Note:  My references to the ac system below are based on my 91 Vanagon Multivan.  Other systems might differ so be careful.

I have working A/C!!!

I had a "mobile hose doctor" vendor come out to my work earlier this week and take the hoses away with him to perform the job.  Although most of his jobs are fabricating hi pressure hydraulic hoses for heavy equipment, he also does fun projects like this on request.  He is fabricating the hose couplers for me as we speak.  As you are likely aware, the stock vanagon hoses connected to the vw ac pump with two disk like fittings.  I cut those fittings off of the lines exposing at least 1-1/2" of steel tubing onto which the "doctor" could crimp.
From my donor subaru, I kept both subaru ac hoses, cutting them at the aluminum tubing just past the first section of rubber hose, ensuring that again, 1-1/2" of aluminum tubing was exposed to make way for the crimp.
All of the crimp connections can be done on a bench except the connection from the hi side of the vw hose which I pulled back and routed outside of the drivers side rear wheel well to make it easier for him to access when he comes back.

The "doctor" fabricated two hoses of different diameters.  Both have a piece of rubber hose with crimp fittings at each end.  Those crimp fittings secure the hose to the vw steel tubing on one end and the suby aluminum tubing on the other end.  I have my ac service ports right at the suby ac compressor as was stock with suby.  My hoses route around the back of the engine, against the firewall, for the low pressure and around the taillight area for the high pressure.
On his return trip 3 days later, Gary returned to the van and crimped the one remaining connection to the vw hi pressure line.  I've since connected the 2 subaru hose ends to the ac pump, and connected the vw lo pressure hose by screwing the threaded o-ring fitting back together.

HOSES
	Mobile Hose Doctor - Portland
	Gary Hunt
	(503) 804-2602
	Cost Parts/Labor/Warranty
	$285.00

DRIER
	I picked up a brand new replacement drier for the vw
	www.acsource.net 
	108525-P/N: 33374A
	$18.00


REFRIGERANT
	Used HC12A coolant which I purchased in kit form.  Comes with 51oz of coolant, hose to tap and refill, conversion fitting for R12 lowside inlet.
	Info at http://www.hcrefrigerant.com/english/
	Purchased kit from duracoolky@hotmail.com
	$52 for kit includes shipping
	+ $22 for ester oil from same vendor

Hose Fab		$285
Drier			$ 18
Refrigerant		$ 53
Oil			$ 22
___________________

TOTAL COST	$378


She's cooling VERY well.  Damned if the weather didn't go cloudy on me just after I got it going!!!



Brent
www.weidefamily.net/vanagon/





The large diameter hose feeding from the area behind the drivers side wheel well is the suction (lo pressure) hose.  This hose has a threaded o-ring fitting at it's end which will allow you to remove the last 4 or so inches of the steel fitting and work with it off of the vehicle.

The smaller diameter hose feeding into the engine bay on the front drivers side, just near the black junction box, is the discharge (hi pressure) hose.



I will prep and fill the system with a commercially available HFC refrigerant which is as effective as R12 and much better than the overrated 134A.  I'll buy the kit to service the system which includes stop leak, oil, and refrigerant along with a fill hose and necessary gauges.  All told, I should have about $250 into it before I feel the first cool draft.

Best of luck,
Brent
www.weidefamily.net/vanagon/