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Old 10-05-2012, 12:17 AM   #1
motorcycleMonkey OP
Joined: Sep 2012
Location: Sin City
Oddometer: 44
Fab'd up a headlight protector

Could only find one headlight protector for the 950 SE and it's yellow ... no thanks!

Super easy to build your own!

1. Hit Home Depot for -
---- small sheet of Lexan - $5 (I got a bigger sheet though for $13 but the small $5 one will do.)
---- heat gun (1000 degree model) - $23
---- Industrial Velcro - $4 (I bought white ... on second thought shoulda gotten the black ... see pics.)
---- 320 grit sand paper - $4
---- small metal saw - $5
---- Tot = $41

2. Cut Lexan to desired shape.

3. Sand edges smooth.
---- I layed the sand paper on the flat cement garage floor and just ran the edges of the cut Lexan smooth.

3. Bend Lexan with heat gun.
---- I laid it over a 2" wooden dowel (it's all I had laying around).
---- Put the gun on the 1000 degree setting.
---- Hold approx 3-4 inches from Lexan and act like you're graffiting ... I mean spray painting ... sweep back and forth in slow even motions.
---- As soon as the Lexan begins to fold, lay down the heat gun and bend the Lexan to desired shape. I used 2 rags to insulate my hands.
---- Mine didn't quite bend in the center. But it still works ... I'm planning on making a much larger one with the left over Lexan later.

4. Cut Velcro.
---- Place headlight protector in desired location.
---- Stick the two halves of the Velcro together.
---- Place Velcro underneath with the backing still on it.
---- Mark with a pen where to cut.
---- Cut Velcro.
---- Do both sides.
---- Remove backing and stick Velcro to Lexan.
---- Remove backing on other side.
---- Hold headlight protector in the exact location you want it and press to bike.

5. Take pictures and post on ...

As stated, mine is bent a little (ok, a LOT) off center but it's not bad for prototype #1.

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