Cooling


making a ducted blower from a computer fan

making a ducted blower from a computer fan
DIY in line ducted fan
I need a battery box vent for my solar batteries enclosure. Many people sell fans that can be installed in PVC piping, but they are expensive.
I have a bunch assorted fans from 2" to 4" from the MIT swap meet, so I set out to make a ducted fan assembly for them.
I found that the white PVC reducers were just the right size, so I took some white expanded PVC foam board, and using a 4" hole saw bade a simple flange. I glued the flange to the reducer, and used some long 6-32 screws and now have a nice ducted fan that can be inserted into the 1.5" PVC vent line. Made another for a 2.5" fan.

Insight Battery pack turbo cooler

Insight Battery pack turbo cooler
Insight Battery Turbo Cooler
As any owner will tell you, when you are pumping charge in and out of the pack with MIMA, it can get hot, especially in summer. The battery is cooled with a two speed fan that draws air into the battery pack from behind the passenger seat inlet vent.MIMA will force the two fans on at full speed when the temperature of the battery gets over 95F.
I made a Turbo Cooler for my pack by ducting the passenger foot AC outlet to the battery pack input duct. I set the fan on high, and the duct to foot only. The driver side vent is ducttaped over, so that all the air comes out of the passenger side.
The increased air flow helps a lot, with mild MIMA use, but if you are really pushing the hybrid ratio to the electric side, the pack can still get into the 100 F range. Because of the large thermal mass of the heavy batteries, it takes a lot to cool them even a few degrees. To Turbo Cool the pack, I wait till I am going down hill, so the power is nearly free, and turn on the AC to full, set to 60 F. A long hill and you can cool the pack several degrees.