VintageAir a/c install starting with the firewall and room behind the dash. The GenIV Magnum is too big to fit in the available space without doing one of two things. Building a recessed panel for the opening in the firewall deep enough to allow you to keep the glovebox, about 6" deep or so. Or, using a flat panel to cover the opening, ditching the inner piece of the glovebox lid and notching the dash frame about an inch. Since I never kept anything of importance in the glovebox anyway, I chose to just ditch it.
The panel I made is 1/8" aluminum, bolted in with 1/4" bolts and sealed to the firewall with black silicone. Fairly straightforward, just a bunch of eyeballing measuring and then cutting. Used a holesaw for the line holes, nothing much to it.
Once I got the placement of everything figured out, dash brace modified slightly and the upper plenum brace made it was time to start putting things together. Also blocked off the hole in the right kick panel since the VA has no provision for outside air. A piece of 1/8" aluminum, some black silicone and pop rivets took care of that. Covered the firewall with 1/2" Dynaliner heat/noise insulation and then started assembly.
Various pics. Blocked one defrost outlet on the plenum and used a tee in the hoses. Defrost ducts are E body pieces, minor trimming and drilled a couple holes for #8 machine screws and bolted them in. The white tabs holding the wiring and ductwork up are 3M peel and stick wall hangers. Used WeldOn 3 ABS glue to cement them in place.
I made a bracket to relocate the a/c compressor a few years back never had an a/c to hook it to, planning to do this install someday. Had my doubts about the amount of belt contact with the crank and a/c clutch pulleys when I made it, so I've added a flat idler pulley to give almost 180 dregrees of contact on both of those pulleys. Fan, water pump, alternator and a/c is asking a whole lot of two A section belts. If it prematurely eats belts running the a/c a lot I'll have to do something to reduce the load, maybe go with an electric fan. It's been fine without the a/c in the equation for five years, see how it goes.
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