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 Baja Wes
Bishop of Volkswagenism
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| posted on July 30th, 2006 at 08:43 PM |
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Progress has been slow. I got married in May, so most of the year leading up to that I was busy doing wedding stuff, so the car got neglected.
Then I had a honeymoon, came back to normal life and had to do a few things around the house.
Now, finally, I've had a chance to work on the car again!
So in my last post I had all the dash finished, and the main climate control unit fitted, but didn't know where to fit the fan.
After a lot of thinking, I decided to pull the fan apart a bit more. It was fitted with a servo actuated flap that selected inside and outside air. I
have pull that off, and may mount it somewhere else later. but pulling it off it made the fan a lot smaller.
The fan did have a steel plate mounted as part of the casing before the flap, so it was almost a sealed unit when pulled apart. But it had a section
where the metal was missing, so I fiberglassed over that part. I welded old wheel studs onto the metal plate and put rubber table leg covers on the
wheel studs. This lets the fan sit on the fuel tank.
[ Edited on 30-7-2006 by Baja Wes ]
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Baja Wes
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| posted on July 30th, 2006 at 08:51 PM |
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unfortunately the brake fluid reserviour was in the way of the fan and ducting, so I had to relocate it. Quite a pain.
Then I put the fan in place and started making a cardboard duct.
You can also see a bit of PVC pipe and 32NB flexible hoses, these are the demister lines and connect to the vents at the corner of the windscreen.
Making the cardboard duct was difficult, mainly because I had to make sure it cleared the bonnet hinge.
Once I had it made up with cardboard, masking tape and hot glue, I could start fibreglassing. I don't really like fibreglassing, it's a messing job,
but I seem to do a fair bit of it. It will take a while to finish all the fibreglassing.
I also soldered copper water piping elbows onto the heater unit. This lets the water pipes turn up and clear the fan.
[ Edited on 30-7-2006 by Baja Wes ]
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bajachris88
A.k.a.: Chris Leete
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| posted on July 30th, 2006 at 08:53 PM |
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HOLY CRAP! Ur car wiring is scary... let along the room left in the bonnet, lol.
At least u know what ur doing, hopefully it works out for ya mate, GOOD STUFF!
By the way, congrats on the wedding too dude!
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears. 
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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MickH
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| posted on July 30th, 2006 at 08:57 PM |
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Looking great Wes...Congratulations on the wedding as well!!!! Wondered where you had been hiding:kiss now we all know !! Cant wait to see this
finished.....
tssnq.com.au
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gerrelt
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| posted on July 31st, 2006 at 04:33 AM |
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Looking good Wes! It's almost done, isn't it?
And congratulations on your wedding!
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pete wood
A.k.a.: figure itout
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| posted on July 31st, 2006 at 12:31 PM |
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Congrats Wes, getting married was the second best thing I ever did. :thumb
Very interesting fan setup. I have to say your interior looks great. Leave the bonnet closed and you'll win an award for the setup for sure. Will we
see the car at valla?
BTW, I'm thinking the 300 bucks I paid for my heater/aircon unit is looking better by the second. I know you'll come up with a more interesting
solution, but for ease of installation, you can't beat two bolts, two hoses and two wires.
There is certainly a lot of stuffing around there with fibreglassing and such. 
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Baja Wes
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| posted on July 31st, 2006 at 01:33 PM |
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I won't be at Valla this year. It seems everyone I normally go there with can't make it this year.
Pete, for sure your set-up is a great solution. It's so easy. Trust me, I thought about doing the same myself.
But I'm a sucker for trying to things that normal people would think is too hard. If it's been done before then I'm not interested in doing it. I
mean how many other type 1 VW's have digitial climate control in them? 
And yes, under the bonnet is rather unattractive at the moment
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pete wood
A.k.a.: figure itout
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| posted on July 31st, 2006 at 06:36 PM |
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oh, i didn't mean it looks unattractive. looks no worse than ubder the dash of a modern jap car. It's just that people might notice that the heating
and aircon don't actually work. 
good on you for trying something new. i gave up trying to out do people years ago. these days i settle for working and cost effective. 
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Baja Wes
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| posted on August 2nd, 2006 at 12:30 PM |
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well the Mazda climate control ain't easy, but it's cost effective so far (as it all came in the engine's front cut).
If I didn't care about cost I could go for this cool aftermarket climate control;
http://www.dakotadigital.com/index.cfm/page/ptype=product/product_id=475/prd475.htm
US$1100 for the Vintage Air air-con module and then even more for the digital control unit!!!
