BC Broncos - Class 3 Racer BC Broncos - Class 3 Racer
Unique upgrades & Performance Mods
BC Broncos - Early Bronco Restoration BC Broncos - Early Bronco Restoration
Classic & Custom Restoration

 
A/C SYSTEM
 
 
INTRODUCTION TO A/C

Today's A/C systems are far better than systems from only 10 years ago. The refrigerant is different and that means everything else is too. The new GEN II systems (Read more about GEN II) use solid state servos not inefficient vacuum actuators, the evaporators cores are more efficient the condensers transfer heat better, the compressors are smaller, quieter and put out more pressure, the hoses have an inner liner to with stand the higher pressure and to hold in the smaller molecule HFC-134A refrigerant. Click on the link (Basic A/C) to get more Basic A/C info from Vintage Air.

This system runs HFC-134A refrigerant and PAG (Poly Alkaline Glycol) oil. Charging info

                 

This is a cut away of the  Sanden 508 compressor. With 5 pistons this thing can compress some serous R134A 8cfm to be exact.

This is a cut away of a dryer with the desiccant (water remover) missing. The dryer removes condensation from the R134A to keep the system running smoothly.



 
THE IMPORTANCE OF INSULATION

A/C basically removes heat from the air in your Bronco. If you have holes in the floor or firewall or have bad weather striping then it will be harder to get the Bronco cool and keep cool. If you have all of the holes plugged and good weather striping then you should be fine. When you add insulation, not only do you help cool your Bronco faster it also makes your Bronco quieter making a much more comfortable ride all the way around.

Keep Cool insulation has many benefits over insulation that is much thicker. Keep Cool is an olefin film-covered, low density, irradiation cross-linked closed-cell polyolefin foam insulation. What does that mean? The olefin film coating reflects the transfer of radiant heat, while the closed cell foam insulates against convective heat transfer. It keeps you warm in the winter and cool in the summer this 1/4 thick insulation will reduce noise levels by over 40% compared to fiberglass insulation.

  • It is a better thermo insulator than fiberglass.

  • It has a melting point of 350* and has no flash point so it will not catch fire like fiber insulation.

  • It will not conduct electricity in the event of an electrical short.

  • It is gas, oil, chemical resistant and flame retardant.

  • It reflects 100% of sound waves it receives therefore keeping unwanted noise out while keeping music and conversation in.

  • It will not absorb moisture and will not rot or deteriorate.

       

Click for price

Part Number
                   PART            

buy now

75-27010
5X5 INSULATION

buy now

75-27020
5X10 INSULATION

buy now

75-27030
5X20 INSULATION

 

 
BC BRONCOS A/C SYSTEM

This is not the same A/C system everyone else sells, it was designed by BC Broncos fit in the 66-77 Ford Bronco and is built exclusively for us by Vintage Air. This system is not just A/C it is also heat and defrost. The A/C comes out of the vent and the heat comes out of the vents and out at the floor also and the defrost comes out the top of the dash.   Using GEN II technology the system is controlled by servos (Read more about GEN II) for more air flow and ease of installation. We wanted to make sure that the evaporator (the part behind the dash) allowed for the use of a stock type glove box or Tuffy box without trimming  the evaporator, glove box or dash. We also needed it to be tucked up under the dash out of the way as much as possible. To get the A/C hoses through the fire wall you need to cut a hole with what ever system you use, so we decided to do it with some style and make it more of a center piece than an eye sore, the kit comes with an Aluminum bulk head and fittings to run the A/C and heater hoses through the firewall, keeping all of the hose connections behind the engine giving a less cluttered appearance. The evaporator is mounted using two of the original heater mounting holes. This system is extremely efficient thanks to the super cooler condenser and HFC-134 refrigerant.

      The BC Broncos complete A/C system comes with :

  • GEN II servo activated evaporator

  • Servo activated heater control valve

  • Aluminum bulk head

  • Heater hose fittings

  • Super cooler condenser 

  • Condenser saver bracket

  • Sanden 508 compressor

  • Multi steer bracket

  • Pre crimped Barrier hoses

  • Aluminum hard line

  • Dryer

  • Binary Safety switch

  • 3 standard vents

  • Switches

  • Kick panel cover

  • Wiring harness

  • Driver side heat crossover

  • Air duct hose

  • Seals and hardware

  • Instructions

  • ** When using this A/C system for V belts you will need to use STOCK type 2 GROOVE crank and water pump pulleys or our pulley kit part # 15-00411
  • ** When using this A/C system for Serpentine belts you have 2 options stock Bronco offset (like BCB part #15-00220)/ 86-93 Mustang offset or the short dress 96-01 Explorer We don't offer a bracket for the 94-95 short offset at this time

