[T3] type3-vwtype3.org Digest, Vol 146, Issue 5
B Fye
vwfye311 at gmail.com
Sat Nov 19 16:46:36 PST 2022
This has me thinking for the pink notch and a top on it in the summer.
Hmmmm
On Sat, Nov 19, 2022, 4:23 PM <type3-vwtype3.org-request at lists.vwtype3.org>
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> Today's Topics:
>
> 1. Electric A/C Install in Jill's Type 34 Karmann Ghia
> (john carartbyjohn.com)
> 2. Re: Electric A/C Install in Jill's Type 34 Karmann Ghia
> (Keith Park)
>
>
> ----------------------------------------------------------------------
>
> Message: 1
> Date: Sat, 19 Nov 2022 23:20:59 +0000
> From: john carartbyjohn.com <john at carartbyjohn.com>
> To: "type3 at vwtype3.org" <type3 at vwtype3.org>
> Subject: [T3] Electric A/C Install in Jill's Type 34 Karmann Ghia
> Message-ID: <018DFDC4-62C9-4EC9-AC73-D671065F7F6A at carartbyjohn.com>
> Content-Type: text/plain; charset="utf-8"
>
> I have been getting a lot of questions and interest in the A/C that I
> recently installed in Jill?s Type 34 Karmann Ghia. First a little
> background on the motivation for the install. Jill has driven her Ghia to
> a number of the Type 3 Invasions, including 2018 in Scottsboro, AL and 2016
> in Prescott Valley, AZ. Both of these were long, 1328 and 3938 miles round
> trip respectively, in the middle of June and the weather can be a bit warm
> with temps over a 100F on each of those trips. On top of that, the Ghia is
> like driving in a fishbowl with all the glass, small roof panel, and narrow
> pillars. It can get a little warm in there. <G>
>
> After the Alabama trip, she asked what it would take to add A/C to her
> Ghia before making the next long drive for an Invasion or other event. I
> started to do some research on it. Gilmore Enterprises makes a Type 3
> specific kit (
> https://www.gilmore-enterprises.net/inc/sdetail/air_conditioner_kit__type_3__black_textured_under_dash_unit/138/551),
> but I didn?t like the idea of running the extra belt off of the fan pulley
> with a bolt on pulley that looks like it might compromise the cooling air
> intake a little and that requires you to cut into and slightly compromise
> the sheetmetal housing around the pulley/fan. I also didn?t like the idea
> of running the hoses all the way from the rear at the engine to the front
> along the underside of the vehicle. The under-dash unit is also a little
> plastic/modern looking for the styling of the Type 34. I have little doubt
> that the Gilmore system would work fine, but it was really not what I was
> looking for.
>
> A little more research led me to look at electrically driven compressors.
> There is no ?kit? available for the Type 3s or VWs in general for an
> electrically driven A/C system, so I had to piece one together. The best
> option I found for the compressor is a unit from RenCool, the MD-18
> compressor. I found mine on ebay for about $800 back in March of 2020.
> Looks like they are about double that now. Also looks like there are
> cheaper options for electrically driven compressors these days due top the
> growth of Electric Vehicles and their need for electrically driven A/C.
> Anyway, this is the unit I used?.
>
> RenCool MD-18 Electric A/C Compressor:
> https://www.streetfx.com.au/md18-dc-compressor
>
> The rest of the bits I got from Summit Racing and other suppliers and are
> a combination of Vintage Air parts and Powermaster parts. Here are link to
> the various parts?
>
> Vintage Air Mark IV Underdash Unit.