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Baja Wes
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| posted on August 6th, 2006 at 08:12 PM |
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I didn't get a lot done this weekend. I finished fibre-glassing the duct, and it fits! Now I have to make all the little ducts to the internal vents.
I have the demister connections done, but the 4 vents are more painful.
I have started by getting the original MX5 and MX6 ducting and modifying it to mostly fit. Then I'll either have to rivet extra plates and pieces in,
or fibre glass again. I borrowed a hole saw to cut through to the lower vents and add some flexible hose, but I borrowed the wrong size hole saw 
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Baja Wes
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| posted on August 16th, 2006 at 08:53 PM |
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More work and fibreglassing. I had to modify the main AC unit to change where the feet air goes. The original set-up went into weird flat square
plastic ducts that went under the carpet to the rear seats, and out side vents under the dash. I had to cover all those holes with fibreglass and make
a new big hole out the bottom. I later put compressible foam strips around the hole to make it seal once it's installed.
And below are the 3 holes that I cut for the big foot air vent to blow through.
Then I had to start work on the ducting to go from the main unit to the in dash head/body vents. I used the Mazda MX5 (Miata) duct that connects to
the rear of the in dash vents, the MX6 square duct piece that connects to the main duct body, and made the ducting in between using roof flashing. The
PVC pipe is to run flexible hoses out to the sides to go to the side head/body vents.
After I had the metal parts made and trial fitted it (about a hundred times), I covered it in fibreglass (as the roof flashing isn't very strong). I
also fibreglasses the demister PVC tube onto the main unit.
And below is the whole assembly sitting together. I painted it all black as you can see.
Hopefully on the weekend I will install everything in the car. I just have to make up some support brackets to hold everything in place (so it
doesn't move around when I brake and corner).
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bajachris88
A.k.a.: Chris Leete
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| posted on August 16th, 2006 at 08:59 PM |
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i think someones going to be very nicely ready for the up coming summer... don't ya think  :P
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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Baja Wes
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V6 Baja Pioneer
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| posted on August 19th, 2006 at 10:46 PM |
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I managed to get it all mounted in the car today. I bought some 32NB flexible piping for the side air vents, but they had ran out of the black pipe so
I now have a combination of black and white pipe which looks a bit odd.
I looks messy, but it's tricky to make it neater. There's just a lot of wires, and a lot of ducting! You can see the two air con lines on the right
above the fibreglass duct. They will be connected once I get the condensor mounted on the bull bar. I still have to make a few more brackets to make
sure everything stays still when I hit big bumps offroad.
Above are some shots of the digital climate control in action. At the moment I don't have the air conditioning part set-up, so it is currently just
normal air or heating. I'm glad that it all seems to work so far. Set it to a temp below ambient and it blows normal air, set it to a temp above
ambient and heated air comes out. It varies the fan speed depending on how far from the ambient temp it is set. The feet, body and demister settings
all work and operate the ducting flaps correctly. It is certainly a cool toy to play with.
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pete wood
A.k.a.: figure itout
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| posted on August 20th, 2006 at 02:44 PM |
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good stuff Wes. Looks great. Amazing how much nicer it is in a car with a heater isn't it.
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Baja Wes
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| posted on August 20th, 2006 at 06:34 PM |
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yeah. I put a heater in it 3 years ago when I first put the V6 in, because to get the engine conversion approved I had to have a working demister. But
it was just a real simple heater, out of a troopy or something.
So now I have a heater with automatic temperature control and a computer that varies the fan speed in 8 different settings. And I can direct it to
feet, body or demister, or various combinations.
Althought the wiring looks a little messy, it is heaps better than it was straight after the conversion (when I was in somewhat of a rush)....
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pete wood
A.k.a.: figure itout
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| posted on August 21st, 2006 at 09:12 AM |
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I actually thought the wiring looked alright. Afterall, there's a heck of a lot of stuff going on in there. And it's certainly an improvement on the
last pic you posted there.
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Baja Wes
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| posted on August 26th, 2006 at 06:22 PM |
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I decided to fast track the last part of the climate control and drop into Custom Offroad for some assistance. Brad made some new bull bar support
brackets (the old brackets were complete crap). The new brackets are use to mount the condensor on. We decided to put the condensor in the nose cone
in the end, and I cut about 80mm off the bottom of the nose cone to help with air flow.
The main problem I am having is the half jut was 92/93 so it used R12, and now it has to be converted to the new R134a. This means all no o-rings (no
probs) plus new dryer, new filling fittings, possibly new expansion valve.
