1989 744 (Chassis 22375) 107,000mi

I am updating my 740 to R-134a and have replaced the Diesel-Kiki compressor with a Sanden 709 drained and refilled with Ester Oil, R-134 accumulator, and installed a R-134 variable orifice for better performance. I also installed a new R-134 adjustable compressor switch, and wired the electric pusher fan to a new relay I installed that will run it whenever the compressor clutch is activated.

The car has been in my family since new, and it was assumed when the A/C quit, it had just leaked out its R-12 past old seals or O-Rings a decade ago, and before I "inherited" the car. Now we are taking the car to Phoenix and will NEED A/C badly, of course.

Got everything hooked up and found a leak when I could not hold a vacuum w/ my pump-

The leak (one I've found so far at least) is in the low pressure return line (fat one) from the accumulator to the compressor right where it transitions from above the right front frame rail down to beneath the car. The aluminum flex hot-air-pipe to the intake (warm-up air pipe) rubbed against the aluminum part of the OEM hose assembly and wore a small hole in it in a curved section.

Looking at FCP, the only hose replacement available for my chassis number is their part # 1348538 which is different and requires a complete re-route above and behind the engine rather than under the front of the engine like the OEM one.

The OEM "type" hose (really LONG like my original) says only for use after Chassis #225079 (mine is Chassis #22375), so while their "See-if-it-fits" check says it DOES fit, I suspect the Chassis # warning check supersedes the Model/Year alone, so I will need to use the vastly different hose.

Has anyone ACTUALLY USED one of the new style hoses on their car, and how did it fit in?
Here's a link to the instructions: http://www.fcpeuro.com/products/volvo-a-c-hose-740-760-accumulator-to-compressor-1348538

My Condensor appears good, but for another $80 I plan to replace it with FCP's Nissen 1362149 (http://www.fcpeuro.com/products/volvo-a-c-condenser-740-760-780), and the other flex hose (FCP Part 3537728) http://www.fcpeuro.com/products/volvo-a-c-hose-740-760-780-940-compressor-to-condenser-3537728 as well while I am in there, so any feedback on these parts would be helpful.

I GUESS maybe I could have the old hose repaired by aluminum TIG welding (I have a relative who TIG welds aluminum for a living), but given its age, that would be a last resort if the new part will not fit?

The ONLY original component left will be the evaporator, and I HOPE that it's OK. I trust that these rarely go bad?

Any help/Advice appreciated!

Thanks,
Bob