Vintage Air A/C System - Cool RunningSummer feels like winter with Vintage Air's new Gen IV Sure Fit A/C system. From the June, 2012 issue of Vette By Jerry Heasley Photography by Jerry Heasley
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If you're like Mike McComas, you've thought about adding air conditioning to your classic Corvette. McComas drove Vettes in the 1960s, and he doesn't remember being too upset about the lack of A/C on his '67 big-block coupe. Then, he was just a teenager. Today, he says the Texas summers are just too hot to drive his current ride, a '66 coupe. Times sure do change. Corvette didn't even offer A/C until 1963, but today, this critical comfort feature is standard equipment. When McComas learned about Vintage Air's new Gen IV Surefit air-conditioning system, he wanted to know more. How hard was it to install? Did it look stock? How cool did it get the cabin? We were similarly curious, so we obtained a system to install on his car for evaluation purposes. 1 The system is all encompassing,... 1 The system is all encompassing, making for a hassle-free installation. The big news is that the system is fully electronic. Switches eliminate pull cables and vacuum connections. Rotating an electric switch blends air between defroster and dash, similar to a late-model. Turning another switch regulates fan speed. A third switch regulates temperature, from hot to max air. The system comes complete with a 14x24-inch condenser; an "evaporator sub case," which contains both the evaporator and the heater core; a Sanden compressor with brackets; coolant and heater hoses; left and right console panels; ducts; a glovebox liner; "louver" assemblies to direct air; and various wires and switches. In addition to a Gen IV universal control harness, the kit includes a pair of rotary pot assemblies to replace the stems on the control knobs on the stock dash; a rotary temperature knob is fitted to the left console panel. Installed, the system looks very much like factory issue. We took photos and notes while McComas installed the system on his '66. What follows are the major portions of the job.  2 It's a good idea to remove...  2 It's a good idea to remove the hood, to ease installation. Next, disconnect and take out the battery, drain the radiator, and remove the radiator hoses.  3 Remove the OEM expansion...  3 Remove the OEM expansion tank and save it for reuse.  4a Remove the OEM blower...  4a Remove the OEM blower motor assembly from the passenger-side firewall.  4b Next, take out the stock...  4b Next, take out the stock heater core, located inside. This one caught a handful of leaves.  5 The kit comes with a new...  5 The kit comes with a new glovebox. To remove the old one, first take off the glovebox door, followed by the mounting panel.  6 Remove the right console...  6 Remove the right console panels, seen here, and retain the screws. Next, remove the left console panel, which incorporates the electric antenna switch. These plastic panels incorporate ducts directing air into the cabin.  7 Using an Allen wrench,...  7 Using an Allen wrench, remove the OEM control knobs and bezels in the center of the dash. You will replace the stems but reuse the factory knobs, to retain an original appearance.  8 Reach under the dash to...  8 Reach under the dash to remove the heat-distribution duct, seen here. Also remove the defroster duct, but retain the nuts.  9 Remove the OEM heater-box...  9 Remove the OEM heater-box assembly from under the dash, behind the glovebox.  10 Remove the center console....  10 Remove the center console. Reach up and under the dash to install the new defroster duct, reusing the OEM nuts. McComas felt this was the hardest part of the installation.  11 The Vintage Air instructions...  11 The Vintage Air instructions feature detailed illustrations to help ease the more complex portions of the job.  12 Install four grommets...  12 Install four grommets in the firewall blower cover, starting with the #10 hose seen here. Apply a bead of silicone 1/4-inch wide around the circumference of the backside of the cover. Then, attach the cover to the opening in the firewall with three 1/4-inch nuts, backed by star washers and flat washers.  13 The heart of the system...  13 The heart of the system is the "evaporator sub case," containing both the heater coil and the evaporator coil. Preparing the case for installation is easy. Install the heater fittings and the rear evaporator bracket, as seen here. Next, install the front evaporator bracket on the case.  14 It may be necessary to...  14 It may be necessary to pull the carpet back from the firewall to install the evaporator sub case under the dash. The installation is tight, and we definitely needed the extra room to lift the case up under the dashboard.  