Upgrading A/C and Radiator While I'm In There

You gotta hand it to the Chinese. When I pulled it apart, I noticed that the wiring was one way on the board, and reversed on the case
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So I bench tested it (on the old fan, in case I fried something). The little readout shows 34% power.
Worked like a charm
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And on the new fan. Blows a bloody hurricane.
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The PWM uses Mosfets as switches, so it's very efficient, and doesn't generate nearly as much heat as a resistor pack, but it still needs a bit of air. And there happened to be a hole in the housing...
You can see it in the side of the rear fan housing Image Unavailable, Please Login

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And the PWM just about fits... Image Unavailable, Please Login

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With a bit of modification Image Unavailable, Please Login

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The problem is, it will be completely inaccessible, and if it fails, I'd have to remove the evaporator again to get to it. So I needed to ensure it was going to be reliable. The capacitors were rated to 63 volts - not even the Chinese margin of error would cause problems at 12 volts. Someone told me they save money by skipping using contact paste on the heat sinks. So I had a look. Yep, dry as a bone.
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So that was sorted
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In the end, I decided that the risks outweighed the benefits of having it so neatly tucked away, so, after spending many hours going up this blind alley, I have given up yet another dream.
I'll probably stick it here
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Back to the housing, I relieved a little bit of the metal casing the was slightly shrouding the fan exit Image Unavailable, Please Login

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And made up some closed cell foam gaskets Image Unavailable, Please Login Image Unavailable, Please Login

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One side of the housing is plastic, which was a bit wonky in places, so a bit of heating, bending, and clamping was in order (sounds like a weekend in Vegas)
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Time to put it all together
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And now...
The unboxing of the new radiator! The new condenser is behind Image Unavailable, Please Login

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Checking for fit - as usual, I've cut it very fine
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Back to the evaporator. Just showing how i put a littl dab of glue on the bolts for added security
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Evaporator coil fitted
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A couple of the rivet holes in the plastic were a bit dodgy, so a thin alloy reinforcement plate glued in Image Unavailable, Please Login

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A bit of extra epoxy to strengthen where I mounted the 50mm duct


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Forgot the pic
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Trial fitting the radiator and condenser. Very tight where the a/c lines attach.
Won't be able to attach the pipes normally, so some outside the box thinking required. Image Unavailable, Please Login

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Before I work out a condenser solution, I'll see if I can get the radiator and fans to fit.
First, the fan mounting. They come with plastic zip tie things that mount through the coil, but my welder guy was adamant that it was too naff, so we'll make up brackets to the top and bottom tanks. Before we do that, I had to invent something to fasten them togethet.


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Forgot the pics again
A couple of small nuts and bolts to hold the flats together. I also glued the nuts for security. Image Unavailable, Please Login

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Etch priming some brackets for the other side.
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Fans now bolted together. Quite solid.
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