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CAT-200 r12 test prep

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Rejuvenating your old air con will also be a cool task

a large clock mounted to the side © supplied by Hagerty a close up of a clock: Rob Siegel © supplied by Hagerty Rob Siegel

With the birth of summer time around the nook, a gearhead’s fancy turns to thoughts of… air conditioning—so you’re no longer sweating like a pig for your favourite vintage car.

good enough, maybe that’s just me.

Granted, my domestic in Boston doesn’t hang a blowtorch to Phoenix or Brownsville or Orlando, and some would argue that, for a guy from the temperate Northeast, I’ve long gone to insane lengths to have cold cars, however if you have real winters as we do, the driving season is already brief ample, and i find that while possessing different air-conditioned vehicles, those and not using a/C are likely to take a seat most of the summer time.

a couple of years again, when i used to be attending a antique BMW experience, I purchased a full-up A/C gadget from a guy who’d eliminated it from his BMW 2002. The equipment had been sitting in my basement, but when Boston had its first ninety-degree day just a few weeks in the past, I decided it was time to drag it off the shelf and set up it in my ’seventy two BMW 2002tii. I’m as much as my hips within the installation at the moment. So, whereas it’s all fresh in my mind, i believed I’d outline what’s involved.

Overview

Why is A/C distinctive in historical cars? when I say “old air con,” I mean a equipment where the A/C and warmth are separate (that is, no local weather control), it originally used R12 refrigerant (“Freon”), and it probably had flare fittings on some or all the add-ons. at the conclusion of this text there’s a link to my ebook, which matches into all the concerns in excruciating aspect.

Refrigerant: take into account that, whether you’re resurrecting an current gadget or setting up one from scratch, you need to contend with the difficulty of changing refrigerant. before the early Nineteen Nineties, automotive A/C programs used R12 (“Freon”). due to its effect on the earth’s ozone layer, the use of R12 in cars stopped in 1994, and automobile refrigerant switched over to R134a, which doesn’t cool in addition to R12. creation of R12 was banned in 1996, however individual cans of historic inventory are nevertheless available on eBay. It’s widely cited that buying or the use of R12 is illegal, however that’s without difficulty now not proper. It is right that, legally, you’re speculated to have an EPA 609 certificates to purchase R12, but sellers on Craigslist and facebook marketplace, and at yard earnings, on no account investigate. When R12 become discontinued, costs spiked to $a hundred a can, but at the moment, demand is so low for you to usually discover cans for roughly $25.

when you have a decent, leak-free device that at first used R12, there’s no doubt that the quickest route to getting it bloodless is to recharge it with R12, however the concern is that if the device was tight and leak-free, it will nevertheless have R12 in it, so if it doesn’t, it’s received a leak that first must be discovered and fixed (a car under no circumstances “just needs a recharge”). There are huge fines in case you’re caught venting R12 or any refrigerant into the atmosphere. shooting R12 requires R12-selected recycling gadget, and so few automobiles use R12 at the moment that fewer and fewer retail outlets have the recycling machine anymore. sure, there are “choice refrigerants” (issues like hot Shot), however you run into the same issue as R12 in that only a few shops have recycling gadget for them, so that you back your self right into a corner the place you’re the most effective adult who can service it. And if you’re a hobbyist, you practically definitely don’t have the recycling gadget both.

a can of soda: The R12 / R134a dilemma. Rob Siegel © offered by using Hagerty The R12 / R134a dilemma. Rob Siegel

For all these factors, these days I’m much less and less sanguine about the usage of R12; I best use it in one car whose evaporator assembly and console were so fragile that I didn’t need to take it out to flush it (because R12 and R134a use distinctive lubricating oils, all traces of the ancient R12-particular mineral oil should be flushed out earlier than the R134a-certain PAG oil is brought). for most individuals resurrecting an old A/C device, it makes sense to convert to R134a as part of the retrofit or resurrection manner. however seeing that R134a doesn’t cool in addition to R12, it’s smart that A/C rejuvenation include enhancements to the equipment in the variety of a brand new rotary-style compressor and a big parallel-circulation condenser and fan to make it perform enhanced.

