Detailed ?'s for going Non-A/C in a mk1

[bhonnold at pac-cap.com (Brian Honnold)]

For the cleanest look;

Remove the a/c ducting in the rain tray, then working underneath fiberglass
in a panel to block off the hole then bondo over the top and sand level
before paint.

Remove all the current HVAC ducting in the car and replace with the non-ac
stuff from the donor.

Definetely remove the stock HVAC airbox and fan setup as it contains the
harder than hell to replace heater core and you save a little weight by
removing the a/c condensor.  

Find a non-a/c center console and heater controls.  This isn't easy but with
the number of MkI's available in Northern CA junkyards I'm sure we can find
some for you.

You will also need to re-wire the heater/a-c fan as it is only 3 speed in
the non-ac cars and has a different plug leading to the ballast resistor
pack.  The positive wire for the fan/a-c setup is connected to a large fuse,
often screwed into a special holder above the fusebox.  You can either keep
this, or working from a non-a/c bentley, rewire correctly.

As for the alternator, you need the non-ac pulley and non-ac water pump
pulley from the donor.

I know there is more but we can chat about that later.

BcH
78 MkI Ragtop ABA 16vT boxes of parts




> -----Original Message-----
> From: scirocco-l-bounces@scirocco.org 
> [mailto:scirocco-l-bounces@scirocco.org] On Behalf Of Jeff Toomasson
> Sent: Thursday, September 04, 2003 8:19 AM
> To: scirocco-l@scirocco.org
> Subject: Detailed ?'s for going Non-A/C in a mk1
> 
> 
> I'm going to be yanking the a/c out of my 81S and have some 
> major questions about how far I should take it and what I 
> need to do it (properly/completely). My first inclination is 
> take everything out - including hacksaw'ing the piece of the 
> rain tray where a/c vent box penetrates and welding it into 
> the recipient rain tray. I have a distaste for just removing 
> the A/C yet having the 2-lever control pod making it still 
> looked like I have A/C in the cab...
> 
> I have access to a donor that has _everything_
> 
> So far, I know I would need the non-A/C alternator bracket at 
> a minimum, but do I need the alt. pulley too?
> 
> If I go balls to the wall on it and do it "completely", I 
> think I would need:
> 
> the bracket (obviously)
> rain tray section
> HVAC/heater core box from donor
> HVAC ducting from donor
> HVAC 3-lever control pod (including control cables) from 
> donor ashtray from donor
> 
> Is there anything I'm missing? I'm also open to opinions on 
> how far to take it...
> 
> Thanks!  Jeff
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