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  • Rob's 1960 non AC 430 to AC Install

    Rob McLellan and his mechanic, Don, started the installation of the Classic Auto Air "Perfect Fit" aftermarket AC system on his non AC equipped 430 1960 Squarebird yesterday. Rob said he will be making detailed notes and taking pix as they go to document the install. First an overview of parts that I was able to locate for him. We want to thank Carl Heller ~ partsetal, John Pizzi ~ jopizz, Ken Harkema, Jim Dottling, John Draxler ~ Tbird Ranch, Steve & Dwight at CAA, and others who assisted us in determining what parts were needed and in helping us find them.

    I was never able to locate an EDJ-2882-B York mounting bracket off a 1959-1960 Squarebird from any used parts dealers. I did find two, but they were not for sale because they are going to be used by the owners for their own AC conversion on their 430 equipped Squarebird. However, one was able to send me detailed pictures of what their EDJ-2882-B mounting bracket looks like. I was able to find an XE-48002 York mounting bracket off a 1958 Lincoln 430 equipped parts car! After comparing the EDJ-2882-B to the XE-48002 it was determined that they were identical to each other, and Rob bought it, cleaned it up, painted it and will use it in his install. The only difference is a different version of the L shaped mounting bracket, but it should work. The one that had not been painted yet is the XE-48002 mounting bracket and it is stamped as such, though you cannot see the stamping in these pix. The stamping is right below the L bracket, which covers part of it.








    While the hunt for the mounting bracket was going on, I was also looking for the AC water pump pulleys required to make this conversion. Apparently, at some point in 1960, Ford put out some AC Installation Instructions, I.S.-359-D, and a kit on upgrading a non AC 430 Squarebird to an AC equipped 430 one. Included in that kit for the 430 were a new, smaller, 6" double sheave water pump pulley, an add-on 6 3/4" compressor drive single sheave water pump pulley, new fan spacer, and the five bladed cooling fan. Notice the smaller diameter size of the 2 groove WP pulley compared to the Non AC WP pulley, and the slightly larger size of the single groove AC WP pulley.




    Luckily, I was able to find those components through Carl Heller ~ partsetal here on the Forum. No one else had them! Rob has ordered a 6 bladed fan for better cooling, although he has a dual pusher fan mounted in front of the aftermarket radiator he has had installed. That pusher fan may be removed out of necessity, or replaced with a single pusher fan. As for the spacer, they will attempt to use the OEM one they have on the car, but know that they have a shorter one available to them should they need it.

    So, we are at the point where the install is beginning, as Don and Rob go about unpacking parts, and start scoping out how and where they are installed. As they progress, I will add the comments and pix they send me to this so we can see how they go about installing this CAA AC system on his '60 430MEL engine.
    Last edited by YellowRose; August 12th, 2018, 01:16 PM. Reason: Added comment...

    Ray Clark - Squarebirds Administrator
    '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
    "It's Hip To Be Square"
    Thunderbird Registry #33025 VTCI #11178

    Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

    http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

  • #2
    Rob's 1960 non AC 430 to AC Install

    Here is what Rob has to say today and some pix of the parts we needed to come up with for the install..

    "Hello Ray, I took these photos for the website. They are just of the parts that are necessary to acquire when adapting the 352 A/C kit to a 430 engine. In addition, I will find the necessary belts. Plus the 6 blade fan from Thunderbird Headquarters.

    Since Don has limited time to work together with me due to other commitments, we may only work together once or twice a week. He will be here Tuesday. We hope to have this project completed in one month."

    Here are the pix Rob sent, after cleaning, treating and painting the parts.
    Attached Files

    Ray Clark - Squarebirds Administrator
    '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
    "It's Hip To Be Square"
    Thunderbird Registry #33025 VTCI #11178

    Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

    http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

    Comment


    • #3
      Rob's 1960 non AC 430 to AC Install

      Rob and Don continued their work on the CAA "Perfect Fit" AC install yesterday. They have been working in the interior of the car, putting in the new pieces that will give them improved AC air distribution. They will not have that one central AC vent above the radio, but the four that comes with the kit, one to the left of the driver, one to his right, and one to the left of the passenger and one to the right. I am told by those who own the "Perfect Fit" system that the cold air can nearly run you out of the car with it being so cold!.. Which is great! Hopefully, Rob will have me some pix of the interior install. that I will be able to share with you. It is their hope that on Friday, they will be able to complete the interior work and get to the engine bay work. He said that the instructions have been really easy to follow so far.

