+1 for Patrick

This weekend I reinstalled the AC Compressor Brackets to the engine. I've created a separate thread for that should anyone else require it, at:

http://forums.pelicanparts.com/porsche-911-technical-forum/867634-how-install-ac-compressor-brackets.html

Skip, how is the system? Did you get it charged up at blowing cold yet?

I've booked the car in for Monday morning to drop it off, for a complete system test (i.e. pressure etc.), and finalizing the adjustments / connection of compressor. I can only pick it up Thursday, but am hopeful, that cold air emanating from the vents will be the result. I'm going to try to install the Kuehl vents this weekend - only step left.

If I get to the vents, I'll continue the post series as the final piece as well.

Cool, er Kuehl!

I'm sure you'll be very happy with the results!

This morning I started with the installation of the vents (may not have time to finish them yet, but will give it a go). Note: I used a head mounted flashlight, which made life a lot easier to see what I was doing. Starting with the centre vent, you have to remove the bowtie vent from behind the centre console and reinsert the two 8mm hex bolts into the bulkhead, as you don't use them again.

http://forums.pelicanparts.com/uploa...1433663221.jpg

http://forums.pelicanparts.com/uploa...1433663253.jpg

Once removed, you're going to carefully (so not to drop...) one of the two nuts and washers on the rear of the ashtray (1/4" drive with 8mm socket worked throughout).

http://forums.pelicanparts.com/uploa...1433663377.jpg

You're going to install two hex (13mm) offset nuts which have their own attached bolt successively to the two mounting bolts on the back of the ashtray (don't tighten yet). Attach only one at a time - don't take off both nuts and washers simultaneously. This is the result:

http://forums.pelicanparts.com/uploa...1433663515.jpg

Now insert the vent into place and pressure fit the hose to the bulk head vent tube. Slide the slotted vent holes over the new offsets and carefully place the new lock nuts in place. Adjust the position of the ashtray, and then using a 13mm open end wrench carefully tighten up the offsets first. You'll note there is enough space to get the wrench between the vent and the back of the ashtray. Do final adjustments to the vent position, and tighten up the final two 8mm locknuts on the vent. Recheck that the hose is properly attached to the bulk head and you're done. Next post will be the passenger / driver side vents.

http://forums.pelicanparts.com/uploa...1433663702.jpg

Picked up the car around noon today (+31 C), and daringly adjusted the fan and thermostat, within just a short distance of driving, the new system was blowing ICE cold air into the cabin - unbelievable, that after an unknown number of years of no functional AC, it's been resurrected and I am TOTALLY impressed. Thanks Griff for your exceptional product and assistance in answering my questions during my install. I had a lot ot reticence when I started a few short weeks ago, but... JOB DONE! I will work on the last two vents in the cabin shortly but have visitors coming this weekend, so may not get to it. It's supposed to be a hot day tomorrow, so testing WILL be done. SmileWavy

http://forums.pelicanparts.com/uploa...1434034098.jpg

http://forums.pelicanparts.com/uploa...1434034387.jpg

Skip,

That's great! Congratulations! Nothing is as satisfying as a job well done.

I've been following your thread with great anticipation of your results. Glad you are happy with the results.

Thanks tirwin, appreciate it.

Right on Skip. Great job!

Hi Skip,
Did you ever get the duel kuehl vents installed. They look like a slight challenge to fit with the footwell blowers and the carpeted covers.
Great job.
Thanks,
Dave

Dave,

Thanks. No Not yet. When I had finished installing the centre vent I went to work on the passenger side, and the AC feeder hose which runs from the bulkhead to the three way blower manifold was torn and in fact the wrong type of hose. So before proceeding I have to acquire the new hose, which is in the works right now. As soon as I get it, I'll be back at it to complete the full install. The driver side will likely be more problematic as the hose that I have to replace on the passenger side, has a completely different design on the driver's side and is internal vice external to the carpeted kick panels. I will post my results as soon as I start - likely in the next couple of weeks - fingers crossed.

Thanks Skip.

OK folks, well, I've been able to get the replacement hose from the bulk head to the passenger auxiliary blower, so finished off the installation of the two Kuehl side vents. Overall, not difficult, just took a little time and some patience. Due to the design of my vehicle ('84 model year), as with many others, the blowers behind the kick-panels create an additional challenge for hose routing to the vents. As part of replacing the one hose, I had to access the clamp through the smuggler's box, which was a PITA, as it kept rotating on the old torn tube. Once off however it wasn't too bad to attach it to the new cardboard (aluminium lined) hose and reinsert it from the passenger area, align the clamp and carefully tighten it through the smuggler's box - especially easy if you have either a long standard screw driver or hex driver (about 1 foot long). This hose is removed from the blower y-junction and can be seen hanging, just below in the pic:

http://forums.pelicanparts.com/uploa...1436728094.jpg

Once removed, you cap the y-junction point to avoid any lost air flow from heater system, and reinstall the kick-panel. I did this, to ensure I could align the hose on the outside of the panel and into the back of the new vent. I had to extend the hose carefully to pretty much full length and gently curve the end and squeeze it into an elliptical shape to fit it into the vent, then heat shrunk.

http://forums.pelicanparts.com/uploa...1436728257.jpg

The driver side is a little trickier, as the hose actually comes from roughly above and forward of the hood release and goes to another y-junction. It therefore can't simply be run along side of the kick-panel. The hose is a fabric hose vice cardboard on my car:

http://forums.pelicanparts.com/uploa...1436728455.jpg

You have to notch / cut the kick-panel to allow for the hose to pass from behind it, forward to the vent location. The hose is about 4 1/2 cms diameter. I peeled back the carpet carefully (enough to be able to cut a U-shaped hole from the upper edge about 1 1/2 cms away from the existing hood release notch.

http://forums.pelicanparts.com/uploa...1436728719.jpg

Once cut, I did a dry fit to ensure the hose reached the vent. After capping the y-junction point where the hose had been removed. Reglue the carpet carefully trimming off any excess noting how it was previsouly installed, with necessary overlap. I then reinstalled the kick-panel with the hose now protruding and installed the hose the same way as the passenger side before carefully mounting the vent.

http://forums.pelicanparts.com/uploa...1436728766.jpg

That completes my Kuehl AC Rebuild - :DSmileWavy

Nice job, Skip. My dual vents worked exactly the same.
Enjoy.
Dave

Skip,

Glad we could help you out with your project


Griff

Kuell Air
 

Thanks for the excellent photo documentation of your installation.
Everybody appreciates your handling of the TROLL.
I can't wait to install my Kuehl upgrades but would be intimidated by his sick distraction.
Congratulations, and keep up the good work Griff.

plus 100 on Griffith. Charlie is really an awesome guy, very fussy, and does great work.

Thanks for posting about your experience with Griffith's AC kit. I'm on the fence about what to do with my '80 Targa.