simple cooler/valance mod

k9handler · 06-15-2003, 09:19 AM

Well I decided with the warmer weather that my fender mounted Mocal cooler could use some additional airflow. I went into my storage room and pulled out my trusty Dremel tool and went to the valance like a mad man! Once I had the opening cut out, I figured some sort of screen would help keep unwanted junk and stuff out of the opening...so it was off to the storage room to search through the junk. I found a small 10" metal speaker grill that was also covered in rubber...just the right size to be cut down for a perfect fit.

And before attaching the screen I did remember to paint over the fresh cut metal to help prevent rust!

Here are the end results...not bad for a non-mechanical dogboy!

Chuck Moreland · 06-15-2003, 09:31 AM

Did you also box in the bottom so air is forced through the cooler, not under it? Similarly seal around the cooler edges to the inside of the fender so air doesn't slip by.

These two mods will help you get the most of your valance cutout.

You can also put a notch in the bottom of the bumper to further improve flow without changing the appearance. '84+ carreras had this from the factory. Wayne has a tech article someplace that shows how to do it.

k9handler · 06-15-2003, 10:10 AM

That's what I have planned Chuck...I am looking at making a one piece fiberglass unit that will channel the airflow through the cooler. Sounds like a simple idea, just need to make some cardboard templates and get a fiberglass guy to make it.

Dutchie · 11:29 AM

If you have a good template it,s not so hard to do it yourself Smitty. Just go to a German "modelbauladen" and ask for some "Epoxyharze" and "Glasfaservlies" thats all you need. Warning do this outside because it smells really bad

great mod btw

k9handler · 06-15-2003, 11:29 AM

Thanks Ed...I may have to give it a go, may save a few bucks as well.

Jack Olsen · 06-15-2003, 11:32 AM

I used thin aluminum for the ducting. It's easy to work with.

Dutchie · 06-15-2003, 11:33 AM

try to make the template from some kind of plastic material, you just cover it with some epoxy first and over that two layers of glassmatt, after that one more layer of epoxy and your done

It wont look very good but hey you wont see it anyway

k9handler · 06-15-2003, 11:35 AM

hmmmm...both seem like good ideas, which one would be the lightest of the two applications?

Dutchie · 06-15-2003, 11:39 AM

I guess Jack,s solution is best it doesent smell bad and is stronger as well. The weight would be the same i think.

k9handler · 06-15-2003, 11:45 AM

true, and there is a guy at the local auto skills center who has the sheet metal and would probably be able to assist me with it.
Thanks Ed and Jack for the inputs, always great info from the Pelicanites.

widebody911 · widebody911's Garage

I'd made a duct for my '77, but in fiberglass. Fiberglass is easier to work with than aluminum, and only smells for a short period of time.

What I do is lay up a single piece of 6oz over a piece of glass. Once it's cured beyond the tacky stage, I fold, spindle and mutilate it into the shape I need. I then lay up more cloth over that, in-situ, to get a piece that fits perfectly. I then remove it, and add extra material for strength as needed. You just can't work with aluminum like that.

Dutchie · 06-15-2003, 12:04 PM

Thom this may sound stupid but what is 6oz ? Your idea sounds great and may help me to make some coolducts for my brakes. Do you have some pictures maybe ?

k9handler · 06-15-2003, 12:28 PM

Thom is good with this stuff...I REALLY like the heater tube!

masraum · 06-15-2003, 10:52 PM

I used alum and I can tell you that yes, it is a ***** to work with. I have seen the how to that Thom has on his site, and the F/G looks much easier to work with.

ruf-porsche · ruf-porsche's Garage

Quote:

Originally posted by Dutchie
Thom this may sound stupid but what is 6oz ? Your idea sounds great and may help me to make some coolducts for my brakes. Do you have some pictures maybe ?

6oz means the weight of the fiberglass mat or cloth. We are still using the english standard instead of the metric standard.

oz is abbreviated for ounce.

Dutchie · 06-16-2003, 05:06 AM

Thanks for clearing that up Ruf-Porsche

i got the idea now

thrown_hammer · 06-16-2003, 05:30 AM

I also used alum. Here is a sample.

I also added a peice up the side. The air has no choice but to go thru the cooler.

k9handler · 06-16-2003, 07:06 AM

excellent...

I like what you did Shawn, I am going to print the pics and take em to the metal guy...he should be able to match that.

Thanks!

thrown_hammer · 06-16-2003, 07:15 AM

No prob. Us Franken cars got to stick together.

masraum · 06-16-2003, 09:43 AM

Yeah, that's much prettier than mine. I have the same functionality, but it's not nearly that pretty. That's why you won't find pics of mine on the web.