, I have seen that van on RU-vid. That video gave me the idea to install the GMC cargo van grill on my 2000 Astro. small world.

Sweet build. I did an astro van myself. 20mpg AWD and the Vortec v-6 is very powerful. Great vans

Nice looking van, I like what you did with it. There's just something about a small van.

I bought a 1995 Astro Van a month ago for a project, the ladder, racking top, the fan, and the rubber spray in a great idea. Thanks. Your GMC is 🔥 good team.

Those vortex v6 engines have been known to go 300k without issue.

Great build! That roof rack is definitely next level. I like that this is so stealth- I want to do one in basic white just like this so it looks like a basic work van from the outside when I’m urban camping

I had an AWD Safari and loved it. One thing you should know that might help you at some point. On a road trip I had a CV joint go out on the front drive shaft. Took the shaft out and drove home in 2wd. Here’s the thing to remember..... Park wont hold as it uses the front wheel part for that so remember to set your parking brake.... Oh, you can have a custom shaft made cheaper than you can buy a stock one from GM.

Just bought a 99 Chevy Astro. Can’t wait to build it through

I had a AWD Astro. Best factory 4x4 van built. I took mine out on low tide thru the channels on the Pacific, and up steep hills in the snow. Made the kids sledding have to wait for me. LOL!

Nicely done I've always wanted a 1986-93 Gmc Safari or Chevy Astro Van earlier models

my 03' Astro with 127k well cared for miles without warning developed a high oil pressure problem blowing the oil filter gasket and then immediately shaved an engine rod bearing. I hope that you have better luck with that Vortec V-6. But hey I was lucky enough to be a GM employee that with my discount brought the cost of a GM rebuilt crate engine down to the low low cost of just $2,400 and labor is only $2k. I love my beautiful southern rust free raised roof Astro conversion van. P O S. A very rare problem I had indeed,yet it did occur. Evidently a pressure relief valve in the oil pump failed. A new oil pump is a relative easy job for a DIYr and total only about a 100 bucks for pump n gaskets. Ya might want to consider. Good vid, good job,looks great sir. thumbs up

You put a lot of time, effort, and resources into this. My favorite part has to be the rack, MAN that thing looks beefy!

That rhino lined paint job makes the van! Love it!

Very thoughtful and intelligent build. Like the roof rack platform especially! Happy trails!

Dude, that's so frickin awesome! I have a 2001 safari and I love it. Imma painter and its perfect. Ladder racks, shelves in the back and everything . I live in the bay area and I could totally live in the back of it especially if I had the skills you do which I dont. Either way, very cool.

Great build. I just bought myv4th Astro this week. It is my first AWD, though.

Nice build! 👍🏻 I have 2 of those fans in my RV, moves a tremendous out of air 👍🏻

that roof setup is exactly the setup im going for

i had an Astro a while back and had to sell it to help out my family and finally found another one in good shape and low mileage being a 2000 it still needs lots of small things that add up quick but as long as it runs i can throw $200 a week into it but since i got it i have done the ignition control module, distributor cap and rotor, I am doing the plugs and wires this week and next week i will do the brakes and the week after that the suspension, next will be the wiring for the gauge cluster which has my gas gauge broken, then the turn signal switch and wires, then finally something fun, some custom exhaust! probably going to have to adress the passenger side window motor soon also lol its small stuff nothing bug like an engine and transmission but holey moley the never ending list of little things gets overwhelming quick

great project and great result, only issue with the video is the audio keeps going in and out, so miss alot of commentary, but over all awesome job, i love these vans and think chevy did a real disservice to its customers by dis continuing the line

This rig is freaking gorgeous. Excellent job brother

I'm looking into buying an Astro for work and life in general, this setup fits both criteria wonderful. Your Van belongs to a museum.

What a beauty! Thanks for the details and ideas.

I watch a lot of this kind of videos this is definitely my fav build out there.

Dude, I love it. Bad ass. Super simple and at the same time super functional in so many ways. Well done.

love the minimalistic style!

I counted 4 times where you cut the mic off in the middle of the sentence, and I wasn't paying close attention. Something wrong with the recording software?

looking forward to seeing how you evolve

I wasn’t a fan off rhino lined paint jobs, but I got to say it looks good when done right!

Love it! from a Safari owner.

That looks amazing! I’m still day dreaming about building one.

The coolest van build I've seen yet! Well done dude!

Thanks for this video! I really enjoy hearing your reasoning and intentions behind the build.

Awesome! Thanks for sharing.

I do hope you get a good alarm system to protect this baby! I mean she is nice, I would get a good page alert + noise maker to ward off any sort of break in. Sayer you did a great job here. best of luck to you and your good times to come!

You are number 1 my friend the best van build that I ever saw, just incredible

Beautiful rebuild. Thanks for sharing. I love the roof rack.

