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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
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9,959 Posts
Discussion Starter #381
AC line situation appears to be under control. I spoke with the tube bender today and he says he can do a radius of 2x the diameter of the tube. So that means the best I can do is 3/4" CL bend. So I redesigned with an offset just past the drier. I mocked up the lines and came to the conclusion I have a solution.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #382
Coming down to the ultimate challenge in this AC installation. The manifold tubes off the compressor. As it is one of the things that was in the way on my car was the hydraulic pump portion of the tandem pump mounted on the M120 engine. The cars that were fitted with the M120 all had hydraulic suspension, which Samson does not. Therefore to get around that for the past 10 years I have been running the hydraulic pump into a tiny reservoir form a 2006 Nissan Altima. This allowed hydraulic fluid to circulate around doing nothing but lubricate the front bearing in the pump. For the AC compressor lines and well as the future cold air intakes this reservoir and associated tubing was now in the way. Plus it was such an unprofessional way of addressing the problem so it had to go. I found this to be a simple fix. The M120 ZF pump reservoir will bolt in place of the M119 ZF Pump cap from earlier SL500's and E300's, and they have the same mounting pattern, pulley mount and offset. That was easy, 4 screws for the reservoir and maybe you will have to swap pulleys, and you have a single power steering pump without the hydraulic stage. So I got the pump, rebuilt it and now I'm ready to attack the AC compressor lines.

The installation of the M120 into the 107 required extensive modifications of the 107 subframe especially around the compressor area to allow clearance for the compressor. Needless to say there is not much clearance in this area. When I first looked at this, I was under the impression that either the sunframe or engine would have to be removed to replace the compressor. Looking at it now I believe I will be able to remove the compressor out the front with the radiator and condenser removed. Still not ideal but a lot better than removing the sub frame. In any case that is for the very near future.

In any case the immediate challenge is routing the lines to a compressor that is shoe horned in. This will require making my own manifold. To do that I took my best guess at what the manifold needed to look like and what direction the tubes had to exit. I then 3D printed a plastic model of the manifold and will be testing to see if it bolts in in the very near future, See attached pictures. Preliminary test shows that the manifold hits the subframe at the corner where im pointing to in the last picture but just a 0.020" grind will give it positive clearance. Since the engine rocks on the subframe that clearance will need to be increased significantly. It looks like it can be done. The outlet ports are small for the moment so that if an angular correction needs to be made. It can be done by re'drilling to the next larger tube size.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #383
Well version two went much better. Based on the information I got out of the first block, I was able to see I nailed it on the angles and with the small tubes I put in the holes I was able to assure myself I had a path out for both suction and discharge lines. With the angles now known I could model it up with the full size tubing and it turns out that the lower tube turns out of the way of the upper tube, allowing me to not have to stagger the holes. So I modeled up the new design along with the tubes. This 3D printing stuff is usefull. Everything falls right in place. Only problem now id finding someone that will mandrel bend the tubes in steel.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #385
Amazing work. How long did it take to 3D print parts that size?
It took 11 hr. But that machine is an inexpensive $270 machine. Not bad for the price.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #387
Yeah... I have a cheap 3D printer and it takes hours to make even small parts. The parts are good quality but painfully slow.
Yes but its not like you have to be present for the process.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #389
In tubing hell, but I think I found the path out. I thought I had everything figured out but then I realized the tubes would have to be crimped onto the tubes before brazing them in place. I might be able to do that if I keep a wet rag around the breadlock fitting when I braze but I decided not to risk it and design for at least 1 removable tube. In any case I have the work around, more 3D printing to check. In the mean time I practiced making a manifold out of Aluminum. The real one will be steel.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #392
Well, I'm trying to work on my AC. I have been stuck in shipping hell. A line was delivered by UPS bent. I have another 15mm end mill being shipped via USPS, see the tracking below.

