I want to make a new windshield sort of like the Britania,to do it I need to make a mold of the original shield from the KLR.Plaster of paris? fiberglass? foam from a can ? I am going to use the mold to heat lexan to form the new shield.Yes I know,just go out and buy one, A.not a lot of extra $ B.I am Scotish,some call me cheep,I like frugal C.3 months till the snow is gone here in Vermont lots of time to work on the bike. D.I like to make stuff. Thanx for any help.
I haven't tried it myself yet but I've heard that it pretty easy to shape Lexan Plexi Glass. Just put it in the oven on 350 for 20 minutes to a half hour, pull it out with gloves on and bend it carefully in to the shape you desire... Repeat as necessary... Like I said, haven't tried it yet myself. I have cut shaped lexan with a Jigsaw and a bandsaw. Just tape it off, draw lines and cut with a hacksaw/metal type blade. Drill mount holes slowly with a sharp bit. Drill press is an added bonus. Let us know how it works.
Check out this thread, it isn't windshields but should give you some ideas. http://www.advrider.com/forums/showthread.php?t=395705 <object width="480" height="295"><param name="movie" value="http://www.youtube.com/v/dX5KxUm0Pf4&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><param name="allowscriptaccess" value="always"></param><embed src="http://www.youtube.com/v/dX5KxUm0Pf4&hl=en&fs=1" type="application/x-shockwave-flash" allowscriptaccess="always" allowfullscreen="true" width="480" height="295"></embed></object>
Looks like that 20 to 30 minutes I recommended in my earlier post is way too long. 350 degrees, pull it out every couple minutes and give it a try...
If the bends aren't too complex, lexan will bend easily with the judicious application of a heat gun. As others said, a fine tooth saw blade, tape the cut lines, etc.
