fresh air/ heat ducts behind the dash

[chocolatelab]

Hi All

Not sure how I started this project sunday but non-the-less it happened.

Started out by cleaning out the front trunk and it occured to me that the air vent levers on the dash are a little sticky and not responsive.

So I started taking apart vents, fans, ducts ect.

Found a ton of junk in the ducts, open close flaps gunked up, and cables had kinks in them. Fan appears to be resonable shape.

Removed fan from smugglers box also. Makes me think i should go ahead and upgrade the ac while im in here.

Next step is to find new ducting and replace the cables.

I found 16 guage wire at the local hardware shop and bought cable housing from the local bike shop.

Anybody have recommendations for replacement ducting up front?

[Cdnone1]

Chris
What is the red wire running from the pass compartment down to the battery for?
Steve

[chocolatelab]

Thats a great question.

Love to know the answer.

I am tempted to guess that it is part of the alarm system that came originally with the car. I think it was partially removed by the PO.

Do you think I can remove it? How about the one that goes into the front wheel well?

[kerthunk]

I went through this process recently. If you follow the link in my signature, you can see some pics of it. I don't have A/C in my car, so the tubing is laid out slightly differently. I picked up some CEET tubing from Aircraft Spruce that it seems a lot of people in these forums use. While I had all of the diverters and such out, I pulled off the snap rings to open them all up and give them a good soap and water cleaning.

[Cdnone1]

If it's a direct feed to the radio you might find that it becomes a constant draw on the battery. Have you had any battery drain problems or do you drive the car everyday?
The factory power for the radio is the yellow wire off the ignition switch and does not draw power without the key on. A lot of after market installers just ran a direct constant feed right from the battery rather than figuring out the proper way. Also lot's of radios need constant on to keep the presets.
I had the same thing and removed it and rewired the radio correctly.
If I remove something I alway trace the wires back to the power source and remove them completely so I eliminate the possibility of shorts and fires

Steve

[chocolatelab]

John

What are the 2 sizes of ceet tubing you used?

[kerthunk]

I order 10' of 2 1/2" and 6' of 1 1/2" figuring that it should be enough to allow me to screw things up a couple of times. I really only used like 7' of the 2 1/2" and 4' of the 1 1/2". I replaced all of the hosing in the trunk area as well as the ones under the dash in the passenger compartment. You should measure yours yourself though, because I have seen a few different routings of the tubing under the dash.

The 2 1/2" tubing really would be best if it was more like 2 3/8". It needs to get cinched down onto the fittings a bit, which is a tad tricky with the metal wiring in the tubing. Just be patient when you are putting it in and make sure that it doesn't twist or slide out of clamps too much.

[chocolatelab]

I just looked them up and they have an office about 20 minutes from my house. I am going to swing by there tomorrow and see whats going on. I am going to bring the parts. Maybe the 2 and 1/4 actually fits better.

Ill let you know.

[chocolatelab]

Just an update in case you ever considereed getting into this area.

Hopefully there are a couple things in here that can make it easy for you in the future if you need to get in there for maintenance.

Don't do it. Kidding Finally done and glad that everything up there works now. I can even control airflows.

Here are some pictures and some thoughts if you want to try.



After everything is out go ahead and wipe it all down and wash out all the air distribution units. Do it now because you will never want to get back in there again.



I replaced all the hoses with the CAT version of the aerospace hoses that are recommended on many threads. Spruce is the aviation supply house. I looked through the PO's paper work and about 10 years ago the smaller hose was replaced at a shop in Anahiem and it looks like they used the same stuff way back when. Strange coincidence.



On my first attempt to reinstall I tried to do the distribution boxes first then connect the cables.




After removing everything again i assembled the cables and wires on the right side control box ( as you are facing the hood from the front of the car) Then installed the right side, then hooked the balance of the cables, then locked in the left side box.




When using the spruce hoses i noticed that by unwinding one or two coils of the wire it was much easier to clamp ir zip tie the ends




I was able to save the push/pull wire ( i think its about 16 guage) but the cable guides were just to foul. I bought this red cable at the local bike shop. Worked out great. Dont forget to lube it!!!!







Thats all i got.

[kodioneill]

You just gotta love it!!!

[chocolatelab]

It was a solid hundred degrees outside and in the garage yesterday. My son was going between the pool and the garage helping me test the levers all day.

I wouldnt have been anywhere else but screwing with that car yesterday.

Today. Golf.