When riding down the highway on your motorcycle, there's nothing quite like the sound of cars whizzing past and the feel of wind in your hair. But if the windscreen on your bike is broken, you could feel blown away by gusts when travelling at high speeds. You can make and install a motorcycle windscreen quickly to replace a broken one or to simply swap out your old one for a windscreen with a different style or a different size. Once installed, you'll be out and riding again before you know it.
- Skill level:
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Things you need
- Thin cardboard
- Felt-tip marker
- Plexiglas windscreen blank
- Masking tape
- Sabre saw
- Palm sander
- 80- to 120-grit sandpaper
Draw out the shape and design of the new windscreen on a sheet of thin cardboard with your marker. Base its shape and size on your old windscreen. Make sure to mark the bolt holes correctly. Cut out the pattern and place it on the motorcycle. Make sure the shape is right and the existing bolt holes in the bike line up with the bolt marks on your template.
Cover the Plexiglas windscreen blank with strips of masking tape. This will help protect the new windscreen from scratching and chipping when cutting. Attach the cardboard pattern to your new windscreen blank and trace the pattern and bolt holes onto the masking tape-covered windscreen blank.
Cut the new windscreen blank with a sabre saw. Make sure the blade is new and has about 12 to 14 teeth per inch. Cut slowly and carefully. Take your time and follow the pattern you marked out.
Attach a 1/8-inch or 3/16-inch drill bit to your power drill. Drill pilot holes for the bolt holes. Switch out the bit with one that's a little larger than the bolts and drill the final bolt holes. When drilling, use the slow speed setting and use firm pressure.
Remove the masking tape. Sand down the edges of the windscreen with a palm sander using an 80 or 120 grit sandpaper. Smooth the hard edges and even out the cuts.
Wash the windscreen with warm water to remove dust from the sanding. Install the windscreen onto the motorcycle. Line up the bolt holes on the windscreen and the bike. Be sure not to overtighten the mounting bolts as this could crack the windscreen. Tighten each side of the windscreen a little at a time to make sure it fits flush with the bike.
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