Finally got all my bits'n'pieces gathered together this weekend to
build my on-board air system on my 200tdi 90.

Bits used:
A/C compressor off a 1990 Saab 900
Non-return valve
Pressure switch
1025mm fan belt
various iron plumbing fittings.
A bit of wire to feed the clutch 12V via the pressure switch

I also had to fabricate two simple brackets, 1 to mount the compressor
and one to mount the pressure switch and PCI connector.

Only other thing i had to do was have a new pully made to attached to
the existing water pump pulley - this was the expensive bit (£50).
The other alternative was to buy the LR crankshaft pully which has
provision for 3 belts (mine only has room for 2) but this also means
changing the fan.

Compressor is mounted where (I think) the standard LR A/C compressor
would normally fit - sat on the timing belt case in line with the
rocker cover.

New pully is fixed onto the long waterpump pully shaft and the bracket
to hold the pressure switch and PCI connector is mounted off the
clutch pedel housing cover plate.

The whole thing seems to work a treat - works no bother at 150psi.

The only thing i have overlooked is the lack of an oil filter in the
system. Due to the compressor design there is some, but not much oil
passed into the air and ultimately into tyres etc. A simple in line
filter will cue this. Apparently York compressors get around this
problem by having a dedicated oil sump but they are physically MUCH
larger so will be heavier and much more difficult to accomodate in a
200tdi.

On the whole I think this is a great mod for any offroader, and not as
hard as i thought it might be.

Phase 2 is to mount an air tank somewhere. I have aquired a CO2 tank
from a pub, thinking of strapping it to a chassis rail somewhere and
using that. Ideally i would use a small air-brake tank off a small
truck.

Jon

Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote:

> The only thing i have overlooked is the lack of an oil filter in the
> system. Due to the compressor design there is some, but not much oil
> passed into the air and ultimately into tyres etc. A simple in line
> filter will cue this. Apparently York compressors get around this
> problem by having a dedicated oil sump but they are physically MUCH
> larger so will be heavier and much more difficult to accomodate in a
> 200tdi.

Without oil the compressor is not lubricated and therefore will be
ruined shortly. You need to use a oil-water separating device (don´t
know the english term) so you have an oiled circuit for the compressor
and clean air for your tires.

Raoul
--
..sig-Simulator 0.07ß
==To e-mail me exchange das_liest_keiner with anything else==
****This space to rent****Hier könnte Ihre Werbung stehen****

This dude used his roll cage as an air reservoir. Good thinking!

http://www.off-road.com/4x4web/faqs/tech/aircompr.html

"Raoul Donschachner" <das_liest_keiner@don-moto.at> wrote in message
news:1gli31v.rg1t8caymo9iN%das_liest_keiner@don-moto.at...
> Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote:
>
> > The only thing i have overlooked is the lack of an oil filter in the
> > system. Due to the compressor design there is some, but not much oil
> > passed into the air and ultimately into tyres etc. A simple in line
> > filter will cue this. Apparently York compressors get around this
> > problem by having a dedicated oil sump but they are physically MUCH
> > larger so will be heavier and much more difficult to accomodate in a
> > 200tdi.
>
> Without oil the compressor is not lubricated and therefore will be
> ruined shortly. You need to use a oil-water separating device (don´t
> know the english term) so you have an oiled circuit for the compressor
> and clean air for your tires.
>
> Raoul
> --
> .sig-Simulator 0.07ß
> ==To e-mail me exchange das_liest_keiner with anything else==
> ****This space to rent****Hier könnte Ihre Werbung stehen****

"Adam Swire" <adam@[127.0.0.1]> wrote:

> This dude used his roll cage as an air reservoir. Good thinking!

Cheap alternatives are used O2-flasks from divers.

