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Old 06-12-2015, 03:18 AM   #1
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Default Vent window air inlet DIY

I have access to a laser cutter at school so I decided to make my own vent windows. I had to choose between the NACA air inlet, or the project-g snap cap thingy. It took a while to find the same round vent that those have so thought I'd post it up.
<br /><a href="http://www.aircraftspruce.com/menus/ap/airinletkits.html" target="_blank">http://www.aircraftspruce.com/menus/ap/airinletkits.html</a>
<br />I'll also post the NACA duct I use whenever I find one.
<br />Getting these.
<br />https://www.pegasusautoracing.com/pr...p?Product=3627
<br />After I throw together the vent window in CAD I'll post it up too!

Last edited by aidandj; 06-12-2015 at 03:40 AM.
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Old 06-12-2015, 08:48 AM   #2
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These will be sweet, and getting them to be exact side to side will be awesome.

Do NOT under estimate the importance of blocking them off though. They will be too cold at PIR in March/September morning sessions, and the drive there.
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Old 06-12-2015, 09:25 AM   #3
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I am very interested to see how this turns out....
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Old 06-12-2015, 05:51 PM   #4
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Awesome! I have a laser cutter at school too and was thinking about doing the exact same thing. If yours turn out well I'd definitely be interested in your cad file so I can cut myself a set.
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Old 06-16-2015, 12:42 AM   #5
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<p>Thinking about going with the pop out window instead. After figuring out I should be using lexan, and that cutting lexan with a laser cutter yellows the **** out of the cut I think I will be using a hole saw and laser cutting the outer edge. deezums pulled his vent windows and is doing some measurement now.</p>
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Old 06-16-2015, 01:38 AM   #6
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I think I've got something workable, I'm gonna cut a chunk in cardboard tomorrow to check how close I am. I'm thinking I'll wait for my pop-outs then, so I can use the cardboard templates to find the best placement. It took all my best data logging tools, but this is what I've got.







I'm thinking of using the flat pop outs that fit in 3 1/4" round hole, I forget who, but drilling for a long locking cotter pin seems like a perfect DD solution.

Lexan isn't the best for burning, sometimes it makes corrosive or poisonous gas, other times it just always cuts like garbage. I'm trying to figure how I might be able to cut a template then use a router and bearing to cut lexan, because anything, naca or popout, would be easy then.

I've got a DXF if anyone wants, no guarantees on how accurate it is!
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Vent window air inlet DIY-cl8p2wd.jpg   Vent window air inlet DIY-z6nepjw.jpg   Vent window air inlet DIY-ehorav3.jpg  
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Old 06-16-2015, 10:38 AM   #7
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I've got Project G Vented Windows and LOVE them. They're a life saver with no AC. Given the time and effort to pull this off I feel like $80 is going to be tough to beat by building them yourself.
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Old 06-16-2015, 05:00 PM   #8
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Nah, I've got the material already, plus a laser cutter, and the two popouts can be had on ebay for $25 bucks.

Even if I had to pay for lexan, I'd be at $20 bucks total or thereabouts for two, with 5 minutes of laser cutting time.

Sans laser cutter, yeah I'd buy the expensive acrylic ones. Otherwise I'll make my own from safer lexan.

Vent windows are $97.99 after shipping, plus tax if you live in cali. Easy peachy, like 1/3 the cost.
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Old 06-16-2015, 05:03 PM   #9
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Lol @ 80 being tough to beat. These materials are cheap.
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Old 06-16-2015, 10:44 PM   #10
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I did some "nesting" and two windows fit inside the 300x500mm cutting area, barely!

So a 12x20 piece of lexan for two windows, home depot conveniently sells 12x24 sheets for $15 bucks which is cool because I have acrylic, not lexan.

I found a neat trick over on the spec miata forums. A pint glass and some sandpaper makes a excellent mandrel to perfectly circularize and enlarge the hole to fit the duct snug.

Now I'm thinking screw the hole saw, I'll just sand through the yellowed cut with beer glass.
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Old 06-18-2015, 03:06 AM   #11
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I think I've got something that will work, unfortunately I don't have enough laser power to cut lexan. I cut two different hole positions, now I wait for the snapvents.

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Old 06-19-2015, 12:29 PM   #12
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What's the best method for removing the glass?
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Old 06-19-2015, 12:42 PM   #13
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http://clubroadster.net/vb_forum/86-...e-windows.html
I know CR.net, but deal with it. Sometimes there is useful stuff there.
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Old 06-20-2015, 09:21 PM   #14
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Quote:
Originally Posted by Monk View Post
What's the best method for removing the glass?
Remove side window and front vertical window track. Then the window just slides out with its seal.
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Old 06-20-2015, 11:57 PM   #15
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That's what I was after.
I guess I should have remembered that after taking apart a few doors over the winter.
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Old 06-21-2015, 12:21 AM   #16
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This is awesome.
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Old 06-21-2015, 12:22 AM   #17
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Humming. Does your waterjet place do vent windows?
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Old 06-21-2015, 01:52 AM   #18
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Quote:
Originally Posted by aidandj View Post
Humming. Does your waterjet place do vent windows?
My waterjet place does whatever I send them. Styrofoam, ceramic tile, balsa, you name it! They only stock Aluminum, 304 stainless, and A36 mild though. I have to provide the material for anything else, which isn't too big a deal, I just drop it off after I place my order, they return me parts+scrap. If they have had a bad experience with something in the pass, they'll warn me in advance it may not work out and offer to do a test cut free of charge. Acrylic would cut fine.
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Old 06-21-2015, 02:44 AM   #19
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We need lexan, acrylic likes to break into little pieces.

In my experience plastic cuts fine if you remove the top plastic protection sheet, otherwise it lifts it and makes a mess on starts. I used to use hardyboard backer sheets so the jet doesn't damage the backside if a cut happens to cross a table slat.
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Old 06-21-2015, 07:03 PM   #20
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Lexan then, no problem. Send me the CAD file, I'll get a quote on it!
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