Monday July 1, 2024
Making a Oil Cooler Diffuser Mold (Firewall Forward)
3.3 Hours

I started working on making a foam mold for a fiberglass diffuser to the oil cooler. I bought some pink insulating foam at Home Depot and glued several layers together.

I sanded/filed down the lower area and then started building out the air intake end (which is 4"). I wrapped that around the engine mount up toward the rear baffle.

I will make another fiberglass duct for the upper end and connect the two with 4" silicon hose.

Here it is after some additional sanding.

I need to get an idea of where the baffle will need to be trimmed and how far the air seal material will come down before I can see where I can make the hole in the rear baffles.

I also need to decide where to put a valve in the ducting so I can vary the amount of oil cooling from the cockpit. I intend to use a butterfly valve in one of the two fiberglass ducts.

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