DIY small Windshield (spoiler type) - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 7 Old 09-27-2009, 07:36 PM Thread Starter
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DIY small Windshield (spoiler type)

So, after playing with the stock windshield, and really getting nowhere with reducing the buffeting aside from removing it entirely, I decided to work on making my own spoiler-style windshield out of Lexan. I used to ride sportbikes, so I like clean air over my helmet, not a dead spot to sit in. I also don't like to look through a windshield when riding. I haven't seen a lot of posts like this, so I thought some might find it interesting to see what I did...

I used .093 Lexan, found in the window section of your neighborhood Home Depot. They have any thickness you want, as long as it's .093.



I started by using the stock windshield and a dry erase marker to draw a rough outline of what I wanted my finished product to look like.



Then I used some printer paper to draw one half of my shape using the lines on the windshield.



Folding the paper in half and cutting it yields a symmetrical shape, and when I had something I was happy with, it is layed on the Lexan and taped down.



To cut the Lexan, I used a 20TPI Bosch jigsaw blade in my cheapie Ryobi cordless jigsaw. Going slow and holding the Lexan firm minimizes how much it jumps around. The blade cut it much cleaner than I expected.



After making small adjustments to the shape, I gently clamped the new piece to the old windshield and marked where to drill the required holes. I used a UniBit to drill the holes - worked like a champ with no cracking.



Lots of test fitting.



Little bit of sanding and off comes the protective plastic and I used the stock hardware to mount it up. The sheet is so thin that it bends to the shape of the bracket just fine - the locating posts hold it in place as long as the holes are drilled carefully and in the correct place.



The finished product, minus paint, which I'll do once I do any necessary fine-tuning to the shape.



From the riding position...



Total cost: $11 for lexan, $6 for jigsaw bit, $5 for 6-pack, and 2 hours of time.

I'll update tomorrow to let y'all know how it works out in the wind.

Marker
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post #2 of 7 Old 09-27-2009, 08:32 PM
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I like it. Easy cheap way to try different spoilers. I was going to do the same but thought I needed to heat.

Another good source for sheet is www.mcmaster.com. They have just about everything.

Can't wait for a ride report. I plan to do the same in the spring.
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post #3 of 7 Old 09-27-2009, 08:34 PM
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sweet job!

thats nice man, I'm working on a lexan project for the Vee as well. I want to make two small fairing pieces to mount on the mirror stems o decrease buffeting. can't wait to see your results!
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post #4 of 7 Old 09-27-2009, 09:31 PM
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Originally Posted by corvetteii View Post
thats nice man, I'm working on a lexan project for the Vee as well. I want to make two small fairing pieces to mount on the mirror stems o decrease buffeting. can't wait to see your results!
Please let us know the results of this experiment and pictures. I have been thinking for a while that the mirrors are at least a part of the wind problem even with the mirror extenders.
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post #5 of 7 Old 09-27-2009, 09:52 PM
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windshield extender

I made a windshield extender from Lexan and I got it into the desired shape by baking it in an electric oven at 300 F for like 3-5 min. Once heated, it bends so much easier over the existing windshield, making an almost perfect copy. You need to heat it up, clamp it over the existing windshield and let it cool down. If you do it a few times, you can get the desired shape. For better results, try baking a small scrap piece of lexan, and play with the timing.

Let me know if you have any q's.
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post #6 of 7 Old 09-27-2009, 10:00 PM Thread Starter
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Quote:
Originally Posted by ro_manian View Post
I made a windshield extender from Lexan and I got it into the desired shape by baking it in an electric oven at 300 F for like 3-5 min. Once heated, it bends so much easier over the existing windshield, making an almost perfect copy. You need to heat it up, clamp it over the existing windshield and let it cool down. If you do it a few times, you can get the desired shape. For better results, try baking a small scrap piece of lexan, and play with the timing.

Let me know if you have any q's.
Thanks for the tip - maybe I'll try that before I paint it. Does the Lexan offgas any fumes when it heats up?

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post #7 of 7 Old 09-28-2009, 10:50 PM Thread Starter
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Rode the Wee 200 miles today - to and from work at 75 or so. I have to say - I think I nailed it. Clean air starts right at my chin. No buffeting, and no street-fighter wind push in my chest. 2 weeks of experimenting with the stock windshield and no windshield paid off!

Paint this weekend, maybe.

For anyone interested in using the design, I'm 6'0", 32 inch inseam to give you an idea of how high my dome sticks up.
Marker

Last edited by PermanentMarker; 09-28-2009 at 10:55 PM. Reason: stupid misspelling
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