I see this thread has been dead for some time but wanted to comment.
I Came across it using Google looking for info on 4WD parts for Astros.
I am in the market for something that i can also camp/sleep in comfortably. I do a lot of climbing and would like a vehicle that I can sleep inside of at the trailhead without having to unload it. Since these trips usually involve 400-600 miles of driving something that gets good mileage would be ideal. While it doesnt have to be very off road worthy it would be a bonus. At times we have approaches using unmaintained mining roads etc... some of which can be nasty ( my friends get by with stock jeeps and a stock Yukon)
To make it even more appealing I saw a place that convert them and will install a pop top and/or bed or..?
http://coloradocampervan.com/Camper...nversion/chevrolet_astro_van_conversions.html
Regarding the crash worthiness I thought I read that it improved in later year models.
I also considered a Ford E series as the "estimated average" mileage was only like 1mpg less than that of the Astros, and the same place could convert it for camping as well. (but have heard stories of that they get <10 MPG and I couldnt afford to drive it if that was the case.
So just curious, did you ever pull the trigger on an Astro? IF not what did you end up with?
Regarding E series vans. Any opinions on them? Reliability etc... How about vans converted to 4wd? Anybody have any recomendations on shops that make the conversions?