> https://www.summitracing.com/parts/vta-672001vhy
> Powermaster 150 Amp Alternator
> https://www.summitracing.com/parts/pwm-477491
> Remote Condenser/Fan https://www.summitracing.com/parts/vta-03500-ova
> Drier w/Trinary Switch https://www.summitracing.com/parts/vta-07323-vuc
> Battery Cable https://www.summitracing.com/parts/pwm-1-567
> Fittings and Hoses https://coldhose.com/
>
> https://www.carartbyjohn.com/GhiaACInstall/AC_Parts.jpg
>
> I really liked the look of the Vintage Air Mark IV Underdash Unit as it
> fit the looks of the 60s era of Jill?s Ghia. The 150 Amp alternator was
> probably a little bit of overkill, but the Rencool Unit can draw unto 60
> amps so upgrading the generator was a necessity. Probably didn?t need to
> go quite that big, but figured, go big or go home. The modification to the
> fan housing were going to be similar for a 90 Amp alternator as the 150
> Amp, anyway.
>
> So let?s get to the install. First order of business was to upgrade the
> electrical system. The main change here was to swap out the 30 Amp
> Generator for the 150 Amp Powermaster Alternator. I pulled the engine to
> make everything easier to work on.
>
> https://www.carartbyjohn.com/GhiaACInstall/Engine_Pull.jpg
>
> After removing the stock generator and the sheetmetal belt housing, I was
> left with this?
>
> https://www.carartbyjohn.com/GhiaACInstall/StockFanHousingSaddle.jpg
>
> My goal was to keep everything under the stock engine cover. This
> required me to carefully grind away the saddle on the fan housing for the
> generator to provide clearance for the large diameter alternator. This is
> what I started with?
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorChallenge.jpg
>
> After lots of careful grinding (remember that that the housing is
> magnesium and the grinding dust is flammable) with 2? diameter 36 grit on
> my 90 degree die grinder, I ended up with a nice flat surface as low as I
> could get it. I also was able to keep the two generator strap mounting
> studs that I will use for mounting the alternator brackets. I removed the
> stud on the left in these pictures to make the grinding easier.
>
> https://www.carartbyjohn.com/GhiaACInstall/Saddle_Grinding1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Saddle_Grinding2.jpg
>
> This is how the alternator will end up sitting on the fan housing. The
> center of the pulley lines up nicely in the hole in the sheetmetal belt
> housing and everything is low enough to fit under the stock engine cover.
> Now I just needed to make brackets to mount the alternator and allow for
> some adjustment for belt tensioning. BTW, the alternator shown in these
> pictures is the multi-groove belt pulley. The alternator also came with a
> single v-belt pulley which I ultimately used so I did not have to modify
> the stock fan pulley.
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit4.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit2.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit3.jpg
>
> I started out by mocking up the brackets using some heavy duty card
> stock. The small bracket on the left bolts to the fan housing using one of
> the existing strap mounting studs and one of the bolts that holds the two
> halves of the fan housing together. The small bracket on the far right
> bolts to the housing with one of the bolts that holds the fan housing
> halves together as shown in the second picture. The larger bracket on teh
> far left bolts to the small bracket on that side and to the pivot bolt on
> the alternator. The large bracket on the right is the alternator tension
> bracket that bolts to the small right hand bracket and the other generator
> strap stud. The 3rd picture shows them mocked up with the alternator.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_2.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_4.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_5.jpg
>
> Next I had to make the brackets in steel. Lots of cutting and welding and
> grinding later, I ended up with these steel versions. I did add a few
> gussets to the brackets to stiffen them up. If I were to do it again, I
> would probably go at least 1/8? thick steel stock for the brackets. The
> material I had on hand was only 2mm thick versus the 3+mm of the 1/8?
> stock. I would still add the gussets as well. These brackets have worked
> just fine though too.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_7.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_8.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_9.jpg
>
> Here is shot of the brackets painted up and installed...
