I want to put mesh grills on my fairing vents
The standard material for this modification is gutter guard from Home Depot, Lowes, Wal-Mart, etc. This is the mesh that is used to cover home gutters and keep leaves out.
The project featured here used automotive grill material from an Auto Zone-type accessories store. It comes in a big, flat sheet and is a little more expensive than the gutter guard, but is also much stronger.
If you can't find something you like locally, Grille Guy will sell you some.
You cut the mesh to size with tin snips (or scissors if it is the plastic variety), then paint if so desired. Use 3M car molding tape or silicon adhesive to attach the pieces. You can even manage to do it without taking off the front fairing if you have itty bitty hands.
There are many ways to do this mod. Use your imagination, and you can customize your bike the way you like it. Here is one man's example:
The first grill we'll tackle is the smallest grill, which is located under the seat.
step 1. Remove the panel under the seat by first removing the seat, then taking out the black screw at the bottom of the panel. The panel should pop right off.
step 2. Take a piece of cardboard and hold it behind the panel, so it covers up the vent. Use a pen to trace the outline of the vent.
step 3. Once you trace the opening onto the cardboard, you want to go out about 1/4 inch and re-draw the design again to give room for the bend. Then, cut the design out with scissors.
step 4. Next, take the stencil and transfer that onto the material you plan to make your grills out of.
step 5. You then want to use your tin snips, grinder, dremel, (tool of choice) to cut out the pattern
step 6. Your cutout should look something like this.
step 7. You then want to take your cut piece and test fit it. Also trace it again, but this time on the back side of the panel, so you know where to make your bends.
step 8. Next, clamp it down and use a hammer to make all your bends. Test fit again and adjust as needed.
step 9. When done bending you should end up with something like this.
step 10. Once you get your grills bent you want to primer, then paint.
step 11. When the grills are dry, you want to get some automotive grade double-sided tape and apply it to the backside rim of the air vent. Then apply your grills, and they are complete. (Sorry, no picture of this step.)
The larger grills
You do not have to remove the fairing to do this if you don't want to. It would most likely make it easier but isn't needed. The process is practically the same as for the smaller grills.
step 1. Once again, take a piece of cardboard and place it behind the panel to trace your vent.
step 2. Transfer that stencil onto the metal and make your cuts. Remember to make it bigger to allow for the bending.
step 3. Once the cuts are made, make your bends. Then primer and paint.
step 4. Install the double-sided tape on the inside of the 2 longer rims, then install your completed grill.
The lower grill
This is very easy. There are no pictures because it is very straightforward. Just remove the lower grill and trace the pattern onto your metal. Cut out the design, then take the stock grill and remove the 2 upper tabs. Once they are removed, use some 5 minute epoxy and epoxy them to where they were located on the stock grill. Once the epoxy is dry, primer then paint. Next, slip the grill back onto the tabs where the stock grill was hooked, then use a small nut and bolt to hold the bottom of the grill in place where the stock one was screwed in.
For the upper grill, once again take it off the bike and trace out the pattern onto your metal. Once done, cut it out and prime and paint.
The stock grill does not sit flat against the radiator. The majority of it sits about half an inch away from it. So, to keep the new grill off the radiator, use steel spacers to hold it out.
Here is the finished product.