Hi, older newbie out here in So Cal riding my Super 8 for the past year and a half. Our winters don't get as cold as some of you other folks, but commuting 20 miles in 40-50 degree morning temps with that wind chill factor can frost your body up. I wear thermals underneath, a snowmobile jacket, scarf and those battery heated gloves to stay warm, but decided I needed a larger windshield this winter for my chest area and to help keep the cold air from flowing under into my helmet.
So I got my coworker in our maintenance shop to cut some 3/8" plexi to the size and shape I wanted (hope pics come out clear). Then he sanded the edges to make them safe. I lined up the windshield with the scoot face and marked the first hole for drilling. Drilled the shield, then attached it with the first bolt (bought same diameter as original, but 2" long). Then marked, drilled and inserted the 2nd bolt. Then did the 3rd bolt, and then the 4th. Do it sequentially because the first try, when I marked the 4 holes and drilled them all at the same time, 3 were off because of the angularity of the face. Use flat rubber washers on the outside bolt/windshield sides, and larger rubber grommets on the inner side of the bolt/windshield to dampen vibration. Also attach a flat strip of self-stick rubber or velcro down the angular centerline because the windshield will press directly against there when you tighten down the bolts.
It may not be pretty or professional, but with the free plexi, it only cost a few bucks for the bolts and washers and really works! I hit 60mph on a downhill stretch during my regular commute and the wind stays off of my chest and blows mostly up and over my helmet. No problems with the plexi bending or cracking so far after one month so the 3/8 inch seems to be thick enough to withstand the strong airflow. I think I'm actually getting better speed and mileage cuz that wind flows over the shield instead of hitting my chest all the time. So I had my coworker make me 2 more shields so I could paint on some other designs. And he also made me some side shields which I attached with flat washers and longer screws, and these also help direct the cold airflow away from your leg/knee area...
