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Old 10-30-2012, 06:01 PM   #1 (permalink)
Diaric
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How To Do The AC/S10 Box Mod For A Turbo

After doing extensive searching on the subject, I came up with a couple of pics from the garage of an old member, 4DR4X4. That was it a few pics and no instructions.
Heres what we had.


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1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
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well to make your pump retarded, you could let it hang out with me for a day
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Diaric wins thread derailment......
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Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
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Old 10-30-2012, 06:14 PM   #2 (permalink)
Diaric
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Going with that info, countryboy90 and happypunch were ahead of me to try it out. They did a great job going with basic info and I learnt from them.
Heres countryboy90's mod.
Quote:
Originally Posted by countryboy90 View Post




this is my handy work grafting a s10 blazer air box to mine



just how much room there is with the s10 air box



factory replacement 6.5 downpipe. ill just cut the flange off and turn it in a bit and it will work fine.



__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
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Old 10-30-2012, 06:16 PM   #3 (permalink)
Diaric
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Heres the mod done by Happypunch.
Quote:
Originally Posted by happypunch View Post
got the a/c box finished. of course it was dark by the time i got it installed, but here are some pictures ofthe work involved. it was actually a lot easier than i expected. we used a very precise saws-all for the cuts... so it was really rough. and cut the evaporator box from the blower and just kept trimming to fit. put it up against the firewall to check size and fit.
first cut:

after more trimming, this is the evap box from the s10:
you can see the s10 ac evaporator points towards the fender where the original pointed towards the engine. also it is about an inch shorter.
test fit. still needed a little trimming, but getting close!
this is how it looked after all the trimming was done. looks pretty good from this angle, but will need fiberglass to patch all the holes.
this shows all the work that still needs done with the fiberglass. it was kind of a pain to glass, especially since it was my first attempt. but will show the final result pictures in a couple days.
__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
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Old 10-30-2012, 06:45 PM   #4 (permalink)
Diaric
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First of all, I hate fiberglass.

here are the two complete setups side by side. Notice I traced out the original pattern so I had a good idea where I was at trimming. I used a small air bodywork saw to do the cuts

next, I sized it up on the firewall to see what other trimming was needed.
I left it there to glass in place so I was sure nothing moved.
__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
Alberta Coal Roller Member #2

Last edited by Diaric; 10-30-2012 at 06:46 PM.
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Old 10-30-2012, 06:52 PM   #5 (permalink)
Diaric
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Next, blocked out inside of opening with duct tape so I could form a wall surface.
Now here is where there is an issue. When cutting up, i discovered this half is plastic, the other half is fiberglass. Fiberglass doesn't like stickning to plastic, so everything must be scuffed up with about 40 grit to make it rough to stick. Along the edges, I drilled holes so the glass could make anchors and not break free.
First coat on. The joints that are close together, I epoxy'd with JB Weld
__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
Alberta Coal Roller Member #2
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Old 10-30-2012, 07:02 PM   #6 (permalink)
Diaric
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smooth out with 40 grit between coats so it can grip and get the high spots off. 2nd coat on, now its stong enough to put on the bench and get the bottom and the inside

do 3 to 4 coats on everything. the masking tape is there to stop resin from getting on the rubber sealing strip

Here we are with complete coats, starting to grind it smoother
__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
Alberta Coal Roller Member #2
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Old 10-30-2012, 07:06 PM   #7 (permalink)
Diaric
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Nearly done. Put a coat of short strand filler on it and sanded it out.

Quick coat of flat paint

And here is how it looks with one coat of paint.
__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
Alberta Coal Roller Member #2
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Old 10-31-2012, 12:19 AM   #8 (permalink)
happypunch
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I did use the s10 evap since it angles away from the turbo. for the most part the holes lined up, but i did need to use a couple self tapping screws. i was happy with how close things lined up.

I think I forgot to take pictures of the glassing stage (did it at night) but all i did was line the parts up how i wanted, stretched some fleece (cheap stuff from walmart) and super glued it down to keep it in place while I painted on the fiber glass resin. After it dried up I went back and added a few extra layers of fiberglass chop mat for strength then spray painted it all black. for good measure i used some expanding foam sealer all the way around, but wish i hadnt. should have used a good sealer that wouldnt look like crap! spent a lot of time with a razor blade cleaning up the excess and still looks rough.

Now to finish up the a/c I need to get a new receiver drier since being exposed to the air for a while would have ruined it. hook up the a/c lines, though im not sure how they will fit with the modifications, might have to get creative. Then I need to grab a r-12 to r-134a conversion kit (walmart has them for ~$40). install the new fittings, top her off and check for leaks. If all went as planned I should have a new a/c system up and running, gonna need it for this summer!

A new reciever drier from oreilly's is about $40, so that and the kit will give me the fittings i need, 3 cans of refrigerant and should be straight forward (unless I have leaks or my compressor craps out). Assuming all goes as planned this will have cost me a little over $120 including junk yard parts and fiber glass material and have a functioning a/c!!! lets hope it works out that easily
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Gave it another chance at life and enjoying every minute

Last edited by Diaric; 10-31-2012 at 01:06 AM.
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Old 10-31-2012, 12:37 AM   #9 (permalink)
04colyZQ8
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Quote:
Originally Posted by happypunch View Post
that's some great info, thanks!
sounds like a good plan. don't forget to flush the system out, especially when switching from r12 to r134a the two are not compatible. You can use mineral spirits, and compressed, dry filtered air to flush it out, or sometimes I use brake clean. you want to drain your compressor oil, there should be a drain on it some where. Measure the amount you drain, and add that amount plus the estimated amount of oil you lost while draining the system, and the amounts that would have remained in the rest of the components before flushing. You will need to get the proper oil for your compressor, and it needs to be compatible for r134a. Add the oil to the suction port of the compressor. Connect up the lines and hand turn the compressor about 25 revolutions, to move the oil around, so you don't hydrolic the pump. Also you need to vacuum the system down to 25 inches of mercury for about 20 min. minimum, to remove moisture and draw the new charge in. Also it should hold this for about 15min. If it doesn't you have a leak somewhere. Vacuum pumps are available online for about 60.00 that use shop air as an venturi to create a vacuum. Lastly add the charge slowly, allow time to stabilize between cans, and check your low and high side pressures. Don't over charge, you have a custom system now, you don't know what the capacity is, you will have to rely on pressure readings.

No problem. Another thought might be to try the propane based refrigerants, like 12a, durracool, redtek, they say they can me mixed with r134a or r12, and I think there compatible with, all oils. They don't cool as well as r12, or r134a, but it's a cheap easy alternative. Also technically mixing refrigerant, is illegal, so it's always best to flush it, and vacuum it.

Last edited by Diaric; 10-31-2012 at 01:07 AM.
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Old 10-31-2012, 01:08 AM   #10 (permalink)
Diaric
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copied some info from happypunch's thread talking about charging the system

__________________
1987 6.2l Jimmy , being restored,4" lift, 35 mudders 1993 W350 5.9 , custom stretched cab, duelly flatdeck
2001 VW TDI Jetta 4 door loaded 2001 VW TDI Golf 2 door swapped engine project
Quote:
Originally Posted by 4320diesel View Post
well to make your pump retarded, you could let it hang out with me for a day
Quote:
Originally Posted by Hawkstrong View Post
Diaric wins thread derailment......
Quote:
Originally Posted by High Sierra 2500 View Post
Yeah Diaric, I gotta say, I'm afraid I'm going to have to give you an official warning on that.
6.2 FAQ's AND ANSWERS Click Here
My Restoration Thread Click Here
Alberta Coal Roller Member #2
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