I have this posted on the softail forum
and someone suggested I should also post it here
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Note: It actually looks alot clearer in person, you can see inside the throttle body.
The pics showed alot of background reflections.
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Hey guys, so I was contemplating this in my head ever since I got the RSD clarity derby and cam cover. Anyway, since I dont have $499 to burn for the RSD clarity a/c cover, I figured I make my own
After some research, I found a suitable clear polycarbonate material made by Bayer, it's called "makrolon" and it has a good heat resistance and strength. I found an ebay seller that sells them in 6" diameter so I ordered a few (in case I make mistakes).
The K&N filter I used is the model E-3330. It fits my black Arlen Ness big sucker backing plate.

Anyway, for this mod I used the following:

1/8 by 6" clear polycarbonate lexan by bayer- $2.65 each
K&N E-3330 (5.125 ID, x 6.125OD by 2.063 HT)-$34.00
Ness big sucker basic stage I in black- $134
Misc-3 washers and 3 self stick foam washers.
Drill and drill bits- I started with the smallest 1/16
up to the final one I used, which is 15/64.
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Here are the pics:
What u guys think?
I'll update and let u guys know how it holds up.


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looks really good nice job

just so you know
gas will attack Lexan and craze it, making it brittle, will look almost like broken glass .. keep an eye on it .. lexan is also softer then plexi and will scratch very easy when cleaned..

just a heads up !
but it looks damn good

 

Thanks, It's still on testing phase, I'll update when I see some problems, like heat issues and cracking. So far from the manufacture's website,(Bayer-makrolon) this thing is pretty resilient to heat and less prone to cracking. I'll let u guys know how it holds up after a few rides.

 

Just an update, I also posted this on the softail forum
100 miles Update 5-20-13
So This has been on my bike for approx 100miles.
Here are the pics from today's ride, No visible oil build up on the
poly itself, oil stayed in the backplate.
After getting home, I took some temperature readings using a handheld IR gun:

Cylinder heads 235-241 F
A/C backplate 103F,
A/C poly clear cover 93.5F
Oil in tank 140F (guess the K&N oil filter and syn3 is doing its job)
RSD cam clarity cam cover 163.5F
RSD derby clarity cover 135F
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Very clean looking ride !

 

Thanks!

 

Update 5/31/13
@ 240miles since this DIY clear poly a/c cover was installed:
Rode yesterday and today wth temps at 86F, a bit humid
but breezy near the shores.

Anyway, After I got home I took temps again using my
handheld IR thermo scanner:
Front and rear cylinder heads= 238-248F
DIY clear poly a/c cover= 115-117F
Ness bigsucker backplate=155-165F
RSD clarity cam cover=158-174F
RSD clarity derby cover=122F
Oil temp gauge reading=198F
K&N oil filter=159-168F
So far, the clear poly cover has remained clean, with no oil smudges or build up.
(oil stays on the backplate of the a/c)
No warping, cracking esp near or around the screw holes.
Just thought I update you guys

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You deserve a medal, excellent work/reporting.

 

Thanks,
Just got back from a ride with my son.
he gets a kick out of all the see-thru covers I have on my bike.

 

(Also updated in the softail thread)
Update 6/30/13
I have about 400 miles on the 1/8" thick clear poly with NO problems.
Since I have a few pieces of 6" round 1/4" (Bayer makrolon) clear poly, I decided to upgrade it.
I also took a few pics for comparison. What a difference, the 1/4" is double the thickness, but still same clarity.
At first I was concerned that the screws were'nt long enough, but they DO fit! and because the 1/4" is alot thicker and beefier, I was more confident in tightening the screws and also found that I did'nt need the washers.
BTW, start with the smallest drill bit and then final drill bit size I used was 1/4" bit.

To recap: Since I had more than 400 miles on the 1/8" thick poly cover without any problems, I dont anticipate any with the 1/4" thicker poly. However, nothing is perfect so If I find any issues, I will update this thread.


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