After what felt like a couple months of researching existing installs and setups I decided to go with the Accuair 5-Gallon tank, Dual 400cc VIAIR compressors and Accuair eXo Mounting System. The
eXo System consists of three split tank mounting rings, two compressor mounting brackets and an ECU/Manifold mounting bracket. Bottom section of the rings are bolted to the new trunk floor, tank is set in place then the other half of rings bolt together. Since the trunk floor has to sit flush the hole locations for mounting the tank rings were counterbored.
Hardlines are 3/8” Type K Copper Tubing, wall thickness is 0.035”and were ordered in straight lengths that are hardened. Used a Parker 3/8” tubing bender and annealed each section of tubing that needed to be bent using a BernzOmatic TS8000 and a bucket of water. This was my first hardline setup and it took a long time making sure all the bends were correct and mirrored for the opposite side. Have the SMC water traps after the compressors but have since learned it is better to have them prior to the VU4 manifold. I may rebend the compressor to tank lines and install the water traps prior to the VU4 manifold but have not made up my mind on this yet.
Replaced the VIAIR check valves with SMC check valves and installed the directly to the compressors. All fittings have been changed to 316 Stainless Steel, purchased from
http://www.stainlesssteelfittings.com/. The PTC (Push to Connect) fittings are pressed into the VU4 manifold and cannot be changed, come to find out they do offer a NPT version of this manifold but has to be specified when placing an order. There is no issue using the tubing with these PTC connections. All other hardline connections use a double ferrule compression fitting. Opting for a clean looking install I elected to run my hardlines to bulkhead fittings keeping all pressure sensors, DOT air lines and mufflers underneath.
If I went with 1/2" MDF I would not have needed to use a step bit to allow enough male threads to be exposed on the top side of the trunk floor. By dumb luck the OD of the hole on the bottom side is the same width from point to point of the male and female NPT side of the bulkhead fittings. ECU connectors have to be fed from underneath which required a rectangular opening to be cut directly below the ECU. A slot was cut for the 90° drain fitting located on the bottom of the tank and holes were drilled for the compressor power wires as well.
Some kind of pressed carpet/felt material was purchased to go on top of the wooden trunk floor and is very similar to the OEM trunk carpet material. It leaves a clean edge when cut with a blade and does not fray. Used hollow punches to cut clearance holes for the bulkhead fittings and cut X’s for the ECU connectors, drain and power wires. Setup has been test fit with carpet in the trunk but without hardlines and looks exactly how I thought it would. Should have the setup test fit with all hardlines early next week and can’t wait to see how it will look with the hardlines polished. Wrapping up my wiring this weekend and then on to installing the e-level sensors and bags.
Cutouts for harness connectors, tank drain and motor wires were not cut/drilled when these pictures below were taken. Not sure what nickname to give her but it kind of looks like a spider!?:
Wiring to follow...