15 This schematic shows how...  15 This schematic shows how the evaporator sub case bolts to the firewall. McComas used a second person to hold it in place while he secured it with the supplied bolts and flat washers.  16 To mount the compressor,...  16 To mount the compressor, first bolt the two mounting brackets to the engine block. Snug all the bolts loosely until you’ve achieved correct alignment. Install the compressor on the bracket and slip the belt over the pulley.  17 Install the mounting brackets...  17 Install the mounting brackets on the condenser using the supplied pan-head screws and nuts with star washers. Use the OEM bolts to attach the condenser to the top of the radiator support.  18 This specialized heater...  18 This specialized heater hose from Gates (PN 18084) measures 3/4-inch on the end connecting to the expansion tank (or water pump if there is no tank), and 5/8-inch on the end connecting to the evaporator top fitting. You can use a 3/4-inch to 5/8-inch reducer fitting. (Heater hose is not supplied in the kit, but it's available from Vintage Air or your local parts store.)  19 The heater-control valve...  19 The heater-control valve is wired to the ECU, and blocks hot-water flow whenever the A/C switch is in the  20 Drill two 1/8-inch holes...  20 Drill two 1/8-inch holes in the dash brace. Next, align the passenger- side underdash louver with the brace, using the front-side evaporator bracket and supplied sheetmetal screws. Install plastic plugs on ends of the screws.  21 Installing the driver-side...  21 Installing the driver-side underdash louver requires that you loosen the two OEM nuts from the steering-column bracket. Drop the column from the dash brace and slide the bracket between the brace and the column bracket. Adjust and secure the louver housing to the column bracket using the OEM nuts.  22 McComas' Vette came with...  22 McComas' Vette came with an electric antenna, the switch for which is located on the backside of this console-panel vent. Using the supplied template, mark the cut lines with chalk. After drilling out the center of the fiberglass, cut along the chalk lines in the panel. Finally, drill holes and insert the OEM screws to retain the antenna switch.  23 The kit comes with a control-panel...  23 The kit comes with a control-panel conversion kit. Locate the rotary-pot assembles and plug into the wiring.  24 File a 1/8-inch slot into...  24 File a 1/8-inch slot into the two openings for the two top control knobs.  25 Reuse the old bezels with...  25 Reuse the old bezels with the new system. This top right knob turns to direct air upward (for defrost), through the dash, or in a mixture of both.  26a Turning the top left...  26a Turning the top left knob increases the blower speed, as before...  26b However, "temp pull"...  26b However, "temp pull" is no longer a function. Instead, to increase or decrease temperature, Vintage Air engineered a third knob mounted on the driver-side console.  27 Mount the 30-amp circuit...  27 Mount the 30-amp circuit breaker under the hood, as close to the battery as possible, as shown here. McComas wrapped the wires with electrical tape on either side of the breaker.  28 Note how the hard line...  28 Note how the hard line from the dryer/core fits neatly under the inner fender. Vintage Air supplies a #2 Adel clamp and pan-head screws with nuts and star washers.  29 Attach the passenger-side...  29 Attach the passenger-side console louver. Do the same on the drivers side, then attach the flexible duct.  30 Shaun Hon of Thomas Automotive...  30 Shaun Hon of Thomas Automotive in Pampa, Texas, charged the system with R134a refrigerant to complete the installation.  31 McComas was surprised...  31 McComas was surprised how quiet the system is. The fan motor is infinitely variable, and the motors open and close doors with very little noise. Another shocker is the temperature of the air coming from the vents: a chilly 42.1 degrees Fahrenheit.  32 The installed Vintage...  32 The installed Vintage Air system looks OEM--just a single louvered vent on each side of the dash, plus another one on each side of the console. Best of all, McComas can now drive his vintage Corvette in the murderous Texas heat.
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