 

Evaporator instructions

Bulkhead

Condenser/ Hoses

 

Click for price

Part Number
                   PART            

buy now

75-21100
COMPLETE A/C SYSTEM V-BELT

buy now

75-21200
COMPLETE A/C SYSTEM SERPENTINE BELT

buy now

75-24100
EVAPORATOR ONLY

 

Click for price

Part Number
                   PART            

buy now

75-21101
COMPLETE A/C SYSTEM V-BELT NO COMPRESSOR

buy now

75-21201
COMPLETE A/C SYSTEM SERPENTINE BELT NO COMPRESSOR

 

 

 
GEN IV A/C SYSTEM

  

vINTAGE AIR gen 4

The Gen IV™ is Vintage Air's most powerful and intelligent climate control system. Gen IV systems utilize our exclusive fully electronic microprocessor control servomotor drives to eliminate cables or vacuum connections. Separate high capacity copper parallel-flow heat coil and aluminum plate and fin cooling coils provide outstanding performance and instant temperature adjustments. Our new Bronco SureFit ™ system includes a three individual rotary controls and factory style knobs that install in the stock dash location. Additional features include variable blower speed and dash/floor/defrost blend. SureFit ™ Systems are engineered specifically for each vehicle application and require minimal alteration to the vehicle for installation.

 

Click for price

Part Number
                   PART            

buy now

75-21104
Vintage air GEN 4 A/C SYSTEM V-BELT

buy now

75-21105
GEN 4 EVAPORATOR ONLY

 

 

 

 
LETS COMPAIR OTHER A/C SYSTEMS

First off we are not trying to talk bad about the quality of anyone's A/C system. This comparison is to show you about the different features so you can make an informed decisions before you buy. A/C is a big step you don't want to buy a system and go through the time to install it only to find out that there is something that fits better, is cleaner and easier to install.

The Vintage air Sure fit system for the Bronco (74076-LFU-A) sold by Vintage Air,Jeff's, toms, Bronco hut and if you want it BC can sell it to you also.

Installed the system looks like this in the engine compartment. The Vintage air kit puts the compressor on the passenger side this customer moved it to the driver side and had to add on to the hoses. As you can see the system Adds a lot of clutter to your engine compartment, and requires you to run the A/C and heater hoses through the passenger air vent. This kit has a smaller condenser and puts the dryer between the grill and core support. This system also uses a universal bracket (AKA lots of fab work) The compressor is only V-Belt (but probably could be changed out when ordered).

 

Vintage air Bronco kit

SureFit kit installed in the engine compartment

 

The BC Broncos A/C system (made for BC Broncos by Vintage air) for the Bronco (75-21100 vbelt 75-21101 serpentine) sold by BC Broncos and special ordered through Wild Horses.

 

BC A/C installed

Installed the system looks like this in the engine compartment. The BC Broncos A/C kit puts the compressor on the driver side so you can change over to serpentine later. As you can see the system does not really add a lot of clutter to your engine compartment. This system requires you to run the A/C and heater hoses through a bulk head located behind the engine at the firewall . This kit has a bigger condenser and puts the behind the battery. This system also uses our multi steer (compressor/power steering bracket)bracket ( the same one that comes in our power steering and serpentine belt kits if you have one of those kits let us know and we will sell you the A/C kit without a Bracket saving you some money). You can order the kit for Serpentine or V belt.

 

The Arizona air kit is an A/C only kit sold by Toms. See the classic under dash A/C kit below to compare the two

 

 
UPGRADE STREAMLINE CONTROLS  

This Polished aluminum control panel has engraved lettering for a smooth look and the knobs are back lit for easy viewing at night. This 4 knob panel controls all functions of our servo motor GEN II system. The lighted rotary switches operate A/C temp, fan, system mode and heater temperature.

            

 

blue upgrade

With our snake lights you can customize this panel in Amber,Red,Blue or Green for only $10

Click for price

Part Number                    PART            

buy now

75-28023 STREAMLINE CONTROL PANEL 5.318" X 1"

 
UPGRADE OVAL STREAMLINE CONTROLS  

This Polished aluminum control panel has engraved lettering for a smooth look and the knobs are back lit for easy viewing at night. This 4 knob panel controls all functions of our servo motor GEN II system. The lighted rotary switches operate A/C temp, fan, system mode and heater temperature.

