Defrost Vent Solution
#1
Defrost Vent Solution
Ok, I recently repaired and wrapped my cracked defrost vents. Of course I like many others would have loved to just buy some new ones and pop them in place, but again as we all know these two plastic vents come as part of the 3k dash assembly, that’s some expensive vents... So as I was looking at my options, just in case my repair didn’t go well and it seemed like a simple layover would work since the vents are tucked down into the dash pad... So I decided to make a template of the vents while I had them out. I started with paper, then a thin piece of sheet metal and have a final pattern made out of 1/8” aluminum. Now I still have some trimming to do on final pattern but I feel once done it should be a really good fit... I am thinking about finding a machine shop with a cnc machine and getting a quote for what these overlays would cost. Of course they will need to cut some louvers in the overlays. My thoughts were if they could make them so that both sides are finished, you can use the overlay for either side since they are mirror image. I figure that these overlays could even be used in XK’s that don’t have cracks as a preventative, kind of as a UV blocking shield. Would love to get everyone’s input and ideas on this.
points:
Needs to be a material that is somewhat UV resistant and certainly heat resistant
Needs to be material that has some flexibility because of the contour of dash, but strong enough that the louvers aren’t going to sag.
Needs to be a material that doesn't rust
Final product needs to be black in color or at least paintable or both.
Last edited by TexasTraveler; 08-20-2018 at 10:58 AM.
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Ranchero50 (08-20-2018)
Popular Reply
09-25-2018, 10:06 AM
Well I finally have what I believe will be the final set of the defrost overlays. I had the shop make some adjustments to make it as close to perfect as possible. I went ahead and wrapped the set with some wrap I had. As you can see I did bend the pieces slightly to mimic the curve of the dash. I will put some very thin double sided tape on the back side and install tonight when I get home to assure it is a good fit. I have spoken with the shop and it looks like the price for these per set if anyone is interested will be $70 of course you would need to add shipping cost for me to get them to you... They would be just the raw material, not wrapped or painted, that would be up to you to decide how you want to finish them... Once installed tonight I will try and get a few pics to show you them installed in car...
#2
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TexasTraveler (08-20-2018)
#3
Last edited by TexasTraveler; 08-20-2018 at 11:00 AM.
#4
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TexasTraveler (08-20-2018)
#5
Here is the prototype so far... I haven't had the opportunity to see if it will be cost affect to have CNC shop make them.. Maybe a member or vendor would have the machinery to go forward with prototype? Open to suggestions...
#6
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TexasTraveler (08-20-2018)
#7
I have not had the opportunity to look into what the options are. But certainly would want to do whatever makes it cost effective for the masses... I just hate that there isn't a simple solution for something that should be so easy to replace...
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#8
I think you'll lose a lot of volume with the smaller slots. Maybe it'll be made up by the pressure difference increase across the ports but there may be some increases in noise as well.
I was thinking more along the lines of a thin overlay or cover that uses as much of the original porting as possible. Or do an overlay and then a front and back formed panel with a couple aiming slats to direct the air flow. Tricky part to make on a small scale, especially if you try to make it look original.
Lasers and plasma don't play well with thin parts (heat). CNC needs good fixturing to hold the part steady. My machine only has a 18" X x 12" Y work envelope so I don't think it would cut the whole part in one pass.
I was thinking more along the lines of a thin overlay or cover that uses as much of the original porting as possible. Or do an overlay and then a front and back formed panel with a couple aiming slats to direct the air flow. Tricky part to make on a small scale, especially if you try to make it look original.
Lasers and plasma don't play well with thin parts (heat). CNC needs good fixturing to hold the part steady. My machine only has a 18" X x 12" Y work envelope so I don't think it would cut the whole part in one pass.
#9
I think you'll lose a lot of volume with the smaller slots. Maybe it'll be made up by the pressure difference increase across the ports but there may be some increases in noise as well.