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_11.jpg
>
> and one with the alternator installed. I ended up buying several
> different v-belts of different lengths for test fitting to get the right
> tension and still have the alternator pulley close to being centered in teh
> hole of the sheetmetal belt housing which is obviously not installed yet in
> this photo.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_12.jpg
>
> Next up was one of two significant body modifications I had to make for
> the system. I need to provide a little more room under the dash for the
> Mark IV Underdash Unit. For the Ghia, I was able to simply cut out a
> portion of the under dash sheetmetal (as outlined in Sharpie here) and then
> flip it over and weld it back in. I added end plates to close it off and
> provide a convenient vertical surface for the bulkhead fittings for the A/C
> lines. I don?t have a picture of the finished sheetmetal work with the end
> plates, but you get the idea.
>
> Before - Topside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_1.jpg
>
> Before - Underside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_2.jpg
>
> After cutting out the panel - Underside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_6.jpg
>
> After cutting out the panel and flipping it. I liked how it let me retain
> the factory beads, even if they were reversed.
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_5.jpg
>
> The only modification necessary to the engine bay was routing the large
> single wire for the alternator around to hook up to the positive cable at
> the starter. Easy peasy. With the single wire alternator, you do lose
> your idiot light for the generator. I will eventually install a voltmeter
> so that we can have some indication if the belt fails. The nice thing
> about the Type 3 is that the belt only runs the alternator and not the
> cooling van like on the Beetles so loosing the belt is not as catastrophic.
>
> https://www.carartbyjohn.com/GhiaACInstall/EngineBayWiring.jpg
>
> The other body modifications were up in the spare tire well for the
> condenser, fan, compressor, and dryer. I modified the removable spare tire
> well to use as a mount and ducting for the condenser and fan. I also cut
> to opening in the front apron below the bumper to let in cooling air, as
> seen below. I also welded in a piece of 1/2? square tubing between the
> inner fenders to be used to help mount the compressor.
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_2.jpg
>
> I welded a few studs to the inside of the apron to mount some metal mesh
> to protect the air inlets. With Jill?s car being as low as it is, you
> can?t even see these inlets unless you lay down on the ground to look for
> them. Very stealth. <G>
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_4.jpg
>
> I built a couple of mounting brackets for the dryer and attached it the
> inner fender with sheetmetal screws.
>
> https://www.carartbyjohn.com/GhiaACInstall/DryerMount.jpg
>
> These are the mounting plates for the compressor bracket. One welder to
> the crossmember in front of the fuel tank and one welded to the crossmember
> I added.
>
> https://www.carartbyjohn.com/GhiaACInstall/CompresorMounts_1.jpg
>
> These next two photos show the modifications and the sheetmetal duct/mount
> that I built for the condenser and electric fan. This worked out really
> nicely.
>
> https://www.carartbyjohn.com/GhiaACInstall/Condensor_1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Condensor_2.jpg
>
> Next up was mocking up and fitting all of the A/C lines. I bought my
> fittings from ColdHose. Good stuff. This is the fitting from compressor
> out to the evaporator in the under dash unit. The blue cap is the fill
> service port. One of the challenges I had was with the compressor location
> I chose, I did not have enough clearance between the fill port and the
> sheetmetal to get the fill hose fitting on. In my case, I was able to
> simply mount the compressor bracket with two of the 4 bolts temporarily for
> filling and then move it back over and bolt it with all 4 after it was
> filled. Could have also chosen to use a simple elbow here and get a
> straight fitting with the fill port and put it inline elsewhere with
> clearance.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_1.jpg
>
> These are some of the other fittings needed. The two at the top of the
> photo end up under the dash panel at the under dash unit. I chose to use a
> bulkhead fitting do pass from the outside to the inside of the car These
> fittings or on the lower right of this photo. The lower center fitting is
> for the trinity switch that controls the fan and compressor. The fitting
> on the fuel tank is an extra one that I didn?t end up using.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_4.jpg
>
> These are the fittings at the condenser and dryer. All 90 degree elbows.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_3.jpg
>
> These are the fittings on the under dash unit. Even with the body
> modifications, these were a tight fit.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_5.jpg
>
> Starting to get everything installed for the final time. You can see the
> bracket I fabricated for mounting the compressor. It is two pieces of
> angle iron welded back-to-back. The compressor has rubber soft mounts to
> help with vibration isolation. You can also see the small vertical brace I
> added at the center of the 1/2? square tubing crossmember I added. It goes
> up to the crossbar between the fog lamp housings and really stiffens up the
> added crossmember. The compressor is quite heavy.
