DIY Vents / Let the hot air out

[snowfever27]

Last season I rode with un-insulated hiking boots because my XF7000 dumps so much heat out the foot wells. Heat robs power.... so I started looking at ways to get rid of the engine/exhaust heat. First thing I did, which was free, was make the upper vent hole in the exhaust side panel bigger. Hopefully now I will pick up almost 50% more air flow through the larger vent hole. The black panel shown is stock, white is modified. I used a hack saw blade and then cleaned the edges up with a utility knife with a brand new blade. I was a little aggressive, the vent is almost larger than I’d like, but it sure will breath better now.

After looking at some of the aftermarket vents I decided to pick up some 1/8” abs textured plastic at the hardware store and make my own. This plastic is rugged and I’ve used it before. I made a template out of poster board, traced it onto the plastic with a fine point silver sharpie marker and cut it out with a jigsaw. I cut very slowly, and very carefully. I’d be lying if I said I got it right the first try. I bought some ‘pet rated’ window screen and then stretched it over the abs cut outs and superglued the screen to the plastic. Then I drilled holes with a 1/2 Schrader bit and riveted the vents on.

The vents cost me a total of 10.49. 6.49 for the plastic, 4.00 for the screen material. But they took about 2 hours to make. Below is the drilling template I made out of the left over plastic.

Also, I removed some of the foam around all the stock vents. The vents on the bottom plastics are all but blocked by that foam, so I cut a few inches out so that air can actually move through the vents now.

 

[FrozenTows4]

Looks like some very nice work! Let's see the fully assembled product. I'm kind of following, but not 100%.

 

[Sevey]

What hardware store did you get the abs plastic from?
Never seen that product before.
Nice job
MS

 

[snowfever27]

Looks like some very nice work! Let's see the fully assembled product. I'm kind of following, but not 100%.

I’ll post some better pictures this weekend for you, I’m away on a work trip until Sunday.

 

[snowfever27]

What hardware store did you get the abs plastic from?
Never seen that product before.
Nice job
MS

Aubuchon Hardware, I’ve only seen them in VT, MA, and NH. But you can get it online too, partsexpress has it. Go to their website and search for 1/8” textured abs plastic. Buy a few sheets, make some vents for your buddies too. Here:

https://www.parts-express.com/Search.aspx?keyword=1/8” abs plastic&sitesearch=true

 

[snowfever27]

My wife took some pictures for me. This is the finished product.

This is the stock sized opening in the side panel.

This is the modified side panel opening that I trimmed to make it larger.

 

[FrozenTows4]

That most certainly should let the heat out! Bonus material....warm air blowing on your legs & torso.

 

[cannondale27]

That most certainly should let the heat out! Bonus material....warm air blowing on your legs & torso.

Yes its very nice on the legs!

 

[Mtnviper]

Looks good, nicely done.

 

[Sevey]

Question - did you use an olfa cutter to cut the plastic.
Did you do anything to round the edges
What did you find was the best glue to hold the screen on

Ms

 

[JStat17]

nice work..........

 

[snowfever27]

Question - did you use an olfa cutter to cut the plastic.
Did you do anything to round the edges
What did you find was the best glue to hold the screen on

Ms

I used an Olga knife to take the edges down a little after I had cut the shape out. But you need something more heavy duty to do the majority of the cutting. I traced the shape I wanted. Drilled 3/8 holes in strategic spots so I could use a jigsaw to cut the shape out.
It was a little tricky. I cleaned up a few jagged spots with a flat file. I’m going to make some more vents for the side panels and I take some better step by step pictures.

 

[snowfever27]

I used an Olga knife to take the edges down a little after I had cut the shape out. But you need something more heavy duty to do the majority of the cutting. I traced the shape I wanted. Drilled 3/8 holes in strategic spots so I could use a jigsaw to cut the shape out.
It was a little tricky. I cleaned up a few jagged spots with a flat file. I’m going to make some more vents for the side panels and I take some better step by step pictures.

I scuffed up the gloss side of the plastic with 220 grit sand paper, then placed the screen on the scuffed side, then ran a super glue soaked brush over them. Carefully.