      Ray Clark - Squarebirds Administrator
      '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
      "It's Hip To Be Square"
      Thunderbird Registry #33025 VTCI #11178

      Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

      http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

      Comment


      • #4
        Rob's 1960 non AC 430 to AC Install

        Today, Rob and Don were working on finishing the interior work on the AC install on his 430. Hopefully, he will have some pix of what it looks like now. Then they were planning on starting the serious work in the engine bay. So far, Rob has said that the install instructions with the kit are pretty straight forward and has been easy to follow. They are going to have to determine what to do with the pusher fan he has on the outside of the radiator. It will probably have to come off because the AC condenser goes there. In conversation with John ~ jopizz today, he suggested that they may want to forego the 6 bladed mechanical fan he has ordered and spacer, leave it off, and place the pusher fan on the back of the radiator and make it a puller. If he has a Flex-A-Lite electric fan, it can quickly be converted from a pusher to a puller or vice versa.. I sent them the link on how to do it. I am looking forward to some pix and if I get them tonight, I will post a Before and After picture.

        Ray Clark - Squarebirds Administrator
        '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
        "It's Hip To Be Square"
        Thunderbird Registry #33025 VTCI #11178

        Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

        http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

        Comment


        • #5
          Looking forward to the pic's Ray.
          I'm thinking they may have enough room in the center of the grille area for the pusher fan - it is tight.
          You can see on mine that the condenser sits forward of the front frame cross piece (white) and pretty much lines up with that crease in the splash guard or air deflector - what ever it is called (the black piece).

          Here's my before...


          and after...(or at least during )


          My vote is to install a engine driven flex fan similar to the 72 Thunderbird fan I installed on mine. Much quieter than the OEM non flex style and they pull a lot of air at idle plus they quiet down on the interstate. It can always be added later though.







          Sort of wish I had gone the CAA route - I'd be cool now - wait I'm already cool - I'd be cold - HA!

          Comment


          • #6
            Rob's 1960 non AC 430 to AC Install

            Hi Eric, thanks for the post! I will bring it to Rob's attention. As I recall, he has a dual pusher fan on the front of the radiator, not a single fan. They are going to see how things work out with a 6 bladed flex fan. If it continues to keep the engine from overheating they will probably keep it that way. If Don thinks they can keep that fan on the front, they will leave it in place. If they have to move it, and he doesn't think the mechanical flex fan will do the trick, they will look at removing it, and installing a puller fan on the back of the radiator...

            Ray Clark - Squarebirds Administrator
            '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
            "It's Hip To Be Square"
            Thunderbird Registry #33025 VTCI #11178

            Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

            http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

            Comment


            • #7
              Rob's 1960 non AC 430 to AC Install

              I just got an email from Rob. They had quite a lot of success yesterday. Here is what he had to say.

              "Hello Ray, We got a lot done yesterday and our next work day will be Monday. If all goes well, on Monday we will test the A/C. We will then need one more day to complete the work. I found that the interior had missing upholstery screws and some incorrect ones so the interior is still not back together. I will find what I need next week. Yesterday, we pulled the radiator and last night I received the fan and some parts. This weekend, I will be sending you scans of the instructions and some photos of our work. More photos next week. Best wishes, Rob"

              Rob just sent me a "Before" pic of the interior. They still have a slight amount of cleanup work to do, install some screws, and he will send me "After" pix.. Here is what she looked like before they started, minus the dice...
              Attached Files
              Last edited by YellowRose; August 18th, 2018, 03:23 PM. Reason: Add B4 Pic

              Ray Clark - Squarebirds Administrator
              '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
              "It's Hip To Be Square"
              Thunderbird Registry #33025 VTCI #11178

              Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

              http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

              Comment


              • #8
                Rob's 1960 non AC 430 to AC Install

                Rob just sent me pix of his dual electric pusher fan set up and the new 6 blade mechanical fan he just got. I did some checking on his Hayden Automotive dual fan setup and I found they are reversible. I sent him the .pdf instructions on how to take the blades off, reverse them to make them a Puller, and also the wiring reversal needed. So if he decides to use them on the back side of the radiator, he has the instructions on how to do it. Here are the pix he sent me.
                Attached Files

                Ray Clark - Squarebirds Administrator
                '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                "It's Hip To Be Square"
                Thunderbird Registry #33025 VTCI #11178

                Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                Comment


                • #9
                  Rob's 1960 non AC 430 to AC Install

                  Rob sent me some more pix that Bea took while she was watching do the interior and engine bay work today. He also sent me a copy of the CAA AC Installation Instructions in .pdf format. If anyone else wants them, let me know and I will send them to you via email. I already sent them to Henry ~ OX1. Here are 8 pix, showing some interior work and engine bay work done yesterday..