>
> https://www.carartbyjohn.com/GhiaACInstall/CompresorMounts_2.jpg
>
> I had to crimp on some of the heavy cable lugs for the plug connecting the
> compressor power feed to the cables coming from the battery. I sprung for
> the hydraulic crimping tool from Harbor Freight and it worked great.
>
> https://www.carartbyjohn.com/GhiaACInstall/PowerCableEnds.jpg
>
> You can start to see some of the hose and electric routing here. The
> upper block in the the red cabling is a 125 Amp mega fuse and the lower
> block is the quick-disconnect plug that has the crimped-on ends I showed
> above.
>
> https://www.carartbyjohn.com/GhiaACInstall/Wiring_1.jpg
>
> Here is the Underdash Unit installed. One thing I don?t have pictures of
> is the mounting brackets for this unit. Basically, I fabricated a U-shaped
> bracket that bolts to the unit and then to the pencil braces that run from
> the instrument panel sheetmetal to the underwood dash panel. These are
> stock pencil braces on the Type 34 Ghia. There is also a mounting strap
> from the blower motor up to the stud for the radio mounting bracket.
> Pretty basic mounting. You can also see the black and red cabling that
> runs along the passenger side of the tunnel from the battery up through the
> under dash panel and to the quick-disconnect for the compressor.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_1.jpg
>
> The Vintage Air Mark IV Underdash Unit really fits in nicely with the
> styling of the Ghia. The clearance to the shifter when shifting into 1st
> and 3rd is sub-optimal. There is room, but if you forget it is tight and
> are jamming through the gears, you get a quick reminder of the clearance
> when you bang your knuckles agains the unit. <G> I am going to look at
> getting new bushings and maybe shorter throw shifter to try and tighten
> things up a little bit and reduce the slop in the shifter throws.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_2.jpg
>
> You also have to worry about provide a drain for the condensate water that
> is produced by the under dash unit. Vintage Air provides the tubing and
> fittings for this. In the Ghia, I had to modify the outlets of the unit
> and the elbows to get everything more compact to the unit so that we had
> foot clearance. It worked out just fine and there is plenty of clearance
> even with my 10.5 size boots on. The drinks hose simply goes down through
> a grommeted hole in the corner of the floorpan and exits under the
> vehicle. You can see any of this while sitting in the car.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_3.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_4.jpg
>
> One last shot with the wiring complete and everything installed. The two
> relays on the dash panel are for the fan power and the compressor signal
> power. You an also see the start of the spare tire mount that I built over
> the fuel tank since the spare tire well is now full of A/C bits and pieces.
>
> https://www.carartbyjohn.com/GhiaACInstall/Wiring_2.jpg
>
> I am really happy with the way this turned out and the performance of the
> system. The MD18 Compressor is super quiet and I have it wired to operate
> at the lowest of the three speed that are available and it makes more than
> enough cold air to keep the relatively small interior volume of the Ghia
> comfortable. Of course we haven?t tried it on a 100F degree day yet
> either. It is a simple wiring swap to change the speed to one fo the
> higher settings if necessary.
>
> Happy to talk more about this with anyone and provide more details if
> necessary. Happy cooled Type3ing!
>
>
> ------------------------------
>
> Message: 2
> Date: Sat, 19 Nov 2022 19:22:47 -0500
> From: "Keith Park" <topnotch at nycap.rr.com>
> To: <type3 at vwtype3.org>
> Subject: Re: [T3] Electric A/C Install in Jill's Type 34 Karmann Ghia
> Message-ID: <000901d8fc76$37e93340$a7bb99c0$@nycap.rr.com>
> Content-Type: text/plain; charset="UTF-8"
>
> Wow! Thanks for the write-up and posting, ive seen it... quite impressive
> but seeing what it took to put it together is priceless!
