Radiator baffle DIY – what is latest material and template?

vanis13 · Last edited by vanis13 on Thu Sep 11, 2014 6:26 am; edited 1 time in total

Radiator baffle DIY – what is latest material and template?

Got the radiator out and wondering what to use to replace my deteriorated radiator baffles.

Would prefer to make my own rather than wait for shipping. I've seen some topics on this periodically but no luck in the search.

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83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace

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Syncro Jael · Posted: Thu Sep 11, 2014 6:18 am Post subject:

I purchased these recently, from GoWesty, getting ready to install new radiator, fan, hoses. These are very well manufactured and should last as long as I am needing them. The material used is much better than stock.
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Ahwahnee · Posted: Thu Sep 11, 2014 6:28 am Post subject:

This is the time of year for my favorite material -- election signs from losing candidates.

The signs I use are made of a plastic material that is formed like corrugated cardboard -- very easy to work with yet quite durable even in the wet.

I may still have some patterns that you can print on your printer and tape together - PM me if you want a copy.

shadetreetim · Posted: Fri Sep 12, 2014 7:36 am Post subject:

I used FRP (fiberglass reinforced panels). They are normally used to cover the walls of commercial kitchens, bathrooms, showers, etc. Pretty durable and easy to work with. You don't need much, but Home Depot / Lowe's sells 4X8 sheets.
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LandSailor · Posted: Fri Sep 12, 2014 10:58 am Post subject:

Coroplast is the name of the sign material. It will last for years and handles water superbly. (I have a piece of it as a temporary wall in our shower to test the custom shower setup I installed.) The melting point is 324°F/162°C and the performance range is -17°F to 160°F.

However, I have the GoWesty setup and aside from the fact that they don't include (nor sell) the screws and connectors, it's excellent. The only downside to the Coroplast (and this is just a WAG) is that it's not as "sturdy" as the TPE in the GoWesty set.

Merian · Posted: Fri Sep 12, 2014 11:47 am Post subject:

do I need to find a black sign or will the white show thru the grill?

?Waldo? · Posted: Fri Sep 12, 2014 12:28 pm Post subject:

The color will show through the grill some if viewed from the correct angle but it is not particularly noticeable. I made some out of yellow/black election signs some 6 or 8 years ago. Very easy and still look perfect today. If I have them off again some day I may spray them with some black paint made for adhering to plastic.

Syncroincity · Posted: Fri Sep 12, 2014 5:58 pm Post subject:

Are your originals still there, just in bad shape?

I made a set of replacements using fiberglass mat, but instead of resin I used black POR-15, using the remnants of my originals for molds.
Put down a layer of Saran wrap to separate the mold, then laid up 2 layers of thin mat.
The POR-15 remains flexible, as opposed to resin, and is super-easy to work with. Been running these for about 10 years now, no issues.
As a bonus, the finished product looks kind of like carbon-fiber. Razz

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ThankYouJerry · Posted: Fri Sep 12, 2014 6:03 pm Post subject:

By the time you "wait for shipping" and the amount of time it takes to do it right... you could be done with the new GW baffles for $39.95. What is your time worth and why reinvent the wheel?

http://www.gowesty.com/ec_search_results.php?search_phrase=Baffles

No affiliation... just a very satisfied GW Baffel customer Wink

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1990 Multivan - "Ohana"
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chojinchef · Posted: Fri Sep 12, 2014 6:12 pm Post subject:

Some folks enjoy the thrill of the chase, and will want to make these up from a recycled product. Good for you.

I went with the pre made Go Westy ones, and then spent the time trying to recreate and replace the panels that were once affixed to the rear of my grill.

The Go Westy ones are spot on, and seem to be made from a recycled rubberized compound that installs quickly.nice product.
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vanis13 · Posted: Fri Sep 12, 2014 6:50 pm Post subject:

Yeah, the GW ones look good.

1) Want to get the radiator in this w/e and 2) for me there is a high level of satisfaction on a DIY project using things I already have.

Optimist view - Think of all the greenhouse gasses I am saving not shipping and not throwing out the coroplast I already have.
_________________
83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace

www.SuperVanagon.com - some stuff I make

Gregicon · Posted: Fri Sep 12, 2014 7:15 pm Post subject:

ThankYouJerry · Posted: Fri Sep 12, 2014 7:40 pm Post subject:

unibagel · Posted: Sat Sep 13, 2014 4:23 am Post subject:

Are the baffles even needed?

chojinchef · Posted: Sat Sep 13, 2014 5:17 am Post subject:

?Waldo? · Posted: Sat Sep 13, 2014 6:53 am Post subject:

They will make a significant difference in the amount of air that goes through the radiator and consequently how well the radiator can cool. They aren't needed until they are. That one time when you overheat while climbing a 7% freeway grade in 115 degree ambient temps might make the deflectors seem really worthwhile.

madspaniard · Posted: Sat Sep 13, 2014 9:33 am Post subject:

I have the GoWesty kit sitting in my garage for over a year waiting for me to pull the grilles. Does anybody have recommendations or a parts list that includes all the hardware needed? I'm still trying to figure out why hardware is not included in this kit.
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Ahwahnee · Posted: Sat Sep 13, 2014 10:34 am Post subject:

greggearhead · Posted: Sat Sep 13, 2014 10:55 am Post subject:

It's not exactly the same thing, but older B-chassis VW & Audi models have cardboard type material that always degrades and goes away.

On my Fox Wagon, I built some new ones from Masonite because I had a free chunk of time, some masonite, and Foxes are known for being marginally cooled when you start pushing them.

I made sure to spray paint both sides for better water resistance. Should last several years or more.

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Altoona · Samba Member Joined: November 14, 2011 Posts: 505


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Radiator baffle DIY – what is latest material and template?
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