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It was 2003 and I found myself with
out a job! My employer decided that the older employees were
around too long? 28 years punching a clock in a Steel Mill and
suddenly, I’m without a job!
A few years earlier, on a return trip from a local Van Club we
hang with, BVA, we stopped to spend an afternoon with some former
van club friends of ours.
At some particular point in time on our afternoon there, my friend
mentioned that he had an NOS Econoline Van complete front end!
Did I possibly know someone that may be interested in it, he
asked?
Well needless to say, I took it off of his hands!
I stored it for just a couple of years, till I had the rest of
the front end parts, ie. Headlights, trim, bezels, etc. I figured
that one day I’d have the time to build this Van Bar?
Well here I was forced out of an old dirty place of work and
all of this time on my hand! I took about two months off for
good behavior! Lol I always wanted to construct a bar from an
old Van front end. My original plans were for one from the front
end of a 60’s Chevy Van, but this would work quite nicely.
The design and construction begins:
1. I “Jigged” up the front end on a ¾ “
Melamine board, and attached it via clamps so as to obtain measurements.
2. Once I had obtained the measurements…I started laying
out the compartments for the sub woofer speakers
3. I found the exact spot where the mid range speakers would
clear the vent grills,...and designed pedestals for them
4. Now about this time…the thought of rollers came into
mind and I designed them around the shape of the base, keeping
in mind the end height of the bar itself.
5. Now with the whole project on the floor and able to move about,
and move on to the next phase of design and construction, the
internal support.
6. I selected some of my straight 2 x 4’s and drilled and
used lag bolts and plenty of wood glue to secure them.
7. I made templates out of cardboard…to fabricate the “Contour”
shape of the front end, I then fastened these sections to the
vertical 2 x 4’s both front and rear
8. With the “Contour” sections attached…I was
able to fasten “BeeBoard” to these with plenty of wood
glue
9. On both side contour sections…I used terminal strips
to land wires for the onboard sound system and 12 volt devices
10. Since I had an old 1982 era Kenwood laying around…it
became the anchor of the system for sound…I made a slide
out drawer to hold it…makes for getting to the rear wiring
much easier
11. Since ease of access became a necessity…I constructed
a slide out for the mix board as well
12. I then added to slide out vertical drawer setups…one
for each side and for a change…I designed them at a slight
inward angle…looks so cool!!
13. Since I had a couple inch void in the lower middle section,
both left and right, I decided if I angled it properly, I could
store CD’s there conveniently
14. During the whole process of design, I wanted the bar to perform
as if an original VAN. Headlights, turn signals, horn so it does!
I use a craftsman 12 volt battery pack attached via cable
15. The bumper is mounted using laminated plywood , I fabricated
two “T-Bone” shapes, they mount in the location that
the stock metal ones would
16. The hardwood top surface…I bought off of a neighbor
friend of mine…he had planned to make a coffee table, but
scuttled the idea for a few $$$ Lucky me! ?
17. I did have an Experienced woodworking friend of mine attach
the Bar Mouldings though
The body shop originally shot the “Wrong”
color of yellow, thus the mismatched color in the view in the
Vanport. I was trying to get the whole project assembled for
a “Debut” party a day later!
We Debuted the “EconoBar” for
all to see the end of summer 2003… and it was a huge success!
Since the “Debut” it has been visited by Vanners from
England, Germany, Canada, Finland and made many website mentions!
I’m currently in the process of designing a “Personalized”
logo for the EconoBar! It should be finished very soon?!
In closing, I found this project to be a very satisfying one,
but I never knew how much attention it would garner?! We have
a lot of fun entertaining the Vanner friends we have each and
every time they stop by! |
