Has anyone tried using an '87-'93 heater/air conditioner with a Modular installation? I'm using the A/C from an '88 Mustang and ran into some problems. Hindsight being 20/20, I should have used a '94 or later A/C but didn't find the problems until after I cut the hole in the firewall. Both the inlet and outlet ports to the A/C evaporator clear the engine but the hose going into the inlet port interferes with the cylinder head. Also, the outlet port has a threaded connection that doesn't mate with the dryer used in the Modular Mustangs.
I solved the problem by having a tubing shop make a couple of S-bends, one out of 1/2 ; O.D. 6061-T-6 aluminum and the other from 5/8; O.D. aluminum. A welder/metal fabricator expanded the 5/8; piece on one end to accept the dryer. It turns out the 5/8; S-bend wasn't necessary because the dryer clears the head, so he cut off the expanded end of the 5/8; tube and the threaded connection on the A/C outlet, then welded the expanded piece to the A/C outlet. He also cut off the original expanded end of the A/C inlet, welded it to the 1/2 S-bend, then welded that to the A/C inlet. Everything fits and the system otherwise uses '98 Mustang lines, condenser, etc., and is compatible with R-134a coolant. This weekend I'll take more pictures and try to use less memory space.
I solved the problem by having a tubing shop make a couple of S-bends, one out of 1/2 ; O.D. 6061-T-6 aluminum and the other from 5/8; O.D. aluminum. A welder/metal fabricator expanded the 5/8; piece on one end to accept the dryer. It turns out the 5/8; S-bend wasn't necessary because the dryer clears the head, so he cut off the expanded end of the 5/8; tube and the threaded connection on the A/C outlet, then welded the expanded piece to the A/C outlet. He also cut off the original expanded end of the A/C inlet, welded it to the 1/2 S-bend, then welded that to the A/C inlet. Everything fits and the system otherwise uses '98 Mustang lines, condenser, etc., and is compatible with R-134a coolant. This weekend I'll take more pictures and try to use less memory space.