MrYeats
XS400 Addict
I did this on my 83 xj550
I made my first windshield today and it turned out nice...I will get some pix on how I did it and for now I will tell about it.
I bought a stock fairing on ebay for $65 shipped. It is from a 82 550 Seca, so I knew it would fit my 83. The only drawback was that there was no windshield on the fairing, so I started poking around to find what to do next.
After reading about finding some clear 1/8" Plexiglas, I discovered a different, stronger, and more flexible product. That being Lexan or polycarbonate. It is at least 3 times stronger than plexi and takes cutting and drilling easier.
I got a 16x24 piece on ebay for $16.
I took a piece of poster paper and traced the pattern to cut the Lexan and traced it. Advice is to leave the protective film in place till the cutting is done. Good advice.
I cut the poster pattern out and placed it on the Lexan to mark it.
I did that then took a box cutter blade and scored a mark along the inked marking.
I then took my Dremel tool and cut out the pattern.
Using a clamp to hold it in place on the fairing, I drilled the first screw hole and put on a fastener and did this on the first 3 holes. I then moved the clamp to the opposite side and clamped the corner down.
This made it easier to continue to drill and fasten each hole in the order I had started. By the end hole and screw, it was a very nice fit.
I am impressed with how well the Lexan will bend to the shape of the fairing without distortion and can be done as I did, without heat.
Now I will remove it and polish the rough cut edges and reinstall after I paint the fairing
I made my first windshield today and it turned out nice...I will get some pix on how I did it and for now I will tell about it.
I bought a stock fairing on ebay for $65 shipped. It is from a 82 550 Seca, so I knew it would fit my 83. The only drawback was that there was no windshield on the fairing, so I started poking around to find what to do next.
After reading about finding some clear 1/8" Plexiglas, I discovered a different, stronger, and more flexible product. That being Lexan or polycarbonate. It is at least 3 times stronger than plexi and takes cutting and drilling easier.
I got a 16x24 piece on ebay for $16.
I took a piece of poster paper and traced the pattern to cut the Lexan and traced it. Advice is to leave the protective film in place till the cutting is done. Good advice.
I cut the poster pattern out and placed it on the Lexan to mark it.
I did that then took a box cutter blade and scored a mark along the inked marking.
I then took my Dremel tool and cut out the pattern.
Using a clamp to hold it in place on the fairing, I drilled the first screw hole and put on a fastener and did this on the first 3 holes. I then moved the clamp to the opposite side and clamped the corner down.
This made it easier to continue to drill and fasten each hole in the order I had started. By the end hole and screw, it was a very nice fit.
I am impressed with how well the Lexan will bend to the shape of the fairing without distortion and can be done as I did, without heat.
Now I will remove it and polish the rough cut edges and reinstall after I paint the fairing
