Introduction: Homemade Motorcycle Hand Wind Deflectors (V Star 650)
Hand Wind Deflectors are used primarily to block cold air during winter riding, which makes gloves capable of withstanding older temperatures than without deflectors. Numb fingers are not good for working motorcycle controls. Deflectors are also used for deflecting stones, bugs, cigarette butts and the like. Objects hitting your hands at 65 mph can sting.
The homemade set of deflectors I made are from simple materials and were fabricated at home using basic tools. The deflectors are secured to the mirror mount using the mirror bolt itself.
These were made to fit my 2003 V Star 650 Classic.
Materials used: Aluminum sheet (I used .030' aluminum that I scavenged from a decorative lay-in (24' x 24') architectural ceiling panel; 1/8' x 1' flat aluminum bar, small nuts/bolts
Tools used: Sheet metal shears, hammer, clamping bench (I used a Black & Decker Workmate), steel pipe as form for panels, Dremel tool or file, small clamps, drill, bench vise
(Update: I know these look bulky and all, but it was an experiment. Please see the improved, revised, updated design at https://www.instructables.com/id/Motorcycle-Hand-Wind-Deflectors-version-21/)
Step 1: Make Pattern and Cut Sheet Metal
Make a pattern out of stiff paper/light cardboard. I made mine a kind of rounded trapezoid shape.
Transfer the pattern to the sheet metal. I used a nail.
Cut out the shape with sheet metal shears, leaving approximately 1/2" extensions on each side. These extensions will be folded over to create a stiffer panel. The rounded corners do not get extensions.
Step 2: Bend Panel Edges Over for Added Stiffness
Insert panel edge extensions into the work bench/vise. I used a Black & Decker Workmate.
If you don't have one of these, clamp a straight piece of wood (with sharp corner edge) to the top of a workbench or table.
Push on the panel so that it bends 90 degrees.
Gently hammer on the bent edge until it works it's way back over the panel and then hammer down flat
Step 3: Smooth Corners
Smooth the rounded panel corners and the sharp edges of the folded panel extensions using either a Dremel tool, a file or sandpaper
Step 4: Form Panel Into Radiused Shape
Gently, slowly bend the completed panel around a cylindrical object.
I used a piece of steel pipe (approx. 3" diameter).
Working from the center towards the outer edges, angle the panel such that the inner radius (small part of the trapezoid) is a smaller radius than the outer edge. This creates a flared radius.
Step 5: Form Bracket Material and Fit to Panel.
Bend flat bar stock over the same object used to form the panel radius.
Leave enough extra bar so that you can cut the bracket to length to suit your particular motorcycle mirror mounting configuration.
Cut the bent bracket to length and hand fit the bracket and panel to each other.
The bracket mounts to the smaller, inner radius of the panel.
The overall radius of the panel and bracket can be adjusted later.
Clamp panel to bracket and drill holes to fit bolts. I used (3) 1/2" long, stainless steel #10 machine bolts.
Step 6: Fit Bracket to Mirror Mount
Disassemble the assembly after all the bolts are drilled so that the bracket can be finish fit to the mirror mount.
I bent the back edge of the bracket down to fit over the back of the mirror mount.
This will prevent the bracket from rotating under wind pressure.
Drilled a hole to align with the mirror mounting bolt.
File down all rough edges.
Step 7: Assembly and Adjust
Assembly the components and remount the mirror with the bracket secured between the mirror and the mount.
The bracket and panel can now be hand formed to suit the particular configuration of your handlebar mounted controls.
I think I might paint this, as the sheet metal is a bit too flashy for my tastes.
I may trim the panel down a bit also.
I hope this was helpful.
Step 8: Final Tweaking
I ended up trimming down the panels because they looked to darn big and really didn't need to be so long to adequately block the wind.
While on the test ride, I had to adjust the panels simply by bending them by hand to get adequate clearance for gloved fingers and to lower the bottom edge to deflect the wind from my fingertips while they were wrapped around the grips.
I've got to say that these things work great.
I was able to ride in colder weather (28 degrees) for a significant length of time (1 hour) without getting numb fingers.
Previously, 20 minutes in that temperature would have been numbing.