Raoul
--
..sig-Simulator 0.07ß
==To e-mail me exchange das_liest_keiner with anything else==
****This space to rent****Hier könnte Ihre Werbung stehen****

"Raoul Donschachner" <das_liest_keiner@don-moto.at> wrote in message
news:1gli31v.rg1t8caymo9iN%das_liest_keiner@don-moto.at...
> Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote:
> Without oil the compressor is not lubricated and therefore will be
> ruined shortly. You need to use a oil-water separating device (don´t
> know the english term) so you have an oiled circuit for the compressor
> and clean air for your tires.


Not sure about the Saab compressor but the York compressor found on many
models has an oil sump to keep the piston well lubricated. This however does
not preclude the system from passing oil through the lines.
The oil/water separator IS the English term.
I used an old fire extinguisher in my project. They are far more plentiful
and hydrostat tested to over 500 lbs. Be sure to install a drain as these
can rust from the inside out and explode if not drained regularly.

Have fun.

Jack Kerouac <nomail@microsoft.com> wrote:

> Not sure about the Saab compressor but the York compressor found on many
> models has an oil sump to keep the piston well lubricated. This however does

Really? Nice, that puts my to-be-built system in reachable dimensions!

> not preclude the system from passing oil through the lines.
> The oil/water separator IS the English term.

;-) Ah, fine, thanks!

> I used an old fire extinguisher in my project. They are far more plentiful
> and hydrostat tested to over 500 lbs. Be sure to install a drain as these
> can rust from the inside out and explode if not drained regularly.

Fire extinguisher, good idea, would be even cheaper bought new than a
used divers-bottle. Was there no possibility to rustproof the whole
thing?

Raoul
--
..sig-Simulator 0.07ß
==To e-mail me exchange das_liest_keiner with anything else==
****This space to rent****Hier könnte Ihre Werbung stehen****

Raoul Donschachner wrote:
>
> Fire extinguisher, good idea, would be even cheaper bought new than a
> used divers-bottle. Was there no possibility to rustproof the whole
> thing?

For a cheap solution use an empty freon jug from your local air-con
specialist - I've used them for this on several vehicles. For a rust
proof solution use a stainless steel fire extinguisher body.

--
EMB
change two to the number to reply

EMB <embtwo@ihug.co.nz> wrote:

> For a rust
> proof solution use a stainless steel fire extinguisher body.

Are there any? How can I tell that one is stainless steel, if I remember
correctly they are all painted red ;-)

Raoul
--
..sig-Simulator 0.07ß
==To e-mail me exchange das_liest_keiner with anything else==
****This space to rent****Hier könnte Ihre Werbung stehen****

Raoul Donschachner wrote:
> EMB <embtwo@ihug.co.nz> wrote:
>
>
>>For a rust
>>proof solution use a stainless steel fire extinguisher body.
>
>
> Are there any? How can I tell that one is stainless steel, if I remember
> correctly they are all painted red ;-)

There's plenty of stainless water type ones around and many are left as
SS finish with labels attached.


--
EMB
change two to the number to reply

Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<m25lm05sd3nt20umrbucsn3t1b5eok4j94@4ax.com>...
> Finally got all my bits'n'pieces gathered together this weekend to
> build my on-board air system on my 200tdi 90.
>
> Bits used:
> A/C compressor off a 1990 Saab 900
> Non-return valve
> Pressure switch
> 1025mm fan belt
> various iron plumbing fittings.
> A bit of wire to feed the clutch 12V via the pressure switch
>
> I also had to fabricate two simple brackets, 1 to mount the compressor
> and one to mount the pressure switch and PCI connector.
>
> Only other thing i had to do was have a new pully made to attached to
> the existing water pump pulley - this was the expensive bit (£50).
> The other alternative was to buy the LR crankshaft pully which has
> provision for 3 belts (mine only has room for 2) but this also means
> changing the fan.
>
> Compressor is mounted where (I think) the standard LR A/C compressor
> would normally fit - sat on the timing belt case in line with the
> rocker cover.
>
> New pully is fixed onto the long waterpump pully shaft and the bracket
> to hold the pressure switch and PCI connector is mounted off the
> clutch pedel housing cover plate.
>
> The whole thing seems to work a treat - works no bother at 150psi.
>
> The only thing i have overlooked is the lack of an oil filter in the
> system. Due to the compressor design there is some, but not much oil
> passed into the air and ultimately into tyres etc. A simple in line
> filter will cue this. Apparently York compressors get around this
> problem by having a dedicated oil sump but they are physically MUCH
> larger so will be heavier and much more difficult to accomodate in a
> 200tdi.
>
> On the whole I think this is a great mod for any offroader, and not as
> hard as i thought it might be.
>
> Phase 2 is to mount an air tank somewhere. I have aquired a CO2 tank
> from a pub, thinking of strapping it to a chassis rail somewhere and
> using that. Ideally i would use a small air-brake tank off a small
> truck.
>
> Jon

