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Building Integrity
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Date:  12-16-2015
Number of Hours:  2.00
Manual Reference:  Section 2
Brief Description:  Bingo. Found it

My hunch was accurate. The Voltage regulator is done for. As long as I was flying my airplane and only using about 22amps, everything was fine, but as soon as I flipped on those heaters and my Alternator started pumping out 45amps, the Voltage regulator would heat up inside the hell hole and shut down. Unfortunately, the hell hole has no airflow to it and now that it has been heat damaged, it can't be brought back to life but I have found my solution.
Instead of adding another draggy air scoop or trying to route longer wires and air ducts to the regulator, I wanted to find a place it could be installed and get really good airflow from a source of air I already have. I've decided to duct some air to the alternator from my plenums which will help raise my CHT's and cool the alternator but I needed air for this regulator. Then it dawned on me..it has fins to help like a heat sink, so why not inside the fins, facing down into the oil cooler NACA, exposed to the air! How this will affect oil temps I don't know, but having that much air racing over the fins then into the oil cooler will ensure it will NOT overheat again. Plus, this means I can keep it clean, inside the hell hole and may not even have to add wire :)
I'm going to create a 4 ply BID Plate that the regulator will mount to using 2 bolts. The plate will then be floxed onto the top of the NACA Duct. The regulator will then get a small border of red rtv to seal it to the plate. If I need to remove it in the future, it will be 2 bolts and it's off :) An air tight seal wont' allow air into the cabin, and when I need 45 amps for those heaters, it will be in the winter when freezing air is flowing over that regulator. So...my fault for no airflow. $330 is my punishment. But what comes of this is a plan for higher CHT's, cooler alternator temps, and airflow to the regulator. a win, win, win. :)
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No volts, but the alternator is working

No volts, but the alternator is working

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