Recall that this project was started last August when the wife requested that I tackle the X1/9s AC and get it going again (http://xwebforums.com/forum/index.php?threads/18173/). But was interrupted by Fall and by a heater/AC blower motor that required rebuilding. http://xwebforums.com/forum/index.php?threads/20043/ This turned out to be a good thing since the AC-Heater box resulted in significant clean-up and improvements in the efficiency of the air inlet system overall. But it was a big project and I used the winter to do it. But if you can, this is definitely a good idea since the box was pretty dirty, the gasket that forces air through the evaporator was crumbling, and the fresh air door was stiff. Now that part of the system is factory fresh with a new expansion valve and other goodies. At the same time I continued to collect some of the parts necessary for a thorough rebuild of the AC system. This included new 134a barrier hose after determining the lengths and sizes required to replace the original hoses. You can re-use the old fittings if you are possessed of sufficient time and shop equipment to restore each for crimping on new hoses. But the X1/9 uses standard beadlock O-ring hose fittings in hose sizes 6, 8, and 10, so one simplier option is to just get new fittings. Selection of the required fittings is a fairly simple task once you understand the jargon. But then you must determine the different types and sizes of beadlock O-ring fittings used in the X1/9 system, and where they are used. There is at least one (low pressure switch block) that must be cut and re-brazed with a new beadlock ferrule (the thing that gets crimped on the final hose end). To make this easier for folks doing future X1/9 AC restorations, I have compiled the required fittings, hose sizes, and other useful details about the X1/9 AC system in a simple graphic attached here. I even listed the length of barrier hose and the sizes. So, in the following I will post what I learned about each of the systems. I will start with the condenser, since that is the main upgrade aside from barrier type 134a hoses. I will post these as installments since it's too much to post at one time. Overview of AC Conversion and Upgrade for the X1/9 I pulled together the diagram below as a schematic of the X1/9 AC system, that otherwise does not exist anywhere, and as a summary of all the components. This is focused on upgrades to a modern 134a system, but the arrangement and fitting sizes are the same as stock. And here is a list of the components, their sources, costs, and parts numbers. 1. Receiver-dryer -Part: Jaguar XJ6 4.2 (78-81) - OE# CAC2338 -Source: Rock Auto 31.25 -The drier has the correct forward #6 male insert O-ring (same as condenser on that line) and rearward #6 female O-ring fitting ends 2. Expansion Valve -Part: O-ring expansion valve -Source: http://www.nostalgicairparts.com/air-conditioning/o-ring-expansion-valve-52.php part 94-9873 3. O-Rings (AC type) Source: Cold Hose, http://www.coldhose.com/ O-rings Pack Of 20 # 6 Hose ,1.99 O-rings Pack Of 20 # 8 Hose ,1.99 O-rings Pack Of 20 # 10 Hose ,1.99 4a. Fittings for new barrier hoses Source: Cold Hose, http://www.coldhose.com/ 2 0 B131FS # 6 45 Degree FOR O-ring Fitting $5.25 1 0 A133FS # 10 Straight FOR O-ring Fitting $5.75 1 0 B132FS # 8 45 Degree O-ring Fitting $5.50 1 1 A142 # 8 Straight MIOR O-ring Fitting $6.25 1 1 WS571 # 8 Weld On Beadlock Barb (outer) $2.99 (for low pressure switch block) 4b. Fittings with Service ports at compressor Source: Nostalgic Air 1 A132-3 # 8 Straight Female O-ring Fitting with R-134a Port $9.49 1 A133-3 # 10 Straight Female O-ring Fitting with R-134a Port $9.99 4c. Fittings for short drop/right angle connection attaching 4b above to compressor Source: Nostalgic Air If the hi and lo ports on the compressor are same size, it is tube-O (OEM compressor) then use 90° compressor adapters, with #8 & #10 connections 1 TO1606 Tube-O Fitting Discharge High Side Port R-134a $14.99 1 TO1605 Tube-O Fitting Suction Low Side Port R-134a $14.99 or Source: Pure Choice Motorsports Part: If the hi and lo ports on the compressor are 7/8-14 (#10) and 3/4-16 (#8) fittings respectively, it is standard O-ring (not tube-O) (new compressor) then use Source: Pure Choice Motorsports (http://www.purechoicemotorsports.co...ategory_id=98/home_id=-1/mode=prod/prd301.htm) 1 15160 Tight Fit 90° AC Elbows #8 $39.95 1 15170 Tight Fit 90° AC Elbows #10 sizes $39.95 5.134a Barrier Hose Source: Cold Hose, http://www.coldhose.com/ 10 feet BH6 # 6 (5/16") Barrier A/C Hose Per Foot $3.49 13 feet BH8 # 8 (13/32") Barrier A/C Hose Per Foot $3.75: 5 feet BH10 # 10 (1/2") Barrier A/C Hose Per Foot $3.99 6. Compressor Part: equivalent 134a Sanden: SD5H14 or SD7H15 #8 discharge fitting 3/4"-16 threads #10 suction fitting 7/8"-14 threads Part: Sanden 4709 (SD7H15) PN: 15-5001 Source: http://www.nostalgicairparts.com/air-conditioning/new-sanden-style-709-v-belt-double-groove-2.php $184.99 or -Source: Summit VTA-04808-VUA $198.00 7. Condenser Part: Nostalgic Air 11 X 19 Superflow (parallel flow) R-134a Condenser 11" tall x 22" wide (Core size: 10" tall x 20" wide x 7/8" thick) Part Number: 44-1119 Source: Nostalgic Air $84.99 http://www.nostalgicairparts.com/air-conditioning/11-x-19-superflow-r-134a-condenser-328.php Top: #8 Male insert (3/4"-16) Bottom: #6 Male insert (5/8"-18) So these are the "ingredients." In the next installment I will start reviewing details of each of the components and any tricks that I discovered along the way. Stay tuned!