Another Classic Auto Air Install Review

[GoldSwinger71]

I am finally moving forward on my Classic Auto Air install. I ordered a 6.4 crate Hemi with Holley Front Accessory kit (including the A/C compressor). I'm getting to the "wife would like air conditioning" phase of the project.

The instructions all imply that you'll use pre-existing bolt holes / mount points on one side, and you'll pinch the mount between the radiator ear and the core support? The problem with this approach is the screws that attach the bracketry to the back of the condenser would be in direct contact with the radiator tanks and would eventually rub through the metal.

So it's time to re-engineer the "direct fit" kit.

This is one of the mounting holes that they want you to use - There's several other options I found which were unused.

Using rubber isolators, I moved the mounting point from the engine side of the core support to the grille side.

I ended up drilling a few extra holes in the radiator "ears" so I could pass the isolator bolts through and secure them.

I had to make two new mounts for the driver's side. The passenger side mounts were the appropriate length, but I have no idea what they intended for my particular core support. I made them out a flat sheet of cold rolled steel that I cut and drilled the holes to match. Then I used high temp black paint to pretty up the brackets.

And here's the final install. I moved the transmission cooler to a zip-tie style mount through the condenser. The issues now are - the provided hard lines which were supposed to pass through the firewall will require some re-work. The A/C shop is planning on doing some cutting, bending and welding to resolve the angles. I chose to leave the dryer install up to them along with the lines so they can shorten and place it correctly.

I removed both horns to make room for the mount - I'll have to relocate them for space.

I also need to drain the coolant system first so I can pass the connectors through the firewall plate - my last guy didn't put the plate on before hooking up the heater core. It gives me an excuse to put a thermostat back in the system. I have a replacement which drops the temp from 202 to 180F.

"Direct Fit" means mostly bolt-in.

 

[Dana67Dart]

"Direct Fit" means mostly bolt-in

It might fit with OEM radiator etc

 

[GoldSwinger71]

Knee Knockers are in! Now to have the shop do the lines. My kit apparently had a mis-manufactured control interface. I had to calibrate the vent selection backwards... but - it was pretty slick to use the app to determine what was going on.

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[JDMopar]

Are there more vents towards the ends of the dash, or the 2 in the pic the only ones?

 

[GoldSwinger71]

Are there more vents towards the ends of the dash, or the 2 in the pic the only ones?

I have 4 vents, they’re basically mirrored one side to the other

 

[Map63Vette]

It might fit with OEM radiator etc

I just posted in my thread as well, but I don't think that's even possible with the brackets they include in the kit. I had a similar issue where my passenger side brackets seem to line up okay and position things relatively well, but the driver's side bracket are way short. In my case it's ~2" short, so they hardly even reach across the opening in the core support to be able to bolt to anything, let alone pre-existing holes. I also seem to have a much different passthrough hole in my core support for the hardlines as I just have a ~1.5" diameter hole or something like that compared to the nice big square opening shown in the pictures here. It's going to be tight for mine, but it looks like they will just fit.

@GoldSwinger71, how did your box fit on the firewall? I mocked up the lines today to see what orientation of fittings I'm going to need and suffice to say I hope I never have a problem with my #8 coil pack or spark plugs as I'm not sure if I'm ever going to be able to change them again without pulling the A/C line every time.

 

[GoldSwinger71]

I just posted in my thread as well, but I don't think that's even possible with the brackets they include in the kit. I had a similar issue where my passenger side brackets seem to line up okay and position things relatively well, but the driver's side bracket are way short. In my case it's ~2" short, so they hardly even reach across the opening in the core support to be able to bolt to anything, let alone pre-existing holes. I also seem to have a much different passthrough hole in my core support for the hardlines as I just have a ~1.5" diameter hole or something like that compared to the nice big square opening shown in the pictures here. It's going to be tight for mine, but it looks like they will just fit.

@GoldSwinger71, how did your box fit on the firewall? I mocked up the lines today to see what orientation of fittings I'm going to need and suffice to say I hope I never have a problem with my #8 coil pack or spark plugs as I'm not sure if I'm ever going to be able to change them again without pulling the A/C line every time.

At this point I’m taking it to a shop to have them custom make the lines. I am resigned to the fact that I might have to evacuate the system and disconnect for that coil / plugs, but if they can do a hard 90 hard 90 to provide some clearance that might do the trick. I’d like to continue tucking lines under the vanity cover of the engine if at all possible for the run to the compressor at least.

 

[Dana67Dart]

I bet a quality shop can shorten the tubes out of the firewall and silver solder on 90s that he hoses can attach to

I get the look your going for but IMHO
Coming out and heading to the passenger inner fender will get the best results of not in the way and ease of future work.

If you go the shorten 90 route be prepared to remove the main unit from the car for best results.

 

[Map63Vette]

Looks like your engine is slightly further forward than mine, but maybe it's just the angle of the picture. There's a chance I might be able to get the coil pack off, but I'll definitely have to put some pressure on the lines to do it. I took it off today to pull the valve cover to look at something and I could squeeze it out past the tube coming through the firewall, but the fitting is going to add to that fun for sure. Mocked up the lines at least at it should be straightforward enough. Hopefully I'm not further reducing whatever limited ability I have to work on things. It's not like this engine was designed to go in the car, it just technically "fits" from a physical standpoint. There are things I probably would have done differently if I was doing everything from a clean sheet with all the parts already in hand, but my car has been an evolution since day 1, so it is what it is and I'm okay with that.

 

[GoldSwinger71]

Looks like your engine is slightly further forward than mine, but maybe it's just the angle of the picture. There's a chance I might be able to get the coil pack off, but I'll definitely have to put some pressure on the lines to do it. I took it off today to pull the valve cover to look at something and I could squeeze it out past the tube coming through the firewall, but the fitting is going to add to that fun for sure. Mocked up the lines at least at it should be straightforward enough. Hopefully I'm not further reducing whatever limited ability I have to work on things. It's not like this engine was designed to go in the car, it just technically "fits" from a physical standpoint. There are things I probably would have done differently if I was doing everything from a clean sheet with all the parts already in hand, but my car has been an evolution since day 1, so it is what it is and I'm okay with that.

It almost looks that the correct radius "S" would position at least the one side correctly to the compressor.