York On-Board Air Compressor System ($560, Jan 2000):

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Table of Contents for On-Board Air Pages

To facilitate quicker load times, this write-up is broken down into several pages.  You can navigate one of two ways:  Read each page in sequence, clicking the "Next" button at the bottom of each page.  Or, click on one of the Table of Contents topics below (listed in chronological order) to go directly to that section.

	Introduction
	On-Board Air Options
	York On-Board Air Bracket Kit for YJ's and TJ's with A/C
	Modifying the Engine Air Intake System
	Installing the Compressor Mounting Brackets
	Compressor Acquisition and Testing
	Compressor Lubrication
	Compressor Installation
	Air Tank Acquisition and Installation
	Plumbing (Fittings, Hoses, Regulator, Gauges, Electrics, etc.)
	The Finished Product and First Use of My New Air System
	Schematic Diagram of the Whole System
	Parts & Price List
	Sources of Information
	Airing Down
	ARB Air Lockers

 

It wasn't long after moving to New Mexico that I became serious about equipping my Jeep with an on-board air system.  I didn't bother much with airing down for the trails we rode in Ohio.  It never seemed to make much of a difference for me. However, I've learned that it can be quite beneficial on the rocky trails of the Southwest.  And it sure makes the ride a lot softer (rocks are much harder than wet mud)!  But when it's all over, you have to air up again.  If there's one thing I hate more than airing down, it's airing back up!  If you ask me, the whole thing is just a big hassle. Then again, I guess it's just another one of those "Jeep Things"!  ;-)

On-Board Air Options:  There are several different products and configurations available for setting up an on-board air system; you could write a whole book on the subject!  I considered three basic options:

Electric compressor; with or without a supplemental air tank (e.g., ARB or Quick Air)

Pros:  Very easy to install, depending on the configuration.  One of the Quick Air models comes in a little box; all you do is clip the power cables to your battery and turn it on.  Adding an air tank will greatly reduce air-up time, but only for the first tire or two. 

Cons:  The compressor alone sells for between $200 - $300.  With an air tank and all of the accessories, this system can easily run you $400 or more.  Limited runtime; then you have to let the compressor cool down (plenty enough time for you to air up, but don't plan on airing up all of your trail buddies).  And finally, they really don't produce all that much air.

Compressed liquid CO2 (e.g., Power Tank)

Pros:  Totally self contained; zero installation, no electrical or engine power required.  Not quite as expensive as the electric compressor option--you get everything you need for between $200 - $300 (depending on what size tank you want).  And they produce a huge volume of air.

Cons:  They take up a lot of space (again, depending on the size tank you get)--a big negative for short wheelbase Jeeps!  They produce a limited amount of air; then you have to get them refilled (i.e., you may not have any air when you need it).

Engine-driven compressor; with or without a supplemental air tank (e.g., York)

Pros:  Produces a huge, never-ending volume of air.  You can run air tools, seat tire beads, air up your tires, as well as those of all your trail buddies!  Can be considerably less inexpensive than the other two options, depending on the configuration and where you get your parts (e.g., a York compressor from a salvage yard will set you back only 20 or 30 bucks!).

Note:  On the other hand, this option can also be quite expensive.  Except for my compressor, I bought the best components I could find, including industrial-grade air hoses and fittings (because of the temperature extremes and harsh environment they will experience, I didn't want any of the hoses splitting on me).  Combined with the compressor bracket kit I purchased, the whole set-up cost me a little over $500.  But I'm not complaining; I think I have a very solid and reliable air system.

Cons:  Complex installation, especially if you have a factory air conditioner!  This is a totally custom project.  It takes lots of research and planning.  Creativity, special tools, and good fabrication skills are a big plus.  As of this date, there isn't anyone (that I know of) who manufacturers a complete bolt-on, engine-driven air compressor kit.

York On-Board Air Bracket Kit for YJ's and TJ's with A/C.  Well, you already know which option I chose.  Besides wanting to get the biggest bang for my buck (doesn't everyone?), I love a challenge!  Along with my various welding projects, "creating" an on-board air system for my Jeep has been one of the most satisfying projects I've taken on to date.   I ended up spending much more money on this project than I could have otherwise gotten away with, but there were just some things I didn't feel like messing with.  For example, instead of designing and fabricating my own compressor mounting brackets, I decided to purchase the Kilby Enterprises York On-Board Air Bracket Kit for YJ's and TJ's with A/C (Part Number KE-1000).  The kit sells for $200 and comes with all of the brackets and hardware needed to mount a York compressor alongside your factory A/C compressor.  It also includes the input and output manifolds that bolt to the top of the compressor, a combination serpentine belt/V-belt pulley for your alternator, the belt that drives the compressor via your stock alternator, an adjustable (50 - 200 psi) pressure relief valve, and installation instructions.  

This is a high-quality, well-engineered kit that will save you an incredible amount of time, while still allowing enough of a challenge to keep the whole project interesting.  For more information on the York On-Board Air Bracket Kit, contact Brad Kilby at:

Kilby Enterprises
www.onboardair.com
www.kilbyenterprises.com
1847 N. Keystone Street
Burbank, CA 91504
brad@onboardair.com
818-465-4529

Modifying the Engine Air Intake System.  The first thing I had to do was to modify the engine's air intake system (specifically to get rid of the stock air intake box) to make room for the compressor.  I purchased a high-flow, cylinder-shaped air filter from Turbo City Performance Headquarters, Orange, CA, for $39.95 (plus s&h).  It's a "permanent" air filter--the kind that you can clean and "recharge" with the K&N Filter Care Kit.  Installation was a breeze.  I removed the air intake box, cut the air intake tube, slipped on the new air filter, and tighten the strap.  BTW, I had previously replaced my stock air filter with the K&N filter that fits in the stock air box.  I was told to expect an increase in performance--I didn't get any that I could recognize.  But with this high-flow cone filter, I can definitely feel the power difference!  Here's a picture of the new filter and all the space it freed up for the air compressor.

Installing the Compressor Mounting Brackets.  The next step was to install the compressor bracket kit that I purchased from Kilby Enterprises, which was also a cinch to install--it took me less than an hour.  The hardest part was removing the stock pulley from the alternator; and that was only because I didn't have an impact gun (now that my system is complete, I have since purchased one!).  Anyway, I tried using a strap wrench to hold the pulley while trying to loosen the nut with a socket wrench, but I just couldn't get it; the pulley kept slipping on the alternator shaft.  Luckily, I found someone who lived close by who had some air tools.  It took my friend less than 30 seconds to get the old pulley off and the new one on!  Here are a couple of pictures of the completed installation.  The picture on the left was taken from the passenger side of the Jeep.  You can see two of the three holes that previously secured the stock air box, as well as the new pulley on the alternator.  The picture on the right was taken from the driver's side.  With the Kilby bracket kit, none of the stock A/C hoses need to be rerouted or otherwise modified!

                   

                    Copyright 1998 - 2008 Ó by Glenn Bontly