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Old 11-19-2017, 09:38 AM   #38 (permalink)
Daox
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Join Date: Dec 2007
Location: Germantown, WI
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CM400E - '81 Honda CM400E
90 day: 58.68 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)
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Yesterday I continued this mod on the Insight. I started with a good ol cereal box as any reasonable ecomodder would do, and started marking it and trimming it as needed to make a template to cut the aluminum sheet.


I had to be careful for things like bolt clearance.



I decided to go with a single sheet. There will be some forming / bending involved in it, but it shouldn't be too bad. I kept it as simple as possible. It wraps as much of the transmission case as possible. It also wraps the transmission pretty tight, so it won't hold a huge volume of coolant which was also a design goal. Once the valve opens, I don't want a huge volume of coolant rushing in and cooling the engine off. The circles are the inlet and outlet.




I also marked where the sheet will attach to the transmission case, and I started sanding down to raw / clean metal so that the brazing will bond well with the case.





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