The top of the Naca duct used for my oil cooler is not a flat surface. Knowing this, it would be foolish of me to build a flange meant to be bonded to it that wouldn't fit flush. I therefore need to build a flange using 4 plies BID on TOP of the duct itself allowing for a perfectly mated surface. I plan to do this by laying up a prepreg 4 ply layup at home, then transporting it to the Duct for cure. After cure, I can drill 2 small holes through the flange and duct for locating it perfectly in position. I will then remove it, cut out the opening using a premade template as seen here. Tonight, I used cardboard to make a basic template for the required cutout on the flange and naca. Most likely, the flange will have slightly larger borders to accomidate its mounting hardware. The first idea I had was to mount the flange permanently, however, only using 2 bolts to secure it may have it's issues. instead I may rely on the Red RTV for a bond and seal and then use a simple zip tie or strap to keep the regulator in place. I will make this decision once I have the flange made and can trial fit the parts onto the duct. The space I have inside the hell hole is very limited so I need to make sure nothing is contacting. tomorrows layup will be the first tast while I tackle the wires for the regulator. BTW: I've discovered "liquid electrical tape." Stuff is awesome. found that it creates a water, and air tight seal around the solder joints which is perfect to go underneath some heat shrink. And it dries in 5 min. thanks Home Depot!