I'm thinking of doing the same on my Tdi300. I have sourced a dirt
cheap V8 a/c compressor that's basically going for around a tenner. I
know it still works fine because it was mounted on my friend's V8
rangy before he changed engine to a tdi300 due to fuel costs. So
basically he just wants to get rid of it. I have no problem mounting
the thing. My problem is that the pulley on the compressor is a v-belt
(triangular cross section) pulley while the crankshaft pulley on my
300tdi accomodates the newer, thick flat belt (i think it's called a
polyvee belt... it's got 3 or 4 grooves along the belt), and there is
a provision for the a/c compressor's belt on it.

What are my options? Is is possible to change the pulley on the a/c
compressor or do I have to find a rare crankshaft pulley with one
polyvee and one pulley instead of 2 polyvees? Does anyone supply these
pulleys or would I have to get one manufactured?

Sorry for all the questions. It's just that getting powerful onboard
air for a few tenners (including pulley costs) sounds too tempting to
me

Thanks for any reply.

Dennis

Firstly, many people will tell you not to bother because the
compressor wont last long because it will cease up due to lack of
lubrication. So what if it does, its cost you £10 for a compressor +
a few airline fittings and a pulley. What you get when its working is
FAR better than an electric one and MUCH cheaper than the "Endless
Air" option that uses a Sanden A/C compressor anyway!!! If it ceases
get another from another doner!

The way to avoid it ceasing up is simple:
1. install an air filter in your airline. That way you can monitor
how much oil it throws out (mine is very little).
2. Mount the compressor so that the oil filler is easily accessible.
that way you can simply put more oil in to keep it topped up.
3. Put a switch in the cab in the 12V feed to the clutch so that it is
not running all the time.
4. I would advise putting a pressure switch into the system also.
Mainly for safety, but additionally it means the compressor will keep
starting and stopping as the pressure builds and drops.


As for the installation:-

I cant remember how the 300tdi connects the fan to the waterpump
shaft. On the 200tdi there is a v-belt pulley linking the crankshaft
pulley and then importantly about a 2 inch flange that is "doing
nothing". I had a new pulley (6.5" DIA) fabricated onto this flange
and then got a 1025mm long fan belt to connect the new pulley to the
compressor.

So, I guess you may have 2 options:
1. Get a new pully for the compressor - I think this will be expensive
though because I think the electric clutch is part of the pulley!
Then all you need is a longer belt to replace the existing.
2. have a new v-belt profile pulley fabricated to an existing shaft
and get a belt to fit between that and compressor.

Unfortunately I dont have a lathe so I had to pay £50 to get a new
pulley turned up, heat shrunk onto the existing shaft and then dutch
screwed to secure it.

If you decide to look at changing the pulley then Hella Climate
Control can probably help you (01932 41 17 11).

Out of interest what model / make is the compressor?

