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  #1  
Old September 14th, 2013, 11:19 AM
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Oscar
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AC into 200TDi D110

Here is a modified copy and paste from Piekas':

http://www.defendersource.com/forum/...+tdi+ac&page=2

and Wolf Fabrication's AC threads:

http://www.defendersource.com/forum/...025&highlight=

Here's my Nostalgic air parts list:

UD 350 Under dash 36" valance
5589 2.5" duct hose tube 36"
DH 25 2.5" flexible duct hose
119-9907 Female Trinary Switch with inline switch port
HK923 Universal R-134a Hose kit with drier
5000 2.5" Pro Series Round Vent

total NAP order: $324.13

Old Air Products:

IP-1000 Heat, AC & Defrost electric switching Evaporator
IP-2000T AC Evaporator for rear AC
51-1037 Hose kit (rear AC)
25-1022 Rear AC Solenoid
21-321 AC Drier (might not need)

Old Air Products order: $1344.32

Automotive Alchemy:
ETC 5422 Water Pump Pulley
BTR1301 Compressor, A/C, 1993-1994 RRC, V-Belt
Dual 10" pusher Fan 10
STC3963 A/C Condenser
Custom compressor bracket

Automotive Alchemy parts: $675

Mastercool AC hose crimper:
http://www.amazon.com/Mastercool-715.../dp/B000WBQ4U2

Hose crimper: $165.80

Total for all parts so far: $2509

"Next Step, starting the install!" I will post pics of the test fitting for both the front and rear AC evaporators.

Oscar



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  #2  
Old September 14th, 2013, 12:58 PM
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Easy fix for rear evaporator. Need to make a braced bracket up to the fender well and to that rear tab that is conveniently positioned for a brace.



It will also need a splash guard.

big square hole is where the AUX fuel tank fill port used to be. It will be patched when truck goes to the body shop.
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  #3  
Old September 14th, 2013, 01:52 PM
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I have to flip the snail over. Basically remove it cut a hole and patch the other hole so it will exit closer to the existing air duct through the bulk head.


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  #4  
Old April 26th, 2015, 09:53 PM
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how did this turn out?? Did you install it?
thanks
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  #5  
Old April 27th, 2015, 11:35 AM
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Well...

I have completed the bracket and splash guard frame. It's powder coated and ready for install.

I'm working on a sheet metal rear trim panel to conceal all the vents and wiring for the cargo compartment. I have all the sheet metal tools I need to complete the job now (Brake, dies, nibbler, tub of dykem blue and a scribe) just waiting on the metal.

This project has been a bit delayed due to my move and career change but I'm slowly getting back on track.

One delay was the decision to run AUX heat as part of the package. I have since decided to make the AUX heat independent from the AC but they marry up easily should I decide to swap over.

I'll post pictures of what I have and hopefully will have AC before I don't need it anymore this year!
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Old October 21st, 2015, 02:04 PM
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Well I didn't get the AC in for this past summer AND its cold and I don't have heat, so time to get back to work.

Here is the evaporator on the bracket, also the FPHE for the rear heater (pew pew):



2x4 is temporary (yes my relay bank that I just installed is going to have to move:



Need to connect this to the wing plenum:







After I connect the plenum to HVAC I need to make another adapter from HVAC to bulkhead then through bulkhead to HVAC manifold. The plan is to have everything concealed behind the TD5 dash.

I thought initially I would make a rigid piece from the plenum to the evaporator but have since decided to have a flex piece in there just in case.
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Old October 27th, 2015, 10:17 AM
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Defroster/ Dash Plenum:



















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  #8  
Old October 28th, 2015, 05:45 AM
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  #9  
Old October 28th, 2015, 12:48 PM
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Old manifold vs modified one:





clears TD5 dash so far:

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  #10  
Old November 1st, 2015, 07:02 PM
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Finished in-dash plenum:



Evaporator to cabin manifold:













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  #11  
Old November 1st, 2015, 08:44 PM
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Nice install! What material are you using to build the plastic box and what glue to hold them together?

Thanks!
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  #12  
Old November 8th, 2015, 06:49 PM
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I didn't see your post Michael, I'm using ABS plastic sheet between 1/16 and 1/4 inch thickness. I'm using 2 part epoxy and sometimes I add ABS shavings into the mix.

Engine bay plenum:



Dash vents:



I didn't cut that squarish patch out for this FYI. PO.



Need to connect that hole (added a lip shown in second picture) with the manifold. Probably using 2.5 inch round hose.

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  #13  
Old November 29th, 2015, 02:55 PM
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  #14  
Old July 12th, 2016, 03:14 PM
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Had any chance to finish up the climate control work?
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  #15  
Old August 8th, 2016, 11:53 AM
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It works ok. I'm not crazy about the diverter so I'm just going to 3D print (ABS) a new manifold and kill off the air defrost. Going electric windshield anyway so why not.

It gets very hot in the winter but the flow out of the vents isn't impressive. I should have sealed every transition in the manifold but I didn't and I think that lead to the lower flow rate.
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