E9 A/C Condensate Drain

[CharlesJ]

Not sure how flexible the elastomer actually is. But I agree if it is pretty squishy, then making the top ring taller would assure a solid seal.

I am not super clear on the "indented slot" suggestion.

My original design had two grooves, one for the trans tunnel, and one for the mounting plate, but we thought it might be too difficult to seat both grooves. So are you suggesting making the barb smaller so it is easier to insert, but adding a stop above, so it doesn;t get pushed too far in? That seems like an interesting idea. Here's a version like that.View attachment 222120

View attachment 222121

This is exactly what I was thinking. I used this part below and it clicked in perfectly to the tunnel hole. The top part was a bit too tall, and does not seat into the top of the bracket like the original or your design making it very hard to put on, but the bottom was spot on:

 

[rsporsche]

yes, that was my original thought too - as i have a spare one, but it is a bit tall.

 

[ScottAndrews]

Based on the measurements I made at Dons, I think the structure below is the right design. This may not work for vehicles that have a different morning plate or evaporator, since the idea here is to have the funnel extend about 5-7 mm below the tunnel. If the routing plate is taller, or shorter than 21 mm then the funnel will extend into the tunnel less or more. A few mm won't hurt anything but if it is a lot shorter, the funnel tip may hit the transmission.

The curve of the inside of the funnel is also important , since you want the evaporator tube to seal against the funnel. I have shown this in the cross-section diagram below (note this is a HALF cross section, since to make the part in 3D I revolve the section 360 degrees). The rectangle in the upper right represents the evaporator tube, which is 15 mm dia and 6.5 mm long. You can see it interferes with the funnel at the bottom by about 1mm, which is good. The funnel will deform slightly and seal the tube.

And here is the finished part.

 

[rsporsche]

i like it Scott. i think this will be great. i should have my gen 4 pieces next week and will try to fit them. if it doesn't work well, i will go to this gen 5 piece.