By Frorule 04/2005

Hey Naked guys and gals,

I just wanted to share with you what I accomplished this morning. I have a 45 mile commute on the interstate and wanted to get some of the wind off me. Didn't want to spend 80+ bucks for a windscreen, so I made my own. Here are the details.

1) Buy yourself from plexiglass. 30x36" from Lowes/Home Depot for $13.00.

2) Make a pattern.

3) Bust out your favorite tool...the dremel... with this bit. Use it like a pencil and cut around the trace you made on the plexi. It doesn't have to go all the way through. The windshield will snap off where you made the cut. Don't worry too much about rough spots. The sanding dremel bit can smooth them out. Pic 2 below.

4) Take windscreen and place into oven (about 300 degrees for a few minutes, check on it often!) Use something round to push the screen on while it's hot. I used a round trash can.

5) Finished product.

6) Buy some brackets similar to these... @ Wal-mart- 2 bucks.

7) Bend brackets til everything fits. Drill holes in the screen with cone shaped dremel bit. (I think regular drill bits may lead to cracking!) Get some rubber washers and some nuts and bolts and you have this....

Finally.....

Took her for a spin.... It gets all the air off my chest, but the main air stream hit about halfway up my visor. If I had only made it a few inches longer, I'd be sitting in almost perfectly still air. But as you can see, I have lots of plexiglass left, so I may make a longer one just for the fun of it..... someday...when the wife lets me!!

Total time was about 2 hours. Cost, 15 dollars.... 13 for the plexi and 2 for brackets. Definitely worth it I think.

UPDATE:
I've used my new screen a couple of times for my commute, so here are some more details. The screen holds up fine to speeds in excess of 100 mph (speedo indicated). No cracks, chips, or bad markings have formed anywhere. However, it has managed to kill about 1000 bugs. Those same bugs would've been plastered to my jacket/helmet, so I certainly don't mind that!

Yes, the screen is propped up against the tach at speed. The bottom edge is also pressed up against the top edge of the headlight. Throw in the 2 brackets and it makes for a sturdy windshield. I have no complaints.

Helmet noise is increased. At 70 mph (speedo indicated, which seems more closer to 60 mph actual) I stood up on the pegs and got above the turbulence. The helmet was about 50% quieter sitting in clean passing air. It's not obnoxious or anything, but the extra noise is noticeable.

Tinting would definitely be a possibility, whether it be by using spray tint or the film. I personally wanted it clear, so as not to be very noticeable. I really like the naked look, and felt the clear screen would not detract too much from it.

TIPS & COMMENTS:
Goro - You can also use an hairdryer (but you need some more patience) or a thermic gun: it allows you to work on narrow hot parts of your plexi. Suggested for unusual shapes.

andmoon - care: some types of Plexiglass may shatter and some won't (lexan IIRC).

wyatt79 - The only thing I would have done differently is tape off the inside and shoot some paint on the bottom portion which would make it look smaller and more integrated. Or maybe you could tint the whole thing?

Tundra Tom - I wonder if smoked plexi-glass is available?

IndySV1K - If you can't get smoked plexi, I'm sure it'd be really easy to apply some automobile window tinting film to the INSIDE of the windscreen. I know Autozone carries it in all sorts of colors.

BJAM - Applying film to the inside will help if it does decide to shatter on that very cold morning when a stone hits it.

AndyW - re wind noise/turbulence , maybe worth experimenting with the size, shape and curvature of the screen.  Maybe take a look at some screens available from aftermarket parts manufacturers to get ideas on a revised pattern. A visit to the local metalwork shop to get some stainless steel brackets fabricated would be a nice finishing touch.

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