Picture of Motorcycle Windshield - Curved
Front View   IMAG1035.jpg
Side View  Right  IMAG1049.jpg
My motorcycle windshield was broken right after I bought the bike (used).  I was initialy planning to replace the plastic and reuse the existing hardware, but I really did not like the large size of the old windshield, and the mounting was really ugly.  New motorcycle windshields are available in a variety of sizes and shapes, but they are expensive, and I just could not find exactly what I wanted. 

Molding acrylic plastic is not hard to do (I have made a couple of items this way before, but not a windshield), and the material is readily available, so I decided to try making one.  This one has a slight compound curve (bend in two diections) but most windshields are just a simple curve.

The bike in the picture is a 2001 Honda Magna 750, with my homemade windshield installed.  This type of windshield would probably work for most any bike.  It is fairly small, and I did not see any need for metal bracing on the windshield.  It is mounted with four struts of 1/4" all-thread, bolted through the plastic.  It has held steady at up to 75 MPH (legal, here in Texas), with no vibration or movement.  It has killed allot of bugs that would otherwise have been splatttered all over me!

ahorton61 year ago
This worked great !!! I just finished it tonight. Hardest part was the plastic melting back together behind the jigsaw blade as I cut, from the hot blade. Not sure how to avoid that. Did anyone else have that problem?

I used a Dremel with a cutoff wheel and adjusted the speed to what I needed. Worked great, no melting plastic at all.

Kev13 ahorton610 months ago

Not hard - if you have a helper, they can squirt cold water (spray bottle) on the cut as you go, or if solo, rig up something that does the same.

tawodi1 year ago

This is an awesome instructable. I would recommend a lexan or polycarbonate due to its impact resistance. Plexiglass or acrylic can crack or explode on impact. Take a spare piece of acrylic and hit with a hammer and see for your self.

very good instruct able. I miss my motorcycle..
Cool! I didnt really ever think of using cardboard as a jig for plastic sheet material, and heat forming.

magnawing2 years ago
A good hair dryer set to high heat works well for the shrink tubing without the danger of scorching the tubing with a flame (or burning your fingers)
doc.kennedy2 years ago
Great job and good detailed instructions - thanks!