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Building Integrity
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Date:  1-18-2015
Number of Hours:  5.00
Manual Reference:  Section 2
Brief Description:  Oil Cooler plenum begins

I was debating between removing the oil cooler for a true fitting plenum or not. I decided I could get a plenum made much easier on a flat surface and spare the abuse of removing the oil fittings again and losing oil in the process. Besides, any imperfections can be easily fixed using red RTV or a little more glass work later. I am, however, very confident in my design here.
I took extremely precise measurements of the cooler face before leaving the airport yesterday. I first spread aluminum foil tape over my bench as a release. I removed the center section of the cooler lines and bonded a green foam block to the bench underneath using spray adhesive. This worked out REALLY WELL and was incredibly stable for sanding and shaping the foam. I had to add 2 more blocks to create the plenum but it worked out really really well.
I decided to go for a 2" hose opening, hoping it will get enough air to the cooler. We'll see. I'm thinking ram air at 200mph should shove enough through to cool the small face of the cooler. I had a section of 2" pipe and pressed it into the foam giving a perfect outline for sanding. This is the same technique I used when creating my CHT intake openings. After contouring the plenum to what I feel is the most efficient shape regarding expansion, I laid up, 2 plies Glass BID and 1 ply Carbon. This should be more than rigid enough for the job. Tomorrow I will begin molding the lower cowling intake scoop which I'm actually pretty excited about :)
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cooler dimensions on foil tape

cooler dimensions on foil tape

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Foam plug shaped

Foam plug shaped

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2 plies glass, 1 ply carbon

2 plies glass, 1 ply carbon

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