Hello Riders--

I've been researching for a replacment windscreen for the past several months and while there are a few really nice screens available, I was not that impressed to spend nearly $150 or more. Having built a screen for my KLR, decided to use the same plan for my K5 DL1000.

Using a sheet of Lexan from Home Depot for $13, I built a screen which extends to the edge of the fairing and is 3" higher than stock. I previously purchased the Madstad adjustable bracket which make my screen that much better.

See image. If anyone needs specific details on how to make it, I can post a follow-up. If you think I'm crazy, keep in mind, Lexan is as tough as nails.

Cap
K5 DL1000
'06 KLR

Attached Images

Windshield 002.jpg (76.9 KB, 877 views)

Your design looks very good, how did you bend a sheet that large?

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Mastery is not learned in an instant.
DL650-04- Blue

I made one similar to that one.

I do anything special to bend it, just kinda force it where you need it to go. I used to make 'em like that for my Connie as well.

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Roger ('07 Wee, '06 FJR (For Sale), COG 5903)

great idea, what thickness of lexan?

I am very interested in doing this project. Just can't bring myself to paying $200 for a factory made shield.

Anyway, here are the questions......

1. How is the best way to cut Lexan? I don't want to scratch it in the process. I do not have a band saw, which in my mind might be the best choice. My thought is.....put down masking tape and then us a jig saw with a very fine blade.

2. Is it possible to get the shield to contour/bend? I reemeber reading something about a guy who strapped the lexan to an empty BBQ Propane tank and heated the lexan???????

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Big John

2007 Suzuki DL650 - Well Equiped for Adventure
2001 Yamaha YZ426 - Single Track Beast

Rocky Mountain Adventure Riders Website

I'm interested in seeing the details.

Thanks.

Last time I built a windscreen I used plexiglass from Tapp Plastics, cut to shape, then heated it in the oven until it was flexible. I had to be quick after it came out of the oven as it "set up" hard quickly. It was soft as toffee when hot, and stayed in the shape it was bent to.

Hi,

I'm the same guy who posted the original. ( Forgot my username at the time and couldn't log on so created new name. Dah!)

Instructions:

I first made a template out of poster board. 18" x 24" This is the same size as is Lexan which by the way is carried by Home Depot for $12.99. I copied my template using an image of the MP Design off of a website. This take some artistic ability, something I recruited my wife to do!

Once I was satisfied my template was drawn out with pencil & I liked the design , I folded it in half and cut the poster board with scissors. This allowed a perfect cut on both sides of the template.

Next I laid the poster board template onto of the full sheet of Lexan (18"x24"), I drew out the sketch onto the Lexan. Using a new blade an a zig saw, I simply cut the material. Lexan is a great product and it will cut really clean with no cracking. (Watch out for the dust!) This was actually very easy.

Now we have a flat screen cut to shape. Right? Tricky part coming.

Set you oven for 210F-215F, maybe 220F. Using a clean pizza box or cardboard, bake the screen while constantly watching for any signs of wrinkle
I seem to remember, 10mins maybe 12mins..

Once you believe it is time You will need to quickly remove the screen and put a bend on it using the Suzuki factory screen as the template for the correct curvature. This can take two sets of hands and you need to act quickly and carefully as not to bend it the wrong way. (Remember, it's lost it's hardness at this point and is on a few degrees from becoming a liquid state.)

Carefully bend the warmed Lexan around the factory screen and hold it there for 30-45 seconds, Use clean leather gloves and only touch the Lexan on the edges.

Now you have a curved screen. I mounted my screen directly on top of the factory screen for extra stability. Line up all holes and drill.

The Home Depot Lexan is only .125" thick. Plenty strong enough but I thought it might flap at high speeds if not the extra support of the stock screen. (You may have to use slightly longer metric hardware found at Home Depot). You may want to also use some small & thin rubber stickys to prevent the screens from rubbing together. If not, some wear marks will appear within weeks.

In the end, I used this screen for over 10,000 miles and it worked as good and I believe better than the Givi I now have. My homemade screen provided more protections along the bottom.

The downside, the two screens trapped moisture between leaving behind some crud. But this can be cleaned every so often.

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Cap
'07 DL650

Nice write-up Cap! I think I'm going to try this but have a few questions for you:

While the Lexan is hot and pliable, was there any concern about it adhering to the stock windscreen while holding it against that as a form?

Is it soft enough to be concerned about take imprints of the glove material texture onto the screen?

Any thoughts on beveling the edges with a dremel tool?

Did you just happen to buy the Lexan in .125" or was that the only thickness available? I would rather use a Madstad and mount it without the stock screen and wonder if I should try to find something a bit thicker.

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2008 DL650 Matte Black
2006 Yamaha WR450F
1973 Moto Guzzi El Dorado

"America is at that awkward stage. It's too late to work within the system, but too early to shoot the bastards."
--Claire Wolfe

--NO. If you get it this hot, it will drop out while in your hand and become badly disfigured. Practice the heating process of this task using a scrap piece first to get oven temps correct.

--YES, Only hold on edges, again, it will not get it this hot. If you mistakingly overheat, leave in oven with door open and cool off for a few seconds. And it cools fast

--Yes, but I don't posses a dremel.

--I also used a Madstat. This project really worked out well for $12.99 and a few hours on rainy Sat. Home Depot only carries the .125". If I could find .25 or .375, that's be great.

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Cap
'07 DL650