Hi again,
Thanks for the quick response Canoe. I am indeed trying to improvise on the original design, but that's only because I'm having trouble sourcing a lot of the spec'd parts. I've decided not to mess around with the fan specs since that's one of the few things I CAN get easily. I'll bring an lower CFM fan with me to see how it works... unless I get too distracted to bother with the experiment. I'm going to go with a high powered 120/140mm fan as suggested. The endless breeze looks like a good idea, but the one I found looks too big for my setup -- unless I found the wrong one? I'll keep looking around. I'm doing the 5 gallon pail cooler.
I'm trying to stay as true to the design as possible. As mentioned earlier in the thread somewhere, I'm of the mind that it's better to master the basics that you folks have already painstakingly experimented with. However, I'm having a lot of difficulty sourcing a cooler pad where I live. I'm in Vancouver, Canada. It's humid all year round here, so swamp coolers and their associated parts are non-existent here. In fact, most people here have never heard of such a thing. I've found an online supplier in New Mexico that will ship to Canada. After inquiring about shipping costs, I found that the cost of a pad (actually, a roll that could make 3-4 coolers) jumped to over $100 CDN. Ouch! I have yet to convince friends to co-invest. Obviously this is plan A though.
I may have found an alternative. I can get Excelsior here (i.e. loose Aspen wood wool). I have no idea how much I'll need for one cooler, but I have seen many designs that use aspen wool PADS. I figure I'll need to fashion an inner and outer tubular structure to support the loose wool, possibly using wire mesh. My thinking is that it needs to form a wool "pad" seal from the bottom of the pail to the lid. Furthermore, there needs to be a bit of a space between the walls of the pail and the pad (?). Would the wire mesh alone provide enough of a space, or are we talking more like a 1/4 or an 1/8th of an inch? Wow. Am I over-thinking this or what?! Here's the link for the excelsior:
http://www.uline.ca/Product/Detail/S-12 ... dyed-Aspen
Oh, and I do plan to have an exhaust vent built into the structure. Canoe, I believe I saw an earlier post in which you said it was best to have a passive vent near the top of the structure? I plan to install furnace filter material in said vent, and have a way to close it when the fan is off and not providing positive pressure. My guess is that my vent should be near equal in area to my intake? My intake from is a 5 inch diameter pipe (19.6 inches squared). Should the vent be the same size? Bigger/smaller?
I hope my over-thinking doesn't scare everyone away... I kind of have to improvise.
Thanks FIGJAM and Canoe,
D