Removing air con - hole left in bulkhead

[twenty valve]

Right then, I've removed the AC from my S2, including replacing the original heater box and evapourator for a standard system from a non AC audi 80. (I had to do it properly or not at all)

This obviously leaves me with a large hole in the bulkhead where the pipes went through.

So did audi make a grommet or blanking plate for cars which wern't fitted with AC or was the hole just never made? If anyone has had the same problem, what did you do?

Welding doesn't look like an option as the wiring loom is too close on the inside, and the paint and seam sealer on the engine bay side would burn off.

I'm not looking for a debate whether AC is good or bad, I have my own reasons for removing it and thats that

1. its heavy
2. its makes life difficult when working doing jobs in the engine bay,
3. the condenser blocks airflow to the main rad
4. future replacement of the main rad for a larger aluminium item will be easier
5. it always breaks and spare parts are expensive

[wildoliver]

I've considered this on mine too.

But yesterday on the motorway my mind was changed back to keeping it!!

However when I considered it (I've actually stripped a car removing air con in the process so have seen the hole in detail) as bodgy as it sounds I think a plate sikaflexed in with expanding foam behind it is probably the best bet.

[s2_bo]

When i removed this on mine i used a pice of flexible tar covered roof flashing. It stuck on very well and covered the whole with out any leaks for several years.

[s2_bo]

this is the stuff i used:

[johne]

So did audi make a grommet or blanking plate for cars which wern't fitted with AC or was the hole just never made? If anyone has had the same problem, what did you do?

The bodyshell was made with no hole for A/C, there is just a "score" in the metal to let you knock the hole out if A/C is going to be fitted so there was no need for Audi to make a plate or grommet for non A/C cars as they already have the metal there.

I'd suggest making up two oval plates just larger than the hole you're left with and riveting them together either side of the hole with sealer in between.

John

[twenty valve]

the offending hole





I'm a service engineer/machinist/welder by trade and have all sorts of equipment at hand and materials at my disposal (including sheet stainless) so hoping to make a proper job of it.

[s2driveruk]

i painfully repaired mine last summer and i'm so glad i have, warm weather back...cold air to enjoy

Can completely agree with the pain and expense of keeping it running on a 20yr old car though and the extra access!!!

[twenty valve]

The bodyshell was made with no hole for A/C, there is just a "score" in the metal to let you knock the hole out if A/C is going to be fitted so there was no need for Audi to make a plate or grommet for non A/C cars as they already have the metal there.

thats what I suspected... shame really, I could have made it look original otherwise!

[twenty valve]

i painfully repaired mine last summer and i'm so glad i have, warm weather back...cold air to enjoy

Can completely agree with the pain and expense of keeping it running on a 20yr old car though and the extra access!!!

I'd rather have the window down and soak up the hot rays while I've got the chance.... its not often we get nice weather, so why would you want to isolate your self from it?

If I lived somewhere that was hot all the time I might get sick of it though!

[epic]

When i removed my AC I cut an oval of black plastic about 1/2 cm bigger on each side and used black sikaflex to stick it in place. I think i might have cut a black paint tray up for the plastic. Works perfectly and you can't see it easily.

[twenty valve]

When i removed my AC I cut an oval of black plastic about 1/2 cm bigger on each side and used black sikaflex to stick it in place. I think i might have cut a black paint tray up for the plastic. Works perfectly and you can't see it easily.

I thought you may have come across the same problem as well Richard as I remember your car having no trace of AC. I would have given you a call but I've lost your number

[Dan]

this is the stuff i used:

Flashing... tape?





On a serious note, I'm considering getting rid of my AC... it's on the blink and this country isn't warm enough for my liking anyway. Brrrr.

[Phil Payne]

I was walking along behind some houses with a friend last year and he suddenly started whistling. I looked back and he was walking along trying to look innocent with his hands behind his back.

Not until later did I discover the lid of a recycling bin in the workshop, being carved up to cover such a hole.

[twenty valve]

On a serious note, I'm considering getting rid of my AC...

Just do it. Removing the dash and changing the heater box isn't even a days work if you want to do it properly.

[johne]

Just do it. Removing the dash and changing the heater box isn't even a days work if you want to do it properly.

I don't understand the need to change the heater box, not least because there isn't any difference between the A/C one and a non A/C one. I assume you're refering to the condensor unit with the pipes that go through the bulkhead you're on about that fits between the fan motor unit and the heater box.

If I was removing my A/C I'd leave the condensor unit in place and just remove everything else, the weight difference would be negligible and you won't have a hole to fill.

If you remove the condensor unit you've got to find the replacement tube from a non A/C car and you've also got to go down to the non A/C fan motor, housing and fan speed resistor pack. I say "down" because the A/C fan motor is more powerful than the non A/C one and you'll need all the air you can get coming into the car to keep cool on hot days with no A/C any more

On the up side, with the condensor unit gone you could then fit the bigger glove box the non A/C cars have.......

John