1985 AC project

[SpyderMike]

Okay, so when I backdated my car about 9 years ago:

https://forums.pelicanparts.com/porsche-911-technical-forum/819396-so-how-backdate-project-starts.html

During that project I removed all of the AC components as most of them had failed. Since then I kludged together a fresh air blower system and that worked "okay". Now I am ready to start a new project and a newer AC system is it. I sold some of the old parts and that was a bit of a mistake. I had to buy a used EVAP box recently and that was way more than I sold mine for. Oh well!

The first bit of help I need (more to follow I am sure) is that I don't see in the PET how the outlet for the evaporator blower (the large round duct on top) connects to the bulkhead. I see images of a duct piece, but I don't recall what that flex duct joins to. Anyone know what I should be looking for in my hangar full of parts? Thanks in advance!

[SpyderMike]

I have the following parts on order already:

CR Electric Compressor
CR Front Fender Condenser
CR Heavy Duty Relay
CR Belly Pan Condenser fittings

Griffiths Hurricane Motor
Griffiths Evaporator
Griffiths Front Condenser
Griffiths Center AC Vent

Maradyne Blower for front condenser

[SpyderMike]

Here is the "stock" ducting scheme I will be using except I will be routing the two side ducts to some kind of vents, and will be getting rid of the bowtie for the Griffiths center vent.



My backdated heater hoses go direct to the defog vents. I don't need a complex fresh air system as this is a targa with windows that work.

[r_towle]

I have an 84 with AC.
Specifically, what are you looking for?
I’m about to remove the carpet and bent board to sort out some wiring in the front trunk.
Happy to take pics if you need some.

Rich

[SpyderMike]

I will be documenting my system build here. Right now I am looking for a passenger footwell to evap blower box connection piece (the trapezoid with the resistor pack in it), but if I can't find that I will conjure up something.

Thanks for your kind offer! Stay tuned

[Anjizkit]

subscribed!

[SpyderMike]

Okay, so the initial bench tests of the front condenser blower I found are very encouraging. It is quiet and moves alot of air. It can be located where I want it (where the original system blower was). It is a blower from a Marine Heater application. Here are the specs:





I got at Summit Racing for ~$100 delivered. I plan to wire it for highest speed with a PWM that I have to adjust it down if needed.
I am working on an adapter piece to go between it and the original mounting points. It will have a hole matching this unit's output hole and closing off a little of the original hole. Foam tape will be between any mounting surfaces.

Proposed orientation:

[jmz]

sub'd, following along on this one.

[SpyderMike]

I am actually going to turn the unit around. I dawned on me that the air supply to the blower would then be right near the original cutout in the front bulkhead for the Bosch fan. That way if I need to make a duct for that it would be a 90 degree fitting...pretty easy.

[SpyderMike]

Blower motor adapter plate is made...need foam tape to seal between it and car and between blower and it. The plate will be riveted to the car and the motor will be bolted to the plate. Gotta find some durable foam tape...

[SpyderMike]

Got some stuff done today...

Before pic:



Removed the battery - I will need a larger one with more capacity. Removed the battery bracket as well.

Removed the PWM controller for "old" kluged fresh air blower (marine bilge blower fan).

Disconnected fuel pump wiring so that I could remove the fuse block.

Put some new insulation tape on Evap Blower outlet ducting and installed both pieces. Connected the one main outlet to the center console vent. I used original car ducting but I might switch to a smooth inner flex duct down the road.

I think I will relocated the fuse block vertically where the cruise control computer used to be. A single bracket between upper and lower attach points on the car should do it. This should be out of the way of ducting and slightly closer to the new battery location (the car's original battery location).

After Pics:







I need to clean up the wiring and add some of the smaller eval blower outlet ducting. I also need to reroute the main starter cable as I moved it and cut it shorter when putting the battery in the Smuggler's Box. Maybe a fuse or a disconnect to join the two battery cables...

[SpyderMike]

Today I received my shipment from Griffiths in four separate boxes. It all looks packaged well!

Center Vent:


Evaporator:


Front Condenser:


Evaporator Blower Motor:

[SpyderMike]

Today I spent an hour or so getting the stiff Battery + wire routed back through the tunnel and into the footwell. I need a method for connecting it to an extender cable and have been researching Junction Boxes. Not too happy with the few choices out there...included the one for Porsche 997s. I may have to order a couple to get my hands on them.

I am also a bit concerned about the front condenser hanging below the front bumper...more so for aesthetics than performance. I may need to clean it up with a black piece of metal hanging in the front of it.

[SpyderMike]

My used adapter to the pax footwell came in today too:





It just needs a little cleanup and I need to remove the resistor pack. I have plenty to do now!

[911obgyn]

Nice blower setup probably moves more air.
I gotta do this! I removed most of the AC components on my 85 and its black. I have kept most of the components but it never worked

[SpyderMike]

It does move a lot of air...

I found a PEX adapter at the local HD and modified it to fit as a drain for the Evap Box as the one I received had it broken off. I need to glue it on once the parts are all prepped.







Then I cleaned up the old foam adhesive residue from the parts using som Goo Gone, removed the resistor pack from the Footwell to Evaporator Box connection.

I cut the motor supports for the Evap Blower motor to prepare for the Griffiths upgraded one and generally cleaned the parts up.



I am thinking about painting the black plastic bits black satin...not sure just yet.

[SpyderMike]

Yesterday's effort was focused on the evaporator box. Lots of little details to take care of:

making things line up properly,
installing the new evaporator blower motor,
clearancing for the evaporator exit tubes,
sealing unneeded holes,
locating and making a hole for the thermostat probe in a good location,
dressing slightly bent fins,
weatherstripping air paths for better efficiency,
rerouting my previously modified fresh air drain,
trimming the outgoing flex duct to be able to allow the eval box install,
installing and sealing the footwell connection piece after removing the resistor pack bracket,
buying and installing new bolts, washers and nuts to the two halves (6mmx1.0 X 20mm long).

I need to find my other eval box bracket - the one that attaches to the rear bulkhead to finish the install.

[SpyderMike]

Okay, so the evaporator box is okay in the smuggler's box once again. I still need one mount bracket and one clip to close it up. I also need to check cable routing for the power cable. I am thinking it will go with the fuel pump cable up through a grommet under the ducting.



So I need to move the car and I need to get it running to do so. I had disconnected the electrical to move the battery. I just ordered a 33" 1 AWG extender and will route that to the new battery position and then bolt it and insulate to the shorter original cable in the cockpit. I have a few ideas for that. I also made a temporary bracket for the fuse box using the cruise control box bracket mounting bolts. I might just leave it here as it is out of the way but accessible. It is at an angle due to the offset in chassis mount bolt locations. I might make one that attaches to the same location but puts the fuse box vertical...we will see.



I made a paper template and then transferred the shape to the cutting board as the new battery hold down floor. I will purchase a thicker and longer cutting board as I am thinking I might want to mount the AC Compressor there as well. I need to get the new battery in place and hook it up and start the car to move it.



The new battery is a 385CCA 30Ah Weize YTX30L-BS for $80. Classic Retrofit states that they have no problem running with this capacity battery. We will see!

[shamrok]

Great project, following closely.

[RSTarga]

Where will the front condenser fan get air from? The trunk?