One Paragraph of concept and layout: similar to your fridge or freezer or window A/C unit, automotive air conditioning works on the precept that gasoline cools when it expands. You adventure this phenomenon in the event you spray paint from a can or feel the cannister of propane on the barbecue grill getting bloodless. The compressor compresses the gas so it may possibly extend and do its cold-introduction thing. The evaporator assembly (evaporator core, enlargement valve, and blower fan) is the unit that sits below the dashboard, taking pictures that growth-created cold and blowing it at your face. The condenser sits in front of the radiator, dissipating the warmth. A receiver-drier has a desiccant pack in it to eliminate moisture from the refrigerant. The most effective material change between automobile A/C and a window A/C unit or fridge is that within the home software, the components are all internal the equal rectangular container, however in the automobile software, the accessories are distributed all the way through the automobile. The compressor is bolted to the engine block and pushed off the crankshaft with a belt, the evaporator is within the passenger compartment, the condenser is in front of the radiator, and the accessories are interconnected with hoses.

diagram: The basic layout of the A/C components. Just Needs a Recharge © offered through Hagerty The primary layout of the A/C accessories. simply wants a Recharge From-Scratch setting up

In many ways, retrofitting an A/C system from scratch is less demanding than rejuvenating an present device as a result of if every little thing is new, you don’t need to troubleshoot or examine the fitness of the current equipment. whereas A/C retrofit is a considerable job for which a forte store may additionally charge $4000–$6000 in substances and labor, if you’re already a DIY mechanic accustomed to different restore work, installing A/C your self is totally attainable, the elements bill can be in the $800–$1500 range, and it breaks up nicely into sub-projects, between which the vehicle continues to be drivable. The major steps are:

  • investigate if there are any showstoppers entertaining to your vehicle.
  • Procure and set up the evaporator assembly that lives below the dash and a console to surround it.
  • Procure and deploy a compressor and the bracket that holds it to the engine block.
  • Procure and deploy the condenser and fan that fit in entrance of the radiator.
  • Procure and installation a receiver-drier.
  • Punch two holes within the firewall for the evaporator hoses.
  • Make custom hoses that interconnect these 4 accessories.
  • join the electrical accessories.
  • Leak-examine.
  • Evacuate and cost.
  • below, I contact on the essential considerations you need to comprehend for every.

    pleasing showstoppers: each as soon as in a long time, whatever bites you. this can encompass having an engine block that isn’t drilled to acquire a compressor bracket, or your crankshaft pulley not having the extra groove obligatory for the compressor belt. The latter became the case with my 1972 BMW 2002tii, and because the car is routinely gasoline-injected, the crankshaft hub needed to be changed to one that had each the cog for the toothed injection belt and the compressor pulley, a really rare half.

    The non-A/C crankshaft hub (right) had to be replaced with one with a compressor pulley on it (right). Rob Siegel © offered through Hagerty The non-A/C crankshaft hub (right) had to be replaced with one with a compressor pulley on it (right). Rob Siegel

    Evaporator meeting: If the vehicle at first become attainable with A/C as a manufacturing facility or broking option, buying an normal evaporator assembly and console will give the indoors the most fashioned/factory look. in spite of this, contemporary aftermarket alternatives, in the event that they exist for your motor vehicle, can also work improved—they might also have a fan that blows tougher than the original, and an evaporator core and expansion valve that are optimized for R134a. Suppliers similar to old Air, historical Air products, Nostalgic Air, and others offer up to date evaporator assemblies in numerous sizes and configurations, but whether they’ll healthy between your vehicle’s transmission hump and dashboard, or even if a console is obtainable to surround them and looks at home in your automobile, is an extra depend. For a standard vehicle like a vintage Mustang, there are probably assorted options, but for an imprecise automobile, you’re commonly generally to your own. You could beginning off pondering that you just’d set up any evaporator meeting if it’s reasonably-priced and receives the vehicle cold, and lower back off when it’s top-rated to consult an enthusiast forum in your vehicle. Be mindful that in case you’re purchasing a used usual evaporator assembly, it’ll need to be disassembled so the enlargement valve can also be eliminated and the condenser flushed to eradicate any particulate count and traces of ancient oil.

