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Hi David,
1. Nylon nuts and bolts are available at **** Smith Launceston, I have purchased them for mounting power transistors to heatsinks, may also be at the new Jaycar shop.
2. Polystryene is a better insulator (has a less thermal conductivity than perspex I'm told). If sandwiched between two aluminium plates one the cooling vane the other having theh the heatsinks and fan attached it should be pretty stong, if not try the perspex. It is actually better if the insulation protrudes further out (about 10mm) than the diameter of aluminium sheets. It lessens the thermal feeback due to air flow around the diameter or edges.
3. If you have the aluminium powder coated make sure there is a bare patch where the peltier modules mount, the powder coating will effect the close coupled thermal conductivity required between the module and the aluminium.
Hope this makes sense. Good luck with it
Kind regards, IanG
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