S1 AC: complicate and add weight

[jbcollier]

No ifs and/or buts about it, fitting AC to a Europa is not easy or straight forward.  You add weight and complication and complicated complication it is indeed.

I also wanted to keep the front luggage compartment and glovebox.  This left me with having to delete the spare wheel to free up space for the evaporator:

https://jbcollier.smugmug.com/Lotus-Europa/i-cTwnCVZ/A

It is a conventional (and cheap) unit that I modified to suit:

https://i.ebayimg.com/images/g/x-cAAOSwmSdae~fB/s-l1600.jpg

I removed the front vent/electrical panel unit and plastic welded up two garage vacuum nozzles to get the outlets I wanted.  I made up a harness to located the electrical controls under the dash:

https://jbcollier.smugmug.com/Lotus-Europa/i-bTWwMWv/A

I then fibreglassed in AC duct work to get the air from the evaporator to the stock dash vents:

https://jbcollier.smugmug.com/Lotus-Europa/i-BJMF2BN/A

https://jbcollier.smugmug.com/Lotus-Europa/i-ddWcWr8/A

https://jbcollier.smugmug.com/Lotus-Europa/i-xfVhGjD/A

https://jbcollier.smugmug.com/Lotus-Europa/i-nqFzxFR/A

A thick alloy rad with a similar sized condenser is used along with the highest CFM fan I could find:

https://jbcollier.smugmug.com/Lotus-Europa/i-cTwnCVZ/A

In the upper left corner you can see the fan controller.  It provides a 50% duty cycle to the rad fan anytime the AC compressor is engaged. Tucked behind the evaporator is a electric water pump that kicks in when the rad fan switch engages at 88°C:

https://jbcollier.smugmug.com/Lotus-Europa/i-wS2KWM4/A

You can see it between the two red air hoses.

I also fit a front oil cooler so there are four stainless lines that run from front to back: 2 - 5/8” for the oil cooler and 1 - 5/8” and 1 - 1/2” for the AC.  Lines were run through grommeted holes in the chassis and fittings were silver-soldered to each end in situ.  As you can well imagine, it’s very crowded in the main spine:

https://jbcollier.smugmug.com/Lotus-Europa/i-zTW9WSt/A

Having a cable shifter helps free up some space but does add complication.

https://jbcollier.smugmug.com/Lotus-Europa/i-PBZg2MS/A

I’m looking at using a linear actuator to work the e-brake as the adjuster is now completely hidden.

Now we just have to fit the compressor!  I used an R17G engine with a front crank pulley in the vain hope that I could mount the AC compressor up front.  I spent the best part of a day with no joy.  The only other alternative is to run it off the cam pulley.  Having worked on Citroën SMs, I was not wild about this option but it turned out the be the only way:

https://jbcollier.smugmug.com/Lotus-Europa/i-ThQHBh2/A

https://jbcollier.smugmug.com/Lotus-Europa/i-2d4stwD/A

I imagine that timing chain life will be shortened but hopefully not as much as it is in the SM!

It all works very well but the idler off the cam pulley is too small in diameter.  I’m going to have to sleeve it to a much larger size so the v-belt is not bent backwards to such an extreme degree.  Right now I’m getting a belt life of 2K — depending on how often the AC is run.  Not too bad as it is quick and easy to change and I have to change air filters at that interval any way.  Belts have to be TIGHT as the alt goes to pretty much full output when the AC kicks in.  I imagine this will shorten water pump life as well.

How does it all work?  Pretty good actually.  Not much cool air at idle but that all changes at 3K rpm.  Then there is lots of cold air and you end up turning it right down as you can see from this photo:

https://jbcollier.smugmug.com/Lotus-Europa/i-bTWwMWv/A

Yes, power takes a hit but not too much and the compressor doesn’t run that often either.  So far, I have only had it out in 32°C weather, and, frankly, it saved my life what with the stock configuration being non-opening windows and super-deluxe, flow-through ventilation.

Would I do it again?  Sweet Mother of Pearl, it was a lot of work, but, yes, I would for a street car.

YMMV...


PS:  As the eagle-eyed among you will have spotted, yes, the stock heater fan is gone.  I fit the stock fan and motor from a Spitfire instead:

https://jbcollier.smugmug.com/Lotus-Europa/i-fQ3LFT6/A

https://jbcollier.smugmug.com/Lotus-Europa/i-XrkzXPq/A

Fits right in.  Not sure it will in an S2/TC though.

[Rosco5000]

This is a great modification!  I love the detailed post on the set up it really is well thought out.  I am looking at installing AC as I get softer by the year.  I would like to install something like this for my S2 as it isn't going to be an original restoration by any means.  You seem to have a lot of experience (understatement of the year if anyone follows your posts).  Have you ever seen these AC pumps before?

https://www.seanhylandmotorsport.com/blog/12-v-air-conditioning-compressor-how-can-you-decide-if-one-is-right-for-you/

Any thoughts on these.  It draws a ton of amps when its working I was thinking it might be easier to install a bigger aftermarket alternator than adding another accessory, I just don`t know if it will work well in the long run.

