Front a/c condenser

[tim_fogelsong]

Am adding a front a/c condenser to my '76 911. Have all the proper parts except for the ducting at the front of the trunk which I fabricated. What type of opening do I need to cut to allow the blower air to reach the condenser? Is the opening a rectangle or a series of large diameter holes? Also, do I need to cut a hole in the front of the trunk for air intake to the condenser fan? Is a template to mark the locations of these openings available?

Thanks

[evill]

The openings are rectangular. One on the trunk floor facing down towards the condenser. The second is in the front pan behind the bumper and valance. You can make templates from a manilla folder or cardboard of the mounting flanges on the blower motor and then use them to locate and cut you holes. I would place the blower where you want it to be and fits best, then use an awl to mark the screw holes. The blower holes are located towards the drivers side of the car. Drill the holes with an 1/8-in bit and then use them to locate your templates. Mark and cut your air opening holes.

I may have the hole locations and sizes written down in my notes somewhwere. I iwll look for them in the garage today.

Regards,
Ed

[tim_fogelsong]

Ed,

Thanks for your reply. If you are able to locate and share your notes about sizes and locations, it would be appreciated also.

Best regards,
Tim

[WoodSport]

I just removed the front blower and condenser, and I'm fab-ing some block-off plates today. I'll try to get pictures and measurements, if you want. Mine is an '84, so there may be some differences, I don't know.

/Jon

[tim_fogelsong]

Jon,

Pictures, dimensions and locations of the openings would be very helpful. I'm guessing that the '84 and '76 layout is the same but who knows. Thanks a lot for your help.

Best regards,
Tim

[WoodSport]

Here's the pic looking towards the driver's side:


The lower opening is 5-7/8" by 2-7/8" and the right edge is on the centerline of the car.

The upper opening is 2-1/8" by 3-7/8" and the right edge is offset 4-7/8" from the centerline.

In the lower right of the pic, you can see part of the moulded grommet that fits the upper opening with the dog-leg bend. The lower opening was sealed with weatherstripping around the flange of the blower.

I didn't have much time to play with it today. I can get more details tomorrow night.

/Jon

[Mysterytrain]

My 78SC was delivered with factory air but no front unit so I have also been collecting these parts so that I have the option of adding the front condenser when I upgrade the A/C.
I think that lower air baffle, part number 911-501-581-01, is key to proper fit. It looks to me that you will need to mount the fan assembly to the air baffle first and then position it inside the trunk to get a ball park as to where to cut the small hole. Measure ten times..cut once! You also might want to drill small holes in each corner of the outline before you commit to hogging out the opening. This would allow you one last tweek of the position with minimal sheet metal damage. Once the small front opening is in place you can fit the gasket [911-573-515-00] in place, re- assemble it all and then mark where the big opening will be. Make sure you cut on the inside of the mounting lip which is about a half inch wide all the way around it. I would clean and prime the cut and then use auotbody panel adhesive to secure the baffle in place.

[tim_fogelsong]

Jon --
Thanks for the picture and dimensions -- it sure helps to see how the factory did it. As I understand it, there is another larger opening cut through the trunk floor below the baffle which contains the 5 7/8 X 2 7/8 opening. If you happen to be underneath the front of the car, the dimensions of this larger hole would be quite helpful.


Ron Pierce --
I think you are right about the baffle (915-501-581-01) being key to getting the holes cut in the right location. Do you have any idea where one of them can be located? I have not seen one so I tried to fabricate one from sheet metal but I would be much more pleased with the real thing. From the picture that Jon sent, the baffle looks quite substantial and may add some structural rigidity to compensate for the cutting of the hole in the trunk floor. Other than structural adhesive, how is the baffle attached (spot-weld, screws, etc.)?

Thanks and best regards to both,
Tim

[WoodSport]

The baffle is peaked in the center, about 1-1/2" deep, and slopes down to 1" on the right and 3/4" on the left. The blower housing will give you the proper angle, if you assume that the upper opening is level with the car.

The larger opening is 14-3/4" by 4-1/4"


And a better view from the top:


/Jon

[tim_fogelsong]

Jon,

The latest pictures illustrate the situation very well. I think I will try to find a baffle since it looks like it may compensate for the weakness created by cutting the hole in the trunk floor.

Thanks and best regards,
Tim

[WoodSport]

Yes, probably best. And it should give better airflow through the condenser.

Good luck!

/Jon

[tim_fogelsong]

Front condenser baffle (aka condenser deflector plate) is still available through the dealer network for the relatively modest sum of $110.00.

Thanks again,
Tim

[Mysterytrain]

I lucked out this summer and found a baffle on ebay. New Old Stock for $10 bucks!
If you think about it $100 for a new part might save you hours of time from searching or re-engineering a part...and no doubt less stress to you and the tub because you will know it's what belongs there.

[tim_fogelsong]

Ron,

I was a little premature about the baffle still being available through Porsche dealers. After I ordered the part, the dealer called back and said it was no longer available. However, the good people at Pelican Parts located one in Germany at a still reasonable price.

Best regards,
Tim