Cooling...
Well I finally got to my cooling project. The Summer pretty much sealed the deal. Global Armageddon (Warming, Cooling, Flooding, etc.) has lead to the hottest year in recent memory in good old SoCal. October 10 and it's still 95 degrees, and that's down from 102 last week! I had two projects to contend with: The first was getting the factory AC working for the first time since I've owned the car. I already had a modern compressor installed on the engine as I was unable to complete the pulley setup without one. I put that on when the engine was installed more than a year ago, but I hadn't messed with the rest of the system until recently.
I messed around with the interior switches and wiring in order to get the compressor clutch actuator and fan functioning, but that was about the, limit of my expertise with air conditioning systems. I gave up and took the car to a local shop that specializes in AC and had them complete the project. Either way, I new that I'd need custom hoses and a fill with R134, so the car would have had to go in sometime. They ended up ordering me a new condenser and drier and setting up the engine compartment side of the system for me. Inside I simply set the air control doors on the Heating/AC box in the AC position and left the levers alone. I do not have the complex vacuum control system hooked up, as my engine pulls very little vacuum in the first place and, well, I don't really need anything but AC! Overall the system is reasonably clean (for a Road Racing Engine with air conditioning). Most of the components are in the stock locations but for the Sanden compressor.
I drove the car for about a week with the new AC running, and I'd say it works reasonably well. I know some guys talk about "ice cubes" coming out of the dash and all... I wouldn't claim to have THAT problem, but it's much cooler in the car than before - tolerable in the summer after the car has been outside in the sun for a bit... BUT, the engine WAS running hotter than before. I guess fair is fair: it's a 493 cubic inch motor with 10.5 to 1 compression and running AC and pump gas on a 102 degree day! Kinda figured this might happen. I was running a stock (but reconditioned) 26" Mopar radiator with a Flex Fan and a 160 degree thermostat. The car would generally run around 180 (on my Dakota Digital gauge) but would push to as high as 211 with the AC on in the sun - before I shut it off to cool down. This is with the AC on, a big Mopar AC condenser AND a trans cooler in front of the radiator.
As I said, I kinda figured I'd be looking for a radiator and had done some research. I finally settled on a Wizard Cooling radiator and, after a really good discussion with Scott at Wizard, also settled on one of their shrouds rather than an all-electric system. I can't say enough about the customer service there. Every time I called, someone picked up the phone, and most of the time I could get Scott - and he remembered me and my project. I know there are cheaper solutions, but they probably don't look like this:
All in all the radiator and shroud look to be of very high quality, and are clearly hand built - in a good way. The welds are beautiful.
I was actually shocked at how well the radiator fit in the stock location. Lots of companies SAY that their parts are a direct replacement for the factory parts, but this one required literally not the slightest mounting modification. Again, granted, it's only four bolts, but the hoses line up and the whole thing FITS! The shroud is a good fit as well, but could have used just ONE little instruction (none are provided). You'll see above in the picture of the radiator on the floor with the shroud mounted that there is, across the bottom inside of the fan opening, a small 1/2" by 12" piece of 1/16 aluminum "bar" across the opening. There is another at the top not visible in the picture. It turns out that these are added during the welding process to keep everything true as the shroud heats and cools, but they are not needed once the part is mounted to the radiator. With them in place, they just barely interfere with the fan. I discovered this after I had everything together - but before I tried to turn over the motor - good thing I guess! Everything was MUCH easier once they were removed.
Luckily I hadn't filled the cooling system yet as in my case I actually had to remove the radiator to get the shroud back off. The fan bolts which hold the fan, spacer and water pump pulley on are so close to the radiator that I just couldn't get the fan on last (or off first) as you would normally. If I have to take the system apart again I'll give those bolts another shot, but I just couldn't get my hand in there in the right position to mount the fan with the shroud and radiator already in place, even with the shroud "hung" back over the pulleys. Now that I think about it, maybe it WILL work now that those un-needed shroud supports are cut out...
My car is an automatic so I purchased the radiator with the transmission cooler at the bottom. One thing to note about this cooler is that the fittings are 1/4 NPT rather than the 1/8 NPT size used by the factory. Some time ago when I added an external transmission cooler I switched from the factory steel trans cooler lines to #6 hoses and fittings so, as pointed out by the guys at Wizard, my factory radiator with its 1/8 NPT fittings was probably actually something of a restriction to fluid flow through the coolers. With the 1/4 NPT fittings and the larger lines inside of the Wizard radiator I'm hoping to see better trans fluid flow and better trans cooling as well.
I started the car to check for leaks and watched for the radiator fluid start moving as the water temp climbed to 160 degrees. Everything looks good. Hoping to go for a test drive this evening. Sorta starting to look like a race car. Except for the Air Conditioning!