cagie

I had promised someone that I would show them how to make a "classic" style windsheild. Here are the results:

Materials:
1- 3/4" x 1/8" x 48" Alum bar
1- 3/4" x 1/8" x 36" Steel bar
1- 18" x 24" x .093" Lexan Polycarbonate Sheet
1- Chunk aluminum sheet scrap (.060 or thicker) ( I got mine from a sign shop)
4 - 1 1/2" hose clamp
4 - 1/4" x 20 x 3/4" countersunk bolt
9 - 1/4" x 20 x 3/4" pan head bolt
2 - 1/4" x 20 x 1 1/4" pan head bolt
4 - 1/4" x 20 x 1/2" hex bolt
19 - 1/4" x 20 Acorn Nut
19 - 1/4" Lock washer
19 - 1/4" Washer


I made paper templates for all the pieces that I would be needing. I used spray glue and tacked the templates to the materials for cutting/drilling. I used a band saw to cut all my aluminum and the Lexan, but most people would probably use a jig-saw.

When cutting the Lexan, go SLOW and take your time. Finish the edges using 220 grit sandpaper. Leave the protective covering on until you are nearly complete to avoid scratching it.



here are all the pieces cut and ready for drilling. Except for the Fork support mount everything was drilled 9/32". Fork support mount was drilled 7/32" and tapped 1/4" x 20 and one peice countersunk. I have included the patterns in PDF format so you can follow along and used/modify to suit you.

Brackets: print size is 11" x 14". (do not scale)
http://lonestargrafix.web.officelive...s/brackets.pdf
Windshield: print size 18" x 24" (do not scale, 6 letter sheets)
http://lonestargrafix.web.officelive...WINDSHEILD.pdf



Pieces cut and bending started. the bend is approximately 1 3/4" deep, with more of the bend at the ends. This type of bend makes the windshield more rigid. The bend at the bottom is primarily for strength, but it also deflects air differently, you may choose to leave it straight.



Mock-up attached to bike, ready to be disassembled and painted/cleaned/polished.



Here is the finished windshield:
Note that this particular design allows up/down adjustment of two inches and tilt adjustment of about 15°. you can adjust to best fit your needs.




A couple of detail shots.



if you have any questions, feel free to PM me or shoot me an email.

__________________
Comments contained in my posts are not intended to cause physical or psychological stress and are mearly my two cents worth, and in this economy, that's cheap!
87 CMX250C 'the Pygmy Pony'
87 CMX450C 'Black Lithium'

flitecontrol

Nice! I'm impressed!

__________________
I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!

2001 Rebel 250, 1989 Vulcan 750
Putting your bike info in your signature helps others help you!

cagie

forgot to mention that this design is quickly removable. just loosen the fork support bracket nuts and swing forward and up. Pops right off.

Inside steel is painted wrinkle black:

__________________
Comments contained in my posts are not intended to cause physical or psychological stress and are mearly my two cents worth, and in this economy, that's cheap!
87 CMX250C 'the Pygmy Pony'
87 CMX450C 'Black Lithium'

colddonkey

How did you manage to print your template sheets? I tried playing around with my printer specs and couldn't come up with the ability to print at 100% size print pages.

I like what you've made and hoping to replace the windshield I have with a copy of yours. NICE JOB!

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cagie

When you print, you should have an option under page scaling to "tile large pages". It should then give you a preview of the printout on 6 pages.

Heck, if you can't print it, let me know and I will mail you a copy (you'll have to paste it together)

__________________
Comments contained in my posts are not intended to cause physical or psychological stress and are mearly my two cents worth, and in this economy, that's cheap!
87 CMX250C 'the Pygmy Pony'
87 CMX450C 'Black Lithium'

Fridgitator

Really nice work. Thanks.

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colddonkey

Oh hell looks like I'm the total idiot. Tried some more but couldn't pull it off. My printer a: Dell AIO photo 926 doesn't have the "tile large pages" option. Thought I had it when I tried the print "current view" but after a few partial pages realized I couldn't get parts of the prints on the view no matter what.

Sending a PM.

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flitecontrol

For those of you that want to cut the Lexan with a jig saw, in addition to Cagie's good advice to go SLOW (to keep from cracking the plastic), would also suggest using a blade with numerous small teeth, like a hacksaw blade.

__________________
I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!

2001 Rebel 250, 1989 Vulcan 750
Putting your bike info in your signature helps others help you!

cagie

Try this set. Make sure when you print that you select "none" for scaling. Also measure after printing to make sure windshiled pattern is 16 x 21" and the brackets match the scale (1" - 1")
http://lonestargrafix.web.officelive...shield-ltr.pdf
http://lonestargrafix.web.officelive...ackets-ltr.pdf

still doesn't work, then I will mail you a set.

__________________
Comments contained in my posts are not intended to cause physical or psychological stress and are mearly my two cents worth, and in this economy, that's cheap!
87 CMX250C 'the Pygmy Pony'
87 CMX450C 'Black Lithium'

flitecontrol

Cagie:

After seeing your handiwork, I'm thinking I could make a larger version for my other bike. I'd like to incorporate some hand shields. All those I've seen so far have been moulded into the plastic. Do you forsee any problems if I extended the horizontal brace enough to support some hand shields? Think I ought to use heavier stock for the horizontal brace?

__________________
I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!

2001 Rebel 250, 1989 Vulcan 750
Putting your bike info in your signature helps others help you!