Fiberglass ducting for oil cooler

I started the process of fabricating a duct to provide high pressure air to my oil cooler. I used a bunch of vinyl tape to protect different surfaces from resin. The resin releases easily from this vinyl tape. I used a few pounds of clay to form a reasonably smooth duct from my existing rear cylinder baffle to the oil cooler.

I painted PVA mold release on the clay. You can see where the mold release pooled near the oil cooler. If my dimensions were absolutely critical, I would have had to do something about the pooling, but since it doesn’t really matter, I’ll just accept the longer dry time and move on.

Here I’ve laid down somewhere between 3 and 4 layers of 6 oz. fiberglass cloth over the clay and PVA mold release. You can see where the green from the pooled mold release shows through the wet fiberglass. As I mentioned before, I wasn’t concerned about the pooling, but it *is* important that the PVA is dry before you start laying the fiberglass cloth over it. I let the mold release dry a full 24 hours before I did the layup.

I try to have multiple projects going on simultaneously while I’m doing fiberglass work. If you don’t do this, you end up wasting a bunch of time because you have to wait for each layup to cure before making any additional progress. This is the start of a mold for the oil cooler exit air diffuser box.

This is all I’m going to do in foam for the exit air diffuser. The rest of the shaping will be done in clay. This would be a huge chunk of clay if I didn’t start out with some foam. I’ve painted the foam with a mixture of resin and micro balloons so that the clay will stick to the foam core more readily and my clay won’t be contaminated.

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