                  Ray Clark - Squarebirds Administrator
                  '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                  "It's Hip To Be Square"
                  Thunderbird Registry #33025 VTCI #11178

                  Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                  http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                  Comment


                  • #10
                    Rob's 1960 non AC 430 to AC Install

                    Rob sent me some more pix that Bea took while she was watching them do the interior and engine bay work today. He also sent me a copy of the CAA AC Installation Instructions in .pdf format. If anyone else wants them, let me know and I will send them to you via email. I already sent them to Henry ~ OX1. Here are 7 pix, showing some interior work and engine bay work done yesterday..
                    Attached Files
                    Last edited by YellowRose; August 19th, 2018, 01:10 AM.

                    Ray Clark - Squarebirds Administrator
                    '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                    "It's Hip To Be Square"
                    Thunderbird Registry #33025 VTCI #11178

                    Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                    http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                    Comment


                    • #11
                      Noticed on Rob's car there is a space between the front frame member and the radiator splash shield or air deflector. Can't remember if that is a 2 piece design and possibly they have the piece closest to the frame removed for the condenser install.

                      Ah - just thinking - if 2 piece - maybe it was removed earlier for the electric fans

                      Looking good though - can't wait to see what the A/C vent temps are and how well the big ole 430 keeps cool.

                      Thanks for posting the pics Ray.

                      Comment


                      • #12
                        Rob's 1960 non AC 430 to AC Install

                        Earlier in the evening, Rob sent me an update. I was hoping he would have some more pix, but they have been out of pocket tonight. Here is what he had to say, though he did not go into details as to what they ran into. Hopefully, tomorrow.

                        "Hello Ray, Today we accomplished 3 hours of work in 8 hours. A lot of things went wrong and we ran errands for parts. Tomorrow we will hopefully finish up."

                        Hopefully, he will be able to tell me about the problems they ran into that caused them to have to looking for some parts and what they were. But, from the sounds of it, it looks like they hope to finish it up later today! I am looking forward to some good, up close pix of the work.

                        Ray Clark - Squarebirds Administrator
                        '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                        "It's Hip To Be Square"
                        Thunderbird Registry #33025 VTCI #11178

                        Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                        http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                        Comment


                        • #13
                          Rob's 1960 non AC 430 to AC Install

                          Here is this mornings report on yesterdays work on the AC conversion and some pix...

                          "Hello Ray, We are back to working on the car this morning. A few photos. I am doing this fast so delete the ones not of use. Yesterdays problems were mainly in adjusting things which made for taking things on and putting them on repeatedly and running for parts, hose crimping, etc. Best wishes, Rob."

                          Here are the pix he sent. One was a duplicate.
                          Attached Files

                          Ray Clark - Squarebirds Administrator
                          '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                          "It's Hip To Be Square"
                          Thunderbird Registry #33025 VTCI #11178

                          Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                          http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                          Comment


                          • #14
                            See if he can get a pic from a forward view of that AC bracket.
                            So far it looks like it may be difficult to get to PS fill and dipstick.
                            59-430-HT

                            Comment


                            • #15
                              Rob's 1960 non AC 430 to AC Install

                              Hi Henry, I see your concern. I just tried to all Rob, but he is away from the phone at the moment. Either they are out getting parts to finish off the installation, or he does not have the phone out in the garage with him. I will see if he can get a better picture, or will be able to tell us if they can still get to the PS unit to fill it, or check it. I certainly hope so!

                              Ray Clark - Squarebirds Administrator
                              '59 Tbird "The Yellow Rose Of Texas" aka "Tweety Bird"
                              "It's Hip To Be Square"
                              Thunderbird Registry #33025 VTCI #11178

                              Contact me via Private Message for my email address, or (Cell) 210-875-1411 (Home) 210-674-5781

                              http://www.squarebirds.org/picture_gallery/TechnicalResourceLibrary/trl.htm

                              Comment

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