               

Click for price

Part Number                    PART            

buy now

75-28024 OVAL STREAMLINE CONTROL PANEL 5. 5" X 2. 5"

 
UPGRADE DIGITAL CONTROLS

Dakota Digital is proud to release the DCC-2200 Digital Climate Control system designed for Vintage Air Gen-II Air Conditioning systems! Created to interface directly to a Gen-II Air Conditioning system, the DCC-2200 provides convenience of full climate control. 
     Similar to other Dakota Digital instruments, the DCC-2200 offers a full character Vacuum Fluorescent Digital readout for a simple and beautiful approach to updating your A/C system. With a direct plug-in into the Vintage Air Gen-II's wiring harness and the addition of three temperature senders installation is nearly effortless. Backed by a Limited 24-month Warranty against manufacturer defects, Dakota Digital provides the accuracy and performance you've come to expect from an American Made Product!

             

Click for price

Part Number                    PART            

buy now

75-28025 DIGITAL CONTROL PANEL

 
UPGRADE CONTROLS

With this Aluminum control panel you have two options Horizontal or Vertical mounting. This aluminum panel has a back lit face with sliding knobs and operates temp, fan and mode systems.

             

Horizontal control Vertical Control

Click for price

Part Number
                   PART            

buy now

75-28021
HORIZONTAL

buy now

75-28022
VERTICAL

 
UPGRADE IN-DASH STREAMLINE VENTS

These are the vents we use on our Broncos and are the most common vents people ask for. These vents feature Polished aluminum bodies and plastic louvers that move up and down and left to right. We run two of the 4" vents on the side and the 4.875" vent in the center.

Even though it looks more uniform to run 4 vents, the system is designed to run 3 vents we tried using a Y hose splitter but it severely limited the air flow to the two center vents so we don't recommend running it that way.

   

Click for price

Part Number
                   PART            

buy now

75-28011
STREAM LINE IN-DASH VENT 1.75" X 4"

buy now

75-28012
STREAM LINE IN-DASH VENT 1.75" X 4.875"

 
UPGRADE IN-DASH ROUND VENTS

There are many options for round vents, we like these because with the double lain louver you can turn the vent 360* to get the cold / hot air to you or close them off completely  This vent requires a 2.875 hole in the dash.

 

Click for price

Part Number                    PART            

buy now

75-28013 ROUND IN-DASH VENT

 
SUPERFLOW CONDENSER

This new Super Flow condenser does an amazing job at cooling. The importance of this unique new micro tube design and its improver refrigerant flow cannot be over emphasized.     (As the illustration to the right shows) providing increased refrigerant contact with the micro tube walls and multiple passes per circuit for low restriction pathway, the Super Flow condenser provides up to 40% more capacity than a comparably sized tube and fin condenser. This is the condenser that comes with the BC Bronco A/C kit, it measures 20.75" tall X 14" wide X .75 thick. This condenser is meant to be installed vertically, if you need to mount it differently let us know and we can exchange it for the horizontal condenser.

New uncoated condensor

We now have two options for condensers the standard black and aluminum, we now have this option for the guys that are running Aluminum radiators and want their condenser to match.

 

Click for price

Part Number
                   PART            

buy now

75-23000
SUPERFLOW CONDENSER BLACK
buy now
75-23030
SUPERFLOW CONDENSER ALUMINUM
 
REMOTE SUPERFLOW CONDENSER
This is the same new Super Flow condenser but it is designed to be mounted in a remote location because it has it's own high performance SPAL fan and ABS shroud, it measures 20" long X 14" wide X 4"thick. We can upgrade the BC Bronco A/C kit with this condenser, please call for mounting options and hose length options.


Click for price

Part Number
                   PART            

buy now

75-23010
 REMOTE SUPERFLOW CONDENSER

 

 
ALUMINUM BULKHEAD
The Aluminum Bulkhead is a great way to have the hoses go through the fire wall, this way you don't have to worry about the hose getting cut on sharp metal or putting ugly grommets around the hole. This bulkhead has 4 ports two for the A/C lines and two for the heater hoses. We know this increases the cost of the kit but we feel it is worth it. One you mount the bulkhead you can remove any or all of the lines from either side and the bulkhead stays  in place. This is a nice feature if you need to remove the complete engine you can still keep the hoses on the inside intact, just a plug the out side to keep the system sealed. This bulkhead and fittings come in the BC Broncos A/C kit.

