Lower & Upper Grille Block Ideas (Toyota Echo)

[CigaR007]

I removed the upper insulation pipe and the temperature has reached a maximum of 190F during 2 recent trips. It usually sits @ 186F for most of the time though. Seems like it there has to be a small opening even at low winter temperatures. I will be modifying the partial upper grille block to make it 100% sealed and more water resistant.

Mileage seems normal @ 47.5 MPG (114 miles with 2.4 gallons). Too early to say if it is the mod or just the nut behind the wheel making the necessary adjustments.

Stay tuned !

[NeilBlanchard]

Have you tried a small opening in the center of the lower grill? Having the upper grill completely covered is better because this moves more air up and over the car. If the opening is at or just below the stagnant point, the air flow into the opening is better, so you can get by with a smaller opening, than if it is less optimally located.

Does the "chin" area have holes in it? If it does, then blocking them will force more air through the radiator, which then lets the lower grill opening to be smaller than it otherwise could be.

Here's my current grill block on the Scion xA, which is virtually the same car as yours:


(click on image for link)

[CigaR007]

Thanks for that pic. I understand now what you meant by "chin" area. I am constantly thinking of new designs for the grille blocks...I should have a new one soon enough.

[alohaspirit]

I have been thinking the same


block the upper with a partial on the lower

ive had almost no chance to test so im living vicariously through Cigar

[CigaR007]

Here's my version of an adjustable grille block. Hope it provides some food for thought.

Basically, two solenoids pull the 3 flaps to create an opening, hence providing sufficient cooling to the radiator. The sidewalls are there to provide an improved cooling efficiency.

I would like the flaps to be more distant from the opening, but most solenoids only have a reach of 1 inch or so. A linear actuator is a possibility, but its cost makes it a bit prohibitive for now.

Still haven't decided if the system will be automatic based on coolant temperature or fully manual. This is simply a basic conceptual drawing.

Any thoughts and/or suggestions ?

[alohaspirit]

well drawn

but i think its too complicated


what about something spring loaded that you pull with a string

[CigaR007]

Originally Posted by alohaspirit

well drawn

but i think its too complicated


what about something spring loaded that you pull with a string

Thanks for the input.

The mechanism is far from being final. Still debating whether or not it will be an electronic or mechanical system too. I have a background in avionics, so the electronic part of the system is the least of my worries.

I was wondering if an opening that small could be a source of drag due to the high pressure entrance of the relative wind. Could the "tear drop" flaps (as per the drawing) provide a significant decrease of such drag ?

[COcyclist]

Originally Posted by CigaR007

Thanks for the input.

The mechanism is far from being final. Still debating whether or not it will be an electronic or mechanical system too. I have a background in avionics, so the electronic part of the system is the least of my worries.

I was wondering if an opening that small could be a source of drag due to the high pressure entrance of the relative wind. Could the "tear drop" flaps (as per the drawing) provide a significant decrease of such drag ?

I like the sketch. I think the idea is to divert as much air around the car as possible so the small opening is a good thing. The AeroCivic and AeroHead's T100 have very small manually adjustable grill openings. IIRC I read on here that the opening only needs to be 1/5th the area of the radiator if it is ducted, which it appears to be in your sketch. IMHO if the adjustable blockers are teardrop shaped I don't think you have to worry about drag behind your grill opening. All cars sold in cold climates should come with automatic grill blocks.

[COcyclist]

Originally Posted by CigaR007

I would like the flaps to be more distant from the opening, but most solenoids only have a reach of 1 inch or so. A linear actuator is a possibility, but its cost makes it a bit prohibitive for now.

Could you use a lever to actuate the flaps and increase the range of the solenoids?

[CigaR007]

Originally Posted by COcyclist

Could you use a lever to actuate the flaps and increase the range of the solenoids?

That's definitely something to consider given the range limitations of most solenoids.

As alohaspirit mentionned, perhaps a spring-loaded system and a wire to pull the flaps might be an easier and more efficient approach.

Thanks for the feedback !