Thought I would follow up my thread with the final outcome. It's always nice to know how a problem was fixed for board members. It ended up being a seized Evap blower motor in the smugglers box. I pulled just the blower, yes you can do this without evacuating the system or removing the expansion valve. Just knock loose the 4 PITA clips with a long flat blade screwdriver and hammer and grab them with a needle nose before they are totally off and in the bottom of the cave. then peel back the insulation around the bottom of the valve only, this is to be able to remove the power wire connector when you pull the top of the blower assembly off. You only have to remove the 3 bolts and 1 nut that holds the 2 brackets to the housing. The other 2 bolts secure the motor to the housing once you have it off. If you do take those 2 off you risk dropping the nut thats on the inside. Now you need to pull out gently the capillary tube which is sleeved in a copper tube that's inside the housing and push off to the side. Loosen the clamp that holds the flex discharge duct to the housing. You only need to loosen the one at the housing. Now the entire top of the housing comes off with a little bit of maneuvering and the evap coil is exposed. Now you can flip the housing upside down and remove those 2 bolts I mentioned before which releases the motor housing from the bigger housing. There is a set screw you undo at the squirrel cage shaft and then just flip it and hold the cage in your hands and tap the whole assembly firmly down a piece of wood or anything. That round sleeve that the set screw went into is attached to the cage pemanently so don't try to pry it of the shaft while the cage is on the shaft. It should pop off with a couple of soft slams. Now the motor is attache dto that housing via 4 spring clips and remove them with a flat blade. Now you can twist the motor so that things line up to slip it out of the motor housing. It can only slip out one way, you'll see what I'm talking about. But just before you remove the motor you need to disconnect the power connection and the little clip that holds the wires tight to the motor. You'll see what I mean. Now pull the motor and spin the shaft until it frees up a bit. You can pry off the pressure clip at the shaft end opposite where the cage was just to allow more vertical movement of the shaft to be able to spray it with lot's of electric motor cleaner. Spray the crap out of it everywhere, the pickups the wiring the magnet area everywhere. Keep spinning it the more the freer it will spin. Now lubricate the shaft and the shaft bearing with what you like. I used WD-40 and PB blaster and let it soak in and kept spinning it. It spun nicely after that. An important thing to remember when reinstalling is to make sure you have that copper tube that the capillary slides into in place when you put the housing top back on cause if you don't it will be impossible to stick in without bending it and then the cappilary tube won't slide in and you'll have to remove the housing and stick it in. Now installation is reverse. It's a bit of a hassle to get the flex duct on but use a skinny flat blade to work it on the housing. The bottom of the duct should slip on forst. Now those damn clips. This is what I did. Each clip has 2 holes on them on eithe rend. I thought why and figure the Porsche mechanics have some nifty tool that installs them because they are cursed. I figurd out that I could take a skinny 2 inch long nail and bent the tip into a hook shape and use that to loop in the holes on the clips and then use a pair of needle nose vise grips to hold the nail. It's tricky but you have to hook the bottom of the clip onto the tab on the housing and then yank up with the nail hook and whalla..it's on. Saves a ton of time. Buttoned it all up and re-pressed the insulation around the valve and power wiring and man the thing has never blown so hard since I've had the car. It works great. So when your blower motor is screeching or finally seized this is the fix or if the motor died and you want to replace it then this is the way too.

Hope this helps everyone.

Gordon

Another follow up. I just installed the HC-12a drop in refrig substitute in my 85 R-12 system. It was 95 degrees today and the A/C was nice and cold. It took a total of 18oz of HC-12a which is equivalent to about a full system charge of R12. I was almost totally empty of R-12. It was easy and total cost with the filler hose delivered to my door was $49.
This is where I got it. http://www.foxtoolsupply.com./ Mr. Fox is super nice and helpful and explained it all to me and only took 2 days to get.