    a chair sitting in front of a car: The more valuable a car is, the more likely it is you want to have the original evaporator assembly and A/C console in it. Rob Siegel © provided by Hagerty The greater effective a motor vehicle is, the more possible it is you are looking to have the normal evaporator assembly and A/C console in it. Rob Siegel A vintage evaporator assembly showing the evaporator core and the housing for the “squirrel cage” blower motor. Rob Siegel © supplied by Hagerty A vintage evaporator meeting showing the evaporator core and the housing for the “squirrel cage” blower motor. Rob Siegel

    Compressor and bracket: earlier than the 1980s, most normal A/C compressors have been tremendous, heavy, noisy, upright piston devices that looked like lawnmower engines. For a from-scratch installation, purchase a modern compact rotary-vogue compressor such because the Sanden 508, or one among its chinese-made clones, and a bracket to hang it to the engine block. The bracket is usually greater tricky to obtain than the compressor. As with the evaporator assembly, analyzing on an fanatic discussion board to your car is constantly necessary. standard bracket adapters (bracket-on-a-bracket) should still simplest be considered as a last hotel, as they add weight, can also be sources of rattles and buzzes, and may trigger belt misalignment.

    a close up of an engine: The ubiquitous Sanden 508 rotary-style compressor (this one’s actually a clone) and an application-specific bracket to mount it to the engine block. Rob Siegel © offered by using Hagerty the ubiquitous Sanden 508 rotary-style compressor (this one’s really a clone) and an application-selected bracket to mount it to the engine block. Rob Siegel

    Condenser and fan: ahead of about the year 2000, car A/C condensers have been “serpentine” fashion, which means a single thick tube snaked back and forth through the cooling fins. contemporary condensers, however, are of a parallel-move design, enabling refrigerant to movement through many small tubes simultaneously, expanding the volume of heat transferred. As such, if refrigerant is being changed from R12 to R134a, it’s strongly informed that you just purchase and installation the greatest parallel-circulation condenser that’ll fit in the nose, and the largest fan that’ll mount on the condenser. again, a fine consumer’s discussion board is your friend, as you’ll likely discover somebody else who has already decided these maximum dimensions. typical-healthy parallel-movement condensers are reasonably priced (commonly beneath $80) however require you to cobble collectively your personal mounting brackets. Drop-in parallel-stream condensers with mounting brackets within the fashioned places are simplest obtainable for a small handful of automobiles. company-name fanatics reminiscent of Spal are recommended over established affordable lovers both for motives of durability and the potential to in reality bring the quoted cubic-feet-per-minute (CFM) specifications.

    a circuit board: An old serpentine-flow condenser (black) and a modern parallel-flow unit (silver). Rob Siegel © supplied through Hagerty An historical serpentine-circulate condenser (black) and a modern parallel-circulation unit (silver). Rob Siegel

    Receiver-drier: Any established well-known-healthy receiver-drier can be used, set up the usage of a bracket anyplace it’s handy in the engine compartment.

    Holes in the firewall: individuals focal point on the should drill holes within the firewall as a disturbing or difficult a part of A/C installation, but gap saws do the job simply high-quality. Rubber grommets to seal between the hole and the hose can be found in general A/C hose sizes. Or, bulkhead fittings will also be used as an alternative. You nevertheless deserve to drill the holes, however the lock nuts take the location of the rubber grommets.