> Hmm... something next for the Square??
>
> Keith
>
>
> Topnotch Restorations
> topnotch at nycap.rr.com
> http://www.topnotchresto.com
> 71 Squareback ?Hothe?
> 65 Notchback ?El Baja Rojo?
> 93 RX7 ?Redstur?
> 13 Subaru Outback "Blendin"
>
> -----Original Message-----
> From: type3-vwtype3.org <type3-vwtype3.org-bounces at lists.vwtype3.org> On
> Behalf Of john carartbyjohn.com
> Sent: Saturday, November 19, 2022 6:21 PM
> To: type3 at vwtype3.org
> Subject: [T3] Electric A/C Install in Jill's Type 34 Karmann Ghia
>
> I have been getting a lot of questions and interest in the A/C that I
> recently installed in Jill?s Type 34 Karmann Ghia. First a little
> background on the motivation for the install. Jill has driven her Ghia to
> a number of the Type 3 Invasions, including 2018 in Scottsboro, AL and 2016
> in Prescott Valley, AZ. Both of these were long, 1328 and 3938 miles round
> trip respectively, in the middle of June and the weather can be a bit warm
> with temps over a 100F on each of those trips. On top of that, the Ghia is
> like driving in a fishbowl with all the glass, small roof panel, and narrow
> pillars. It can get a little warm in there. <G>
>
> After the Alabama trip, she asked what it would take to add A/C to her
> Ghia before making the next long drive for an Invasion or other event. I
> started to do some research on it. Gilmore Enterprises makes a Type 3
> specific kit (
> https://www.gilmore-enterprises.net/inc/sdetail/air_conditioner_kit__type_3__black_textured_under_dash_unit/138/551),
> but I didn?t like the idea of running the extra belt off of the fan pulley
> with a bolt on pulley that looks like it might compromise the cooling air
> intake a little and that requires you to cut into and slightly compromise
> the sheetmetal housing around the pulley/fan. I also didn?t like the idea
> of running the hoses all the way from the rear at the engine to the front
> along the underside of the vehicle. The under-dash unit is also a little
> plastic/modern looking for the styling of the Type 34. I have little doubt
> that the Gilmore system would work fine, but it was really not what I was
> looking for.
>
> A little more research led me to look at electrically driven compressors.
> There is no ?kit? available for the Type 3s or VWs in general for an
> electrically driven A/C system, so I had to piece one together. The best
> option I found for the compressor is a unit from RenCool, the MD-18
> compressor. I found mine on ebay for about $800 back in March of 2020.
> Looks like they are about double that now. Also looks like there are
> cheaper options for electrically driven compressors these days due top the
> growth of Electric Vehicles and their need for electrically driven A/C.
> Anyway, this is the unit I used?.
>
> RenCool MD-18 Electric A/C Compressor:
> https://www.streetfx.com.au/md18-dc-compressor
>
> The rest of the bits I got from Summit Racing and other suppliers and are
> a combination of Vintage Air parts and Powermaster parts. Here are link to
> the various parts?
>
> Vintage Air Mark IV Underdash Unit.
> https://www.summitracing.com/parts/vta-672001vhy
> Powermaster 150 Amp Alternator
> https://www.summitracing.com/parts/pwm-477491
> Remote Condenser/Fan https://www.summitracing.com/parts/vta-03500-ova
> Drier w/Trinary Switch https://www.summitracing.com/parts/vta-07323-vuc
> Battery Cable https://www.summitracing.com/parts/pwm-1-567
> Fittings and Hoses https://coldhose.com/
>
> https://www.carartbyjohn.com/GhiaACInstall/AC_Parts.jpg
>
> I really liked the look of the Vintage Air Mark IV Underdash Unit as it
> fit the looks of the 60s era of Jill?s Ghia. The 150 Amp alternator was
> probably a little bit of overkill, but the Rencool Unit can draw unto 60
> amps so upgrading the generator was a necessity. Probably didn?t need to
> go quite that big, but figured, go big or go home. The modification to the
> fan housing were going to be similar for a 90 Amp alternator as the 150
> Amp, anyway.