I was thinking more along the lines of a thin overlay or cover that uses as much of the original porting as possible. Or do an overlay and then a front and back formed panel with a couple aiming slats to direct the air flow. Tricky part to make on a small scale, especially if you try to make it look original.
Lasers and plasma don't play well with thin parts (heat). CNC needs good fixturing to hold the part steady. My machine only has a 18" X x 12" Y work envelope so I don't think it would cut the whole part in one pass.
I was thinking more along the lines of a thin overlay or cover that uses as much of the original porting as possible. Or do an overlay and then a front and back formed panel with a couple aiming slats to direct the air flow. Tricky part to make on a small scale, especially if you try to make it look original.
Lasers and plasma don't play well with thin parts (heat). CNC needs good fixturing to hold the part steady. My machine only has a 18" X x 12" Y work envelope so I don't think it would cut the whole part in one pass.
#10
#11
So I dropped off my prototype to a shop yesterday that does water jet cutting. The guy emailed me today and said that to do a single set of these overlays would be $89.00 + tax so basically $100. He did said that if we were to do multiple sets that he would take off between 15%-25%. These would be the open cutout like Ranchero suggested. So I guess I will do a first set and see how they come out. I am going to meet with him on Friday to go over the cad drawing and make sure I get the cutouts were I want them to cover as much of the oem vent as possible but still having the widest opening for airflow. I will update with pics when I have them in my possession. Would like to know if there is any interest from other members to buy these, assuming they do the job of hiding/protecting the oem vents and look good of coarse.
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10XKR (08-22-2018),
guy (09-26-2018),
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#12
I would make the prototypes by hand with a fine tooth blade jig saw setup and wood files. Even a metal nibbler from Harbor Freight will eat through 16 aluminum like butter. No shears or tin snips as they distort the finish too much. Once the design fits and works, source vendor help. You'll find your drawings will not fit the actual space once cut and if you farm that work out it's a complete waste of the vendors time. Lock in a design and then source outside help. I think your idea has merit but is very difficult to execute well.
I actually like that Jaguar hid the vents behind / under the visible plane to the windshield. At best there is a dark strip of fabric and the vents disappear into it.
I actually like that Jaguar hid the vents behind / under the visible plane to the windshield. At best there is a dark strip of fabric and the vents disappear into it.
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TexasTraveler (08-22-2018)
#13
I would make the prototypes by hand with a fine tooth blade jig saw setup and wood files. Even a metal nibbler from Harbor Freight will eat through 16 aluminum like butter. No shears or tin snips as they distort the finish too much. Once the design fits and works, source vendor help. You'll find your drawings will not fit the actual space once cut and if you farm that work out it's a complete waste of the vendors time. Lock in a design and then source outside help. I think your idea has merit but is very difficult to execute well.
I actually like that Jaguar hid the vents behind / under the visible plane to the windshield. At best there is a dark strip of fabric and the vents disappear into it.
I actually like that Jaguar hid the vents behind / under the visible plane to the windshield. At best there is a dark strip of fabric and the vents disappear into it.
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#14
#17
My plan is to use a very thin 3m molding double-sided tape along the entire outer edge on the underside to hold in place, so rattle shouldn't be a problem. I think going with Ranchero's suggestion on the open slots should take care of any blower noise, but I will certainly test before and after install. TBH, I haven't used my defrost once, but I know some do depending on climate... Cost for one off set was quoted $75-$90... I have made friends somewhat over the past two weeks with the guys at this local shop and I did a lot of the ground work for the design, so they only charged me $60 cash today for the two pieces... Not sure if that price will hold up on future sets but I would think the more we had made at one time would help to keep cost down. Not sure about shipping cost, but pieces are made out of 16g aluminum, so weight is very light... I am not trying to make anything off of these, so whatever shop charges is what it would be. The shop is 5 minutes from my work, so its not an inconvenience, would just be doing it as a courtesy for other members...
#18
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TexasTraveler (08-29-2018)
#19
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TexasTraveler (08-29-2018)