Regards,
Jon


On 18 Oct 2004 14:57:06 -0700, nitehawk@di-ve.com (Dennis) wrote:


>I'm thinking of doing the same on my Tdi300. I have sourced a dirt
>cheap V8 a/c compressor that's basically going for around a tenner. I
>know it still works fine because it was mounted on my friend's V8
>rangy before he changed engine to a tdi300 due to fuel costs. So
>basically he just wants to get rid of it. I have no problem mounting
>the thing. My problem is that the pulley on the compressor is a v-belt
>(triangular cross section) pulley while the crankshaft pulley on my
>300tdi accomodates the newer, thick flat belt (i think it's called a
>polyvee belt... it's got 3 or 4 grooves along the belt), and there is
>a provision for the a/c compressor's belt on it.
>
>What are my options? Is is possible to change the pulley on the a/c
>compressor or do I have to find a rare crankshaft pulley with one
>polyvee and one pulley instead of 2 polyvees? Does anyone supply these
>pulleys or would I have to get one manufactured?
>
>Sorry for all the questions. It's just that getting powerful onboard
>air for a few tenners (including pulley costs) sounds too tempting to
>me
>
>Thanks for any reply.
>
>Dennis

Yes I've had people tell me it will blow up due to lack of
lubrication. However I'm not exactly sure if this thing has an oil
sump or not (haven't looked at it closely yet). However I already had
everything planned for the air filter to filter out the oil, and using
a tool oiler to keep it relatively happy as far as lubrication in case
it needs them. Also I'm not planning on using this thing everyday.
Actually using it will be rather rare so if it ceases up after pumping
up 50 tyres that would probably mean a good 5 years or so! Then, as
you say, it only cost me a tenner and with some careful looking around
I could get another one. It's more of a "if i don't do it now, I'll
lose my chance of getting a perfectly good compressor for a tenner!".
Who knows, maybe I'll eventually decide to use it for a/c.

I still need a pulley though. It sure is a pity that changing the
compressor's pulley will work out to be expensive. My 300tdi uses a
single serpentine polyvee belt (the thick belt with longitudinal
grooves) to drive everything (power steering, water pump, fan, and
alternator). The crankshaft pulley is actually 2 pulleys in 1. One
drives everything as mentioned above and one is empty, presumably for
fitting a 2nd polyvee belt to operate the a/c pump. That's why I was
hoping to have the compressor's pulley changed, so as not to "waste"
the currently unused pulley for this very purpose.

The compressor is off a 1983 V8 range rover classic. It's pretty big
compared to the standard 300tdi compressor so I'll be fabricating a
custom bracket to mount it. I don't have a lathe either so I'll
probably have to fork out for the pulley like you did. Or else admit
defeat and let it go to another friend who will have much less
complications since he's got a 200tdi which uses v-belts . But then
again, £10 for a compressor and £100 for a new compressor pulley still
works out cheaper than £300 for a 300tdi compressor...

Decisions, decisions ....

Thanks a lot for the information though.
Very much appreciated.

