Classic Retrofit Electrocooler installation report

[Synchro Joe]

Good review of one of these systems in UK. Classic Porsche Air Conditioning Test Drive - Ferdinand

[austria3]

Originally Posted by Canada Kev

Thanks for the write up. For the hole you don't know what to do about next to your power switch in the console, you could fill it with a USB accessory plug...

Thanks for the tip!
That's exactly what I did

[dyerkes]

Stefan,

Question, you indicated that you connected the “Blue/yellow – top of fuse 6 (arrow ‘1’)”, but won’t hooking the wire to the top essentially mean that the connection will bypass the fuse since you are taking the power from the hot side?

Thanks,
David

Originally Posted by austria3

3. Electric

Routing all the wires through existing holes in the bodywork took some time but adds to the smooth optic of the whole installation.




View inside the smuggler box. Red arrow points to the stud I used as ground point for the compressor unit. The blue arrows point to the exiting openings from the original AC which I closed.


Grey connector:
Blue/Red – wiper pin 53i (green wire)
Blue/white – switch for rear/front windshield heating - pin 3

Looking through the clock opening in the dashboard to the wiper motor. Red arrow indicates pin i53 (green wire) – wiper at full speed. To test if you have found the right pin/cable, just turn the wiper to full speed, if he doesn’t work, you disconnected the right one.


I used the original mounting bracket, which is still available from Porsche for around 10€, for the on/off push button. I had to enlarge the original hole slightly. I am not sure what to do with the second hole.


Fusebox:
Blue/yellow – top of fuse 6 (arrow ‘1’)
Black/yellow (switched live) – fuse 15 (arrow ‘2’)
Yellow (switched live) – fuse 15 (arrow ‘2’)
Red – fuse 18 (arrow ‘3’) (empty on my car), I also connected the red wire from the fan and the red wire of the on/off button to this fuse

[austria3]

from the ElectroCooler Install Manual

...the 3 defeat signals (Blue/Yellow, Blue/Red, Blue/white, all Grey Connector Harness) tell the ECU whether to slow or stop the AC compressor. Wire them to the 12V feed for higher current accessories…... These connections are not mandatory, the ECU can operate without them.

so to my understanding (not an electric expert) there is no power taken and no fuse bypassed.

[dyerkes]

I too am no expert in electrical wiring, however, based on my understanding these wires do draw power, and because you chose to attach them on the top of the fuse panel, you are drawing unfused power. The downside of this is that if there is a spike in power in this circuit, that the devices connected to the topside of the fuse block will not be protected by the surge as they will get power regardless of that fuse on he circuit having failed. If you or others feel my understanding is incorrect please let me know as I certainly want to have an accurate understanding.

[sithot]

Bring it here. LOL

914World.com - The fastest growing online 914 community!

[austria3]

It's been a while since my last post on this subject but all I can say is that I can't imagine the car without a proper air conditioning anymore. How could I live without one for so many years (14years to be exact)? I may get older and don’t like to drive around at highway speed with wide open windows anymore and I don’t like to arrive in soaking wet shirt anymore.

Anyway, here is a modification / additional part I want to present to you:

ElectroCooler foot well / blend valve cover

This is an improvement of the original 'snorkel' design by Jonny.
It was a long way which even included the purchase of a 3D-printer


a lot of hours spent on the computer and a lot of design changes later…


… I came up with this version:


installed it looks like this (passenger side on the LHD car shown):


inside it futures a dividing wall to separate the cold air coming from the ElectroCooler and the air sucked out of the cabin.




You can download the 3D printing files here


----------------------------------------------------------------------------------------------
Blend valve cover plug

My car came to me with a dealer fitted air-conditioning, one of the modification which was done back then was an additional opening in the blend valve top cover for the small side vents in the dash board.



Since this opening is no longer need with an ElectroCooler installed I designed this plug to shut this hole.



You can download the 3D printing file here

I also noticed that the cover had some sort of block of half way across the pipe diameter


I removed this


and not surprisingly the airflow was improved

[Jonny H]

Originally Posted by austria3

all I can say is that I can't imagine the car without a proper air conditioning anymore.

I'm with you on that - completely changes the car. I swear it feels bigger inside.

Very elegant design for the vents and thanks for sharing the files!

I found those blockages too in the factory parts. I think it was there to balance the air flow with the small hose (that you have deleted). I did exactly the same and removed the blockage.

[gremlin]

Austria3 Thank you for the files, awesome to have. What material did you print them from? I used PLA to begin with but I'm thinking it won't survive when the heat is coming out of them, so wondering if I should go PetG or ABS?

Also did you print them with supports? I don't know if my printer would run them without supports, but man are they a pain to clean off!

[rennch]

Did you make these files available? Maybe I can get them printed locally.

[rwest]

Originally Posted by emptyo

Did you make these files available? Maybe I can get them printed locally.

See post 27, he has links there.

[rennch]

Originally Posted by rwest

See post 27, he has links there.

Thank you!

[rsrguy]

I know tons has been written on this, but I can't find th answer at this point.
I had factory air... With the condenser up front, do I need or want to use this?
Will my factory vent manifold work with this system?

[harv666]

My question has been answered

[TrickySF]

Yes, you block the blend valve 40mm outlets. The 40mm hoses go directly from the outlets on each side of the blower to the metal outlets that feed the side vents.

[Fixer]

Who needs AC in a classic Porsche?

Asking for a friend.

[Jonny H]

Originally Posted by Fixer

Who needs AC in a classic Porsche?

Asking for a friend.

Well there are those that absolutely NEED it ( Florida, Texas, Thailand, Philippines, Hong Kong).

Then there are those that want it, which includes everybody who has ridden in my SC.

[austria3]

since I changed my website and I can not edit such old threads I have to quote myself

Originally Posted by austria3

Parts arrived:


separately ordered hoses


parts overview:

[austria3]

and more

Originally Posted by austria3

1. Condenser and fan assembly

The left hand head light has to come off to get access to the screw holding the top of the horse shoe bracket


Test fitting the fan assembly, it is tight!


This is the position I had to move the mounting screw


It is a very tight fit, red arrow points to edge of fan/bottom of front spoiler, green arrow points toward front of car.


red arrow point to bracket that holds the impact bumper damper, green arrow points toward front of car.


Everything lined up and connected


This is all you can see from the condenser on my car.

[austria3]

and more

Originally Posted by austria3

2. Routing hoses

I did choose the existing holes from the wind screen washer bottle to pass the hoses from the condenser to the luggage compartment. I had to slightly enlarge the holes to get enough space for the rubber grommet.


This is how I modified a standard rubber grommet






This is the tool I used to crimp the hose connectors. It is usually used to connect steel for reinforced concrete by twisting around some thin wire.