>
> So let?s get to the install. First order of business was to upgrade the
> electrical system. The main change here was to swap out the 30 Amp
> Generator for the 150 Amp Powermaster Alternator. I pulled the engine to
> make everything easier to work on.
>
> https://www.carartbyjohn.com/GhiaACInstall/Engine_Pull.jpg
>
> After removing the stock generator and the sheetmetal belt housing, I was
> left with this?
>
> https://www.carartbyjohn.com/GhiaACInstall/StockFanHousingSaddle.jpg
>
> My goal was to keep everything under the stock engine cover. This
> required me to carefully grind away the saddle on the fan housing for the
> generator to provide clearance for the large diameter alternator. This is
> what I started with?
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorChallenge.jpg
>
> After lots of careful grinding (remember that that the housing is
> magnesium and the grinding dust is flammable) with 2? diameter 36 grit on
> my 90 degree die grinder, I ended up with a nice flat surface as low as I
> could get it. I also was able to keep the two generator strap mounting
> studs that I will use for mounting the alternator brackets. I removed the
> stud on the left in these pictures to make the grinding easier.
>
> https://www.carartbyjohn.com/GhiaACInstall/Saddle_Grinding1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Saddle_Grinding2.jpg
>
> This is how the alternator will end up sitting on the fan housing. The
> center of the pulley lines up nicely in the hole in the sheetmetal belt
> housing and everything is low enough to fit under the stock engine cover.
> Now I just needed to make brackets to mount the alternator and allow for
> some adjustment for belt tensioning. BTW, the alternator shown in these
> pictures is the multi-groove belt pulley. The alternator also came with a
> single v-belt pulley which I ultimately used so I did not have to modify
> the stock fan pulley.
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit4.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit2.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Alternator_Fit3.jpg
>
> I started out by mocking up the brackets using some heavy duty card
> stock. The small bracket on the left bolts to the fan housing using one of
> the existing strap mounting studs and one of the bolts that holds the two
> halves of the fan housing together. The small bracket on the far right
> bolts to the housing with one of the bolts that holds the fan housing
> halves together as shown in the second picture. The larger bracket on teh
> far left bolts to the small bracket on that side and to the pivot bolt on
> the alternator. The large bracket on the right is the alternator tension
> bracket that bolts to the small right hand bracket and the other generator
> strap stud. The 3rd picture shows them mocked up with the alternator.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_2.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_4.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_5.jpg
>
> Next I had to make the brackets in steel. Lots of cutting and welding and
> grinding later, I ended up with these steel versions. I did add a few
> gussets to the brackets to stiffen them up. If I were to do it again, I
> would probably go at least 1/8? thick steel stock for the brackets. The
> material I had on hand was only 2mm thick versus the 3+mm of the 1/8?
> stock. I would still add the gussets as well. These brackets have worked
> just fine though too.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_7.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_8.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_9.jpg
>
> Here is shot of the brackets painted up and installed...
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_11.jpg
>
> and one with the alternator installed. I ended up buying several
> different v-belts of different lengths for test fitting to get the right
> tension and still have the alternator pulley close to being centered in teh
> hole of the sheetmetal belt housing which is obviously not installed yet in
> this photo.
