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Classic Retrofit Electrocooler installation report


austria3

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After preparation for classic retrofit electrocooler Installation ist compleated its time for my report of the installation to my car.

It is a Porsche 911S ’77, left hand drive car with a brake booster, originally a US delivered car which came to me with an original AC (probably dealer fitted as there was no front condenser but all parts used where factory) which I ripped out completely during the restauration as most of the parts (especially all the hoses) where shot.

Unlike most other left hand drive cars owner I did choose to route the hoses from and to the fan/compressor inside the luggage compartment instead of underneath the car because as mentioned above I had no front condenser and I didn’t want to drill holes in my bodywork. Also I didn’t feel comfortable having some hoses hanging under my car while my stone guard under the front axle has a lot of dents and marks in it.   

All in all I did work on the car for around 35 hours which was much more than I thought I would need. One reason I was so slow was that I only had time for this during the week after work (typically from 6:30 pm – 10:00pm). I think if I would have worked on this project for two days in a row it would have been enough time to finish this project.

Parts arrived:                                                                                                                                   separately ordered hoses:

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parts overview:

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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

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Test fitting the fan assembly, it is tight!

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This is the position I had to move the mounting screw

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

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

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Everything lined up and connected

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

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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.

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This is how I modified a standard rubber grommet

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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.

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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.

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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.

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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.

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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. (just for the record: I love my center console!)

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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  

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4.  Ductwork

Almost done, only the T-pieces and the ductwork.

That’s was what I thought but it was really hard work especially at the left hand side of the car because of the almost non existing space for anything (duct, hand, srewdriver,…)

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Done! 

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4. Filling

Picture taken at the shop while filling. Notebook for system testing prior to filling

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First attempt didn’t work because some of the fittings where not screwed together properly (I didn’t notice it during installation).

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After tightening and replacing the seals the second attempt did work just find and after one month the system is still working properly.  

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6.  Further Projects

-  smuggler box lid

To reinstall my smuggler box lid I have to make a cut out  

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-   steering tunnel cover

I also have make a new steering tunnel cover as mine did fell into pieces when I tried to make a cut out for the second (left hand side) drain hose.

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-     thermal insolation of hoses 

I am thinking about adding some thermal insulation to the hoses running inside my luggage compartment so I can use my carpet again and do not have to worry about condensation. I learned that I have to use rubber insolation because of the vapour diffusion. These type of insolation is available in 2m pieces  

 

-     scuttle panel support

I still need to work out a solution for that. I don’t like the idea of adding a support bracket to the blower housing which itself is mounted to the scuttle panel.

I found a second, original support in my parts box so I might cut that up and play around. 

 

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