The DIY $12 windshield

[Sunapee]

Yea, I'm cheap. So I made my own windshield.



First, check ebay for a sheet of Lexan. Mine was 1/8" X 12" X 16" smoke colored.
Cut it into a tombstone shape, I used a joint compound bucket for the top corners, a coffee can for the botton 2. Cut it with a saber say, band saw, coping saw, whatever you have with a fairly fine tooth.
Peel off the backing paper, pre-heat your oven to 350 degrees, place two 2"X4" scraps just under the long edges, and bake for 12 minutes. The lexan will sag into the right shape. Then you can use oven mitts to remove and tweak the shape. It'' cool in about 2 minutes and retain it's shape.



I used two 6" bolts with washers through the turn signal brackets and marked where to drill through the lexan. The bolts won't match the curve of the lexan, so I carefully warmed the lexan with a blowtorch to change the curve where the bolts attached. I used a piece of 1/2" pvc pipe to cover the threades, then dressed the pipe with chrome tape from the auto parts store.
The botton of the windshield attaches to the cage around the headlights with some zip-ties through small holes drilled for them.



It works real well, when small bugs hit it they fly right over my head. The \big ones still hit my head.

[Craig]

Wow, simple and cheap. I am going to have to do this this weekend. Just bought a 2009 Ruckus yesterday afternoon.

[finippino]

Made my own too. It makes a big difference in deflecting the wind. I wanted mine to be adjustable so I made the shield pivot. What do you guys think?

[sonicsix]

I am cheap, too. I have two 08 Rucks and made windshields for both for $19. Here's how I did it:

Step 1: Head to Home Depot and purchase 1 sheet of clear Lexan 12" x 24", Item #726941133019 for $9.22 US... 1 piece of 1/8 x 3/4 x 24" aluminum flat bar, item #030699446506 for $5.59 US... Two 3/8 x 1" bolts and nuts for $0.46 US... and finally a packet of 4 galvanized washers that have a rubber coating on one side, Item# 030699892785 for $0.70 US. Total bill with tax for me was $18.52.

Step 2. Leave the protective coating on the Lexan for now. Cut the sheet of Lexan in half with a jigsaw or cutting tool of your choice. Take a standard coffee can or other object with the circumference of your choice and hold it in the top corner of the Lexan, mark off the curve that will be the top corner of the windshield.. Repeat for other side.

Step 3. Cut the corners off the top of the windshield. Use 220-400 grade sandpaper and smooth off any edges you cut with your jigsaw. You now have a sheet of Lexan that looks somewhat like a tombstone. If you want a different size or shape, decide that before Step 2. A taller windshield will likely require a different shaped mounting bar!

Step 4. Hold this newly cut piece of Lexan to the front of your Ruckus and rest it on the light frame between the blinkers, pressed up against the support brackets that have a hole in them. If you look at the front of your Ruckus, the brackets that hold the blinkers on have a hole in them, this is what I am talking about. Now use a pencil and mark these holes from the backside on the protective paper that is still on the Lexan. Once marked, drill a 3/8" hole in the center of these marked circles.

Step 5. BENDING YOUR FLAT BAR - Place your aluminum flat bar 3/4 of an inch into a vice and tighten. Bend it to just past 90 degrees (this is what will give the windshield it's curve when mounted). From your first bend measure 6" and mark with a pencil. Place this mark at the top of your vice, tighten and bend the bar the opposite direction of your first bend. Now measure 1" and bend the bar in the same direction as the 6" bend... you are essentially making a V shape with the bar. Measure 6" out from the base of the last bend and make another bend like the very first one you made. Use your jigsaw or a hacksaw and cut off the excess bar leaving 3/4" to match your very first bend. Grind smooth any rough edges on your bar. Scratch it on concrete if you don't have a grinder.

Here is what the outer part of the bar should look like when done:


Step 6: Now drill a 3/8" hole into each "ear" of the mounting bar as well as in the 1" flat area at the base of the V shape. Place the bar into your vice before drilling for safety reasons! The 2 holes on the "ears" are for mounting the Lexan and the one on the base of the V is where it attaches to your Ruckus.

Step 7: Remove the protective coating from the Lexan. Attack the Lexan using the aforementioned nuts, bolts and washers. Place a washer on a bolt, rubber side up, put that through the hole in the Lexan, place another washer on the bolt rubber side down then the nut. Tighten, but not too tight. Repeat for the other side and you will need to bend the Lexan a little to make it fit, this is what is intended. You can bend your bar a little if you need to but do it before attaching it to the Lexan. The Lexan will have a slight curve at the bottom but not so much at the top.

Step 8: Remove the top bolt that holds your light assembly on. Place this bolt through the last hole in your mounting bar and re-install the bolt. Before you tighten it down for good, make sure the windshield is not tilted or off kilter. Tighten it down but don't overdo it.



Step 9: Celebrate! You now have a windshield (or two) for less than $19.00 US. IMO, the ride is nicer and my top end improved. More pics at: www.flickr.com/photos/sonicsix and www.wessingtonfarm.com/scooternation

Note: I like the OP's windshield better than mine, I never saw any smoke colored Lexan at my Home Depot nor did I think to put it in the oven!

[jody]

This is mine.

[finippino]

Nice bracket system! The shield seems a little small, does it deflect the wind ok?

[chanito]

What's up with the competition
Just buy a Chanito unit and stop with the fabricating
But seriously, great job guys ;D ;D

[jody]

Oct 2, 2008 13:39:55 GMT -5 finippino said:

Nice bracket system! The shield seems a little small, does it deflect the wind ok?

It's OK for me cos the ruckus can't run too fast.
It won't vibrate while I'm driving.
It is strong enough to deflect the wind.
Thanks for your warm remind.

[sr50r]

Sorry Chanito ;_;






Finally hauled out my big camera