DIY plexiglass windshield

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willg
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DIY plexiglass windshield

Post by willg » Fri Sep 15, 2017 9:23 pm

I thought I'd show some pics and document my windshield fabrication. After looking into this online I figured there could always be a little more info available. This is .22" plexiglass from HDepot. I had enough material from one sheet to make 2 windshields. I first used heavy paper to make a template on my console to get the gist of what I wanted, then transferred it to a piece of ply to make a permanent template. I didn't worry much about exact measurements for the template, just made sure it was symmetric. I transferred the template pattern to the plexiglass, but drew it wide so I could rough cut the plexiglass on the table saw. Then I taped the plexiglass to the template and ran it on the router table using a straight pattern-following bit. The router does a clean job on the plexiglass (the table saw does not). I then rounded the edges on both sides with a 1/4" roundover bit. I then flame polished the edge with a MAP torch (also HDepot). This turned out nice. I used the console itself as the bending form for the corners. After slowly heating the bend line with a hot air gun I taped it to the console, did the bend and held it till it set. It's hot as hell and you need gloves for this! Despite all the warnings about drilling plexiglass, I drilled the holes carefully beginning with little bits and worked my way up - no problem. It was attached with finish washers and rubber washers.

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Jaysen
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Re: DIY plexiglass windshield

Post by Jaysen » Fri Sep 15, 2017 9:37 pm

Nice! Looks great.
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Fuzz
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Re: DIY plexiglass windshield

Post by Fuzz » Fri Sep 15, 2017 11:51 pm

Really nice custom windshield :!: Thanks for posting this.

Browndog
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Re: DIY plexiglass windshield

Post by Browndog » Sat Sep 16, 2017 6:26 am

Great job. This is really helpful to have here on this site.

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topwater
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Re: DIY plexiglass windshield

Post by topwater » Sat Sep 16, 2017 8:08 am

Great info and nice Job :!:
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Eric1
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Re: DIY plexiglass windshield

Post by Eric1 » Sat Sep 16, 2017 10:08 am

I'll tell you what I think. I think that is Absolutely Gorgeous! Great Job!!! :D

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Re: DIY plexiglass windshield

Post by Jeff » Sat Sep 16, 2017 11:19 am

Really well done, better than production!!! Jeff

Dougster
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Re: DIY plexiglass windshield

Post by Dougster » Sat Sep 16, 2017 11:50 am

Love that. Thanks for taking the time to document it.

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Re: DIY plexiglass windshield

Post by jtdums » Sat Sep 16, 2017 2:21 pm

This was very helpful and I too appreciate it being documented. I'm very impressed at how well the router/round over/ torch did on making very professional edges.
Sanding is cathartic...

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pee wee
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Re: DIY plexiglass windshield

Post by pee wee » Sat Sep 16, 2017 3:20 pm

I agree, that turned out very nicely. Question- you say you used .22" plexi, and a 1/4" round over bit on the router; obviously you would only be able to ease the edges. If you had had a smaller radius bit would you have used that instead?

I imagine while you were handling that hot plexiglass with your tape and gloves, it wasn't convenient to take a photo . . . did you do one bend at a time or try to make it all in one go?
Hank

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