Homemade "Laminar Lip" For Windshield, (Pics) - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 10 Old 08-08-2009, 07:50 AM Thread Starter
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Homemade "Laminar Lip" For Windshield, (Pics)

Yesterday, I spent a little time puttering around on my bike, getting it ready for my Jame Bay Road trip coming up next week. I wanted to experiment in making my own Laminar Lip for my windshield.

Previously, I had brought home a piece of 1/8" Lexan from the shop where I work with the idea of modifying my windshield. Yesterday, I pressed it into use.

I ripped and cut the 1/8" Lexan to a dimension of 6" wide x 16" long.
(I am using a Shopsmith Mark 5 that I purchased 27 years ago. It's been a great tool for the kind of home projects I do.).


Next, using a c-clamp and a couple of blocks of wood, I clamped the Lexan to my windshield at a location that looked about right.
(I did this whole thing by sight and feel. Very little measuring.)


Using my heat-gun, I softened up the Lexan sheet so that I could bend it around my windshield to reduce the stress, compared to just forcing the plastic into place with fasteners. ( There is a blue, protective covering on the Lexan to keep it from being scratched while I work with it. It will be peeled off at the end of the project.)


On the rear side of the the Lexan, I traced the top edge of the windshield using a magic marker.


The windshield line gave me a reference for me to "eyeball" as I laid out the actual shape of my Lexan extension.


I cut the shape out on my Shopsmith bandsaw.


I faired the outside line using the Shopsmith disc sander.


I faired up the inside line using my Shopsmith flipped up to a drill press and a barrel sander.


I then clamped the Lexan to my windshield to have a "look see".


Next, it was time to "drill" the holes I needed through the Lexan and through the OEM windshield. My experience with drilling through plastics is, if you don't have the specially ground drill bit, or haven't ground your own, thin plastics like the one I am working with WILL crack. I chose to drill with a hot metal rod; melting the plastics.

I clamped a short piece of metal rod into a pair of vise-grips and heated the tip of it to "red hot" with a torch.


I then "drilled" through both the Lexan and the windshield.


It took a couple of "drillings" to get the holes to the size I needed.


After drilling the holes, I removed the Lexan extension and deburred all sides of each hole with my utility knife.


I then did some final fairing of my homemade Laminar Lip with some sandpaper.


I fastened the extension to my windshield using stainless steel fasteners I purchased at my local Lowe's store.


The fastening sequence was this: (from back of the windshield to the front).

10:24 Nylock nut > 1" fender washer > OEM windshield > 1" fender washer > 1/4" tall nylon bushing > 1" fender washer > Lexan extension > 1" fender washer > 10:24 x 1 1/2" pan head machine screw.

I would have preferred 3/4" fender washers, but Lowe's didn't have any.

The 1 1/2" machine screws ended up getting cut down to a length of about 1 3/16".





The extension makes a positive difference to the wind pattern around my helmet and when I hold my camera for shooting videos while riding.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"

Last edited by Black Lab; 08-08-2009 at 07:53 AM.
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post #2 of 10 Old 08-08-2009, 08:12 AM
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That looks really good. I've made a few windshields from Lexan with good results.

What are those two wires/cables going to your left hand gaurd?

Roger ('14 Tenere ES, COG 5903)
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post #3 of 10 Old 08-08-2009, 08:23 AM
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Looks good
I envy some of your workshop tools.
Question; did you do the black on the windshield for personal preference on looks or did it help with something?
Mike

Last edited by mikefryman; 08-08-2009 at 08:27 AM.
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post #4 of 10 Old 08-08-2009, 08:40 AM Thread Starter
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Quote:
Originally Posted by roger123 View Post
That looks really good. I've made a few windshields from Lexan with good results.

What are those two wires/cables going to your left hand gaurd?
Each switch independently triggers my left and right PIAA driving lights; left switch = left light; right switch = right light. The lights are mounted in steel "cages" that I made and welded to my SW-Motech crashbars.

The right light can be seen below.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"

Last edited by Black Lab; 08-08-2009 at 09:48 AM.
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post #5 of 10 Old 08-08-2009, 08:42 AM Thread Starter
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Quote:
Originally Posted by mikefryman View Post
Looks good
I envy some of your workshop tools.
Question; did you do the black on the windshield for personal preference on looks or did it help with something?
Mike
Personal preference, (and some other reason that I can't remember!). It's a "Rhinoliner" like product that is sold in an aresol can at my local autoparts store.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"
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post #6 of 10 Old 08-10-2009, 09:18 PM Thread Starter
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I have now ridden about 300 miles with my extension. I really like it. The air shoots over my head and the "foil" design seems to add a sort of "stabilizing effect" to the front end of the bike.

The extension is staying on the bike and is going with me on my James Bay Road ride for its real test starting this Wednesday.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"
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post #7 of 10 Old 08-10-2009, 10:07 PM
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Nice job, Thanks for sharing....

I have an MRA shield with spoiler extension which is pretty similar to what you made.

I love the spoiler but often thought on how I can make the shield wider. Your idea inspired to add extensions on either side of the Windshield as well.

PS; did you use Rhino liner on the skid plate?
Thanks again

Ken

2007 DL650 Gray
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post #8 of 10 Old 08-11-2009, 05:19 PM Thread Starter
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Quote:
Originally Posted by maggot View Post
Nice job, Thanks for sharing....

I have an MRA shield with spoiler extension which is pretty similar to what you made.

I love the spoiler but often thought on how I can make the shield wider. Your idea inspired to add extensions on either side of the Windshield as well.

PS; did you use Rhino liner on the skid plate?
Thanks again

Ken
Hi Ken,
I am glad that you found some inspiration in this thread and have taken off in your own direction. That's why I take the time to shoot as many pictures as I do. It kind of sets a "spring-board" for others to bounce their own ideas off of and forge ahead with the modifications they may want to make. Let's see what you come up with when you are done. It may be an inspiration for me!!!!

Check out post #7 in this THREAD. It should answer your questions about the Rhinoliner.

Barry

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"
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post #9 of 10 Old 08-14-2009, 06:23 PM
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Comepletely off topic but man does that Shopsmith Mark V bring back memories. One of the best tools ever made for anyone with limited space (or heck even a lot of space).. My dad used one for years before getting divorced and being forced to sell it. I actually looked a few years back to by one for myself.
Seeing this has me "wanting" one again. I think they made a newer Mark 7 also. Wasnt as popular though.

I made a lip like you did also but on a different 2 wheeled machine. It worked quite good. And cost next to nothing.

Good write up and nice finished product.
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post #10 of 10 Old 08-21-2009, 12:01 AM Thread Starter
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Quote:
Originally Posted by Dntouch View Post
Comepletely off topic but man does that Shopsmith Mark V bring back memories. One of the best tools ever made for anyone with limited space (or heck even a lot of space).. My dad used one for years before getting divorced and being forced to sell it. I actually looked a few years back to by one for myself.
Seeing this has me "wanting" one again. I think they made a newer Mark 7 also. Wasnt as popular though.

I made a lip like you did also but on a different 2 wheeled machine. It worked quite good. And cost next to nothing.

Good write up and nice finished product.
My 84 year old father still has one of the original Shopsmith 10ER models. That goes way back!!! I have built a lot of things with my machine over the years.

2007 DL-650 (I gave away in 2012 with 111,000 + miles)
"A word grows to a thought; a thought to an idea; an idea to an act. All the pieces are put together, and the whole is yours."
1942, Beryl Markham: "West With the Night"
"You can talk about doing a thing until everyone finally talks you out of it, or you can actually do the thing"
James Baldwin "Across Islands and Oceans"
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