Another boring AC thread - installing a 993 condenser in a 3.2 Carrera

[NathanR]

By the end of the day, I had all the miscellaneous bits and pieces in place and was able to return the car to the garage floor on her own wheels. Now I just need a high side service port adapter and I'm ready to charge.

Does anyone remember how much 134a Karl (discseven) put In his system?

[NathanR]

Originally Posted by NathanR

Also, today I confirmed one needs a 7/16th inch hi side service port adapter.

This one didn't fit



I did order the right one, I just didn't get the right one.

I'm surprised none of you caught me in this mistake. Today I called Nostalgic AC and they explained the port in the picture measuring 3/8ths is the binary switch port, not the service port. Doh! I just wish they had replied to my email a week ago...

Plus this resolves the fitment issue since the actual correct port rotates...

[ganun]

Karl put 26 oz exactly.

[NathanR]

Originally Posted by cvhchj

Do people typically remove the washer tank to route hoses to the front condenser?

I did, but if you go back to the first few pages of this thread Charlie gives a tip on how not to. Having it out helped me visualize that space better, but putting it back in was a serious PITA. And I've done it before. somehow I managed to break both hoses that go to the vapor recovery pod just above the tank. Another trip to Napa and I was ok.

[NathanR]

Originally Posted by ganun

Karl put 26 oz exactly.

Wow, not much at all. Thanks George!

[ganun]

BTW, When the two hoses are routed over the bumper shock where there is a sort of channel in the body (might have come like this from the factory) road debris gets packed in there and promotes rust. Keep the channel clear so it can drain.

[NathanR]

I had a ton of dirt packed up In that area, it's out now.

[Ronnie's.930]

Originally Posted by NathanR

Question for Ronnie: did you get you smuggler box insulation from a muffler shop? What is it, exactly? (I have insulation envy and must know details).

Originally Posted by Wavey

Have you decided what to use to insulate the smuggler's box?

Originally Posted by NathanR

I still want do this, but today I got on a roll putting things in order, and I reinstalled the stereo amp that blocks access to the smugglers box. Doh!

Nathan, it beckons, bro!




PS - good deal about the fitting (even though you had it all along), and really sweet progress overall!

PSS - I learned from Griff after doing it (when he saw this picture last year), that mummifying the expansion valve is not necessary, even though they often came that way from Porsche (like my original one did).

[Pazuzu]

Nathan, can you give me an idea of how much hose you used? Would 25 foot rolls of #6 and #8 be enough, with a single length of #10 as needed? I know every setup is different, but it'll give me an idea if 25 is far too much or far too little.

[Wavey]

Originally Posted by NathanR

Wow, not much at all. Thanks George!

That bottle of oil I sent you? Whatever is not in it is how much I put in my system. I didn't have the extra condenser, but the desert-duty front condenser and extra hose lengths for the procooler required a bit more.

[Wavey]

Originally Posted by NathanR

I had a ton of dirt packed up In that area, it's out now.

Thank God for galvanizing.

[NathanR]

Originally Posted by Pazuzu

Nathan, can you give me an idea of how much hose you used? Would 25 foot rolls of #6 and #8 be enough, with a single length of #10 as needed? I know every setup is different, but it'll give me an idea if 25 is far too much or far too little.

Mike,

I'm going to go back and check all my orders and get back to you... More to follow. I do have notes.

If you have existing hoses, I highly recommend removing all of them and figure out everything you need and order it once. I spent a lot of time waiting for additional orders to come in, which was frustrating.

Cheers,
Nathan

[NathanR]

Charging starting in 20 minutes!!!! By then the vac pump will have run 4 hours.

[NathanR]

First attempt at charging was, unfortunately, unsuccessful.

Things were progressing ok, I think, then the o-ring on the binary pressure switch blew out.

I did capture some P&T data

OAT = 85F at beginning of test
Static charge = 80 psi

Before the big blowout,

Hi = 250 psi
Lo = 65
Vent T = 55F
Charge weight = 17.2 oz

Note: I didn't have the deck lid closed or a box fan blowing on the car. Next time...

Will post pic of o-ring, not sure what to do about it.

[NathanR]

Argh. When I installed this switch, if I over tightened it, the o-ring would squish out the side. I'm not sure what else to do with it.

[Ronnie's.930]

Nathan, does the boss (the hole) that the switch screws into have a groove in it to accept an O-ring? If not, what you see there is exactly what happens. I ran into that problem (no groove) with my home built setup, so used a tiny copper washer instead - worked perfectly.

If it does have a goove for the o-ring, and it is squishing out like that, then the o-ring must not be the correct size (either too large of a diameter, or to "thick").

[NathanR]

Originally Posted by Pazuzu

Nathan, can you give me an idea of how much hose you used? Would 25 foot rolls of #6 and #8 be enough, with a single length of #10 as needed? I know every setup is different, but it'll give me an idea if 25 is far too much or far too little.

Mike,

I originally planned to delete the decklid condenser but changed my mind once I started. so I have some extra #8 hose but here are my original estimates

Comp to R.Cond = 7' of #8 (I'm guessing I used roughly 5')
R. Cond to F. Cond 11' of #6
F. cond to R/D 5' of #6
R/D to Evap 3'4" of #6
Evap to Comp 13' of #10

[Pazuzu]

Originally Posted by NathanR

Mike,

I originally planned to delete the decklid condenser but changed my mind once I started. so I have some extra #8 hose but here are my original estimates

Comp to R.Cond = 7' of #8 (I'm guessing I used roughly 5')
R. Cond to F. Cond 11' of #6
F. cond to R/D 5' of #6
R/D to Evap 3'4" of #6
Evap to Comp 13' of #10

Excellent, I did some rough measuring for mine (which is different with the underbelly condenser) but things like the 13 ft of #10 is most helpful. Everything you have from the front condenser on is the same on mine, so that gives me some clear measurements for 60% of the system.

Where did you buy your fittings from? I have 12 fittings to buy, and have sourced them for anywhere from $35 to $85 (same fittings, often the same part number!). huge markups with some companies, which I'd be fine with if they had spectacular service as well.

A/C Compressor and A C Compressor from AC Parts was by FAR the cheapest, but they might be crap service...

[NathanR]

Originally Posted by Ronnie's.930

Nathan, does the boss (the hole) that the switch screws into have a groove in it to accept an O-ring? If not, what you see there is exactly what happens. I ran into that problem (no groove) with my home built setup, so used a tiny copper washer instead - worked perfectly.

If it does have a goove for the o-ring, and it is squishing out like that, then the o-ring must not be the correct size (either too large of a diameter, or to "thick").

Ronnie,

No groove for o ring. Copper washer sounds like a good idea. Hardware store item?

Thanks a ton. I was out of ideas.

Cheers,
Nathan

[NathanR]

Originally Posted by Pazuzu

Excellent, I did some rough measuring for mine (which is different with the underbelly condenser) but things like the 13 ft of #10 is most helpful. Everything you have from the front condenser on is the same on mine, so that gives me some clear measurements for 60% of the system.

Where did you buy your fittings from? I have 12 fittings to buy, and have sourced them for anywhere from $35 to $85 (same fittings, often the same part number!). huge markups with some companies, which I'd be fine with if they had spectacular service as well.

A/C Compressor and A C Compressor from AC Parts was by FAR the cheapest, but they might be crap service...

I bought half of my stuff from acsource.com and half from nostalgic ac. Both gave good service, but not perfect. Prices were similar. I also found a surprising amount of stuff from my local NAPA, which saved one weekend... No clear difference in quality, sometimes one had what wanted and the other didn't.