My Honda XR650L Oil Cooler Project

[SpudRider]

Originally Posted by katoranger

Check with the local places that do window screens.

Thank you for the good tip, Allen!

Spud

[Weldangrind]

Originally Posted by SpudRider

I have not yet plumbed my oil cooler into the stock oil lines. The weather is cool, and I am also awaiting shipment of my NPT brass fittings. Therefore, I intend to test my placement of the oil cooler by riding the bike with the oil cooler unplumbed. For the final installation I will also need to cut some holes in the front fender to allow good air flow to the oil cooler. However, I don't plan to perforate my front fender until the muddy part of the riding season is past.

Spud

I haven't examined one of these Polisport fenders, but they might do the trick without the mesh and holes: Polisport Front Fender with RADS Scoop You certainly can't beat the price, and I'm sure that the CRF version can be made to fit your bike.

[Weldangrind]

Originally Posted by SpudRider

Can anyone recommend a good size wire mesh, and a good place to purchase it?

The galvanized material will eventually rust, so I'd look to a local metal shop for stainless. I have a piece of woven stainless that I intend to use for an exhaust screen, and I think it came from Metal Supermarket. Perhaps you have a shop like that.

[SpudRider]

Originally Posted by Weldangrind

I haven't examined one of these Polisport fenders, but they might do the trick without the mesh and holes: Polisport Front Fender with RADS Scoop You certainly can't beat the price, and I'm sure that the CRF version can be made to fit your bike.

That's an interesting fender, Weld. Thanks for providing the information, and the link! I wonder if the radiator scoops would deflect enough air to cool the oil? My oil cooler is located directly behind the fender. Brother Andy has warned me the heat from the oil cooler might melt my front fender if I am not careful. 8O I was thinking the holes in the fender would help prevent this from happening. :?

Spud

[SpudRider]

Originally Posted by Weldangrind

The galvanized material will eventually rust, so I'd look to a local metal shop for stainless. I have a piece of woven stainless that I intend to use for an exhaust screen, and I think it came from Metal Supermarket. Perhaps you have a shop like that.

This afternoon I found some 1/8", hardware cloth at the local, CAL-Ranch store. It is galvanized, but it only costs $4.99 per running foot; the roll is 3 feet wide. The helpful gentlemen at the store said they would see me 1/2-foot of the mesh, so I could get enough screen to cover 6 fenders for $2.50. However, I think I could also get aluminum, plastic, or fiberglass mesh from some other source. What do you guys think?

Spud

[Weldangrind]

Plastic that looks like expanded metal would be very good for your project, although I'm not sure where to find it.

[Weldangrind]

Originally Posted by SpudRider

That's an interesting fender, Weld. Thanks for providing the information, and the link! I wonder if the radiator scoops would deflect enough air to cool the oil? My oil cooler is located directly behind the fender. Brother Andy has warned me the heat from the oil cooler might melt my front fender if I am not careful. 8O I was thinking the holes in the fender would help prevent this from happening. :?

Spud

For the $8.00 investment, it would be interesting to learn if the scoops would direct air to the cooler. You'd get a good idea of how the air would flow once you installed it.

[SpudRider]

Originally Posted by Weldangrind

For the $8.00 investment, it would be interesting to learn if the scoops would direct air to the cooler. You'd get a good idea of how the air would flow once you installed it.

I can't tell from the photograph, but I don't see how the the air scoops can accommodate the fork boots on my XR650L. :? If the fork boots fit inside the fender, won't they block the air flow? Thank you for providing the interesting link to that fender, Weld. However, I must admit, I also don't care for the looks of that fender.

I can buy a number of vented fenders. Here's an Acerbis vented fender.



Here's a Polisport vented fender.



However, I really want to cut air holes in the stock fender. If I screw up, I can always buy another fender. Also, this afternoon I just got the front fender shimmed properly to clear the oil cooler, so I don't want to repeat this process all over again with another fender.

Spud

[pete]

Nice job..
I have made a cooler for my XT
getting it on is a winter job..
The Xt is dry sump so I will pumb
it into the return line back to the
oil tank in the frame..


By petenz at 2012-03-29

[Weldangrind]

pete, that's really cool! Where did you find a heat exchanger like that?

[SpudRider]

Thank you, Pete. I am using the same plumbing method as you. The oil pump will feed oil into the bottom line of my oil cooler. After the oil exits the top of my oil cooler, it will flow into the oil reservoir in the frame. I plan to install a digital temperature gauge in the oil line before it feeds into the oil cooler, so I can monitor the oil temperature directly after the oil exits the engine.

Spud

[pete]

Originally Posted by Weldangrind

pete, that's really cool! Where did you find a heat exchanger like that?

I made it...
2 peices of 40mm solid 200mm long..
bored a 6.5mm hole though them then
put the fins in with a 3mm parting tool
leaveing a 12mm dia section up the centre
14mm deep fins..then mill flats on so they
can fit togeather

[Weldangrind]

You've got skills! Did you make that on a milling machine? I can see the fitting that joins the two reservoirs; does fluid fill one cylinder and then dump into the other?

[pete]

Originally Posted by Weldangrind

You've got skills! Did you make that on a milling machine? I can see the fitting that joins the two reservoirs; does fluid fill one cylinder and then dump into the other?

Most of its made in a lathe apart from the flats that were milled..
oil goes in one section flows across though the brass nipple into
the other sction then out... It was only going to be one section but
I had the room so made a second section in the end..

I have a lathe & mill in my home shop..


By petenz at 2012-03-29

[SpudRider]

I found some plastic, 1/8" mesh at the following website.

http://www.countryporch.com/darice/view.asp?item=33400

What size mesh do you guys think I should get? Perhaps 1/4" mesh is less likely to clog with mud?

Spud