Any ideas for attaching expanded metal to aluminum skin?

[gus]

Many screens block much more air than EM, all depends.

I would use SS screws with large washers and plastic lock nuts on the EM. That way, if what you do doesn't work, you can easily remove and change it.

Any kind of glue is pretty much permanent, same with rivets. Rivets can always be drilled out but it is a mess. SS screws look good and won't corrode.

You can make the holes with any drill bit since the Al is pretty soft.

If you do use rivets be sure to make the holes snug on the rivets. Rivets are easily loosened by vibration unless properly done.

[bevans6]

FWIW, you can undo epoxy joints pretty easy with an industrial heat gun.  I epoxy race car floors on and to take them off, heat gun and a putty knife and off they come...

Brian

[belfert]

My generator is required to have 400 square inches of ventilation.  I measured the venting now and I have a minimum of 560 square inches if the holes allow 50% flow through.  One thing I thought of is just drilling a bunch of holes with a hole saw, but I'm not sure I could get nice looking holes that way.

One thing I just noticed is that the replacement door does not have the marker light hole centered like the vented door.  I am going to have to change my game plan a little bit and not put ventilation as close to the center.

[belfert]

I ended up running over to a local metal supplier and getting some expanded aluminum.  I was able to get a drop piece about 36"x48" for a whole $10 plus tax.  If it doesn't work out I am not out much money.

[Boomer]

Wire cloth in second picture down that Jeremy posted.  Good stuff, very strong.

[belfert]

Here is a picture of the start of the project.  I only cut one hole out of six before I realized I had broke the cutting wheel at the center.  It is so hot and humid (Forecast 100F with 70F dewpoint) I'm just going to work inside the air conditioned bus on another project for the rest of the day.

I went with expanded metal because it only cost me $11 for a 40" x 48" piece.  The local metal supplier didn't haven't stainless wire cloth and the places online wanted $70 and up for it.

For some reason the picture makes it look like everything is not straight, but it is straight.