Modern Vespa

In the past, I've undertaken a few windshield modifications. Like a lot of folks, I've done a couple of cut-down projects to custom tailor the height on screens that are too tall.

But my latest project is the inverse...adding an extension to my new to me Yamaha SMax to make it taller. This is one of the mods for Scooter Cannonball.

While out riding my new to me Yamaha Smax, I came to the conclusion that the OEM windscreen is far too short for me. Wind blast, bugs, and other debris would hit me at neck/chin area. There is a taller screen available from Givi, but the mounting hardware is out of stock everywhere and Givi has discontinued making it.

So I was on my own to find a solution. There are numerous clip on style deflectors available, but none were really tall enough to make a real difference on this scoot. But I had an ace up my sleeve. I had not one, but two extra pieces from the Faco Twin Screen I use on the Vespa. These are the clear inner screens that I never used.

With a high level design in mind, I headed to Lowe's. My plan was to drill 4 holes in the OEM screen and 4 corresponding holes in the spare screen. Then line them up and bolt them together. At Lowe's, I bought 4 stainless steel bolts and nylock nuts and 8 washers. I also bought 8 rubber grommets to insert into the holes to act as bushings.

So, after masking of a portion of the screen, I carefully measured and marked the correct locations for 4 holes in the OEM screen. I busted out the drill and soon enough there were 4 holes. This part went fairly well.

I then masked off a portion of the spare screen and transferred the locations of the holes in the OEM screen. Then I grabbed my drill and started drilling.

This is where my project derailed a bit. Whilst drilling the 1st hole in the spare screen, there was suddenly the sound of fracturing plexiglass. The piece I was drilling was now useless. Remember when I said I had 2 spare screens….this is where I had to use the 2nd one. So I carefully masked and marked where the holes should be in the last piece of plexiglass.

Not wanting a repeat of the earlier incident, I set my drill aside. I went to my basement and returned to the project scene with my blowtorch and steel awl. I then heated up the awl with the blow torch and plunged the red hot tip into the plexiglass; the hot awl pierced the screen with relative ease and no fractures. I repeated this process 3 more times so the I had 4 pilot holes for my drilling. At this point though I was still concerned about drilling and potentially breaking this last spare screen. I decided to enlarge the holes by heating a large carriage bolt with the blow torch and pushing that through. Then I only had to use the drill to slightly enlarge the holes, minimizing the stress on the spare screen.

Final assembly was working the rubber grommets into the holes and lining the bolts up and tightening everything down. The bolts and grommets are low enough that they are out of my line of sight.

I also took some time to polish some scratches out of the OEM screen; it's not perfect, but it is better. I used a cordless drill with a polishing pad from a headlight restoration kit and some Micro Gloss plastic polish. I'm pleased with the final result, but need to go for a test ride soon. Overall, it's a 5 inch extension that will hopefully direct air up over my helmet.

I've made a couple windscreens over the years. The last one was for my Yamaha Vino 125. IIRC, Gary at Gary's Plastic Place told me that people call a lot of different plastics Plexiglass. He told me the right material to use is Urethane. I used 1/8". I had some left over and tried breaking it in half by folding it. It never broke. Unfortunately, I don't have any pictures of it.

Nice job carl.
Miguel

Plexiglass is a trade name for sheet acrylic. It is brittle, cracks easily and won't bend. Lexan is the trade name for polycarbonate. It is used in bullet proof glass. You can bend it in half, and it will not break. It's what is used in safety eyewear. Lexan is far superior to plexiglass for scooter windshields.

Abner, you are probably correct on the using of Lexan rather than acrylic. I'll double check with Gary's Plastic Place tmw. Thanks!
Miguel

I used Plexiglass as a generic term, so I was not quite accurate with that bit of info. The piece I broke was the clear inner screen from a Faco Twin Screen. I wasn't able to find any description of the material, although SIP indicates Faco as one of the manufacturers using transparent acrylic - for whatever that is worth.

Abner, you were absolutely correct. Gary at Gary's Plastic Place nearby told me Lexan would be better than acrylic for windshields. Lexan is a trade name but its made of polycarbonate. Thanks forth correction.

Miguel

Very clean install!

Many of them used this glass. Plexiglass is used by many people but now here we compare the Lexan and Plexiglass. Lexan is much better than Plexiglass for scooter windshields.

Lexan is what is used in light aircraft windscreens, windows etc.

CrazyCarl,

You guys are amazing. Way over my pay grade. Good work.

Bob Copeland

Plexiglas and Lexan are both trademarks. For various compositions of polycarbonate thermoplastics. Both have high number of "copies" available.
Thermoplastic means it becomes soft when heated but firms up when cold. So any stretching or bending you do to the material while hot becomes permanent when you cool it.

Great job! I have used a Dremel with a pointed grinding tool in the past to make holes; does not grab and chip the plastic.