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

This is the year I'm finally fixing my AC.

Disclaimer: I know nothing about AC, despite having bookmarked and read 38 threads on this board. What I may do next may be dumb. I typically have to do things a couple times before I'm satisfied with the results.

I've decided to add a 993/964 condenser to my otherwise factory setup, and convert to 134a. I've purchased a Robinaire vacuum pump and a set of gauges, as well as a hose crimping tool.


outhttp://forums.pelicanparts.com/uploa...1434256682.jpg

Here are a few pics of the new condenser, purchased from our host for ~$100.

http://forums.pelicanparts.com/uploa...1434256840.jpg

The fan is from nostalgic AC. About $40, it's 10" diameter and reversible. Makes around 800 CFM. I tested the polarity w. A power supply and the flow was pretty huge.


http://forums.pelicanparts.com/uploa...1434257030.jpg

I messed around with a couple different bracket arrangements and settled on 1x1x1/8 aluminum angle on top 3/4" square al tubinghttp://forums.pelicanparts.com/uploa...1434257305.jpg

I glued cork gasket material down to Cushion the condenser. The hardware is SS. I cut the 45 angle off the end of the tubing in the final.

Here it mounted. I used 1" rubber stoppers from Ace hardware for the legs and 5/8x1/8 flat al bar for the top brace. This stuff was a lot less easy to bend than I expected, it wanted to break so I bent it very gradually, hence the curvy line.


http://forums.pelicanparts.com/uploa...1434257599.jpg

The flat bar in front will hold rock guard, to be finalized once I figure out the hose routing.

The fan will push for obvious reasons.

Feeling fairly satisfied on the condenser install, I decide to starting taking the original system apart

Look what I found on top of the deck lid condenser:

http://forums.pelicanparts.com/uploa...1434258142.jpg

This gob on the left was the consistency of dryer lint that had "set up" over the years. It didn't seem to be animal in origin (no bones or other hard chunks).

I cleaned it up, flushed it out and reinstalled it. Debated about leaving it out but decided to use it still. It's here, and it can't hurt right?

I removed my original denso condenser in order to drown the oil. Only got out a teaspoon or so

I was puzzled by this. It's still in the pan so maybe more will ooze out overnight. Yes I rotated it. Planning to add fresh ester oil on reinstall.

http://forums.pelicanparts.com/uploa...1434258585.jpg

When I removed the line from the deck lid condenser to the front condenser, it dribbled a good amount of oil on the floor, I'd guess 3-4 oz.

Tomorrow I'm going to build some hoses and try to get the front condenser out and flush it. I couldn't figure that out today despite removing the screws at both ends and removing the cover screen. (Any hints out there?)

Has anyone tried cutting the ferrules off the old hose fittings and re-crimping on barrier hose with new ferrules? I may cut one open tomorrow to see what it's like.

I remember reading a thread where someone reused fittings. Seems it should be possible if you're patient. Fitting sure don't wear out. I kept a box full when I upgraded my hoses, cut and disposed of the rubber.

Great job, Nathan. I think fittings are cheap, maybe $6-10. I would use new. You will need #6 and #8, and maybe a #6 that fits on a #8 hose.
Good luck,
Dave

Dave,

I actually bought a #6 to #8 fitting, yesterday I realized i don't really need it. The hose from deck lid is an 8, so I assumed the front condenser inlet was an 8, but it's really a 6! The outlet of the 993 condenser is a 6. For this reason I have a lot of #8 hose that should be 6. So, either use 2 #6 to #8 and have an oversized long hose, or I get more #6 hose.

Cheers
Nathan

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

You don't want to put on a new ferrule exactly where the old one was. The tubing diameter is reduced under the ferrule and it will not crimp down effectively the second time.

use the proper size hose for the fitting, no reducers. You will lose cooling efficiency.
Nice job.

What do you suggest when you are connecting condensers in series and the outlet of the first is #6 and the inlet of the next is #8?
Thanks,
Dave

As long as we're on an AC thread, I was wondering what sort of numbers folks are shooting for on the high and low side after converting to R134a? I had my Carrera converted a few months ago (but not with exchanging to barrier hoses), and I'd like to keep track of these as well as the outlet temps achieved.

I can see a total rebuild of the system coming up as a winter project, and like seeing the additional condenser threads.

Hi Jack,
Here's some average good numbers:
low 25-35 PSI, High 180 PSI OAT 90 degrees vent temp 38 degrees @ 1500-2000 RPM. Windows closed fans speed high.
Good luck,
Dave

My question also.

The only "bridge" I found was a #8 hose with a #6 fitting. I was going to run 8 hose the whole length and step it down. Happily, that wasn't necessary, and I ordered more 6 hose and fittings This afternoon.