On my trip back home today the fan did not come on at all. Outside temps were between 50-65F and the coolant temps were between 184- 198F. I think that I may only need a slightly larger open area.
I also found that the air pressure has bent the colorplast in enough that it will not slide. I would need to add some more bolts to hold the sliding piece to the stationary one but I will likely try to remake the grill block instead.
I am thinking that I might make it with the grates again, but make it default to the open for half of it. the other half will need to be counterbalanced or have a spring to keep it in whatever place I put it. I think that for short trips (into town) I will keep this side closed (and most of the winter, since I only had a 4"x3.5" opening last winter). On longer trips I will need to be able to open both sides.
I think I know how to make the one side be open unless I keep the actuator powered. I am not sure how I want to do the other side.
Ideas?
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