Lots of great info, for sure!
Dan, thanks for the amplification on the cowl flap's (variable-size exit's) effect on oil cooler performance. Very interesting. Perhaps related, as I don't have a ducted oil cooler, but after shrinking my exit, the impact on oil temp was also more marked than the impact on CHT, though both are higher during slower operations than before. However, both still move with speed changes, whereas it sounds like your CHTs are fairly steady. Still thinking through this effect.
Tom, great description of the corner seals...I'm all over that! Any chance you can post a pic? I think I get it, but you know what a picture is worth!

As for louvers, I completely agree. My thought with them is to make them interchangeable with flat plates, so for anything but racing, cooling is improved...and racing performance is maintained with little impact from cowl flap internal parts clutter...kind of a KISS "cowl flap" version. Then again, it's kinda like a ground adjustable prop...it leaves a lot to be desired in terms of flexibility. A variable exit also maintains cruise performance...and heck, every flight has some low-speed elements that could use additional cooling.
Testing appears to be on the horizon...good lead on the custom louvers Pooner.
Neat info!!
Cheers,
Bob