Thanks again for the info on your AC install it looks great!
Cheers,
Ross

[jbcollier]

Even with their seemingly large amp draws, 12v electric compressors are only putting out a fraction of what a traditional compressor does.  See this article for more info:

http://vintageair.com/wp-content/uploads/2016/12/Electric-Compressors.pdf

To do it right, you need the highest output you can get and then a very sophisticated controller to manage and balance your electrical and cooling needs.  These chaps have a system with some good reviews:

http://classicretrofit.com/electrocooler-compressor-and-ecu/

As you can see, it isn't cheap!

[dakazman]

JB, Bravo!!!!
I see your build going to the technical articles section very soon . The layout is superb. I don’t think the cost is out of line at all . I was also thinking of some linear actuators for the shifter linkage . Lol.
Dakazman

[BDA]

Amazing job, JB! Just fantastic! It was certainly a lot of work but I appreciate all the thought that went into it. At first I was thinking that it took a lot more space than it should but then I remembered that the A/C unit that was installed at some dealerships on TCs took up half the front trunk so your installation has some advantages.

After seeing all you did to put A/C in your car, I am glad I didn't attempt it on my car. It would have been way more than I could handle!

I'm sure you don't miss your spare tire - after all, some new cars don't come with one. The complication and the weight are unfortunate but then you have A/C!

I can't say it enough. You've done a spectacular job on this! Very creative and very elegantly done! 

 

[lotusfanatic]

Hi JB,

that’s impressive!
I’m glad the S1A has clip in windows as a short term measure but AC is the way forward if we continue to get the warmer weather we have currently here in the UK!
(not that my car is anywhere near to seeing a road yet)

Mark

[surfguitar58]

Amazing bit of engineering JB! (Just don't let my wife know A/C is even a possibility in the Europa.)
I also want to say thanks for sharing your sage advice on this forum, we're lucky to have you.
Tom

[jbcollier]

Fit an alloy sleeve to the idler pulley.  Reduces the amount the belt is folded backwards by quite a bit.  Also increases wrap on both pulleys.  Here’s hoping it does the trick:

https://jbcollier.smugmug.com/Lotus-Europa/i-Gs6fMpG/A

[dakazman]

JB
Looks much better, now you have a really perfect Europa.
I’ll tell my wife it’s possible now to put A/C in. (lol,surf ).
Congrats JB!
Dakazman

[jbcollier]

Don't get excited yet.  have to wait and see if the belt holds up better.

[surfguitar58]

Looks great JB! Keep us posted on how your belts survive.
D-man, if we meet someday and your wife emerges from the Europa all cool and fresh, and mine is a hot frazzled mess, I will never hear the end of it! 
t

[314159td]

The infamous AC on a Renault-engined car...
I think I may also go down this path, considering the Europa is going to have to be driven a lot to justify this full mechanical rebuild.

I'm curious about that compressor+pulley you're using, and other components if you happen to have any receipts/buy lists lying around.

I think there's a way the compressor could be driven from the flywheel, but would require hacking up the bellhousing somewhat and I'd rather not. Either a belt from a oddly shaped pulley that sits on the clutch cover like a hat, or off the ring gear and involving some kind of reduction. I don't trust the tooth profile on the ring gear to be very efficient though.
What you've come up with on the reverse bending belt all driving from the camshaft and such seems reasonable enough.   

Where I'm planning to diverge is in the front region. I would put the condenser venting into the FL wheel well, so I get twice the area for cooling fans and can independently run said fans. I was planning to change the hood mechanism to something more elaborate than the standard bolt hinge, and push the spare wheel forward and to the center. That'll split the incoming air off to either side. I think that'll leave enough space for a smaller evaporator unit up front, which will probably vent into the plenum? Still thinking over recirculation and such   
I have very few reservations on cutting holes in the wheel well, as that entire front end isn't correct to my car.

[Dilkris]

That is a gargantuan achievement JB and the written account even more so - I'm pleased I live in the UK where we generally have 4 seasons in one day - think I can live without the AC...   

[Clifton]

I think that'll leave enough space for a smaller evaporator unit up front, which will probably vent into the plenum? Still thinking over recirculation and such   
I have very few reservations on cutting holes in the wheel well, as that entire front end isn't correct to my car.

A Vintage Air Gen II mini with heat will fit where the stock heater is.

[314159td]

The S1 is reeeeeally cramped up there without cutting into the under dash fiberglass, but it's something to investigate. Would take care of the recirculation more simply than other options.

Getting the thin heater box out the first time took about two hours and removing the steering column to get it to perfectly slide out.