Windscreen fabrication advice.........

Discussion in 'General' started by Lee57, Oct 25, 2021.

  1. Lee57

    Lee57 Well-Known Member

    Requesting tips to fabricate a proper windscreen from flat plastic......
  2. nigel smith

    nigel smith Well-Known Member

    For a race bike? I always just used thin plexiglass and a fresh pair of tin snips. You would think that it would crack, but I just taped both sides with masking tape, drew the cut, and had at it.
    dtalbott likes this.
  3. Lee57

    Lee57 Well-Known Member

    Yes, for this upper:

    Attached Files:

  4. pfhenry

    pfhenry Well-Known Member

    i worked on a bike that had an acrylic windscreen... it was crystal clear molded custom but boy did it crack easily. find an old windscreen, bust out a sharpie, draw lines, proceed to nearest cut off wheel and hand drill.
  5. TurboBlew

    TurboBlew Registers Abusers

    become friends with Gustaffson?
  6. L8RSK8R

    L8RSK8R Well-Known Member

    Ducati89 likes this.
  7. matt2491

    matt2491 Active Member

    RSC has brand new Speedfiber windscreens for 100 bucks. Even comes pre-drilled, and fit my factory 125 upper fairing almost perfectly. I'd just buy that, but you do you.
  8. tophyr

    tophyr Parkour Champion

    Tips to get a windscreen? Buy one.

    If you really want to make your own, plexiglass becomes very pliable with heat. Get a good heat gun (not just your ol lady's hairdryer) and some gloves (you will burn your hands otherwise) and start heating and shaping. It is similarly easier to cut when hot.

    But seriously, unless you're doing this for the fun of it (which I totally would get) you're going to spend less money just buying one.
  9. Lee57

    Lee57 Well-Known Member

    I bought the plastic material to fabricate a screen >15 yrs ago and never used it, so now the only cost is time, and probably considerable frustration.
  10. Motofun352

    Motofun352 Well-Known Member

    When you're done cutting and bending, make sure to polish the edges. 2000 grit paper.
  11. Britt

    Britt Well-Known Member

    Use Lexan.
    Canadian Bacon and Sabre699 like this.
  12. OldSwartout

    OldSwartout Well-Known Member

    I did one for a 60's era Windjammer, larger than what you need. Cut a couple pieces of 2x6 with the proper curve, bent a piece of thin paneling over it for a form, then just heated the plexiglass with a heat gun until it sagged down over it.
  13. crashman

    crashman Grumpy old man

    I know that this is overkill but I made a windscreen form that was exactly the shape I wanted out of thin aluminum, put a piece of lexan on it and threw it in the oven. I forget what the temperature needed was but I just slowly upped the heat until it started to sag and left it in until it was the desired shape. I think it was around 300-350 degrees. Heat gun is definitely faster for shaping though. As others have said, wear gloves or you will burn the shit out of yourself.
  14. Lee57

    Lee57 Well-Known Member

    Thanks much for the tips, OldS and crashm.
  15. tgold

    tgold Well-Known Member

    Yes, use Lexan or other polycarbonate. Plexiglass (acrylic) isn't as tough.
  16. backbone

    backbone scarred for life

    You can blow it up like a balloon into the mold or clamp and press. Heat it in your oven slowly, it will bubble when too hot.

    Better to buy one unless you are going to make 100 of them and sell them
  17. Hotfoot

    Hotfoot Well-Known Member

    That looks a lot like the upper for a Moriwaki 250 and you can order a windscreen that will fit, Zero Gravity, Speedfiber and Gustaffson are some companies that make them, here is a link to one on the Technical Sports One site:
    Moriwaki MD250H - Windscreens (
    TSO also has screens for RS125 or NSF250R if it is one of those instead.

    Here's a link to the Speedfiber one on Rising Sun Cycles website:
    MD250H Bodywork (
  18. AssClown

    AssClown Well-Known Member

    Attached Files:

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