Tracking History

March 21, 2020, 11:23 pm
Arrived at USPS Regional Facility
COLUMBIA SC PROCESSING CENTER
Your item arrived at our USPS facility in COLUMBIA SC PROCESSING CENTER on March 21, 2020 at 11:23 pm. The item is currently in transit to the destination.

March 21, 2020, 9:07 am
Arrived at USPS Regional Facility
GREENSBORO NC DISTRIBUTION CENTER

March 21, 2020, 2:54 am
Departed USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 20, 2020, 6:32 pm
Arrived at USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 20, 2020, 9:05 am
Arrived at USPS Facility
MILTON, WV 25541

March 20, 2020, 7:25 am
Arrived at Post Office
MILTON, WV 25541

March 20, 2020, 4:08 am
Departed USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 19, 2020, 9:35 pm
Arrived at USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 18, 2020, 9:28 am
Forwarded
TRINITY, NC

March 18, 2020, 9:27 am
Arrived at USPS Facility
TRINITY, NC 27370

March 18, 2020, 5:58 am
Arrived at Post Office
TRINITY, NC 27370

March 17, 2020, 7:54 pm
Departed USPS Regional Destination Facility
GREENSBORO NC NETWORK DISTRIBUTION CENTER

March 17, 2020, 5:33 pm
Arrived at USPS Regional Facility
GREENSBORO NC NETWORK DISTRIBUTION CENTER

March 17, 2020, 2:24 pm
Arrived at USPS Regional Facility
GREENSBORO NC DISTRIBUTION CENTER

March 17, 2020, 5:44 am
Departed USPS Facility
CINCINNATI, OH 45246

March 16, 2020, 10:51 pm
Arrived at USPS Origin Facility
CINCINNATI, OH 45246

March 16, 2020, 9:36 pm
Accepted at USPS Origin Facility
HEBRON, KY 41048

March 16, 2020, 1:54 am
Shipping Label Created, USPS Awaiting Item
HEBRON, KY 41048

March 16, 2020, 12:00 am
Departed Shipping Partner Facility, USPS Awaiting Item
HEBRON, KY 41048
Shipping Partner: WINIT
 

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Outstanding Contributor , Bob's Your Uncle!
-----'83 280 SL----- 5 speed....The PIG
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29,341 Posts

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Premium Member
1983 380 SL
Joined
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2,644 Posts
More like the path of someone seeking toilet paper.
Or paper towels. :)

My daughter went to Target yesterday morning... they had both toilet paper and paper towels on the shelves, but you were only allowed to buy one or the other... not both. So she bought paper towels, went back and put them in her car... then went back in and bought toilet paper. Who knew?

The paper towels I understand... dry your hands with paper towels and throw them away rather than using the same cloth towel that everyone else uses... but toilet paper? That I don't get?
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #396
Pee Wees great adventure continues. Third time in Greensboro. Bets please.

March 24, 2020, 7:21 am
Arrived at USPS Regional Facility
GREENSBORO NC DISTRIBUTION CENTER
Your item arrived at our USPS facility in GREENSBORO NC DISTRIBUTION CENTER on March 24, 2020 at 7:21 am. The item is currently in transit to the destination.
March 24, 2020, 3:23 am
Departed USPS Regional Facility
COLUMBIA SC PROCESSING CENTER
March 23, 2020
In Transit to Next Facility


Well, I'm trying to work on my AC. I have been stuck in shipping hell. A line was delivered by UPS bent. I have another 15mm end mill being shipped via USPS, see the tracking below.

Tracking History

March 21, 2020, 11:23 pm
Arrived at USPS Regional Facility
COLUMBIA SC PROCESSING CENTER
Your item arrived at our USPS facility in COLUMBIA SC PROCESSING CENTER on March 21, 2020 at 11:23 pm. The item is currently in transit to the destination.

