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Halloween Prop Menu : Fog Chiller

Fog Chiller

I modified a set of plans off another website for this effect. This Fog Chiller allows you to simulate fog that stays close to ground level. The problem with fog machines is that the fog coming out of them is hot. Since heat rises, so does the fog. A Fog Chiller cools down the fog coming out so it stays close to the ground.
  1. Buy your supplies:  You will need to have these items:
    • Fog Machine and fog fluid.
    • 48 Qt. Cooler
    • 4 inch hole saw and drill
    • (2) 4 inch 90s and a length of 4 inch ventilation duct.
    • (2) small pieces of wire screen and (2) 4 inch hose clamps
    • 5 foot length of 4 inch diameter flexible dryer hose.
    • Silicone Sealant
    • 3 inch 12 volt computer exhaust fan
    • Pushbutton switch
    • 12V Universal power adapter (120VAC down to 12VDC)
    • Coaxial DC power jack (panel mount)
    • Misc. tools and hardware.

  2. Cut Holes in Cooler: You will need to cut two holes in the cooler, one in each end (see pictures below). The holes don't have to be perfectly placed, but I chose to measure out the exact center of each side (it just looks nicer). With your drill and 4 inch hole saw, cut both holes.

  3. Put in the Duct: For the outlet hole you will need to cut a straight piece of duct about 6 inches long. It should be inserted into one of the holes, centered so that there is an equal amount of duct sticking out of the outside and inside of the cooler. For the other hole where the fog will enter the cooler, you will have to construct that differently. Connect the two 90 degree pieces of duct together so it makes a 'U-shaped' piece. Cut another straight piece of duct about six inches long and connect it to one of the 90 degree pieces. Once connected, insert the end of the straight piece into the cooler so that about two inches sticks out on the inside. See pictures 1 and 2 below. You will need to buy a reducer that will adapt your 4 inch duct to the smaller size of the outlet of your fog machine.

  4. Silicone Sealant: Fill any gaps between the duct and the cooler (on the inside AND outside) to make an air-tight seal.

  5. Wire Screen: Cut two pieces of wire screen about six by six inches. On the inside of the cooler, put the two pieces of screen over the duct and fasten them with the hose clamps.

  6. Fan and Switch: First you need to attach your fan to the outlet piece of duct on the inside of the cooler. I put two pieces of 6-32 threaded rod through the two top mounting holes of the fan, then put two nuts (one on either side of the fan) on each piece of threaded rod to hold the fan tight. I then loosened the hose clamp of the outlet duct and slid the threaded rod pieces connected to the fan underneath the hose clamp and tightened it back down. To mount my switch and power jack, I just drilled holes on the outlet side of the Chiller, pulled the wires through to the inside of the cooler and sealed them in tight with a tube of Liquid Nails. (See pictures below)

  7. Finishing Up: Now you are about done. Put a bag or two of ice inside the cooler, connect a piece of flexible dryer hose to the outside of the outlet duct, put the fog machine on top of the cooler and connect it to the duct and fog away!

Fog Chiller

Inside of

Power jack
and Switch

Fan Mounting

Chiller in Action

Fog Stays Low

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