Hoses and brake lines are a challenge on this Frankenstein
project.
Brake lines a combination of metric DIN bubble flares and ISO imperial double
flares, with a super odd metric double flare on the Tesla master
cylinder. Plus, the original ATW front calipers have two redundant
circuits so the original master had 5 ports. The Tesla iBooster only has
two. And the original rear-mounted proportioning valve isn't practical
with this new setup.
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Brake and power steering lines complete (less hose clamps)
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With barely any room between the battery box and inner fender aprons, and the
need to add a Y fitting to split each front brake circuit into the dual
caliper configuration, I was forced to relocate the holes in the fender aprons
higher to allow enough room.
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Old (and one accidental new) holes filled and line run in higher to
allow for branching
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| Hole relocated |
Power steering presents similar problems with limited room and OEM banjo
fittings on the original hoses to the ZF steering box that need to be adapted
to the modern electric Mini Cooper pump.
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Modified high pressure banjo fitting to AN-6
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| Banjo to AN |
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A nod to originality by using the stock reservoir for power
steering
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A very tight fit to get power steering hoses onto original ZF steering
box
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| Banjo fittings |
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Mini Cooper electric P/S pump with hoses now. Still need to wire
it up.
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A/C hoses are also a challenge with limited room and all new components (Tesla
electric compressor, new dryer and condenser, all with modern o-ring fittings
for R-134a but (maybe) the original R-12 flare fitting equipped evaporator and
expansion valve.
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AC hoses to bulkhead fittings on firewall, just enough room to run along
side battery box
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AC fittings to Tesla electric AC compressor in trans tunnel
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Thanks to
Mike Swan
for his magic with hoses and lines.
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Aluminum tubes run the length of the car to bring coolant to/from the
drive unit, onboard charger, and rear batteries
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Aluminum tubes run the length of the car to bring coolant to/from the
drive unit, onboard charger, and rear batteries
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Cooling tubes connected to Tesla drive unit motor
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Coolant tubes connected to onboard charger/DC-DC converter and Tesla
drive unit inverter
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Printing clamps to route cooling tubes and 0/2 gauge HV cables
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Clamps for cables and coolant tubes
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