I have done ALL of the mods (with the exception of Frank's temp switch) that have been posed to me and still this does not cool to my satisfaction. I am just going to scrap the evap. unit in favor of the "King Kool" unit:
http://www.air-tique.com/evaporators.htm
I have been in contact with Harold (another kind and knowledgeable Texan
) over there at Airtique and he assures me that the unit he manufactures and sells is no comparison to what I have now! He knows the boys at Old Air real well and knows of the deficiencies that the "Hurricane" system has, namely, too small of an evaporator and a "suck-through" design which is old technology. Yes, the system does work good but not good enough for me. I am a picky sum-bi**h! I got the Old Air for the price and I got what I paid for
I realize that the aftermarket units won't throw icicles at me but I know I can at least drive in comfort. I am going to yank my Old Air evap unit, modified heater controls, wiring, hoses & louvers and replace them with the King Kool piece. I will use my existing condenser, fan, compressor, some hoses, etc. and bolt this one in. Although it is not a "custom" piece it will fit just right under the dash. Check out the website and you will see the other installs in our trucks. This has a MUCH BIGGER evaporator, vacuum actuated doors, heater control valve (for blending if so desired), adjustable A/C temp control, dehumid. defrost, floor heat exit (YES!)..overall a far better unit. I should have done my homework first
Now, I have to find a buyer for my Old Air stuff to offset the cost of the King Kool...
Hopefully in a few weeks I will have this up and running and I will let y'all know how it works...