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.
