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Old 09-02-2014, 02:58 AM   #1
thewarrior53 OP
Arise, Goforth, Conquer
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Joined: Dec 2007
Location: North Carolina, USA
Oddometer: 87
Wind Screen Modification:

I own a Ducati Monster 900. I have installed the standard small fairing with wind screen. I'm thinking of buying a taller screen and cut it to fit my fairing. Has anyone done this. And if so, how did you do it? Bandsaw?
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Old 09-02-2014, 06:03 AM   #2
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Joined: Feb 2013
Location: Oxfordshire, UK
Oddometer: 28
I made a windscreen from sheet lexan for my strom.

Scroll-saw cuts it fine (use masking tape both sides to prevent it melting back together) and a sheet metal bender/brake bends it quite happily.

I wouldn't recommend using acrylic - it shatters.
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Old 09-02-2014, 06:18 AM   #3
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Joined: Nov 2009
Location: Hiding off Hwy 6, B.C.
Oddometer: 4,406
As I found out recently,angle grinder with a zipcut blade works very well.Had to cut a large free sheet to fabricate a rear window for the bushcar, was faster than resetting the bandsaw with the right blade.

Wear protection if you do plastic does stick to skin.

Whatever tool you use....tape first, mark the cut on the tape and cut through the tape.
Have tools, will travel!
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Old 09-02-2014, 06:52 AM   #4
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Joined: Feb 2010
Location: Barrie Ont
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I used a jig saw.

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Old 09-02-2014, 12:44 PM   #5
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Joined: Jan 2008
Location: Hot, Flat, Straight Texas
Oddometer: 179
I used a jigsaw and a fine blade. Blue masking tape on each side, trace the line and cut the screen while still mounted on the bike.

Wet sandpaper the cut edge to make it "clear" again. It is quick to do when still mounted on the bike, so consider making a few cuts, working your way down. First cut, then ride. If too tall, cut another inch and test ride again.

I was nervous to try this, but it really is pretty easy.
A fast moving target...
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Old 09-02-2014, 04:57 PM   #6
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Joined: Jun 2012
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Blue painters tape to mask. Dremel with a cutoff wheel to make the cut. Flame polish with a propane torch. Heat gun or hairdryer to make compound bends.
Mixing metaphors is like killing two birds with a dog that won't hunt.
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Old 09-02-2014, 05:20 PM   #7
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Joined: Apr 2010
Location: Berkeley Springs, WV
Oddometer: 197
You can soften the plexi in the oven at about 250 degrees after you have it cut so you can put a curve in it that will remain permanent. Use good gloves to handle it because it'll be hot. I built a laminar lip like that once. It worked very well.
2001 KLR250 | 2005 KLR650

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Old 09-02-2014, 06:00 PM   #8
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Joined: Sep 2011
Oddometer: 664
masking tape, jig saw, belt sander.
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