I'll report back when I get some prices

Regards,
Dennis


Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<deh9n0lrp96abf9llss2viccc11ur7j440@4ax.com>...
> Firstly, many people will tell you not to bother because the
> compressor wont last long because it will cease up due to lack of
> lubrication. So what if it does, its cost you £10 for a compressor +
> a few airline fittings and a pulley. What you get when its working is
> FAR better than an electric one and MUCH cheaper than the "Endless
> Air" option that uses a Sanden A/C compressor anyway!!! If it ceases
> get another from another doner!
>
> The way to avoid it ceasing up is simple:
> 1. install an air filter in your airline. That way you can monitor
> how much oil it throws out (mine is very little).
> 2. Mount the compressor so that the oil filler is easily accessible.
> that way you can simply put more oil in to keep it topped up.
> 3. Put a switch in the cab in the 12V feed to the clutch so that it is
> not running all the time.
> 4. I would advise putting a pressure switch into the system also.
> Mainly for safety, but additionally it means the compressor will keep
> starting and stopping as the pressure builds and drops.
>
>
> As for the installation:-
>
> I cant remember how the 300tdi connects the fan to the waterpump
> shaft. On the 200tdi there is a v-belt pulley linking the crankshaft
> pulley and then importantly about a 2 inch flange that is "doing
> nothing". I had a new pulley (6.5" DIA) fabricated onto this flange
> and then got a 1025mm long fan belt to connect the new pulley to the
> compressor.
>
> So, I guess you may have 2 options:
> 1. Get a new pully for the compressor - I think this will be expensive
> though because I think the electric clutch is part of the pulley!
> Then all you need is a longer belt to replace the existing.
> 2. have a new v-belt profile pulley fabricated to an existing shaft
> and get a belt to fit between that and compressor.
>
> Unfortunately I dont have a lathe so I had to pay £50 to get a new
> pulley turned up, heat shrunk onto the existing shaft and then dutch
> screwed to secure it.
>
> If you decide to look at changing the pulley then Hella Climate
> Control can probably help you (01932 41 17 11).
>
> Out of interest what model / make is the compressor?
>
> Regards,
> Jon
>
>
> On 18 Oct 2004 14:57:06 -0700, nitehawk@di-ve.com (Dennis) wrote:
>
>
> >I'm thinking of doing the same on my Tdi300. I have sourced a dirt
> >cheap V8 a/c compressor that's basically going for around a tenner. I
> >know it still works fine because it was mounted on my friend's V8
> >rangy before he changed engine to a tdi300 due to fuel costs. So
> >basically he just wants to get rid of it. I have no problem mounting
> >the thing. My problem is that the pulley on the compressor is a v-belt
> >(triangular cross section) pulley while the crankshaft pulley on my
> >300tdi accomodates the newer, thick flat belt (i think it's called a
> >polyvee belt... it's got 3 or 4 grooves along the belt), and there is
> >a provision for the a/c compressor's belt on it.
> >
> >What are my options? Is is possible to change the pulley on the a/c
> >compressor or do I have to find a rare crankshaft pulley with one
> >polyvee and one pulley instead of 2 polyvees? Does anyone supply these
> >pulleys or would I have to get one manufactured?
> >
> >Sorry for all the questions. It's just that getting powerful onboard
> >air for a few tenners (including pulley costs) sounds too tempting to
> >me
> >
> >Thanks for any reply.
> >
> >Dennis

Just out of pure speculative curiosity, how about getting a polyvee
belt profile pulley fabricated onto the compressors current pulley and
leave the v-profile pulley unused?. I'll have to mount the compressor
