Technical Aircon leak from an aluminium pipe

[chesh]

Don't know how many MK1's came with A/C in europe.
The one I have has an original A/C.

A few months ago, I've noticed a leak under the bumper. it was a wet aluminium pipe that is going all the way from the dryer to the end of the condenser.
the aircon was good enough so I didn't think it was a problem.
couple of days after, the compressor hasn't kicked in.

I've noticed a bad A/C pressure unit that is ripped off:

I've changed that one but still the compressor wasn't working.
I've checked, and there was no gas in the system.

In the first place, I thought it was some bad seal rings and decided to change them:

Bumper out:

Set of seal rings:

Old vs New

New seals for the dryer:

other side before placing the seal ring:

testing with a vacuum:

After a few tests, without finding the leak, I've decided to put 150psi air to the system. then I found a damn hole in the aluminium pipe.

I had to take the condenser out:

the damn pipe:

:-x

What would you suggest me to do?
My current option is to fix the hole at some local business.
I can't seem to find a new pipe like that here.
and there are no scrap yards who would sell me just the pipe.
taking the pipe off takes more than 1 hour.

 

[fingers99]

If the aluminium is weldable (chances are that it is) it should be fixeable by anyone with A/C TIG equipment. This is probably the best fix.

Alternatively, it may respond well to epoxy (with something like glass fibre tape as reinforcement).

In either case, vacuum -- mityvac or similar is ideal -- (or low pressure) test afterwards. High pressure testing with compressed air can be dangerous.

 

[maggers]

Euro do some repair sections, not sure if they go that small though.

 

[Noddy]

Aircon, a van and the red paint that was cabriolet only are the last things to tick off for me in my Mk1 had everything box. I even looked at fitting aircon as an aftermarket option but then changed car.
As for the repair to the pipe I would be worried about why it went? if it looks corroded then the rest of the pipe could be as well and having it repaired may only reveal another fault in the pipe if its looks good though then go for a weld repair and then put something like liquid metal as well.

 

[maggers]

By the look of it it has rubbed on something else.

 

[chesh]

Finally fixed it.

The condenser was loose when I took off the bumper. It missed some bolts, so probably the pipe touched that edge:

got that pipe fixed for 10£

 

[Noddy]

Glad you got it fixed.