Dashboard strip

[Bubble Meister]

Covkid. Can you explain PWM and the practical application on the van. Where do you get the parts from? Maybe it should be a separate thread so that this one stays on track.

[Bubble Meister]

How do you remove the heater controls facia? I tried a while back but thought it was gonna snap so I stopped.

[multisi]

Put a blunt screwdriver under bottom left and top right of facia and evenly prise off .

[slowcoach]

Here's the heater facia, showing one of the remaining plastic stubs on the reverse that pushes into the dash holes. One of mine snapped on first removal few years ago, it can survive with one..





And here's the replacement bolts for the shear bolts, M8 shortened to rightish length.

[slowcoach]

Remember to supply the controller from an ignition only feed rather than constant live.

Yep- the black w red stripe wire going to the original fan speed switch is ignition live i believe?? And is already in the perfect spot to connect to the PWM leads.

[slowcoach]

It's in! And it all works even. With all the dash cowling and binnacle off, it's still possible to get a good view and access of most of the wiring once the actual dash is back on.




Here's where i stuck the PWM controller to the back side of the dash, with a double sided foam pad thing.

Got a nice gust of wind now from it!

I'm.assuming the heater matrix self bleeds after a good run? No one seems to talk about bleeding it once it's been empty and reconnected?

[CovKid]

Covkid. Can you explain PWM and the practical application on the van. Where do you get the parts from? Maybe it should be a separate thread so that this one stays on track.

I think I've covered it a few times plus this WIKI article. https://club8090.co.uk/wiki/VW ... ol_Upgrade" onclick="window.open(this.href);return false; and the youtube videos (parts 1&2)

The motor, by default, runs flat out. The only thing that slows the motor down is two frankenstein resistors for speeds 1 & 2 using the existing switch. It works, no doubt about that, but its incredibly inefficient since so much is lost in the resistors themselves. A PWM controller works very differently. It 'pulses' the motor (akin to connecting and disconnecting the power at very high speed), so less power is used/wasted to run motor on lower speeds, the space between 'on' states increasing as the speed is reduced - ie motor is off more an it is on.

You get infinite control, and you don't have hot resistors being used to soak up power. If the controller packs up, its easy (and fairly cheap) to replace. Resistors are not as Its a dash-out job again unfortunately unless you go to the trouble of relocating them.

In graphical form, PWM looks a bit like this:



You need to search ebay for a 20amp controller with the speed adjustment on a flylead. They're usually 0-60v input.

My speed controller sits behind the stereo as my stereo is a shallow depth model.

[Bubble Meister]

So how is the speed controlled? Can you use the original rotary switch? I can't see how as it' has 3 discrete outputs rather than a proportional single output like a potentiometer.

[CovKid]

controller has a pot attached. You just fit it through where original switch was. You have read my WIKI article yes? Its all in there otherwise (politely) this topic running off course.

[slowcoach]

I just have the controller dial hanging below the dash right now, pretty stylin ! I also need to reduce the thickness of the heater facia sonic can get the pot stub through the hole with enough length for the nut. Cov kid has that written up in the wiki.

[Bubble Meister]

Thanks Covkid. I'm busy moving house this week so have only scanned the thread and missed the wiki link. Thank you for the polite reminder.

I'll have a proper read when life settles down!

[slowcoach]

Some pictures of the mod to the back of the heater facia, if you're changing the knob... Might supplement the wiki pictures if needed?

[CovKid]

Great idea. Thanks for pics Thats exactly how I did mine although the PWM controllers can vary a bit and may or may not require removal of parts or any of the facia sandwich. I'll certainly add them though

I've got some new mods coming up. Will WIKI them when I get time.

[crazyhorse]

Great idea. Thanks for pics Thats exactly how I did mine although the PWM controllers can vary a bit and may or may not require removal of parts or any of the facia sandwich. I'll certainly add them though

I've got some new mods coming up. Will WIKI them when I get time.

I dont know about the rest of you, but I am pretty excited by this... New mods eh.

I have just done this mod, works well. Pretty chuffed with myself. Thanks for detailed explanation as well. If I can do this anyone can. Did break handles pulling facia off though. Got replacements from Brickwerks.

I might add that my mod of the facia isnt as tidy as slowcoach, but on the front all looks good, will post picture up soon.

[irishkeet]

Looking good SC, what PWM unit did you go for, I went for this may well be the same.

Have you insulated the switch behind the facia?