a bit further back so it will align with the crank pulley but that's
not a problem since I'm fabricating the mounting bracket for it
anyway. And that way I can use my crank pulley's provision for the a/c
belt.

It should work right? (please say yes )

Regards,
Dennis


Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<deh9n0lrp96abf9llss2viccc11ur7j440@4ax.com>...
> Firstly, many people will tell you not to bother because the
> compressor wont last long because it will cease up due to lack of
> lubrication. So what if it does, its cost you £10 for a compressor +
> a few airline fittings and a pulley. What you get when its working is
> FAR better than an electric one and MUCH cheaper than the "Endless
> Air" option that uses a Sanden A/C compressor anyway!!! If it ceases
> get another from another doner!
>
> The way to avoid it ceasing up is simple:
> 1. install an air filter in your airline. That way you can monitor
> how much oil it throws out (mine is very little).
> 2. Mount the compressor so that the oil filler is easily accessible.
> that way you can simply put more oil in to keep it topped up.
> 3. Put a switch in the cab in the 12V feed to the clutch so that it is
> not running all the time.
> 4. I would advise putting a pressure switch into the system also.
> Mainly for safety, but additionally it means the compressor will keep
> starting and stopping as the pressure builds and drops.
>
>
> As for the installation:-
>
> I cant remember how the 300tdi connects the fan to the waterpump
> shaft. On the 200tdi there is a v-belt pulley linking the crankshaft
> pulley and then importantly about a 2 inch flange that is "doing
> nothing". I had a new pulley (6.5" DIA) fabricated onto this flange
> and then got a 1025mm long fan belt to connect the new pulley to the
> compressor.
>
> So, I guess you may have 2 options:
> 1. Get a new pully for the compressor - I think this will be expensive
> though because I think the electric clutch is part of the pulley!
> Then all you need is a longer belt to replace the existing.
> 2. have a new v-belt profile pulley fabricated to an existing shaft
> and get a belt to fit between that and compressor.
>
> Unfortunately I dont have a lathe so I had to pay £50 to get a new
> pulley turned up, heat shrunk onto the existing shaft and then dutch
> screwed to secure it.
>
> If you decide to look at changing the pulley then Hella Climate
> Control can probably help you (01932 41 17 11).
>
> Out of interest what model / make is the compressor?
>
> Regards,
> Jon
>
>
> On 18 Oct 2004 14:57:06 -0700, nitehawk@di-ve.com (Dennis) wrote:
>
>
> >I'm thinking of doing the same on my Tdi300. I have sourced a dirt
> >cheap V8 a/c compressor that's basically going for around a tenner. I
> >know it still works fine because it was mounted on my friend's V8
> >rangy before he changed engine to a tdi300 due to fuel costs. So
> >basically he just wants to get rid of it. I have no problem mounting
> >the thing. My problem is that the pulley on the compressor is a v-belt
> >(triangular cross section) pulley while the crankshaft pulley on my
> >300tdi accomodates the newer, thick flat belt (i think it's called a
> >polyvee belt... it's got 3 or 4 grooves along the belt), and there is
> >a provision for the a/c compressor's belt on it.
> >
> >What are my options? Is is possible to change the pulley on the a/c
> >compressor or do I have to find a rare crankshaft pulley with one
> >polyvee and one pulley instead of 2 polyvees? Does anyone supply these
> >pulleys or would I have to get one manufactured?
> >
> >Sorry for all the questions. It's just that getting powerful onboard
> >air for a few tenners (including pulley costs) sounds too tempting to
> >me
> >
> >Thanks for any reply.
> >
> >Dennis

