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8) After searching for several years for a solution to the excessive noise caused by my windscreen, I have an 86 GS 1150 EF, I had to take matters into my own hands and custom make my own windscreen.
This is how to do it:
1. Buy a piece of 1/8 lexan, 24'' x 24'' should be enough. I bought extra because I made several windscreens.
2. Buy some bristle board and decide on the design of the windscreen.
3. Make a bristle board windscreen. I did this by holding the bristle board at the angle I wanted and pressing the bristle board around my fairing where the windscreen bolts on, this makes an indentation that you can highlight with a pencil and makes it easier to see when you cut it out. I used several different pieces taping them in place and filing in where ever there were spaces. This makes an almost perfect pattern.
4. Once you are satisfied with the way the bristle board windscreen looks on your bike take it off and tranfer the pattern onto the lexan.
5. Cut out the pattern from the lexan, leave the plastic film on until you are finished, using a jig saw with a fine blade.
6. Get a piece of plywood that's a little wider than your old windscreen. Place your old windscreen onto the plywood and trace around the outside.
7. Screw wooden blocks along the line in several places.
8. Take the lexan that you cut out and bend it so it fits onto the plywood. The wooden blocks will hold it in place.
9. Make a piece, I used plywood, that fits the contour of the top of the windscreen. This will stop the top of the windscreen from collapsing when heated.
10. place the contour piece onto the top of the windscreen and attach it to the base plywood, I used wire.
11. Make sure your plywood jig fits into your oven. Mine fit right into the rack grooves in the oven.
12. Preheat your oven to about 250 degrees F.
13. Place your plywood jig wit
h new lexan windscreen in place into the oven.
14. Bake it for about 12 minutes, this will vary depending on what oven you use, and watch it the whole time.Do not over heat as the lexan will sag
15. When you think it's done, take it out and let it cool.
16. When cold take it out of the jig, it will relax a bit but not enough to cause a problem.
17. Fit the new windscreen onto your bike and mark where to drill the holes.
18. Drill holes, I drilled a pilot hole first.
19. Bolt the beautiful new lexan windscreen that you have created onto your machine.
20. Saddle up and start riding
A note on the lexan that I used.
I used XL 10 which has a coating on one side that resists the sun. A piece 1/8 x 24'' x 24'' cost me $ 22 Can. Alot cheaper than the store bought kind.
It took me a couple of tries before I got it right but it was worth it.
Be patient and don't give up.
Good luck
Jari Paavola
This is how to do it:
1. Buy a piece of 1/8 lexan, 24'' x 24'' should be enough. I bought extra because I made several windscreens.
2. Buy some bristle board and decide on the design of the windscreen.
3. Make a bristle board windscreen. I did this by holding the bristle board at the angle I wanted and pressing the bristle board around my fairing where the windscreen bolts on, this makes an indentation that you can highlight with a pencil and makes it easier to see when you cut it out. I used several different pieces taping them in place and filing in where ever there were spaces. This makes an almost perfect pattern.
4. Once you are satisfied with the way the bristle board windscreen looks on your bike take it off and tranfer the pattern onto the lexan.
5. Cut out the pattern from the lexan, leave the plastic film on until you are finished, using a jig saw with a fine blade.
6. Get a piece of plywood that's a little wider than your old windscreen. Place your old windscreen onto the plywood and trace around the outside.
7. Screw wooden blocks along the line in several places.
8. Take the lexan that you cut out and bend it so it fits onto the plywood. The wooden blocks will hold it in place.
9. Make a piece, I used plywood, that fits the contour of the top of the windscreen. This will stop the top of the windscreen from collapsing when heated.
10. place the contour piece onto the top of the windscreen and attach it to the base plywood, I used wire.
11. Make sure your plywood jig fits into your oven. Mine fit right into the rack grooves in the oven.
12. Preheat your oven to about 250 degrees F.
13. Place your plywood jig wit
h new lexan windscreen in place into the oven.
14. Bake it for about 12 minutes, this will vary depending on what oven you use, and watch it the whole time.Do not over heat as the lexan will sag
15. When you think it's done, take it out and let it cool.
16. When cold take it out of the jig, it will relax a bit but not enough to cause a problem.
17. Fit the new windscreen onto your bike and mark where to drill the holes.
18. Drill holes, I drilled a pilot hole first.
19. Bolt the beautiful new lexan windscreen that you have created onto your machine.
20. Saddle up and start riding
A note on the lexan that I used.
I used XL 10 which has a coating on one side that resists the sun. A piece 1/8 x 24'' x 24'' cost me $ 22 Can. Alot cheaper than the store bought kind.
It took me a couple of tries before I got it right but it was worth it.
Be patient and don't give up.
Good luck
Jari Paavola
Once I get a garage I'll go into full production. I've been buying lots of tools though...
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