Stag Aftermarket AC System

[Rumbo]

Now that I have sorted the engine mounts in my Rover 3.9EFI stag it is time to fit an after market AC system.

I decided to go aftermarket as I had already done a similar fit to my Alfa 105GTV so I knew what I was getting myself in for.

Like the Alfa I decided to put the evaporator in the space where the glovebox normally sits, loosing the glovebox is a small price to pay to having AC in warm climates like Australia.

I needed to move the fuse relay panel to make space but luckly there was still enough room to leave the fuse box in its original position.

The evaporator came with a mounting bracket which I attached to the dashboard support bracket by making a couple of L shaped brackets and then bolting it all together.

I had to make sure there was enough room for the air ducting tubes to be fitted to the front outlets which will feed the vents at the end of the dash and the centre air vent.

Started to make a trunking to join up with the centre air vents from some leftover thin gal sheeting.

[mjheathcote]

Interesting solution, so I assume you are keeping the original heater box too?

[Rumbo]

Yes I have kept the heater box as standard, except I have added trunking to the centre vent outlets so that when the fresh air flap on the heater unit is closed, half of the AC cool air will be coming out of the centre vent and not back into the heater.

The trunking is coming along and I have tried to make more air come through this to make up for the smaller outlet pipes that divert cool air to the vents at the end of the dash.

[tvrgeek]

Is this because you do not have the factory AC unit? Just rebuilding mine, the evaporator seems it may be large enough. Going to a much bigger condenser, modern Sanden compressor, etc.
Fortunatlly, AC is more of a packaging nightmare than rocket science. I just ordered the Hayden PWM fan controller to manage a pair of larger pushers out front. It has an AC over-ride.

[malc4d]

Im also rebuilding my A/c. Can you tell me which condenser and compressor you will be using. Are you using an adapter plate York to sanden too ?

[tvrgeek]

Not got that far yet. Just refurbred the inside part. Yes, I'll use the adapter Vintage sells. Which condenser is whatever off-the shelf is as big as will fit. Generic drier with binary switch. I already modified the controls so to use a servo heater valve. ( I posted that). I did a complete DIY in my TVR and boy was that a shoehorn. Next step is just to get some hoses so I can button up the inside portion, put my dash back in and finish re-wiring. All new VDO gauges should get here this week.

[Rumbo]

I am going to use a sanden compressor and will get some brackets made up to suit my Rover 3.9L EFI so that it will fit on the RHS near the alternator using a serpentine belt to suit.

Here is the evaporator installed with some insulating foam over it and it fits nicely behind the glove box lid. Air flow from the 3 speed AC fan is also good.

I have also modified my centre console where I removed the useless ashtray and lighter to make way for a USB charger with volt meter.

Also fitted AC and other more modern switches to make the console less busy looking.

[malc4d]

Must say that looks good. I have the original A/cc heater box Etc. and will replace the other parts of the system. Tring to find out which compressor others have used ..

[trunt]

I am in the same boat, original a/c heater box but should I ever go for the a/c it will be a sanden with modern condenser etc. I have the original York bracket but was leaning towards a fabricated bracket and was considering weather one of those alternator repositioning brackets could be re-purposed to hold it.

One thing I did was replace the txv valve on the evaporator with one suitable for R134 gas. In the USA I found www.coldhose.com useful. They will make up custom hoses with the different type of fittings I will need. e.g. flare to o-ring. Also looked at reduced barrier hose, which is thinner and more flexible.

Terry

[Rumbo]

I have now begun more work on the AC system now that I have had to change the battery location and which is now in the boot with wiring supplying a new aftermarket power distribution point in the engine bay that will feed live power to Relays for the AC Clutch, AC Fan and also relays for the headlights.

I made up a couple of brackets from some mild steel angle, welded M5 nuts and M5 bolts to them. These brackets now bolt to the car and support the AC condenser and the combined AC/radiator fan that sits in front of the condenser.

I tried to reduce obstructing the air flow where possible and have also enlarged the inlet grill to allow more air to get to the condenser and radiator.

Next is locating the dryer.

condenser brackets (768x1024).jpgcondenser and fan (1024x768).jpg

[trunt]

nice..

What size Condenser, 16x16??

Terry

[Rumbo]

Thanks Terry.

The condenser is a 14 x 18 size, the Sanden compressor is a SD7H15.

I will move the transmission oil cooler to a new location as I did not want to block the air flow to the radiator anymore now that the AC condenser is in front.

Next I make up some brackets to mount the dryer and then the tricky bit making up brackets to mount the compressor.

[Rumbo]

I have now made a bracket with some mild steel sheet metal off cuts and welded nuts to it so that the AC dryer now bolts to it.

I temporarily ran the AC hoses from the condenser and the evaporator to ensure the dryer fittings line up with the hoses when it comes time to fitting the hoses and then charging the system.

Just need to fit the switch to the dryer and connect the new wires to the terminals.

The next task is making the compressor brackets and getting a serpentine belt to match .........this will probably be another MDF template job like I did with my engine mounts..... may take a while.

dryer bracket (1024x768).jpg

[STypeR]

I wanted a parallel flow condenser, a Sanden type compressor and a 16" main radiator fan.
All this meant I had to mount the condenser in the Mark 1 position (which sits on an angle between the front chassis rails), which I didn't mind as it gives greater airflow to the main radiator.
I ditched the very heavy (but robust) York compressor and its locally made bracket, found a period Sanden bracket, fabricated a receiver/dryer bracket and managed to get a hybrid (Australian market) modified Smiths heater/AC box. All fairly easily replicated.

[STypeR]

I made some brackets for the condenser in aluminium which will sit on anti vibration studs minimising fan vibrations.
It was possible to fit a 16" fan in front of the radiator as well as 2 small fans on top of the condenser. I made some brackets for the 16" main fan as well and mounted the main fan on anti vibration studs as well.
Unlike the beautiful original factory AC design the Australian made hybrid boxes whilst a smart local design has no ability to seal the middle dash vents when the heater is on to channel maximum airflow from the Japanese 2 speed fan trough the heater core. Despite this limitation there's reasonable airflow trough to the heater core.
The 'hybrid' Smiths box photos are supplied of the unrestored unit are from one of the local Stag owners.