Here's a breakdown of the process and what you should consider:
1. System Selection:
* Vintage-Correct Reproduction System: This is the most desirable option for purists, aiming for a look and feel as close to what might have been offered as a factory option (if it was available). These kits are often expensive and may require significant fabrication and adaptation.
* Modern Underdash Unit: A more affordable and simpler option, but it alters the interior aesthetics. These units typically require less fabrication but still need careful installation to ensure proper airflow and secure mounting.
* Custom System: This option offers the most flexibility but also the most complexity and cost. You'd source components individually and build a system tailored to your specific needs and preferences.
2. Components:
Regardless of your chosen system, you'll need the following components, though the specifics will vary:
* Compressor: The heart of the system, driven by the engine.
* Condenser: Located at the front of the vehicle, dissipates heat.
* Evaporator: Located inside the cabin, cools the air.
* Expansion Valve or Orifice Tube: Controls refrigerant flow.
* Receiver/Drier: Filters and stores refrigerant.
* Refrigerant Lines and Fittings: High-pressure lines connecting the components.
* Compressor Mounting Bracket and Pulley: To attach the compressor to the engine.
* Electrical Wiring Harness: To power the compressor clutch and blower motor.
* Blower Motor and Fan: To circulate cooled air.
* Control System (switches, knobs, etc.): To operate the system.
* Refrigerant (R134a is common for modern systems): Must be added by a certified technician.
3. Installation Process (General Overview):
* Research and Planning: This is crucial. Find detailed installation instructions specifically for your chosen system and year/model of Falcon. Consider consulting with experienced mechanics or restoration shops.
* Compressor Mounting: Fabricating or adapting a mounting bracket for the compressor is usually necessary. This requires careful consideration of belt routing and engine clearance.
* Condenser Installation: Mounting the condenser in front of the radiator requires careful attention to airflow and fitment.
* Refrigerant Line Routing: Routing the high and low-pressure lines will require careful planning to avoid sharp bends and potential leaks.
* Evaporator Installation: This usually involves integrating it into the existing HVAC system or mounting it under the dash.
* Electrical Wiring: Connecting the electrical components requires careful attention to detail and proper fusing.
* Vacuum and Leak Testing: Before charging with refrigerant, the system must be rigorously tested for leaks.
* Refrigerant Charging: This should *only* be done by a qualified technician with proper equipment and safety precautions. Incorrect charging can damage the system and is dangerous.
* Interior Modifications: Installing the controls and vents requires potentially significant modifications to the dashboard or interior panels.
4. Challenges Specific to a 1961 Falcon:
* Space Constraints: Older cars have less space for modern A/C components.
* Limited Existing Infrastructure: There's no existing A/C system to work with, meaning everything needs to be added.
* Finding Parts: Sourcing correct parts, especially for a reproduction system, can be challenging and expensive.
* Fabrication Skills: Significant fabrication and custom work are often required.
Recommendation:
Unless you have extensive mechanical and fabrication experience, strongly consider hiring a professional automotive air conditioning specialist to install the system. This is a complex project that can easily result in costly mistakes if not done correctly. The cost of professional installation will likely be less than the cost of parts and time if you attempt it and encounter problems. A professional will have the right tools, knowledge, and refrigerant handling expertise to ensure a safe and effective installation.
