Holes in bulkhead for A/C - Defender Source
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  #1  
Old October 29th, 2010, 06:44 PM
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Holes in bulkhead for A/C

Getting my new bulkhead ready to galvy and want to add A/C as part of my build and would like to drill holes for A/C prior to dipping it.

Does anyone have pictures or directions for an A/C install that would show what holes are needed for A/C?

Thanks
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  #2  
Old October 30th, 2010, 04:52 PM
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Well I thought it would be easy to answer your question however it proved to be more difficult than I thought since having installed a wright acoustical mat.

This is from a 95 with "factory" air. I don't know if the new elite models have the same hole locations.

The condensation drain hole is basically a 3/4" hole, 5" to center line off the floor, and 1 3/4" to centerline to the left of the break in the bulkhead. See first 4 pic's. The hose is pretty flexible so I wouldn't imagine it would have to be exact. LR definitely didn't do a very good job drilling mine.

The high pressure and low pressure lines as well as the wire loom exit to the right of the fuse panel. I wasn't able to get a very good measurement on this. Maybe someone with a bulkhead out of the truck could do better. Measuring from the fuse panel to the right it is 1 7/8" to the center of the hole. Not the best reference but the only one I could get to. From the break in the bulkhead down to the top of the hole it is 1 3/8" and 3 1/8" to the bottom of the hole. The hole is elongated 1 1/4" wide x 1 3/4" tall.

Surely someone has the installation instructions anyway hope this helps.
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  #3  
Old October 31st, 2010, 02:02 AM
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The newer units use a completely different set-up than the old "factory" units. Units that came in NAS defenders had pipes that exited the inboard side of the condesor and went through an oval-shaped hole in the trans tunnel. New units from Elite have pipes exiting the back and terminating in an aluminum block that fits into a larger hole in the footwell.

Bottom line is that if you install an old system, you probably already have the holes, if you install a newer system you'll have to drill. I don't have a template for the positioning of the holes for the newer-style system.
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  #4  
Old October 31st, 2010, 07:47 AM
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This is good to know as i plan on updating mine too. Let us know what u come up with dave.
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  #5  
Old October 31st, 2010, 09:27 AM
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Like Jim said.. new units need 2 holes drilled into the passenger foot well.
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Old October 31st, 2010, 10:14 AM
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It would be buying a new new system so I guess the holes will be in a diffrent location that the ones posted. My bulkhead started life as a TD5 bulkhead so maybe it already has the proper holes... Hopefully not the ones I plugged yesterday

I will post a pic of my bulkhead later and maybe someone wil be able to tell if it has the proper holes.

also have an email in to ECR asking about price and availability, when they reply I will ask them about the holes as well and see if they have directions, a template or maybe pictures of where to drill the bulkhead holes for the new style.

Just noticed safarirover has some as well, not sure if they would work or not since they are 300tdi and I have a 200tdi.

FWIW I found some good photos that cgalpin posted for the old style.

Lines pass through here
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02054
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02072
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02078

Drain tube
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02061
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02062
Bolt holes in bulkhead to hold blower
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02066
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02070
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02071

Studs on bracket to firewall
http://gallery.lhsw.com/view_photo.p...AC&id=DSC02065

http://gallery.lhsw.com/view_photo.p...AC&id=DSC02068
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  #7  
Old October 31st, 2010, 12:51 PM
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Dave, the Td5 bulkhead has the 2 holes for the new system... its a large hole and a smaller hole in the passenger side front foot well. One hole is about 3/4 and the other is about 2" of the top of my head
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Old October 31st, 2010, 07:14 PM
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Randy,

Can you confirm if the 2 holes show in the following picture are the proper holes?

I patched the large hole as someone had posted that it is only used for the main harness of the TD5.

The large hole is about 2" and the small hole is about .900
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  #9  
Old October 31st, 2010, 07:48 PM
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Yup, the hole you plugged is for the new style A/C and the other small one is the drain hole. Just stick a rubber plug in it for now. Relax with the welder... lol
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