Emptying the Smugglers' Box

Superman · 02-14-2002, 09:19 PM

I know I could do a SEARCH, but you guys know I probably won't. Heck it's hard enough to get me to open the Bentley.

I'm quitting smoking and I thought this would be a good time to remove my A/C parts. I counted just over a thousand of those little half-moon hose brackets and I think there was about 150 feet of hose. Just as I thought. I think it weighs about 300 lbs altogether.

Anyway, I've removed just about every fastener I can see in the smugglers box and the big black thing won't come out. I'm just about to use my 16-oz framing hammer to pulverize it for ease of removal. Is the hammer the easy way, or can it come out in re-usable pieces. In truth, it's never going to go back in, at least certainly not as A/C. Blower perhaps. But in the meantime I need a place to store my drugs. Suggestons anyone?

campbellcj · 02-14-2002, 09:26 PM

There must be something wrong with your car. A proper 911 has nothing in there except for a bit of steering linkage

Superman · 02-14-2002, 09:30 PM

Exactly!

911pcars · 02-14-2002, 09:50 PM

Superman,
Part of the AC evaporator stuff protrudes into the vehicle interior. Take your hammer and flashlight and take a look under/beside the passenger foot panel. With a Vaughn carbon shaft and titanium-tipped, 23 oz. framing hammer, line up your shot. Head down; then lock that front arm and bend that forward knee. Shorten your backswing (watch out for the passenger side door speaker) and follow through smoothly in the direction of the thermostatic sensor line. In no time at all, you'll be pin high. After the dust (and evaporator) disappears, the hole in the bulkhead will look big enough to drive a truck through. It's a matter of imagery and being one with the hole.

Take some sheet metal and pop rivet this area closed or use this newly found area for additional legroom. I didn't weigh mine and put it on the score card, but others have said the entire system weighs about 75, about par for most 911 AC units.

Let us know how it goes.

Sherwood Lee
http://members.rennlist.org/911pcars

02-15-2002, 03:07 AM

What's the trick to getting the fittings to break free? I can't quite reach down into the box with the acetylene torch - hoses are too short.

orbmedia · 02-15-2002, 03:13 AM

I remember when I removed the A/C on a '73 targa I had it was dealer installed and they put a big blower in that compatment. I recall it being tough to remove but I never had to bang or cut anything. I also recall that the dealer cut a big hole in the bulkhead by the passenger's feet to facilitate access so you might want to check to see if you have that hole too. It may help getting to the lines as Sherwood said.

RoninLB · 02-15-2002, 04:34 AM

Super----under the pass foot rest is a wood support similar to drivers side. Under the pass foot rest is a connection to AC evaporator box. 4 screws to remove. Did you select color and style of engine fan, shroud, etc??

makaio · 02-15-2002, 05:08 AM

Mine had to come out in multiple pieces. I didn't see this as a problem, since all but the compressor and evaporator, are now in the land fill.

KTL · 02-15-2002, 05:20 AM

After you remove the sensor-thing from behind the floorboard and get the sucker out , you'll realize that the foam gaskets are trashed from age. Meaning, when/if you put it back in, you'll have to make some gaskets out of foam or use some foam weatherstripping.

I took mine out last weekend, cleaned up the box, "made" some gaskets and put it back in there. I put it back in because I figured it'd be nice to have the additional fan available when I'm sweating like a hog in the summer months. Word of caution to those silly fellas like me. If you decide to make some new foam gaskets, 3M adhesive remover and citrus cleaner/degreaser melt the plastic of the blower box and the sensor thing housing. Try something else to get the old adhesive off!

stormcrow · stormcrow's Garage

If you look along the outer edge of the box, you will see clips which hold the two parts together. Take a screwdriver and pop them off. Once removed, the top of the box will come off exposing the motor which is in the top half of the box and the evaporator which is in the bottom half.

Disconnect the wires from the motor and remove that part of the system. The Evaporator will have to be disconnected at the expansion valve along with the return line back to the compressor.

Once both lines have been disconnected, you can remove the evaporator. The remaining other half of the box is connected by the supply hose going through the bulkhead. Remove the clip on the hose and the box should come out.

Steve

Superman · 02-15-2002, 05:55 AM

I think I got it. Thanks dudes.

Ron, I just got the parts back from the powder coater and I'm very excited. Placed a Pelican order yesterday and since I'm going on vacation week after next, I imagine my project will extend to perhaps mid-March, but this engine is going to look nice. Fan, chain housings and covers, and valve covers are red like the engine shroud. I took your advice and after some thought, decided to go with a low-gloss black for the fan housing. It's going to look stunning.

MRC · 02-15-2002, 08:29 AM

Superman

Please post some pics, it must look great

Superman · 02-15-2002, 08:35 AM

Oh, I definitely will. Definitely. Right now the engine looks like a porcupine with all the head studs sticking out of it. I have accumulated nearly all the parts I will need (I think), but I am at the furthest stages of disassembly now. I hope I remember how it goes back together. Anyway, I think the engine will look really good and I will certainly post some pics, along with details about the project. Folks have been asking how much I will spend (they know what a cheap superhero I am) and the engine total will be about $1500, with another $500 for other minor but important improvements. Details and pics when they become available.