My Honda XR650L Oil Cooler Project

[Weldangrind]

The slots seem to be closer to what the aftermarket fenders have, so that's my vote.

[SpudRider]

Originally Posted by Weldangrind

The slots seem to be closer to what the aftermarket fenders have, so that's my vote.

As always, thanks for your input, Weld. I think vertical slots will drop mud, and clean themselves better than horizontal slots. Do you have any recommendations regarding slot width and length?

The Honda fender is pretty tough. I think if I leave enough material between slots, the fender can absorb rock hits without fracturing. I also think slots might spray less mud on the oil cooler than a larger hole covered with hardware cloth.

I'm going to aim for 3/4" inch clearance between the fender an oil cooler, as you suggested.

Spud

[Weldangrind]

I think that the slots as you have them laid out would be good. How do you plan to trim the slots?

[FastDoc]

That's my question too. Maybe a router?

For me the holes would be easier to make cleanly with a step drill.

[SpudRider]

Originally Posted by FastDoc

That's my question too. Maybe a router?

For me the holes would be easier to make cleanly with a step drill.

Thank you so much for the "step drill" idea, Brother Bill! I certainly do plan to use a step drill, no matter what pattern I select.

Originally Posted by Weldangrind

I think that the slots as you have them laid out would be good. How do you plan to trim the slots?

If I cut any slots, I plan to use a "step drill" to punch holes at each end of the slot. Then I can use a small cutoff wheel on my Dremel Tool to "connect the dots," and manufacture the slot. Here are the current, favorite hole patterns I am considering.









If I cut slots, I want to keep them about 3/16" wide, to maintain fender strength. I also want to space the slots about 5/16" apart, for the same reason. I would make the slots about the length of a Dremel cutoff wheel, to minimize labor, and to maintain the strength of the fender. Finally, I would stagger the slots in each row, also to maintain the strength of the fender.

Spud

[SpudRider]

I'm going to buy these Harbor Freight, step drills today.

http://www.harborfreight.com/3-piece...lls-91616.html

Once again, thanks for the superb tip, Brother Bill!

Spud

[SpudRider]

How do you guys like this pattern?



I want an attractive pattern, that is not too difficult to manufacture. However, function is more important to me than form. I want a hole pattern that maximizes the following attributes.

Provides good air flow
Cleans itself from mud
Protects against rocks
Maintains fender strength
Looks as attractive as possible

Spud

[FastDoc]

Originally Posted by SpudRider

I'm going to buy these Harbor Freight, step drills today.

http://www.harborfreight.com/3-piece...lls-91616.html

Once again, thanks for the superb tip, Brother Bill!

Spud

You're welcome. You will be impressed at the perfectly clean hole they make. Those are the same ones I use. Remember to put some tap to tell you where to stop so you don't drill a size too big.

[FastDoc]

As far as the specif pattern goes you can't go wrong.

No matter what you're going to run cooler than stock. You win no matter what. :wink:

Personally I'd go with holes rather than slots. Faster, cleaner, easier.

Personally I know I'd not cut a perfectly straight line with a Dremel, and my experiance shows that cutoff wheels don't do so well on plastic. The plastic overheats, melts, and makes a mess and 'clogs' the cutoff wheel in short order. :?

I'd drill holes and go for a ride and declare victory. 8)

[SpudRider]

Here are two more ideas.





After all, my bike is a Honda XRL.

Spud

[Weldangrind]

Originally Posted by SpudRider

How do you guys like this pattern?

That one makes me dizzy.

I agree with Doc on holes being easier. I've struggled with trimming plastic before, and that's why I asked what you used. I'll trim the new blue fender to suit the TS185, and I don't want to make a mess of it.

[SpudRider]

My Dremel tool worked great when I trimmed 2 inches off the front of my XR650L's fender. I guess you guys don't like the Xs. :?

In any event, drilling holes is certainly much easier, especially with the step drills. I suppose starting with fewer holes is better; I can always add more holes later, if I wish. What do you guys think of this pattern?



Do you think I should drill 3/16", or 1/4" holes?

Spud

[FastDoc]

Hey I just had an idea :idea: . Go figure. :roll:

Don't drill anything yet.

Ride it with no holes and monitor the oil temp. Maybe INSULATE the cooler so you have a starting point to follow.

Then un-insulate it and retest. Then drill some holes and retest. See if more holes helps.

This should really amuse the OCD scientist/engineer inside ALL us Chinariders!

[katoranger]

I would go with 1/4" holes after experimenting with the no holes test.

The holes will be easier to make. With the step drill you can start at 3/16" and then move to 1/4". If that is not enough move to the slots. Final resort would be the mesh I sent.

I think you will be able to clean it enough with a stick if it plugs up.

[SpudRider]

OK. If I space the fender 3/4" away from the oil cooler, the fender should not melt.

I could duct tape a sleeve of cardboard around the oil cooler to establish baseline temperatures without the oil cooler. Then I could remove the cardboard to measure drops in oil temperature with the stock fender. I could drill a few 1/4" holes, and once again note oil temperatures. If oil temperatures drop with a few holes, I could drill more holes, if desired, to discover if oil temperatures drop even more.

If necessary, I think I can clean the plugged, 1/4" holes by poking my ignition key through them.

Spud