After talking to numerous installers about options, and being taken round a bend by a certain installer in mumbai, i finally got round to getting the install done from a local fellow here in Pune. He had never worked on a Gypsy before and mostly specialized in making refrigerated containers for transporting medicines etc! Fortunately he knew all the issues and challenges with regards to mounting the AC in a Gypsy.
Compressor chosen was a Sanden 5H11 series with a Superking II blower unit both brand new. Fans and other components were labelled Denso but not sure if these were original. Condensor unit was Shovak make.
Did not want to use the integrated temperature cum blower control switch that came with the Superking as these had caused trouble in my old gypsy. Opted this time to retain the stock Gypsy control unit for blower control and a separate Bosch make thermostat controller mounted on the switch-pad to the right of the driver. Works fine so far.
Attached below some pictures of the AC install.
Monster superking blower unit. This one must be twice the size of the stock blower that came with the Gypsy.
Attaching the larger condensor unit took a fair amount of jugaad.
Condensor with 80W electric fan
Chalo jee: Done!
Gypsy without the front bumper looks killer eh?
Birth of an idea!
Dashboard removed to remove Stock blower and mount the Superking unit in its place. Stock blower seen here.
Space behind the dashboard with the stock blower unit removed.
I needed to make space on the center of the dashboard for mounting a Touchscreen LCD. The only way to achieve that was to reroute the 2 central vents to a custom made vent unit mounted in place of the stereo holder of the standard gypsy. Managed to fabricate one using vents borrowed from a Sumo. Even managed to make space on this unit for a cigarette lighter socket, so no need to cut the dash to make space for that!
Total cost of install was 34160 and time taken was 2 days. Fabrication of the custom AC vents to replace the stock central vents took its own sweet time however and i got them only on Tuesday. Got the vents fitted in and immediately hit the highway to Mumbai where I had some meetings scheduled with my investors.
AC performed flawlessly with the superking blowing chilled air literally into your face even at Speed 2. These blowers are also more silent than the stock blowers. Around Kamshet the AC seemed to cutoff on its own. Problem was traced to a loose electrical connector.
The vehicle seemed to have become slightly sluggish as compared to before, but the sluggishness seems to be there even with the AC off, so i am not sure there is a connection. Could be a recurrence of that old clutch problem.
There was no heating up issues at regular travel. But idling for 2 mins or above resulted in a dramatic increase in temperatures. Need to find a fix for this.