>
> https://www.carartbyjohn.com/GhiaACInstall/AlternatorBRKT_12.jpg
>
> Next up was one of two significant body modifications I had to make for
> the system. I need to provide a little more room under the dash for the
> Mark IV Underdash Unit. For the Ghia, I was able to simply cut out a
> portion of the under dash sheetmetal (as outlined in Sharpie here) and then
> flip it over and weld it back in. I added end plates to close it off and
> provide a convenient vertical surface for the bulkhead fittings for the A/C
> lines. I don?t have a picture of the finished sheetmetal work with the end
> plates, but you get the idea.
>
> Before - Topside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_1.jpg
>
> Before - Underside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_2.jpg
>
> After cutting out the panel - Underside
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_6.jpg
>
> After cutting out the panel and flipping it. I liked how it let me retain
> the factory beads, even if they were reversed.
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashMod_5.jpg
>
> The only modification necessary to the engine bay was routing the large
> single wire for the alternator around to hook up to the positive cable at
> the starter. Easy peasy. With the single wire alternator, you do lose
> your idiot light for the generator. I will eventually install a voltmeter
> so that we can have some indication if the belt fails. The nice thing
> about the Type 3 is that the belt only runs the alternator and not the
> cooling van like on the Beetles so loosing the belt is not as catastrophic.
>
> https://www.carartbyjohn.com/GhiaACInstall/EngineBayWiring.jpg
>
> The other body modifications were up in the spare tire well for the
> condenser, fan, compressor, and dryer. I modified the removable spare tire
> well to use as a mount and ducting for the condenser and fan. I also cut
> to opening in the front apron below the bumper to let in cooling air, as
> seen below. I also welded in a piece of 1/2? square tubing between the
> inner fenders to be used to help mount the compressor.
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_2.jpg
>
> I welded a few studs to the inside of the apron to mount some metal mesh
> to protect the air inlets. With Jill?s car being as low as it is, you
> can?t even see these inlets unless you lay down on the ground to look for
> them. Very stealth. <G>
>
> https://www.carartbyjohn.com/GhiaACInstall/CondensorCutOuts_4.jpg
>
> I built a couple of mounting brackets for the dryer and attached it the
> inner fender with sheetmetal screws.
>
> https://www.carartbyjohn.com/GhiaACInstall/DryerMount.jpg
>
> These are the mounting plates for the compressor bracket. One welder to
> the crossmember in front of the fuel tank and one welded to the crossmember
> I added.
>
> https://www.carartbyjohn.com/GhiaACInstall/CompresorMounts_1.jpg
>
> These next two photos show the modifications and the sheetmetal duct/mount
> that I built for the condenser and electric fan. This worked out really
> nicely.
>
> https://www.carartbyjohn.com/GhiaACInstall/Condensor_1.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/Condensor_2.jpg
>
> Next up was mocking up and fitting all of the A/C lines. I bought my
> fittings from ColdHose. Good stuff. This is the fitting from compressor
> out to the evaporator in the under dash unit. The blue cap is the fill
> service port. One of the challenges I had was with the compressor location
> I chose, I did not have enough clearance between the fill port and the
> sheetmetal to get the fill hose fitting on. In my case, I was able to
> simply mount the compressor bracket with two of the 4 bolts temporarily for
> filling and then move it back over and bolt it with all 4 after it was
> filled. Could have also chosen to use a simple elbow here and get a
> straight fitting with the fill port and put it inline elsewhere with
> clearance.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_1.jpg
>
> These are some of the other fittings needed. The two at the top of the
> photo end up under the dash panel at the under dash unit. I chose to use a
> bulkhead fitting do pass from the outside to the inside of the car These
> fittings or on the lower right of this photo. The lower center fitting is
> for the trinity switch that controls the fan and compressor. The fitting
> on the fuel tank is an extra one that I didn?t end up using.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_4.jpg
>
> These are the fittings at the condenser and dryer. All 90 degree elbows.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_3.jpg
>
> These are the fittings on the under dash unit. Even with the body
> modifications, these were a tight fit.