Brad had run the R134a hoses from front to back, and now they need the special fittings added on each end. Unfortunately air con hose isn't cheap,
about $20/m. Not cheap when running from the back to the front of the Baja, and back again.
Then the air con shop has to thoroughly flush all the lines and components to ensure there is absolutely no old R12 lubricating oil left in the system
before they can refill it with R134a. Hopefully this will happen during the week.
So the air con is proving to be more painful than the engine conversion itself :P
But it should be just as rewarding :thumb
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Baja Wes
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| posted on August 29th, 2006 at 10:30 PM |
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Some piccies.
new and old dryer;
compressor cleaned and ready to go (new seals and stuff)
Evaporator cleaned and fitted with a new expansion valve (for the R134a gas)
evaporator in duct
condensor flushed out and ready to go. Thermo needs mounting
new bull bar braces tacked in test position. lower part of nose cone trimmed.
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Baja Wes
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| posted on September 1st, 2006 at 01:14 PM |
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well, after a huge amount of effort, I can now happily say I have working digital climate control!
:bounce
It gets the air coming out the vents down to about 6 degrees :P
The hose lady took about 4 hours to do all the end fittings, so all up her labour, the cost of hose, and the fittings cost a bit over $400.
The new dryer, new TX valve, reco'ing the compressor, all new o-rings and testing and gassing the system was another a bit over $400.
Then probably another $200 on thermo and materials for the bull bar brackets.
The hidden cost is the huge amount of time it took me to fit the whole thing into my car (more work than the engine conversion almost) .
And of course the time Brad put into it at the end, I'm sure I will pay him back for that in some way with my engineering / drafting services.....
So anyway, It all works!!!
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MickH
A.k.a.: Michael Hutchinson
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| posted on September 1st, 2006 at 02:00 PM |
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"COOL" Congrats on the instal. Now you can take your wife wife out in comfort?:alien
tssnq.com.au
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Baja Wes
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| posted on September 3rd, 2006 at 08:12 PM |
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Some pics of the mess of hoses and dryer mounted in the front. When I get a chance I will try to make things look neater. There's a cover over the
condensor / thermo and some insulation to keep the heat away.
:thumb
and here's the compressor all mounted and working (needs a good clean back there);
And I made a little animated gif to show just how much fun the climate control is :P . Driving around today it was great to just set it to 24 degrees
C and let it do it's thing
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gerrelt
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| posted on September 4th, 2006 at 04:11 AM |
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Click this link!
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vw2b
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| posted on September 4th, 2006 at 12:07 PM |
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Awesome, wanna do it to my 74 Super ?
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Baja Wes
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| posted on September 4th, 2006 at 12:46 PM |
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hmm, there's a lot of work in it. I don't think you'd wanna pay my fee 
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vw2b
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| posted on September 5th, 2006 at 11:12 AM |
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Oops
| Quote: | Originally
posted by Baja Wes
hmm, there's a lot of work in it. I don't think you'd wanna pay my fee
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I thought I read that it only cost you around $1000, how much labour can it take and what would that cost ?
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Baja Wes
Bishop of Volkswagenism
V6 Baja Pioneer
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| posted on September 5th, 2006 at 01:02 PM |
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| Quote: | Originally
posted by vw2b
I thought I read that it only cost you around $1000, how much labour can it take and what would that cost ?
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ah, the selective reading bug again :P
The costs listed above was the cost to finish the install. The cost to make custom hoses and have the thing converted from R12 ti R134a and gassed.
You have to actually buy all the climate control pieces in the first place. I got all mine when I bought my V6 front cut (so I already had all the
pieces). So if you buy a front cut with climate control then you can use those pieces. A good front cut would be around $2500. You could sell the
engine and box to make some money back.
Then you'd need to get someone to attack the loom and isolate all the climate control wiring. A custom engine loom for something weird would be about
$1000, so you'd be looking at something similar. I didn't need to do this as I installed the V6 with the complete engine and climate control loom in
tact. I did however spend a good 20hrs of messing around with the loom removing unnecessary parts like headlights etc.
Then once you have the parts and a simplified wiring loom, you have to modifiy the car to physically fit all the stuff in. I reckon if I went flat out
at it I would still have taken about 2 weeks - 80hrs. It really was a lot of messing around, just read through this post. :o
So yes, if you paid someone labour to do it all, it would cost a heck of a lot. Probably similar to what it costs to pay someone to do an engine
conversion. :thumb
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