I don't have any knowledge of how windshields are made, so don't let me discourage you. But here's something to consider. The Harley lexan windshields are curved. I assume this is done by some kind of heating procedure, probably with some very specialized equipment. How could a flat piece of lexan be made into an acceptable curved windshield without such equipment? Let us know how this turns out. If it works I may attempt it to replace my cracked shield

 

Memphis Shades, Rifle, and National Cycle all have replacement lexan for OEM windshields. You can probably find some in the J&P Cycles catalog or web site.

 

boogie -- didn't mean for my post to infer I got the short end of the stick. When I found out it was cut down, I contacted the seller, told him of the discrepancy and suggested he knock of 40 bucks in order to pay approximately 1/2 for a replacement windshield. Initially he offered me a full refund, but took my suggestion. It was a win-win situation for both of us, really. If I have to buy a replacement windshield, I'm still ahead (meaning: still much cheaper than buying a new one).

dynageez - You've got a point there, but I figured the HD hardware is stiff enough to pull the windshield into a slight curve. I could be wrong on this. I figure it is worth a try if the Lexan is not too prohibitively expensive.

Gary - I've been looking at J&P as I have one of their catalogs on hand. They appear to be the most reasonable - I believe something this side of 100 bucks. Thanks for the tip.

 

OK danieldd....feel free to do so.
If the price of the Lexan (be sure to pick a thickness close to what you are replacing) is within reason, compared to buying a new shield, here are a couple more thoughts I had....
The Lexan is bullet proof, as we all know. The weak point of Lexan is the fact that it scratches fairly easy. So, leave the paper on it (both sides) for cutting out the shape, sanding the edges etc. You can draw on the paper as well as mark where you need to drill those holes.
If you want to put some bend in the shield, just support it at both sides with a couple of 2x4's and lay a weight in the middle to deflect it similar to the bend you wish to put in it. Let it sit there for a week or two. It will spring back some, so be sure it has a pretty good bend in it when you apply the weight. The bracket hardware off your current windshield should hold it in the proper position. The hardware will have a bend in it and is going to be your templet for drilling the Lexan. Metal strips inside and outside will trap the Lexan between them.
Now, you are ready to remove the paper and do the flame polishing.......pg
ps: Save all of the cut off pieces when you cut the shield out of your rectangular piece. These can be used to practice on for the sanding and flame polishing you will do later on.

 

Gotcha D! I'm sure the hardware alone isn't cheap new.

 

ok if your going to do it yourself, do it right,here is a easy way of makeing a windsheild. first it isnt just cutting a peice of plastic and bolting it on and your done, there is more to it then you think, but not hard at all.but you have to be safe about it, dont want your windsheild popping off down the road at 70 mph. i have made a few windsheilds in my time out of lexus for concept and test vechiles in my time. first you will have to get your lexan, motorcycle windshields are usally 3/16 thick, check before purchaseing just incase. never buy lexan from a window company or a hardware store, you will pay out your *** for it. find a platic supplier in the yellow pages or online close to your area, a companythat all they do is sell plastic, it will cost you about $50-$60 for a 4ft x 8 ft sheet, unless they will precut. ok now you have your lexan, now you need the rest of your tools, 1. heat gun 2. razor blade 3. a sharp marker 4. disc sanderor sanding device5. bandsaw or jig saw w/bi metal blade 6. blue painter's tape 7. a piece of posterboard 8. scissors 9. propane tourch-cheap hardware one.ok now you have your tools, take your windshield apart, so you just have the old lexan in your hands. grab the peice ofposterbarod and tape it to your windsheild and use the marker to trace the profile of your windsheild with the bolt pattern. after tracing the windshield, feel free to change the outside profile to your liking, bigger, smaller, wider, thinner etc.. after you have the profile you want, cut the pattern out andlay it on top of the lexan andtrace it with the marker. after the lexan is marked, take the blue painter tape and stick it to the marker line you have on your lexan, then do the same on the other side of the lexan with the tape. after you put the tape on the outline on both sides, re-trace your pattern onto the painters tape, so when you cut and sand the lexan it will not chipthe edges of the lexan. ok now cut out your pattern and drill your holes. after you cut out the pattern, do not remove the tape yet. nowsand it with the disc sander or sanding device of your choice. after you sanded the lexan, now you can take off the blue painters tape. now you will have to deburr it, first break off the big clumps with your fingers, then take the razor blade and hold it at a 45 degree angle and run it along the edges until it is smooth and not sharp, dont go to deep though just enough to take the edge off. now take the propane torch and practice on a piece of scrap lexan first before doing it to the windsheild. aim the flame straight at the edge and move it kinda slow-medium pace, a few times back and forth,then work your way around the windsheild, do not over heat it, it dont take long to do this part. now take the lexan wrapper off the lexan and mount it to your barckets. it should take the form of your brackets somewhat, but it will still have alot of tension on it, that you MUST get out. if not your windshield could pop off the bike. ok now that i have scared you a little, all you have to do to get this out is easy. take the windsheild mount it to the bike, it might be a little struggle since there is so much tesion, but install it anyways. now with the windsheild on the bike, we have to get the tension out.take the heat gun and heat the lexan up a little, working the heat gun up-down- side to side and not staying in the same spot to long, this could warp the lexan. after you have heated the lexan up for a little while, you will start notice the windsheild relaxing.DO NOT TAKE IT OFF THE BIKE,let it set over night still mounted to the bike. this will allow the lexan to curr and take shape of the mounting brakets and this will give youthatcurve and take the tension out. you will notice itwhen you take the windsheild off the next day and it stays curved and how much ea

 

WS are cool..............

and yeah...........what jackyl said[8D].

Good explanation man!

 

How much is your time worth???

IMO, you're not going to save enough money on this project to be worth the time involved, and then when you are not happy with the results, you will lose even more money, having to buy one anyhow.

 

I have never let any dealer work on my bike! But when you start messing around with something that can come apart and cause infury to you or your passinger you need to do whats right(by getting a new windshield)! And don't assume anything about me! Dave...

 

Psycho - How much is my time worth? When I'm doing it for myself - it's always free - and I can live with that! When I'm doing it for somebody else, then it costs big time. The fine folks here on this forum have given me enough detailed information that I am confident I can do this myself.