Fab'd up a headlight protector

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by motorcycleMonkey, Oct 5, 2012.

  1. motorcycleMonkey

    motorcycleMonkey Adventurer

    Sep 29, 2012
    Sin City
    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 advrider.com ... :evil

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