Making a windshield.

[Bob Falter]

I made a windshield for the V-Max in 2005 and one for the Dyna in 2006. After 11,000 and 14,000 miles both are still working fine and no yellowing. I used the Lucite that you can buy at Menard’s (think it is just another name for Lexan). Thought I would make one with the thin stuff to see how it would work and then go back and get the thicker (more expense) Lucite once I had some experience. Never got around to getting the thicker stuff. Wind tunnel tested both of them to over 100 mph. Both still in one piece.

I could only heat it to 180 degrees without having problems but it is thinner. You can use a heat gun and an IR temperature sensor to make special curves if needed but you have to be careful and it takes a lot of time. If you over heat it you ruin the sheet and have to start all over.

Bob

[webbcraft2150]

Lexan is much tougher than the acrylic plastics. My OEM Vetter is made from acrylic plastic which is less expensive than Lexan but not as tough (like if I am sailing thru the windshield its gonna make a difference). Most Lexan will have a coated side for UV protection, which is why the protective paper will say "this side out" or "this side toward the sun". Forming it requires heat, just the right amount or you will deform the plastic. Most of

With that said, and a chance for you find a OEM windshield, I hope your riding skills have improved to the point you wont have to replace it 'cause you found a gravity pocket.

[trbig]

I hope your riding skills have improved to the point you wont have to replace it 'cause you found a gravity pocket.

Naw, they still suck. I think I need to practice a LOT more!

I think I'll get this new OEM-ish one, then later get some Lexan and try it out so I have a spare. That way I have one to compare it to to try to get it shaped and formed right. Will the Lexan turn yellow with age, or does it have to be exposed to UV to get that way? I was wondering about extended storage in my shop.

Tod

[webbcraft2150]

I had a lexan windshield on one of my boats for years and it did not ever yellow. The acrylic one on my XS now is about 10-12 years old and the sun has beat it up pretty bad. It was a dark tint so I would not be able to tell if it yellowed. One thing I found with plastic windshields is wax em with a good paste wax that has a UV inhibitor and when you clean em make sure you "flood" em with water to keep from scratching. Avoid window cleaners with ammonia, it will accelerate the aging process. The big hassle with storing plastic with the protective cover is after a few years, it can be near impossible to peel off. Store it in the house somewhere where the temps are a better controlled.

[DJinNH]

Hey Tod,


Took me a few moments to find my old photos, they are from a 2003 post: My paint job and aux lights have changed!

Ya, I would think that cutting/trimming a windshield like that one or maybe even one like I have could possibly work.



Good luck with the project.

Don

[CatatonicBug]

Lexan is much tougher than the acrylic plastics.

Yep. That's why bullet-proof glass is made outta the stuff.

[nubee]

Hey trbig.

Here is a good read on the different types of plastics.

Down at the bottom there is a list of Windshield Replacement Manufacturers.

[Cobia]

Shoei on sale on ebay

Hey Tod,
Before you go spending your hard earned cash on having the windshield made, I just found these on cheapbay. The guy currently has 42 silver ones and 25 in black.
Here's the link:
http://cgi.ebay.com/ebaymotors/_Moto...1%7C240%3A1318

They look real nice, wish my bikes had round headlights. Don't know how it would look on the XJ.

[b.walker5]

Check this site for instructions for working with Lexan polycarbonate.

http://www.gcip.co.uk/EP/lexan_polycarbonate_sheet.htm

I used some for a curved window when building a trailer for our horses. They say it can be cold formed but I have access to a sheetmetal shop with roll formers etc and I'll be damned if I get a curve to stay in it cold.

Gotta be really careful with heat guns as it's easy to bubble the stuff. Heated in an oven over a former is the way to go. A potters kiln is a good option if you can get access to one.

Good luck.