    People stress out about this, but it’s not really that big of a deal. Rob Siegel © provided by using Hagerty americans stress out about this, but it surely’s no longer definitely that massive of a deal. Rob Siegel

    Hoses: even if customary A/C hoses can be found for a vintage automobile, the chances that they’ll fit up-to-date accessories are slim, considering the fact that the element locations, mounting angles, and fittings are doubtless all distinct. in addition, each retrofit and rejuvenation are opportunities to upgrade the original leak-inclined flare fittings to contemporary o-ring fittings wherever viable. This potential custom hoses could be quintessential. by means of a long way the choicest solution to do this is to discover an A/C store if you want to make them at the motor vehicle with the aid of choosing probably the most acceptable angle for each fitting (straight, forty five levels, or 90 levels), crimping it onto one conclusion of a long hose, snaking the different conclusion via to where it must go, reducing it to size, and crimping the different conclusion on right there at the automobile. that you would be able to as an alternative are trying to measure with rope or an historical garden hose and order custom hoses from a dealer, reminiscent of coldhose.com, however because of the stiffness of A/C hoses, it’s in fact difficult to get it appropriate (longer isn’t all the time superior). The expensive crimping tool essential to installation the beadlock A/C hose fittings used to only be purchasable from remarkable companies like Mastercool, but chinese language-made knockoffs have made the device more low in cost for the do-it-yourselfer.

    a close up of items on a tabletop: You or a hose-making shop need this (Mastercool Hydra-Krimp 71500 or equivalent) … Rob Siegel © provided by way of Hagerty You or a hose-making store want this (Mastercool Hydra-Krimp 71500 or equal) … Rob Siegel … to turn this … Rob Siegel © supplied by way of Hagerty … to turn this … Rob Siegel a close up of a metal object: … into this. Rob Siegel © supplied via Hagerty … into this. Rob Siegel

    Electrical connections: Electrically, antique A/C techniques are very elementary. A multi-velocity blower fan change usually powers the blower and temperature switch and sends vigour to a relay that turns on the condenser fan. When the evaporator temperature is beneath a threshold price, the temperature swap turns on the compressor. If gadget force turns into too excessive, a swap cuts vigor to the compressor.

    diagram, engineering drawing: Basic electrical diagram of a vintage A/C system. Just Needs a Recharge © provided with the aid of Hagerty fundamental electrical diagram of a vintage A/C equipment. simply wants a Recharge

    Leak check: The greater work you do upfront to make sure a leak-free system, the stronger. I bring together the gadget, then drive-check it with nitrogen. If it doesn’t dangle pressure, leaks ought to be discovered. Engineered cleaning soap solution such as big Blu works smartly; spray it on all fittings and look for bubbles.

    a close up of a bottle: A nitrogen bottle and manifold gauge set used for pressure testing. Rob Siegel © provided by using Hagerty A nitrogen bottle and manifold gauge set used for pressure testing. Rob Siegel a close up of an engine: Large leaks show up fairly easily with soap solution. Rob Siegel © supplied by using Hagerty big leaks show up relatively quite simply with soap answer. Rob Siegel

    Evacuate and recharge: once the equipment is tight, you evacuate it (put a vacuum pump on it for 90 minutes to boil off any moisture internal), then can charge it with refrigerant. if you don’t have the equipment to do this yourself, that’s great; just pay somebody else to do it. You’ve already saved thousands of greenbacks via installation the A/C accessories yourself. however be certain you are taking it to an A/C area of expertise shop that knows a way to can charge a custom equipment, not only 1 that shoots in the volume of refrigerant on the sticky label below the hood.