 

4 port bulk head

2 port bulkhead

 

Click for price

Part Number
                   PART            

buy now

75-26010
 BULKHEAD 2 PORT

buy now

75-26020
 BULKHEAD 4 PORT

buy now

75-26032
 BULKHEAD 90* HEATER FITTING

buy now

75-26031
 BULKHEAD 45* HEATER FITTING

 

 
A/C HOSE KIT
We use Barrier type Refrigerant hoses in our A/C systems. The hose is called Barrier hose because of the special barrier preventing water from entering or refrigerant from leaking through the hose material. This hose kit comes with the BC Broncos A/C system.

Click for price

Part Number
                   PART            

buy now

75-22110
HOSE KIT STANDARD

buy now

75-22120
HOSE KIT WITH 2 BATTERIES ON THE PASSENGER SIDE
A/C DRYER
This dryer has a threaded port on both sides to make installing the Binary or Trinary switch easy. The BC Broncos A/C system comes with a vertical dryer  The dryer needs to be installed standing up in order for it to work correctly if you want to do a custom install with a horizontal dryer let us know and we can upgrade your kit but we designed the kit to work with the vertical dryer.

Remember when installing the A/C kit and hoses do not open the dryer until you are ready to install it in a closed system. Leaving the system open will cause the dryer to PULL MOISTURE OUT OF THE AIR AND MAKE IT GO BAD.

                             

Click for price

Part Number
                   PART            

buy now

75-29011
DRYER WITH BINARY SAFETY SWITCH

buy now

75-29012
DRYER WITH TRINARY SAFETY SWITCH

 

 
A/C SAFETY SWITCH
There are two types of safety switches a Binary and a Trinary. The Binary safety switch will cut off the compressor if the pressure gets too high (380psi)or too low (30 psi). The Trinary safety switch will cut off at the same pressures but will also turn on an electric fan when the pressure reaches 220psi helping to cool the system. The BC Broncos A/C system comes with a Binary switch but can be upgraded if needed.

Trinary safety switch

Binary safety switch

Click for price

Part Number
                   PART            

buy now

75-29021
BINARY SAFETY SWITCH

buy now

75-29022
TRINARY SAFETY SWITCH
 
CLASSIC UNDER DASH A/C
The classic under dash A/C unit is just like some of the dealer installed units that came in Broncos, In fact Vintage Air installed A/C in Broncos for some of the dealers in the San Antonio area in the 1970's. The Mark IV features an all steel case built from the original tooling. This is a great option if you want to add A/C only and not change out your heater or if you want to have a more retro looking set up. You can buy just the unit or a hole kit.

  Under dash unit  

Click for price

Part Number
                   PART            

buy now

75-24110
UNDER DASH  A/C ONLY

buy now

75-21102
UNDER DASH  A/C KIT V BELT

buy now

75-21202
UNDER DASH  A/C KIT SERPENTINE

 

 
LETS COMPAIR OTHER A/C SYSTEMS

First off we are not trying to talk bad about the quality of anyone's A/C system. This comparison is to show you about the different features so you can make an informed decisions before you buy. A/C is a big step you don't want to buy a system and go through the time to install it, only to find out that there is something that fits better, is cleaner and easier to install.

The Arizona air kit is an A/C only kit sold by Toms.

The Mark IV unit is A/C only and is sold by Vintage Air,Jeff's, toms, Bronco hut and BC Broncos. But this complete Bronco kit is only sold by BC Broncos.

 

 
SANDEN COMPRESSOR CLUTCH
If you are running a V-belt system and have A/C but now you are upgrading to Serpentine  and don't want to have to replace the hole compressor you don't have to, you can just replace the clutch without having to recharge the system. We have both V-belt and Serpentine clutches available.

      

Click for price

Part Number
                   PART            

buy now

75-25041
SERPENTINE COMPRESSOR CLUTCH

buy now

75-25042
V-BELT COMPRESSOR CLUTCH

 

 
SANDEN 508 A/C COMPRESSOR 
The Sanden 508 is a great compact and powerful compressor it has 5 pistons yet it is quite and doesn't vibrate like the old York compressor. You can actually mount it 90* left or right of center this gives you the flexibility to do some custom mounting This compressor comes pre-field with PAG oil DO NOT ADD ANY OIL TO THE SYSTEM  The BC Broncos A/C system comes with a Sanden 508 compressor with your choice of V-belt or Serpentine belt pulley.            

