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Author: Subject: Advantages of a jap engine - climate control!
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posted on November 23rd, 2005 at 08:44 AM



why not nick the vents out of a bay kombi (you can take their holders out of the dash as well with a bit of care) or the classy little ones from a late t3? the late t3 ones fit in about the position you are thinking of and are a nice simple look.



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posted on November 23rd, 2005 at 09:59 AM



Quote:
Originally posted by baybuscamperkid
why not nick the vents out of a bay kombi (you can take their holders out of the dash as well with a bit of care) or the classy little ones from a late t3? the late t3 ones fit in about the position you are thinking of and are a nice simple look.


Wes considered Kombi vents but they are bigger and don't look as cool as the Mx5 ones.




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posted on November 23rd, 2005 at 12:14 PM



I like the reposted first one

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posted on November 23rd, 2005 at 12:47 PM



You can dress up those plastic vents with stainless steel dress rings. I've put them in my MX-5 and they look great.
Another option would be the vents out of the Toyota RAV4. They are round as well but have flaps that can be closed, unlike the MX-5 ones.
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posted on November 23rd, 2005 at 01:03 PM



a friend recommended closing vents from an S15 Nissan. They look cool too but would probably be pricey and hard to find...

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posted on November 23rd, 2005 at 01:22 PM



Yes, they look similar to the RAV4 ones
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posted on November 24th, 2005 at 07:13 PM



What about some old mini air outlets?

The ones I have in my Libra must be pretty cheap and easy to get hold of, I've never looked tho'

http://www.ricola.co.uk/images/Libra_images/interior_5.JPG

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posted on November 25th, 2005 at 09:32 AM



looking good wes cant wait to see it up close and personal!!
cheers
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posted on December 12th, 2005 at 12:54 PM



The climate control has been moving along slowly. Too many other things going on this time of year (xmas parties, birthdays, Motorcycle toy runs, broken house air con, planting gardens, putting up xmas lights, mowing the lawn that grows too damn fast). I was planning to finish the wiring on Saturday, but the 36 deg C temperature meant I lost motivation.

But I did get something done. I finished all the welding (hopefully) and the main unit seems to fit very well in it's new home. I welded up the old fuse box hole and painted everything black.

http://www.offroadvw.net/bajawes/images/ac/painted_front.jpg

Under the dash is looking mostly complete too, and is also now painted black. I just have to vacuum all the dust out and retrim the carpets a little. I was speaking to the guy who made my carpets in the first place, and he still had some of my colour carpet sitting around from when he first did my car (3 years ago). So hopefully I will have enough to pad and carpet the section under the dash so it really won't be noticeable.

http://www.offroadvw.net/bajawes/images/ac/painted_underdash.jpg

Hopefully this week I will quickly get the old wiring together so the car is driveable for next weekend (I want to go offroading at Mt Mee). Then during my xmas break I will redo the wiring probably and make all the air con ducting. If I get time and find an air-con shop open over the xmas break I might even get it all working.




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posted on December 12th, 2005 at 01:44 PM



Looks like a neat fit.Good stuff!!



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posted on January 12th, 2006 at 11:54 AM



I've been looking into air vents for my Eureka and stumbled upon a company called Flexible Drive Agencies.Thay have outlets in most States. Anyway, they sell and eyeball type vent like the MX-5 but with closeable vents. The part number is 061405 and it retails for $22.56 + gst. the catalogue is here http://www.fdrive.com.au/docs/Automotive%20Electrical.pdf 
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posted on January 24th, 2006 at 10:12 AM



Nearly 6 weeks has passed, and I haven't really gotten too far. I blame xmas (shopping and festivities), going for a trip up 40 mile beach with friends, getting side tracked on other projects and the ridiculous heat :) . I procrastinated about working on the car many times but retired to the comfort of an air conditioned house most of the time.

The first side-track project was the radiator scoop. You can read about that in the rear radiator post.

Next side-tracked project was a third brake light. I have had friends complain they can't see my brake lights many times, so I figured a third brake light was a good idea. My friend bought me a suitable LED light on his trip home to Singapore / Malaysia. I decided to put it in the rear spoiler above the engine. I couldn't screw it there, double sided tape didn't work, so I fiberglassed it in place.

http://www.offroadvw.net/bajawes/images/ac/light1.jpg

http://www.offroadvw.net/bajawes/images/ac/light2.jpg

http://www.offroadvw.net/bajawes/images/ac/light3.jpg

http://www.offroadvw.net/bajawes/images/ac/light4.jpg

So back to the climate control. I spent a long time rewiring the car (and part of that was another side project where I fitted later model beetle splined windscreen wipers as opposed to the early grub screw wipers I had). I lost my alarm and immobiliser wiring diagrams, but the supplier (Autostrada) was very helpful and photocopied another set for me. Wiring is slow and sometimes frustrating, but I have redone all the VW loom. I also tried to install a Jaycar speedo corrector kit, but it doesn't work and I am currently trying to sort out the problem with Jaycar.

