Cooling System
Machining Water Cooling Plates
Aluminum was CNC machined to create the heatsinks. The deep trenches serve as a manifold to distribute the water flow evenly over the plate. The hatch pattern serves to turbulate the water flow to improve heat transfer.
Finishing Water Cooling Plates
The water cooling plate was sandblasted. The side where the IGBTs mount was fly cut then lapped with silicon carbide grit on a glass plate. John Forcina and Logan Walker hand tapped the hole for the heat sink temperature sensor.
Connectorizing Water Plates
A polycarbonate plate covers the water flow area. It is sealed on with silicone. Ben Guengerich tapped the plate for the hose fittings. An NPT-to-hose barb fitting is used to connect the cooling plate to the pump, reservoir, and radiator.
Let's Get Wet
The pump, radiator and reservoir were extracted from a pair of Lytron cooling systems. The pump is a nice high flow magnetically coupled unit. Bill Rabbitt admires the cooling components install in his finely TIG welded chassis.
Modifying Reservoir
The reservoir fittings needed to be moved to properly fit in our custom chassis. We cut gaskets from rubber sheet, made new holes in the reservoir, moved the fittings and plugged the old holes. Ian Charnas showcases the modified reservoir.
Leak Testing
Yes, it did leak the first few times it was pressurized with the pump. It's amazing how much the water pressure deflects the 1/2" polycarbonate. But with proper silicone application, washers on the bolts, and proper tightening of the bolts, the leaks stopped. George Daher and Ed Burwell are pleased to see the water cooling system operating without leaks.