Charging info

Click for price

Part Number
                   PART            

buy now

75-25110
SANDEN 508 COMPRESSOR V-BELT

buy now

75-25210
 SANDEN 508 COMPRESSOR SERPENTINE BELT

 
MULTI STEER SANDEN 508 A/C COMPRESSOR BRACKET
        

 We wanted to cover Five major points when we designed this bracket.                                          

1st  We wanted it to work on all 289,302, 5.0 or 351W engines.                              

 2nd  We wanted to make sure it fit all popular power steering pumps including. Saginaw with caned ham or ford van reservoir, mid 70's- 80's plastic reservoir pump and Stock.                                                                                        

3rd  We wanted to be able to use this system for "V" belt and serpentine belt setups, with the option to go from one to the other by just changing the pulleys.     

4th To be able to bolt on a Sanden A/C compressor without any extra brackets.

5th Making sure it all fits under the hood as low as possible and out of the way of the steering box.

It works with your choice of serpentine or V belt pulleys on all engines that are commonly put in Early Broncos and is set up for a Sanden 508 compressor for A/C or on board air.

Options    We are also testing two different add on brackets to bolt up a York compressor and  a separate power steering pump for hydro boost.

 The BC Broncos A/C system comes with a multi steer bracket for the Sanden 508 compressor.

  

Click for price

Part Number

                   PART            

buy now

48-14021

MULTI STEER A/C COMPRESSOR BRACKET

 
SANDEN 508 A/C COMPRESSOR ADAPTER BRACKETS
We have optional brackets if you are using other types of engine brackets.   

                

Sanden 508 compressor to 86-89 Ford car power steering bracket

York bracket to Sanden compressor

Click for price

Part Number
                   PART            

buy now

15-00610
SANDEN 508 COMPRESSOR ADAPTER BRACKET

buy now

75-25330
YORK TO SANDEN 508 COMPRESSOR ADAPTER BRACKET
 


BC Broncos -110 Business Drive / PO BOX 69 Ingram, TX 78025
Tech line: (830) 367-1300 Order line: (888) 304-2945 <Fax: (830) 367-1304


PLEASE READ THE FOLLOWING

Before ordering products from B.C. Broncos, please read the following information, including warranty information and statement of liability. By placing an order to purchase products from B.C. Broncos, you are confirming that you have read and agree to our warranty and statement of liability.

INTERNET PRODUCT & PRICING POLICY
Due to the constant market changes, prices listed online are subject to change without notice. Additionally, sometimes parts will very from the picture shown due to slight manufacturing changes and or different sources.

WARRANTY POLICY
Within 30 days of receiving a product, if you find the product defective or incorrect, return it to B.C. Broncos. We will repair or replace any product found to be defective, subject to our inspection. Warranty is limited to the cost of the replacement part. Some items purchased from B.C. Broncos and built by other manufacturers may or may not carry warranty's issued by the manufacturer. B.C. Broncos is not a party to such warranty's, and all claims on manufacturer warranty's should be made directly to the manufacturer. No further warranty's are expressed or implied.

RETURNED GOODS POLICY
All items returned to B.C. Broncos which were originally paid for by credit card are subject to a 10% restocking fee.

STATEMENT OF LIMITED LIABILITY
Because B.C. Broncos has no control over the installation and/or other uses of our products, B.C. Broncos will not be held liable for personal, property, legal, or financial damages or claims stemming from the use or misuse of any product we manufacture or sell. The purchaser assumes all responsibility for the safety, proper installation, performance, and applicability of these products. If you have any doubts or concerns about the installation, function, performance or proper use of any of our products, please call our toll free number before proceeding with the installation or use of the product

SHIPPING POLICY
Please note: B.C. Broncos will not pay premium shipping for any reason. We will ship next day, same day, 3 day or any other premium shipping method that you like but you will have to pay the cost and take the risk that it will get to you when you want it and that it is what you wanted. We will do our best to get what you want to you when you want it. But premium shipping is extra work for us that we are doing for you as a favor and we make no money on any shipping and will not  refund shipping if things do not turn out the way you expected.

We hope you find some valuable information on these pages. If you need more information, give us a call or check back later. We will be updating often. Input for improvement on this page or our products is always welcome.