Todd,

I'm going to build a returnless system based on your design.  I found this fuel cooler at Jeg's for about $40.  Jeg's P/N 771-1009.  The finned area is 4.5 X 5 X 7/8 (inch), which I think is a little bigger than the one you made.

http://www.jegs.com/cgi-bin/ncommerce3/ProductDisplay?prrfnbr=3532&prmenbr=361

I'm sure it's nicer looking than anything I could build myself.  I'll post pictures of my alternator bracket one of these days to prove it.

Bob White

--
http://www.bob-white.com
N93BD - Rotary Powered BD-4 (real soon)