I bent the evap lines just as you said. The front edge of a desk along with a try square and ruler made a good reference. At my employment place is a superb journeyman machinist who made me a mandrel for bending each tube without disturbing the expanded part or the flare. This was a straight piece about 45 cm long so just a steady modest force was really needed (and the long extension made it easy to see what angle was achieved).
Thanks for the web reference - I think we should conclude a silicone product is the thing to use with sealing rings, because mineral oil is not compatible with R134A, only with R-12 (see www.sanden.com where there is an article on retrofitting R-12 systems to R134a).
Regarding reinstalling the climate unit, I understand the heater core can be removed and replaced with the climate unit in place (no need to remove the dash, just several kick panels and probably both knee bolsters). If that's so then it might be easier to install the climate unit without the heater core and cover (or at least without the 2 hot water lines) then fit them in. This would save aligning 2 items at once. Have you got any opinion on this idea?
Again, many thanks for your comments.
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