Generally, I don't care for the bedliner look as folks try to hide imperfections with it. Yours looked pretty damned sweet though. Nice prep work. 👍

looks awesome. great job

I like these old GM vans because these engines will last forever

Makes me wish I still had my '98 AWD Astro. Really awesome, sir. Very impressed. Probably my favorite one yet.

This van build is identical to the drawings I've made up for my 2001 safari. I was having trouble deciding if I wanted a roof rack or panels installed on top and I love the way you've incorporated both. I've recently decided I cannot continue my build without the help of a carpenter. If you have any schematic drawings, or a material list you used for this van please give me a shout!! I travel a lot for work, and although the super 8's I usually stay in are nice, I want a space I can call my own anywhere I may end up.

Nice we have a Chevy Astro Cargo Van awesome Rigs

Rad build! I plan on doing something very similar to a 2006 awd sienna

wow ,must to be really nice have a talent to make something like that. Really nice

I like your editing your video on the transfer case straight to the point good content good camera angles can’t wait to watch all your videos new subscriber

What a great build so far! exterior is super finish. Rich

That was a good video, try to make another one so you don't leave the viewers hanging

Great job on the build! Looks real clean!

To others watching, that insulation will cause mold and rust. It is perfect food for mold, an unlimited buffet with perfect conditions for growth, just add a tiny bit of moisture. Unfortunately, there are very few insulation options that are not food for mold. ANYTHING organic is food for mold. Wood, cotton, even the paper on fiberglass batting.

Awesome build! Looks great!

GREAT BUILD! WITH THAT DO ALL SHOP, MAYBE YOU ARE "THAT GUY" THAT SHOULD BE FABRICATING ROOF RACKS, FRONT AND BACK BUMPERS? I'M TOO OLD TO START A BUSINESS THAT INTENSE. ENJOYED THE VIDEO, GOOD STUFF!

Dynamat Extreme the both outside AND inner door skin sheet metal, before insulating with sheep wool. Relextik is not effective, as well.

I found one with 160k 2002 for $800 I'm going to try and get it

Looks great dude. My teardrop trailer is rhino-lined black and looks cool. I like your choice of van. Nicely done.

I went to a local salvage yard for my 97' and was astonished as to how many Astros are lined up, given up on way too early.

Exactly what I want in my e150. A work van/camper

I like how you didn’t put music in your video and the van is sick !!

Why don't my astro look like this all I got is a usb fan and a pillow.

Verrrrry nice. Can't wait to watch part 2!

Such a rad build! Really digging that color!

You did a great job! Love the sea foam color!

Awesome van! Great job hope you are still using it!

Fabulous job!

Beautiful work bro congratulations.!

you could rhino the inside bottom of the doors and other places that rust from inside out. that would be awesome.

Dude this is exactly what I want for myself. Keep us posted if you decide to sell her!

A 4wd hi/low transfer case from an S-10 Blazer works very well in the awd Astro / Safari vans.

Very Nice Build!

This thing is inspirational

I own a '98 Astro and you gave me some great ideas

I wonder if it wouldn't be easier and cheaper to just replace damaged doors, hood etc that you can easily replace sense you're going to paint it anyway. Spend a lit of money on a door that can be bought cheaper then replaced in a half hour.

love this colour, just about to get ready to paint my GMC and can't find this colour anywhere!!!!

nice, looking chevy van. Random vanners east coast VA. 2%

Looks good. Nice job.

Very similar to what I’m doing with my Ford e-250. cheers

looking very good! can't wait to see some more updates.

Looking Awesome Van Great work 👍

very beautiful

Hey man, I just wanted to say thank you for this video. It really inspired me a lot. So much that I bought a 2004 Chevy Astro and plan to do a very similar build to yours. I was really stressing on not being able to find the right vehicle for van living for months now and your video really opened me up to the idea that a van that small could still be really bad ass and fun to live in. I'll definitely post my own youtube video of the process once i get started here in the next few weeks. Anyways I'm curious what your new rig might be? Hope to see more videos like this from ya in the future!

Rock Wool ! No water,no bugs nontoxic !

nice work and I like this car Ive got one right now 1993 AWD it's awesome

Great job. Very cool build.

Nice attention to details!! Enjoy

GREAT BUILD! Love that Rhino stuff! Great ideas for mine. I have a 96 Astro.

And did a wonderful job with the van

good looking van! nice mint blue!

“It’s like the green stuff that’s good for the environment, whatever” Hahahha!!

dont use that insulation it can mold super easy. Use spray foam

I may not be fond of your color choice for van but that gold ladder needs to be the same color as the roof rack. The van build looks great but I wonder if the painter was high on LSD. Lol. Does it have the 2.8L V6 or the 4.3L V6?