Rear Air-conditioning Delete / Add Maxxair + Solar

Ok I finally did it this weekend. After 2 years of enjoying summer and not working too much on the van. I pulled off the factory rear air-conditioner (after having it professionally decommissioned at the compressor with smaller belt and emptying the system).

(BTW van is out of warranty.)

Thanks to Paul http://paulsince72.wixsite.com/padams/sprinter. AND hein!

Macro steps:
1. remove aircon and prep brackets
2. test fit fan and solar supports
3. install fan on van
4. mount panels to solar supports (on floor)
5. lap seal fan and all openings
6. wait
7. mount solar array on van
8. complete wiring
9. test for water tight
10. replace interior


Here are the more detailed steps:

Previously
1. remove all the interior rear air-conditioner trim parts
2. remove the headliner
3. measure the hole
4. have an 1/8" aluminum plate made to fit the hole - including maxxair hole (I had a local sheet metal shop make me this on their water jet - $75.). Drawing is included - it fit perfectly.
5. create 3/4" mahogany wood "hoop" for the maxxair interior screw support.

Major steps
1. get on roof on some platform (I used my rack for much of this work).
2. uncover the system
3. unbolt the major parts of the condenser
4. cut the pipes where necessary
5. unbolt the interior fan unit from interior
6. hang a plastic drop cloth below the hole

Now you will have - a large hole in the roof :) and a couple of aluminum brackets with some weird shapes. AND 3 other openings: 1) 2 pipe fittings and 2) 1 power opening.

My goals
1. maxxair fan install
2. 2 x 100W solar panels

Tools
- angle grinder with cutting wheel (you should be comfortable with this tool with aluminum - you don't want to hit the roof with it).
- drill - for new holes
- jigsaw with metal cutting blade
- rivet gun
- cold galvanizing paint

Next steps
1. cut off the pipe fittings flush with the existing OEM roof fittings.
2. push the electrical whip inside the van.
3. *delicate work* use angle grinder to trim the aluminum brackets to about 3-4" above the roof. You will have a jagged angle sticking up from the roof on both sides - but it will be ok!
4. dry fit the plate and the maxxair.
5. I found that the factory roof whole was slightly too small - I jig sawed it and painted it. It only needed about on 1/8" off on the whole - toward the front of the van.
6. dry-fit again.
7. cut piece to cover the the electrical hole.

Solar plan
- Get 2 x 8' - 2" Aluminum angle in 1/8" material.
- Test mount angles to the factory brackets.
- Test mount solar panels to the angles
- Make sure the panels will clear the maxxair fan - front and back. (measurements)

Next Steps - mount the panel to cover the main hole (and other openings)
1. dry fit the panel (and the hole piece) and clamp it in place.
2. pre-drill the rivet holes
3. add the maxxxair roof bracket, clamp and predrill all maxxair holes.
4. vacuum all drill shavings

Next Step - dry-fit solar before sealing maxxair and hole.
1. place angles on roof
2. clamp angles to the remaining factory air com mounting brackets
3. drill hole to attach angle to factory bracket
4. test fit
5. cut angle "foot" for the front of the solar angle (one for each side).
6. dill hole for the foot in angle.
7. test fit angle with foot
8. repeat for other side.

test fit solar wiring roof entry gland
1. cut hole in the roof panel.
2. clean and prep for mounting gland

Next Step - mount the maxxair
- this has been covered elsewhere.
- I used GRK cabinet screws into mahogany interior "hoop".

Next step - Seal the maxxair, roof holes and solar gland.
- self-leveling Lap seal - covered in depth elsewhere.

Final step
- after assembling solar panels to angles (on floor)
1. lift assembly on to the roof
2. bolt to solar assembly to the existing air con angles
3. glue angle "feet" to the roof with 3m 4000.

Let the entire thing set overnight.

Interior
- caulk all the remaining pipe openings with 4000.
- pull fuse for the AC.
- wrap all remaining electrical connectors and secure to interior ceiling.

Observations
- WOW the van drives better without all that weight up in the air.
- love the solar power
- Victron is really great - I'm using the MPPT 75/15 with the bluetooth dongle and the iPhone app.
 

Attachments

jrr

New member
Hey - how cool, as I am just doing this now during my vacation days - fantastic description, and yeah, when I researched this several months ago I only found paulsince72. The first dumb question I have is whether you actually have to replace the large belt with the small belt that bypasses the rear compressor? Can't a person just have the freon (or whatever is used) evacuated and then just not engage the rear compressor, like, by pulling the fuse, as you suggest? Thanks much for the excellent pictures.
 
Hi Sorry for the delay - just got back from vacation in the van. It was amazing with the new panels and the fan. Why did I wait so long!

BTW - I had my mechanic swap the belts a while ago. I guess you could leave the compressor in the loop - but it would be an unnecessary drag on the system(?). Not sure what I am going to do with the dash button. I might go to the dealer and order the blank piece for that area and swap it out.

Best, C
 
I also just started this project! I decided to cut off all the bolts with my oscillating tool to have a fresh surface to install three solar panels. I was wondering if anyone had any ideas for filling in the large hole in the headliner. I was thinking about taping masonite or something of a similar thickness and then replacing the upholstery before cutting the hole for the fan.
 

Attachments

DanielMenne

New member
Hey guys!
Wow that really looks great! You did an awesome job!

Me and my partner got the rear aircon removed by a mechanic and replaced it with a fan/hatch aswell, but now we got some issues with the front aircon.
It still works, but sometimes needs probably about 30 minutes to produce cold air.
Do you guys have an idea what the problem could be or got similar issues after removing the rear aircon?

Cheers Daniel
 

pkamps

New member
Hey All,

Does anyone have a link to the belt needed for the A/C delete? I tried looking for the one paulsince72 posted and can't seem to find it. Thanks
 

Top Bottom