Introduction: Cheap Winter Motor Scooter Fairing

About: I find it very challenging to stop altering things - not to mention making things. So I embrace it and make something everyday.

Riding in winter can be comfortable and affordable.

Very little material, time, and money need be invested.

Step 1: Ride Your Motor Scooter in Very Cold Weather.

Once you know what you want,

you can use what you have,

to make what you need.

I wanted a very high mileage, very low cost, all weather vehicle.

Using very primitive tools I made a winter fairing for my motor scooter from discarded signs, a short length of EMT, some cardboard, duct tape, and zip ties.

Bend the EMT into a "J" shape. Bolt this near the tail end of the scooter frame.

Step 2: Secure the "J" to the Front of the Scooter Frame.

Cut down a small piece of straight grained 2x4 - or any wooden block. Drill two holes in it. The EMT slips through one hole. The other hole, perpendicular, slips onto a forward facing tube - already welded on the frame by the OEM. Look for the wooden block in front of the handlebars in the video.

Later I may edit this very rough instructable to include the very easy manufacture of the inverted vee handlebars seen inside the fairing. These make the vehicle narrower than stock and work quite well.

You will likely need to cobble together some brackets in addition to the "J" support - to reduce fairing flexing.

Step 3: Position Your Coroplast.

Next place your old sign material, corrugated plastic sheet, or some laminated double or triple corrugated cardboard, on the "J" support and mark where you will drill holes to zip tie the sheets. Then just insert and tighten your zip ties.

You can also use hardboard for your panels. Scrounge the thin hardboard that furniture makers sometimes use - look for old dressers on trash night. Some of the most appropriate hardboard for a fairing is found on the back of projection TV cabinets and MDF shelving.

Another very flexible option is to laminate paper or cardboard to EPS foam. Be sure to glue the sheet reinforcement to both sides of the foam.

Latex outdoor housepaint can effectively seal your panels.

You can also dilute PVA glue and paint your fairing with it. Scrounged foam, PVA, and cotton fabric or paper is the poor man's FRP. Experiment with it. You will be very surprised.

Step 4: Add More Panels.

By cutting only half-way through the coroplast you can quickly create a sturdy hinge for a door.

You can vary the shape and size of panels to suit your aesthetic or aerodynamic goal.

Even a relatively crude and incomplete fairing, like the one in the video, is surprisingly effective in keeping the rider warm. The pictured fairing is the first step in an adventure to make a much more refined super-cheap fully enclosed street legal vehicle.

Follow the journey at