March 21, 2020, 9:07 am
Arrived at USPS Regional Facility
GREENSBORO NC DISTRIBUTION CENTER

March 21, 2020, 2:54 am
Departed USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 20, 2020, 6:32 pm
Arrived at USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 20, 2020, 9:05 am
Arrived at USPS Facility
MILTON, WV 25541

March 20, 2020, 7:25 am
Arrived at Post Office
MILTON, WV 25541

March 20, 2020, 4:08 am
Departed USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 19, 2020, 9:35 pm
Arrived at USPS Regional Facility
CHARLESTON WV PROCESSING CENTER

March 18, 2020, 9:28 am
Forwarded
TRINITY, NC

March 18, 2020, 9:27 am
Arrived at USPS Facility
TRINITY, NC 27370

March 18, 2020, 5:58 am
Arrived at Post Office
TRINITY, NC 27370

March 17, 2020, 7:54 pm
Departed USPS Regional Destination Facility
GREENSBORO NC NETWORK DISTRIBUTION CENTER

March 17, 2020, 5:33 pm
Arrived at USPS Regional Facility
GREENSBORO NC NETWORK DISTRIBUTION CENTER

March 17, 2020, 2:24 pm
Arrived at USPS Regional Facility
GREENSBORO NC DISTRIBUTION CENTER

March 17, 2020, 5:44 am
Departed USPS Facility
CINCINNATI, OH 45246

March 16, 2020, 10:51 pm
Arrived at USPS Origin Facility
CINCINNATI, OH 45246

March 16, 2020, 9:36 pm
Accepted at USPS Origin Facility
HEBRON, KY 41048

March 16, 2020, 1:54 am
Shipping Label Created, USPS Awaiting Item
HEBRON, KY 41048

March 16, 2020, 12:00 am
Departed Shipping Partner Facility, USPS Awaiting Item
HEBRON, KY 41048
Shipping Partner: WINIT
 

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Premium Member
1973 450SL, 1999 c230
Joined
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924 Posts
My bet is it's being held to ransom by Postal Workers who are putting pressure on the Senate to get their Pelosi Dollars. If they don't get their Pelosi Dollars John don't get his Schiff.
 

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Premium Member
1986 560SL with M120 V12 Engine, 1988 560SL Stock
Joined
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9,959 Posts
Discussion Starter #399
Back to work today. The other 15mm end mill I ordered came in today. The original one is still in the cloud. I also received my aluminum lines yesterday and was able to have them bent up this morning. The one line with the 180 degree bend came out not so good. It will work but it looks fugly. I will probably get that one remade by a guy I found on line. Now I have to make the compressor manifold out of steel and it really needs to be CNC machined. I have 2 days of CNC availability if I can get to my workspace. The Governor just shut down the state effective Friday night due to Corona virus. With the lines now complete the only this left for me to buy is the compressor. There will be three setups and 5 programs involved. I will never get the 5 operation one as I will need a tapered end mill. But in reality it can be done with a die grinder. I have an aluminum plate fabricates so I can easily clamp it down to the mill. All is ready to go if I can get the CNC mill tomorrow.
 

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Premium Member
1983 380 SL
Joined
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2,644 Posts
Back to work today. The other 15mm end mill I ordered came in today. The original one is still in the cloud. I also received my aluminum lines yesterday and was able to have them bent up this morning. The one line with the 180 degree bend came out not so good. It will work but it looks fugly. I will probably get that one remade by a guy I found on line. Now I have to make the compressor manifold out of steel and it really needs to be CNC machined. I have 2 days of CNC availability if I can get to my workspace. The Governor just shut down the state effective Friday night due to Corona virus. With the lines now complete the only this left for me to buy is the compressor. There will be three setups and 5 programs involved. I will never get the 5 operation one as I will need a tapered end mill. But in reality it can be done with a die grinder. I have an aluminum plate fabricates so I can easily clamp it down to the mill. All is ready to go if I can get the CNC mill tomorrow.
Amazing work. (y)
 
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