I need some lexan, project ideas?

[Atomic Dog]

Okay, I've been kicking around the idea of getting a larger windshield for my bike. I liked the double bubble but i'm too cheap to spend the cash when the stock shield works fine for most of my rides.

I found this guy who makes shields out of lexan and I like them. Not as cool as a double bubble, but they will work.
http://members.aol.com/dukestor/wind...indshield.html





After thinking it over I decided to make one myself. As you can see his shields use the mirror mounts to keep the curve and add security. my plan is to make that my main mounting point and mount it directly over my existing shield. This will allow me to quickly add and remove it when needed. It will come in handy during winter and on the highway and I can take it off in 5 minutes when I don't want it on there.


So I'm looking for suggestions, and a place where I can pick up some lexan at a decent price. I'll be making my measurments and designs in the next few days so I have plenty of time to plan.

Thanks guys!

~Brian

[soberbyker]

Okay, I've been kicking around the idea of getting a larger windshield for my bike. I liked the double bubble but i'm too cheap to spend the cash when the stock shield works fine for most of my rides. ......
~Brian

You can probably pick some up plexi-glas at Home Depot.

On my Road King I wanted to cut down my full size windshield because the top of it is right at my line of sight, I have to tilt my head up or down to see properly. I found a windshield Harley made that was about a third the height, it was even smoked gray, would look great on my black bike, but man was it expensive.

I decided against cutting my own and saved enough to buy the smoked one, aerodynamics and looks were my main reasons. Start putting all kinds of stuff not specifically designed for the bike and you start to lose money, in gas if it's not aerodynamically designed for the bike, not to mention possible safety issues at high speeds.

I spent more than I wanted but I think it was worth it. Looks good, and keeps the wind from pushing me out of the seat at high speeds.

Take it for what it's worth.

Bill

[Emptymag]

Have you ever cut the stuff?

It's stinky, and the shavings like to melt back together as you cut.
I'm sure theres a "right way" to do it... when I did it, I didn't need the finished piece to look good, so I wasn't concerned with how it looked.

[Atomic Dog]

That is one sexy windshield!


My problem is that the wind hits me right at the chin and my neck gets cold. Same with the hands. I really only need an inch or two to make a huge difference.


You are right about gas mileage, and I'm hoping that because it's not much bigger it won't have a huge effect, but we will have to see.




Oh, I considered plexiglass because it is cheaper but wouldn't lexan be better? Considering I'm only using a small mounting point I don't want it to break off at speed. If it's strong enough I can pick some up tonight.

[Atomic Dog]

Have you ever cut the stuff?

It's stinky, and the shavings like to melt back together as you cut.
I'm sure theres a "right way" to do it... when I did it, I didn't need the finished piece to look good, so I wasn't concerned with how it looked.

Actually, I just remembered that I don't have access to a band saw anymore. I do have a coping saw, but that might take a while.



(slight kink in my plans....)

[brian]

plexi is bittle to start with, get it cold an see what happens.

lexan on the other hand is bulletproof.
lexan can also be shaped using heat. one of those little propane bottles that sears has would be more than enough. warm it up, form to the shape you wish, let cool, presto.

[soberbyker]

.... Oh, I considered plexiglass because it is cheaper but wouldn't lexan be better? Considering I'm only using a small mounting point I don't want it to break off at speed. If it's strong enough I can pick some up tonight.

To be honest I thought they were the same, I stand corrected, Lexan is stronger.

Never to old to learn.

Bill

Acrylic (Plexiglas) vs. Polycarbonate (Lexan)

What are these? They are glass-like plastics, hard, clear, and are used in place of glass for many projects such as display boxes, racecar windshields, and bullet proofing your pope mobile.


Polymethyl methacrylate vs. Polycarbonate would the correct scientific title for this text, Also ‘Lexan’ is a trademark. So for this text I’ll refer to Lexan as Polycarbonate and Acrylic as Acrylic since that is the correct, non-trademarked name.

Lexan = Polycarbonate!

I simply want to write about the differences between the two materials, no scientific explanations of why they are different, what they are, or anything of that nature. So, I’ll divide the rest of this into three sections; popular uses for each, general differences and a very general how to work with each. I will be focusing on consumer goods, omitting information such as injection moulding.


Popular Uses for Acrylic:

Motorcycle helmet visors
Spectator protection in ice hockey
Police riot control vehicles modifications
Computer case mods (windows)

Popular Uses for Polycarbonate (Lexan):

Compact discs, DVDs
Lighting lenses, sunglass/eyeglass lenses, safety glasses, automotive headlamp lenses
Drinking bottles
Computers: Apple, Inc.’s MacBook, iMac, and Mac mini
Cases
Riot shields, visors
Instrument panels

Key characteristics/differences, Acrylic compared to Polycarbonate (Lexan):

More likely to chip, less impact resistance then Polycarbonate. (still 10-24 times more resistant than glass)
Less likely to scratch.
More of a consumer (household) level and is easier to find at hardware stores.
Does NOT yellow after time.
Better clarity and can be restored to optical clarity.

Key characteristics/differences, Polycarbonate (Lexan) compared to Acrylic:

Impact/chip resistance is much higher with Polycarbonate. (about 30 times more resistant than glass)
More likely to scratch.
Substantially more expensive. (roughly 2 to 3 times)
Used for more industry applications
Bulletproof when thick enough.
More bendable.
More formable.
Yellows over time due to ultraviolet rays
Easier to work with (cut, less likely to break)
Poorer clarity, diffuses light, can lighten (could be positive).

Working with Acrylic and Polycarbonate:

Cutting, fine aluminum/acrylic cutting saw blades or knife (with 3/16”-1/4” or smaller sheet acrylic).
Drilling: use special acrylic bits or modified regular bits.
Welding (gluing): Acrylic/Polycarbonate only glue.
Information on working with acrylic is much easier to find.


Resources:
http://answers.yahoo.com/question/in...1102041AAyK7Xi
http://case-mods.linear1.org/acrylic...-plastics-faq/
http://fins.actwin.com/diy/acrylic.html
http://plaskolite.com/downloads.htm
Wikipedia.com
YouTube.com (Acrylic how-to videos)

[LastManOut]

I just picked up some plexi at Home Cheapo for a project, the lexan is 3/32" and 2x4' piece is about $45.

[phillyd2]

Lexan is stronger.

Just not bulletproof. I think they make football helmets out of Lexan and am more sure they also make astronaut helmets visors from it. Don't ask how I know.....

Humbly ETA: Add me to the list of not too old to learn "Lexan is similar to polymethyl methacrylate (Plexiglas/Lucite/Perspex) and is commonly described as acrylic in appearance, but is far more durable, often to the point of being described as "bulletproof" (depending on the thickness of the sample and the type of weapon used)"

[Atomic Dog]

Just called Lowes (closest store) only to find that a sheet of Lexan is just under $60!

At that price I'm saving too much at all unless I can really drop the size of this windshield.