Hello from Germany, Hello all, I searched a lot regarding my A/C project and I indeed found many useful hints. Therefore I will limit on unexpected trouble and problems with my project. I feared, that will be unexpected things while trying to reactivate my A/C-system after several years. Therefore I decided to start my own thread and keep you updated about what's all involved. First I planned to install the Retroair kit, but while I noticed, that the cars are going up more and more in value over here I decided to stay as original as possible. So I purchased a new York-style compressor, a new expansion valve, a dryer and a new pressure switch. I remembered, that some years ago I had a leaking evaporator housing. Sometimes there was a lot of ice-cold water on my wife's feet . Back then I just sealed the housing gap with some kind of sealing tape and things were fine. Therefore I started with the evaporator. But today I looked into the evaporator housing with my endoscope through the drain hose and saw a lot of deteriorated foam. Therefore I removed the evaporator this afternoon. .... And found a cracked housing. It seems, that the leak problem has already existed some time in the past with previous french owners . -- I told you in my introduction, that my car was in France till 1994. --Because I found different kinds of sealing stuff, a cracked housing and evaporator fins badly out of shape. I'm glad, that I decided to remove the evaporator, because I wouldn't like finding all the foam residue in my eyes after the rebuild. My main questions at the moment for you are; Do you have any suggestions how to repair this cracked housing. What stuff would be the best ? And what kind of foam should I use to replace the old one. And because the french botchers removed most of the foam, but not between the fins: Where to put the new foam ? I have no clue. No offense for the french; I like to travel in France, like the lancscape, the food (!!!). I live 10 mls. distand from the border. Have I forgot cars and car workshops ? No, I haven't Here are some photos of the evaporator with its bent fins and the cracked housing. Best Regards and many thanks in advance for your help. Martin Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
Hi Martin It looks like your housing is ABS plastic. I think I have seen these housings in fiberglass (or at least the housing cover with the air outlet). The best thing for the ABS plastic is the cement for ABS plumbing fittings that is sold in hardware stores. It makes a joint that is as strong as the original material.Of course, for a fiberglass part, the choice would be fiberglass. The foam just seals around the outside of the evaporator core to force the air through the core and not allow it to flow around the sides. Foam is subject to age, but there are types that are much more durable. I would avoid the stuff sold in stores that is meant to make seat cushions, generally white. I am sorry that I don't have names or brands to give you. A friend on the mainland got this black foam for me. He said he found a store that specialized in foam!! This black, closed cell foam was represented as being very durable. I have attached a picture of an evaporator drain that I had to move to fit a hole in the chassis that is glued with the ABS cement and a picture of the foam that I used for a new gasket. Image Unavailable, Please Login Image Unavailable, Please Login
Thank you; Yes this housing half seems to be ABS. The other half, which goes to the vents is fiberglass, which would be easier to repair. I will try to repair it with a special ABS glue I already have. A small strip of fiberglass for reinforcement perhaps. It shouldn't be too unsightly, but since this area is completely out of sight when installed, function ( watertightness ) is more important. And for the foam; I have closed cell foam tape, approx. 5mm thick and 30mm wide. I will look, whether I can use this. I like the idea, to use something in this area, that doesn't get soaked with water. BTW; the original material used to seal the housing halfs after riveting, was rock-hard but brittle. At the moment I wonder, whether this was original Ferrari or french workshop style. Did anyone of you ever remove the the evaporator on a 308 and dismantle the housing ? How was the old sealing stuff ? Best Regards from Germany Martin
I'm in the middle of this project myself. I made a quick reverse mold of my evaporator housing and popped off a fiberglass piece. Even you could fix the abs plastic it is so old and brittle it will likely break again, if not during reassembly. Image Unavailable, Please Login
Andy, Nice job on the evaporator housing, How about some more detail how you did it? Tommy, you are correct on max out condense, R-134 needs larger confessor to work. Ago
Hello all, really nice housing. Is this really fiberglass ? Perfect surface. My full respect for your projects, but I do not plan to upgrade or optimize my A/C system. I just want to have it working again keeping the system as close to original as possible. The 308 cars have been discovered by the classic car community recently, while so far they have just been old sportscars. Over here extensive and visible modifications, especially those, which are irreversible, aren't appreciated. I don't plan to sell my car in the near future, but I'm thinking in a similar way. Two years ago I planned to install the retroair upgrade kit, but market development cancelled these plans. I have no interest, in making my 308 GTB faster or colder If this would be my intention, a Nissan GTR would be my choice. Talking about R12 vs. R134a; I know, that R12 would work better, but better a warm car interior with poor a/c, than a hot car interiour with 'dead' a/c. What cabin temperatures do you expect on your cars ? I'm glad, when I reach inside temperatures which are the same like outside. If I went too deep in the past, I caught a cold. Best Regards Martin
FWIW I replaced all the rings and changed over the oil, then added R134a. For as little as I drive car in the hot heat it works fine for me (308 2v) Just need to fix the leaky drain now!!!
Yep, all fiberglass finished with a textured spray that matches the original texture. As you can see by the below pics the unit looks original. I doubt many would ever know the fans are a Spal upgrade even if they took the time to try and contort their body under the dash for a peek. One could simply improve this housing and use the original condenser, drier, etc. All the things that are visible can be left stock. At least you won't have to worry about the plastic housing shattering when you have a passenger there. I do understand the desire to keep things original. I just think if something is out of sight and you can improve upon a bad, 30 year old design why not? Living in Florida it's a must for me. I would rather enjoy my car year round then melt in the summer months while driving. Originality is great but not when it's 100 degrees outside with 90% humidity! Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login Image Unavailable, Please Login
