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Old 03-13-2015, 10:26 AM   #1
szurszewski OP
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Joined: May 2010
Location: Portland, OR
Oddometer: 22
DIY sidecar windshield - how thick?

Hey all -
I'm in the process of putting a lightly damaged Hannigan sidecar back to work. It's going to be a bit before I can get my hands on the "stock" wraparound/connects to the removable roof windshield, so I'm plannign to make a low fly-screen type shield to help get some air off the monkey.

Planning to go with polycarb, and I'm only looking to go 12" high or so at most. I am thinking with the curve I have to follow, and the low height, flexibility is going to be more imporant than rigidity - but I'm not sure what thickness to use.

I'm thinking 1/8" but wondering if it would be better to go a little thinner or a little thicker. It's not a huge investment in plastic if I don't like the first one, but I'd like to get something workable on their soon, so if you have a suggestion that will help me avoid some of the trial and error, that would be great!

thanks,
josh
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Old 03-13-2015, 11:31 AM   #2
claude
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Joined: Mar 2002
Location: Middleburg, Pa. (Snyder County)
Oddometer: 3,771
I would go with 1/8" easy to work with should be able to form into place with no hassle at all and not heat. Make holes slighty larger than needed as too tight a fit at holes can promote some cracking. We use 1/8 for our curved windshields. By all means use a polycoabonate as you mentioned! NOT an acrylic.
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Founder: Internet Sidecar Owners Klub at SCT
http://autos.groups.yahoo.com/group/SCT/

President: C Stanley Motorsports Inc.
http://autos.groups.yahoo.com/group/...rsandTrailers/

http://freedomsidecars.com/
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Old 03-13-2015, 11:57 AM   #3
szurszewski OP
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Joined: May 2010
Location: Portland, OR
Oddometer: 22
Hi Claude -
Thanks for the reply (and for all the information you've shared here and other places online - I have read, and reread LOTS of it over the last few years). I've been out in the garage and think I have a good cardboard template made up - was just about to call a local plastic shop and see about ordering some material, so your timing is perfect.

I'll go with the 1/8" and definitely polycarb. We lived for years out on the arctic tundra in AK - I've spent lots of time with plastics and snowmobiles so I've learned (mostly through error) all about keeping the hardware away from the edges of the holes and spreading the force out on as much surface as possible. (Glad I won't have to worry about hitting ice berms at high speed when it's -50 .... that tends to crack just about everything.)

thanks again!
josh
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Old 03-13-2015, 08:13 PM   #4
szurszewski OP
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Joined: May 2010
Location: Portland, OR
Oddometer: 22
Hi Claude -
Thanks for the advice (and for all the other advice you've shared here and elsewhere - I've read LOTS of it over the last few years). I tried posting this reply earlier but for some reason it popped up a message saying a mod needed to approve it first - so apologies if this ends up being duplicate.

Anyway - I'd just come back in from some time in the garage making a cardboard template and was about to call and order up some polycarb from a local plastics shop when your reply came though. I did indeed go with the 1/8" - haven't trimmed it down or put it on yet, but I think it's going to work great. I'll have to get some pics of the rig as it sits and with the new windshield (once I get it finished) online so I can post them up here.

thanks again -
josh
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Old 03-13-2015, 09:14 PM   #5
claude
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Joined: Mar 2002
Location: Middleburg, Pa. (Snyder County)
Oddometer: 3,771
__________________
Claude

Founder: Internet Sidecar Owners Klub at SCT
http://autos.groups.yahoo.com/group/SCT/

President: C Stanley Motorsports Inc.
http://autos.groups.yahoo.com/group/...rsandTrailers/

http://freedomsidecars.com/
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Old 03-14-2015, 08:31 PM   #6
szurszewski OP
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Joined: May 2010
Location: Portland, OR
Oddometer: 22
If all goes well, here should be some before and after pics. For anyone doing the same search I started with, I used 1/8" clear polycarbonate sourced from http://www.tapplastics.com/ . I mocked up a template out of cardboard and figured I'd need a sheet about 15" x 44" - the shop cut a piece that size for $30 and I bought a couple of blades for my jigsaw for $5.

I traced the template, trimmed it with the jigsaw, sanded the edges and also ran a torch around the edges lightly to get rid of the white/cut edge. The holes were drilled in four steps to reduce the chance of cracking. I think the 1/8" is perfect - easy enough to bend and should be plenty strong to stand up to highway speed winds.

Now...let's see if I know how to add pictures to a thread here:


Before (please ignore as best possible the very cluttered garage):


In progress - little guy assembling and staging fastener sets:


Fly screen in place - he looks through and his mom probably will as well - for me it's just under my line of sight:


And here's where I tried to get fancy with the corners - didn't come out too bad considering I don't know what I'm doing - having the right blade probably helped:


I think it looks fine - way better than nothing - but it will be interesting to see how it works with airflow. In any case, it's only $35 so far...

cheers-
josh
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Old 03-14-2015, 08:46 PM   #7
claude
Sidecar Jockey
 
Joined: Mar 2002
Location: Middleburg, Pa. (Snyder County)
Oddometer: 3,771
Very good job!!
__________________
Claude

Founder: Internet Sidecar Owners Klub at SCT
http://autos.groups.yahoo.com/group/SCT/

President: C Stanley Motorsports Inc.
http://autos.groups.yahoo.com/group/...rsandTrailers/

http://freedomsidecars.com/
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Old 03-15-2015, 04:12 AM   #8
DianneB
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Joined: Dec 2014
Location: Manitoba, Canada
Oddometer: 69
I just made one from a sheet that is (I think) about 0.100" thick, glued to a 1/4" Plexiglas base so that it is easily removable.




It seems to be working out okay though I have yet to do any sustained riding at highway speeds.

Total investment was $7.00 for the polycarbonate sheet from the local lumber yard. The Plexiglas was surplus shop supplies, as was the stainless steel fasteners, and I had the glue on hand. For $7.00 I can afford to replace it if it doesn't stand up!
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Old 03-15-2015, 08:24 AM   #9
szurszewski OP
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Joined: May 2010
Location: Portland, OR
Oddometer: 22
Looks great and you can't beat the price!
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