    Rejuvenating an ancient equipment

    consider: The steps in rejuvenating an old equipment overlap extensively with a from-scratch installation, but they start with an comparison of the existing device. Is it comprehensive? became it working unless these days, but the refrigerant leaked out, or had been the hoses cut and the compressor thrown within the garbage someday during the Carter administration? every now and then, the best add-ons closing are the evaporator assembly under the sprint and the console round it, which on the one hand is ok as a result of that’s constantly the simplest component you’d need to reuse anyway, but if hoses were reduce or you’re changing to R134a, the evaporator will deserve to be removed and flushed, and counting on the automobile, getting it out without damaging historic fragile vinyl, particle board, and plastic can be essentially the most challenging a part of the restore.

    a dirty pan on a stove: If, when evaluating the status of your long-dead A/C system, you find this, it’s not good. Rob Siegel © provided by Hagerty If, when evaluating the reputation of your lengthy-lifeless A/C gadget, you discover this, it’s not good. Rob Siegel

    make a decision if you’re changing to R134a: If the gadget is intact, you need to decide if your basic strategy is a) Get it leak-free and recharge it with the usual R12 refrigerant, or b) Convert it to R134a and function the suggested compressor and condenser improvements. Many ’60s and ’70s American automobiles had one of the most overbuilt A/C programs ever installed. charge them returned up with R12 and that they’ll freeze a side of red meat. Flush them and charge them lower back up with R134a and that they may additionally nevertheless work nice. however in contrast, it doesn’t get as scorching in most of Europe (at least it didn’t in the 1960s and ’70s), and so European vehicles tended to have anemic A/C techniques that, even when charged with Freon, carried out correctly at most excellent, so converting them to R134a with out additionally upgrading the compressor and condenser is frequently a recipe for disappointment. be aware that the alternative of refrigerant contains with it the choice of oil—mineral oil for R12, PAG oil for R134a. Ester oil will work for both, however for some motive, it’s no longer favourite.

    Leak trying out: One major difference between rejuvenating and retrofitting is the nature of leak-testing. With retrofitting, you’re starting up with all new hoses, so except you screwed something up, the equipment should be leak-free, and if there is a leak, it’s continually at an incorrectly crimped becoming. In distinction, on an ancient gadget, leaks may also be anyplace and in every single place—within the middle of hoses, from the compressor seal, from interior the evaporator assembly … any place.

    If an A/C device had been working except currently, and if the compressor turns freely (isn’t seized) and all of the blower fanatics work, then the chances are strong that the refrigerant leaked out. This may also be validated with the aid of connecting a group of manifold vacuum gauges. if you’re fortunate, dye turned into delivered to the refrigerant right through a prior A/C service, through which case a U/V light and yellow glasses can be used to seek where the dye is leaking out. If not, pressurizing with nitrogen and staring at the pressure gauge is extraordinarily useful. If the gauge automatically drops, that you could constantly hear the nitrogen hissing out, and simply listening with a bit of hose to your ear, or feeling with your fingers, may be all it takes to locate the leak. then you definately pressurize it again to peer if it holds and repeat the manner except it’s tight.

    a close up of a bottle: In theory, if the system already has dye in it, you just shine the U/V light to look for the source of the dye. In practice, well … Rob Siegel © provided by using Hagerty In concept, if the gadget already has dye in it, you just shine the U/V light to look for the source of the dye. In follow, smartly … Rob Siegel

    This all can also sound intimidating, but it surely’s truly rather manageable. This 2002tii challenge is my third from-scratch installation, and that i’ve rejuvenated historical, useless A/C systems in eight different vehicles. the way I examine it, with the entire work we just do to keep automobiles at a base stage of functionality, A/C rejuvenation or retrofit is a project that, in the end, gives you anything fully marvelous that the automobile didn’t have earlier than, whatever that both increases your enjoyment of the motor vehicle and makes you greater comfortable while driving it. What may be more satisfying than that?

    ***

    Rob Siegel’s A/C publication, just needs a Recharge: The Hack MechanicTM book to antique air con, is accessible on Amazon. His new book, The better of The Hack MechanicTM: 35 years of hacks, kluges, and diverse car mayhem is available here. His different seven books are additionally accessible on Amazon, or you can order individually-inscribed copies from Rob’s web page, www.robsiegel.com.

    The post Rejuvenating your antique air con can also be a groovy assignment regarded first on Hagerty Media.


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