So I ordered this oil cooler kit from ft86speedfactory.com for my 2015 FRS in December.
http://www.ft86speedfactory.com/full...l#.Wm4nVqinFhE
I was able to install it without much problem using the provided instructions, and it worked fine for daily driving and spirited mountain driving for about a month since then. But then I took it to a track day at Mazda Laguna Seca...
After the first 20 minute session I took a paper tower and checked all of the connections for oil leakage. All of the threaded points, on both the cooler and the sandwich plate, were holding tight with no signs of oil leak. However, there was a very small amount of oil seeping past the gasket between the sandwich plate and the spacer. The amount was extremely minor, a smudge of oil visible on the paper towel.
After the second session I found that the leak had become much more significant. A larger amount of oil had pushed past the same gasket and had splattered around the inside of the engine bay. I cleaned up the oil and checked the oil level of the engine. The oil level of the engine was not noticeably affected. I used an oil filter wrench to tighten down the oil filter in the hopes that it would help stop the leak. I noticed that even after tightening the filter, I could rotate the sandwich plate with a moderate amount of force.
After the third session the leak was the same. More oil splattered around the engine bay. I removed the oil filter and inspected all of the gaskets: One on the underside the the spacer, one under the sandwich plate (this appeared to be the source of the leak) and one on the oil filter. All appeared normal with no obvious sources of the leak. I reinstalled the parts and used a wrench to tighten the pipe piece with screw that holds the sandwich plate down onto the spacer. I then screwed the oil filter back in place, hand tight.
After the fourth and fifth sessions the leak was still the same, each time with new oil in the engine bay. The oil level in the engine remained not noticeably affected. I cleaned the engine bay of oil after each session.
After driving home, approximately 2 hours, (not pushing the engine) there was new oil spattered around the engine bay.
So I talked to FBM and they said they have had some issues with some spacers, so they sent me a new spacer and O-rings. I put them on, putting a bit of torque on the center bolt with a wrench and hand tightening the filter. I started up the car, and guess what: The leak is way worse. I left it idleing and watched oil slowly drip out of the space between the sandwich plate and spacer. Here's video and a picture.
[ame="https://www.youtube.com/watch?v=D4mjG_9Ml0Q"]2015 FRS Full Blown Motorsports Oil Cooler Sandwich Plate Leak - YouTube[/ame]
I talked to FBM on the phone and they seemed to have no idea what to do, which is.... disappointing.
Anyone have any ideas on how to fix this?
Solution
After working with FBM I was eventually able to fix this problem, and now the cooler has stood up to a couple months of daily driving, some spirited mountain driving and a track day without issue. See my posts for more detail and oil temp data.