What
Modified Sanden SD-508 air conditioner compressor from a Mitsubishi/Chrysler Sigma.
8 cubic feet per minute air flow.
Nitto air couplings and a 10 litre tank.
How
Certainly the biggest mod I have done so far. Over a year in the making.
I've done plenty of research both here and on other forums and the web in general
Grungles instructions Grungles Homepage were extremely helpful and I have followed these pretty much step by step. So I will list out the bits I had to do differently, to overcome my specific problems.
First off was sourcing the compressor. I hunted around a few local wreckers, but no one had the Sanden SD-508. Plenty of TRS-90 from the VT-on Commodores, but being that I had specific instructions I was following, and the fact I knew that the factory Rodeo A/C bracket would fit the SD-508 I had to try and find one. I was tipped off that the early Sigmas used a Sanden, and it just so happened a close friend had several wrecks sitting around that had A/C. He gave me one for free.
Now the problem began that it had twin V pulley on the front. And sourcing a genuine 6PK multigroove pulley was not an option as they are no longer made, as they are superseded by the SD7H model, which uses different shaft, bearings and clutch diameters on the front.
As "luck" would have it, a few months later I was on a trip up the east coast and the power steering pump bearing shat itself and snapped the pulley off the shaft. It just happened to be exactly the right size to fit up to the compressor, with a little work on a lathe.
I dropped it in to Ian Weatherhead engineering and for $25 he machined the centre out of the PS pump pulley, and lathed down the original twin V pulley and mated the two together.
Alignment was spot on, so it was welded into place.
Now that I knew I had a semi functional compressor, I ordered a a factory rodeo A/C compressor bracket for the 6VD1 engine. $75 from QLD to Hobart in a couple of days.
Next problem was fitting up the suction and discharge hoses. The make fittings on the compressor head were going to be too long to fit female threads with 1/2" barbs. So I had to get the male threads cut off and drilled and tapped to take the 1/2" male to 1/2" barb 90' fitting and 5/8" to 1/2" barb 90'
Again a local engineering place did this for me.
As I mentioned a few posts back I ordered the brass fittings, hoses - normal and high temp, check valve, pressure switch etc from a mate at Wellco and in this last week I had to source a couple more bits for the tank, the hose coil, tyre inflator and nitto fittings and got these from Brierly Hose and Handling
With a trip to the Tassie West Coast fast approaching and only a few weekends to get work done, I put in a 2 day marathon effort to get the compressor assembled, and mounted to the car, purchase a new 6PK2300 belt for the front of the engine, clean and weld a bracket to the tank, then bolt it to the chassis below the passenger side front seat, and wire up the pressure switch, dash switch and relay.
It got completed and pushing the dash switch and hearing it kick into life and start filling the tank was a great feeling!! The tank fills to 125psi in about 20-30secs. Testing tyre re inflate times is still to be done.
Sanden SD-508
Busted power steer pump pulley
Completed machined front pulley, and showing the grease nipple fitted to body.
Factory Rodeo A/C bracket, ground in key spots to fit the Sanden.
Test fitting for alignment
Mounting ear which might hit when engine moves - will be cut off later
Tapping the oil return port to M6 thread
6mm M6 allen head grub screw loctited in place
Head male threads machined off and tapped to accept the brass barb fittings
brass barb fittings
Compressor bolted in place, with blue hose for suction and black high temp hose (400'C rating) for discharge
Tank from local Truck spares, degreaser can for size comparison
Condor MDR2 pressure switch, currently set to 90psi on 125psi off. and a 140psi gauge and 165psi high flow safety valve, all mounted on the powersteer resevoir bracket.
Tank with bracket for mounting to the chassis welded on and coated in "cold gal" zinc paint.
Blue coil 5m with Nitto fittings, Assorted 1/2" barbs 3/8" threaded, one way check valve, drain valve, some 3/8" barbs etc and 75mm x 10mm bolts and nyloc nuts. (not shown, tyre inflator, same as below picture)
Dash switch, Carlingswitch Contura V series part# R403-12G-04 (switch type - 12 volt Green - air filter picture) from Jay-Dee auto cables in Melbourne. Same style as the ARB compressor and locker switches, but with a green light.
Cost
Compressor - Free
Machine Pulley - $25
Brass Parts, Hose, High Temp Hose Pressure Switch - $206
Extra Brass Bits, Coil hose, $90
Stainless hose clamps, Tyre chuck / gauge, 12mm Hose x 4m - $50
Tank - $40
Tank Bracket - $11
second hand factory compressor Bracket - $75
6PK2300 belt - $59
Total $556
Time spent & busted knucles... Priceless
Issues
In addition to those posted in how it was built...
It would be almost impossible with factory A/C still in place. Some custom bracketting to place the compressor above the drivers side cam cover might be possible, and is how EndlessAir fitted them to the RACV service vehicles which were 2WD Rodeo V6.
Limited space to fit a tank.
Perhaps the cost, but an electic compressor comes no where near the speed or relability.
Results
The speed test is in. We spent 4 days on the Tassie West Coast, aired down to 16psi for some beach work. At the end of the track we raised the pressures again to 30psi in approx 20-30secs per tyre.
I reinflated 12 tyres from my home made endless air in 11mins total time, including moving between wheels and getting the other drivers to turn their car around so I could reach all sides.
All this was without the tank as well, as I had a small pin hole in the air line from pressure switch to the tank, I think from it accidentally touching the exhaust before I had zip tied it into place.
I just ran the hose from the pressure switch T joint to the tyre inflater.
All up I'm very happy with the results.
Tags: onboard air compressor
