Vent Grill Repair

[ghostler]

Over a year ago, the right lower fairing vent broke. For some odd reason, which appears to be related to vibration and who knows what (I bought it used), a chunk fell off that held the bottom of the vent. This included the fairing skin flange and the vent's mounting flange. The chunk was irrecoverable as it fell to the roadside during a ride to who-knows-where.

While I got the fairing apart to replace speakers, I came up with the following fix.

I trimmed the broken off vent flange with a hacksaw blade. Then I made a new flange using HVAC (heating, ventilation, air conditioning) sheet steel flashing. It is about 28 or 30 gauge galvanized sheet steel that comes in a roll about 6 inches wide. Using tin snips, I cut a 2 inch x 2 inch piece, bent a 1/2 inch 90 degree flange on it. I cut another 1/2 inch x 2 inch for the front cover. Using a hand held sharpened center punch, carefully dimpled the hole locations in the sheet metal, drilled 1/8 inch holes. With small pieces of duct tape, I temporarily held the new flange in alignment, drilled matching holes in the plastic. Then I pop riveted them together using 1/8th inch diameter pop rivets with backing washer.

Once I had the first hole drilled in the fairing vent opening, I used a pop rivet to temporarily hold the piece in alignment while I drilled the other hole. Then I remounted the vent grill with its good upper screw and nut. Using longer 1/8 inch rivets, I pop riveted the bottom with backing plate to the fairing.

[ghostler]

Here's how the repair looks from the back side of the fairing.

At a later time, I will mask this off and spray it with black paint. I felt it easier to do first, then paint as I don't have black rivets. Also, I decided to semi-permanently rivet the vent grill assembly to the fairing. I could have used screws and nuts, but it was simpler to do as this is a part that is rarely ever disassembled. Aluminum rivets are easy to drill out and replace.

One thing I had to do is using the metal edge of a tool to bend the edges of the sheet metal to contour so the ductwork could mate to the vent grill. If I had to do again, I would trim the back about 3/16 inch narrower on each side, so no bending was required. Also, initially I made the flange repair mount holes too close to the corner, which then didn't allow the rivet backing washer to sit flat. (These are the two extra holes in one of the photos.)

However, I am in no danger of vent further breaking now that it is fixed. It reminds me of some of the helicopter airframe repairs I've seen done on older helicopters. Looks good, but a close eye will notice it as a repair. It certainly beats having to shell out say a hundred dollars for a used fairing for such a small discrepancy.

[Mr Jensee]

I know it is too late now but for everyone else with broken vents, I was at an 18 wheeler accessory supply the other day and they had our lower vents there in chrome no less. I am thinking of getting a couple just for the bling. Check to see if you have a big truck supply in your neighborhood. If you don't I would be happy to purchase one or two here and ship it to you, at your cost of course.

As for spray painting the repair you might want to just check out you local auto supply for a Duplicolor touch up applicator in black. Works for me and I didn't have to spray paint small areas. BTW, great job on the repair. Necessity really is the mother of invention.

[ghostler]

You're welcome, Mr Jensee.

About the only potential "gotcha" I see is getting a good enough fit between the aftermarket vent grill and the ductwork. There might have to be some adapting to get that to work, which would make for a good "how to" for others who want to give it a shot.