As part of installing the climate control the whole dash needed to be finished off (the instrument cluster was never in there properly). I decided to cut up the plastic mazda dash to use the instrument cluster and climate control unit plastic surrounds.

http://www.offroadvw.net/bajawes/images/ac/plastic.jpg

and then test fit it in the dash

http://www.offroadvw.net/bajawes/images/ac/plastic_test.jpg

the instrument cluster is quite a different size. I could either spend weeks trying to weld and shape metal, or think or another way of making it look neat. The mid section of the dash was now a bit weak with so much cut out, so I figured adding a mdf panel onto the front of the dash would give some strength back, and give me something to work with so I could inset the plastic surrounds in the dash. This would mean that I will need to carpet the dash, which I was leaning towards anyway. It will be charcoal marine carpet like my floor.

http://www.offroadvw.net/bajawes/images/ac/mdf1.jpg

First I cut the mdf panel to shape and moulded the climate control surround into place (above). Then I had to attach the mdf to the dash (rivets in countersunk holes) and fibreglass the dash surround from behind.

http://www.offroadvw.net/bajawes/images/ac/mdf2.jpg

The mazda surround had gaps at the side due to the shape of the Mazda dash, so I fiberglassed those over too. Now I just need to spread bog over it all and sand it to shape. Once the carpet is on there you'll never know. I also hopefully have another climate control heat unit coming that still has black buttons (mine have peeled off).

http://www.offroadvw.net/bajawes/images/ac/plastic_fit.jpg




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posted on January 25th, 2006 at 05:24 AM



Quote:
Originally posted by Baja Wes I procrastinated about working on the car many times but retired to the comfort of an air conditioned house most of the time.


I know what you mean, but then the other way around, it below freezing over here.....

You're bug is going to be really nice!! Aircon, the ability to go everywhere AND with lots of power, very nice!!:thumb

It's looking good!


[ Edited on 24/1/2006 by gerrelt ]
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posted on January 25th, 2006 at 02:00 PM



Wes If you weren't doing something crazy to that car I'd be worried about you:smilegrin:
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posted on January 25th, 2006 at 09:04 PM



Nice going Wes!

I'm doing a similar job grafting the subaru instruments into my 1303 dash...

http://www.ricola.co.uk/images/cabrio/bug_dash_2.JPG

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posted on January 28th, 2006 at 09:10 PM



after many people objecting to my plans to carpet my dash, I have gone for the painting option. This of course means more work, and hours of sanding and preparation to get it all smooth. I'm getting pretty close though, it's pretty smooth...

my only concern is that offroading the dash might flex and cracked the filler out, but it never did that before I guess...

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posted on February 3rd, 2006 at 09:40 AM



here are two pics of my painted dash. I painted it with my air brush. It just needs a clear coat to make it shiny like the rest of the car. The very left part of the dash is still the original clear coated colour. I blended the colour across. The preparation wasn't perfect, they are still some small marks, but it's pretty good and I didn't feel like sanding for another week to get it perfect.

http://www.offroadvw.net/bajawes/images/ac/painted_dash1.jpg

http://www.offroadvw.net/bajawes/images/ac/painted_dash2.jpg




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posted on February 3rd, 2006 at 11:31 AM



love your work



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posted on February 3rd, 2006 at 05:01 PM



thats damn sexy, i personally think it was worth the time to prep the dash to be painted it looks the good :tu:



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posted on February 3rd, 2006 at 07:57 PM



That looks like ex-factory! Better than shag-piling the dash, for sure.



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posted on February 7th, 2006 at 09:39 AM



Your dash looks great. All your guages should work since you are using the original instrument cluster. But what are you going to do for the fuel level guage because the VDO sender is probably different OHMs that the instrument cluster?
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posted on February 7th, 2006 at 05:54 PM



yes they don't like each other. I have been running the mazda cluster for 2+ years. The fuel sender kinda works. Full is full, half is 1/4, and 1/4 is empty. So it works for me but will confuse others. I think I may be able to fix it by modifying the stock sender (bend or shorten the arm) or by adding a resistor.



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posted on February 8th, 2006 at 08:27 PM



I put the dash together for a trial fit, and it looks pretty good.

I had Troy send his climate control face unit down to me, and his was not perfect either so I will try repainting the buttons on mine black.

I also had dramas with my instrument cluster. I got a little overspray on the clear cover, and decided to try cleaning it with metho. I dabbed it on one corner and then wiped it straight off to test to see if it melted the surface (which I could have buffed back out). To my disappointment (even after wiping it off) the metho caused the plastic to start crazy cracking. So now the left of the clear cover is cracked. I'll have to get another from a wreckers :(

Now I just have to make the under dash panel which will basically be an extension of the one already there. I will make it full width with the vents in each corner. I will probably also carpet the boxed out section under the dash.

http://www.offroadvw.net/bajawes/images/ac/new_dash.jpg




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posted on February 11th, 2006 at 08:12 PM



Lookin Good! :tu:
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posted on February 12th, 2006 at 10:53 AM



I dunno, purple leapard skin could do it!


Quote:
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That looks like ex-factory! Better than shag-piling the dash, for sure.




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posted on February 19th, 2006 at 08:53 PM



I'll add more words later, but I am just posting to show the new dash.

http://www.offroadvw.net/bajawes/images/ac/new_dash2.jpg

I carpeted the section that is boxed down below the dash, so you virtually don't notice it, especially behind the lower velour panels I made for the dash (to house the outer vents). I also added some little MX5 courtesy lights that come on with the door light in the under-dash panels.




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posted on February 19th, 2006 at 09:53 PM



Looks great!!!!:bounce:bounce



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posted on February 20th, 2006 at 02:18 AM



Looks fantastic Wes :tu:

How does the AC work?

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posted on February 20th, 2006 at 06:20 AM



So what are you using the switch on the gearstick for?



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posted on February 20th, 2006 at 08:35 AM



the switch on the gearstick is just for my rear offroading spotlights.

The AC doesn't work yet, as I still haven't finished the ducting, or mounted the condensor at the front, or run all the AC lines.

I'll try to get all the ducting finished so at least the heater and fan of the climate control work before winter. But I will probably wait until winter to mount the condensor and run the AC lines. That way the AC shops will be low on business (in winter) so I will have more chance of finding one that will be helpful and patient when running the new hoses.




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