>
> https://www.carartbyjohn.com/GhiaACInstall/Fittings_5.jpg
>
> Starting to get everything installed for the final time. You can see the
> bracket I fabricated for mounting the compressor. It is two pieces of
> angle iron welded back-to-back. The compressor has rubber soft mounts to
> help with vibration isolation. You can also see the small vertical brace I
> added at the center of the 1/2? square tubing crossmember I added. It goes
> up to the crossbar between the fog lamp housings and really stiffens up the
> added crossmember. The compressor is quite heavy.
>
> https://www.carartbyjohn.com/GhiaACInstall/CompresorMounts_2.jpg
>
> I had to crimp on some of the heavy cable lugs for the plug connecting the
> compressor power feed to the cables coming from the battery. I sprung for
> the hydraulic crimping tool from Harbor Freight and it worked great.
>
> https://www.carartbyjohn.com/GhiaACInstall/PowerCableEnds.jpg
>
> You can start to see some of the hose and electric routing here. The
> upper block in the the red cabling is a 125 Amp mega fuse and the lower
> block is the quick-disconnect plug that has the crimped-on ends I showed
> above.
>
> https://www.carartbyjohn.com/GhiaACInstall/Wiring_1.jpg
>
> Here is the Underdash Unit installed. One thing I don?t have pictures of
> is the mounting brackets for this unit. Basically, I fabricated a U-shaped
> bracket that bolts to the unit and then to the pencil braces that run from
> the instrument panel sheetmetal to the underwood dash panel. These are
> stock pencil braces on the Type 34 Ghia. There is also a mounting strap
> from the blower motor up to the stud for the radio mounting bracket.
> Pretty basic mounting. You can also see the black and red cabling that
> runs along the passenger side of the tunnel from the battery up through the
> under dash panel and to the quick-disconnect for the compressor.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_1.jpg
>
> The Vintage Air Mark IV Underdash Unit really fits in nicely with the
> styling of the Ghia. The clearance to the shifter when shifting into 1st
> and 3rd is sub-optimal. There is room, but if you forget it is tight and
> are jamming through the gears, you get a quick reminder of the clearance
> when you bang your knuckles agains the unit. <G> I am going to look at
> getting new bushings and maybe shorter throw shifter to try and tighten
> things up a little bit and reduce the slop in the shifter throws.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_2.jpg
>
> You also have to worry about provide a drain for the condensate water that
> is produced by the under dash unit. Vintage Air provides the tubing and
> fittings for this. In the Ghia, I had to modify the outlets of the unit
> and the elbows to get everything more compact to the unit so that we had
> foot clearance. It worked out just fine and there is plenty of clearance
> even with my 10.5 size boots on. The drinks hose simply goes down through
> a grommeted hole in the corner of the floorpan and exits under the
> vehicle. You can see any of this while sitting in the car.
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_3.jpg
>
> https://www.carartbyjohn.com/GhiaACInstall/UnderDashUnitInstall_4.jpg
>
> One last shot with the wiring complete and everything installed. The two
> relays on the dash panel are for the fan power and the compressor signal
> power. You an also see the start of the spare tire mount that I built over
> the fuel tank since the spare tire well is now full of A/C bits and pieces.
>
> https://www.carartbyjohn.com/GhiaACInstall/Wiring_2.jpg
>
> I am really happy with the way this turned out and the performance of the
> system. The MD18 Compressor is super quiet and I have it wired to operate
> at the lowest of the three speed that are available and it makes more than
> enough cold air to keep the relatively small interior volume of the Ghia
> comfortable. Of course we haven?t tried it on a 100F degree day yet
> either. It is a simple wiring swap to change the speed to one fo the
> higher settings if necessary.
>
> Happy to talk more about this with anyone and provide more details if
> necessary. Happy cooled Type3ing!
>
> _______________________________________________
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>
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>
> Subject: Digest Footer
>
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> ------------------------------
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> End of type3-vwtype3.org Digest, Vol 146, Issue 5
> *************************************************
>
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