It should work but obviously it will need to remain clear of the
clutch arrangement.

Assuming you get the pulley fabricated on top of the existing pulley
the only downside I can see is that the new pulley will be larger than
the original and therefore you are lowering the gearing, thus the
compressor will turn slower and mean you need higher rev's to get the
same amount of air.

FYI: Thats why I had my pulley made at 6.5" DIA so that I geared it up
slightly - compressor pully is 5" DIA (high compressor rpm at
tickover is what you need as you are unlikely to need high rpm on the
move).

You could also add a resevoir to the system, then high(er) rpm will
not be needed.

Good Luck.
J


On 19 Oct 2004 10:07:54 -0700, nitehawk@di-ve.com (Dennis) wrote:

>Just out of pure speculative curiosity, how about getting a polyvee
>belt profile pulley fabricated onto the compressors current pulley and
>leave the v-profile pulley unused?. I'll have to mount the compressor
>a bit further back so it will align with the crank pulley but that's
>not a problem since I'm fabricating the mounting bracket for it
>anyway. And that way I can use my crank pulley's provision for the a/c
>belt.
>
>It should work right? (please say yes )
>
>Regards,
>Dennis
>
>
>Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<deh9n0lrp96abf9llss2viccc11ur7j440@4ax.com>...
>> Firstly, many people will tell you not to bother because the
>> compressor wont last long because it will cease up due to lack of
>> lubrication. So what if it does, its cost you £10 for a compressor +
>> a few airline fittings and a pulley. What you get when its working is
>> FAR better than an electric one and MUCH cheaper than the "Endless
>> Air" option that uses a Sanden A/C compressor anyway!!! If it ceases
>> get another from another doner!
>>
>> The way to avoid it ceasing up is simple:
>> 1. install an air filter in your airline. That way you can monitor
>> how much oil it throws out (mine is very little).
>> 2. Mount the compressor so that the oil filler is easily accessible.
>> that way you can simply put more oil in to keep it topped up.
>> 3. Put a switch in the cab in the 12V feed to the clutch so that it is
>> not running all the time.
>> 4. I would advise putting a pressure switch into the system also.
>> Mainly for safety, but additionally it means the compressor will keep
>> starting and stopping as the pressure builds and drops.
>>
>>
>> As for the installation:-
>>
>> I cant remember how the 300tdi connects the fan to the waterpump
>> shaft. On the 200tdi there is a v-belt pulley linking the crankshaft
>> pulley and then importantly about a 2 inch flange that is "doing
>> nothing". I had a new pulley (6.5" DIA) fabricated onto this flange
>> and then got a 1025mm long fan belt to connect the new pulley to the
>> compressor.
>>
>> So, I guess you may have 2 options:
>> 1. Get a new pully for the compressor - I think this will be expensive
>> though because I think the electric clutch is part of the pulley!
>> Then all you need is a longer belt to replace the existing.
>> 2. have a new v-belt profile pulley fabricated to an existing shaft
>> and get a belt to fit between that and compressor.
>>
>> Unfortunately I dont have a lathe so I had to pay £50 to get a new
>> pulley turned up, heat shrunk onto the existing shaft and then dutch
>> screwed to secure it.
>>
>> If you decide to look at changing the pulley then Hella Climate
>> Control can probably help you (01932 41 17 11).
>>
>> Out of interest what model / make is the compressor?
>>
>> Regards,
>> Jon
>>
>>
>> On 18 Oct 2004 14:57:06 -0700, nitehawk@di-ve.com (Dennis) wrote:
>>
>>
>> >I'm thinking of doing the same on my Tdi300. I have sourced a dirt
>> >cheap V8 a/c compressor that's basically going for around a tenner. I
>> >know it still works fine because it was mounted on my friend's V8
>> >rangy before he changed engine to a tdi300 due to fuel costs. So
>> >basically he just wants to get rid of it. I have no problem mounting
>> >the thing. My problem is that the pulley on the compressor is a v-belt
>> >(triangular cross section) pulley while the crankshaft pulley on my
>> >300tdi accomodates the newer, thick flat belt (i think it's called a
>> >polyvee belt... it's got 3 or 4 grooves along the belt), and there is
>> >a provision for the a/c compressor's belt on it.
>> >
>> >What are my options? Is is possible to change the pulley on the a/c
>> >compressor or do I have to find a rare crankshaft pulley with one
>> >polyvee and one pulley instead of 2 polyvees? Does anyone supply these
>> >pulleys or would I have to get one manufactured?
>> >
>> >Sorry for all the questions. It's just that getting powerful onboard
>> >air for a few tenners (including pulley costs) sounds too tempting to
>> >me
>> >
>> >Thanks for any reply.
>> >
>> >Dennis

Ahhh good to know it should work. I'll be asking some experts how is
best to do it in the coming days. I already planned to have a
reservoir in the system to help the compressor.

Certainly looking forward to this. If I can get that pulley sorted my
problems will be over. Will be picking up the compressor on Saturday
so I could examine it more closely because details are a bit sketchy
at the moment.

I'll definitely be reporting back if I go ahead with it.
Thanks for all the help Jon!
Will let you know how it goes.


Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<4n3cn0lqg1hvp8jt67vgaqn3vdfq3t85o3@4ax.com>...
> It should work but obviously it will need to remain clear of the
> clutch arrangement.
>
> Assuming you get the pulley fabricated on top of the existing pulley
> the only downside I can see is that the new pulley will be larger than
> the original and therefore you are lowering the gearing, thus the
> compressor will turn slower and mean you need higher rev's to get the
> same amount of air.
>
> FYI: Thats why I had my pulley made at 6.5" DIA so that I geared it up
> slightly - compressor pully is 5" DIA (high compressor rpm at
> tickover is what you need as you are unlikely to need high rpm on the
> move).
>
> You could also add a resevoir to the system, then high(er) rpm will
> not be needed.
>
> Good Luck.
> J
>
>
> On 19 Oct 2004 10:07:54 -0700, nitehawk@di-ve.com (Dennis) wrote:
>
> >Just out of pure speculative curiosity, how about getting a polyvee
> >belt profile pulley fabricated onto the compressors current pulley and
> >leave the v-profile pulley unused?. I'll have to mount the compressor
> >a bit further back so it will align with the crank pulley but that's
> >not a problem since I'm fabricating the mounting bracket for it
> >anyway. And that way I can use my crank pulley's provision for the a/c
> >belt.
> >
> >It should work right? (please say yes )
> >
> >Regards,
> >Dennis
> >
> >
> >Jon <jonathan.kelly@no-spam-linesurveys.co.uk> wrote in message news:<deh9n0lrp96abf9llss2viccc11ur7j440@4ax.com>...
> >> Firstly, many people will tell you not to bother because the
> >> compressor wont last long because it will cease up due to lack of
> >> lubrication. So what if it does, its cost you £10 for a compressor +
> >> a few airline fittings and a pulley. What you get when its working is
> >> FAR better than an electric one and MUCH cheaper than the "Endless
> >> Air" option that uses a Sanden A/C compressor anyway!!! If it ceases
> >> get another from another doner!
> >>
> >> The way to avoid it ceasing up is simple:
> >> 1. install an air filter in your airline. That way you can monitor
> >> how much oil it throws out (mine is very little).
> >> 2. Mount the compressor so that the oil filler is easily accessible.
> >> that way you can simply put more oil in to keep it topped up.
> >> 3. Put a switch in the cab in the 12V feed to the clutch so that it is
> >> not running all the time.
> >> 4. I would advise putting a pressure switch into the system also.
> >> Mainly for safety, but additionally it means the compressor will keep
> >> starting and stopping as the pressure builds and drops.
> >>
> >>
> >> As for the installation:-
> >>
> >> I cant remember how the 300tdi connects the fan to the waterpump
> >> shaft. On the 200tdi there is a v-belt pulley linking the crankshaft
> >> pulley and then importantly about a 2 inch flange that is "doing
> >> nothing". I had a new pulley (6.5" DIA) fabricated onto this flange
> >> and then got a 1025mm long fan belt to connect the new pulley to the
> >> compressor.
> >>
> >> So, I guess you may have 2 options:
> >> 1. Get a new pully for the compressor - I think this will be expensive
> >> though because I think the electric clutch is part of the pulley!
> >> Then all you need is a longer belt to replace the existing.
> >> 2. have a new v-belt profile pulley fabricated to an existing shaft
> >> and get a belt to fit between that and compressor.
> >>
> >> Unfortunately I dont have a lathe so I had to pay £50 to get a new
> >> pulley turned up, heat shrunk onto the existing shaft and then dutch
> >> screwed to secure it.
> >>
> >> If you decide to look at changing the pulley then Hella Climate
> >> Control can probably help you (01932 41 17 11).
> >>
> >> Out of interest what model / make is the compressor?
> >>
> >> Regards,
> >> Jon
> >>
> >>
> >> On 18 Oct 2004 14:57:06 -0700, nitehawk@di-ve.com (Dennis) wrote:
> >>
> >>
> >> >I'm thinking of doing the same on my Tdi300. I have sourced a dirt
> >> >cheap V8 a/c compressor that's basically going for around a tenner. I
> >> >know it still works fine because it was mounted on my friend's V8
> >> >rangy before he changed engine to a tdi300 due to fuel costs. So
> >> >basically he just wants to get rid of it. I have no problem mounting
> >> >the thing. My problem is that the pulley on the compressor is a v-belt
> >> >(triangular cross section) pulley while the crankshaft pulley on my
> >> >300tdi accomodates the newer, thick flat belt (i think it's called a
> >> >polyvee belt... it's got 3 or 4 grooves along the belt), and there is
> >> >a provision for the a/c compressor's belt on it.
> >> >
> >> >What are my options? Is is possible to change the pulley on the a/c
> >> >compressor or do I have to find a rare crankshaft pulley with one
> >> >polyvee and one pulley instead of 2 polyvees? Does anyone supply these
> >> >pulleys or would I have to get one manufactured?
> >> >
> >> >Sorry for all the questions. It's just that getting powerful onboard
> >> >air for a few tenners (including pulley costs) sounds too tempting to
> >> >me
> >> >
> >> >Thanks for any reply.
> >> >
> >> >Dennis