Country Honk, Camaro Revival Part 6 - 1968 Chevy Camaro Adding AC & Exhaust System

This segment is gonna blow big-time! Once again, since the amount of detail is so great, we had to cut the topic coverage to shoving air, and leave pushing fluids for next month. That said, we'll start with the installation of the Vintage Air system, which takes in hot and humid air (the bad air) and blows out the cool, dry air we desperately need during the summer months. Having the top down is nice, but you can't beat having the air on max to help cool you off; although nothing seemed to help much driving through the monsoons at last year's Hot Rod Power Tour! From there, we'll wrap up this month by installing the Flowmaster American Thunder system with their Series 40 Delta Flow mufflers. Not only will it expel the spent fumes out of the LS2, it'll produce that recognizable Flowmaster exhaust note we've grown to love!

Keep in mind, when you first start taking apart a car that's been sitting idle for an unknown number of years, expect to see some sort of a mess. Case in point, in our Camaro someone had actually retrofitted this non-air car with factory air, which had to be removed before installing the Vintage Air Sure-Fit heat and air-conditioning system in its place.

On the plus side, Detroit Speed made our job easier with their nifty hanger system for the first-gen Camaro/Vintage Air install, which saves you the trouble of having to fabricate your own hangers. Detroit Speed also produces a mounting bracket for the Vintage Air controller, which enables the controller to be mounted onto the stock dash location. All said and done, we'll address the difficulty level and leave you with a clear idea on what you may or may not want to attempt when installing a Vintage Air System by yourself. So get in, sit down, start reading, and keep your cool.

This is the basic underdash...        read full caption This is the basic underdash unit comprising the interior portion of Vintage Air's Sure-Fit kit for the first-gen Camaro/Firebird. The kit comes complete with easy-to-read instructions and wiring diagrams, plus all the necessary ducting and connectors...

...The defroster adapters...        read full caption ...The defroster adapters come in two shapes on the early F-bodies, so be sure to let Vintage Air know whether you have the wide or narrow defroster vents. The Detroit Speed mounting bracket is attached loosely and, as shown in the detail, clearly labeled.

Kyle Tucker informed us we...        read full caption Kyle Tucker informed us we would need to drill out the holes in the dash brace, so after a quick test fit of the bracket, the holes were enlarged. Next, the Detroit Speed mounting bracket was securely attached to the Vintage Air unit and the entire unit eased into place under the dash. As you can see, the compact Sure-Fit unit looks right at home!

Once the location of the Vintage...        read full caption Once the location of the Vintage Air unit was checked for clearance, the Detroit Speed bracket was secured to the firewall and kick panel. Now take it out; take it all out! Seam sealer, primer, paint, and Dynamat have to be installed before the final assembly. Can you do this? Of course. This would require intermediate-level mechanical skills, but wait--there's more to come.

It's always nice to start...        read full caption It's always nice to start with new, clean spaces, only to clutter them with wires and ducts and the like. The Dynamat Extreme was obtained from Detroit Speed, and we first sectioned around the Vintage Air area before the unit was installed.

It pays to read the instructions...        read full caption It pays to read the instructions so that you know if tab A goes into slot B before the widget assembly is installed! After figuring out how it all went back together...

...it was only a matter of...        read full caption ...it was only a matter of reattaching the Detroit Speed bracket to the Vintage Air evaporator, hanging the unit underneath the dash, and planning for the hose connection and water-valve orientation.

Vintage Air includes all the...        read full caption Vintage Air includes all the A/C hose fittings, clamps, and a selection of hoses, along with precise instructions on where the hoses are connected. Once the proper A/C and heater-specific fasteners are snugged into position, do not tighten them yet--the hose lengths may be estimated while the heater inlet and outlet hoses can be attached and tightened...

...The A/C hoses and fasteners...        read full caption ...The A/C hoses and fasteners are next; however, the difficulty factor has just jumped from intermediate to advanced by requiring a high-zoot tool, in our case known as unobtainium, which may hold true for most shops.

While you are at this point,...        read full caption While you are at this point, waiting on the expert with the proper tools, make the drain connection for all that humidity the A/C will remove. Take your time and plan carefully, and you will have a drain line that looks better than factory and will disappear from view when the fender is attached.

Here's what the final result...        read full caption Here's what the final result will look like, once the A/C lines are properly bent and clamped. At this point, electrical connections can be started while waiting for your resident Vintage Air professional to show up.

Check out the condenser unit...        read full caption Check out the condenser unit Vintage Air provides for the first-gen Camaro. That old condenser will never deliver the performance of the newer units designed and sized for the demands we put on our new rides. Lucky for us, Kyle Tucker of Detroit Speed is one of Vintage Air's installation dealers and generously offered his help installing the balance of the system.

(Caution: Professional Installer......        read full caption (Caution: Professional Installer... Do not attempt this at home!) Kyle dove right in, explaining the difference in fasteners for the A/C and heater hoses, between AN-6, AN-8, and AN-10 hoses and fittings, and how the unobtainium crimping tools worked. He then proceeded to measure and cut the hoses to be routed over the inner fender, thus hiding the majority of the connections from sight. Can you do this? With the correct tools (and an excellent teacher like Kyle), of course you can! Is it worth your time and investment in tools? For the average home builder, probably not, but that's your decision. It's important to note that professional installers will have not only the knowledge, but also the proper tools to make it right the first time. As for us, we'll stick with Kyle.

As each hose is cut to length,...        read full caption As each hose is cut to length, Kyle moves to the bench vise and uses the correct crimping tool to attach the proper barb or flare fitting. As these pictures show, there are two crimping tools required...

...The secret is to use the...        read full caption ...The secret is to use the proper torque to crimp the fasteners without cutting through the hose. Should you attempt this in your own shop, we recommend practicing with the tool before moving on to the actual project.

The final product! The lines...        read full caption The final product! The lines are wrapped with "Dum-Dum" to reduce vibration against the inner wheel well and keep the hoses stable. Make sure all your fittings are tight and inside the car at this time. They will be virtually impossible to access once the dash assembly is complete and the fenders are installed.

The Vintage Air controller...        read full caption The Vintage Air controller is plug-and-play, and all the wiring is easily and quickly connected. Here's what the final assembly looks like before all the ductwork is connected.