More oil cooler fun

Finding a spot for the new oil cooler was just part of the adventure.  I needed to make room by disconnecting the plug wires and temperature probes from the left side so I could work.  I also needed to find a new spot for the fuel pressure sensor.  Fortunately, that’s easy. I can clamp it to the top strut of the engine mount, pretty much where you see it resting now, top middle of the frame.

Ordinarily, I hate working with steel.  it’s sharp, unyielding, and awkward to work with.   This all changes when you have the proper tools. EAA 96 has a plump machine shop, with a shear, two sheet metal bending brakes, numerous drill presses, grinding wheels, table saws, a massive lathe, and two Bridgeport mills, one of which is working, but neither of which I know how to use.  There are also a number of projects in the hangar that utilize the tube-and-fabric method, so there’s a scrap can full of 4130 steel tubing and sheet cut-offs.  So that’s where I went to get the brackets I needed.   I’m sure there’s some fancy engineer-y math I could have used to bend a bracket so it works in one piece like papercraft, but I was able to get this together with two pieces.  This connects to an angle brace on the cooler and suspends it from the engine mount at the angle and distance I’ll need to get a fiberglass plenum on it, which will connect to the baffle via 4″ SCEET tube.

I chose steel because it was available, I have the tools to work it, and I can get away with less material.  I don’t have the right circumstances to do a solid aluminum webbing, so steel it is.

There will also be a support member on the bottom of the cooler, where I have to battle the mechanics of attaching to the engine mount without blocking the airflow from the cooler.  I paid for 10 rows of cooling, I want all 10 rows cooling.

New oil hoses will also be a necessity.  The top one barely made it to the cooler with an acceptable bend in the line.  There’s no way it makes it now.   I may be able to repurpose the from-cooler line as the to-cooler line, but that’s doubtful, given the fittings necessary.

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