I’ve already built an air cooled version of the EMW and it’s working beautifully in my car. I was going to build a 2nd air cooled version for a friend, but because the kit was different enough I couldn’t use the same CAD files and panel designs for the 2nd charger so it was on to plan B.
Since I had to start from scratch (or at least revise all of the panels) I told my friend he was getting my air cooled version and I’m going to build a water cooled one.
I bought an 8″ x 8″ x 0.75″ aluminium plate for another purpose, however it’s just about ideal for the EMW.
Test fitting the silicone gasket, I’m using a 220mm x 3mm gasket in a 1.9mm deep by 3.5mm wide channel.
Drilling and tapping the G1/4 threads, since the rest of my cooling hardware is computer stuff, standard fittings will thread in.
And a test fit of a 1/2″ barb fitting. I may go with 90 degree fittings, depends on the final mounting location in the car.
Both barbs and the silicone gasket. I still have tons of holes to drill and tap on the top and bottom as well as around the edges. The asymmetrical design of the cooling channel is to leave enough room for the mounting holes on the other side for the IGBT’s, diode, input bridges etc.
Test fitting everything on the block.
The final dimensions including mounting feet will be:
10″ x 8.3″ x 5.5″ This doesn’t include the barb’s or cooling hoses that will run out the side.