Creative air con installation

So I'm trying to install a cheapo Chinese universal a/c kit into my TD5. I bought the a/c condenser frame from YRM and I'm going to forego installing the fan as it shouldn't be sitting in traffic too much and I was hoping I could get away with having to get one of those larger radiator grille frames. I've taken the front off and pulled out the old diagonal thingies that the condenser frame will be replacing. I've been doing a bit of test fitting and with the frame in the main problem is going to be the screws and plastic locknuts that are supposed to hold the plastic grille on. Even without them on I suspect I won't quite be able to fit the bolts in the bottom corners of the radiator grille frame that connect it to the body (top screws should be okay though).

I don't have too much of a question, I just want to throw my idea out there and see what people think. I'm planning on offering the radiator grille frame up and then, where the holes for the plastic grille are, I will drill straight through the condenser frame where it lines up with the holes. I'll then tap the holes and use machine screws to attach the plastic grille and radiator grille frame straight to the condenser frame, maybe with some kind of plastic washer somewhere to give it space if necessary.

The condenser frame is stainless steel and I've never tapped SS before. I assume it's going to be tricky but possible. I've attached a picture with the radiator grille frame off and a close up with it on.

You can get Defender AC Condensors off ebay for £120 + a 15" fan for how ever much you want to spend, I went for Spal for £80.

Why do you want to avoid the the AC grill? Can often be had for £50 look much better imo!

You can tap stainless use tapping/cutting oil. Go slow.

bankz5152 said:

You can get Defender AC Condensors off ebay for £120 + a 15" fan for how ever much you want to spend, I went for Spal for £80.

Why do you want to avoid the the AC grill? Can often be had for £50 look much better imo!

You can tap stainless use tapping/cutting oil. Go slow.

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I don’t really like the look of the AC grilles, but that doesn’t really matter because I can’t get them out here. Second hand parts are hard to come by as well, especially bodywork.

I couldn’t find cutting oil at the local shop, not even WD40 at the moment. All they had was GT7, which I think is no good. I’ll see what I can find. I have some WD40 brand penetrating fluid, maybe that’ll do.

Or grease will do. All youre trying to do is keep the temp down!

Twinnie said:

I don’t really like the look of the AC grilles, but that doesn’t really matter because I can’t get them out here. Second hand parts are hard to come by as well, especially bodywork.

I couldn’t find cutting oil at the local shop, not even WD40 at the moment. All they had was GT7, which I think is no good. I’ll see what I can find. I have some WD40 brand penetrating fluid, maybe that’ll do.

Click to expand...

I just use what is on the bench for drilling/tapping lube, oil/used oil/grease.
If it not a load bearing part you are tapping then you can drill the hole slightly larger than you normally would to make it easier to tap, ie if it is an M8 bolt use a 7mm drill rather than a 6/6.5mm you normally would, I know it is not correct, but I do it quite a bit!