I think I have decided. I have that 6-1/8" x 4-1/2" x 3/16" piece of aluminum alloy plate, I rounded the edges, cleaned maybe 30 years dirt and grime off ... & the DSII is 5-5/8" x 4-1/4" x 1-3/4" so the piece is about perfect for a mount surface. The alloy is hard enough to take threads too. I Measured under the hood, it'll fit against the inner fender apron wall like stock, all the way to the radiator core support. I think the air might flow some better once it got away from that back corner behind the hinge, and maybe cooler too away from rising exhaust manifold heat, and the thick aluminum plate should act as an additional heat sink. I can easily extend the truck's portion of DSII harness with those plugs, maybe a foot and protect the wire too? I'll space the DSII out from the aluminum plate with some long steel coupling nuts to transfer heat to the plate and provide air flow between them.

I might just run a flex pipe or hose from old round hole in the core support (it was for AC hoses but they are gone now) over to the fender apron to direct cooler air towards the DSII ... even without moving it, like just space it out where it's at? Make the pipe easy to remove.

Took a pic, drew idea on one. Tape measure laying in place. Might still move it 10" and space it out too.

Could use simple dark painted exhaust pipe, just poke into hole and zip tie at ignition box end? If I moved it would only be 18", a 12 0r 14" piece would get air over there when the truck is moving.

Simple enough for a warmer day.

 

Well, a year passed. Still in my mind, but where I guessed the potting was for vibrations, I've been thinking that was maybe wrong, that it is likelier to help with heat transfer from interior generated component heat to the housing that acts like a big heat sink? I might dig out the OEM that had lost it's potting on the fender apron and had quit working a time or three before I finally replaced it ..... and even then once cooled, it worked again. I wonder if it would help to fill the inside with J B Weld? Likely be better than spray foam.

Certainly wouldn't hurt to fill the AM one that lost it's potting stored in a box behind the seat.

I could still move it.

05-22-2026: Still intend to attack this ... just forgot.

 

Today, after my walk, listening to rain, I was thinking, then looked, and found a link to this post from 2016, so quoted it here now ....I have been thinking of my move options, I'm not crazy about mounting it under my driver side kick panel fresh air vent, and any moves in the engine compartment still have it in a very warm environment. I looked under the dash, it's pretty crowded there and while I could get it up there, it'd be in my way like if changing bulbs or a switch out, etc. I'd be dropping it to do those things. I have no reservations about splicing, soldering, etc.

It struck me, maybe under the driver's seat, still open side up of course. It should maybe be fastened to metal to help with heat dissipation, but I once had a '81 Ford police car and it was mounted on a plastic inner fender liner under the hood.

I would think under the seat would be much cooler.

Anyway, just a thought at the moment.