Author Topic: $15 Window Extension  (Read 987 times)

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Offline rmills944

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$15 Window Extension
« on: July 14, 2014, 12:24:32 pm »
I have wanted a window extension or touring windshield for a while for long trips, but still need airflow in the Memphis summers. I finally decided to do something about it.  Before taking $120+ to buys something I figured I would try another method.

I bought a sheet of plexiglas and borrowed a heat gun and came up with this extension for a total of $15.

Process:
cut the extension with a table saw to size
clamp the extension to the window to match the curve
heat the plexiglas until the shape matches. I also heated the top and rolled back the corners and added a little lip at the top middle
sand the edges so they round off
torch the edge to melt and get the smoothed look
drill holes to mount the sheets together
I was going to find a way to clamp it on, but couldn't find a mechanism that looked right. For now I'm using wing nuts with rubber and metal washers on each side.
If it ain't fast and won't corner... Crome it.

Offline FL_Cruzin

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Re: $15 Window Extension
« Reply #1 on: July 14, 2014, 12:29:45 pm »
Very nice !!  I like the idea, good tooling on your part.  What was the thickness of the Plexiglas?    :)

Offline Stasch

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Re: $15 Window Extension
« Reply #2 on: July 14, 2014, 12:45:16 pm »
Interesting to hear.  I wouldn't have thought cutting plexi with a table saw would work.  I use a hand held variable speed jig saw and if blade speed isn't kept low enough, the cut melts back together behind the blade. 

Maybe the table saw blade is big enough front to back that the heat dissipates?
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Offline maddoc

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Re: $15 Window Extension
« Reply #3 on: July 14, 2014, 12:48:52 pm »
Very nice, when i was into RC airplanes i use to form my own plastic pieces by sanding a mold out of wood placing it ontop of a 5 gallon bucket with a perforated wood lid and a shop vac attached to the bottom. heat the plastic and lay it on top of the mold the vacuum will suck the plastic down and form it to the mold till it cures. same process could be duplicated to form wind screens but on a larger scale.

Offline Sport Rider

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Re: $15 Window Extension
« Reply #4 on: July 14, 2014, 12:53:26 pm »
I used wing nuts to mount mine so that it could be quickly removed.  put a piece of cushion of some sort between them.  you should be able to find some one-sided foam tape at the auto parts store.  it will help cushion the plastic a bit and reduce chances of cracking around the hole.

Offline rmills944

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Re: $15 Window Extension
« Reply #5 on: July 14, 2014, 01:33:05 pm »
I used a 1/4 piece. I'm just going to leave it on for highway riding and not in town. I used a dremel to drill the hole as a bit that pulls through would have cracked the plexi. It's a bit thin to tell the truth. I'll probably remake it using a thicker sheet. It's just too hot and this one should be fine for now. I figure some cork pads would help with the window touching and keeping it from vibrating. I have a rubber washer between the windows around the bolts to help with Vibration and cracking. They seem to be working alright for now.
If it ain't fast and won't corner... Crome it.

Offline Skiee

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Re: $15 Window Extension
« Reply #6 on: July 14, 2014, 07:34:57 pm »
Well done, sir!!  :bravo_2:
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