Custom Windscreen FINALLY DONE

So I bought a OEM windscreen for a 2002-2005 6th gen viffer off ebay for $20... it was in poor condition so I used Blue Magic headlight restorer on it... works pretty good... I then trimmed it even with the supports.. cleaned up the edges... then masked it off and used VHT nite shades to do the tint portion... the nite shades stuff didn't turn out quite the way I wanted to so I had to do extra coats. At the end of the day I should have used paint... anyhoo here you go.. I will post more on the masking process and cutting if you guys want... let me know

 

very well done... nice!

 

+1, looks great!

 

+1. It looks awesome.

Have you had it out on the road yet? Just wondering what the wind protection is like.

 

Take it easy on yourself brother, that thing turned out great. I've taken a ride with a member here, VWRXTRD, who did the same thing. It looked great and he sweares by it in terms of moving the wind off of his helmet and closer to his chest. I thought about doing it myself after I saw his, but opted for a slightly smaller than stock, Zero Gravity instead. There is a slight lip at the top of the windshield that ended up putting the wind over my head. Had it not worked though, I was definately prepared to chop it.

Nice job!

 

So far around town it's been great. Haven't had it up to highway speeds but at 80km/h it seems to work well. I got the bike with a Zero Gravity Double Bubble so that's all I can compare it to. I definitely like getting wind in the chest as opposed to smack dab in my face. I will take it out on the highway today and give a quick report.

Thanks for the props!

 

Yes, more info on the cutting etc please, I am thinking of doing mine to reduce the blast in the centre of the helmet.

 

I REALLY WISH I HAD SOME PICTURES OF THIS PROCESS.... I could take a picture of the piece I cut off.. but that wouldn't help now would it... I will describe it the best I can... feel free to ask any questions or judge me :tongue:.

Okay... so to layout the cutting line on the front of the windscreen I taped string on the left edge of the windscreen where I wanted to cut it down to (1/4 up from support). I then strung the string across the windscreen with very little tension and taped it to the right edge. The reason you don't put tension on the string is that it will creep up on you when you pull it tight.

then tape the string on to the front every 4 inches or so. now that you have your ideal line use a grease pen, dry erase marker, paint marker, whatever you can use that isn't permanent to mark your line. You can now take the string off. Grab some masking tape (I used the green stuff) and mask along the marks you've put on. Make sure you put the tape on the side that you're keeping. Also put the masking tape 2 strips wide and use some newspaper to cover the rest. ALSO use at least 2 or 3 layers of masking tape! It'll save your ass is you slip.

Now for the cutting... I used a dremel with a friction cut off disk. I will admit this didn't really cut per say. It kinda melted the polycarbonate. That being said if you use speed 2 and be patient you can get an awesome finish on the cut (because of the melting). A little bit of the material will melt over the sides when cutting... it just peels right off when you're done and there is no adverse effect on the finish product.

Now that you're done the cut you'll want to file the cut and bevel the edges. Leave the masking tape on to do this! I just used a single cut smooth file and touched the cut up and smooth it out. Also used the single cut file to bevel the front side. I used a fine half round file on the inside edge to bevel. Try to make the bevel as uniform as you can along the edge. It will make the finish product verrra naaace (said like Borat). The bevel is maybe 1/64th or .0156.. just enough to take the edge off.

Oh one more thing...after the cut the where the edge of the screen and where the cut meet you will be left it a sharp point... you will want to round these off to eliminate the risk of them chipping off and reduce the risk of cutting you or taking an eye out. Put a 1/8th rad on here.. you hold up a 1/4inch diameter drill and mark the material to be taken off. Use a smooth file and take your time doing this. It's all in the details!

Ummm... I think that's it... please feel free to ask any questions.

 

So had her up to highway speeds (100 - 125lm/h) ... couldn't be more pleased. I would say that it's better than the ZG double bubble the bike came with. With the ZG I could barely stand being upright and kept ducking under the windscreen. With the trimmed stocker I didn't have any issues being upright. Almost seems like the wind blast isn't as focused. Spread out more maybe. I don't know why... I don't know how... but it's better. I'm pleasantly surprised.